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1. 3 8 He TORCH ogi 3 26 Connect the remote start pendant 3 26 Connect a machine interface cable aaa wawa aaa aaa aaa aaa aa aaa 3 27 Connect the toreh lead ssania deer aired A A AE A dahon ty RR S YI Ra agg d 3 30 Section 4 OPERATION Controls and indicators i eene and ED tie ie ete d aide iet 4 2 Front controls A 4 2 4 3 Operate the 45 4 4 Connect the electrical power and gas supply eene 4 4 ON the d 4 4 oet th mode ach n ita ih oi a n an di ai wada ddd at atts 4 5 Adjust the gas pressure sss sesenta tates tentat taa trit a a a a AA 4 5 Check the indicator LEDs EA dens acea ntur n dnd 4 6 Attach the work clamp sse entente tentent entente tenente tente tenente tenter 4 7 Understand duty cycle limitations it rtr er ec iieri dian 4 7 How touse the hand torch sain c icon tn cocti 4 8 Operate the safety trigger re eter idet aa 4 8 torch Cutting tne na rice redes ance 4 9 Start a cut from the edge of the
2. 4 10 Pierce Workpiece eene tinens d Ee Ree oret tre mco nc 4 11 Gouge WOFKPlE CO a 4 12 Common hand cutting ttt i 4 14 How t use ihe machinet rch ua nazywana nn Ssn 4 15 Ensure the torch and table are set up correctly sse tnnt 4 15 Understand and optimize cut quality seen trn enne 4 15 To pierce a workpiece using the machine torch seen 4 17 Common machine cutting faults tette AAC 4 18 Section 5 MAINTENANCE AND REPAIR Perform ro tine mainteriahoe oot citet cnini nt ci det endi nb c ist eb 5 2 Inspect the consumables eei AG AR WA urere D nio i en PEIPER EIER 5 3 Basicitroubleshooling eter teense ra 5 4 P MM E M 5 8 ii powermax45 Operator Manual TABLE OF CONTENTS Remove and replace the cover and barrier sss 5 8 Replace the work lead CSA and CE sese tete 5 10 Replace the gas filter element a ta ttte taste A tut 5 11 Section 6 PARTS Power supply A 6 2 ai nte d adu ttti ritui tet 6 5 hand torch
3. 5 8 Remove and replace the cover and Mylar barrier sse 5 8 Replace the work lead CSA and CE scssssssssssssssssssssssssesssesssessessessesssessssssesseessesnsesssssessesseesneessess 5 10 Replace the gas filter element zaa ana a AAA 5 11 powermax45 Operator Manual 5 1 MAINTENANCE AND REPAIR Perform routine maintenance DANGER ELECTRIC SHOCK CAN KILL Disconnect the electrical power before you perform any maintenance AII work that requires removal of the power supply cover must be performed by a qualified technician Every use Check the indicator lights and correct any fault conditions Every 3 months Inspect the trigger for damage Inspect the torch body for cracks and exposed wires Ww Replace any damaged parts Replace any damaged labels Inspect the power cord and plug Replace if damaged Inspect the torch lead Replace if damaged E ths Clean the inside of the power supply with compressed air or a vacuum 5 2 powermax45 Operator Manual Inspect the consumables Shield or deflector Nozzle powermax45 Operator Manual MAINTENANCE AND REPAIR The center hole for roundness The gap between the shield and the nozzle for accumulated debris The center hole for roundness Worn Good The center surface for wear and verify the pit depth The internal surface for damage or wear and
4. Edge start recommended Maximum cut speed is limited by the test table s maximum speed 400 ipm or 10160 mm min 3 20 powermax45 Operator Manual TORCH SETUP T30v Powermax30 30 A consumables 220569 220483 220480 220479 220478 Optional Retaining cap Nozzle Swirl ring Electrode deflector Mild steel Air flowrate Ipm Metric Hot Cold Recommended Maximum Are Material Initial pierce Pierce cut Voltage current thickness time delay Speed 9 amps mm sag height sec mm min W mm min 0 5 8900 105 10160 0 8 j 8100 102 10160 0 9 7100 101 8900 1 5 500 4450 97 5600 1 9 3050 98 3800 2 7 2050 96 2550 3 4 1270 1650 Maximum cut speed is limited by the test table s maximum speed 10160 mm min powermaX45 Operator Manual 3 21 TORCH SETUP T30v Powermax30 30 A consumables Mild steel Hot 280 English fre Material e 2 current thickness 7 Work Initial pierce e delay distance height amps in in sec 0 018 26 Ga 0 030 22 Ga 0 036 20 Ga 0 060 16 Ga 0 075 14 Ga 0 105 12 Ga 0 135 10 Ga 500 Maximum cut speed is limited by the test table s maximum speed 400 ipm 3 22 powermaX45 Operator Manual SETUP
5. 250 3 16 in 0 250 i 1 4 i 0 3751 3 8 i 0 500 i 1 21 0 7501 3 4 i Edge start recommended Maximum cut speed is limited by the test table s maximum speed 400 ipm 3 18 powermaX45 Operator Manual SETUP T45m unshielded consumables Air flowrate Ipm Aluminum Metric Are Material 279760 Pierce Cut Cut current thickness Work Initial pierce ime delay Speed Speed distance height mm mm sec mm min mm min 1 2 0 0 8900 10160 1 5 3 250 0 1 8100 10160 1 9 0 2 5700 7100 10160 10160 9144 250 6858 3175 2286 0 5 Edge start recommended Maximum cut speed is limited by the test table s maximum speed 10160 mm min powermaX45 Operator Manual 3 19 TORCH SETUP T45m unshielded consumables Air flowrate scfh Aluminum Hot 320 English Cold 360 Torch m Pierce time Material to work Initial pierce current delay thickness distance height amps in sec 0 018 in 26 Ga 0 060 in 16 Ga 0 075 in 14 Ga 0 060 in 16 Ga 0 075 in 14 Ga 0 105 in 12 Ga 0 135 in 10 Ga 0 188 in 3 16 in 0 250 in 1 4 in 0 375 in 3 8 in 0 500 in 1 2 in 0 750 in 3 4 in 0 0 0 1 0 2 250
6. SETUP Connect the torch lead The Powermax45 is equipped with FastConnect a quick disconnect system for connecting and disconnecting the handheld and machine torches When connecting or disconnecting a torch first turn OFF the system To connect either torch push the connector into the receptacle on the front of the power supply To remove the torch press the red button on the connector and pull the connector out of the receptacle Red button 3 30 powermaX45 Operator Manual Section 4 Operation In this section 5 wa ccena nt AA R EA AA Aa e da dota o nei anual 4 2 Front controls and WEDS asc citri itis iren n ft ter seni ete 4 2 Rear conttols csse uiam quie SLE EMI DM ELE 4 3 Operate the Powertriax4b on retire m epe ett c m ne i La Lx wk da 4 4 Connect the electrical power and gas supply 4 4 the cue 4 4 Set the mode switch suse aaa awa 4 5 Adjust the gas PreSSUFE m 4 5 Check the indicator LEDS iino ciini tat trt t n iden 4 6 Atiach the work clamp tcn o S n dian E HIER 4 7 Understand duty cycle limitations eessseseeeeeeenne tette tentent tente tint tette tents 4 7 How to use the hand torch senate tees essere Ieri pesi rabat 4 8 Operate the safety trigger entrent ten nente dr
7. na 2a nai la ma HYPI LIIGI HT powermaxeHt Plasma arc cutting system Distributed by Tick Veols c Trick Tools 7 EEE 80 Truman Road fs m Pella IA 50219 T A bor di mem D E 1 CN mail sales trick tools com Operator Manual 805780 Revision 1 Register your new Hypertherm system Register your product on line at www hypertherm com registration for easier technical and warranty support You can also receive updates on new Hypertherm products and a free gift as a token of our appreciation For your records Serial number Purchase date Distributor Maintenance notes powermax45 Operator Manual P N 805780 Revision 1 October 2010 Hypertherm Inc Hanover NH USA www hypertherm com email infoQhypertherm com Copyright 2010 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 ELECTROMAGNETIC COMPATIBILITY Introduction Hypertherm s CE marked equipment is built in compliance with standard EN60974 10 The equipment should be installed and used in accordance with the information below to achieve electromagnetic compatibility The limits required by EN60974 10 may not be adequate to completely eliminate interference when the affected equipment is in close proximity or has a high degree of sensitivity such cases
8. the top of the power supply the gas pressure is set turn the knob clockwise to set the output amperage The torch will not fire when the knob is in the gas test position E Mode switch and LEDs Es The mode switch can be set in one of three positions F Continuous pilot arc to cut expanded metal or grate top m m i m Non continuous pilot arc to cut metal plate middle EY Gouging bottom After you change the mode switch verify that the gas pressure is still set correctly Different modes of cutting require different pressure settings Rear controls CSA 230 V CE 400 V CE ON D OFF O power switch Activates the power supply and its control circuits powermaX45 Operator Manual 4 3 OPERATION Operate the Powermax45 Follow the steps below to begin cutting or gouging with the Powermax45 Connect the electrical power and gas supply Plug in the power cord and connect the gas supply line For more information about the electrical requirements and the gas supply requirements of the Powermax45 see Section 2 Power supply setup Turn ON the system Set the ON OFF switch to the ON I position Bl CSA 230 V CE 400 V CE 4 4 powermax45 Operator Manual OPERATION Set the mode switch Use the mode switch to select the type of work you will be doing rt R 1 1 1
9. chin Aa Eta wd A 2 2 Position the power Supply rcr kinetin w ER 2 3 Prepare the electrical DOW F zi aii ad A A gi enone 2 3 Voltage meos 2 3 Install a line disconnect switch seen AAAA 2 4 Reguirements Tor ep 2 4 Power cordconsideratigns Z a rada dA AAAA 2 5 Extension cord reCOMMENCatlOns 2 5 aan ctc WA ter Aida Annes 2 7 Prepare the gas supply erii e ni ciet i e aes 2 7 Connect the gas SUPPLY tetra teet intct nns tente ntn s Za de dnd a 2 8 Additional gas filtration AAAA ai dried 2 8 Section3 TORCH SETUP 3 2 Consumable ANG 3 2 torch ER O CER ee 3 3 Choose the CONSUMADIES c scssssscssssssssssssssssssseeesesescscscacassceesausssusussssesesesesesescscacacacacasacavacanscaceesesees 3 3 Install the CONSUMADIES cssscssssessesssescssscscscesacsesssssesssesssesesescssscacacacesauacsususnsseseseseseseseseseacataseseranasas 3 5 powermax45 Operator Manual i TABLE OF CONTENTS Machine torch ez czak 3 6 Mount ARA i A Aaa Pep ko ALA Aa AI KC 3 6 Choose the consumables cut
10. 0 375 in 3 8 in 0 500 in 1 2 in 0 750 in 3 4 in 0 0 250 Edge start recommended Maximum cut speed is limited by the test table s maximum speed 400 ipm 3 14 powermax45 Operator Manual T45m unshielded consumables 220717 Deflector 220713 Retaining cap Mild steel Metric qi 220718 Nozzle 220670 Swirl ring n 220669 Electrode TORCH SETUP Air flowrate Ipm Hot Recommended Maximum Arc current amps Material thickness mm Torch to work distance mm Initial pierce height Pierce time delay sec Cut Speed mm min Cut Speed mm min 0 5 0 8 0 9 1 5 5 0 mm 250 5 0 mm 250 9150 10160 8650 10160 8100 10160 5800 7250 10160 10160 7620 5588 4318 2794 1905 1016 Edge start recommended 635 356 254 127 Maximum cut speed is limited by the test table s maximum speed 10160 mm min powermax45 Operator Manual TORCH SETUP T45m unshielded consumables Air flowrate scfh Mild Steel Hot 220 English Arc Torch Pierce time Material to work Initial pierce current delay thickness distance height amps in sec 0 018 in 26 Ga 0 030 in
11. 16 Ga 0 036 in 20 Ga 0 060 in 16 Ga 0 075 in 14 Ga 0 105 in 12 Ga 0 135 in 10 Ga 0 188 in 3 16 in 0 250 in 1 4 in 0 375 in 3 8 in 0 500 in 1 2 in 0 750 in 3 4 in 117 123 250 Edge start recommended Maximum cut speed is limited by the test table s maximum speed 400 ipm 3 12 powermaX45 Operator Manual TORCH SETUP T45m shielded consumables Air flowrate Ipm Aluminum Metric Recommended Maximum Arc Material c Initial pierce Pierce Cut Cut current thickness time delay Speed Speed mm pea height sec mm min mm min 1 2 0 0 9150 10160 1 5 8650 10160 0 2 1 9 5450 6860 10160 10160 9144 250 0 1 0 2 0 3 0 5 Edge start recommended Maximum cut speed is limited by the test table s maximum speed 10160 mm min powermaX45 Operator Manual 3 13 TORCH SETUP T45m shielded consumables Air flowrate scfh Aluminum Hot 320 English Cold 360 Torch 8 em A Pierce time Material to work Initial pierce current delay thickness distance height amps in sec 0 018 in 26 Ga 0 060 in 16 Ga 0 075 in 14 Ga 0 060 in 16 Ga 0 075 in 14 Ga 0 105 in 12 Ga 0 135 in 10 Ga 0 188 in 3 16 in 0 250 in 1 4 in
12. 22 Ga 0 036 in 20 Ga 0 060 in 16 Ga 0 036 in 20 Ga 0 060 in 16 Ga 0 075 in 14 Ga 0 105 in 12 Ga 0 135 in 10 Ga 0 188 in 3 16 in 0 250 in 1 4 in 0 375 in 3 8 in 0 500 in 1 2 in 0 625 in 5 8 in 0 750 in 3 4 in 1 000 in 1 in Maximum cut speed is limited by the test table s maximum speed 400 ipm 250 Edge start recommended 3 16 powermaX45 Operator Manual TORCH SETUP T45m unshielded consumables Air flowrate Ipm Stainless steel Metric Material Pierce Cut Cut current thickness 9 Work Initial pierce ne delay Speed Speed amps mm aa height sec mm min mm min 0 5 9144 10160 0 8 8128 10160 i 250 0 9 7000 9000 1 5 10160 0 0 10160 0 1 9144 0 3 5080 250 0 4 3556 0 5 2032 0 6 1270 0 8 762 457 Edge start recommended 229 Maximum cut speed is limited by the test table s maximum speed 10160 mm min powermaX45 Operator Manual 3 17 SETUP T45m unshielded consumables Air flowrate scfh Stainless steel Hot 320 English Cold 350 Torch Arc or Pierce Material to work Initial pierce current time delay amps thickness a height sec
13. DANES NE ERR 6 8 Powermax4 5 labels ere ace dva es EE 6 8 powermax45 Operator Manual 6 1 PARTS Power supply parts Part number 228269 228268 228270 228267 228281 228283 228300 228307 228561 108616 6 2 Amperage adjustment knob Front panel Work lead Handle Rear panel Power supply cover Description Kit Kit Cover screws Kit Power supply cover Kit Kit Kit Kit Kit Kit Powermax45 front panel Powermax45 rear panel Handle and screws Power supply cover CE Work lead with clamp 20 ft 6 1 m Work lead with clamp 50 ft 15 24 m Ground clamp not shown Amperage adjustment knob powermax45 Operator Manual PARTS Power cord Receptacle for machine interface cable or remote start pendant Part number Description 228278 Kit Powermax45 power cord CSA 200 240 V 228277 Kit Powermax45 power cord CE 230 V 228276 Kit Powermax45 power cord CE 400 V 128650 Remote start pendant for machine torch 25 ft 7 63 m 128651 Remote start pendant for machine torch 50 ft 15 24 m 128652 Remote start pendant for machine torch 75 ft 22 86 m 023206 Machine interface cable start plasma arc transfer and ground 25 ft 7 63 m 023279 Machine interface cable start plasma arc transfer and ground 50 ft 15 24 m 123966 Powermax45 machine interface cable sta
14. T30v Powermax30 30 A consumables Air flowrate Ipm Stainless steel MERE Recommended Maximum Arc Material Torch Pierce Cut current thickness to work Initial pierce time delay Speed amps mm z height sec mm min 0 5 10160 0 8 i 10160 0 9 6850 1 5 500 4800 1 9 3450 2 7 7 1900 3 4 1400 Maximum cut speed is limited by the test table s maximum speed 10160 mm min powermaX45 Operator Manual 3 23 TORCH SETUP T30v Powermax30 30 A consumables Stainless steel English Arc Material TOT Pierce current thickness Work Initial pierce ime delay distance height amps in in sec 0 018 26 Ga 0 030 22 Ga 0 036 20 Ga 0 060 16 Ga 0 075 14 Ga 0 105 12 Ga 0 135 10 Ga Maximum cut speed is limited by the test table s maximum speed 400 ipm 3 24 powermaX45 Operator Manual SETUP T30v Powermax30 30 consumables Air flowrate Ipm Aluminum Hot 131 2 2 Cold Recommended Maximum Arc Material Pierce Cut Cut current thickness 9 ok Initial pierce ne delay Speed Speed amps mm wam height sec mm min mm min 0 5 8100 10160 0 8 0 9 1 5 1 9 Aluminum Air flowrate Ipm English 146 3 R
15. itr tct tr 6 6 T30v Powermax30 30 A consumables 6 6 T45m machine torch trip n rein om aiuti ated dd Pda d 6 7 T45m machine torch consumables eese nete terne aaa aaa aaa 6 8 E 6 8 Powermax4b labels fae nds A 6 8 powermax45 Operator Manual iii TABLE OF CONTENTS iv powermax45 Operator Manual this section System description eene Where to find information Power supply dimensions and weights Dimensions i e m irt e ded IC M Power supply ratings nt ttes T45v torch dimensions T45m torch dimensions eee T45v and T45m torch specifications Symbols and markings tenens IEC SYMONS ana a temen powermaX45 Operator Manual Section 1 SPECIFICATIONS 1 1 SPECIFICATIONS System description The Powermax45 is a highly portable 45 amp handheld and mechanized plasma cutting system appropriate for a wide range of applications The Powermax45 uses air or nitrogen to cut electrically conductive metals such as mild or stainless steel or aluminum With it you can cut thicknesses up to 1 inch 25 4 mm and pierce thicknesses up to 3 8 inch 9 5 mm The standard Powermax45 sys
16. Ez Adjust the gas pressure To cut expanded metal or grate cutting top position Use this setting to cut metal with holes in it or for any job that requires a continuous pilot arc Leaving the mode switch on this setting to cut standard metal plate will reduce consumable life To cut metal plate middle position Use this setting to cut metal up to 1 inch 25 4 mm thick or pierce metal up to 1 2 inch 12 7 mm thick Gouging bottom position Use this setting to gouge metal Leaving the mode switch on this setting while cutting results in poor cut quality Look at the gas pressure LED If it illuminates green in the center of the pressure bar the incoming gas pressure is correct for the mode you have selected If the LED illuminates yellow either above or below the center the gas pressure needs to be adjusted To adjust the pressure 1 Turn the amperage knob counter clockwise to the gas test position as show below powermax45 Operator Manual 4 5 OPERATION 2 With the amperage knob in the gas test position pull up on the pressure regulator knob on top of the system to unlock it Pressure regulator knob 3 Turn the pressure regulator knob until the gas pressure LED illuminates a green in the center of the pressure bar 4 Press down on the pressure regulator knob to lock it in position 5 Turn the amperage knob to the cutting current appropr
17. 16 Ga 0 075 in 14 Ga 0 105 in 12 Ga 0 135 in 10 Ga 0 188 in 3 16 in 0 250 in 1 4 in 0 375 in 3 8 in 0 500 in 1 2 in 0 625 in 5 8 in 0 750 in 3 A in 1 000 in 1 in Maximum cut speed is limited by the test table s maximum speed 400 ipm 117 116 250 Edge start recommended 3 10 powermaX45 Operator Manual TORCH SETUP 45 shielded consumables Air flowrate Ipm Stainless steel Metric Are Material 19160 Pierce Cut Cut current thickness 9 Work Initial pierce ne delay Speed Speed amps mm wa height sec mm min mm min 0 5 9150 10160 0 8 8650 10160 250 0 9 8100 10160 1 5 3750 4700 10160 0 0 10160 0 1 9144 0 3 5080 250 0 4 3810 0 5 2159 0 6 1397 0 8 813 457 Edge start recommended 229 Maximum cut speed is limited by the test able s maximum speed 10160 mm min powermaX45 Operator Manual 3 11 TORCH SETUP T45m shielded consumables Air flowrate scfh Stainless steel Hot 320 English Arc Toren Pierce time current Material to work Initial pierce Voltage Voltage A i delay amps thickness height sec V V 0 018 in 26 Ga 0 030 in 22 Ga 0 036 in 20 Ga 0 060 in
18. If this LED illuminates the power must be turned OFF the consumables installed properly and the system turned ON again to reset the LED Fault LED yellow When illuminated this LED indicates that there is a fault with the power supply Some fault conditions will cause one or more of the LEDs to blink For information on what these fault conditions are and how to correct them see Basic troubleshooting in Section 5 Power ON LED green When illuminated this LED indicates that the power switch has been set to I ON and that the safety interlocks are satisfied powermax45 Operator Manual OPERATION Gas pressure LED and pressure bar green or yellow aa When the LED indicator in the pressure bar illuminates green and is centered in the vertical bar the gas pressure is set correctly for the mode of cutting selected with the mode switch If the pressure is too high for the selected mode the indicator in ky a the pressure bar will be above the mid point of the If it is too low the indicator 4 will be below the mid point At the highest and lowest points on the bar the indicator will illuminate yellow LI If the indicator is at the lowest part of the bar and flashes then the gas pressure is less than the minimum required pressure m Amperage adjustment knob 7 D Set this knob to the gas test position fully counter clockwise before adjusting the gas pressure with the pressure regulator knob
19. head and press the red torch trigger as show below 4 8 powermaX45 Operator Manual OPERATION Hand torch cutting hints With shielded consumables drag the nozzle lightly along the workpiece to maintain a steady cut With unshielded consumables maintain an approximate 08 inch 2 mm distance between the tip of the torch and the workpiece This is between a 1 16th and 1 8th of an inch While cutting make sure that sparks exit from the bottom of the workpiece The sparks should lag slightly behind the torch as you cut 15 30 angle from vertical If sparks spray up from the workpiece move the torch more slowly or set the output current higher Hold the torch nozzle perpendicular to the workpiece so that the nozzle is at a 90 angle to the cutting surface and watch the arc as it cuts along the line If you fire the torch unnecessarily you will shorten the life of the nozzle and electrode Pulling or dragging 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 See Section 6 Parts for part numbers for the Hypertherm plasma cutting guides for cutting circles and making bevel cuts powermaX45 Operator Manual 4 9 OPERATION Start a cut from the edge of the workpiece U KD 1 With the work clamp attached to the workpiece hold the torch nozzle perpend
20. is on the left and the Three edge with 4 notches is on the right notches We Four notches 2 There is a perforation across the top about 1 75 inches 4 45 cm down from the top edge If you are replacing the Mylar barrier with a new you will need to fold it along this perforation so AG that the top edge bends away from you x 3 Position the barrier so that the folded ERA section will cover the top of the power board Slide the barrier into place with the bottom edge between the ribs on the base and the power board The notches on each side 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 Tab edges are in the tracks and that the slot Cover slot in the top of the cover is aligned with the tab on the front endcap so that the louvers in the cover are in front of the fan Position the handle over the holes in the top of the cover then secure the cover with the 2 screws powermax45 Operator Manual 5 9 MAINTENANCE AND REPAIR Replace the work lead CSA and CE 1 2 Turn OFF the power disconnect the power cord and disconnect the gas supply Remove the cover from the power supply and remove the Mylar barrier from in front of the power board Remove the screw from J21 also labeled work lead
21. on the power board that attaches the lead to the board Set the screw aside Front panel 1 Work lead Ex Strain relief Work lead connection to power board J21 Gently tilt the front panel away from the power supply From the inside of the panel unscrew the nut that secures the strain relief to the endcap Thread the connector end of the new work lead through the front panel and fit the strain relief into the hole in the panel Slide the nut over the work lead s connector Gently tilt the front panel away from the power supply and screw the nut onto the strain relief Attach the work lead to the power board at J21 using the screw that you removed earlier The torque setting for this connection is 20 inch pounds 23 4 kg cm Realign the front panel 5 10 powermax45 Operator Manual MAINTENANCE AND REPAIR 9 Replace the Mylar barrier and slide the cover back onto the power supply Position the handle over the holes in the top of the cover then secure the cover with the 2 screws 10 Reconnect the electrical power and the gas supply Replace the gas 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 drain in the bottom of the power supply s base 4 Compress the hose fitting s collar on the gas supply hose and pull the gas hose from the fitting 5 Unscrew t
22. rotate the torch 90 in its holder and repeat the process If the angles are the same in both tests the problem is in the drive system If a cut angle problem persists after mechanical causes have been eliminated see the previous page Ensure the torch and table are set up correctly check the torch to work distance especially if the cut angles are all positive or all negative Also consider the material being cut if the metal is magnetized or hardened you are more likely to experience cut angle problems Dross Some amount of dross will always be present when cutting with air plasma However you can minimize the amount and type of dross by adjusting your system correctly for your application Dross appears on the top edge of both pieces of the plate when the the torch is too low or voltage is too high if using a torch height control Adjust the torch or the voltage in small increments 5 volts or less until the dross is reduced Low speed dross forms when the torch s cutting speed is too slow and the arc shoots ahead It forms as a heavy bubbly deposit at the bottom of the cut and can be removed easily Increase the speed to reduce this type of dross 4 16 powermaX45 Operator Manual OPERATION High speed dross forms when the cutting speed is too fast and the arc lags behind It forms as a thin linear bead of solid metal attached very close to the cut It is welded to the bottom of the cut and is difficult to remove To reduc
23. spray out from the nozzle Point the torch away from yourself and others 1 Hold the torch so that the nozzle is within 1 16 inch 1 5 mm from the workpiece before firing the torch 2 Hold the torch at a 45 angle to the workpiece with a small gap between the torch tip and the workpiece Press the trigger to obtain a pilot arc Transfer the arc to the work piece 3 Maintain an approximate 45 angle to the workpiece as you feed into the gouge In other words push the plasma arc in the direction of the gouge you want to create Keep a small distance between the torch tip and the molten metal to avoid reducing consumable life or damaging the Direction of travel gt torch Changing the torch s angle changes the dimensions of the gouge Note A heat shield is available for added hand and torch protection part number 220049 4 12 powermaX45 Operator Manual OPERATION You can vary the depth of the gouge by varying the angle of the torch to the workpiece The following tables show the gouging profile at 45 and 60 on mild steel and stainless steel Mild steel gouging profile Torch angle Speed Width Depth 10 ipm 254 mm min 0 3051 in 7 75 mm 0 0415 in 1 05 mm 20 ipm 508 mm min 0 2550 in 6 50 mm 0 1158 in 2 94 mm 30 ipm 762 mm min 40 ipm 1016 mm min 0 2267 in 5 76 mm 0 2087 in 5 30 mm 0 0735 in 1 87 mm 50 ipm 1270 mm min 10 ip
24. the specific periods of time set forth herein and as follows if Hypertherm is notified of a defect i with respect to the power supply within a period of two 2 years from the date of its delivery to you with the exception of Powermax brand power supplies which shall be within a period of three 3 years from the date of delivery to you and ii with respect to the torch and leads within a period of one 1 year from its date of delivery to you and with respect to torch lifter assemblies within a period of one 1 year from its date of delivery to you and with respect to laser heads within a period of one 1 year from its date of delivery to you and with respect to Automation products one 1 year from its date of delivery to you with the exception of the EDGE Pro CNC and ArcGlide THC which shall be within a period of two 2 years from the date of delivery to you Compliance Information WARRANTY This warranty shall not apply to any Powermax brand power supplies that have been used with phase converters In addition Hypertherm does not warranty systems that have been damaged as a result of poor power quality whether from phase converters or incoming line power This warranty shall not apply to any Product which has been incorrectly installed modified or otherwise damaged Hypertherm provides repair replacement or adjustment of the Product as the sole and exclusive remedy if and only if the warranty set forth herein
25. 0 psi 170 l min 6 2 bar Do not allow the gas supply pressure to exceed 135 psi 9 3 bar The filter bowl may explode if this pressure is exceeded If gas supply quality is poor cut speeds decrease cut quality deteriorates cutting thickness capability decreases and the life for consumables shortens For optimum performance the gas should have a maximum particle size of 0 1 micron at a maximum concentration of 0 1 mg m3 a maximum dewpoint of 40 C 40 F and a maximum oil concentration of 0 1 mg m per ISO 8573 1 Class 1 2 2 powermax45 Operator Manual 2 7 POWER SUPPLY SETUP Connect the gas supply Connect the gas supply to the power supply using an inert gas hose with a 3 8 inch 9 5 mm internal diameter and a 1 4 NPT quick disconnect coupler or a 1 4 NPT x G 1 4 BSPP CE units quick disconnect coupler 80 100 psi 5 5 6 9 bar gas supply maximum 135 psi or 9 3 bar with a flow rate of at least 350 scfh 165 2 l min The recommended flow rate and pressure is 360 scfh 90 psi 170 l min 6 2 bar Additional gas filtration When site conditions introduce moisture oil or other contaminants into the gas line use a 3 stage coalescing filtration system such as the Eliminizer filter kit part number 128647 available from Hypertherm distributors A 3 stage filtering system works as shown below to clean contaminants from the gas supply Water and particle filter Oil filter Oil vapor filt
26. 45m cap sensor switch replacement 058503 O ring 228317 T45m torch lead replacement 25 ft 7 6 m 228318 T45m torch lead replacement 35 ft 10 67 m 228319 T45m torch lead replacement 50 ft 15 24 m The torch assembly also includes one set of the consumables listed on the next page powermaX45 Operator Manual 6 7 PARTS T45m machine torch consumables Part number Description Shielded 220669 Electrode 220670 Swirl ring 220713 Retaining cap 220719 Ohmic sensing retaining cap 220671 Nozzle 220673 Shield Unshielded 220717 Deflector 220718 Nozzle The swirl ring retaining cap and electrode for the unshielded application are the same as those for the shielded application The T30v Powermax30 30 A consumables can be used on the T45m as well The part numbers are listed on page 6 6 Accessory parts Part number Description 024548 Leather torch sheathing 25 ft 7 5 m 128658 Gouging heat shield 127102 Basic plasma circle cutting guide 027668 Deluxe plasma circle cutting guide 127219 Powermax45 dust cover 127217 Powermax45 shoulder strap 128647 Kit Eliminizer air filtration Powermax45 labels Part number Description 228272 Kit Powermax45 labels CE 228264 Kit Powermax45 labels CSA The label kits include the consumable label appropriate safety labels as well as front and side decals The consumable and safety labels are pictured on the next page 6 8 powermax45 Operator Manual T45v CONSUMABLE
27. 5 45A 50 208 45 A 132 V 50 200 240 VAC 45 A 132 V 34 28 55 45 35 or 50 A 400 VAC 45 A 132 V 15 20 A 220 VAC 45 A 132 V 35 or 50 A 380 VAC 45 132 V 15A Use the higher amperage fuse for applications that require a long arc stretch powermax45 Operator Manual 2 3 POWER SUPPLY SETUP Install a line disconnect switch Use a line disconnect switch for each power supply so that the operator can turn off the incoming power quickly in an emergency Locate the switch so that it is easily accessible to the operator Installation must be performed by a licensed electrician according to national and local codes The interrupt level of the switch must equal or exceed the continuous rating of the fuses In addition the switch should solate the electrical equipment and disconnect all live conductors from the incoming supply voltage when in the OFF position Have one OFF and one ON position that are clearly marked with O OFF and I ON Have an external operating handle that can be locked in the OFF position Contain a power operated mechanism that serves as an emergency stop Have slow blow fuses installed as recommended in the table on the previous page Requirements for grounding To ensure personal safety proper operation and to reduce electromagnetic interference EMI the Powermax45 must be properly grounded The power supply must be gr
28. Equipment used for calibration or measurement 9 Immunity of other equipment in the environment User shall ensure that other equipment being used in the environment is compatible This may require additional protection measures h Time of day that cutting or other activities are to be carried out The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place The surrounding 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 EMC 1 9 10 ELECTROMAGNETIC COMPATIBILITY EMC be necessary to take additional precautions such as filtering of the mains supply Consideration should be given to shielding the supply cable of permanently installed cutting equipment in metallic conduit or equivalent Shielding should be electrically continuous throughout its length The shielding should be connected to the cutting mains supply so that good electrical contact is maintained between the conduit and the cutting power source enclosure Maintenance of cutting equipment The cutting equipment must be routinely maintained according to the manufacturer s recommendations All access and service doors and covers should be closed and properly fastened when the cutting equipment is in
29. Extension cord recommendations English Input voltage Phase lt 10ft 10 25 ft 25 50 ft 50 100 ft 100 150 ft 208 VAC 1 8 AWG 8 AWG 8 AWG 6 AWG 4 AWG 220 VAC 1 8 AWG 8 AWG 8 AWG 6 AWG 4 AWG 200 240 VAC 1 8 AWG 8 AWG 8 AWG 6 AWG 4 AWG 380 VAC 3 12 AWG 12 AWG 12 AWG 10AWG 10AWG 400 VAC 3 12 AWG 12 AWG 12 AWG 10AWG 10AWG Metric Input voltage 208 VAC 220 VAC 200 240 VAC 380 VAC 400 VAC 2 6 powermaX45 Operator Manual POWER SUPPLY SETUP Generator recommendations When using a generator with the Powermax45 it should produce 240 VAC nominal current Engine Engine drive drive rating output current Performance Good arc stretch at 45 A cutting current Limited arc stretch at 45 A cutting current Good arc stretch at 30 A cutting current Notes Based on the generator rating age and condition adjust the cutting current as needed fault occurs while using a generator turning the power switch quickly to OFF and then to ON again sometimes called a quick reset may not clear the fault Instead turn OFF the power supply and wait 30 to 45 seconds before turning to ON again Prepare the gas supply The gas supply for the Powermax45 can be shop compressed or cylinder compressed A high pressure regulator must be used on either type of supply and must be capable of delivering gas to the filter on the power supply at 360 scfh 9
30. PARTS Pieces Consommables T45v GI 220718 Data plate Plaque signal tique 220674 220713 220671 220670 220669 axe qw 220675 220672 Consumable label Read and these instructions employer safety practices and material safety data sheets Refer to Safety in Welding Cutting and Alied 1 Cutting sparks can cause explosion or fire 1 1 Do not cut near flammables 1 2 Have fro extinguisher nearby and ready to use 1 3 Do not use a drum or other closed container as a cutting table can injure and burn point the Arc starts 2 1 Tum power before disassembling torch 22 Do not grip the workpiece near the cuting path 2 3 Wear complete body protection insulating gloves Replace gloves when wet or 8 2 Protect from shock by insulating yourself from work and ground 2 3 Disconnect power before serving Do not touch parts 4 Plasma fumes can be hazardous 4 1 Do nat inhale fumes 4 2 Use forced ventilation or local exhaust to remove the fumes aa Do not operate in closed spaces Remove fumes with ventiation 5 Arc rays can burn eyes and injure skin 5 1 Wear correct and appropriate protective equipment to protect head eyes ears hands and body Button shirt collar Protect ears from noise Use welding helmet with correct shade of fiter 6 Become trained Oniy qualified personnel should operate this equipment Uso torches specifie
31. a 4 8 Hand torch cutting hints rmt 4 9 Start a cut from the edge of the workpiece sse eene 4 10 Pierce a WOIKDIBCO esee stituit e stai Ere s kaz a R AG AE R Rd R A 4 11 Gouge a E 4 12 Common hand cutti g faults saseta 4 14 How to use the machine Torch esit dene estie AE 4 15 Ensure the torch and table are set up correctly sse 4 15 Understand and optimize cut 4 15 To pierce a workpiece using the machine torch seen 4 17 Common machine cutting taulissa irisaren 4 18 powermax45 Operator Manual 4 1 OPERATION Controls and indicators The Powermax45 has an ON OFF switch an amperage adjustment knob a pressure regulator knob a mode switch 4 indicator LEDs and a gas pressure LED which are described below Front controls and LEDs Pressure regulator knob Gas pressure LEDs Indicator LEDs and pressure bar Amperage Mode switch adjustment knob Temperature LED yellow When illuminated this LED indicates that the power supply s temperature is outside the acceptable range Torch cap sensor LED yellow When illuminated this LED indicates that the consumables are loose improperly installed or missing For information on the possible fault conditions see Basic troubleshooting in Section 5
32. ause a regular wavy pattern on the cut surface Ensure that the torch does not touch the workpiece during cutting Contact with the workpiece can damage the shield and nozzle and affect the cut surface Understand and optimize cut quality There are several factors to consider in cut quality Cut angle The degree of angularity of the cut edge Dross The molten material that solidifies on the top or bottom of the workpiece Straightness of the cut surface The cut surface can be concave or convex The following sections explain how these factors can affect cut quality Cut or bevel angle A positive cut angle or bevel results when more material is removed from the top of the cut than from the bottom A negative cut angle results when more material is removed from the bottom of the cut powermax45 Operator Manual 4 15 OPERATION Problem Cause Solution Negative cut angle The torch is too low Raise the torch or if you are using a torch height control increase the arc Positive cut angle The torch is too high Lower the torch or if you are using gt a torch height control decrease arc voltage Notes The squarest cut angle will be on the right side with respect to the forward motion of the torch The left side will always have some degree of bevel To determine whether a cut angle problem is being caused by the plasma system or the drive system make a test cut and measure the angle of each side Next
33. bility breach of warranty failure of essential purpose or otherwise and even if advised of the possibility of such damages National and local codes National and local codes governing plumbing and electrical installation shall take precedence over any instructions contained in this manual In no event shall Hypertherm be liable for injury to persons or property damage by reason of any code violation or poor work practices Liability cap In no event shall Hypertherm s liability if any whether such liability is based on breach of contract tort strict liability breach of warranties failure of essential purpose or otherwise for any claim action suit or proceeding whether in court arbitration regulatory proceeding or otherwise arising out of or relating to the use of the Products exceed in the aggregate the amount paid for the Products that gave rise to such claim Insurance At all times you will have and maintain insurance in such quantities and types and with coverage sufficient and appropriate to defend and to hold Hypertherm harmless in the event of any cause of action arising from the use of the products Compliance Information Transfer of rights You may transfer any remaining rights you may have hereunder 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 With
34. ch per the manufacturer s instructions and following the instructions below for disassembly if necessary If you need to disassemble the torch follow these steps 1 Disconnect the torch lead from the power supply and remove the consumables from the torch 2 Remove the gear rack from the positioning sleeve by removing the 2 black screws that secure it to the positioning sleeve Remove the 6 screws 3 at each end that secure the positioning Sleeve to the brass strain relief and to the torch body Slide the positioning sleeve off the torch 3 6 powermaX45 Operator Manual TORCH SETUP 3 10 11 12 Disconnect the wires for the cap sensor switch at the connector in the middle Gas supply line connection Screw to connect the Wire connector for power cable to the plunger the cap sensor switch Use a 2 Phillips screwdriver and 1 4 inch nut driver or adjustable wrench to remove the screw and nut that secure the torch s power cable to the plunger Turn the plunger if necessary to gain access to the screw Use 5 16 inch 8 mm and 3 8 inch or adjustable wrenches to loosen the nut that secures the gas supply line to the torch lead Set the torch body aside Note Cover the end of the gas line on the torch lead with tape to keep dirt and other contaminants from getting in the gas line when you route the lead through the track Route the torch lead through the cutting table s track Reattach the torch s pow
35. d in manual Keep non qualified personnel and chidren away 7 Do not remove destroy or cover this label Replace itis missing damaged or wom PN 110673 Rev D CSA safety label powermax45 Operator Manual 110672 Rev B T Les tincelles de coupage peuvent provoquer une explosion ou un incendie 1 1 No coupar pr s des matiros infammablos 1 2 Un extinctour doit tro proximit ot prt utis 1 8 No pas utiliser un f t ou un aura contenant form comme table d Tension dangereuse Risque de choc lectrique ou de br lure gants isolanta Remplacer les gants quand sont humides ou endommag s 2 2 Se prot ger contre les choos on s isolant de la pi ce ot de later 3 3 Couper l alimentation avant entretien Ne pas toucher les par ventilation 5 Les rayons d arc peuvent br ler les yeux et blesser la peau 5 1 Porter un bon quipement de protection pour se prot ger latte les youx los orales los mains ot lo corps Boutonnor Jo co de la chemise Prot ger os contro o bruit Utlisor un masque de soudeur avec un fire de nuance appropride je Suivre une formation Sedi personnel qualifi a le droit do taire fonctionner cet quipement Utliser exclusivement les torches indiqu es dans lo manual Le personnel non qualifi et les enfants doivent so tenir l cart 7 Ne pas enlever d truire ni couvrir cette tiquette La remplacer si l est absente endommag e o
36. e Notice that the retaining cap swirl ring and electrode are the same for shielded unshielded and gouging applications Only the shield deflector for unshielded consumables and the nozzle are different For the best cut quality on thin stainless steel you may prefer to reduce the amperage setting to 30 amps and use the T30v Powermax30 30 A consumables available from Hypertherm powermax45 Operator Manual 3 3 SETUP T45v shielded consumables m 0 cD mel 2 T45v gouging consumables 220675 220713 220672 220670 220669 Shield Retaining cap Nozzle Swirl ring Electrode T45v unshielded consumables C 220717 220713 220718 220670 220669 Deflector Retaining cap Nozzle Swirl ring Electrode Unshielded consumables are not available for use in CE regulated countries T30v Powermax30 30 A consumables dr O 220569 220483 220480 220479 220478 Optional Retaining cap Nozzle Swirl ring Electrode deflector 3 4 powermaX45 Operator Manual SETUP Install the consumables WARNING INSTANT ON TORCHES PLASMA CAN CAUSE INJURY AND BURNS The plasma arc comes on immediately when the torch is activated Make sure the power is OFF before changing the consumables To operate the T45v torch it must have a complete set of consumable parts installed a shield or deflector retaining cap nozzle swirl ring and electrode With
37. e high speed dross Decrease the cutting speed Decrease the torch to work distance Notes Dross is more likely to form on warm or hot metal than on cool metal For example the first cut in a series of cuts usually produces the least dross As the workpiece heats up more dross may form on subsequent cuts Dross is more likely to form on mild steel than on stainless steel or aluminum Worn or damaged consumables may produce intermittent dross Straightness of the cut surface A typical plasma cut surface is slightly concave The cut surface may become more concave or convex Correct torch height is required to keep the cut surface acceptably close to straight Worn consumables also affect the straightness of the cut A strongly concave cut surface occurs when the torch to work distance is too low Increase the torch to work distance to straighten the cut surface A convex cut surface occurs when the torch to work distance is too great or the cutting current is too high First try lowering the torch then reduce the cutting current To pierce a workpiece using the machine torch As with the hand torch you can start a cut with the machine torch at the edge of the workpiece or by piercing the workpiece Piercing will result in a shorter consumable life than with edge starts The cut charts include a column for the recommended torch height when starting a pierce For the Powermax45 the pierce height is generally 2 5 times the cut
38. e just finger tight The torch does not cut completely through the workpiece The causes can be The cut speed is too fast The consumables are worn The metal being cut is too thick Gouging consumables are installed instead of cutting consumables The work clamp is not attached properly to the workpiece The gas pressure or gas flow rate is too low Cut quality is poor The causes can be The metal being cut is too thick The wrong consumables are being used gouging consumables are installed instead of cutting consumables for example You are moving the torch too quickly or too slowly The arc sputters and consumables life is shorter than expected The cause can be Moisture in the gas supply The gas pressure is too low 4 14 powermax45 Operator Manual OPERATION How to use the machine torch Since the Powermax45 and the T45m can be used with a wide variety of cutting tables track burners pipe bevelers and so on you will need to refer to the manufacturer s instructions for specifics on operating the machine torch in your configuration However the information in the following sections will help you optimize cut quality and maximize consumable life Ensure the torch and table are set up correctly Use a square to align the torch at right angles to the workpiece The torch may travel more smoothly if you clean check and tune the cutting table s rails and drive system Unsteady machine motion can c
39. ecommended Maximum Arc Material Torch Pierce to work Initial pierce Voltage current thickness time delay amps in T height Sec 0 036 20 0 060 16 0 075 14 0 105 12 0 135 10 107 104 500 104 103 101 Maximum cut speed is limited by the test table s maximum speed 400 ipm or 10160 mm min powermaX45 Operator Manual 3 25 TORCH SETUP Align the torch Mount the machine torch perpendicular to the workpiece in order to get a vertical cut Use a square to align the torch at 0 and 90 Connect the remote start pendant Configurations of a Powermax45 with a T45m also can include a 25 foot 7 62 m 50 foot 15 24 m or 75 foot 22 86 m remote start pendant To use the Hypertherm remote start pendant plug it into the receptacle on the rear of the power supply Note The remote start pendant is for use only with a machine torch It will not operate if a handheld torch is installed Receptacle for the remote start pendant or a machine interface cable 3 26 powermaX45 Operator Manual TORCH SETUP Connect a machine interface cable The Powermax45 is equipped with a factory installed voltage divider that is designed to be safely connected without tools The built in voltage divider provides a 50 1 arc voltage A receptacle on the rear of the po
40. ection 3 for AR AOA AON 400 VAC 10 400 V more information Gas type Air Nitrogen Clean dry oil free per 0 ISO 8573 1 Class 1 2 2 99 995 pure Gas quality Recommended gas inlet flow and pressure 360 scfh 90 psi 170 l min 6 2 bar Equipment complies with IEC 61000 3 12 Equipment complies with IEC 61000 3 12 provided that the short circuit power S is greater than or equal to 692 KVA at the interface point between the user s supply and the public system It is the responsibility of the installer or user of the equipment to ensure by consultation with the distribution network operator if necessary that the equipment is connected only to a supply with a short circuit power greater than or equal to 692 KVA 1 4 powermax4s Operator Manual SPECIFICATIONS T45v torch dimensions 4 8 72 in 22 1 cm 8 5 in 21 6 cm T45m torch dimensions 14 36 in 36 5 cm iin 12 in 1 43 in 3 6 cm outer 2 5 cm a di WET 30 5 cm imension 1 3 in 3 3 cm flat sides 13 in 33 0 cm powermax45 Operator Manual 1 5 SPECIFICATIONS T45v and T45m torch specifications Handheld cut capacity material thickness Recommended cut capacity hand cutting 1 2 in 12 7 mm Maximum cut capacity hand cutting or mechanized edge start 3 4 19 1 mm Severance capacity
41. ents Verify the items in the box against the illustration Operator Manual Quick Setup Card Registration Card Setup DVD Box with extra consumables Remote start pendant optional Shoulder strap ET u 2 2 powermaX45 Operator Manual POWER SUPPLY SETUP Position the power supply Locate the Powermax45 near an appropriate 200 240 volt power receptacle for CSA or CE 1 phase power supplies or a 400 volt receptacle for 3 phase CE power supplies The Powermax45 has a 10 foot 3 m power cord Allow at least 10 inches 0 25 m of space around the power supply for proper ventilation Prepare the electrical power The maximum output voltage will vary based on your input voltage and the circuit s amperage Because the current draw varies during startup slow blow fuses are recommended as shown in the chart below Slow blow fuses can withstand currents up to 10 times the rated value for short periods of time Voltage configurations The following chart shows the maximum rated output for typical combinations of input voltage and amperage Acceptable input voltages can be 10 of the values given below Caution Protect the circuit with appropriately sized time delay slow blow fuses and a line disconnect switch Input input Recommended current Input voltage Phase Rated output current at slow blow fuse during arc 6 kw output stretch size 200 240 VAC 45 A 132 V 34 28 5
42. er Gas supply Powermax45 The filtering system should be installed between the quick disconnect coupler and the power supply 2 8 powermaX45 Operator Manual this section Introductionis uci cercare A Consumable life ets Hand torch inc nim iiem Choose the consumables Install the consumables Machine torch setup Mount the torch Choose the consumables cut charts Align the torch Connect the remote start pendant Connect a machine interface cable Connect the torch lead powermax45 Operator Manual Section 3 Torch setup 3 1 TORCH SETUP Introduction Both T45v handheld torch and the T45m machine torch are available for the Powermax45 The torch quick disconnect makes it easy to remove the torch for transport or to switch from one torch to the other if your applications require the use of both torches This section explains how to set up your torch and choose the appropriate consumables for the job Consumable life How often you will need to change the consumables on your Powermax45 will depend on a number of factors The thickness of the metal being cut The length of the average cut Whether you are doing machine or hand cutting The air quality presence of oil moisture or other contaminants Whether you are piercing the metal or starting cuts from the edge Proper torch to work distance when gouging or cutting with unshielded consumables Proper pierce height Which con
43. er cable to the torch plunger using the screw and nut Rotate the plunger so that the screw does not interfere with the cap sensor switch Reconnect the gas line to the torch lead Press the two halves of the cap sensor switch s wire connector together Slide the positioning sleeve over the torch body and check the alignment of the screw holes Replace the three screws at each end If you will be using the gear rack re attach it with the 2 black screws you removed earlier Attach the torch to the lifter per the manufacturer s instructions powermax45 Operator Manual 3 7 TORCH SETUP Choose the consumables cut charts WARNING INSTANT ON TORCHES PLASMA CAN CAUSE INJURY AND BURNS The plasma arc comes on immediately when the torch is activated Make sure the power is OFF before changing the consumables A complete set of shielded consumables is shipped with the T45m machine torch In addition an ohmic sensing retaining cap is available for use with the T45m shielded consumables Unshielded consumables and the T30v Powermax30 30 A consumables are also available for use with the T45m How to use the cut charts The following sections provide illustrations of the consumable sets and cut charts for each set Maximum cut speeds are the fastest speeds possible to cut material without regard to cut quality Recommended cut speeds are a good starting point for finding the best quality cut best angle least dross and b
44. erations 2 ai veut Pon ra n 2 5 Extension cord recommendations zywa zyk Z et ad 2 5 Generator recommendation sei ain was 2 7 Prepare the SUPP asza Rn 2 7 Connect the gas supply 2 8 Additional gasilifaUOM 2 8 powermax45 Operator Manual 2 1 POWER SUPPLY SETUP Unpack the Powermax45 1 Verify that all items on your order have been received in good condition Contact your distributor if any parts are damaged or missing 2 Inspect the power supply for damage that may have occurred during shipping If there is evidence of damage refer to Claims below All communications regarding this equipment must include the model number and the serial number located on the bottom of the power supply 3 Before you set up and operate this Hypertherm system read the Safety and Compliance Manual Claims Claims for damage during shipment If your unit was damaged during shipment you must file a claim with the carrier Hypertherm will furnish you with a copy of the bill of lading 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 Cont
45. est cut surface finish You will need to adjust the speeds for your application and your table to obtain the desired cut quality T45m shielded consumables 4 C1 220673 220713 220671 220670 220669 Shield Retaining cap Nozzle Swirl ring Electrode or 220719 Ohmic sensing retaining cap The cut charts for these consumables are shown on the next pages 3 8 powermaX45 Operator Manual TORCH SETUP T45m shielded consumables Air flowrate Ipm Mild steel Metric Recommended Maximum Arc Material 9 Pierce Cut Cut current thickness 9 Work Initial pierce ne delay Speed Speed amps mm m height sec mm min mm min 0 5 9150 10160 0 8 8650 10160 250 0 9 8100 10160 1 5 5650 7100 10160 10160 9144 6096 4445 2794 1905 1016 635 356 Edge start recommended 254 127 Maximum cut speed is limited by the test table s maximum speed 10160 mm min powermaX45 Operator Manual 3 9 TORCH SETUP T45m shielded consumables Air flowrate scfh Mild Steel Hot 320 English Cold 360 Arc Torch Pierce time curant Material Initial pierce Voltage Voltage delay amps thickness distance height sec V V 0 018 in 26 Ga 0 030 in 22 Ga 0 036 in 20 Ga 0 060 in 16 Ga 0 036 in 20 Ga 0 060 in
46. f the power supply is turned on while the torch trigger is pressed the system will be disabled Release the trigger and restart the power supply Inlet gas supply pressure is lower than the minimum acceptable level The LED continues to blink for 10 seconds after the gas pressure is restored to the acceptable range Clean the area where the work clamp contacts the workpiece to ensure a good metal to metal connection Inspect the work clamp for damage and repair it if necessary The torch to work distance may be too large Move the torch closer to the workpiece and fire the torch again See Section 4 Operation Inspect the consumable parts and replace them if they are worn or damaged See nspect the consumables in this section Replace the gas filter element if it is contaminated See Replace the gas filter element in this section powermax45 Operator Manual MAINTENANCE AND REPAIR The arc sputters and hisses The cut quality is poor powermax45 Operator Manual The gas filter element is contaminated Replace the element See Replace the gas filter element in this section Inspect the gas line for moisture If necessary install or repair the gas filtration to the power supply See Prepare the gas supply in Section 2 Verify that the torch is being used correctly See Section 4 Operation Inspect the consumables for wear and replace as necessary See nspect the consumables in this
47. ge The power ON LED is illuminated and Turn the amperage knob to the gas test position the gas pressure LED is illuminated then unlock the pressure regulator by pulling up on yellow and is above or below the center the knob Turn it to adjust the pressure then push of the pressure bar it down to lock it Verify that the gas supply line is connected to the power supply and the gas is turned on Inspect the gas supply line for leaks and verify the incoming gas pressure The power ON LED is blinking The input line voltage is either too high or too low a variance greater than 15 of the rated voltage Have an electrical technician check the incoming power See Section 1 Specifications and Prepare the electrical power in Section 2 for more information 5 4 powermax45 Operator Manual MAINTENANCE AND REPAIR Poem Soto The power ON LED is illuminated and the yellow temperature LED is illuminated The power ON LED is illuminated and the torch cap LED is illuminated The power ON LED is illuminated and the torch cap LED blinks xk The fault LED blinks PSN powermax45 Operator Manual 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 the temperature LED may illuminate Move the power supply to a warmer location Turn OFF the power supply Verify that there are consumables installed See nstall the co
48. hand cutting or mechanized edge start 1 in 25 4 mm Mechanized pierce capacity material thickness Pierce capacity for edge starts the capacities are the same as the handheld capacities 3 8 in 9 5 mm Recommended cut speed on mild steel 1 4 in 6 35 mm 60 ipm 1524 mm min 3 8 in 9 53 mm 1 2 12 mm 32 ipm 813 mm min 20 ipm 508 mm min 3 4 in 18 mm 8 ipm 203 mm min 1 in 24 mm 4 ipm 102 mm min Gouging capacity Metal removal rate on mild steel 6 2 Ibs hr 2 8 kg hr Weight torch only 0 6 Ibs 0 27 kg T45v with 20 ft 6 1 m lead 3 4 Ibs 1 55 kg T45v with 50 ft 15 24 m lead 7 8 lbs 3 54 kg T45m torch only 1 0 Ibs 0 45 kg T45m with 25 ft 7 62 m lead 5 0 Ibs 2 27 kg T45m with 35 ft 10 7 lead 6 4 Ibs 2 9 kg T45m with 50 ft 15 24 lead 8 5 Ibs 3 85 kg 1 6 powermax45 Operator Manual SPECIFICATIONS Symbols and markings Your Hypertherm product may have one or more of the following markings on or near the data plate Due to differences and conflicts in national regulations not all marks are applied to every version of a product 5 8 us ce mark symbol The mark symbol indicates that the power supply and torch are suitable for operations carried out in environments with increased hazard of electrical shock per IEC 60974 1 CSA mark Hypert
49. he nut that holds the filter in the bracket Tip the bottom of the filter away from the power supply 6 Unscrew the filter bowl from the body and remove it Gas supply hose Nut Bracket Filter bowl Drain hose 7 Unscrew the element from the filter body while being careful not to allow the element to rotate 8 Screw the new element to the filter body powermax45 Operator Manual 5 11 MAINTENANCE AND REPAIR 9 Reattach the filter bowl 10 Reposition the filter assembly in the bracket and replace its retainer nut 11 Reconnect the gas supply hose and press the drain hose onto the drain in the bottom of the power supply 12 Reconnect the gas supply and check for leaks 13 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 14 Reconnect the electrical power and the gas supply 5 12 powermax45 Operator Manual Section 6 PARTS In this section Power supply 6 2 T45v hand torch 6 5 T45v hand torch consumables 6 6 T30v Powermax30 30 A consumables 6 6 T45mimachirie torch parts eor ae ee rb AAAA 6 7 T45m machine torch consumables eese enne rnt aaa az tnter ttn rinse tata satanas 6 8
50. herm products with a CSA mark meet the United States and Canadian regulations for product safety The products were evaluated tested and certified by CSA International Alternatively the product may have a mark by one of the other Nationally Recognized Testing Laboratories NRTL accredited in both the United States and Canada such as Underwriters Laboratories Incorporated UL or T V 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 filters needed to comply with the European EMC Directive are incorporated within versions of the product with a CE marking GOST R mark CE versions of Hypertherm products that include a GOST R mark of conformity meet the product safety and EMC requirements for export to the Russian Federation c Tick mark CE versions of Hypertherm products with a c Tick mark comply with the EMC regulations required for sale in Australia and New Zealand CCC mark The China Compulsory Certification CCC mark indicates that the product has been tested and found compliant with product safety regulations required for sale in China powermax45 Operator Manual 1 7 SPECIFICATIONS IEC symbols The following symbol
51. iate for your application If you are using T30v Powermax30 30 A consumables do not set the amperage knob above 30 A Check the indicator LEDs Verify that the green power ON LED on the front of the power supply is illuminated that the gas pressure LED shows a green bar in the center of the gauge and that none of the other LEDs are illuminated or blinking If the temperature torch cap sensor or fault LEDs are illuminated or blinking or if the power ON LED blinks correct the fault condition before continuing See Basic troubleshooting in Section 5 for more information OX 4 6 powermaX45 Operator Manual OPERATION Attach the work clamp The work clamp must be attached to the workpiece while you are cutting Note If you are using the Powermax45 with a cutting table you can ground it through the table instead of using the work clamp See your table manufacturer s instructions for more information Ensure that the work clamp and the workpiece make good metal to metal contact For the best cut quality attach the work clamp as close as possible to the area being cut Do not attach the work clamp to the portion of the workpiece to be cut away Work clamp When the power ON LED is illuminated none of the other LEDs are illuminated or blinking the gas pressure LED indicates pressure is in the correct range the amperage knob is set and the work clamp is attached then the system is ready for use Understand du
52. icular 90 to the edge of the workpiece If you are using the shielded consumables no torch to workpiece standoff is needed With unshielded consumables maintain an approximate 08 inch 2 mm standoff 2 Press the torch s 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 Maintain a steady even pace powermax45 Operator Manual OPERATION Pierce a workpiece SPARKS 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 Point the torch away from yourself and others 1 With the work clamp attached to the workpiece hold the torch at an approximate 30 angle to the workpiece with the nozzle within 1 16 inch 1 5 mm of it before firing the torch N Fire the torch while still at an angle to the workpiece then slowly rotate the torch to a perpendicular 90 position 3 Hold the torch in place while continuing to press the trigger When sparks exit below 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 powermax45 Operator Manual 4 11 OPERATION Gouge a workpiece SPARKS AND HOT METAL CAN INJURE EYES AND BURN SKIN When firing the torch at an angle sparks and hot metal will
53. in 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 as set forth herein the Warranty set forth herein shall be null and void and you will have no further recourse against Hypertherm under the Warranty or otherwise Compliance Information WARRANTY W 3 9 10 Safety information Before operating any Hypertherm equipment read the separate Safety and Compliance Manual 806690 included with your product for important safety information TABLE OF CONTENTS Electromagnetic compatibility 2 iter teet trc tete EEE EMC 1 W 1 Section 1 SPECIFICATIONS System JeSCIPUONA Lm 1 2 Where to find Inferis 1 2 Power supply dimensions and weights sss 1 3 DIMENSIONS EP 1 8 lcum 1 8 Power SUPPLY roc 1 4 GIMEMSIOMS er 1 5 TAM torch dIME SIO S sda yz 1 5 T45v and T45m torch Specifications iaaiiai n aeara ariaa aiai ariii a ania 1 6 Symbols arid Marking Siaina ionnann 1 7 W WER DATA AE aa aadA aE 1 8 Section2 POWER SUPPLY SETUP Unpack the 5 2 2 2 2
54. is set too low See the cut charts in Section 3 for more information The consumables are worn and need to be replaced The cut angle is not square Causes can be The direction of the torch travel is incorrect The high quality cut is always on the right with respect to the forward motion of the torch The distance between the torch and the workpiece is not correct The cutting speed is not correct See the cut charts in Section 3 for more information The consumables are worn and need to be replaced 4 18 powermax45 Operator Manual OPERATION The consumables life is shortened Causes can be The arc current arc voltage travel speed and other variables are not set as specified in the cut charts Firing the arc in the air beginning or ending the cut off of the plate surface Starting at the edge is acceptable as long as the arc makes contact with the workpiece when started Starting a pierce with an incorrect torch height For the Powermax45 the pierce height is generally 2 5 times the cutting height Refer to the cut charts for specifics powermaX45 Operator Manual 4 19 OPERATION 4 20 powermaX45 Operator Manual Section 5 MAINTENANCE AND REPAIR this section Perform routine maintenance eese eene zaa a O 5 2 Inspect the consumables iiti aceti a tnt deat ra rne sb rte m dea ania Dates 5 3 1029115150119 5 4
55. it may be necessary to use other measures to further reduce interference This cutting equipment is designed for use only in an industrial environment Installation and use The user is responsible for installing and using the plasma equipment according to the manufacturer s instructions If electromagnetic disturbances are detected then it shall be the responsibility of the user to resolve the situation with the technical assistance of the manufacturer some cases this remedial action may be as simple as earthing the cutting circuit see Earthing of Workpiece In other cases it could involve constructing an electromagnetic screen enclosing the power source and the work complete with associated input filters In all cases electromagnetic disturbances must be reduced to the point where they are no longer troublesome Assessment of area Before installing the equipment the user shall make an assessment of potential Compliance Information electromagnetic problems 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 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 pacemakers and hearing aids f
56. m 254 mm min 0 1863 in 4 73 mm 0 3173 in 8 06 mm 0 0517 in 1 31 mm 0 0406 in 1 03 mm 0 1645 in 4 18 mm 20 ipm 508 mm min 0 2423 in 6 15 mm 0 0941 in 2 39 mm 30 ipm 762 mm min 0 2351 in 6 00 mm 0 0546 in 1 39 mm 40 ipm 1016 mm min 0 2281 in 5 80 mm 0 0476 in 1 21 mm 50 ipm 1270 mm min Stainless steel gouging profile Torch angle Speed 0 1816 in 4 61 mm Width 0 0289 in 0 73 mm Depth 10 ipm 254 mm min 0 2508 in 6 37 mm 0 1200 in 3 05 mm 20 ipm 508 mm min 30 ipm 762 mm min 0 2258 in 5 74 mm 0 2077 in 5 28 mm 0 0772 in 1 96 mm 0 0428 in 1 09 mm 40 ipm 1016 mm min 0 1901 in 4 83 mm 0 0680 in 1 73 mm 50 ipm 1270 mm min 10 ipm 254 mm min 0 1739 in 4 42 mm 0 2580 in 6 55 mm 0 0580 in 1 47 mm 0 2330 in 5 92 mm 20 ipm 508 mm min 0 2526 in 6 42 mm 0 0792 in 2 01 mm 30 ipm 762 mm min 0 2329 in 5 92 mm 0 0569 in 1 45 mm 40 ipm 1016 mm min 0 2110 in 5 36 mm 0 0432 in 1 10 mm 50 ipm 1270 mm min powermax45 Operator Manual 0 2003 in 5 09 mm 0 0322 in 0 82 mm 4 13 OPERATION Common hand cutting faults The torch sputters and hisses but does not produce an arc The cause can be The consumables are too tight Loosen the consumables about 1 8th of a turn and try again The consumables should b
57. nd moisture from damaging the receptacle when not in use This cover should be replaced if damaged or lost number 127204 See Section 6 Parts for more information powermaX45 Operator Manual 3 27 TORCH SETUP Installation of the machine interface cable must be performed by a qualified service technician To install a machine interface cable 1 Turn OFF the power and disconnect the power cord 2 Remove the machine interface receptacle s cover from the rear of the power supply 3 Connect the Hypertherm machine interface cable to the power supply 4 If you are using a cable with a D sub connector the other end plug it into the appropriate pin connector on the torch height controller or Secure it with the screws on the D sub connector If you are using a cable with wires and spade connectors on the other end terminate the machine interface cable inside the electrical enclosure of listed and certified torch height controllers or CNC controllers to prevent operator access to the connections after installation Verify that the connections are correct and that all live parts are enclosed and protected before operating the equipment Note The integration of Hypertherm equipment and customer supplied equipment including interconnecting cords and cables if not listed and certified as a system is subject to inspection by local authorities at the final installation site The connector sockets for each type of signal a
58. nsumables in Section 3 If you have just installed the consumables verify that the consumables are only finger tight Loosen them 1 8th of a turn and then restart the power supply If the consumables appear to be installed correctly the torch may be damaged Contact your Hypertherm distributor or authorized repair facility This indicates either a torch stuck open or a torch Stuck closed situation If the consumables became loose or were removed while the power supply is ON turn OFF the power supply correct the problem and then turn ON the power supply to clear this fault See nstall the consumables in Section 3 If the consumables appear to be installed correctly the torch may be damaged Contact your Hypertherm distributor or authorized repair facility A blinking fault LED indicates a major fault with the system A qualified service technician must service the system Contact your distributor or authorized repair facility 5 5 MAINTENANCE AND REPAIR The gas pressure LED and the temperature LED alternately blink when the system is turned on The gas pressure bar s LED illuminates yellow at the bottom of the gauge and blinks The arc does not transfer to the workpiece The arc blows out but re ignites when the torch trigger is pressed again This situation indicates that the power supply is receiving a start signal It is sometimes referred to as a stuck start I
59. on about the controls and LEDs steps for system operation and hints for improving cut quality see Section 4 Operation Routine maintenance and repair see Section 5 Maintenance and repair Part numbers and ordering information for accessories consumables and replacement parts see Section 6 Parts 1 2 powermax4s Operator Manual SPECIFICATIONS Power supply dimensions and weights Dimensions 42 6 cm Weights Power supply weights given below include the hand torch with 20 ft 6 1 m lead a 20 ft 6 1 m work lead and a 10 ft 3 m power cord CSA power supply 37 lbs 16 8 kg CE 230 power supply 36 5 Ibs 16 6 kg 400 V power supply 35 Ibs 15 9 kg powermax45 Operator Manual 1 3 SPECIFICATIONS Power supply ratings Rated open circuit voltage Ug CSA CE single phase CE 3 phase BRD Rated output current lo 20 45 Rated output voltage Us 132 VDC Duty cycle at 40 C 50 96 15245 A Us 132 V See data plate on power supply for 60 96 1 41 A Us 132 V more information on duty cycle 100 1 232 A Us 132 V Operating temperature 14 to 104 F 10 to 40 C Storage temperature 13 to 131 F 25 to 55 C Power factor 200 240 V 230 V CE 1 phase 0 99 400 V 3 phase CE 0 94 Input voltage U Input current l4 at 200 240 VAC 34 28 A CSA rated output lo See Voltage configurations S
60. operation The cutting equipment should not be modified in any way except as set forth in and in accordance with the manufacturer s written instructions For example the spark gaps of arc striking and stabilizing devices should be adjusted and maintained according to the manufacturer s recommendations Cutting cables The cutting cables should be kept as short as possible and should be positioned close together running at or close to the floor level Equipotential bonding Bonding of all metallic components in the cutting installation and adjacent to it should be considered However metallic components bonded to the workpiece will increase the risk that the operator could receive a shock by touching these metallic components and the electrode nozzle for laser heads at the same time The operator should be insulated from all such bonded metallic components EMC 2 9 10 Earthing of workpiece Where the workpiece is not bonded to earth for electrical safety nor connected to earth because of its size and position for ex ample 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 necessary the connection of the workpiece to earth should be made by a direct connection to the workpiece but in some count
61. ounded 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 and must comply with national and local requirements Do not use a 2 wire service Three phase service CE only must be of the 4 wire type with a green or green yellow wire for the protective earth ground and must comply with national and local requirements Refer to Grounding safety in the Safety and Compliance Manual for more information 2 4 powermaX45 Operator Manual POWER SUPPLY SETUP Power cord considerations Powermax45 power supplies are shipped with CSA and CE power cord configurations The power cords on the CSA power supplies are shipped with a 50 A 250 V plug NEMA 6 50P on the power cord The CE power supplies are shipped without a plug on the power cord Obtain the correct plug for your unit either 230 V or 400 V and location have it installed by a licensed electrician Extension cord recommendations Any extension cord must have an appropriate wire size for the cord length and system voltage Use a cord that meets national and local codes The tables on the next page provides the recommended gauge size for various lengths and input voltages The lengths in the tables are the length of the extension cord only they do not include the power supply s power cord powermax45 Operator Manual 2 5 POWER SUPPLY SETUP
62. properly is invoked and applies Hypertherm at its sole option shall repair replace or adjust free of charge any defective Products covered by this warranty which shall be returned with Hypertherm s prior authorization which shall not be unreasonably withheld properly packed to Hypertherm s place of business in Hanover New Hampshire or to an authorized Hypertherm repair facility all costs insurance and freight pre paid by the customer Hypertherm shall 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 implied warranties or conditions of quality or of merchantability or fitness for a particular purpose or against infringement The foregoing shall constitute the sole and exclusive remedy for any breach by Hypertherm of its warranty W 1 9 10 WARRANTY Distributors OEMs may offer different or additional warranties but Distributors OEMs are not authorized to give any additional warranty protection to you or make any representation to you purporting to be binding upon Hypertherm Distributors OEMs may offer different or additional warranties but Distributors OEMs are not a
63. ries where direct connection is not permitted the bonding should be achieved by suitable capacitances selected according to national regulations Note the cutting circuit may or may not be earthed for safety reasons Changing the earthing arrangements should only be authorized by a person who is competent to assess whether the changes will increase the 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 entire plasma cutting installation may be considered for special applications Compliance Information Attention Genuine Hypertherm parts are the factory recommended replacement parts for your Hypertherm system Any damage or injury caused by the use of other than genuine Hypertherm parts may not be covered by the Hypertherm warranty and will constitute misuse of the Hypertherm Product You are solely responsible for the safe use of the Product Hypertherm does not and cannot make any guarantee or warranty regarding the safe use of the product in your environment General Hypertherm Inc warrants that its Products shall be free from defects in materials and workmanship for
64. rt plasma arc transfer 50 1 voltage divider and ground 25 ft 7 62 m spade connectors 123967 Powermax45 machine interface cable start plasma arc transfer 50 1 voltage divider and ground 50 ft 15 24 m spade connectors 123896 Machine interface cable start plasma arc transfer 5 1 voltage divider and ground 50 ft 15 24 m D sub connector with screws powermaX45 Operator Manual 6 3 PARTS Filter and regulator Fan subassembly Air filter element inside filter bowl Part number Description 228286 Kit Fan subassembly 228287 Kit Filter and regulator 228302 Kit Air filter element 6 4 powermaX45 Operator Manual PARTS T45v hand torch parts Torch handle So Handle 2 screws Safety trigger and spring The entire hand torch and lead assembly can be replaced or individual component parts can be replaced Part numbers starting with 088 indicate complete torch and lead assemblies Part number Description 088008 T45v hand torch assembly with 20 ft 6 1 m lead 088009 T45v hand torch assembly with 50 ft 15 24 m lead 228313 Kit Handle 075714 Screws 4 x 1 2 SLTD Torx PAN S B 002294 Safety trigger and spring replacement 228346 Kit Torch head replacement 058503 O ring Viton 0 626 x 0 070 228109 Kit Cap sensor switch replacement 228315 Kit Torch lead replacement 20 ft 6 1 m 228316 Kit Torch lead replacement 50 ft 15 24 m The torch assembly also includes one se
65. s may appear on the power supply data plate control labels switches and LEDs Direct current DC Alternating current AC Plasma torch cutting Plate metal cutting Expanded metal cutting Gouging AC input power connection The terminal for the external protective earth conductor Gas test mode OAE Os Power is ON Power is OFF An inverter based power source either 1 phase or 3 phase Volt amp curve drooping characteristic Power is ON LED System fault LED Inlet gas pressure LED Missing or loose consumables LED Power supply is out of temperature range LED 1 8 powermax45 Operator Manual Section 2 POWER SUPPLY SETUP In this section Unpack the 45 2 2 CIAIMS 2 2 USO 2 2 Position the power z 2n ene eile rn d i Cn inet te n tt ee hain 2 3 1 V 2 3 Voltage configurations ttt t trinm 2 3 Install a line disconnect switch aa a r 2 4 Requirements Tor grounding te 2 4 Power cord corisid
66. section 5 7 MAINTENANCE AND REPAIR Repairs DANGER ELECTRIC SHOCK CAN KILL Disconnect electrical power before performing any maintenance work requiring removal of the power supply cover must be performed by a qualified technician Remove and replace the cover and Mylar barrier The first step in most maintenance and repair procedures for the Powermax45 is removing the cover and the Mylar barrier To protect your power supply it is important to replace both items properly when the maintenance is complete Removal 1 Turn OFF the power disconnect the power cord and disconnect the gas supply 2 Use a 2 Phillips screwdriver to remove the 2 screws from the handle on the top of the power supply Gently pull on the end panel nearest the screw you are removing to keep pressure on the screw When the screw is almost out tilt the screwdriver slightly to help pull the screw out of the recessed hole 3 Tip the end panels back slightly so that you can get the edges of the handle out from underneath them Set the handle and screws aside Continue to tilt the end panels outward to release the fan side of the cover from its track Then lift the cover off the power supply 4 Remove the Mylar barrier from the power board side of the power supply 5 8 powermax45 Operator Manual MAINTENANCE AND REPAIR Replacement 1 Hold the Mylar barrier so that the edge with the 3 notches
67. sumables you are using The T30v Powermax30 30 A consumables will have a shorter life when used on the T45v However they provide optimum cut quality for certain applications Under normal conditions the electrode will wear out first during machine cutting and the nozzle will wear out first when hand cutting A general rule is that a set of consumables lasts approximately 1 to 2 hours of actual arc on time for hand cutting depending on these factors For mechanized cutting consumables should last about 3 to 5 hours You will find more information about proper cutting techniques in Section 4 Operation 3 2 powermax45 Operator Manual TORCH SETUP Hand torch setup Choose the consumables The Powermax45 with the T45v handheld torch comes with a full set of consumables for cutting installed on the torch spare electrodes and nozzles in the consumables box and consumables for gouging in the consumables box In non CE regulated countries you can also purchase unshielded consumables that are useful for certain applications With shielded consumables you drag the torch tip along the metal to cut With unshielded consumables you must keep the torch a small distance about 08 inch 2 mm away from the metal Unshielded consumables generally have a shorter life than shielded consumables however you may find that visibility and accessibility are better for some applications Consumables for hand cutting are shown on the next pag
68. t of the consumables listed on the next page powermaX45 Operator Manual 6 5 PARTS T45v hand torch consumables Part number Description Shielded 220669 Electrode 220670 Swirl ring 220713 Retaining cap 220671 Nozzle 220674 Shield Gouging 220675 Shield 220672 Nozzle Unshielded 220717 Deflector 220718 Nozzle The swirl ring retaining cap and electrode for these applications are the same as those for the shielded application Unshielded consumables for the hand torch are not available in CE regulated countries T30v Powermax30 30 A consumables Part number Description 220569 Deflector 220483 Retaining cap 220480 Nozzle 220479 Swirl ring 220478 Electrode 6 6 powermaX45 Operator Manual PARTS T45m machine torch parts Positioning sleeve Torch lead Front mounting ring Rear mounting ring Cap sensor switch Torch head The entire machine torch and lead assembly can be replaced or individual component parts can be replaced Part numbers starting with 088 indicate complete torch and lead assemblies Part number Description 088010 T45m machine torch assembly with 25 ft 7 6 m lead 088011 T45m machine torch assembly with 35 ft 10 67 m lead 088012 T45m machine torch assembly with 50 ft 15 24 m lead 228228 Kit T45m positioning sleeve 228229 Kit T45m removable gear rack 228322 Kit Front mounting ring 228323 Kit Rear mounting ring 228320 Kit T45m torch head replacement 228321 Kit T
69. tem includes a complete set of the consumables needed for cutting shield retaining cap swirl ring nozzle electrode 2 spare electrodes 2 spare nozzles gouging consumables handheld configurations only a quick disconnect air fitting 1 4 on CSA units and 1 4 NPT x G 1 4 BSPP on CE units a consumables box a shoulder strap an Operator Manual a Quick Setup Card and a Setup DVD Mechanized configurations include a remote start pendant as well You can order additional consumables and accessories such as the plasma cutting guide from any Hypertherm distributor See Section 6 Parts for a list of spare and optional parts The power cords on the CSA power supplies are shipped with a 50 A 250 V plug NEMA 6 50P on the power cord The CE units are shipped without a plug on the power cord See Prepare the electrical power in Section 2 for more information Where to find information System specifications such as size weight detailed electrical specifications and cut speeds can be found in this section For information on Safety information see the Safety and Compliance Manual for detailed safety information Setup requirements including power requirements grounding power cord configurations extension cord requirements and generator recommendations see Section 2 Power supply setup Handheld and machine torch consumables cut charts and torch setup information see Section 3 Torch setup Informati
70. the gas holes for blockages The surface for damage wear or a lack of lubrication Replace the shield if the hole is no longer round Remove the shield and clean any material away Replace if the center hole is not round Replace the nozzle and the electrode together Replace if the surface is worn or the pit depth is greater than 1 16 inch 1 6 mm deep Replace the nozzle and the electrode together Replace if the surface is damaged or worn or any of the gas holes are blocked If the o ring is dry lubricate it and the threads with a thin layer of silicone lubricant If the o ring is cracked or worn replace it 5 3 MAINTENANCE AND REPAIR Basic troubleshooting The following table provides an overview of the most common problems that may arise when using the Powermax45 and explains how to solve them If you are unable to fix the problem by following this basic troubleshooting guide or if you need further assistance 1 Call your Hypertherm distributor or authorized Hypertherm repair facility 2 Call the nearest Hypertherm office listed in the front of this manual Sem _ The ON OFF power switch is set to Verify that the power cord is plugged into the ON but the power ON LED is not receptacle Verify that the power is ON at the power panel or at the line disconnect switch box Verify that the line voltage is not too low more than 15 below the rated volta
71. the power switch in the OFF O position verify that the torch consumables are installed as shown Electrode gt a Swirl ring Nozzle Retaining gt Shield or deflector There should be a small gt between the consumables and the torch handle Air will blow out from this gap during normal operation Note Tighten only to finger tight Overtightening will cause the torch to misfire powermax45 Operator Manual 3 5 SETUP Machine torch setup Consumables Positioning sleeve Gear rack Brass strain Strain relief relief Before using the T45m you must Mount the torch on your cutting table or other equipment Choose and install the consumables Align the torch Attach the torch lead to the power supply Set up the power supply for remote starting with either the remote start pendant or machine interface cable Mount the torch Depending on the type of cutting table you have you may or may not need to disassemble the torch to route it through the track and mount it If your cutting table s track is large enough for you to thread the torch through it without removing the torch body from the lead do so and then attach the torch to the lifter per the manufacturer s instructions Note The T45m can be mounted on a wide variety of X Y tables track burners pipe bevelers and other equipment Install the tor
72. ting height Refer to the cut charts for specifics The pierce delay must be sufficiently long that the arc can pierce the material before the torch moves but not so long that the arc wanders while trying to find the edge of a large hole When piercing maximum thicknesses the ring of dross that forms during the pierce may become high enough to contact the torch when the torch begins to move after the pierce is complete powermaX45 Operator Manual 4 17 OPERATION Common machine cutting faults The torch s pilot arc will initiate but will not transfer Causes can be The work cable s connection on the cutting table is not making good contact or the table is not properly grounded The torch to work distance is too large The workpiece is not totally penetrated and there is excessive sparking on the top of the workpiece Causes can be The work cable s connection on the cutting table is not making good contact or the table is not properly grounded The amperage is set too low See the cut charts in Section 3 for more information The cut speed is too high See the cut charts in Section 3 for more information The consumables are worn and need to be replaced The metal being cut exceeds the maximum capacity See 745v and T45m specifications in Section 1 Dross forms on the bottom of the cut Causes can be The cutting speed is not correct See the cut charts in Section 3 for more information The amperage
73. ty cycle limitations The duty cycle is the amount of time in minutes that a plasma arc can remain on within a 10 minute period when operating at an ambient temperature of 104 F 40 C With a Powermax45 At 45 A the arc can remain on for 5 minutes out of 10 minutes without causing the unit to overheat 50 duty cycle At 41 A the arc can remain on for 6 minutes out of 10 60 At 32 A the arc can remain on for 10 minutes out of 10 10090 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 Wait for the temperature LED to extinguish before you resume cutting The next section explains how to operate the hand torch To operate the machine torch see Use the machine torch later in this section powermax45 Operator Manual 4 7 OPERATION How to use the hand torch 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 Operate the safety trigger The T45v is equipped with a safety trigger to prevent accidental firings When you are ready to use the torch flip the yellow safety trigger forward toward the torch
74. u us e JPN 110673 Rev D PARTS www hypertherm com weee CE safety label AIR 9 BAR MAX 135 PSI MAX 110610 REVA Maximum pressure label 6 9 6 10 powermaX45 Operator Manual
75. uthorized to give any additional warranty protection to you or make any representation to you purporting to be binding upon Hypertherm Patent indemnity Except only in cases of products not manufactured by Hypertherm or manufactured by a person other than Hypertherm not in strict conformity with Hypertherm s specifications and in cases of designs processes formulae or combinations not developed or purported to be developed by Hypertherm Hypertherm will have the right to defend or settle at its own expense any suit or proceeding brought against you alleging that the use of the Hypertherm product alone and not in combination with any other product not supplied by Hypertherm infringes any patent of any third party You shall notify Hypertherm promptly upon learning of any action or threatened action in connection with any such alleged infringement and in any event no longer than fourteen 14 days after learning of any action or threat of action and Hypertherm s obligation to defend shall be conditioned upon Hypertherm s sole control of and the indemnified party s cooperation and assistance in the defense of the claim 9 10 Limitation of liability In no event shall Hypertherm be liable to any person or entity for any incidental consequential direct indirect punitive or exemplary damages including but not limited to lost profits regardless of whether such liability is based on breach of contract tort strict lia
76. vailable through the machine interface cable are shown below The table on the next page provides details about each signal type 3 28 powermaX45 Operator Manual TORCH SETUP Refer to the following table when connecting the Powermax45 to a torch height controller or controller with a machine interface cable Signal Notes Sockets Cable wires Start Normally open 18 VDC open circuit voltage at MM START terminals Requires dry 3 4 Green Slack contact closure to activate Transfer Normally open Dry contact closure start when the arc transfers machine Output 120 VAC 1 A maximum at the 12 14 Red black molian machine interface relay or switching device supplied by the customer Ground Ground 13 Voltage Divided arc signal of 20 1 21 1 1 Output 30 1 40 1 50 1 provides a 5 6 Black white maximum of 18 V Accessing raw arc voltage If you should need to access raw arc voltage contact your Hypertherm distributor or authorized Hypertherm repair facility for assistance WARNING HIGH VOLTAGE AND CURRENT Connecting directly to the plasma circuit for access to raw arc voltage increases the risk of shock hazard energy hazard and fire hazard in the event of a single fault The output voltage and the output current of the circuit are specified on the data plate powermaX45 Operator Manual 3 29
77. wer supply provides access to the 50 1 arc voltage and signals for arc transfer and plasma start Caution The factory installed internal voltage divider provides a maximum of 7 V under open circuit conditions This is an impedance protected functional extra low voltage ELV output to prevent shock energy and fire under normal conditions at the machine interface receptacle and under single fault conditions with the machine interface wiring The voltage divider is not fault tolerant and ELV outputs do not comply with safety extra low voltage SELV requirements for direct connection to computer products Hypertherm offers several choices of machine interface cables for the Powermax45 To use the built in voltage divider that provides a 50 1 arc voltage in addition to signals for arc transfer and start plasma Use part number 228350 25 ft 7 62 m or 228351 50 ft 15 24 m for wires terminated with spade connectors example shown below Use part number 123896 50 ft 15 24 m for a cable terminated with a D sub connector Compatible with Hypertherm s Edge Ti and Sensor PHC products To use signals for arc transfer and start plasma only use either part number 023206 25 ft 7 63 m or part number 023279 50 ft 15 24 m These cables have spade connectors as shown here pz jm Note The cover on the machine interface receptacle prevents dust a

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