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powermax45 Service Manual - Red-D

1. 3 Turn the pressure regulator knob until the gas pressure LED shows a green bar 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 appropriate for your application If you are using Powermax30 30 A consumables do not set the amperage knob above 30 A powermaX45 Service Manual 4 5 OPERATION 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 Troubleshooting in Section 5 for more information 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
2. 2 4 Power COP D 2 4 Extensiom cord 2 4 Generator recommendations ees 2 6 un enum ILLE 2 6 Co nectihe gaS SUPPLY i P o An a 2 7 Additional gas tratio 2 7 powermaX45 Service 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 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 li
3. 14 J5 and J6 Retaining screw Retaining screw IGBT attachment ON piis 2 switch wires Ribbon cable 18 ws p ia 7 screw o JA EN A ui Heat sink gt 2 assembly screw Xi P 3 H Ji0andJ12 U New board has slot here J13 Ys J14 Input bridge diode screw J15 we Heat sink Heat sink assembly assembly ore screw screw J18 IL 10227 U Retaining 120 Pressure relief Capacitor screws 4 screw vents J19 Work lead Resistor screws 4 connector J21 NEW 400V Power Board PN 141008 powermax45 Service Manual COMPONENT REPLACEMENT 5 Remove the connectors at J4 J5 and J6 on the heatsink side of the power board 6 Remove the wires for the transformers and inductors at J13 J14 J15 J16 J17 J18 J19 120 7 Remove the work lead ring terminal from J21 and the 4 capacitor screws 8 Remove the 3 retaining screws the 4 resistor screws and the 4 heatsink assembly screws 9 If you have an older 400 V CE power board that has 2 input bridge diodes and without the small slot below the heat sink assembly screw hole remove the 2 screws that attach the IGBTs and the 2 screws that attach the input bridge diodes to the heatsink There are holes in the power board to provide access to them If you have a new 400 V CE power board that has a single input bridge diode and has a small slot below the heat s
4. M powermaX45 Service Manual iii TABLE OF CONTENTS iv powermaX45 Service Manual Section 1 SPECIFICATIONS In this section Systemi descriptio 1 2 Rieti AE LLL 1 2 Power supply dimensions and weights 1 3 Dimensione I PEE 1 3 1 3 Power SUPDIY TAtiN Ss 1 4 148v torch dimensions nce air cnn 1 5 TIom torch GIMENSIONS x scis rct RR ane Max Rr eruere Der inue ets 1 5 4 145m torch icti mi cei iie atl imd td det eir da i i ee dad car d t a 1 6 Symbolsand MALKINGS 1 7 1 8 powermaX45 Service Manual 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
5. O AROSA Ad A d 5 15 Test 2 power board voltage checks itte tette t iei fne dece 5 16 Test 3 VBUS and voltage balance teinte tnter eri dione tcr dra ARGIA 5 17 solenoid valve m a A e isa Ia RR nin RU di 5 19 Test 5 torch stuck open TSO or torch stuck closed TSC eese ttr trennen testes 5 20 Test 6 plasma Stai hie trece hid dada n e tc A Aa ie uoc ei da n ina o edd i 5 21 Test 7 SENSOR 5 22 8 fan umawiania i RR A Ra Ai awa CE AG A T A GTE 5 22 9 pressure transducere R e i 5 23 Test 10 power switch wiz das a c a n i iie dara cf A P ie daa ini a 5 23 powermax45 Service Manual 5 1 TROUBLESHOOTING AND SYSTEM TESTS Theory of operation General Refer to the Functional description and Sequence of operation sections below and to Section 8 Wiring diagrams 200 240 V CSA and 230 V CE 1 phase power supply functional description AC power enters the system through the power switch S1 to the input diode bridges D29 D39 The voltage from the diode bridge supplies the power factor correction PFC boost converter which provides a nominal 385 VDC bus voltage The bus voltage then sup
6. 3 26 powermax4s Service Manual TORCH SETUP Refer to the following table when connecting the Powermax45 to a torch height controller or CNC with a machine interface cable Connector Signal Type Notes sockets Cable wires Normally open 18 VDC open circuit voltage at START terminals Requires dry contact closure to activate Start start plasma Input 3 4 Green black Normally open Dry contact closure when the arc transfers Output 120 VAC 1 A maximum at the machine 12 14 Red black interface relay or switching device supplied by the customer Transfer start machine motion Ground Ground 13 Divided arc signal of 20 1 21 1 1 30 1 40 1 50 1 provides a maximum of 18 V Voltage divider Output Accessing raw arc voltage Connecting a cable to the Powermax45 power board to bypass the voltage divider and access raw arc voltage must be done by a qualified service technician 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 To access raw arc voltage on a Powermax45 you will need kit number 228352 and an 18 AWG 2 wire non shielded cable similar to OLFLEX 190 601802 in the length nee
7. TP 19 1P18 TP47 wo RO 192 VDC 192 VDC powermax45 Service Manual 5 21 TROUBLESHOOTING AND SYSTEM TESTS Test 7 torch cap sensor Test the cap sensor switch and torch leads 1 Set the ON OFF switch to OFF O 2 Measure the resistance between pins 1 and 2 of J10 on the power board It should measure less than 10 If it reads as open the cap sensor switch circuit is not satisfied 3 If the torch plunger moves smoothly and the consumables are correctly installed then either the cap sensor switch is faulty or the torch lead has a broken wire Replace the faulty part Test 8 fan Test the fan for proper operation Place a jumper from pin 1 of J3 to pin 1 of J4 on 200 240 V CSA power supplies and 230 CE power supplies or from pin 1 of J4 to pin 1 of J5 on 400 V CE power supplies If the fan does not operate replace the fan 23 and J4 J and J5 OO OO TT UVUUUUUUUTI a 192 8 0 Z NI 200 240 230 400 V power supplies CE power supplies 5 22 powermax45 Service Manual TROUBLESHOOTING AND SYSTEM TESTS Test 9 pressure transducer Test the pressure transducer to ensure that the system is rece
8. 1 or J4 PE ground TP18 17 RO 192 0 E powermax45 Service Manual 5 19 TROUBLESHOOTING AND SYSTEM TESTS Test 5 torch stuck open TSO or torch stuck closed TSC Before the torch is activated and gas starts to flow the nozzle and electrode should be in contact or touching If not the power supply will detect a TSO or torch stuck open fault If the electrode and nozzle remain closed after the torch receives a start signal the power supply will detect a TSC or torch stuck closed In either case you will have gas flow Use the following test to determine if the torch is stuck in either position 1 Turn OFF O the power 2 Measure the resistance from J17 to J19 for all power supplies The resistance should read as closed very low resistance A Caution To avoid causing a short or damage to your meter do not fire the torch with the multimeter connected to the power board 3 Turn ON I the power Set the amperage adjustment knob to gas test mode The resistance should read as very high resistance 4 If the resistance reads incorrectly then the nozzle and electrode are in contact or touching or one of the wires in the torch lead is broken Make sure that the torch plunger moves freely in the torch head If it does not replace the torch head If the torch parts are working properly replace the torch lead 5 Because TSO and TSC failures can be
9. na nah la a uuaa MYC LIIGI HI Plasma arc cutting system Service Manual 806110 Revision 1 Register your new Hypertherm system Register your product online 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 Service Manual P N 806110 Revision 1 October 2010 Hypertherm Inc USA www hypertherm com Copyright 2010 Hypertherm Inc Rights Reserved Hypertherm and powermax are trademarks of Hypertherm Inc and may be registered in the United States and or other countries Hypertherm Etna Road 5010 Hanover NH 03755 USA 603 643 3441 Tel Main Office 603 643 5352 Fax All Departments info hypertherm com Main Office Email 800 643 9878 Tel Technical Service technical serviceQhypertherm com Technical Service Email 800 737 2978 Tel Customer Service customer serviceQhypertherm com Customer Service Email Hypertherm Automation 5 Technology Drive Suite 300 West Lebanon NH 03784 USA 603 298 7970 Tel 603 298 7977 Fax Hypertherm Plasmatechnik GmbH Technologiepark Hanau Rodenbacher Chaussee 6 D 63457 Hanau Wolfgang Deutschla
10. powermaX45 Service Manual OPERATION Power ON the system Set the ON OFF switch to the ON I position 5 230 Set the mode switch 400 V CE Use the mode switch to select the type of work you will be doing Adjust the gas pressure To cut expanded metal or grate top position Use this setting to cut metal with holes in it or for any job requiring a continuous pilot arc Leaving the mode switch on this setting when cutting standard metal plate will result in reduced 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 ve selected If the LED illuminates yellow either above or below the center the gas pressure needs to be adjusted powermaX45 Service Manual OPERATION To adjust the pressure 1 Turn the amperage knob counter clockwise to the gas test position as show below 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
11. 3 2 Consumable 11 3 2 Hand 3 2 Choose the sss saa aaa aaa aa aaa aaa aaa rad Anais Adrara aa aaa aaa 3 3 Install the consumables iit cic dre ni rei vie d eio AO id in eed Ed 3 5 Machine torch Setup ee c nter d c Pase en Page Pepe an Po REF dak 3 6 Mount cami ri ee d e TEE EX ERN T C E 3 6 Choose the consumables c t charts rite ttc eet AR Ann aa 3 8 Using the Cut charts mee t e te im mienne d asd sri t tn 3 8 145m shielded cons mables tsi ric ic n ei het f n tn GE Fr casa adi E a CR a 3 8 Align the t rch zzz zw M 3 24 Go nectiheremote start pendant is az ddr dera O A ad ad 3 25 Connect a machine interface cable e i cnini WGRA AGE d AE 3 25 FAW ALC jej czte 3 27 Connect the torch aene n end n T e c ri E TERN Ca Fu re E mata ERU E NH 3 30 Section 4 OPERATION Controls and indicator fear EUER D aTa 4 2 Front Controls arid LEDs inttr tercie 4 2 REGFCONUOlS siio crei ree 4 3 Operate the 45 oce te ae een etin e am cen inlaid ped es 4 3 p
12. aaa aaa aaa aaa 4 7 Operatethe safety trigger erect retire cess ceteros been 4 7 allo EP 4 7 Start a cut from the edge of the ossad ata 4 8 FISH SLE WOTKPISCE ian A 4 9 Gouge UII cestata aed 4 10 Common hand cutii g 1805 4 12 Howto use the machine oe el 4 12 Ensure the torch and table are set up 4 12 Understand and optimize cut quality de gens 4 13 To pierce a workpiece using the machine torch 1 sse entente nnne nete nnne tenente tenentes 4 14 COMMON machine cu tting faults 4 15 powermaX45 Service 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 O Pressure regulator knob Gas pressure LED and Indicator LEDs
13. te ee n Fr rer Pa e e es 1 6 Symbols a d markings re titre cedit tte esci de fce dd e cedo ded 1 7 Sedi 1 8 Section 2 POWER SUPPLY SETUP Unpack the Powermax4 Sue saa a itid eor dead Rede Aa dads Cae oratum da ird da decr dana etii a et 2 2 CIAIMS rr 2 2 Contents s o opere A E 2 0 Position the power SUPP nowania haki l 2 3 Prepare the electrical power din d dian a titi da Rai aa ada o rien dr ern 2 3 2 3 Install a li e disco ect switch awa waza maa de et den ad E aaa eee 2 4 Requirements miele lone 2 4 Power cord considerations adeb Ee a AiR de rr o E Se aa darte n 2 4 Extension cord recommendations uccide rete ec o n e eo c PCR Ga RC E AA lite Ru eR HE E 2 4 Generator recommendations ceca etr reiten rdi rere tat iere 2 6 Prepare the Gas e a OE R A RAR iR Od Raki 2 6 Connect the gas supply tt mtt ceci tec rece Aaa wd 2 7 Additional gas filtration tttm sre ki ki faeta iate n AAA WPA FRE tei REWA 2 7 Section 3 TORCH SETUP Introduction xcti ae i
14. Cut Speed mm min Voltage V Cut Speed Voltage mm min V Maximum cut speed is limited by the test table s maximum speed 400 ipm or 10160 mm min 3 22 0 5 0 8 0 9 1 5 1 9 2 7 3 4 500 10160 10160 6850 4800 3450 1900 1400 powermax45 Service Manual T30v Powermax30 30 A consumables Stainless steel English Arc current amps Material thickness in Torch to work distance in Initial pierce height Pierce time delay sec Recommended Cut Speed ipm Voltage V TORCH SETUP Air flowrate Ipm Maximum Cut Speed ipm Voltage V 0 018 26 Ga 0 030 22 Ga 0 036 20 Ga 0 060 16 Ga 0 075 14 Ga 0 105 12 Ga Aluminum Metric Arc current amps 0 135 10 Material thickness mm Torch to work distance mm 500 Initial pierce height Pierce time delay sec Air flowrate Recommended Cut Speed mm min Maximum Cut Speed mm min 0 5 0 8 0 9 1 5 1 9 8100 10160 Maximum cut speed is limited by the test table s maximum speed 400 ipm or 10160 mm min powermax45 Service Manual 3 23 TORCH SETUP Aluminum Air flowrate English Recom
15. 10160 8650 10160 8100 10160 5650 7100 10160 10160 9144 6096 4445 2794 1905 1016 Edge start recommended powermax45 Service Manual 635 356 254 127 3 9 SETUP T45m shielded consumables Mild Steel English Arc current amps Material thickness Torch to work distance Initial pierce height Pierce time delay sec Cut Speed ipm Voltage V Air flowrate scfh Cut Speed ipm Voltage 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 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 250 360 117 400 118 340 400 117 400 Edge start recommended Maximum cut speed is limited by the test table s maximum speed 400 ipm 3 10 powermax45 Service Manual TORCH SETUP T45m shielded consumables Air flowrate Recommended Maximum Torch Stainless steel Metric Arc current amps Material thickness mm to work distance mm Initial pierce height Pierce time delay sec
16. 0 2550 in 6 50 mm 0 1158 in 2 94 mm 30 ipm 762 mm min 0 2267 in 5 76 mm 0 0735 in 1 87 mm 40 ipm 1016 mm min 0 2087 in 5 30 mm 0 0517 in 1 31 mm 50 ipm 1270 mm min 10 ipm 254 mm min 0 1863 in 4 73 mm 0 3173 in 8 06 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 Service Manual 0 2003 in 5 09 mm 0 0322 in 0 82 mm OPERATION Common hand cutting faults The tor
17. There is insufficient voltage to the control circuits or a short circuited power There is insufficient gas pressure to the machine The internal system temperature is either over or under its operating range approximately 30 C to 80 C The system has no incoming voltage or an improper incoming voltage The power board is faulty There is no gas attached to the system The gas supply line has a restriction or the air filter element is dirty The reading at the pressure transducer is below the minimum acceptable gas pressure The power supply is too cold You have exceeded the duty cycle For more information about duty cycle see Section 4 Check to see that the System is plugged into an appropriately sized circuit and that the circuit breaker has not been tripped Perform test 1 to check the incoming voltage and the power switch Ensure that the gas supply is connected correctly Check the gas supply line for restrictions or damage Check the air filter element and replace it if necessary Perform test 9 to verify that the pressure transducer functions correctly Allow the power supply to warm up if it has been extremely cold Check the area around the system to make sure that the air flow is not blocked If the duty cycle has been exceeded let the system cool before using it again Perform test 8 to make sure the fan is operating correctly TROU
18. You may want to remove the hose to make this easier Unscrew the filter bowl from the body and remove it Gas supply hose Nut Bracket Filter bowl Drain Drain hose Remove the glass filter tube by twisting it and pulling gently until it releases Unscrew the element from the filter body while being careful not to allow the element to rotate Screw the new element to the filter body Place the glass filter tube inside the filter bowl and screw the drain onto the bottom of the filter bowl Reattach the hose if you removed it earlier Reattach the filter bowl to the filter body making sure that the drain and drain hose point toward the front edge of the fan powermax45 Service Manual 6 9 COMPONENT REPLACEMENT 13 Reposition the filter assembly in the bracket and replace its retainer nut 14 Reconnect the gas supply hose and press the drain hose onto the drain in the bottom of the power supply 15 Reconnect the gas supply and check for leaks 16 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 17 Reconnect the electrical power and the gas supply Replace the gas filter 1 Turn OFF the power disconnect the power cord and disconnect the gas supply 2 Remove the 2 screws from the handle on the top of the power supply Remove the handle and then lift the cover off the power supply 3 Remove the g
19. 1 Phillips screwdriver through the holes in the fan casing to remove the retaining screw from each corner of the fan Corner clips Top corner clips Corner clips Bottom 6 Slide the old fan out from the power supply 7 Slide the new fan into place 8 Replace the 4 retaining screws 9 Orient the fan plenum so that the wider end is at the bottom and snap it into place 6 8 powermax4s Service Manual 10 11 12 COMPONENT REPLACEMENT Attach the connector for the red and black wires on the left side of the fan to J4 200 240 V CSA and 230 V CE or J5 400 V CE on the power board Being careful not to pinch any of the wires 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 use the 2 screws to secure the cover Reconnect the electrical power and the gas supply Replace the gas filter element 10 11 12 Turn OFF the power disconnect power cord and disconnect the gas supply Remove the cover from the power supply Remove the drain hose from the drain in the bottom of the power supply s base Compress the hose fitting s collar on the gas supply hose and pull the gas hose from the fitting Unscrew the nut that holds the filter in the bracket Tip the bottom of the filter away from the power supply Unscrew the drain from the bottom of the filter
20. 228258 Kit Base 8 3 228265 Kit Magnetics assembly 200 240 V CSA 8 3 228273 Kit Magnetics assembly 230 V CE 8 3 228263 Kit Magnetics assembly 400 V CE 8 3 228284 Pressure sensor cable 8 4 228285 Kit Solenoid valve 8 4 228287 Kit Filter regulator 8 4 228302 Air filter element 8 4 228286 Kit Fan 8 4 058503 Torch o ring 8 5 228313 Kit T45v torch handle replacement 8 5 075714 T45v torch handle screws 5 required 8 5 002244 T45v torch trigger assembly with spring 8 5 228109 Kit T45v torch cap sensor switch replacement 8 5 088008 T45v hand torch assembly with 20 ft 6 1 m lead 8 5 088009 T45v hand torch assembly with 50 ft 15 24 m lead 8 5 228315 Kit T45v 20 ft 6 1 m torch lead replacement 8 5 228316 Kit T45v 50 ft 15 24 m torch lead replacement 8 5 088010 Kit 45 machine torch assembly with 25 ft 7 6 m lead 8 7 088011 Kit 45 machine torch assembly with 35 ft 10 67 m lead 8 7 088012 Kit 45 machine torch assembly with 50 ft 15 24 m lead 8 7 228228 Kit T45m positioning sleeve 8 7 228229 Kit T45m removable gear rack 8 7 228322 Kit T45m front mounting ring 8 7 228323 Kit T45m rear mounting ring 8 7 powermaX45 Service Manual 7 11 Recommended spare parts continued Part number Description Page reference 228321 Kit T45m cap sensor switch replacement 8 7 228317 Kit T45m torch lead replacement 25 ft 7 6 m 8 7 228318 Kit T45m torch lead replacement 35 ft 10 67 m 8 7 228319 Kit T45m torc
21. Compare that value to a reading at pin 21 on J8 They should have the same value 3 Attach E Z Hooks to TP test point 17 and TP 18 Turn the power ON after you have connected the multimeter This value should be 280 VDC or one half of whatever value you found in step 2 Note All values can be 10920 4 Turn the power OFF and move the E Z Hooks to TP18 and TP 16 Turn the power ON after you have connected the multimeter This value should be 280 VDC or one half of whatever value you found in step 2 5 The values found in steps 3 and 4 should be approximately equal If they differ by more than 30 V replace the power board Step 2 TP1 wo 280 VDC 5 18 powermax4s Service Manual TROUBLESHOOTING AND SYSTEM TESTS Test 4 solenoid valve If gas is not flowing properly test the solenoid valve for proper operation 1 There is an LED on the solenoid valve that illuminates red when the torch is fired or when the amperage control knob is set to gas text mode It stays illuminated until postflow stops Turn the amperage knob to gas test and verify that the LED illuminates 2 Place a jumper from pin 4 of J3 J4 for 400 V CE power supplies on the power board to ground You should hear the valve click 3 If you do not hear the valve click or the LED does not illuminate and a voltage check on pin 4 of J3 reads 24 VDC replace the solenoid valve Solenoid valve LED
22. 1 phase power supply functional 5 2 400 CE 3 phase power supply functional description esent aaa 5 2 Se6qu nce of operations ss eas eia sees ten duci ht ee 5 3 Troubleshooting Ore paral On ite A od aa pa a 5 4 RR ARA z i a ibd t in dcc td id 5 4 Troubleshooting procedures and 2 4002 asa iai Ea Rai 5 4 Extermal roo dee e hemmed 5 5 Drei A ia R OR OGAE AGGA RR EA Rn ab A Rf ai ad ab Aida 5 5 Initial resistance Check cai ot db a e cra da a te er dd eda I AO O GE G RA GEE 5 6 200 240V CSA and 230 V CE power supply overview tnter entente tenen 5 7 400 V CE power supply OVetVIew nrc bea ben da a b eod irt i end iar CASA 5 8 Troubleskoocting MM 5 9 Control Board tace rp a ean ere 5 13 Use the control board Error and Reset LEDs to troubleshoot seen 5 14 oystem Testes 5 15 1 volage
23. 131 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 rated output Us MAX lo See Voltage configurations in Section 3 for more information 200 240 VAC 34 28 A CSA 230 VAC 30 A 230 V CE 400 VAC 10 400 Gas type Air Nitrogen Clean dry oil free per ISO 0 8573 1 Class 1 2 2 931999 20 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 S greater than or equal to 692 KVA 1 4 powermax4s Service Manual SPECIFICATIONS T45v torch dimensions lt 8 72 22 1 4 8 5 21 6 45 torch dimensions 14 36 in Lf 36 5 cm 20006 12 in 5 t M 30 5 cm 1 43 in 3 6 cm outer dimension 1 3 in 3 3 cm flat sides 13 in X 330e gt powermaX45 Service Manual 1 5 SPECIFICATIONS T45v and T45m
24. 4 13 To pierce a workpiece using the machine torch 4 14 Common machine cutting faults ttt nnn neret ir nent testen rt tenes A TAAA 4 15 Section 5 TROUBLESHOOTING AND SYSTEM TESTS Iterum 5 2 General 200 240 V CSA and 230 CE 1 phase power supply functional 5 2 400 V 3 phase power supply functional description esee tente tenerent tnter ene 5 2 Sequence of operatlon site da eoe eu et da Ra i d ed ee dc 5 3 Troubleshooting preparalo R BERE REESE AAAA teenie 5 4 Testequipment E 5 4 Troubleshooting procedures and ttn AAA 5 4 External inspection c eoi hic a d cx i i edi b uci Ga b bt db A rius 5 5 Internal 5 5 Initial resistance e nc Reni crt 5 6 200 240 CSA and 230 V CE power supply overview tente tenente tente tenerent nnns 5 7 400 power supply Oveni W bc a da E i e E rca da RA AAA 5 8 8 RR R ARR RER 5 9 Control Board cde rare ed A A OTG ARGIA 5 13 Use the control board Error and Reset LEDs to troubleshoot seen enne 5 14
25. 7 10 Recommended parts retener adi 7 11 Powertnax4b labels weld eens aed d eR THEE 7 12 powermaX45 Service Manual 7 1 PARTS Power supply parts Exterior OOO Item a O O number 228264 228272 228269 108616 228300 228307 229121 229122 228268 228267 228274 228561 OW 7 Sj Description Qty Kit Kit Kit Current adjustment knob Kit Kit Kit Kit Kit Work lead assembly 50 ft 15 24 m Kit Power supply cover with labels CE Kit Powermax45 handle and screws Kit Ground clamp Labels domestic Labels CE Front panel Work lead assembly 20 ft 6 1 m Power supply cover with labels domestic Rear panel FastConnect replacement power supply half k A powermaX45 Service 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
26. Electrode T30v Powermax30 30 A consumables dr 0 a Retaining cap 220480 220479 220478 Nozzle Swirl ring Electrode powermax45 Service Manual SETUP Install consumables WARNING INSTANT ON TORCHES PLASMA CAN CAUSE INJURY AND BURNS The plasma arc comes on immediately when the torch trigger is activated Make sure the power is OFF before changing consumables 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 the power switch in the OFF O position verify that the torch consumables are installed as shown Electrode Swirl ring gt Nozzle g Retaining M Shield or deflector gt There should be a small gap 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 Service Manual 3 5 TORCH 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 wi
27. PCB FAN 190CFM SOL 24v 1 0A pnessueel 24 01uF Y2 300vac INPUT BRIDGES PE 380 400vac 50hz CORD 4C 2 5mm HO7RN F 560vdc LOW INDUCTANCE VBUS LAYOUT 2200uF 400VDC Flyback Circuitry 4a 1500v y 5 942 8 450 1 92 MAX Ht 18REG Circuitry Er vous INVERTER IGBT MODULE Vbus Finv 36khz y 1 965 5 942 0 472 MAX Ht 56uF 1000VDC 10 ohm 120W ISOTOP 8 2nF y 0 00 1 965 1000VDC 1 22 MAX Ht m wal INV IPRIM 100 OUT1 OUTPUT CURRENT SENSOR RODOS Z bzzzzbbul 000900050 amp CONTROL to CHASSIS GND PWM DRV 100 Pin 2nF 1000VDC ARC VOLTAGE 50 1 5 6 OUTPUT DIODE and PILOT ARC IGBT MODULE 1209 1112138 25 26 27 JUMPER MECH IN1 18AWG RED TRANSFER SENSOR ELECTRODE Loutput 014316 NOZZLE LO 480uH 2 L45 205uH amp Rdc25C 12 5mohm WORK Lpfc 014319 10 4 0 L15 1 8MH Rdc25C 80mohm POWER XFMR 014318 Lprim 1 08mH Rprim25C 4 0mohm Rsec25C 6 5mohm Lleak 0 5uH jor bota 8AWG UL1028 MTW BLK MUELLER CLIP ELEC SCH 45A 400V SYSTEM 45A 132v 275v 013367 225 SHEET1OF1
28. Section 7 Parts for part numbers for the Hypertherm plasma cutting guides for cutting circles and making bevel cuts Start a cut from the edge of the workpiece 7 1 With the work clamp attached to the workpiece hold the torch nozzle perpendicular 90 to the edge of the workpiece If you are using the shielded consumables no standoff is needed With unshielded consumables maintain an approximate 08 inch 2 mm standoff 4 8 powermax4s Service Manual OPERATION 2 Press the torch trigger to start the arc Pause at the edge until the arc has cut completely through the workpiece 3 Drag the nozzle lightly across the workpiece to proceed with the cut Maintain a steady even pace 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 2 Fire the torch while still at an angle to the workpiece then slowly rotate the torch to a perpendicular 90 position powermaX45 Service Manual 4 9 OPERATION 3 Hold the torch in place while continuing to press the trigger When sparks exit from the bottom of the workpiece the arc has pierced the material 4 When th
29. and a line disconnect switch Input ach Recommended Input voltage Rated output current at slow blow fuse during arc 6 kw output size stretch 200 240 1 45A 132V 34 28A 55 45A 50A VAC CSA T Caution Protect the circuit with appropriately sized time delay slow blow fuses 45 132 V 34 28 55 45 35 50 Ea 400 VAC 45 132 V 15 5 Use the higher amperage fuse for applications that require a long arc stretch powermaX45 Service 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 be equal to or exceed the continuous rating of the fuses In addition the switch should solate the electrical equipment 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
30. and pierce thicknesses up to 3 8 inch 9 5 mm The standard Powermax45 includes one 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 x G 1 4 BSPP 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 c
31. and will flash during continuous pilot arc operation such as when cutting expanded metal or moving the arc off the plate and then back on Error The Error LED illuminates whenever there is a fault in the system If the Fault LED on the front panel flashes and the Error LED on the control board also flashes there is a major fault in the system The number of flashes between pauses indicates which component may have failed Reset This LED illuminates when the reset circuit is active or the watchdog circuit fires During normal operation the power ON LED on the front of the power supply and the Start and Transfer LEDs on the control board illuminate When a problem occurs with the system one or more of the LEDs on the front of the power supply and the Error LED or the Reset LED on the control board may illuminate or flash powermax45 Service Manual 5 13 TROUBLESHOOTING AND SYSTEM TESTS Use the control board Error and Reset LEDs to troubleshoot The Error and Reset LEDs provide information to use when troubleshooting a system failure If the LEDs on the front of the power supply are flashing look at the Error LED on the control board to determine where the fault may be Count the number of flashes and then look at the table on the following page to determine the corrective action Reset LED When the control board s Reset LED illuminates the voltages on the power board may be incorrect Perform the following tests at J7 on 200
32. 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 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 Ensure the torch and table are set up correctly previous page 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 powermaX45 Service Manual 4 13 OPERATION High speed dross forms when the cutting speed is too fast and the arc lags behind It form
33. grounding To ensure personal safety proper operation and to reduce electromagnetic interference EMI the Powermax45 must be properly grounded The power supply must be grounded through the power cord according to national and local electrical codes Single phase service must be of the 3 wire type with a green or green yellow wire for the protective earth ground 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 the Safety and Compliance Manual for more information 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 amp 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 and have it installed by a licensed electrician Extension cord recommendations Use an extension cord of 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 the
34. i rie iNet n 6 8 Replace Mu e milii ure 6 9 Replace the gas filter oett ndr petite tont id ict dave 6 10 Replace the Control EM 6 11 Replace the power board 200 240 V CSA and 230 6 12 Replace the power board 400 V 6 15 Section 7 PARTS Power supply parts wawy ka ina ae dien 7 2 IEEE 7 2 Interior power board side aaa dao eto edad i i i de denda i ia c c da e G RA etia ten 7 4 Interior fan side hand torch partes e ee uter can R ada a i i Ra dnd 7 6 hand torch coris mables itti etre t net cett e li Rr e a Pu n a d 7 7 T30v Powermax30 30 A consumables eee tentent treten tette treten te tente ttn 7 7 T4bmirmachinetorchr parte re ion itat to ce nen RE Re 7 8 T45mimachine torch 5 ict nr ura i c tiim IR Er ana FER de d 7 9 ACCOSSOLY PH Powermax45 labels Safety critical parts Recommended spare parts etre n nerd a re aed reddo a 7 11 Powermax4b 7 12 Section 8 WIRING DIAGRAMS Control board diagrams m 200 240 V CSA and 230 V CE Power board 200 240 V CSA and 230 V 400
35. 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 countries where direct connection is not permitted the bonding should be achieved by suitable capacitances selected according to national regulations Note The cutting circuit may or may not be earthed for safety reasons Changing the earthing arrangements should only be authorized by a person who is competent to assess whether the changes will in crease 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
36. intermittent repeat the test several times J17 J19 200 240 V CSA and 230 V 400 V CE power supplies CE power supplies 5 20 powermax4s Service Manual TROUBLESHOOTING AND SYSTEM TESTS Test 6 plasma start Verify that the control board LED is receiving a valid start signal 1 With the power ON look at the Start LED on the control board It should illuminate whenever the torch is activated 2 Set the ON OFF switch to OFF O Check the resistance between pins 2 and 3 of J10 on the power board With the trigger or start signal engaged the resistance should be 10 or less With the trigger or start signal disengaged the circuit should read as approximately 3 If this test fails check the torch s start switch and the torch wires NOTE If the torch will not fire after completing this test verify that J10 is connected properly that the pins are not offset and the connector is not backwards Set the ON OFF switch to ON 1 Measure 16 of J7 or J8 for 400 V CE power supplies to ground see Test 2 power board voltage checks earlier in this section It should measure as O VDC for an open circuit or 3 2 VDC for a closed circuit If the values are not correct replace the power board Caution While testing remove the consumables to avoid accidentally firing the torch
37. is complete Removal 1 Turn OFF the power disconnect the power cord and disconnect the gas supply 2 Use 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 6 2 powermax45 Service Manual Replacement Hold the Mylar barrier so that the edge with the 3 notches is on the left and the edge with 4 notches is on the right 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 one you will need to fold it along this perforation so that the top edge bends away from you Position the barrier so that the folded 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 ins
38. machine torch 75 ft 22 86 m 023206 Machine interface cable start plasma 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 start 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 Service Manual 7 3 PARTS Interior power board side 19 TP18 17 192 VDC 192 VDC 2000 number Description Designator Qty 1 228262 Kit Control board PCB1 1 2 228266 Kit Powermax45 power switch 200 240 V CSA 230 V CE 1 3 228288 Kit Powermax45 power switch 400 V CE 1 4 228261 Kit Power board 200 240 V CSA PCB2 1 5 228260 Kit Power board 400 V CE PCB2 1 6 228259 Kit Power board 230 V CE PCB2 1 7 228258 Kit Base 1 8 228265 Kit Magnetics and base 200 240 V CSA 1 9 228273 Kit Magnetics and base 230 V CE 1 10 228263 Kit Magnetics and base 400 V CE 1 228279 Kit Powermax45 insulator 1 228290 Kit Powermax45 wire group 1 7 4 powermaX45 Service Manual Interior fan si
39. nisi istoc misi 3 2 RE 3 2 Choose 3 3 Install the consu mables 6i acit Res 3 5 Machine torch A it ORA O A AE A RA 3 6 Mount the E eU CY E C 3 6 Choose the consumables cut charts ctr eth aiit ei 3 8 Using the cut charts itti ne intct nt ra d s ad iret tna cadere met dn 3 8 145m shielded consumableS 5 0 iniecit cic ie eei ien f n Et E 3 8 Align the torch umarza 3 24 Connect the remote start cius ecd i nnd ti Pe A a dak 3 25 Connect a machine interface cable eene rnnt tnnt tette trita A RAY 3 25 Accessing FAW ALC ere 3 27 Connect the torch leader ecc a cene a aen ir EE E d ER E T vr Re ca cu rc 3 30 powermax45 Service Manual 3 1 TORCH SETUP Introduction Both T45v hand 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 ex
40. optimum performance the gas should have a maximum particle size of 1 micron at a maximum concentration of 0 1 mg m3 a maximum dewpoint of 40 40 and a maximum oil concentration of 0 1 mg m per ISO 8573 1 Class 1 2 2 2 6 powermax4s Service Manual POWER SUPPLY SETUP Connect the gas supply Connect the gas supply to the system 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 three stage coalescing filtration system such as the Eliminizer filter kit part number 128647 available from Hypertherm distributors A three stage filtering system works as shown below to clean contaminants from the gas supply Water and particle filter Oil filter Oil vapor filter Gas supply Powermax45 The filtering system should be installed between the quick disconnect coupler and the power supply powermaX45 Service Manual 2 7 POWER SUPPLY SETUP 2 8 powermaX45 Service Manual Section 3 TORCH SETUP In this section 3 2 Consumable ica tins
41. same way Black CSA Brown CE L N White CSA Black wire CSA ana 4 Brown wire Green CSA Green yellow CE FWWUWWUWWWUJ qi 6 Remove the screw that holds the green wire to the heatsink 7 Onthe outside of the power supply loosen the power cord s strain relief retention nut so that the wires move freely If you will replace strain relief use an adjustable wrench to unscrew the nut on the inside of the power supply as well 8 Pull the wires through the strain relief or through the hole in the rear end panel to remove the old power cord 9 If you have a new strain relief slide it onto the new power cord and route the wires for the new power cord through the hole in the end panel If the old strain relief is still in place route the wires through the strain relief 10 Slide the strain relief s nut over the wires and screw it to the strain relief from the inside of the end panel 11 Screw the connector for the black or brown wire onto the pin on the upper left side of the power switch with a torque setting of 20 inch pounds 23 04 kg cm 12 Screw the connector for the white or blue wire onto the pin on the upper right side of the power switch with a torque setting of 20 inch pounds 23 04 kg cm 13 Tighten the green or green yellow ground wire
42. the power supply Remove the Mylar barrier that protects the power board 3 Remove the amperage control knob by pulling it straight out from the end panel 4 Remove the front end panel or gently tilt it away from the base 5 Detach the ribbon cable from the power board at J7 200 240 V CSA and 230 V CE or J8 400 V CE Caution Static electricity can damage circuit boards Use proper precautions when handling printed circuit boards Store PC boards in anti static containers Wear a grounded wrist strap when handling PC boards 6 Test the new control board before installing it by attaching its ribbon cable to the power board Reconnect the power turn the system on and verify that the start LED on the control board is the only LED illuminated Also the fault LEDs on the front panel should be extinguished Ribbon cable 7 Disconnect the electrical power and the ribbon cable again and set aside the new control board 8 Remove the 3 retaining screws from the old control board and lift it out of the power supply 9 Screw the new control board into place with the 3 retaining screws and then attach the ribbon cable 10 Press the amperage control knob onto the post There is a flat side on the post Ensure that the flat side of the opening in the knob aligns with the flat side on the post powermax45 Service Manual 6 11 COMPONENT REPLACEMENT 11 Reposition the front end panel 12 Being car
43. 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 the system is ready for use Understand duty 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 5000 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 To resume cutting wait for the temperature LED to extinguish The next section explains how to operate the hand torch To use the machine torch see How to use the machine torch later in this section 4 6 powermax4s Service Manual 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
44. 13A 24v 1 0A PFC IGBT MODULE 36 35 34 a 600V 130A Fpfc 24khz Limit 58arms PFC DlopE 60A 600 3 2 CLAMP DIODE 60 600V Ea 1 5600uF 250VDC 30A 003192 240VAC LOW INDUCTANCE VBUS LAYOUT 5600uF 250VDC 16 y 5 942 8 450 JINV SAT 10 1 92 MAX Ht p 15 or 24 11 JUVLO 1m OUT7 28 ssr y 1 965 5 942 0 472 MAX Ht 120W ISOTOP y 0 00 1 965 1 22 Ht V INV IPRIM OUT2 AX100 NP OUT1 OUTPUT CURRENT SENSOR gt TRANSFER SENSOR JDRVFLT 9 CONTROL to CHASSIS GND CAP UNBAL OUTe 29 5 cas OUTS 4 5 OUT423 PADRV MTGA OUT3 22 PWM DRV OUT2 21 PWM DRV OUT1 20 5 pec PWM 100 Pin 8 2nF 1000VDC OUTPUT DIODE and PILOT ARC IGBT MODULE 1200V 60A _ Lpfc 014314 LO 300uh L75 180uh POWER CORD Rdc25C 10 8mohm POWER XFMR CSA 014315 CE 014331 Lprim 0 53mH Rprim25C 2 5mohm Rsec25C 5 7mohm Lleak 0 5uH typ J13 J16 45 132 275v 225 ARC VOLTAGE 50 1 50 6 JUMPER MECH 18AWG RED 18AWG RED ELECTRODE Loutput 014316 NOZZLE 1 cpo s L0 480uH L45 205uH 2 3_CPC 6 6 Rdc25C 12 5mohm WORK 8AWG BLK MUELLER CLIP ELEC SCH 45A 230V SYSTEM 013366 SHEET 1 1 POWER PWA 141008 Level 8 45 h x 13 00 w 202 plated to 302 FACING COMPONENT SIDE OF
45. 240 V CSA power supplies and 230 V CE power supplies or J8 on 400 V CE power supplies the pin numbers are the same for all power supplies on the power board see Test 2 power board voltage checks later in this section Test pin 25 to ground for 3 3 10 Test pin 24 to ground for 5 10 Test pin 12 to ground for 2 2 VDC 1009 0 If the values you find are not within X 10 of the above values detach the control board s ribbon cable and perform the tests again If you find the correct values the second time replace the control board Otherwise replace the power board Error LED The number of times the Error LED flashes indicates the problem detected Each flash is a half second long and each series of flashes is separated by a 2 second pause See System tests later in this section for detailed test procedures The table on the following page shows the meaning associated with each set of flashes Number of error Faulty control board Replace the control board Faulty power board Replace the power board Perform test If any of the values are incorrect replace the power board Perform test 2 If any of the values for pins 5 7 or 12 are Either a faulty power board or incorrect remove the control board and test again If the a faulty control board values are correct replace the control board When performing test 2 if the values for pins 5 7 and 12 are correct but any other values a
46. 5 ft 10 67 1 10 228319 T45m torch lead replacment 50 ft 15 24 m 1 Top assembly includes the following consumables 220669 Electrode 1 220670 Swirl ring 1 220713 Retaining cap 1 220671 Nozzle 1 220673 Shield 1 7 8 powermaX45 Service Manual 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 7 7 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 powermaX45 Service Manual 7 9 Safety critical parts Genuine Hypertherm parts are the factory recommended parts for your Hypertherm system Any damage caused by the us
47. BLESHOOTING AND SYSTEM TESTS Problem ____ Thismaymem cause _ The power ON LED is blinking A 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 The power ON LED is illuminated or is blinking and the fault LED is blinking Xx The power ON LED is illuminated and the fault LED and the temperature LED alternately flash when the system is powered ON MIE The incoming voltage is not correct The cap sensing circuit is not satisfied This indicates either a torch stuck open or torch stuck closed situation A major fault has occurred in the power supply The system was powered on while the plasma start signal was being sent The incoming voltage is either too high or too low a variance greater than 15 of the rated voltage The consumables are loose improperly installed or missing The cap sensor switch is faulty The consumables are installed incorrectly they are worn or were removed while the power supply is ON The torch plunger is stuck The torch or lead has a broken wire Any of the fan solenoid valve control board or power board may be faulty The system was powered on while the torch trigger was being pulled or the trigger was activated too soon after the system was powered on The start circuit is stuck closed powermax4s Service Manual P
48. Cut Speed mm min Voltage V Cut Speed mm min Voltage V 0 5 10160 0 8 10160 0 9 10160 1 5 4700 10160 10160 9144 5080 3810 0 5 0 6 0 8 Edge start recommended Maximum cut speed is limited by the test able s maximum speed 10160 mm min powermax45 Service Manual 3 11 SETUP T45m shielded consumables Stainless steel English Torch Pierce time to work Initial pierce height delay ic A Sinn bia distance in sec Arc current Material amps thickness 0 018 in 26 Ga 0 030 in 22 Ga 0 036 in 20 Ga 250 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 0 750 in 3 4 in Edge start recommended Maximum cut speed is limited by the test table s maximum speed 400 ipm 3 12 powermax4s Service Manual T45m shielded consumables Aluminum Metric Material thickness mm Arc current amps Torch to work distance mm Initial pierce height Pierce time delay sec Recommended Cut Speed Voltage mm min V TORCH SETUP Air flowrate Ipm Maximum
49. Cut Speed Voltage mm min V 1 2 1 5 1 9 0 0 9150 117 10160 120 8650 118 10160 121 5450 118 6860 121 10160 10160 9144 Edge start recommended Maximum cut speed is limited by the test table s maximum speed 10160 mm min powermax45 Service Manual 3 13 SETUP T45m shielded consumables Air flowrate scfh Aluminum English Arc current amps Material thickness Torch to work distance in Initial pierce height Pierce time delay sec Cut Speed ipm Voltage V Cut Speed ipm Voltage V 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 Edge start recommended Maximum cut speed is limited by the test table s maximum speed 400 ipm 3 14 powermax45 Service Manual TORCH SETUP T45m unshielded consumables Up 220717 220713 220718 220670 220669 Deflector Retaining cap Nozzle Swirl ring Electrode Air flowrate Mild steel Metric Recommended Maximum Torch to work distance mm Arc Material current thickness amps mm Pier
50. D SYSTEM TESTS DANGER ELECTRIC SHOCK CAN KILL Turn off the power and remove the input power plug from its receptacle before removing the cover from the power supply If the power supply is connected directly to a line disconnect box switch the line disconnect to OFF O In the U S use a lock out tag out procedure until the service or maintenance work is complete In other countries follow appropriate national or local safety procedures Do not touch live electrical parts If power is required for servicing use extreme caution when working near live electrical circuits Dangerous voltages exist inside the power supply that can cause serious injury or death Do not attempt to repair the power board or control board Do not cut away or remove any protective conformal coating from either board do so will risk a short circuit between the AC input circuit and the output circuit and may result in serious injury or death HOT PARTS CAN CAUSE SEVERE BURNS Allow the power supply to cool before servicing MOVING BLADES CAN CAUSE INJURY Keep hands away from moving parts STATIC ELECTRICITY CAN DAMAGE CIRCUIT BOARDS Put on a grounded wrist strap before handling PC boards External inspection 1 Inspect the exterior of the power supply for damage to the cover and external components such as the power cord and plug 2 Inspect the torch and the torch lead for damage Internal inspection 1 Turn OFF the power di
51. SCHMIDI 5 15 IC SEN 5 15 Test 2 power board voltage checks reete 5 16 Test 3 VBUS and voltage balance 5 17 4 solenoid valve eir ite oin re alere tire eter tc z re v Sd nc ene td tuns 5 19 Test 5 torch stuck open TSO or torch stuck closed TSC seen aaa aaa away nns 5 20 Test 6 plasma Start scs i roe rin x nnmero eai ade DIM LN EE 5 21 Test L orch cap Seng nuno deosque A A A A AE RA A ATA IA Azad tos Ein ended 5 22 So R dk z 5 22 9 pressure transduGeF ss Ue TEES 5 23 Test 10 power switch trip 5 23 Section 6 COMPONENT REPLACEMENT Remove and replace the cover and Mylar 6 2 Removal nz wana ada 6 2 ceca ce PEE 6 3 ii powermaX45 Service Manual TABLE OF CONTENTS Replace the work lead CSA and CE ssssssssssssssssssssesssssssssssssessssssessessussssssnsessesssssecsussuesssesnsessesnsesuessessesssessseseesneessessesseessesseeaseaneesnees 6 3 Replace the power 200 240 CSA and 230 6 4 Replace the power 400 V 6 6 Replace the tan ote dedero rd uero eiui rede
52. SETUP T30v Powermax30 30 A consumables 220569 Optional deflector Mild steel Metric Arc current amps Material thickness mm 220483 Retaining cap Torch to work distance mm 220480 Nozzle Initial pierce height 220479 Swirl ring Pierce time delay sec 220478 Electrode Recommended Cut Speed mm min Air flowrate Maximum Cut Speed mm min 0 5 0 8 0 9 1 5 1 9 2 7 3 4 500 10160 10160 8900 5600 3800 2550 Maximum cut speed is limited by the test table s maximum speed 10160 mm min 1650 powermax4s Service Manual 3 21 TORCH SETUP T30v Powermax30 30 A consumables Mild steel English Air flowrate Recommended Maximum Arc current amps Material thickness in Torch to work distance in Initial pierce height Pierce time delay sec Cut Speed ipm Voltage V Cut Speed Voltage ipm V 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 Stainless steel Metric 500 Air flowrate 1 Recommended Maximum Arc current amps Material thickness mm Torch to work distance mm Initial pierce height Pierce time delay sec
53. Start switch replacement 1 The torch assembly also includes one set of the consumables listed on the next page 7 6 powermaX45 Service Manual T45v hand torch consumables Part number Shielded 220669 220670 220713 220671 220674 Gouging 220675 220672 Unshielded 220717 220718 Description Electrode Swirl ring Retaining cap Nozzle Shield Shield Nozzle Deflector Nozzle PARTS 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 220569 220483 220480 220479 220478 Description Deflector Retaining cap Nozzle Swirl ring Electrode powermaX45 Service Manual T45m machine torch parts number Description Quantity 088010 T45m machine torch assembly with 25 ft 7 6 m lead 1 088011 T45m machine torch assembly with 35 ft 10 67 m lead 1 088012 T45m machine torch assembly with 50 ft 15 24 m lead 1 1 228228 Kit T45m positioning sleeve 1 2 228229 Kit T45m removable gear rack 1 3 228322 Kit T45m front mounting ring 1 4 228323 Kit T45m rear mounting ring 1 5 228320 Kit T45m torch head replacement 1 6 228321 Kit T45m cap sensor switch replacement 1 7 058503 O ring 1 8 228317 T45m torch lead replacement 25 ft 7 6 m 1 9 228318 T45m torch lead replacement 3
54. ad connection Test points J21 Inverter IGBT Output diode and pilot arc New Power Board IGBT module D40 Input diode bridge D48 Old Power Board Input diode bridges D28 D38 5 8 powermax4s Service Manual Troubleshooting guide TROUBLESHOOTING AND SYSTEM TESTS See System tests later in this section for detailed test procedures It is important to note when troubleshooting a problem on the Powermax45 how the front panel LEDs operate To help diagnose transient problems an illuminated or blinking LED including the bottom bar on the gas pressure bar may continue to illuminate or blink for 10 to 20 seconds after the system is powered OFF Once the system is power the LED should not illuminate or blink if the fault has been cleared Also note that there is no static gas pressure reading So the gas pressure LEDs may not indicate a low pressure situation if the gas was not connected when the system was powered ON Attempting to fire the torch without the gas connected will cause the bottom yellow gas pressure LED to blink Promem rnis may mem The ON OFF power switch is set to ON 1 but the power ON LED is not illuminated The power ON LED is illuminated the fault LED is illuminated and the bottom LED on the gas pressure bar is illuminated yellow and is blinking Ge W The power ON LED is illuminated and the yellow temperature LED is illuminated powermax45 Service Manual
55. and yellow ground wire to the heatsink with a torque setting of 17 28 kg cm 15 inch pounds 15 Position the wires in the wire chase up the side of the end panel and out of the way of the power board 16 Replace or reposition the end panel Make sure that the screw hole in the ground clip aligns with the screw holes in the endcap and the power supply 17 Tighten the strain relief retention nut on the outside of the end panel 18 Being careful not to pinch any of the wires 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 use the 2 screws to secure the cover 19 Reconnect the electrical power and the gas supply powermax45 Service Manual 6 7 COMPONENT REPLACEMENT Replace the fan 1 Turn OFF the power disconnect the power cord and disconnect the gas supply 2 Remove the 2 screws from the handle on the top of the power supply Remove the handle and then lift the cover off the power supply 3 Detach the connector from J4 200 240 V CSA and 230 V CE or J5 400 V CE on the power board You may have to lift the top edge of the Mylar barrier to see the connector 4 From the top of the power supply use needlenose pliers to compress and release the 4 corner clips on the fan s plenum After you release the top clips you can tilt the plenum away from the power supply to reach the bottom 2 clips Lift the plenum off the fan casing 5 Insert a
56. as filter element if dirty Perform test 3 to test the voltage balance on the power board TROUBLESHOOTING AND SYSTEM TESTS Troubleshooting guide continued Problem ____ mismaymom __ f you are cutting expanded metal grate or any metal with holes set the mode switch to continuous pilot The work lead or work arc mode lead connection may be faulty The material being cut may require the use of continuous pilot arc mode Check for loose connections at the work clamp and at the power supply Reposition the work lead on the workpiece Arc goes out while cutting or intermittently will not fire The arc lost contact with the workpiece Clean the cutting surface to ensure a better connection with the work lead Inspect the consumables The consumables need to and replace if necessary be replaced Inspect the work lead for The work lead may be damage Reposition it and Th lity i k lead h damaged or not properly clean the work surface to e cut quality is poor work lead connection the connected to the work ensure good contact or the cut does not sever output from the power the metal supply is too low or the Check amps adjustment power board is producing amps adjustment knob setting If your input low current knob may be set too low circuit is 200 V 34 A 240 The power board may be V 28 A or faulty 400 V 10 A turn the knob to th
57. as fitting from the rear of the power supply 4 Remove the drain hose from the hole in the bottom of the power supply s base 5 Disconnect the gas supply hose from the filter supply hose Nut Bracket am SIT Gas fitting u Filter E di a Drain hose 6 Unscrew the nut that holds the air filter in the bracket the bottom of the air filter away from the power supply and slide the filter out of the bracket 7 Position the new gas filter in the bracket and replace the retainer nut 8 Route the drain hose through the hole in the base of the power supply 6 10 powermax4s Service Manual COMPONENT REPLACEMENT 9 Connect the gas supply hose to the new filter If you are replacing the hose cut the new hose to the same length as the old hose 10 Reconnect the gas fitting and then reconnect the gas supply to test it for leaks 11 Being careful not to pinch any of the wires 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 13 Reconnect the electrical power Replace the control board 1 Turn OFF the power disconnect the power cord and disconnect the gas supply 2 Remove the 2 screws from the handle on the top of the power supply Remove the handle and then lift the cover off
58. at value to a reading at pin 21 on 77 They should have the same value 3 Turn the power OFF Attach the E Z Hooks to TP 19 and TP 17 Turn the power ON after you have connected the multimeter This value should be 192 5 VDC or one half of whatever value you found in step 2 Note All values can be 10 4 Turn the power OFF and move the E Z Hooks to TP 18 and TP 17 Turn the power ON after you have connected the multimeter This value should be 192 5 VDC or one half of whatever value you found in step 2 5 The values found in steps 3 and 4 should be approximately equal If they differ by more than 30 V replace the power board Step 3 powermax45 Service Manual 5 17 TROUBLESHOOTING AND SYSTEM TESTS Test for 400 V CE power supplies For this test you can use the test point loops or you can test on the capacitor screws The test points are labeled on the back of the power board as are the voltages and positive and negative capacitor terminals Caution To test using test points do not use a multimeter with test probes Use E Z Hook leads instead and attach them to the test point loops 1 Turn OFF the power 2 Position the multimeter leads to measure the voltage on the power board by attaching the test leads with the negative lead on TP 17 and the positive lead on TP 16 on the power The multimeter should read 560 VDC If you get a value other than 560 VDC multiply the reading by 0 00601
59. ate yellow If the indicator is at the lowest part of the bar and is flashing then the gas pressure is less than the minimum required pressure powermaX45 Service Manual OPERATION wozi Amperage adjustment knob Set this knob to the gas test position fully counter clockwise before adjusting the gas pressure with 47 the pressure regulator knob the top of the power supply Once the gas pressure is set turn the knob clockwise to set the output amperage The torch will not fire when the knob is in gas test position Mode switch and LEDs EL The mode switch can be set in one of three positions 4 Continuous pilot arc to cut expanded metal or grate top Non continuous pilot arc to cut metal plate middle R 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 I OFF O power switch Activates the power supply and its control circuits 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
60. attachment 2 3 switch wires serena US sink Retaining screw Ribbon cable J7 screw Heat sink KONIE suns ox eb assembly g n o ER H1 Screw N 10 and 12 _ kJ diode screws 2 J18 Heat sink J17 assembly screw Heat sink re 5 assembly screw RW SARE 192 VDC 9 6 6 U Z J19 Y 1202 NS Retaining J20 Capacitor screws 4 Pressure relief screw J15 vents Work lead connector J21 Resistor screws 4 OLD 200 240V CSA and 230V CE Power Board 19 Replace the 3 retaining screws and the 4 resistor screws Torque these screws to 15 inch pounds 17 28 kg cm 20 Reconnect the white wire from the ON OFF switch to J1 and the black wire to J2 Torque them to 20 inch pounds 23 04 kg cm 21 Replace the 3 screws that attach the IGBTs and the screw that attaches the input bridge diodes to heatsink The torque setting for these is 20 inch pounds 23 04 kg cm If you replaced an older 200 240V or 230V CE power board you will have an addtional screw left over 22 Replace the 4 capacitor screws Be sure to reattach the black wire to the leftmost screw Torque these screws to 20 inch pounds 23 04 kg cm 23 Reconnect the wires to the transformers and inductors at J13 J14 J15 J16 J17 J18 J19 and J20 and the work
61. cations 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 is set too low See the cut charts in Section 3 for more information The torch parts are worn and need to be changed 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 The consumable 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 torch cutting height Refer to the cut charts for specifics powermaX45 Service Manual 4 15 OPERATION 4 16 powermaX45 Service Manual Section 5 TROUBLESHOOTING AND SYSTEM TESTS this section Theory of operation ette 5 2 EC t 5 2 200 240 CSA and 230 CE
62. ce time Initial pierce height delay sec Cut Speed Voltage Cut Speed Voltage mm min V mm min V 0 5 9150 118 10160 114 0 8 8650 118 10160 116 0 9 8100 10160 120 1 5 5800 7250 119 10160 10160 7620 5588 250 4318 Edge start recommended Maximum cut speed is limited by the test table s maximum speed 10160 mm min powermax45 Service Manual 3 15 SETUP T45m unshielded consumables Mild Steel English Torch Pierce time to work Initial pierce height delay s a dno distance Arc current Material amps thickness 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 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 250 250 Edge start recommended Maximum cut speed is limited by the test table s maximum speed 400 ipm 3 16 powermax4s Service Manual 45 unshielded consumables Stainless steel Metric Arc current amps Material thickness mm Torch to work distance mm Initial pie
63. ch 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 Never tighten the consumables beyond 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 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 such 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 can 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 th
64. ct the gas supply to the air fitting on the power supply Connect the work lead to the workpiece Plug in the power supply and make sure incoming power is ON if using a line disconnect box Set the ON OFF switch 51 to ON 1 The green power ON LED illuminates indicating the system is ready for operation the fault LEDs should be extinguished see Troubleshooting guide for more information Set the mode switch to the desired mode for cutting or gouging Turn the amperage adjustment knob to the gas test position The gas solenoid valve V1 opens to purge the system and to allow the gas pressure to be set Verify that the gas pressure LED illuminates green and is centered in the pressure bar Set the amperage adjustment knob to the desired output current between 20 and 45 amps based on the thickness of the metal to be cut powermax45 Service Manual Set the power switch 81 to OFF O The gas solenoid valve V1 closes The gas flow stops The arc extinguishes Gas continues to flow for 20 seconds Drag the torch lightly across the workpiece to make a cut The workpiece drops after the cut Release the plasma start trigger on the hand torch or the remote start switch for the machine torch The gas solenoid valve V1 opens The gas flow starts The cutting arc starts Position the torch on the workpiece Pull the plasma start trigger on the hand
65. cted set the ON OFF switch to ON I and measure the AC voltage from J1 to 12 labeled on the power board This value should be the same as the incoming line voltage If it is not check the ON OFF switch If the power ON LED is still illuminated perform test 2 to determine whether the power board or the control board is faulty Note All values can be 15 Single phase Black CSA Brown CE Three phase L White CSA Blue CE PE Green CSA Green yellow CE powermax45 Service Manual 5 15 TROUBLESHOOTING AND SYSTEM TESTS Test 2 power board voltage checks With the power ON use a meter to verify the voltages at the J7 pins J8 on 400 V CE power supplies listed in the following table to be certain that the power board is functioning correctly If any of the values are incorrect replace the power board Instead ground to either the ground wire clip on the rear panel or to the heat sink as shown below 1 Caution Do not use VBUS as ground Doing so could destroy power supply Note All values can be 10 J7 or J8 pin number to Test Expected value Expected value ground 200 240 V CSA or 230 V CE 400 V CE VACR rectified AC line voltage 1 95 V 230 line voltage 2 7 V 400 line voltage VBUS DC bus voltage 2 28 VDC 385 VBUS 2 178 VDC 560 VBUS 18 200 240 and 230 IPFC input current lt 0 1 VDC Not applicable 20 Start signal 3 2 VDC close
66. d 3 2 VDC closed 5 0 VDC open open Note test values at 16 you must have the torch and power supply positioned such that you can safely pull and release the torch s trigger Ground to the ground wire o clip or to the heat sink J7 J8 for 400 V 0000 25000000000000 20 o o 5 16 powermax4s Service Manual TROUBLESHOOTING AND SYSTEM TESTS Test 3 VBUS and voltage balance Test the power board to ensure that the circuits are balanced There are two procedures below Use the first procedure if you have a 200 240 V CSA power supply or a 230 V CE power supply Use the second procedure if you have a 400 V CE power supply For this test you can use the test point loops or you can test on the capacitor screws The test points are labeled on the back of the power board as are the voltages and positive and negative capacitor terminals A Caution To test using the test points do not use a multimeter with test probes Use E Z Hook leads instead and attach them to the test point loops Test for 200 240 V CSA and 230 V CE power supplies 1 Turn OFF the power 2 Position the multimeter leads to measure the boosted bus voltage on the power board by attaching the test leads to TP test point 19 and TP 18 Turn on the power The multimeter should read 385 VDC If you get a value other than 385 VDC multiply the reading by 0 00601 Compare th
67. de PARTS CIL number 1 2 3 4 5 6 7 8 228284 228285 015337 015551 015511 228287 228302 228286 228278 228277 228276 Description Designator Quantity Kit Kit Pressure sensor cable Solenoid valve 1 Quick disconnect 1 4 stainless nipple 1 4 brass coupling 1 4 X 2 brass nipple Kit Kit Kit Kit Kit Kit Filter regulator Air filter element Fan M1 CSA power cord 1 ph 200 240 V 10 ft 3 m not shown CE power cord 1 ph 230 V 3 m not shown CE power cord 3 ph 400 V 3 m not shown powermaX45 Service Manual m m m m l m ll PARTS T45v hand torch parts 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 number Description Quantity 088008 T45v hand torch assembly with 20 ft 6 1 m lead 1 088009 T45v hand torch assembly with 50 ft 15 24 m lead 1 1 228313 Kit Handle 1 2 075714 Screws 4 x 1 2 SLTD Torx PAN S B 5 3 002294 Safety trigger and spring replacement 1 4 228346 Kit Torch head replacement 1 5 058503 O ring Viton 626 x 070 1 6 228109 Kit Cap sensor switch replacement 1 7 228315 Kit Torch lead replacement 20 ft 6 1 m 1 8 228316 Kit Torch lead replacement 50 ft 15 24 m 1 9 128642 Kit
68. ded to go between the power supply and the CNC or other equipment plus an additional 18 inches 45 72 cm 1 On end of the cable that will be attached to the power supply strip the outer jacket 4 5 inches 11 43 cm Cut 2 5 inches of off wire 2 so that wire 1 is 4 5 inches 11 43 cm long and wire 2 is 2 inches 5 08 cm long Then strip 5 inches 1 27 cm of wire insulation off of each wire 2 Crimp a 6 ring on the end of wire 1 and a 10 ring on the end of wire 2 3 Remove the cover and the Mylar barrier from the power supply powermax45 Service Manual 3 27 TORCH SETUP 4 Then remove the rear panel from the Powermax45 by removing the screw from the bottom and backing the end panel away from the base so that there is enough room to drill out the access point without risk of hitting the interior components Rear panel Access point 5 Use a drill with a 19 32 drill bit to drill out the access point on the rear panel 6 Route the cable through the strain relief and tighten it down so that 18 inches 45 72 cm of insulated wire is on the side of the strain relief that will go inside the power supply 7 Thread the 18 inches 45 72 cm of wire through the hole you drilled in the rear panel and fit the strain relief into the hole If necessary drill out any remaining rough spots so that the strain relief fits snugly 8 Tighten the strain relie
69. e highest setting The consumables are worn there is a poor Verify that the mode switch is set to continuous pilot arc The pilot arc extinguishes The mode switch may be set incorrectly Perform tests 2 and 3 to The continuous pilot arc The power board or the verify that the power board feature is not working control board may be is functioning properly If faulty the power board is faulty replace it Otherwise replace the control board when you move the plasma arc off the work piece while still pulling the torch s trigger 5 12 powermax45 Service Manual TROUBLESHOOTING AND SYSTEM TESTS Control Board LEDs The Powermax45 control board 1 has 4 diagnostic LEDs Start Transfer XFR Error Reset watchdog B lt B M 1 1 8 m Control board 20 52 1420 8 Ribbon cable The control board LEDs are Start The power supply has a start signal This LED illuminates when the power supply receives a start signal and remains illuminated during normal operation Transfer This LED illuminates when there is proper arc transfer between the torch and the workpiece
70. e of other than genuine Hypertherm parts may not be covered by the Hypertherm warranty In addition the parts listed below are considered safety critical parts that must be replaced only with Hypertherm parts to maintain the warranty and all system certifications including CE CSA GOST and CCC certification Part number Description 1 228261 Kit Power board 200 240 V CSA and subcomponents 228260 Kit Power board 400 V CE and subcomponents 228259 Kit Power board 230 V CE and subcomponents 2 228265 Kit Magnetics assembly 200 240 V CSA 228273 Kit Magnetics assembly 230 V CE 228263 Kit Magnetics assembly 400V CE 3 228287 Kit Filter regulator 4 228286 Kit Fan 5 228266 Kit Power switch 200 240 V CSA and 230 V CE 228288 Kit Power switch 400 V CE 228278 Kit Power cord 200 240 V CSA not shown 228277 Kit Power cord 230 V CE not shown 228276 Kit power cord 400 V CE not shown 7 10 powermaX45 Service Manual PARTS Recommended spare parts Part number Description Page reference 108616 Amperage adjustment knob 8 2 228561 Kit Ground clamp 8 2 228300 Work cable with clamp 20 ft 6 1 m 8 2 228269 Kit Front panel 8 2 228268 Kit Rear panel 8 2 228266 Kit Power switch 200 240 V CSA and 230 V CE 8 3 228288 Kit Power switch 400 V CE 8 3 228262 Kit Control board 8 3 228261 Kit Power board 200 240 V CSA 8 3 228260 Kit Power board 400 V CE 8 3 228259 Kit Power board 230 V CE 8 3
71. e pierce is complete drag the nozzle lightly along the workpiece to proceed with the cut 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 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 4 10 powermaX45 Service Manual 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 torch Changing the torch angle changes the dimensions of the gouge OPERATION Direction of travel Note heat shield is available for added hand and torch protection part number 220049 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 10 ipm 254 mm min 0 3051 in 7 75 mm 0 0415 in 1 05 mm 20 ipm 508 mm min
72. e 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 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 7 10 Earthing of the workpiece Where the workpiece is not bonded to earth for electrical safety nor connected to earth because of its size and position for example ship s hull or building steel work 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
73. e system through the power switch S1 to the input diode bridges D28 D38 The voltage from the diode bridge supplies the power factor correction PFC choke which provides a nominal 560 VDC bus voltage The bus voltage then supplies voltage and current to the inverter and the flyback circuit power supply DC to DC converter on the power board PCB2 The power board provides noise suppression and spike protection A soft start is implemented via the power board resistor and relays K2 The inverter consists of a dual IGBT package Q2 the power transformer a current sense transducer and the control circuit The inverter operates as a pulse width modulated half bridge circuit driving an isolation transformer The secondary of the isolation transformer is rectified by the output bridge D40 The output circuitry consists of 2 current sense transducers located on the power board the pilot arc IGBT inside the 040 module and the output choke The control board s digital signal processor DSP monitors and regulates the system s operation and safety circuits The amperage adjustment knob is used to set the output current to the desired value between 20 and 45 amps The system compares the set point to the output current by monitoring the current sense transducers and adjusting the pulse width output of the inverter IGBT O2 5 2 powermax45 Service Manual TROUBLESHOOTING AND SYSTEM TESTS Sequence of operation Power OFF Conne
74. e workpiece The torch may travel more smoothly if you clean check and tune the rails and drive system on the cutting table Unsteady machine motion can cause 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 4 12 powermax45 Service Manual OPERATION 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 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 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 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
75. ed and found compliant with product safety regulations required for sale in China powermaX45 Service Manual 1 7 SPECIFICATIONS IEC symbols The following symbols 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 O aC I S 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 powermax4s Service Manual Section 2 POWER SUPPLY SETUP In this section Unpack the EA a AAA a 2 2 Claims A dd A SA A ARA AE 2 2 uc ne c 2 2 Position the power supply netter et rini aie inch int Deest E use aa ux B ase B isla iets 2 3 Prepare the electrical OWE 2 3 NER 2 3 Install line disconnect SWITCH acini nerien 2 4
76. eful not to pinch any of the wires replace the Nomex barrier and 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 13 Reconnect the electrical power and the gas supply Replace the power board 200 240 V CSA and 230 V CE Before beginning this procedure make sure you have the correct power board for your system The replacement kit for a CSA power board is part number 228261 The replacement kit for a 230 V CE power board is part number 228259 The procedure below applies to the 200 240 V CSA and the 230 V CE power boards 1 Turn OFF the power disconnect the power cord and disconnect the gas supply 2 Remove the 2 screws from the handle on the top of the power supply Remove the handle and then lift the cover off the power supply Remove the Nomex barrier that protects the power board Caution Static electricity can damage circuit boards Use proper precautions when handling printed circuit boards Store PC boards in anti static containers Wear a grounded wrist strap when handling PC boards 3 Detach the ribbon cable from J7 on the heatsink side of the power board See the illustrations on the following pages for the location of the ribbon cable and the components listed in the next steps 4 Remove the connectors at J10 J12 and J22 on the heatsink side of the power board 5 Remove the connectors at J3 J4 and J5 on
77. entation to you purporting to be binding upon Hypertherm 4 10 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 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 liability breach of warranty failure of essential purpose or other
78. er 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 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 be necessary to take additional precautions such as filtering of the mains supply EMC 1 7 10 ELECTROMAGNETIC COMPATIBILITY Consideration should be given to shielding the supply cable of permanently installed cutting equipment in metallic conduit or equivalent Shielding should be electrically continuous through out 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 b
79. erform test 1 to check the incoming line voltage Correctly install the consumables Perform test 7 to test the cap sensor switch Check the consumables for wear and replace if necessary Make sure they are properly installed Verify that they are finger tight Try loosening them 1 8th of a turn and restarting the power supply Perform test 5 and replace the torch head if necessary The error LED on the control board should be flashing the number of times it flashes between pauses indicates which components to test See Control board LEDs in this section Release the torch trigger and turn OFF the power supply and then turn it ON again to reset the unit Be sure to allow time for the soft start circuit to be satisfied Perform test 6 to test the start signal Troubleshooting guide continued Problem The power ON LED is illuminated and no fault LEDs are illuminated but no gas flows when the torch trigger is pulled Gas flows when the system is powered ON When pulling the torch s trigger gas flows from the torch but the torch does not fire or fires only for a short period of time or the pilot arc starts but extinguishes before the normal 5 second time out period This may mean The start signal is not reaching the control board The incoming gas pressure is too high or the system is in gas test mode The consumables torch or torch lead are not functioning correctly
80. f nut on the inside of the rear panel to hold the strain relief in place 9 Find the grommet closest to the rear panel and at the bottom of the center panel Route the 2 wires through the grommet to the power board side of the power supply Rear panel pulled slightly away from the base Grommet in center panel 3 28 powermax4s Service Manual SETUP 10 Route wires along base of the unit and behind the cables connected to power board 11 Remove the work lead connector screw at J21 and the white wire connector screw at J19 J18 for 400 V CE power supplies 12 Connect wire 1 to J19 J18 for 400 V CE power supplies with the ring connector for wire 1 closest to the power board and the connector for the white wire closest to the head of the screw Turn the ring connector for wire 1 upside down so that the slight bend in the ring connector base creates a little space between the wire and the board Tighten the screw to 20 in lbs 23 1 kg cm 13 Connect wire 2 to J21 This time put the connector for the work lead closest to the power board and put the ring connector for wire 2 closest to the head of the screw Torque the screw to 20 in lbs 23 1 kg cm J19 or J18 white wire TP 19 18 17 192 VDC 192 VDC E o J21 work lead 14 Replace the Mylar barrier in front of the power board Replace the rear pa
81. fer 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 50 1 arc voltage in addition to signals for arc transfer and start plasma Use kit number 228350 25 ft 7 62 m or 228351 50 ft 15 24 m for 6 wires terminated with spade connectors example shown on the next page 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 powermax4s Service Manual 3 25 TORCH SETUP To use signals for arc transfer and start plasma only 4 wires use either part number 023206 25 ft 7 62 m or part number 023279 50 ft 15 24 m These cables have spade connectors as shown here a Note The cover on the machine interface receptacle prevents dust and moisture from damagi
82. h lead replacement 50 ft 15 24 m 8 7 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 below Data plate T45v CONSUMABLE PARTS Plaque signal tique m Pi ces Consommables T45v cd c 220717 220718 LA 0790 E 220674 220713 220671 220670 220669 a 4 220675 220672 110672 Rev B Consumable label CE safety label AIR 9 BAR MAX N2 135 PSI MAX 110610 REVA Maximum pressure label CSA safety label 7 12 powermax45 Service Manual Section 8 WIRING DIAGRAMS this section Control board diagrams ec Pm 8 2 200 240 V 230 V CE 8 2 X 8 3 GFA 8 5 200 240V CSA 230 E E E et E E la do ai tow de b 8 5 ON CE c EI s 8 6 powermaX45 Service Manual 8 1 WIRING DIAGRAM Control board diagrams 200 240 V CSA and 230 V CE MACHINE FRONT IRESET or ERROR R HDRFLT CODE XFR START SERIAL CAPOFF TSO TSC YEL YEL GRN DSP 2806 4x25Mhz 100Mhz 0 78 x 0 78 Stayout for TEST CLIP CPA UP NORMAL MIDDLE GOUGE DOWN Expected value ee VACR rect
83. harts and torch setup information see Section 3 Torch setup Information about the controls and LEDs steps for system operation and hints for improving cut quality see Section 4 Operation Troubleshooting see Section 5 Troubleshooting and system tests Maintenance and repair instructions see Section 6 Component replacement Part numbers and ordering information for accessories and replacement parts see Section 7 Parts Wiring and timing diagrams see Section 8 Wiring Diagrams 1 2 powermax45 Service Manual SPECIFICATIONS Power supply dimensions and weights Dimensions 13 7 in 34 8 cm 12 19 in 31 cm 16 75 in 42 6 cm 17 2 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 10ft 3 m power cord CSA power supply 37 lbs 16 8 kg 230 power supply 36 5 Ibs 16 6 kg 400 V power supply 35 Ibs 15 9 kg powermaX45 Service Manual 1 3 SPECIFICATIONS Power supply ratings Rated open circuit voltage Ug CSA CE single phase CE 3 phase Rated output current lo 20Ato45A Rated output voltage 02 132 VDC Duty cycle at 40 50 45 Us 132 V See data plate on power supply for 60 1 41 Us 132 V more information on duty cycle 100 90 15232 A Up 132 V Operating temperature 14 to 104 F 10 to 40 C Storage temperature 13 to
84. ide of the endcaps Being careful not to pinch any of the wires slide the cover back onto the power supply Make sure that the bottom edges are in the tracks and that the slot in the top ofthe 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 Replace the work lead CSA and CE COMPONENT REPLACEMENT Three notches 5 Four notches i Tab Cover slot 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 on the power board that attaches the lead to the board Set the screw aside 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 powermax4s Service Manual COMPONENT REPLACEMENT Front panel R Work lead 18 18 17 RO f 482 192 VDC i NE Strain relief Work lead connection to power board J21 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 c
85. ified AC line voltage 1 95 V 230 line voltage Bus DC bus DC bus voltage 2 28 VDC 228VDC 385VBUS 385 VBUS 18 200 240 and 230 V only IPFC input current 0 1 VDC 2 FB output current output current current lt 0 1 ITF transfer current lt 0 1 VDC a 24V sensepin sense pin 2 2 22 Start signal 3 2 VDC closed DA 0 VDC open powermax45 Service Manual WIRING DIAGRAM Control board diagrams 400 V CE MACHINE R L FRONT or ERROR HDRFLT CODE XFR START SERIAL CAPOFF1 FAULT1 AC 1 DATA TSO TSC L H LINE YEL YEL GRN O GRN SZ 2 AMPS1 52 2806 4x25Mhz 100Mhz 0 78 x 0 78 Stayout for MORE TEST CLIP CPA UP NORMAL MIDDLE 2 52 OON CASE SZ GOUGE DOWN Expected value VACR rectified AC line voltage 2 7 V 400 line voltage u jesce 21 IFB output current lt 0 1 VDC ITF transfer current lt 0 1 VDC Start signal 3 2 VDC closed SA 0 VDC open powermaX45 Service Manual 8 3 WIRING DIAGRAM powermaX45 Service Manual MACHINE REAR o OAWG 50A 250V with 32v TRIP COIL Y Cap 300vac 8 2uF 8 2uF 630VDC 630VDC 8 2uF 630VDC 2 40 x 1 65 1 60 max zone POWER PWA 230V 141005 Top Level 230V CE 141046 Top Level 8 45 h x 13 00 w 202 plated to 3oz FACING COMPONENT SIDE OF PCB FAN 190CFM GAS SOL 24v 0
86. ink assembly screw hole remove the 2 screws that attach the IGBTs and the screw that attaches the input bridge diode to the heatsink There are holes in the power board to provide access to them s m Retaining screw Retaining screw I 9 IGBT attachment Heat sink screws 2 switch wires assembly Ribbon cable J8 A screw Heat sink S assembly m m m AJ screw NE J10andJ12 ICS Input J13 bridge i diode 114 screws 2 J15 16 Heat sink Heat sink assembly assembly screw screw 21 2 J18 7 1027 17 Retaining J20 Capacitor screws 4 screw Pressure relief vents Work lead Resistor screws 4 connector J21 OLD 400V Power Board 6 16 powermax4s Service Manual 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 COMPONENT REPLACEMENT Remove the screws at J1 J2 and J3 that secure the 3 white wires from the bottom of the ON OFF switch to the power board Stand up the unit again Tuck out of the way all the wires that you detached Pull the board straight out from the power supply Before installing a new power board clean the heatsink with isopropyl alcohol Gently scrub away any residual thermal compound being careful not to scratch the heatsink Wipe it with a clean cloth Spread a thin layer of thermal compound included in
87. ip coil mechanism is functioning properly If it does not stay in the ON position replace the power switch powermax45 Service Manual 5 23 TROUBLESHOOTING AND SYSTEM TESTS 5 24 powermax45 Service Manual Section 6 COMPONENT REPLACEMENT this section Remove and replace the cover and Mylar 6 2 Inda 6 2 Replacement 6 3 Replace the work lead CSA and 6 3 Replace the power cord 200 240 CSA and 230 6 4 Replace the power cord 400 V 6 6 Replace the ara Replace the gas filter element Replace the as Titer Replace the control bOard Aaaa dat kd Aaaa Replace the power board 200 240 V CSA and 230 V CE Replace the power board 400 V powermax45 Service Manual 6 1 COMPONENT REPLACEMENT DANGER ELECTRIC SHOCK CAN KILL Disconnect electrical power before performing any maintenance All 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
88. iting 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 Safety information A Before operating any Hypertherm equipment read the separate Safety and Compliance Manual 806690 included with your product for important safety information 5 Electromagnetic compatibility ttt AAA AA nr tr teet eret EMC 1 M W 1 Section 1 SPECIFICATIONS System dESCHIPLION m MM 1 2 Where to Intormation iia ie ic id 1 2 Power supply dimensioris and weights nitet settembre Rosita sede Ee nes to cte sitet uta 1 8 bnc H MP 1 3 a AZ 1 3 Power supply ratings idit a alive never 1 4 toreh dimensions vacance titia dne c Hua EET or EO ER Rada ka FR qua iii Wi s 1 5 TAbrmitorch uer Cert atta as dar a i A ia Gi 1 5 T45y and 145m totch SpECIIGALIONS
89. ity 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 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 In some cases this remedial action may be as simple as earthing the cutting circuit see Earthing of the work piece 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 electromagnetic problems in the surrounding area The following shall be taken into account Compliance Information a Other supply cables control cables signaling and telephone cables above below and adjacent to the cutting equipment b Radio and television transmitters and recelvers c Computer and oth
90. iving the proper gas pressure 1 Turn ON the power 2 Check the voltage between pins 1 and 2 of J5 for 200 240 V CSA and 230 V CE power supplies or pins 1 and 2 of J6 for 400 V CE power supplies It should read approximately 0 2 V if there is no gas pressure If the gas pressure is within system tolerances the circuit should read approximately 3 3 V The minimum acceptable gas pressure varies by torch type torch lead length and mode switch setting as shown in the following table Continuous pilot arc Handheld 20 ft 50 psi 50 psi 25 psi 6 1 m 3 45 bar 3 45 bar 1 72 Handheld 50 ft 55 psi 55 psi 30 psi 15 24 m 3 80 3 80 2 07 Mechanized 25 ft 50 psi 50 psi 25 psi 7 62 m 3 45 bar 3 45 bar 1 72 bar Mechanized 35 ft 55 psi 50 psi 25 psi 10 7 3 45 bar 3 45 bar 1 72 bar Mechanized 50 ft 55 psi 55 psi 30 psi 15 25 m 3 80 bar 3 80 bar 2 07 bar Test 10 power switch trip coil The 200 240 V and the 230 V CE power supplies have over voltage protection on the power switch in the form of a mechanical trip coil If voltage provided by the incoming circuit is greater than the maximum voltage the trip coil will switch OFF the power supply If the power supply appears to be shutting down unexpectedly test the power switch 1 With the power switch in the OFF position disconnect the electrical power 2 Move the power switch to the ON position If the switch stays in position the tr
91. lead ring terminal at J21 Torque them to 20 inch pounds 23 04 kg cm 24 Replace the connectors at J10 and J12 and the connectors at J3 J4 J5 and J6 25 Reconnect the ribbon cable from the control board to the power board at J7 6 14 powermax45 Service Manual COMPONENT REPLACEMENT 26 Being careful not to pinch any of the wires 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 use the 2 screws to secure the cover 27 Reconnect the electrical power and the gas supply Replace the power board 400 V CE Before beginning this procedure make sure you have the correct power board for your system The part number for a 400 V CE power board is 228260 This power board has a small slot immediately below the heat sink assembly screw hole and a single input bridge diode 1 Turn OFF the power disconnect the power cord and disconnect the gas supply 2 Remove the 2 screws from the handle on the top of the power supply Remove the handle and then lift the cover off the power supply Remove the Nomex barrier that protects the power board 3 Detach the ribbon cable from J8 on the heatsink side of the power board See the illustrations on this page and the following page for the location of the ribbon cable and the components listed in the next steps 4 Remove the connectors at J10 J12 and J22 on the heatsink side of the power board
92. mended Maximum Arc Material Torch Pierce time current thickness to work Initial pierce height delay amps in distance in sec Cut Speed Voltage Cut Speed Voltage ipm V ipm V 0 036 20 Ga 0 060 16 Ga 0 075 14 Ga 0 105 12 Ga 500 0 135 10 Maximum cut speed is limited by the test table s maximum speed 400 ipm 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 3 24 powermax45 Service Manual SETUP Connect 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 rear of the power supply Note The remote start pendant is for use only with a machine torch It will not operate if a hand torch is installed Receptacle for the remote start pendant or a machine interface cable 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 power supply provides access to the 50 1 arc voltage and signals for arc trans
93. nd 49 6181 58 2100 Tel 49 6181 58 2134 Fax 49 6181 58 2123 Technical Service Hypertherm S Pte Ltd 82 Genting Lane Media Centre Annexe Block 01 01 Singapore 349567 Republic of Singapore 65 6841 2489 Tel 65 6841 2490 Fax 65 6841 2489 Technical Service Hypertherm Shanghai Trading Go Ltd Unit A 5th Floor Careri Building 432 West Huai Hai Road Shanghai 200052 PR China 86 21 5258 3330 1 Tel 86 21 5258 3332 Fax 12 17 09 Hypertherm Europe B V Vaartveld 9 4704 SE Roosendaal Nederland 31 165 596907 Tel 31 165 596901 Fax 31 165 596908 Tel Marketing 31 165 596900 Tel Technical Service 00 800 4973 7843 Tel Technical Service Hypertherm Japan Ltd Level 9 Edobori Center Building 2 1 1 Edobori Nishi ku Osaka 550 0002 Japan 81 6 6225 1183 Tel 81 6 6225 1184 Fax Hypertherm Brasil Ltda Avenida Doutor Renato de Andrade Maia 350 Parque Renato Maia CEP 07114 000 Guarulhos SP Brasil 55 11 2409 2636 Tel 55 11 2408 0462 Fax Hypertherm M xico S A de C V Avenida Toluca No 444 Anexo 1 Colonia Olivar de los Padres Delegaci n lvaro Obreg n M xico D F C P 01780 52 55 5681 8109 Tel 52 55 5683 2127 Fax 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 compatibil
94. nel and secure it with the screw Replace the cover 15 Connect the other end of the cable to the equipment according to the manufacturer s instructions powermax4s Service Manual 3 29 TORCH SETUP Connect the torch lead The Powermax45 has a quick disconnect system for connecting and disconnecting the hand and machine torches When connecting or disconnecting a torch first power OFF the system To connect either torch push the connector into 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 powermax4s Service Manual Section 4 OPERATION In this section Controls and 4 2 Froht controls ED W aS 4 2 Rear 4 3 Operate the 4 5 4 3 Connect the electrical power and gas supply sese nter terne ntn tn tenente tenens 4 3 4 4 Set tho mode dio oe DI 4 4 Adiust hegas pressu M RS 4 4 Check the indicator LEDS qu Dm 4 6 Attach the workclampis 55 sunt 4 6 Understand d tyscycle O de aan 4 6 How to use the hand torch
95. ng the receptacle when not in use This cover should be replaced if damaged or lost part number 127204 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 on the other end plug it into the appropriate pin connector on the torch height controller or CNC 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 available through the machine interface cable are shown below The table on the next page provides details about each signal type
96. onnector 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 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 Reconnect the electrical power and the gas supply Replace the power cord 200 240 V CSA and 230 V CE Turn OFF the power disconnect the power cord and disconnect the gas supply Remove the 2 screws from the handle on the top of the power supply Remove the handle and then lift the cover off the power supply Remove the Mylar barrier that protects the power board The 200 240 V power cord has a black wire and a white wire that connect to the power switch and a green ground wire that connects to the heatsink The 230 V CE power cord has a brown wire and a blue wire that connect to the power switch and a green yellow ground wire that connects to the heatsink Remove the rear end panel or gently tilt it away from the power supply 6 4 powermax4s Service Manual COMPONENT REPLACEMENT 4 Remove the screw that secures the connector for the white or blue wire from the power switch to disconnect it Single phase 5 Remove the black or brown wire the
97. 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 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 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 Com
98. owermaX45 Service Manual i 5 Connect the electrical power and gas saseta 4 3 Power ON the toe tnde ER AE Aa t red dai te ie aa dca cad ecu d rias 4 4 Set mode SWICK niece 4 4 Adjust the T 4 4 Check the indicator LEDS EE 4 6 Attach the work clamp et deat ine ee ii a ee oie ed Pia Eel des o ce 4 6 Understand duty cycle limitations int rnt ettet tet etn tentum capt ient kabet ADWARE Aa WRA 4 6 How touse the t e di tnc Fenix itu 4 7 Operate the safety trigger eterne 4 7 Hand torch cutting hints ttt tie 4 7 Start a cut from the edge of the workpiece tnn ttn tent tritt etate treten WAW W RADA AA EASY 4 8 Pierce a WOrkple Ce kai z 4 9 Gouge WOTKPIGCE oaza ia A A EO AA 4 10 Commaon harid cutting faults i n dene i a cci tede ada 4 12 Flow to use the Machine d ehe adt AO c LR HR 4 12 Ensure the torch and table are set 4 12 Understa dia nd optimize quality cort ottiene tee itc Fc ctn ta e e ecu cre
99. place 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 use the 2 screws to secure the cover Reconnect the electrical power and the gas supply powermax4s Service Manual 6 17 COMPONENT REPLACEMENT 6 18 powermax4s Service Manual Section 7 In this section Power Supply parts aiiud nux GAZA A Ada adi ai aC AE 7 2 LE UC do R AE O A 7 2 interiot power Sie pe RE 7 4 lite rior rali Side 7 5 MAD A 7 6 T45v torch CONSUMADIES wii aaa 7 7 Powermax30 30 A consumables 7 7 145mimachi e torch Parts A A AAU ad a l 7 8 T45m machine torch CONSUMADIES s sscscssscsescsssesssssssssessessesesescscscssscesacaususssuesssesesesesesessscacacasecacacauacaaseseseseessseeensseatasereterarens 7 9 a aiw Oi 7 9 Powermax45 5 TE data a 7 9 critical paS R o
100. plains 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 consumables you are using The T30v Powermax30 30 amp 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 good rule of thumb is that set of consumables will last approximately 1 to 2 hours of actual arc on time for hand cutting depending on these factors For machine torch cutting consumables will last about 3 to 5 hours You will find more information about proper cutting techniques in Section 4 Operation Hand torch setup Safety trigger 3 2 powermax45 Service Manual SETUP Choose consumables The Powermax45 with the T45v handheld torch comes with a full set of consumables for cutting installed on the torch spare electrode
101. pliance Information WARRANTY Hypertherm provides repair replacement or adjustment of the Product as the sole and exclusive remedy if and only if the warranty set forth herein 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 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 repres
102. plies voltage and current to the inverter and the flyback circuit power supply DC to DC converter on the power board PCB2 The power board provides noise suppression and spike protection A soft start is implemented via the power board resistor and relays K1 K2 The PFC boost converter consists of an insulated gate bipolar transistor IGBT 02 PFC choke and control circuit It provides a 385 VDC bus voltage when the input AC voltage is between 200 and 240 VAC The inverter consists of a dual IGBT package Q3 the power transformer a current sense transducer and the control circuit The inverter operates as a pulse width modulated half bridge circuit driving an isolation transformer The secondary of the isolation transformer is rectified by the output bridge D38 The output circuitry consists of 2 current sense transducers located on the power board the pilot arc IGBT inside the D38 module and the output choke The control board s digital signal processor DSP monitors and regulates the system s operation and safety circuits The amperage adjustment knob is used to set the output current to the desired value between 20 and 45 amps The system compares the set point to the output current by monitoring the current sense transducers and adjusting the pulse width output of the inverter IGBTs Q3 A trip coil on the power switch provides over voltage protection 400 V CE 3 phase power supply functional description AC power enters th
103. ponent until the problem is found After the problem has been located and repaired refer to the Sequence of operation flow diagram in this section to test the power supply for proper operation 1 With the power disconnected and the torch removed from the power supply set the ON OFF switch S1 to ON 1 2 Check the resistance across the input leads the leads are identified with AC printed on the power board 200 240 V CSA and 230 V CE resistance across the input leads 75 400 V CE resistance across the input leads 2 5 MO 3 Check the resistance from the input leads to ground to verify that it reads as open For all power supplies the resistance from input to ground should read as gt 20 MO Note With the power disconnected and the ON OFF switch S1 set to OFF all circuits should read as open The electrical values shown are 25 4 Check the output resistance for the values shown in the following table Measure resistance 200 240 400 V CE power Approximate from 230 V CE power poate board location values location Work lead to nozzle J21 to J17 J21 to J16 100 Work lead to electrode J21 to J19 J21 to J18 20 Electrode to nozzle J19 to J17 J18 to J16 120 If no problems were found during the visual inspection or the initial resistance check and the power supply still does not operate correctly see the Troubleshooting guide Note The Troubleshooting guide provides mo
104. pply and torch are suitable for operations carried out in environments with in creased hazard of electrical shock per IEC 60974 1 lt CSA mark Hypertherm 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 C 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 ec 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 test
105. pressure bar Amperage Mode switch adjustment knob Temperature LED yellow When illuminated this LED indicates that the power supply 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 If this LED illuminates the power must be turned OFF the consumables installed properly and the system turned ON again to reset it 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 ON and that the safety interlocks are satisfied Gas pressure LED and pressure bar yellow green 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 the pressure bar will be above the mid point of the bar If it is too low the indicator will be below the mid point At the highest and lowest points on the bar the indicator will illumin
106. rce height Pierce time delay sec Cut Speed mm min Voltage V TORCH SETUP Air flowrate 151 Recommended Maximum Cut Speed mm min Voltage V Maximum cut speed is limited by the test table s maximum speed 400 ipm or 10160 mm min 0 5 0 8 0 9 1 5 250906 10160 10160 9000 10160 10160 0 1 9144 0 3 5080 0 4 3556 0 5 2032 0 6 1270 0 8 762 Edge start recommended powermax45 Service Manual 457 229 3 17 TORCH SETUP T45m unshielded consumables Stainless steel English Air flowrate Recommended Maximum Arc current amps Material thickness in Torch to work distance in Initial pierce height Pierce time delay sec Cut Speed mm min Voltage V Cut Speed Voltage mm min V 0 018 in 26 Ga 0 030 22 Ga 0 036 in 20 Ga 0 060 in 16 Ga 250906 Edge start recommended Maximum cut speed is limited by the test table s maximum speed 400 ipm 3 18 powermax45 Service Manual 45 unshielded consumables Aluminum Metric Arc current amps Material thickness mm Torch to work distance mm Initial pierce height Pierce time dela
107. re incorrect replace the power board Faulty gas solenoid valve Replace the gas solenoid valve Faulty fan Replace the fan a Machine motion relay fault Replace the power board 5 14 powermax45 Service Manual TROUBLESHOOTING AND SYSTEM TESTS System tests There is a ground clip near the top of the rear endcap that can be used as ground for any tests that require the multimeter to be attached to ground There is also a ground on the heat sink with access next to the power board and below the power switch Ground wire clip CHEFS ID he Voltages of up to 50 VDC continue to be present on the DC bus for at least 30 seconds after disconnecting the input power Allow bus voltages to dissipate before performing any tests Test 1 voltage input Check the incoming voltage and the line voltage to the top of the power switch S1 2 Disconnect the electrical power and the ON OFF switch to OFF Once you have your test leads in place reconnect the electrical power Leave the ON OFF switch set to OFF The voltage should equal the line voltage of the incoming circuit the AC voltage is incorrect check to see that you have power to the unit If you do have power check the power cord for damage With the electrical power conne
108. s 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 below 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 gauge stainless steel you may prefer to reduce the amperage setting to 30 amps and use the T30v Powermax30 30 A consumables available from Hypertherm 45 shielded consumables A 220674 220713 220671 220670 220669 Shield Retaining cap Nozzle Swirl ring Electrode T45v gouging consumables ma 220675 220713 220672 220670 220669 Shield Retaining cap Nozzle Swirl ring Electrode powermax45 Service Manual 3 3 SETUP T45v unshielded consumables O DM CM 11 220717 220713 220718 220670 220669 Deflector Retaining cap Nozzle Swirl ring
109. s 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 reduce high speed dross Decrease the cutting speed Decrease arc voltage to 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 will likely produce 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 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
110. sconnect the power cord and disconnect the gas supply 2 Usea 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 powermax4s Service Manual 5 5 TROUBLESHOOTING AND SYSTEM TESTS 4 Remove the Mylar barrier from the power board side of the power supply Be certain to replace the barrier when you are finished working on the power supply 5 Inspect the inside of the power supply especially on the side with the power board Look for broken or loose wiring connections burn and char marks damaged components and so on Repair or replace as necessary Initial resistance check resistance values must be taken with the power disconnected and all internal power supply wires attached Perform the steps in Internal inspection before continuing in this section resistance values are not close 250 to the values given in this section isolate the problem by removing wires attached to the resistance check points or com
111. screw and nut that secure the torch s power cable to the plunger Turn the plunger if necessary to gain access to the screw 5 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 6 Route the torch lead through the cutting table s track 7 Reattach the torch s power 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 8 Reconnect the gas line to the torch lead 9 Press the two halves of the cap sensor switch s wire connector together 10 Slide the positioning sleeve over the torch body and check the alignment of the screw holes Replace the three screws at each end 11 If you will be using the gear rack re attach it with the 2 black screws you removed earlier 12 Attach the torch to the lifter per the manufacturer s instructions powermax4s Service Manual 3 7 TORCH SETUP Choose the consumables cut charts WARNING INSTANT ON TORCHES PLASMA ARC 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
112. screws 3 Ribbon cable 17 Heat sink Heat sink assembly Screw eoe oo seos New board has and J12 a slot here Input bridge J13 i amp EJ diode screw J14 J18 J16 Heat sink J17 assembly screw Heat sink 18 17 p RO 192 VDC Retaining Capacitor screws 4 Pressure relief screw Work lead vents Ha connector J21 Resistor screws 4 NEW 200 240V CSA PN 141005 and 230V CE Power Board PN 141046 12 Stand up the unit again Tuck out of the way all the wires that you detached 13 Pull the board straight out from the power supply 14 Before installing a new power board clean the heatsink with isopropyl alcohol Gently scrub away any residual thermal compound being careful not to scratch the heatsink Wipe it with a clean cloth 15 Spread a thin layer of thermal compound included in the parts kit 2 mil thick about the thickness of a sheet of paper on all the IGBTs and the input bridge diodes NOTE Remix the compound if the material separates 16 Line up the holes for the capacitor screws with the capacitors the pressure relief vents should be visible from the two notches in the power board 17 Push the power board straight in 18 Replace the 4 heatsink assembly screws and torque them to 20 inch pounds 23 04 kg cm powermax45 Service Manual 6 13 COMPONENT REPLACEMENT 23 J4 and J5 Retaining screw IGBT
113. st probable causes and solutions Study the system wiring diagram and understand the theory of operation before troubleshooting Before purchasing any major replacement component verify the problem with Hypertherm Technical Service or the nearest Hypertherm repair facility 5 6 powermax4s Service Manual TROUBLESHOOTING AND SYSTEM TESTS 200 240V CSA and 230 V CE power supply overview Control board 1 Flyback circuit PE ground Power board PCB2 Power switch 81 Al a 3 n y v 0 u uu uu 19 18 o 192 VDC 192 vlc v D 8 Q 3 NJ EJ Inverter IGBT V Work lead connection 03 Test points PFC IGBT O2 121 New Power Board Output diode and pilot Input diode bridge IGBT module 038 D48 Old Power Board Input diode bridge D29 D39 powermax4s Service Manual 5 7 TROUBLESHOOTING AND SYSTEM TESTS 400 V CE power supply overview PE ground T Power switch S1 Control board PCB1 Packet __ A 3 W o A 17 7280 280 VD AH v 8 9 il SS y gt lt Work le
114. sted in the front of this manual Claims for defective or missing merchandise If any component is missing or defective contact your Hypertherm distributor If you need additional assistance call the nearest Hypertherm office listed in the front of this manual Contents Verify the items in the box against the illustration Operator Manual N ay CSA Quick Setup Card ZZ 230V Registration Card Setup DVD e CHE 400 CE Box with extra consumables Remote start pendant optional Shoulder strap 2 2 powermaX45 Service 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
115. th either the remote start pendant or a 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 torch 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 ring and to the torch bogy Slide the positioning sleeve off the torch 3 6 powermax4s Service Manual SETUP 3 Disconnect the wires for the cap sensor switch at the connector in the middle Gas supply line connection Cap sensor switch s Screw to connect the wire connector power cable to the plunger 4 Use a 2 Phillips screwdriver and a 1 4 inch nut driver or adjustable wrench to remove the
116. than with edge starts The cut charts include a column for the height at which the torch should be when starting a pierce For the Powermax45 the pierce height is generally 2 5 times the torch cutting 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 4 14 powermaX45 Service Manual OPERATION machine cutting faults The torch pilot arc will initiate but will not transfer Causes can be The work cables connection on the cutting table is not making good contact or the table is not properly grounded The torch to work distance is too great 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 specifi
117. the gas pressure may be too low or too high the air quality may be poor or there is a voltage imbalance on the power board powermax4s Service Manual TROUBLESHOOTING AND SYSTEM TESTS The torch or torch lead may be damaged The power board may be faulty The control board may be faulty Verify that the mode switch is not set to gas test mode The gas pressure from the compressor or cylinder may be too high The gas solenoid valve may be faulty The consumables may be worn or damaged The torch or torch lead may be damaged The gas pressure is too high or too low or the gas supply is restricted The gas filter element is dirty The power board is faulty Ensure that the gas is connected gas pressure LED will illuminate yellow after the torch is activated Inspect the torch and torch lead for damage Verify that the control board start LED illuminates when the trigger is pulled If it does not perform test 6 to check the start signal from the power board Check the gas supply to make sure that it does not exceed 135 psi 9 3 bar If necessary reduce the pressure Perform test 4 to verify that the gas solenoid valve is functioning correctly Inspect the consumables torch and lead Replace any damaged parts Verify that the gas supply is providing at least 65 psi 4 5 bar and does not exceed 135 psi 9 3 bar Repair any restrictions in the supply line Replace the g
118. the heatsink side of the power board 6 Remove the connector for the red and black wires from the power switch at J6 from the heatsink side of the power board J6 is located about an inch down from the top edge of the board 7 Remove the wires for the transformers and inductors at J13 J14 J15 J16 J17 J18 J19 and J20 8 Remove the work lead ring terminal from J21 and the 4 capacitor screws 9 Remove the 3 retaining screws the 4 heatsink assembly screws and the 4 resistor screws 10 f you have an older 200 240V CSA or 230V CE power board that has 2 input bridge diodes and without the small slot below the heat sink assembly screw hole remove the 3 screws that attach the IGBTs and the 2 screws that attach the input bridge diodes to the heatsink There are holes in the power board to provide access to them If you have a new 200 240V CSA or 230V CE power board that has a single input bridge diode and has a small slot below the heat sink assembly screw hole remove the 3 screws that attach the IGBTs and the screw that attaches the input bridge diode to the heatsink There are holes in the power board to provide access to them 11 Remove the screw at J1 that secures the white wire and the screw at J2 that secures the black wire from the ON OFF switch to the power board 6 12 powermax45 Service Manual COMPONENT REPLACEMENT J3 J4 and J5 Retaining screw Retaining screw ON OFF switch wires IGBT attachment
119. the parts kit 2 mil thick about the thickness of a sheet of paper on all the IGBTs and the input bridge diode NOTE Remix the compound if the material separates Line up the holes for the capacitor screws with the capacitors the pressure relief vents should be visible from the two notches in the power board Push the power board straight in Replace the 4 heatsink assembly screws and torque them to 20 inch pounds 23 04 kg cm Replace the 3 retaining screws and the 4 resistor screws Torque these screws to 15 inch pounds 17 28 kg cm Reconnect the 3 white wires from the ON OFF switch to J1 J2 and Torque them to 20 inch pounds 23 04 kg cm Replace the 2 screws that attach the IGBTs and the screw that attaches the input bridge diode to the heatsink The torque setting for these screws is 20 inch pounds 23 04 kg cm If you replaced an older 400 V CE power board you will have an additional screw left over Replace the 4 capacitor screws and torque them to 20 inch pounds 23 04 kg cm Be sure to reattach the black wire to the leftmost screw Reconnect the wires to the transformers and inductors at J13 J14 J15 J16 J17 J18 J19 and J20 and the work lead ring terminal at J21 Torque them to 20 inch pounds 23 04 kg cm Replace the connectors J10 J12 and J22 and the connectors at J4 J5 and J6 Reconnect the ribbon cable from the control board to the power board at J8 Being careful not to pinch any of the wires re
120. to the heatsink with a torque setting of 15 inch pounds 17 28 kg cm 14 Position the wires in the wire chase up the side of the end panel and out of the way of the power board Once the wires are in place tighten the strain relief s retention nut powermax45 Service Manual 6 5 COMPONENT REPLACEMENT 15 Replace or reposition the end panel Make sure that the screw hole in the ground clip aligns with the screw holes in the endcap and the power supply 16 Being careful not to pinch any of the wires replace the Mylar barrier and 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 17 Reconnect the electrical power and the gas supply Replace the power cord 400 V CE 1 Turn OFF the power disconnect the power cord and disconnect the gas supply 2 Remove the 2 screws from the handle on the top of the power supply Remove the handle and then lift the cover off the power supply Remove the Mylar barrier that protects the power board The power cord has 3 wires brown black and grey that connect to the power switch and a green yellow ground wire that connects to the heatsink 3 Remove the rear end panel or gently tilt it away from the power supply 4 Remove the 3 screws that secure the wires to the power switch and gently pull the wires out of the switch Three phase Green yellow 6 6 powermax4s Service Man
121. 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 Using 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 best 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 Kp 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 powermax4s Service Manual T45m shielded consumables Mild steel Metric TORCH SETUP Air flowrate 151 Recommended Maximum Arc current amps Material thickness mm Torch to work distance mm Initial pierce height Pierce time delay sec Cut Speed mm min Voltage V Cut Speed mm min Voltage Maximum cut speed is limited by the test table s maximum speed 10160 mm min 0 5 0 8 0 9 1 5 250 9150 117
122. torch or press the remote start switch for the machine torch The gas solenoid valve V1 closes The gas flow stops The power circuits are ready TROUBLESHOOTING AND SYSTEM TESTS Troubleshooting preparation The complexity of the circuits requires that service technicians have a working knowledge of inverter power supply theory In addition to being technically qualified technicians must perform all testing with safety in mind If questions or problems arise during servicing call the Hypertherm Technical Services team listed in the front of this manual Test equipment Multimeter with a variety of jumper leads including E Z Hooks Troubleshooting procedures and sequence When performing the troubleshooting procedures Read the Safety and Compliance Manual for detailed safety information Refer to Section 8 for the system s electrical schematic Refer to Section 6 for part replacement procedures Refer to Section 7 to locate power supply components and torch components After the problem has been located and repaired refer to the Sequence of operation flow diagram in this section to test the power supply for proper operation Power OFF and disconnected y External inspection y Internal inspection y Resistance checks y N Power ON A Y Troubleshooting guide y Troubleshooting tests 5 4 powermax4s Service Manual TROUBLESHOOTING AN
123. torch specifications Recommended cut capacity hand cutting Handheld cut capacity material thickness 1 2 in 12 7 mm Maximum cut capacity hand cutting or mechanized edge start 3 4 in 19 1 mm Severance capacity hand cutting or mechanized edge start 1 in 25 4 mm Mechanized pierce capacity mater Pierce capacity for edge starts the capacities are the same as the handheld capacities 1 4 in 6 35 mm 3 8 in 9 53 mm 1 2 in 12 7 mm 3 4 in 19 1 mm 1 in 25 4 mm Gouging capacity Metal removal rate on mild steel Weight ial thickness 3 8 in 9 5 mm Recommended cut speed on mild steel 60 ipm 1524 mm min 32 ipm 813 mm min 20 ipm 508 mm min 8 ipm 203 mm min 4 ipm 102 mm min 6 2 Ibs hr 2 8 kg hr T45v torch only T45v with 20 ft 6 1 m lead T45v with 50 ft 15 24 m lead T45m torch only T45m with 25 ft 7 62 m lead T45m with 35 ft 10 7 lead T45m with 50 ft 15 24 lead 0 6 Ib 0 27 kg 8 4 Ib 1 55 kg 7 8 lb 3 54 kg 1 0 Ib 0 45 kg 5 0 Ib 2 27 kg 6 4 Ib 2 90 kg 8 5 Ib 3 85 kg powermax4s Service 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 mark symbol The 5 mark symbol indicates that the power su
124. ual COMPONENT REPLACEMENT 5 Remove the screw that holds the green yellow ground wire to the heatsink 6 On the outside of the power supply loosen the strain relief retention nut that the wires move freely If you are replacing the strain relief use an adjustable wrench to unscrew the nut on the inside of the power supply as well 7 Remove the plug from the old power cord 8 From the inside of the power supply pull the wires through the strain relief and the hole in the endcap to remove the old power cord 9 Route the plug wires of the new power cord through the nut for the strain relief and then through the hole in the endcap Do not remove the tubular ferrite bead from the power switch end of brown black and grey wires 10 If you have a new strain relief slide it onto the new power cord On the inside of the endcap screw the nut onto the strain relief 11 Press the connector for the brown wire into the hole on the top left side of the power switch L1 and replace the screw that secures it Torque the screw to 10 in lbs 11 52 kg cm 12 Press the connector for the black wire into the hole on the top middle of the power switch L2 and replace the screw that secures it Torque the screw to 10 in lbs 11 52 kg cm 13 Press the connector for the grey wire into the hole on the top right of the power switch L3 and replace the screw that secures it Torque the screw to 10 in lbs 11 52 kg cm 14 Tighten the green
125. wise 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 W 2 4 10 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 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 Within thirty 30 days before any such transfer occurs you agree to notify in wr
126. y sec Cut Speed mm min Voltage V TORCH SETUP Air flowrate 151 Recommended Maximum Cut Speed mm min Voltage V Maximum cut speed is limited by the test table s maximum speed 10160 mm min powermax45 Service Manual 1 2 1 5 1 9 250 250 0 0 8900 122 10160 121 0 1 8100 120 10160 118 0 2 5700 121 7100 10160 119 10160 9144 0 1 6858 0 3 3175 0 3 2286 0 5 914 Edge start recommended 3 19 SETUP T45m unshielded consumables Aluminum English Air flowrate scfh Recommended Maximum Arc current amps Material thickness Torch to work distance in Initial pierce height Pierce time delay sec Cut Speed ipm Voltage V Cut Speed ipm Voltage V 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 250 250 0 0 0 1 Edge start recommended Maximum cut speed is limited by the test table s maximum speed 400 ipm 3 20 powermax45 Service Manual
127. y do not include the power supply s power cord 2 4 powermax45 Service Manual POWER SUPPLY SETUP English Input voltage Metric Input 5 7 15 powermaX45 Service Manual 2 5 POWER SUPPLY SETUP Generator recommendations When using a generator with the Powermax45 it should produce 240 VAC nominal current engine Output current Performance drive rating 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 If a 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 the power supply off and wait 30 to 45 seconds before turning it 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 90 psi 170 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
128. 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 cut with the torch flip the yellow safety trigger forward toward the torch head and press the red torch trigger as show below 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 be lagging slightly behind the torch as you cut 15 30 angle from vertical If sparks are spraying up from the workpiece move the torch more slowly or set the output current higher powermaX45 Service Manual 4 7 OPERATION 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 f you fire the torch unnecessarily you 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

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