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Powermax30 XP Service Manual (808150 rev 0)

1. Figure 10 a am 72 o e o SSB lee Letra bie i 6 unl o EUM o y u2 an oo gt ic vio note E cem D 9 ET zz cs oo TNS u3 oo ca ii EH mm m MM I RS Z RNS U5 m8 I NW o 2 z Ho RZ RS am 2 2 2 2 89 oo os mp Ld RN amp Tne EN oo gu m im ET TT cr 3 R23 WE eoo LJ ol LJ m i CG o l oo m wm ug 99 mm m lez a ee Bis E EXE oo C e zm z ae 2 z ko L erum z oo zo 2 oo 2 m Samun zm T 7 a oe z Au o O Joo H HHHH in z BIIIBII C11 30 9 o s S aso d a a a R38 R39 C44 J5 c 1 Reset watchdog 4 Start 2 Error 5 Ribbon cable 3 Transfer XFR 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 fault LEDs on the front of the power supply and the Error LED or the Reset LED on the control board may illuminate or blink Use the control board Error and Reset LEDs to troubleshoot The Reset and Error LEDs provide information to use when troubleshooting a system failure If the LEDs on the front of the power supply are blinking count the number of times the Error LED blinks Then look at the following table to determine the corrective action Reset LED When the control board s Reset LED illum
2. Figure 28 S E g Fe s 1 Raised rib 3 Retaining screw 2 Snap 4 Front panel 5 Insert needle nose pliers into the opening for one of the snaps and use the pliers to squeeze it together B Place a blade screwdriver against the raised rib next to the snap and gently turn the screwdriver to push the panel away from the base 92 Powermax30 XP Service Manual 808150 Revision O 6 Power Supply Component Replacement Figure 29 a 7 Place another screwdriver or similar object into the opening between the panel and the base to keep the first corner of the panel from re engaging the snaps when you release the other corner Figure 30 L G 8 Repeat step 5 and step 6 on the other corner of the panel 9 Disconnect the control panel ribbon cable from the power board by folding the latches back In Figure 31 the center panel is hidden in the image on the left 10 Gently pull the panel away from the power supply Powermax30 XP Service Manual 808150 Revision O 93 6 Power Supply Component Replacement Figure 31 a NATALA LA e ARAIA 1 Latches 3 Ribbon cable 2 Control board 4 Power board Reattach the front panel 1 Push the front panel into the base of the power supply to re engage the snaps 2 Tighten the retaining screw with a torque setting of 8 1 k
3. Part number Description Electrode 420120 TI Swirl ring 420211 239 All applications 1 Retaining cap 420114 Nozzle 420118 LD General purpose Shield 420116 X Nozzle 420117 J FineCut Deflector 420115 194 Use the same electrode swirl ring and retaining cap for both general purpose and FineCut applications Do not use the general purpose nozzle with the deflector do not use the FineCut nozzle with the shield Powermax30 XP Service Manual 808150 Revision O Accessory parts Part number 127102 027668 127144 127410 024548 024877 127217 128647 127169 127416 127103 127239 127105 127243 128836 027055 Description Basic plasma circle cutting guide Deluxe plasma circle cutting guide Dust cover Carrying case Leather torch lead cover brown 7 6 m 25 feet Leather torch lead cover black with Hypertherm logo 7 6 m 25 feet Shoulder strap Kit Eliminizer air filtration Leather cutting gloves Protective glasses shade 6 lens Face shield shade 8 lens Face shield shade 6 lens Replacement lens for face shield shade 8 Replacement lens for face shield shade 6 Thermal grease 1 8 ounce Silicone lubricant 1 4 ounce Powermax30 XP Service Manual 808150 Revision O 8 Parts 195 8 Parts Safety critical parts Genuine Hypertherm parts are factory recommended parts for your Hypertherm system Any damage caused b
4. 5 Place a blade screwdriver against the raised rib next to the snap and gently turn the screwdriver to push the panel away from the base 8 Place another screwdriver or similar object into the opening between the panel and the base to keep the first corner of the panel from re engaging the snaps when you release the other corner Figure 84 7 Repeat step 4 and step 5 on the other corner of the panel Powermax30 XP Service Manual 808150 Revision O 153 154 6 Power Supply Component Replacement 8 Disconnect the control panel ribbon cable from the power board by folding the latches back E In Figure 85 the center panel is hidden in the image on the left Figure 85 A e VA ANNA LENS SN 1 Latches 3 Ribbon cable 2 Control board 4 Power board Powermax30 XP Service Manual 808150 Revision O 6 Power Supply Component Replacement 9 Remove the amperage adjustment knob from the front of the power supply by pulling it away from the front panel It does not have a set screw Set the knob aside 10 Remove the 3 retaining screws from the control board and lift it out of the front panel Set aside the control panel and its screws Figure 86 VY TT E ALALA 1 Front panel 3 Power board 2 Ribbon cable 4 Control board 11 Disconnect the torch lead from the power supply See Remove the torch lead and strain relief on pag
5. p o 1 Retainer nut 3 Air filter regulator 2 Center panel bracket Powermax30 XP Service Manual 808150 Revision O 143 6 Power Supply Component Replacement Install the air filter regulator and pressure switch assembly This kit contains two fittings that are not used in the Powermax30 XP a brass coupler 015550 and a brass pipe 015618 The regulator is pre set at the factory Do not adjust this setting Locate the new brass hex adapter fitting 015846 in the kit Apply a small drop of thread sealant to the middle threads of the fitting Do not apply thread sealant to the threads at the end of the fitting that will be inserted into the air filter regulator assembly See Figure 77 on page 145 If applied too heavily excess amounts of thread sealant can contaminate the gas line Never use PTFE tape on any joint preparation Use only a liquid or paste thread sealant on male threads 2 Screw the hex adapter fitting into the side of the air filter regulator and use a 5 8 inch wrench to tighten 3 Position the new air filter regulator assembly in the bracket on the center panel of the power supply Hand tighten the retainer nut plus a quarter turn Do not overtighten the retainer nut 4 Route the drain hose through the hole in the base of the power supply 5 Connect the red and black wires to the pins on the pressu
6. If you removed any other wires from the WHT and RED studs reinstall them on the studs as well 16 Complete the following procedures a See Reattach the front panel on page 94 b C See Install the component barrier on page 91 See nstall the power supply cover on page 89 Reconnect the gas supply and power cord and set the power switch to ON I Powermax30 XP Service Manual 808150 Revision O 115 6 Power Supply Component Replacement Replacing the fan Kit number Description 428236 Kit Fan assembly with plenum 1 Complete the following procedures a Set the power switch to OFF O disconnect the power cord from the power source and disconnect the gas supply b See Remove the power supply cover on page 88 2 Detach the connector from J5 on the power board See Figure 53 You may have to lift the top edge of the component barrier to see the connector Figure 53 3 Carefully pull the fan plenum 1 straight off the fan casing to release the 4 clips at each corner of the plenum See Figure 54 If necessary use needle nose pliers to compress and release the plenum s top 2 corner clips first before working the bottom two clips free from the fan casing Be careful not to apply too much pressure to any of the clips as you detach the plenum from the fan 116 Powermax30 XP Service Manual 808150 Revision O 6 Power Supply Component Replacement Figure 54
7. Powermax30 XP Service Manual 808150 Revision O 25 2 Power Supply Setup Requirements for grounding Properly ground the system as follows to ensure personal safety proper operation and to reduce electromagnetic interference EMI m The system must be grounded through the power cord according to national and local electrical codes m Single phase service must be of the three wire type with a green CSA or green yellow CE CCC wire for the protective earth ground and must comply with national and local requirements Do not use a two wire service m Refer to the Safety and Compliance Manual 80669C for more information Power cord considerations This system ships with a CSA CE or CCC power cord configuration See Exterior rear on page 187 for part number information CSA power cords and plugs CSA configurations include the following plug and adapters m The power cord is equipped with a NEMA twist lock style plug NEMA L6 20P appropriate for SS use on a 240 V 20 A circuit with a NEMA twist B lock style outlet S m To operate the system on a lower amperage circuit attach the female end of the 120 V 15 A NEMA 5 15P plug adapter to the power supply s NEMA twist lock style plug Do not set the amperage adjustment knob above 20 A or you may trip the circuit breaker See Adjust the gas pressure and output current on page 44 m To operate the system on a 240 V 20 A circuit attach the femal
8. 4 Remove the retaining screw from each corner of the fan 5 Slide the old fan out of the power supply and set it aside B Slide the new fan into place Orient the fan so that the red and black wires are at the upper left corner of the fan the side closest to the rear panel 7 Reinstall the four retaining screws and tighten them to 11 5 kg cm 10 inch pounds Use the new screws included in the kit if needed 07571 1 8 Orient the new fan plenum so that the wider end is at the bottom and snap it into place See Figure 55 9 Route the fan s red and black wires through the notch in the top of the center panel that is nearest the solenoid valve See Figure 55 10 Attach the connector for the red and black wires to J5 on the power board See Figure 53 on page 116 Powermax30 XP Service Manual 808150 Revision O 117 6 Power Supply Component Replacement Figure 55 Route the fan s red and black wires through this 2 Solenoid valve notch in the center panel 11 Complete the following procedures a See nstall the power supply cover on page 89 b Reconnect the gas supply and power cord and set the power switch to ON I 118 Powermax30 XP Service Manual 808150 Revision O 6 Power Supply Component Replacement Replacing the drain hose gas supply hoses and 90 fitting Kit number Description 228095 Kit Hoses drain hose two gas supply hoses elbow
9. 7 Check the resistance at the 2 torch start test points on the power board a With the trigger pulled the resistance should 10 Q or less b With the trigger released the circuit should read approximately 3 kQ 8 If this test fails check the torch start switch and the torch wires 82 Powermax30 XP Service Manual 808150 Revision O 5 Troubleshooting and System Tests Figure 21 TORCH O START 9 Turn ON I the power 10 Measure pin 16 of J7 to ground See Test 2 power board voltage checks on page 76 a With the trigger pulled it should measure as O VDC for an open circuit b With the trigger released it should measure 3 2 VDC for a closed circuit 11 If the values are not correct replace the power board See Remove the power board on page 109 Powermax30 XP Service Manual 808150 Revision O 83 5 Troubleshooting and System Tests Test 7 torch cap sensor Test the cap sensor switch and torch leads 1 2 3 84 Set the power switch to OFF O disconnect the power cord from the power source and disconnect the gas supply Remove the power supply handle and cover See Remove the power supply cover on page 88 Remove the component barrier See Remove the component barrier on page 90 Detach the front panel See Detach the front panel on page 92 Disconnect the cap sensor connector at J12 on the heatsink side of the power board by pushing the tab on the connector towar
10. Figure 7 J16 red J17 white WORK LEAD BLK J22 6 If you do not find any problems during the visual inspection or the initial resistance check and the power supply is still not operating correctly see Troubleshooting guide on page 63 Powermax30 XP Service Manual 808150 Revision O 61 5 Troubleshooting and System Tests Power supply overview Figure 8 1 Output diode and pilot arc IGBT module D27 6 Power switch S1 2 Work lead connection J22 7 PFCIGBT O1 3 Input diode bridges D24 D30 8 Flyback circuit 4 PE ground 9 Inverter IGBT Q2 5 Power board PCB2 10 Control board PCB1 62 Powermax30 XP Service Manual 808150 Revision O Troubleshooting guide 5 Troubleshooting and System Tests This guide provides the most probable causes and solutions Study the Powermax30 XP schematic on page 201 and understand the Theory of operation on page 55 before troubleshooting Before purchasing any major replacement component verify the problem with Hypertherm Technical Service or the nearest Hypertherm repair facility listed in the front of this manual See System tests on page 71 for detailed test procedures Problem This may mean Possible cause s Possible solution s The power switch is set to ON I but the power ON LED is not illuminated There is insufficient voltage to the control circuits or a short circuited power component The system h
11. 24 ours XS ours IG vin 3 80vac zd EOR 75k 2w a PA DRV 2J ouT4 5 gup2 ENDS OVLO 495vdc o o o ag if INL PWM DRv lt 24 OUTS N17 ACPL CB7A Dp SS Ow Y2 MPX5700 BACK UP CONTROL to sz mw pwm Div 2l OUT2 iN18 1S REDUNDANT START 12 Sn m z 2 09 5 51 ipee PRESSURE SENSOR CHASSIS GND u 2 MTG4 PFC PWM ory lt 20 our nrg I ys Xue E vin 3 em i HEAT NOT USED BLUE 1 1 6 5 GND2 GND1 4 0 472 MAX IST in vat 31 sno IGBT TEMP 10 7 Height Zone MG Ne Nx amp INVERTER IGBT MODULE PFC IGBT MODULE AC MFT to 75 3 T 35 36 28 Vbus fiz 33 36 78 Sipos WRT WIRE C3 s Finv 42khz 2 2 Fpfc 28khz J14 t line Limit 3 3 nF G 1000v0c 37 5arms t 600v i C O 1 30k sdb 90A J15 L ll 0 33uF o 33uF L ood 630VDC 630VDC INPUT BRIDGES AC k OUTPUT DIODE and et PILOT ARC IGBT MODULE 1200V PFC DIODE 35A CSA C CCC WED ie Kon 375vde BOA 600v jq 1200V 5 sz i seras ne 28 T 14 1 15 1 K 15 Ac MTG8 LIFT to MTG6 Hipot I mw wv uM zl 47nF 4 7nF 300vac 300 Y TRANSFER SENSOR OUTPUT CURRENT SENSOR t ex 1 WHT J17 y 0 00 2 09 12AWG UL1569 WHT 1 00 MAX T INS ours H ins ouT3 Height Zone int ane exc esowe 0 01uF 20K Axi00 NP OWH HN LAxioo Ne OUT I dM TaN 01u Sw wI A im omfl Um om Mc s amr gy 15 15 15 CAP ENS BLUE INV IPRI I V ORG o T VIOLET Loutput 014309 talcs LO 410uH e 1 i ea MS in Plastic 130727044 T T T Rdc20C 19mohm WHITE
12. 3 Grip the air filter regulator with your right hand to hold it steady With your left hand remove the brass hex adapter from the air filter regulator using a 5 8 inch wrench 4 Apply a small drop of thread sealant to the middle threads of the new brass hex adapter Do not apply thread sealant to the threads at the end of the fitting that will be inserted into the air filter regulator assembly If applied too heavily excess amounts of thread sealant can contaminate the gas line CAUTION Never use PTFE tape on any joint preparation Use only a liquid or paste thread sealant on male threads 5 Screw the brass hex adapter into the air filter regulator Use a 5 8 inch wrench to tighten 6 CSA models Apply a small drop of thread sealant to the middle threads of the quick connect air fitting Screw the fitting into the brass hex adapter Use a 9 16 inch wrench to tighten CE models Apply a small drop of thread sealant to the middle threads on the smaller end 1 4 NPT of the air fitting adapter Screw the air fitting adapter into the brass hex adapter Use a 19 mm wrench to tighten 146 Powermax30 XP Service Manual 808150 Revision O 6 Power Supply Component Replacement 7 Reconnect the gas supply and check for leaks at each fitting and hose connection point on the air filter regulator assembly CAUTION Gas supply pressures not within the specifications in the Specifications section of your system s manual can
13. 6 Power Supply Component Replacement Remove and install the ground wire from the heatsink to the air filter regulator ground clip 1 Complete the following procedures a Set the power switch to OFF O disconnect the power cord from the power source and disconnect the gas supply b See Remove the power supply cover on page 88 2 Remove the ground wire s ring terminal from the screw that attaches it to the heatsink 3 The ring terminal on the other end of the wire is attached to the ground clip on the air filter regulator s brass T fitting See Figure 62 Unscrew the old ground wire from the ground clip 4 Attach the new ground wire s ring terminal to the heatsink with a torque setting of 23 0 kg cm 20 inch pounds Be sure to reattach the ring terminals for the other two ground wires that connect to the heatsink using the same screw 5 Route the new ground wire through the notch in the center panel that is nearest the rear panel 6 Use the screw to attach the wire to the air filter regulator ground clip with a torque setting of 11 5 kg cm 10 inch pounds See Figure 62 7 Complete the following procedures a See nstall the power supply cover on page 89 b Reconnect the gas supply and power cord and set the power switch to ON I 128 Powermax30 XP Service Manual 808150 Revision O 6 Power Supply Component Replacement Figure 62 4 1 Rear panel 4 Center panel 2 Ground clip on air f
14. Start switch wires 1 Cap sensor switch 4 Slot for gas hose fitting s flange 2 Start switch 5 Cap sensor switch connector 3 Slot for torch lead strain relief 6 Trigger s pivot hole 9 Press the torch body into the torch handle with the gas hose fitting s flange aligned with the slot in the handle B Align the strain relief with the strain relief slot in the handle See Figure 106 for the location of the strain relief slot 7 Compress the trigger spring into the front half of the trigger Slide the trigger and spring into place 8 Being careful that the handle does not pinch the wires align the left half of the handle with the right half Verify that the trigger pivots are both located in the trigger pivot holes See Figure 106 9 Install the handle screws 10 Install the consumables 11 Reconnect the gas supply and power cord and set the power switch to ON I 176 Powermax30 XP Service Manual 808150 Revision O 7 Torch Component Replacement Replacing the trigger assembly Kit Description 428156 Kit Torch trigger and spring 1 Set the power switch to OFF O disconnect the power cord from the power source and disconnect the gas supply 2 Remove the consumables from the torch 3 Place the torch on a flat surface with the left side of the handle facing up 4 Remove the screws from the torch handle Set the screws aside Wear eye protection as the trigger spring can launch out of the handle 9 Bein
15. The sparks should lag slightly behind the torch as you cut 15 30 angle from vertical m f sparks spray up you are not cutting all the way through the workpiece Move the torch more slowly or if possible increase the output current m 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 m Pulling the torch toward you along the cut is easier than pushing it or moving from side to side m Forstraight line cuts use a straight edge as a guide To cut circles use a template or a radius cutter attachment a circle cutting guide See Accessory parts on page 195 for the Hypertherm plasma cutting guide part numbers for cutting circles and making bevel cuts m if you fire the torch unnecessarily you shorten the life of the nozzle and electrode Recommendations for cutting at 120 V m Use only the FineCut consumables m Do not use an extension cord m Verify nothing else is drawing power from the circuit m Turn down the current adjustment knob to avoid tripping the breaker Powermax30 XP Service Manual 808150 Revision O 49 4 Operation Edge start on a workpiece U When cutting material thicker than 6 mm 1 4 inch start the torch at the edge of the workpiece to prolong consumable life 1 With the ground clamp attached to the workpiece hold the torch perpendicular 90 to the workpiece and on the e
16. 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 otherwise and even if advised of the possibility of such damages National and local codes National and local codes governing plumbing and electrical installation shall take precedence over any instructions contained in this manual In no event shall Hypertherm be liable for injury to persons or property damage by reason of any code violation or poor work practices SC 16 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
17. lt 120 V 20 A 120 V 15A 45 4 Operation Check the indicator LEDs Verify that the green power ON LED on the front of the power supply is illuminated and that none of the other LEDs are illuminated or blinking If the temperature torch cap sensor or gas pressure LEDs illuminate or blink or if the power ON LED blinks correct the fault condition before continuing See Troubleshooting guide on page 63 section for more information OXY Verify the system is ready When the power ON LED illuminates none of the other LEDs illuminate or blink and the amperage knob is set the system is ready for use Understand duty cycle limitations The duty cycle is the percentage of time out of 10 minutes that a plasma arc can remain on when operating at an ambient temperature of 40 C 104 F With input power of 120 V m At30A the arc can remain on for 2 0 minutes out of 10 minutes without causing the unit to overheat 20 duty cycle m At 17 A the arc can remain on for 6 minutes out of 10 60 m At 15 A the arc can remain on for 10 minutes out of 10 100 With input power of 240 V m At 30 A the arc can remain on for 3 5 minutes out of 10 3596 duty cycle m At 23 A the arc can remain on for 6 minutes out of 10 60 m At 18 A the arc can remain on for 10 minutes out of 10 100 When the duty cycle is exceeded the system overheats the temperature LED illuminates the arc shuts off and the cooling f
18. s bracket to the center panel 6 Orient the new solenoid valve so that the pink and gray J6 wire pair is on the rear panel side of the valve Figure 65 Rear panel Front panel 1 Push to connect fitting 3 Solenoid valve bracket 2 Pink and gray J6 wire pair Powermax30 XP Service Manual 808150 Revision O 131 6 Power Supply Component Replacement 7 Line up the holes in the valve s bracket with the holes in the center panel and attach it to the center panel using the 2 screws with a torque setting of 11 5 kg cm 10 inch pounds 8 Push to connect the gas supply hose you removed in step 3 on page 131 into the fitting on the rear panel side of the solenoid valve See Figure 56 on page 119 Be careful not to kink the hoses as you reconnect them 9 Push to connect the gas supply hose you removed in step 4 on page 131 into the fitting on the front panel side of the solenoid valve 10 Connect the valve s pink and gray wire pair to the power board at J6 See Figure 63 on page 130 Route the wires through the notch in the center panel that is nearest the solenoid valve Figure 66 Route the valve s pink and gray wires through this notch in the center panel Solenoid valve wire pair 11 Reconnect the gas supply and check for leaks at each fitting and hose connection point on the air filter regulator assembly CAUTION Gas supply pressures not within the specifications in the Sp
19. see System operation guidelines on page 47 and Troubleshooting guide on page 63 Voltage configurations The system automatically adjusts for proper operation at the current input voltage without requiring you to perform any switching or rewiring However you must set the amperage adjustment knob to an appropriate output current and verify that an appropriate set of consumables is properly installed in the torch For more information see Adjust the gas pressure and output current on page 44 and nstall the consumables on page 42 The following table shows the maximum rated output for typical combinations of input voltage and amperage The output setting you need to use depends on the thickness of the metal and is limited by the input power to your system Input at rated output Input voltage circuit Rated output 60 Hz CSA or 50 Hz kVA CE CCO single phase Recommended consumables 120V 15A 20A 83V 16 4 A 2 0 FineCut 120 V 20A 25 A 83 V 20 5A 2 5 FineCut 120V 30A 30 A 88 V 25A 3 0 FineCut 240 V 20A 30 A 125 V 225 18 8A 4 5 General purpose or FineCut 1 Input voltages can be 10 of the values in this table See Choose the consumables on page 32 for an explanation of general purpose and FineCut consumables CAUTION A circuit capable of 20 A 120 V or 20 A 240 V is required for proper operation Protect the circuit with appropriately sized slow blow time delay fuses or circuit breakers
20. 17 Safety MMPOMMALON m 17 everti 17 Power SUPPIlY GIMOEMSIONS NR EREREP T EP R 18 SYST Hypertherm system ratings Powermax30 XP Service Manual 808150 Revision O 7 Contents TORCH CUMESMSIOMS er tee curs e e ea eet 20 Torch welglil i ae eeenuedeaaieeenean esa eue A LI NEA LL ac MIA ATI EE 20 ease E Terztodiieriioa e 20 Symbols arid marks inre eed ud he End adc eei abre diae 21 Noise levels xiu etu Mist oue Baie hes iaa I SPESE DU EI MEE 22 IEC symb l re 22 2 Power Supply Setup reisen oaneci nid rn densi uda radar Da id oeu PR M QE dun Ca SENE Ca Nd E Re RR ENS ENS RR MG RR 23 Unpack the Powermax System 5 2 tednnepdns ee fetcstetcnte esci dene diede cci rte iud det c eode evade tuv dde eden g adde 23 ETN s erri entem ter e eem tee een itp ER E EE 23 System conternts iosicoi DA ADS noci LIV Dp te aes EDAD SD ML EP D IU LUN M ID AMA 24 Position the plasma cutting system wine cence tente tentent tente tentent tette tenta testet te tetto testet to tensa testas satanas assa 25 Prepare the electrical power eee esent tenente ttntnnentntntnn intu ta tote to tenet PEANN HAE Kap tts te etin a Pant iato ta tatus tassa tenant 25 Voltage corifiguratlornis asna io etchant ac d alc ame Sot als Sls dla oe cil eo dr ae es 2
21. 85 h x 11 20 w lt o ho MACHINE gen eue menl ced a oe R FRONT L Pan PEA 2oz plated to 3oz XFR ERROR RESET or 2 1 J2 J1 CODE HoR FLT me s n FAN SSR oun N22 PA E36 18 11 D D SERIAL Hou Mer 18PA o K did Hp 18 mw Alf gd fA JTAG EMULATION TIGND GND 4 DATA 3 POWER ON GAS LOW OT TEMP CONNECTOR 1 SAD GND H if 2 L H UNE l i 3 ours M Z COMPA o o COM INVU ex x X Pg X i H 37 43 3 18T o KH 10 150J GRN YEL YEL YEL w o Jz i 9 44 vcc 1 prc PWM 3 e 2 1 i B 443 43 3 EE PROM 43h H2 Nvu PWM T vr 1 5 51 7 85 Jj4 5 Je sP Sree wsH ek 3 amp INL PWM 3 375VDC 1 72 MAX RES 1 a 7L 9 Ims tts PA 2 o kK BET 6 8uf 300voc X2 Height Zone 6 3 40 5 3 3 5 9 T am 8 7 alls DSP 2801 424R 10 9 PME Pre pesar fi aereo ag OP247 TI A SPACE 10 9 C2 1j 2 so1 vss 2 spPi EN lt lt INV DESAT OUT IN OUT IN p ETT FOR lad 4x25Mhz 100Mhz 26 POS stort 14 13 31 spi IN 2 PA DESAT A 2 t E 2 9 jd 720 0 78 x 0 78 RIBBON 9 he ish 30 sei cik 8 ZPFC_OC NA I T al Depan 14 13 Stavout for CABLE hs 7L 29 spi our i ORV FLT CM Choke Installed IZATION 116 15 16 V IN 1 y bo 19 ohm CM Choke 16orms on CE unit only isay ISIN Ne TEST CLIP 28l wus 13IN INL 4 EA f d 72 19 12N INES os 23 43 5 PWRFLT 27 outa ayaa 11 IN IN 7 22 21 NENEN S 6 25 L9 SSR ouT7 ap caa Fsw 66khz J LAX100 NP 24 23 gin v L8 cas 25 oute Thee TE UVLO 110vdc 26 25 UE ran
22. Decreasing the speed of the torch will increase width and increase depth Increasing the standoff of the torch will increase width and decrease depth Decreasing the standoff of the torch will decrease width and increase depth Increasing the angle of the torch more vertical will decrease width and increase depth Decreasing the angle of the torch less vertical will increase width and decrease depth Increasing the current of the power supply will increase width and increase depth Decreasing the current of the power supply will decrease width and decrease depth Powermax30 XP Service Manual 808150 Revision O 53 4 Operation Common hand cutting faults For more information on faults see Troubleshooting guide on page 63 m The torch sputters and hisses but does not produce an arc The cause can be Overtightened consumables m The torch does not cut completely through the workpiece The causes can be D Do oO oO Cut speed is too fast Worn consumables Metal being cut is too thick for the selected amperage Installation of the wrong consumables Poor electrical contact between the ground clamp and the workpiece Low gas pressure or low gas flow rate m Cut quality is poor The causes can be Q Q Metal being cut is too thick for the selected amperage Installation of the wrong consumables Cut speed is too fast or too slow Worn or damaged consumables m The arc sputters and consumables life is shorter
23. Figure 51 and Figure 52 7 Push the power board straight in Figure 52 Red and white wire hole Capacitor holes 8 Reconnect the 2 white wires to the power switch 9 Replace the 4 heatsink assembly screws and the 3 retaining screws Tighten these screws to 17 3 kg cm 15 inch pounds 10 Replace the 3 screws that attach the IGBTs to the heatsink and the 2 screws that attach the input diode bridges to the heatsink Tighten these screws to 17 3 kg cm 15 inch pounds 114 Powermax30 XP Service Manual 808150 Revision O 6 Power Supply Component Replacement 11 Replace the 2 screws and the spring clip that you removed from the snubber resistor Tighten the screws to 17 3 kg cm 15 inch pounds See Figure 49 on page 112 CAUTION A torque setting higher than 17 3 kg cm 15 inch pounds can damage the resistor 12 On the power board side of the power supply reconnect the wires to the transformers and inductors at J13 J14 J15 J18 J19 J20 J21 and the work lead ring terminal at J22 Tighten the screws to 23 0 kg cm 20 inch pounds 13 On the component side of the power board reconnect the connector TORCH START J12 and the connectors at J4 J5 and J6 14 Reconnect the ribbon cable from the control board to the power board J7 15 On the fan side of the power supply reconnect the ring connectors for the red and white wires to the studs labeled RED and WHT and reinstall the nuts
24. LED protective earth conductor E Power supply is overheated LED e e6U 6sS8 l Power is ON o Power is OFF 22 Powermax30 XP Service Manual 808150 Revision O Section 2 Power Supply Setup Unpack the Powermax system 1 Verify that you received all items on your order in good condition Contact your distributor if any parts are damaged or missing See System contents on page 24 2 Inspect the system for damage that may have occurred during shipment If you find evidence of damage refer to Claims 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 separate Safety and Compliance Manual 80669C included with your system for important safety information Claims m Claims for damage during shipment If your unit was damaged during shipment file a claim with the carrier You can contact Hypertherm for a copy of the bill of lading If you need additional assistance call the nearest Hypertherm office listed in the front of this manual m 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 Powermax30 XP Service Manual 808150 Revision O 23 2 Power Supply Setup System contents Th
25. NEMA twist lock style 240 V 20 A NEMA L6 20P plug wired to the power supply CE and CCC units ship without a plug on the power cord See Power cord considerations on page 26 for more information You can order additional consumables and accessories such as the carrying case carrying strap and a circle cutting guide from any Hypertherm distributor See the Parts section on page 185 for a list of spare and optional parts Power supply dimensions a OOOO 292 mm Q 11 5 inches pima q D g b z 254 mm d p 10 inches d B p rr Mem O TST 140 mm 356 mm C 14 inches 5 5 inches System weights The following system weights include the hand torch with 4 6 m 15 foot torch lead a 4 6 m 15 foot work lead with ground clamp and a 3 0 m 10 foot power cord m CSA systems 9 7 kg 21 4 pounds m CE and CCC systems 9 5 kg 21 0 pounds 18 Powermax30 XP Service Manual 808150 Revision O 1 Specifications Hypertherm system ratings Rated open circuit voltage Uo 256 VDC Rated output current I 15Ato 30A Rated output voltage U at U 120 VAC 83 VDC Rated output voltage U at 125 VDC U 200 240 VAC Duty cycle at 40 C U 120 VAC 20 I2 2 30 A U2 83 V See data plate on power supply for more 60 I2 17 A U2 83 V information on duty cycle and for IEC ratings 100 I2 15 A
26. PE ground Green yellow Powermax30 XP Service Manual 808150 Revision O 101 6 Power Supply Component Replacement 4 On the outside of the power supply loosen the strain relief nut so that the wires move freely 5 Are you replacing the strain relief Q If yes use an adjustable wrench to unscrew the retention nut on the inside of the power supply If no continue with the next step Figure 40 Inside Outside 1 Strain relief nut outside the power supply 3 Rear panel 2 Strain relief 4 Retention nut inside the power supply B Remove the power plug from the old power cord 7 From the inside of the power supply pull the wires through the strain relief and the hole in the rear panel You cannot remove the wires from outside the power supply because of the ferrite core installed on the wires 8 Are you replacing the strain relief U If yes remove the strain relief from the rear panel Q_ If no continue with nstall the power cord and strain relief on page 103 102 Powermax30 XP Service Manual 808150 Revision O 6 Power Supply Component Replacement Install the power cord and strain relief CSA power cords 1 Are you installing a new strain relief U If yes slide the strain relief nut and strain relief onto the new power cord then route the wires for the new power cord through the hole in the rear panel If no slide the strain relief nut over the new power cord and ro
27. Power Supply Component Replacement 3 Remove the connectors at J4 J5 and J6 on the component side of the power board See Figure 47 Figure 47 Input diode bridges Capacitors IGBTs Connector TORCH START J12 Snubber resistor a amp Q N 110 375vDC Ribbon cable connector J7 J6 J5 J4 O on Oo Powermax30 XP Service Manual 808150 Revision O 6 Power Supply Component Replacement 4 On the back of the power board remove the wire connectors for the transformers and inductors See Figure 48 a Remove J13 J14 and J15 located on the front panel end of the power board b Remove J18 and J19 located on the rear panel end of the power board c Remove J20 and J21 located on the bottom center of the power board 5 Remove the work lead ring terminal from J22 8 Remove the 3 retaining screws and the 4 heatsink assembly screws 7 Remove the 3 screws that attach the IGBTs to the heatsink and the 2 screws that attach the
28. air fitting adapter and a 5 8 inch wrench for the hex adapter 3 Disconnect the drain hose from the hole in the bottom of the power supply s base See Figure 75 4 Disconnect the red and black wires from the pins on the pressure switch 5 Push to disconnect the gas supply hose from the air filter regulator s brass T fitting See Figure 56 on page 119 B Disconnect the ground wire that is attached to the clip on the air filter regulator s brass T fitting Set the clip aside Powermax30 XP Service Manual 808150 Revision O 141 6 Power Supply Component Replacement Figure 75 7 6 5 4 1 La 2 q q q qd q 3 T I i Uw 1 Air fitting CSA or air fitting adapter CE CCC 5 Red and black pressure switch wires 2 Air filter regulator 6 Pressure switch 3 Drain hose 7 Ground wire clip on the T fitting 4 Gas supply hose 142 Powermax30 XP Service Manual 808150 Revision O 6 Power Supply Component Replacement 7 Unscrew the retainer nut that holds the air filter regulator in the bracket on the center panel See Figure 76 8 Tip the bottom of the air filter regulator and pressure switch assembly away from the power supply and slide the assembly out of the bracket Gently tilt the top of the rear panel away from the power supply as you remove the assembly if needed Figure 76
29. b See Remove the power supply cover on page 88 2 Detach the connector from the ground clip on the rear panel See Figure 60 3 Remove the ground wire s ring terminal from the screw that attaches it to the heatsink 4 Tighten the new ground wire s ring terminal to the heatsink to a torque setting of 23 0 kg cm 20 inch pounds Be sure to reattach the ring terminals for the other two ground wires that connect to the heatsink using the same screw 5 Press the connector on the other end of the wire onto the rear panel s ground clip See Figure 60 6 Complete the following procedures a See nstall the power supply cover on page 89 b Reconnect the gas supply and power cord and set the power switch to ON I Figure 60 1 Ground clip wire from heatsink to rear panel 3 Rear panel ground clip 2 Rear panel 4 Heatsink Powermax30 XP Service Manual 808150 Revision O 125 6 Power Supply Component Replacement Remove and install the ground wire from the heatsink to the magnetics assembly 1 Complete the following procedures a Set the power switch to OFF O disconnect the power cord from the power source and disconnect the gas supply b See Remove the power supply cover on page 88 2 Remove the ground wire s ring terminal from the screw that attaches it to the heatsink 3 The ring terminal on the other end of the wire is attached to the metal base plate of the magnetics assembly See Figure 61 The
30. component barrier See Remove the component barrier on page 90 WARNING ELECTRIC SHOCK CAN KILL Use extreme caution when working near live electrical circuits Dangerous voltages exist inside the power supply that can cause serious injury or death See the WARNING on page 58 before proceeding 4 Reconnect the electrical power Carefully connect the test hooks to the edges of the holes in the power board so that the hook makes contact with the ring on the back side of the power board Figure 17 78 Powermax30 XP Service Manual 808150 Revision O 5 Troubleshooting and System Tests 5 Measure the voltage from W to R See Figure 18 a Position the test hooks on W and R on the power board b Turn the power ON I The multimeter should read 375 VDC If you get a value other than 375 VDC multiply the reading by 0 00601 to convert it to millivolts Test pin 21 on J7 See Test 2 power board voltage checks on page 76 If the values match it is a normal reading 8 Measure the voltage from W to B a Turn the power OFF O b Move the test hooks to W and B c Turn the power ON I d This value should be 187 5 VDC or one half of the value found in step 5 7 Measure the voltage from R to B a Turn the power OFF O b Move the test hooks to R and B c Turn the power ON I d This value should be 187 5 VDC or one half of the value found in step 5 8 The values found in step 6 and step 7
31. connections m Cut speeds can decrease m Cut quality can deteriorate m Cutting thickness capability can decrease m Consumables life can be shortened Powermax30 XP Service Manual 808150 Revision O 151 6 Power Supply Component Replacement 8 Complete the following procedures a See nstall the power supply cover on page 89 b Reconnect the gas supply and power cord and set the power switch to ON I Replacing the front panel Kit number Description 428219 Kit Front panel Remove the front panel Use the following procedure to completely remove the front panel in order to replace it If you just need to move the front panel out of the way to provide better access to the interior of the power supply see Detach the front panel on page 92 and Reattach the front panel on page 94 1 Complete the following procedures a Set the power switch to OFF O disconnect the power cord from the power source and disconnect the gas supply b See Remove the power supply cover on page 88 See Remove the component barrier on page 90 2 Lay the power supply on its side 3 Remove the retaining screw from the bottom of the front panel Figure 82 1 Rib 3 Retaining screw 2 Snap 4 Front panel 152 Powermax30 XP Service Manual 808150 Revision O 6 Power Supply Component Replacement 4 Insert needle nose pliers into the opening for one of the snaps and use the pliers to squeeze it together Figure 83
32. element Tighten the retaining nut to finger tight 3 Does the air filter bowl need to be replaced Uu fyes install the new filter bowl Uu Ifno clean the bowl before reinstalling it by wiping away any oil dirt or other contaminants Tighten the filter bowl to finger tight 4 Connect the drain hose to the fitting at the bottom of the filter bowl Verify the drain hose extends towards the front of the power supply 5 Position the air filter regulator assembly in the bracket on the center panel of the power supply and attach it using the plastic retainer nut Hand tighten the retainer nut plus a quarter turn Do not overtighten the retainer nut 8 Route the drain hose through the hole in the base of the power supply 150 Powermax30 XP Service Manual 808150 Revision O 6 Power Supply Component Replacement Figure 81 9 jo 1 Plastic retainer nut red 4 Brass fitting 2 Air filter element 5 Air filter bowl 3 Airfilter element retaining nut white 6 Drain hose 7 Reconnect the gas supply and check for leaks at each fitting and hose connection point on the air filter regulator assembly CAUTION Gas supply pressures not within the specifications in the Specifications section of this manual can cause poor cut quality poor consumable life and operational problems If the purity level of the gas is too low or if there are leaks in the supply hoses or
33. esses seinem en n 87 Disconnect the power and gas supply eeeeeeeeeeenene entente tete tnt ten ente netten initntet init tetin inte teinte te teniente nin 87 Replacing the power supply COVOr oioi or terit li dieti se dan ea ir Ru D Ce Peek eu pA Pee d Due nS 88 Replacing the component barrier eee eee eene entente tette tete tonnes tnnt tante ta totos tu totis in tutes ta to tatto totis sonos anis 90 Detaching and reattaching the front panel sese esee tette tente tentent tente testet te PE EES 92 Detaching and reattaching the rear panel oot cence nese tenete tentent te tente tentent tente A iata 95 Replacing the power cord and strain relief esee ntnten inten tenente tentent 98 Replacing the power SWItCH Ens EKEn Hingis 105 Replacing the control board dk akan a utum ae dunt cesta tercie subicit carder 107 Replacing the power board rerit re n et re i anv re rn arro eqni REF rtr ce tne Facies 109 Replacirig tlie fat 5 a aeter ettet didis ae atate dites dem eei A tuendo rnt AOR 116 Replacing the drain hose gas supply hoses and 90 fitting eerte entennnnis 119 Replacing the wire Qroup 123 Replacing the solenoid valve airia ia 4 t eddie E A REEE AES POS ERREA EROE 130 Replacing the torch lead and strain relief sse eese R RE S anand testet tates tetas 133 Replacing
34. from the fitting on the bottom of the air filter bowl 4 Remove the gas supply hose that connects to the air filter regulator and the solenoid valve a Push to disconnect the gas supply hose from the air filter regulator s brass T fitting See Figure 56 on page 119 b Push to disconnect the gas supply hose from the fitting on the rear panel side of the solenoid valve 5 Remove the gas supply hose and the plastic 90 fitting that connect the solenoid valve to the torch lead a Push to disconnect the gas supply hose from the fitting on the front panel side of the solenoid valve b Push to disconnect the plastic 90 fitting from the torch lead s brass gas supply fitting inside the front panel of the power supply Push to disconnect the gas supply hose from the top of the plastic 90 fitting 120 Powermax30 XP Service Manual 808150 Revision O 6 Power Supply Component Replacement Figure 57 1 Air filter regulator Brass T fitting Air filter bowl Fitting a kf e N Drain hose Powermax30 XP Service Manual 808150 Revision O o on Oo Torch lead Plastic 90 fitting for torch lead Gas supply hose from solenoid valve to torch lead Solenoid valve Gas supply hose from air filter regulator to solenoid valve 121 6 Power Supply Component Replacement Install the drain hose gas supply hoses and 90 fitting Be careful not to kink any of the hoses as you install them 1 Push
35. hose aside 4 Unscrew the plastic retainer nut that holds the air filter regulator in the bracket on the center panel 5 Tilt the bottom of the air filter regulator assembly towards you with one hand 8 With your other hand unscrew the air filter bowl to remove it from the air filter regulator assembly 148 Powermax30 XP Service Manual 808150 Revision O 6 Power Supply Component Replacement Figure 79 1 Plastic retainer nut red 4 Air filter bowl 2 Center panel bracket 5 Brass fitting 3 Air filter regulator 6 Drain hose Powermax30 XP Service Manual 808150 Revision O 149 6 Power Supply Component Replacement 7 Does the air filter element need to be replaced Q If yes unscrew the plastic retaining nut that attaches the air filter element being careful not to lose the spring that is compressed between the retaining nut and the air filter regulator Do not allow the air filter element to rotate as you remove the nut Remove the air filter element from the plastic retaining nut If no continue with step 3 on page 150 Figure 80 1 Air filter element 3 Retaining nut 2 Spring Install the air filter element and air filter bowl 1 Place the new air filter element on the plastic retaining nut Verify that the spring is in place 2 Install the new air filter
36. input diode bridges to the heatsink Holes in the power board provide access to the 2 input diode bridge screws Figure 48 a9 J amp 35 4 D Mo mee me WORK LEAD BLK 1 Retaining screws 3 Heatsink assembly screws 4 Connector TORCH START J12 J13 J14 J15 Work lead connector J22 n o0 0 Ff Q ND Powermax30 XP Service Manual 808150 Revision O 10 11 12 13 J21 J20 J19 J18 Input diode bridge screws 2 IGBT screws 3 111 6 Power Supply Component Replacement 8 Remove the 2 screws from the snubber resistor spring clip on the top of the heatsink and remove the spring clip Figure 49 1 Spring clip 3 Snubber resistor screws 2 Snubber resistor 9 Disconnect the bottom two wires both are white from the power switch 10 Use an 8 mm 5 16 inch nut driver to remove the nuts that attach the red and the white wires to the studs on the fan side of the power supply The studs are labeled RED and WHT 11 Pull the red and white wires through the hole in the center panel of the power supply Figure 50 White WHT Red RED AOA B 12 From the power board side of the power supply push the wires that you disconnected down and out of the way 18 Pull the board straight out from the power supply and set it aside 112 Powermax30 X
37. lt ELECTRODE a Daze D D 2 D Due MS in Plastic ve s29 N RED 12AWG UL1569 RED Lpfc 014307 98 264voc 12AWG UL1015 BLK LO 335uh i aon E L60 185uh CORD 15T 11T 21 MUELLER Rde206 21 mohim STD Unit 14 3 SO Dia 0 53 Powermax30 XP Service Manual 808150 Revision O POWER XFMR 014389 Twisted Leads Lprim 0 75mH Rprim20C 4 8mohm CE Unit HOSW F3G2 5 Dia 0 39 Rsec20C 10 5mohm Lleak 0 5uH Typ
38. one end of the new drain hose onto the fitting on the bottom of the air filter bowl See Figure 57 on page 121 2 Insert the other end of the drain hose into the hole in the base of the power supply 3 Install the new gas supply hose that connects to the air filter regulator and the solenoid valve a Push to connect one end of the new hose into the air filter regulator s brass T fitting See Figure 56 on page 119 b Push to connect the other end of the new hose into the fitting on the rear panel side of the solenoid valve This kit contains 1 extra gas supply hose not used in the Powermax30 XP system 4 Install the new gas supply hose and the plastic 90 fitting that connect the solenoid valve to the torch lead a Push to connect one end of the new hose into the fitting on the front panel side of the solenoid valve b Push to connect the other end of the new hose into the top of the plastic 90 fitting for the torch lead Push to connect the plastic 90 fitting onto the torch lead s brass gas supply fitting inside the front panel of the power supply 5 Reconnect the gas supply and check for leaks at each fitting and hose connection point on the air filter regulator assembly CAUTION Gas supply pressures not within the specifications in the Specifications section can cause poor cut quality poor consumable life and operational problems If the purity level of the gas is too low or if there are leaks in the
39. panel with the three retaining screws 8 Connect the ribbon cable to the power board and fold the latches up to hold it in place 9 Press the amperage adjustment knob onto the post on the front panel of the power supply 10 Complete the following procedures a See Reattach the front panel on page 94 b See nstall the component barrier on page 91 c See nstall the power supply cover on page 89 d Reconnect the gas supply and power cord and set the power switch to ON I Replacing the power board Kit number Description 428233 Kit Power board CSA 141304 428234 Kit Power board CE and CCC 141309 Although there are some technical differences between the power board for CSA power supplies and the power board for CE CCC power supplies the procedure to replace the boards is the same Remove the power board 1 Complete the following procedures a Set the power switch to OFF O disconnect the power cord from the power source and disconnect the gas supply b See Remove the power supply cover on page 88 c See Remove the component barrier on page 90 d See Detach the front panel on page 92 2 Remove the TORCH START connector J12 on the component side of the power board see Figure 47 on page 110 by pushing the tab on the connector toward the plug and pulling the plug out Figure 46 T4 Push tab toward connector CC J13 Powermax30 XP Service Manual 808150 Revision O 109 6
40. proceeding or otherwise arising out of or relating to the use of the Products exceed in the aggregate the amount paid for the Products that gave rise to such claim Insurance At all times you will have and maintain insurance in such quantities and types and with coverage sufficient and appropriate to defend and to hold Hypertherm harmless in the event of any cause of action arising from the use of the products 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 writing Hypertherm which reserves the right of approval Should you fail timely to notify Hypertherm and seek its approval as set forth herein the Warranty set forth herein shall be null and void and you will have no further recourse against Hypertherm under the Warranty or otherwise Safety and Compliance Section 1 Specifications Safety information Before operating any Hypertherm equipment read the separate Safety and Compliance Manual 80669C included with your product for important safety information System description The Powermax30 XP is a highly portable 30 A handheld plasma cutting system appropriate for a wide range of applications It uses air or ni
41. solenoid valve on page 80 Powermax30 XP Service Manual 808150 Revision O 65 5 Troubleshooting and System Tests Problem This may mean Possible cause s Possible solution s When you pull the torch trigger gas flows from the torch but the torch does not fire or fires only for a short period of time The consumables torch or torch lead are not functioning correctly The gas pressure is too low The gas supply quality is poor There is a voltage imbalance on the power board The consumables are worn or damaged The torch or torch lead is damaged The gas supply line is restricted The air filter element is dirty The power board is faulty Inspect the consumables torch and torch lead and replace if necessary Inspect the gas supply line for restrictions or damage Inspect the air filter element and replace if necessary See Replacing the air filter bowl and air filter element on page 148 Verify that the gas supply is providing at least 4 5 bar 65 psi Perform Test 3 VBUS and voltage balance on page 78 Arc goes out while cutting or intermittently will not fire The work lead connection is poor The work lead is damaged or not properly connected to the workpiece Inspect for loose connections at the ground clamp and at the power supply and repair if necessary Reposition the work lead on the workpiece Clean the cutting sur
42. supply hoses or connections Cut speeds can decrease Cut quality can deteriorate Cutting thickness capability can decrease Consumables life can be shortened 8 Complete the following procedures a See nstall the power supply cover on page 89 b Reconnect the gas supply and power cord and set the power switch to ON I 122 Powermax30 XP Service Manual 808150 Revision O 6 Power Supply Component Replacement Replacing the wire group Kit number Description 228103 Kit Wire group pressure switch wire pair 3 ground wires The wire group kit for the Powermax30 XP includes the following 4 wires Figure 58 Ona nt 2 F 3 4 iss O O 1 Pressure switch to J4 wire pair red black Ground wire from heatsink to magnetics assembly green Ground wire from heatsink to air filter regulator ground clip green 2 Ground clip wire from heatsink to rear panel green Powermax30 XP Service Manual 808150 Revision O 123 6 Power Supply Component Replacement Remove and install the pressure switch to J4 wires 1 1 2 3 124 Complete the following procedures a Set the power switch to OFF O disconnect the power cord from the power source and disconnect the gas supply b See Remove the power supply cover on page 88 Remove the red and black wires from the pressure switch The other end of the red and black wire pair is connected to the power board at J4 See Fig
43. than expected The causes can be m Q Q Q Moisture in the gas supply Low gas pressure Incorrect installation of the consumables Installation of the wrong consumables Minimizing dross Dross is the molten metal that solidifies on the workpiece Some amount of dross is always present when cutting with air plasma However you can control the amount and type of dross by adjusting your system correctly for your application Low speed dross forms when the torch s cutting speed is too slow and the arc shoots ahead It forms as a heavy bubbly deposit at the bottom of the cut and is usually easy to remove Increase your speed to reduce this type of dross High speed dross forms when the cutting speed is too fast and the arc lags behind It forms as a thin linear bead of solid metal attached very close to the cut It forms to the bottom of the cut and is often more difficult to remove Decrease your speed to reduce this type of dross 54 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 is likely to produce the least dross As the workpiece heats up more dross may form on subsequent cuts Worn or damaged consumables may produce intermittent dross Powermax30 XP Service Manual 808150 Revision O Section 5 Troubleshooting and System Tests Theory of operation Functional description AC power enters the system through the power switch S1 to t
44. the handle Screws 5 Trigger assembly Trigger spring Gas hose fitting s flange Strain relief Cap sensor wire connector 172 Powermax30 XP Service Manual 808150 Revision O 7 Torch Component Replacement Replacing the handle Kit Description 428177 Kit Duramax LT torch handle includes handle screws Remove the handle Many repairs require the removal of the handle and other components To remove the old handle and install a new handle you need to remove all components from the handle Several other procedures in this section reference this procedure 1 Set the power switch to OFF O disconnect the power cord from the power source and disconnect the gas supply 2 Remove the consumables from the torch 3 Place the torch on a flat surface with the left side of the handle facing up The left side of the handle is the side with the screws 4 Remove the screws from the torch handle Set the screws aside CAUTION Wear eye protection as the trigger spring can launch out of the handle 5 Being careful to keep the trigger spring from launching out of the handle lift the left side of the handle away from the torch Powermax30 XP Service Manual 808150 Revision O 173 7 Torch Component Replacement Figure 102 8 While holding the spring in place slide the trigger and spring up and out of the handle Set them aside 7 The torch body fits snugly into the right side of the handle While hold
45. 0 1 Tab Start switch 3 Remove the screw that attaches the torch s torch power wire to the torch body Set the nut and screw aside See Figure 108 on page 178 for the location of the screw 4 Use 2 wrenches to loosen the gas fitting that attaches the torch body to the torch lead CAUTION Always use two wrenches to properly loosen and tighten the hex nuts and bolts mentioned in these procedures 182 Powermax30 XP Service Manual 808150 Revision O 7 Torch Component Replacement Figure 111 9 Thread the torch body into the new torch lead to finger tight plus 1 4 turn B Tighten the screw that attaches the torch power wire to the torch body until the terminal is snug against the plunger See Figure 108 on page 178 for the screw position 7 Connect the cap sensor switch and start switch Figure 112 8 Complete the following procedures a Install all of the torch components that you removed See nstall the handle on page 176 b Reconnect the gas supply and power cord and set the power switch to ON I Powermax30 XP Service Manual 808150 Revision O 183 7 Torch Component Replacement 184 Powermax30 XP Service Manual 808150 Revision O Section 8 Parts Use the Hypertherm kit numbers in this section to order replacement parts consumables and accessories for your Powermax30 XP power supply and Duramax LT hand torch You can find procedures explaining how to install these
46. 0 5 Stainless steel 25 825 6 515 7i 205 1 10160 2 5130 3 Aluminum 25 2170 5 920 7i 120 English S gauge inches Material Arc current A inches mibuls 18 GA 330 16 GA 205 12 A Mild steel 25 10 GA 55 1 4 19 18 GA 260 16 GA 160 12 EA Stainless steel 25 10 GA 52 1 4 16 1 25 400 1 16 1 250 Aluminum 25 1 8 65 1 4 15 To cut material thicker than 6 mm 1 4 inch start the torch at the edge of the workpiece Maximum cut speed is limited by the test table s maximum speed 10160 mm minute or 400 inches minute Powermax30 XP Service Manual 808150 Revision O 3 Torch Setup 120 V 30 A cutting FineCut consumables Metric Material thickness mm Material Arc current A URINE T 10160 2 6175 3 2420 5 Mild steel 30 1300 8 535 o 280 13 110 1 10025 2 5755 Stainless steel 30 e 8 410 35i 170 1 10160 2 6805 Aluminum 30 en 8 375 T 150 English pog Materia are current ay Maximum cut speed 22 GA 4002 18 GA 4002 12 GA iv 10 GA Mild steel 30 75 1 4 31 3 8 12 1 2 5 22 GA 400 18 GA 390 2 Stainless steel 30 1 4 24 3 8 9 1 25 4007 1 16 329 1 8 Aluminum 30 105 1 4 22 3 8 8 To cut material thicker than 6 mm 1 4 inch start the
47. 3 On the fan side of the power supply remove the ground wire screw from the base of the magnetics assembly Figure 94 Ground wire screw Powermax30 XP Service Manual 808150 Revision O 163 6 Power Supply Component Replacement 4 Disconnect the air filter regulator s drain hose from the hole in the base of the power supply 5 Use a 8 mm 5 16 inch nut driver to remove the nut that attaches the ring connector for the output inductor s white wire to the stud labeled WHT Figure 95 WNNNNNAN S 1 Drain hose 3 White wire stud WHT 2 Output inductor 164 Powermax30 XP Service Manual 808150 Revision O 6 Power Supply Component Replacement 6 Place the wooden end of a swab a stiff wire or other similar item with a 0 23 cm 0 092 inch diameter in each of the five holes on the power board side of the base Press each one in until the clips release and you can pull the base and the attached magnetics away from the center panel Figure 96 ag e Holes 7 Remove the six screws that hold the magnetics metal mounting plate in place Remove the plate and the magnetics Figure 97 165 Powermax30 XP Service Manual 808150 Revisi
48. 3 Kit Power cord strain relief Powermax30 XP Service Manual 808150 Revision O 187 188 8 Parts Interior power board side AN N ISS FB S E Item Kit number Description 1 228104 Kit Component barrier 2 428233 Kit Power board CSA 141304 2 428234 Kit Power board CE and CCC 141309 Designator PCB2 PCB2 Powermax30 XP Service Manual 808150 Revision O 8 Parts Control board and power switch Item Kit number Description Designator 1 428232 Kit Control board 141336 PCB1 2 428235 Kit Power switch S1 Powermax30 XP Service Manual 808150 Revision O 189 8 Parts Interior fan side Item Kit number Description Designator 1 228106 Kit Air filter regulator with pressure switch 2 3 228095 Kit Hoses drain hose two gas supply hoses elbow fitting 3 428238 Kit Replacement elbow fittings 4 428173 Kit Solenoid valve V1 5 428236 Kit Fan assembly with plenum M1 6 228103 Kit Wire group pressure switch wire pair 3 ground wires 190 Powermax30 XP Service Manual 808150 Revision O 8 Parts Air filter regulator with pressure switch assembly Item Kit number Description 228106 Ki Air filter regulator with pressure switch assembly 1 428171 Kit Air i
49. 5 Requirements for grounding 1 timete etr rera te i di e rc ir rt Ra Dicta DR RR rien Ra Dad 26 Fower cord considerationis eysvecccecticctsdsrscrseserssseiccsesderaydotscherteytabesedney setusdeitanrasieectincenssdeuretsvendstey data eerie epe meer ing let rata eno 26 CSA power cords andplugs s e ERR N N Ua a Bt 0 dt Wee ie eat E 26 CE and CCG power Cords iL een caeca et ete qtac tmn in e ce ite ite moe ei bao end 27 Extension cord recommendations eese eene tette tete ttntn tete ntnten ine ntet itin te toten inte teniente nin 28 Generator recommendations serens e ge ee ed e E RU eee e e need 28 Prepare the gas sUpply trt rr Fert nre rn hr eren noa ne Ern d ion di Era Eee co i D de nara gd 29 CONMECE theGas SUPP M 29 Additional gas hiltration iade bas nid ise lal debut asides ould tee dts 30 EE palio E 31 IMFO GUCTION DER 31 Hand torch components iiec iere ri etta nct denii detada Fas Ran ooi Pu del Pope ede Fel ud Pelea de renard 31 Consumableslite 5 cin eo on ee eee da te et edi eu ie oie 32 Ghoosethle consumibles i SEES aii ee hd EU a REN ES 32 Using the Cut Charts i cce ER Dp EUER E dci ae 33 General purpose consumables sees SSO tette te ttnt tn tnt intent entente tert entente 34 240 V 30 A CURLING zii as cease ce Ac llc ates EES Acla A LM i LT LIE ILL 35 FineCut cons umables iiid rod in in rte de He d ef de
50. 81 58 2123 Technical Service Hypertherm S Pte Ltd 82 Genting Lane Media Centre Annexe Block A01 01 Singapore 349567 Republic of Singapore 65 6841 2489 Tel 65 6841 2490 Fax 65 6841 2489 Technical Service Hypertherm Shanghai Trading Co Ltd Unit 301 South Building 495 ShangZhong Road Shanghai 200231 PR China 86 21 60740003 Tel 86 21 60740393 Fax Hypertherm Europe B V Vaartveld 9 4704 SE Roosendaal Nederland 31 165 596907 Tel 31 165 596901 Fax 31 165 596908 Tel Marketing 31 165 596900 Tel Technical Service 00 800 4973 7843 Tel Technical 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 Rua Bras Cubas 231 Jardim Maia Guarulhos SP Brasil CEP 07115 030 55 11 2409 2636 Tel 55 11 2408 0462 Fax Hypertherm M xico S A de G 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 Hypertherm Korea Branch 3904 Centum Leaders Mark B D 1514 Woo dong Haeundae gu Busan Korea 612 889 82 51 747 0358 Tel 82 51 701 0358 Fax A Safety information 4 Before operating any Hypertherm equipment read the separate Safety and Compliance Manual 80669C included with your product for important safety information Contents Electromagnetic Compati
51. DGE Pro Ti CNC MicroEDGE Pro CNC and ArcGlide THC which shall be within a period of two 2 years from the date of delivery to you and iii with respect to Hylntensity fiber laser components within a period of two 2 years from the date of its delivery to you with the exception of laser heads and beam delivery cables which shall be within a period of one 1 year from its 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 Safely and Compliance 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
52. N Do not use VBUS W as ground Doing so could destroy the power supply Instead ground to either the ground wire clip on the rear panel or to the heatsink See Figure 11 on page 71 All values can be 10 pin numberto Test Expected value ground 19 VACR rectified AC line voltage 0 86 V at 120 line voltage 1 87 V at 230 line voltage 21 VBUS DC bus voltage 2 28 VDC at 375 VBUS 18 IPFC input current 0 1 VDC 20 IFB output current 0 1 VDC 22 ITF transfer current 0 1 VDC 5 3 3 VDC 3 3 VDC 10 7 5 VDC 5 VDC 10 12 24 V sense pin 2 2 VDC 16 Start signal 3 2 VDC closed 0 VDC open Powermax30 XP Service Manual 808150 Revision O 77 5 Troubleshooting and System Tests Test 3 VBUS and voltage balance Test the power board to verify that the circuits are balanced The test points are labeled on the back of the power board as are the voltages and positive and negative capacitor terminals See Figure 18 on page 79 for locations of test points CAUTION Do not use a multimeter with test leads This can cause a short circuit between the BUS and the heatsink Use test hook leads instead and attach them to the test point loops 1 Set the power switch to OFF O disconnect the power cord from the power source and disconnect the gas supply 2 Remove the power supply handle and cover See Remove the power supply cover on page 88 3 Remove the
53. P Service Manual 808150 Revision O 6 Power Supply Component Replacement Install the power board Before beginning this procedure verify you have the correct power board for your system m The replacement kit number for a CSA power board is 428233 m The replacement kit number for a CE CCC power board is 428234 1 Being careful not to scratch the heatsink use a clean cloth with isopropyl alcohol to remove any residual thermal grease 2 Apply a 0 051 mm 0 002 inch layer of thermal grease about the thickness of a sheet of paper on all the IGBTs and the input diode bridges 3 Apply thermal grease to the bottom of the snubber resistor as follows a Avoid getting any thermal grease on the prongs of the snubber resistor b Start from the end closest to the power board and drag away from the prongs Spread an even layer of thermal grease 0 051 mm 0 002 inch thick on the bottom of the snubber resistor See Figure 51 Figure 51 1 Snubberresistor 3 Capacitors 2 Thermal grease Powermax30 XP Service Manual 808150 Revision O 113 6 Power Supply Component Replacement 4 Push the red and white wires on the new power board through the hole in the center panel from the power board side of the power supply to the fan side of the power supply 5 Push the wires that you disconnected down and out of the way B Line up the capacitors on the power board with the holes in the power supply s center panel See
54. Powermax30 XP Plasma Arc Cutting System Service Manual 808150 RevisionO English 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 Powermax Duramax FineCut and Hypertherm are trademarks of Hypertherm Inc and may be registered in the United States and other countries All other trademarks are the property of their respective holders 2014 Hypertherm Inc Powermax30 XP Service Manual 808150 Revision O English February 2014 Hypertherm Inc Hanover NH 03755 USA Hypertherm Inc Etna Road P O Box 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 service hypertherm com Technical Service Email 800 737 2978 Tel Customer Service customer service hypertherm com Customer Service Email 866 643 7711 Tel Return Materials Authorization 877 371 2876 Fax Return Materials Authorization return materials hypertherm com RMA email Hypertherm Plasmatechnik GmbH Technologiepark Hanau Rodenbacher Chaussee 6 D 63457 Hanau Wolfgang Deutschland 49 6181 58 2100 Tel 49 6181 58 2134 Fax 49 61
55. RCHES PLASMA ARC CAN CAUSE INJURY AND BURNS The plasma arc ignites immediately when you press the torch trigger Make sure the power is OFF before changing consumables The Duramax LT hand torch ships with general purpose consumables installed The general purpose consumables are designed for a broad range of cutting applications Also included with your system is at least one FineCut nozzle and deflector The FineCut consumables are designed to achieve more finely detailed results on thin gauge metal The retaining cap swirl ring and electrode are the same for both sets of consumables The consumables that you choose should be determined by the m Input power m Amperage output setting m Thickness of the metal you plan to cut 32 Powermax30 XP Service Manual 808150 Revision O 3 Torch Setup The amperage output setting you need to use depends on the thickness of the metal you are planning to cut and is limited by the input power to your system See Voltage configurations on page 25 Although the visual differences between the general purpose and FineCut consumable parts are minor installing the wrong combination of consumables will affect the life of the parts as well as the cut quality Hypertherm does not recommend the use of any other consumables in the Duramax LT torch except for those listed in this section which are designed specifically for this system The use of any other consumables could adversely aff
56. U2 83 V Duty cycle at 40 C U 200 240 VAC 35 I2 30 A U2 125 V See data plate on power supply for more 60 I2 2 23 A U2 125 V information on duty cycle and for IEC ratings 100 I2 18 A U2 125 V Operating temperature 10 to 40 C 14 to 104 F Storage temperature 25 to 55 C 13 to 131 F Power factor 120 V 240 V 0 99 0 97 Input voltage U Input current I at rated 120V 25A output Us max lo max 200 240 V 22 5 188A See Voltage configurations on page 25 for more information Gas type Air Nitrogen Gas quality Clean dry oil free 99 995 pure Minimum required gas inlet flow and pressure 99 1 l min at 4 7 bar 3 5 scfm at 68 psi Recommended gas inlet flow and pressure 113 3 l min at 5 5 bar 4 0 scfm at 80 psi Maximum gas inlet pressure 9 3 bar 135 psi Powermax30 XP Service Manual 808150 Revision O 19 1 Specifications Torch dimensions 230 mm 9 0 inches 83 mm 3 3 inches 25 mm 1 0 inch Torch weight 45 mm 1 8 inches Duramax LT torch with general purpose consumables only 0 3 kg 0 75 pounds Duramax LT torch with general purpose consumables and 4 6 m 15 foot lead with strain relief 1 1 kg 2 35 pounds Cutting specifications 240 V with general purpose consumables Recommended cut capacity 9 mm 3 8 inch at 500 mm minute 20 inches minute 12 mm 1 2 inch
57. age 90 d See Detach the front panel on page 92 e See Detach the rear panel on page 95 3 On the fan side of the power supply disconnect the air filter regulator s drain hose from the hole in the bottom of the base 4 Lay the power supply on its side with the fan side facing up 5 Remove the six screws that attach the plastic base to the components at the bottom of the power supply 8 Place the wooden end of a swab a stiff wire or other similar item with a 0 23 cm 0 092 inch diameter in each of the five holes on the power board side of the base Press each one until the clips release and you can pull the base away from the center panel Figure 92 5 1 Rear panel 4 Front panel 2 Data plate location 5 Bottom component screws 3 Holes 160 Powermax30 XP Service Manual 808150 Revision O 6 Power Supply Component Replacement 7 Position the new base over the metal plate on the bottom of the power supply so that the screw holes align with the holes in the metal base plate for the bottom components 8 Press the plastic base into the power supply until it snaps into place 9 Attach the plastic base to the bottom components using the six screws 10 Reconnect the air filter regulator s drain hose to the hole in the bottom of the base 11 Complete the following procedures a See Reattach the front panel on page 94 b C See Reattach the rear panel on page 97 See n
58. an continues to run To resume cutting wait for the temperature LED to extinguish The fan may run during normal operation of the system 46 Powermax30 XP Service Manual 808150 Revision O 4 Operation System operation guidelines m Toachieve the highest level of performance Q Operate the system at an input power of 240 VAC whenever possible Avoid using an extension cord whenever possible If you must use an extension cord use a heavy conductor cord of the shortest possible length See Extension cord recommendations on page 28 m If you are operating your system on a 120 V 15 A circuit do not set the amperage higher than 20 A See Voltage configurations on page 25 m Forbestresults when operating your system on a 120 V 15 A circuit Q Do not connect anything else that will draw power from the same circuit Q Be aware that extension cords can reduce the voltage to the machine from what is output by the circuit This reduction in power can impair cutting performance and increase the probability of tripping the circuit breaker m Cutting a thicker workpiece with the general purpose consumables requires a higher amperage setting It is preferable to operate on a higher rated circuit 240 V 30 A when cutting thicker metal See Voltage configurations on page 25 m Additional techniques to reduce the frequency of tripped circuit breakers include Uu Turn down the amperage adjustment knob Avoid stret
59. ance check 2 2 1d nsa me ce b r ca eet en tonc i fad teer de qe iicet tee tether gen Y 59 Check the power switch caccia eint icit cti ed erue tic ta ea cru unica ocaeca aca 60 gs el TelenAe M M vers 62 Bresle foror egere evaluate 63 Controliboard LEDS DLP 69 Use the control board Error and Reset LEDs to troubleshoot sese tnetetnnes 70 Powermax30 XP Service Manual 808150 Revision O 9 Contents DY STSM LOSES ee so EDD EL dant oh t i iE t Saha 71 TLest lv voltage input sic atauicin wish anon Aiousca damian aid nien enam saath ards aus Sadia meagan sana anata 74 Test 2 power board voltage checks sees ce tenente tenente tente tenet seine tette testet te ined testet te tesa sensa 76 Test 3 VBUS and voltage balance seen tente tente tente tenente tente tenente tenens 78 Test4 solenoid valve 25a deiode Ended t eie ada pl Grade ru ale hin PM te 80 Test 5 torch stuck open or torch stuck closed eee tentent nennnnnnen tete 81 IK sal PlASMAStart E 82 Tests torch eap sensor srs ecAtadh c eiie doe eade e re a Aa e uud uc dere ideo 84 tI M A T 85 Test 9 pressure SWITCH e erre nd herr em hera Fe cbe e prae Rl FR erepto Ern Rada co aae 86 6 Power Supply Component Replacement
60. 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 representation to you purporting to be binding upon Hypertherm SC 15 Warranty 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
61. as no incoming voltage or an improper incoming voltage The power board is faulty Verify that the electrical power is connected to an appropriately sized circuit Verify that the system did not trip the circuit breaker Perform Test 1 voltage input on page 74 The power ON LED and the gas pressure LED illuminate DO There is insufficient gas pressure to the system The gas supply line is not attached to the system The gas supply line has a restriction The air filter element is dirty The pressure switch is not reading at least 2 8 bar 40 psi on the gas supply line Attach the gas supply Inspect the gas supply line for restrictions or damage and repair or replace if necessary Inspect the air filter element and replace if necessary See Replacing the air filter bowl and air filter element on page 148 Perform Test 9 pressure switch on page 86 The power ON LED and the temperature LED illuminate The system overheated The system is too cold to operate Youhave exceeded the duty cycle See Understand duty cycle limitations on page 46 The ambient temperature is too low Inspect the area around the system to make sure that the gas flow is not blocked Letthe system cool before using it Perform Test 8 fan on page 85 Let the system warm up before using it Powermax30 XP Service Manual 808150 Rev
62. 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 Safely and Compliance Electromagnetic Compatibility EMC a Other supply cables control cables signaling and telephone cables above below and adjacent to the cutting equipment b Radio and television transmitters and receivers Computer and other control equipment d Safety critical equipment for example guarding of industrial equipment e Health of the people around for example the use of pacemakers and hearing aids f Equipment used for calibration or measurement g Immunity of other equipment in the environment User shall ensure that other equipment being used in the environment is compatible This may require additional protection measures h Time of day that cutting or other activities are to be carried out The size of the surrounding area to be considered will depend on the structure of the building and 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 inter
63. at 250 mm minute 10 inches minute Severance cut capacity 15 mm 5 8 inch at 125 mm minute 5 inches minute 120 V Use the FineCut nozzle and deflector for cutting on 120 V input circuits When you operate the system at the maximum recommended output of 25 A the cut capacities are Q 6mm 1 4 inch at 480 mm minute 19 inches minute Q 9mm 3 8 inch at 200 mm minute 8 inches minute Q 12mm 1 2 inch at 75 mm minute 3 inches minute the consumables on page 32 20 To understand the differences between the general purpose and FineCut consumables and for guidelines on selecting the right set for your cutting applications see Choose Powermax30 XP Service Manual 808150 Revision O 1 Specifications Symbols and marks 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 s GB CE eo zz m mjo Y iQ P E e Ss an w S mark The S mark indicates that the power supply and torch are suitable for operations carried out in environments with increased hazard of electrical shock according to IEC 60974 1 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 p
64. bility EMC sssssssssssssssssssessnsesesscsessnsesessenesenseseseenenensenes SC 13 INtFOCUCTION wiccseccccscsscsscssssscescesseeseseessessesseceuseeseuseuseuseuseuseuseusesseuseusesseuseseesseseseuseusesseuseusoeseeseusesseuseusesseuseasesseusessusseusessusaesenseusans Installation and use Assessment of ara m esterase Methods ofreduecirig emissions eit debutto sini lue Dioni DIE c E EI Ma SUP PLY or Maintenance of cutting equipment Cutting cables Edquipotential bonding 0 tod eee acd eret deperire aa d reticere erect etes Earthing of the workplece cett tct teet tette ditt re dee or a di rb dor d b de ee ra tush AR Screening and shielding teet iecit tet e intandededastagundistantantutescndtedndaayaccaptatnsseienietatancegetiashedapSentananeg MA ARAN E iiu a das sERadi c Eun nanaptnasdacscucasns E A E E T PATE TION n cstanicttot terere E xe emiten ede ETE General ox EROS eum eie eap aene te qui emper fec egi ete NS Patent inderminity ii atin ronda aa tcm tiep Dp dr dicic d i dr se reiner a dies limitationzof liability Soru rte enenatis Ail neci uei tre TI National and local codes Liability cdp e X ante InsSurdli6e em ise d kc eitu LEE ALME tutu rfe luti tT Mol t LENT Tr nster of nghe i nass saeua npede ide ddcdhiinsieui Di pul p e ud dc IA RM laa ALIAD 1 Specifications E
65. c IGBT gated I I Post flow Gas control device LED on l l I I I I I I I I I I I I User set current I I I I I I I I I I I I i Transfer PA current Pilot arc current I I Inverter output on I I I I Transfer threshold 1 6 A Transfer relay and LED on Powermax30 XP Service Manual 808150 Revision O 200 Powermax30 XP schematic 9 Wiring Diagrams Ai CONTROL PWA GAS SOL 1308 tee on MASHINE 24v 0 20A 24v 0 75A Low Press OPEN POWER PWA REAR 141335 Top Level 4 LAYER 00 4 E E DRM LOOKING BOTTOM SIDE of POWER BD 141304 Top Level 16A 250V DPST f i 7
66. cause poor cut quality poor consumable life and operational problems If the purity level of the gas is too low or if there are leaks in the supply hoses or connections Cut speeds can decrease Cut quality can deteriorate Cutting thickness capability can decrease Consumables life can be shortened Figure 78 Ir am E 1 CSA quick connect air fitting 3 Brass hex adapter 2 CE CCC air fitting adapter 4 Air filter regulator 8 Complete the following procedures a See nstall the power supply cover on page 89 b Reconnect the gas supply and power cord and set the power switch to ON I Powermax30 XP Service Manual 808150 Revision O 147 6 Power Supply Component Replacement Replacing the air filter bowl and air filter element Kit number Description 428237 Kit Air filter element 428246 Kit Air filter bowl Remove the air filter bowl and air filter element 1 Complete the following procedures a Set the power switch to OFF O disconnect the power cord from the power source and disconnect the gas supply b See Remove the power supply cover on page 88 2 From the fan side of the power supply disconnect the drain hose from the hole in the bottom of the base 3 Remove the other end of the drain hose from the brass fitting at the bottom of the air filter bowl Set the drain
67. check the AC voltage WARNING ELECTRIC SHOCK CAN KILL Use extreme caution when working near live electrical circuits Dangerous voltages exist inside the power supply that can cause serious injury or death See the WARNING on page 58 before proceeding 5 Once you have the test leads in place leave the power switch set to OFF O and reconnect the electrical power The voltage should equal the line voltage of the incoming circuit for example 120 V or 240 V All values can be 15 74 Powermax30 XP Service Manual 808150 Revision O 5 Troubleshooting and System Tests Figure 14 J1 J2 AC Single phase power supplies CE CCC wire colors Designator CSA wire colors L live Black Brown N neutral White Blue PE ground Green Green yellow B If the AC voltage is incorrect verify that you have power to the unit If you do have power inspect the power cord for damage and replace if necessary See Remove the power cord and strain relief on page 98 7 If the power source and power cord are functioning correctly disconnect the power cord again and reconnect the two wires to the power switch 8 Reconnect the electrical power and set the power switch to ON I 9 Measure the AC voltage from J1 to J2 labeled AC on the back of the power board This value should be the same as the incoming line voltage If it is not check the power switch and replace if necessa
68. ching the arc Instead drag the torch on the workpiece as explained in Edge start on a workpiece on page 50 Powermax30 XP Service Manual 808150 Revision O 47 4 Operation Hand torch operation WARNING INSTANT ON TORCHES PLASMA ARC CAN CAUSE INJURY AND BURNS Plasma arc ignites immediately when you press the torch trigger The plasma arc cuts quickly through gloves and skin Keep hands clothes and objects away from the torch tip Do not hold the workpiece and keep your hands clear of the cutting path Never point the torch toward yourself or others WARNING SPARKS AND HOT METAL CAN INJURE EYES AND BURN SKIN Always wear proper protective equipment including gloves and eye protection and point the torch away from yourself and others Sparks and hot molten metal spray out from the nozzle Safety catch operation The Duramax LT torch is equipped with a safety catch to prevent accidental firings When you are ready to cut with the torch flip the safety catch forward toward the torch head and press the red torch trigger 48 Powermax30 XP Service Manual 808150 Revision O 4 Operation Hand torch cutting guidelines m With either set of consumables drag the torch tip lightly on the workpiece to maintain a steady cut speed Sometimes the torch sticks slightly to the workpiece when you cut with the FineCut consumables m While cutting make sure that sparks exit from the bottom of the workpiece
69. 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 m Multimeter with a variety of test leads including test hooks Troubleshooting procedures and sequence When performing the troubleshooting procedures refer to m Safety and Compliance Manual 80669C for detailed safety information m Wiring Diagrams on page 199 for the system s electrical schematic m Power Supply Component Replacement on page 87 or Torch Component Replacement on page 171 for replacement procedures m Parts on page 185 for power supply components and torch components Power OFF O and disconnected Y External inspection Y Internal inspection Y Initial resistance check Y Power ON I Y Troubleshooting guide Y System tests Powermax30 XP Service Manual 808150 Revision O 57 5 Troubleshooting and System Tests After the problem has been located and repaired refer to Sequence of operation on page 56 to test the power supply for proper operation ELECTRIC SHOCK CAN KILL Turn OFF O the power and disconnect the electrical power before removing the co
70. connect the gas supply and power cord and set the power switch to ON I Powermax30 XP Service Manual 808150 Revision O 89 6 Power Supply Component Replacement Replacing the component barrier Kit number Description 228104 Kit Component barrier Remove the component barrier 1 Set the power switch to OFF O disconnect the power cord from the power source and disconnect the gas supply 2 Remove the component barrier from the power board side of the power supply The barrier is flexible and can be bent slightly for removal Figure 26 7 e p 9 e 3 9 o e e M 4 E 4 9 ie a 90 Component barrier Powermax30 XP Service Manual 808150 Revision O 6 Power Supply Component Replacement Install the component barrier 1 Hold the component barrier so that the edge with the long cutout and the two notches is closest to the rear panel and the edge with the three notches is closest to the front panel N A perforated line runs across the top of the barrier about 25 mm 1 inch below the top edge Fold the barrier 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 The edge with the long cutout and the two notches should align with the front panel the e
71. connection point is just below the bottom right corner of the fan The wire is routed behind the pressure switch and down along the left side of the fan housing Remove the ring terminal from the screw that attaches it to the metal base plate 4 Tighten the new ground wire s ring terminal to the heatsink to a torque setting of 23 0 kg cm 20 inch pounds Be sure to reattach the ring terminals for the other two ground wires that connect to the heatsink using the same screw 5 Route the new ground wire through the notch in the center panel above the pressure switch behind the pressure switch along the left side of the fan and then along the metal base plate of the magnetics assembly to the screw below the bottom right corner of the fan See Figure 61 B Use the screw to attach the ring terminal for the new wire to the metal base plate of the magnetics assembly with a torque setting of 17 3 kg cm 15 inch pounds 7 Complete the following procedures a See nstall the power supply cover on page 89 b Reconnect the gas supply and power cord and set the power switch to ON I 126 Powermax30 XP Service Manual 808150 Revision O 6 Power Supply Component Replacement Figure 61 5 1 Pressure switch 3 Heatsink Screw on the metal base plate of the magnetics 4 Ground wire from heatsink to magnetics assembly assembly that attaches the ground wire 5 Center panel Powermax30 XP Service Manual 808150 Revision O 127
72. d the plug and pulling the plug out Figure 22 4 Push tab toward connector J13 Measure the resistance from the orange wire to the blue wire It should measure less than 10 Q If it measures high resistance the cap sensor switch circuit is open Make sure the torch plunger moves smoothly If it does not replace the torch body See Replacing the torch body on page 178 Make sure the consumables are correctly installed Adjust the consumables if necessary If the torch parts mentioned in step 7 and step 8 are working properly the cap sensor switch is faulty or the torch lead has a broken wire Replace the faulty part See Replacing the cap sensor switch on page 181 or Replacing the torch lead on page 182 Powermax30 XP Service Manual 808150 Revision O 5 Troubleshooting and System Tests Test 8 fan Test the fan M1 for proper operation 1 Set the power switch to OFF O disconnect the power cord from the power source and disconnect the gas supply 2 Remove the power supply handle and cover See Remove the power supply cover on page 88 3 Remove the component barrier See Remove the component barrier on page 90 4 Place a jumper from ground see Figure 11 on page 71 to pin 3 of J5 see Figure 12 on page 72 WARNING ELECTRIC SHOCK CAN KILL Use extreme caution when working near live electrical circuits Dangerous voltages exist inside the power supply that can ca
73. de ro fee En tede de Rodeo 36 120 V 7 25 A GUNNO eie itte eee te teme iiti testas eme eme detegit ees setareedsrasdatistuntsrursadsaneh EFELER AR 37 120 V7 30 A cut ng iios a dias eiue dude na i cie ie feta 38 8 Powermax30 XP Service Manual 808150 Revision O Contents 4 ODerdtiODuscdesiscuci E A CUu EE o Cucakri bu DLVen mos Cua Una CUu E A Ua Cu VER GE En UL RV e DU GMRR SCR CA UERA CLR URER 39 Controls and Indicators 35 sese EE Le EE 39 dun m 39 Front controls arid LEDS eee ibit en cin idee ih adde kd ta nri De PEE eR 40 Operate the Powermax3O XP act ele A ege gd eene qoi caet th cite Gases nate Rer nudes 41 Connect the electrical power and gas supply sse nennen entente ttn tnter tenente teens 41 Install the consumables rt reti tert te t Db Dre B re EI a a Ree Dn a D e oorr ead 42 Attach the gro nd clamp ence de ik eaten enc e taii rent oe Un dated ee ced ced Goin e ont b ten Suse ente 44 pe eh uariycuee t M I 44 Adjust the gas pressure and output current essent tenerent tenente ttn te tente tente tentat te tentes tates to anaes 44 Check the indicator LEDs 2 3 ne ean en qp cain aod ara ient Ro dde tede iet bon de zi Rn indes 46 Verty the Systems ready e cnc iet d ca recie tee ted ete advent d ncc eterna 46 Understand duty cycle limitations rtt n
74. delines on page 47 This set includes an electrode swirl ring general purpose nozzle retaining cap and shield The general purpose nozzle must be installed only with the shield not the deflector Cutting at 120 V with the general purpose consumables is not recommended Figure 3 General purpose consumable set dE Di br 6 OO 00000 o oO 1 Torch 4 Nozzle 420118 2 Electrode 420120 5 Retaining cap 420114 3 Swirl ring 420211 6 Shield 420116 34 Powermax30 XP Service Manual 808150 Revision O Metric 240 V 30 A cutting General purpose consumables 3 Torch Setup Maximum cut speed 1 To cut material thicker than 6 mm 1 4 inch start the torch at the edge of the workpiece 2 Maximum cut speed is limited by the test table s maximum speed 10160 mm minute or 400 inches minute Powermax30 XP Service Manual 808150 Revision O Material thickness mm Material Arc current A mm minute 1 101602 2 7530 3 4185 5 Mild steel 30 1835 8 780 12 320 16 175 1 8355 2 5635 3 2910 5 Stainless steel 30 1245 8 575 10 360 13 215 3 3555 5 2115 8 Aluminum 30 785 10 425 13 205 English gauge Miches Material Arc current A Ainehes
75. dge 2 Press the torch trigger to start the arc You may need to pause at the edge until the arc has cut completely through the workpiece 3 Drag the torch lightly across the workpiece to proceed with the cut Maintain a steady even pace 50 Powermax30 XP Service Manual 808150 Revision O 4 Operation Pierce a workpiece ia If the metal is thinner than 6 mm 1 4 inch use piercing to cut an interior feature Piercing shortens the life of the consumables The type of pierce to perform depends on the thickness of the metal Hypertherm recommends m Straight pierce For cutting metal that is thinner than 3 mm 1 8 inch m Rolling pierce For cutting metal that is 3 mm 1 8 inch or thicker 1 Attach the ground clamp to the workpiece 2 Straight pierce Hold the torch perpendicular 90 to the workpiece Rolling pierce Hold the torch at an approximate 30 angle to the workpiece with the torch tip within 1 5 mm 1 16 inch of it before firing the torch 3 Straight pierce Press the torch trigger to start the arc Rolling pierce Press the torch trigger to start the arc while still at an angle to the workpiece then slowly rotate the torch to the perpendicular 90 position 4 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 metal Powermax30 XP Service Manual 808150 Revision O 51 4 Operation 5 Whe
76. dge with the three notches should align with the rear panel Put the front panel edge of the barrier in place first then the rear panel edge The notches on each side of the barrier should align with the ribs on the inside of the front and rear panels As you slide the barrier into place make sure the bottom edge is between the wires at the bottom of the power board and the side of the plastic base The barrier will not fit in the same track with the power supply cover 5 Reconnect the gas supply and power cord and set the power switch to ON I Figure 27 Q y aS jan A Component barrier edge with long cutout and 3 Track two notches 4 Rear panel 2 Front panel 5 Component barrier edge with three notches Powermax30 XP Service Manual 808150 Revision O 91 6 Power Supply Component Replacement Detaching and reattaching the front panel Several repairs are easier to make if you first detach the front panel from the power supply For instructions on replacing an old front panel with a new one see Replacing the front panel on page 152 Detach the front panel 1 Set the power switch to OFF O disconnect the power cord from the power source and disconnect the gas supply 2 Loosen the strain relief nuts on the torch lead and work lead 3 Lay the power supply on its side 4 Remove the retaining screw from the bottom of the front panel
77. e 133 12 Disconnect the work lead from the power supply See Remove and install the work lead on page 167 Install the front panel 1 Push the new front panel into the power supply base to re engage the snaps 2 Tighten the retaining screw to a torque setting of 8 1 kg cm 7 inch pounds 3 Attach the control board to the new front panel with the three retaining screws 4 Press the amperage adjustment knob onto the post on the new front panel 5 Reinstall the work lead and the torch lead See Remove and install the work lead on page 167 and nstall the torch lead and strain relief on page 137 8 Connect the control panel ribbon cable to the power board and fold the latches up to hold it in place 7 Complete the following procedures a See nstall the component barrier on page 91 b See nstall the power supply cover on page 89 c Reconnect the gas supply and power cord and set the power switch to ON I Powermax30 XP Service Manual 808150 Revision O 155 6 Power Supply Component Replacement Replacing the rear panel Kit number Description 428220 Kit Rear panel Remove the rear panel Use the following procedure to completely remove the rear panel in order to replace it If you just need to move the rear panel out of the way to provide better access to the interior of the power supply see Detach the rear panel on page 95 and Reattach the rear panel on page 97 1 Complete the following procedures a Set t
78. e end of the 240 V 20 A NEMA 6 50P plug to the power supply s NEMA twist lock style plug 26 Powermax30 XP Service Manual 808150 Revision O 2 Power Supply Setup CE and CCC power cords CE and CCC configurations ship without a plug on the power cord To operate at 220 V CCC or 230 V CE obtain the correct plug for your unit and location and have it installed by a licensed electrician 1 Cord grip 4 220 V CCC or 230 V CE plug 2 Outer shell 5 To line 2 terminal blue 3 To line 1 terminal brown 6 To ground terminal green yellow 1 Strip back the cord insulation to separate wires 3 5 and 6 2 Remove each wire s insulation to allow good contact with the plug terminals 3 Make the connections 4 Reinstall the outer shell and cord grip and tighten the cord grip s screws until snug Do not overtighten Powermax30 XP Service Manual 808150 Revision O 27 2 Power Supply Setup Extension cord recommendations Use an extension cord of an appropriate wire gauge for the cord length and system voltage Use a cord that meets national and local codes Input voltage Phase Recommended cord gauge size Length 120 VAC 1 4 mm 12 AWG Up to 16 m 53 feet 240 VAC 1 2 mm 14 AWG Up to 40 5 m 133 feet Extension cords can cause the machine to receive less input voltage than the output of the circuit This can limit the operation of you
79. e following illustration shows the components typically included with all system configurations Additional components such as setup instructions a carrying case and protective glasses and gloves may also be included with your system depending on the configuration you ordered a 00080 1 Operator Manual 7 Ground clamp and work lead 2 Quick Setup Card 8 CE CCC power cord no power plug included 3 Registration card 9 CSA power cord with power plug adaptors 4 Safety and Compliance Manual 10 Power supply 5 Duramax LT torch with lead 11 Carrying strap 6 Consumable kit The specific components included with the system are subject to change over time 24 Powermax30 XP Service Manual 808150 Revision O 2 Power Supply Setup Position the plasma cutting system m Position the Powermax30 XP near an appropriate power receptacle The system has a 3 0 m 10 foot power cord m Allow at least 0 25 m 10 inches of space around the power supply for proper ventilation m Place the power supply on a stable level surface before using m Do not use the system in rain or snow Prepare the electrical power The system s maximum output voltage varies based on the input voltage and the circuit s amperage Additional factors must be considered when you are operating the system at an input power of 120 V as tripped circuit breakers can result under some conditions For more information
80. e gas supply and power cord and set the power switch to ON I 180 Powermax30 XP Service Manual 808150 Revision O 7 Torch Component Replacement Replacing the cap sensor switch Kit Description 228109 Kit Torch cap sensor switch 1 Complete the following procedures a Set the power switch to OFF O disconnect the power cord from the power source and disconnect the gas supply b Remove all components from the torch See Remove the handle on page 173 2 Disconnect the old cap sensor switch by pressing the tab on the connector and pulling 0 the connector apart 1 Tab 3 Connect the new cap sensor switch to the torch lead by pushing the mating plug on the torch lead wires into the socket 4 Complete the following procedures Cap sensor switch a Install all of the torch components that you removed See nstall the handle on page 176 b Reconnect the gas supply and power cord and set the power switch to ON I Powermax30 XP Service Manual 808150 Revision O 181 7 Torch Component Replacement Replacing the torch lead Kit Description 428176 Kit Duramax LT torch lead 4 6 m 15 feet with strain relief 1 Complete the following procedures a Set the power switch to OFF O disconnect the power cord from the power source and disconnect the gas supply b Remove all components from the torch See Remove the handle on page 173 2 Disconnect the cap sensor switch and start switch Figure 11
81. ead CAUTION Always use two wrenches to properly loosen and tighten the hex nuts and bolts mentioned in these procedures Figure 109 4 Thread the torch body into the torch lead to finger tight plus 1 4 turn 5 Tighten the screw that attaches the torch power wire to the torch body until the terminal is snug against the plunger See Figure 108 on page 178 for the screw installation order It is important that the screw be installed as shown 8 Complete the following procedures a Install all of the torch components that you removed See nstall the handle on page 176 b Reconnect the gas supply and power cord and set the power switch to ON I Powermax30 XP Service Manual 808150 Revision O 179 7 Torch Component Replacement Replacing the start switch Kit Description 428162 Kit Torch start switch 1 Complete the following procedures a Set the power switch to OFF O disconnect the power cord from the power source and disconnect the gas supply b Remove all components from the torch See Remove the handle on page 173 2 Disconnect the old start switch by pushing on the tab and pulling the start switch away from the connector Tab 3 Connect the new start switch by pushing the mating plug into the socket 4 Complete the following procedures Start switch a Install all of the torch components that you removed See nstall the handle on page 176 b Reconnect th
82. ecifications section can cause poor cut quality poor consumable life and operational problems If the purity level of the gas is too low or if there are leaks in the supply hoses or connections Cut speeds can decrease Cut quality can deteriorate Cutting thickness capability can decrease Consumables life can be shortened 12 Complete the following procedures a See nstall the power supply cover on page 89 b Reconnect the gas supply and power cord and set the power switch to ON I 132 Powermax30 XP Service Manual 808150 Revision O 6 Power Supply Component Replacement Replacing the torch lead and strain relief Kit number Description 428176 Kit Duramax LT torch lead 4 6 m 15 feet with strain relief Remove the torch lead and strain relief If you are replacing just the torch lead cable not the whole torch assembly refer to Replacing the torch lead on page 182 for details on how to remove the old lead from the torch 1 Complete the following procedures a Set the power switch to OFF O disconnect the power cord from the power source and disconnect the gas supply b See Remove the power supply cover on page 88 c See Detach the front panel on page 92 2 Push to disconnect the plastic 90 fitting from the torch lead s brass gas supply fitting inside the front panel of the power supply See Figure 56 on page 119 Figure 67 1 Torch lead 3 Front panel hidden Plastic 90 fitting connect
83. ect system performance Figure 1 and Figure 2 illustrate the differences between the general purpose and FineCut nozzles and between the deflector and the shield The FineCut consumables have rings or grooves etched onto them as shown in Figure 2 to help you distinguish them from the general purpose consumables Figure 1 General purpose General purpose nozzle Shield Figure 2 FineCut Etched rings L Etched rings Pi FineCut nozzle Deflector Using the cut charts The following topics provide cut charts for each set of consumables Use these cut charts to guide you in selecting the consumables and cutting current based on the thickness and type of the metal you need to cut The maximum cut speeds listed in the cut charts are the fastest possible speeds to cut metal without regard to cut quality Recommended cut speeds are a starting point for finding the best quality cut best angle least dross and best cut surface finish Adjust the cutting speed for your application to obtain the desired cut quality When cutting thin metal 3 mm 10 gauge or thinner you may achieve a higher cut quality by using the FineCut consumables and cut charts Powermax30 XP Service Manual 808150 Revision O 33 3 Torch Setup General purpose consumables Use the general purpose consumables to cut thicker metals that do not require cuts that are as finely detailed See Voltage configurations on page 25 and System operation gui
84. ed to brass gas supply fitting Powermax30 XP Service Manual 808150 Revision O 133 6 Power Supply Component Replacement 3 Locate the 3 pin connector at the TORCH START slot J12 on the power board on the side facing the heatsink where the orange blue and purple wires from the torch lead connect Figure 68 TORCH O START 1 TORCH START slot J12 2 Front panel 134 Powermax30 XP Service Manual 808150 Revision O 6 Power Supply Component Replacement 4 Remove the connector at J12 by pressing up on the tab in the connection slot with a small blade screwdriver and then pulling the connector out toward the power supply s front panel Figure 69 4 Push tab toward connector J13 5 Locate the studs that attach the white wire group and the red wire from the torch lead to the power supply s center panel on the fan side of the power supply 6 Use an 8 mm 5 16 inch nut driver to remove the nuts from the studs and slide the ring terminals off the studs Figure 70 1 Red wire 2 White wire group Powermax30 XP Service Manual 808150 Revision O 135 6 Power Supply Component Replacement 7 Loosen the strain relief nut on the torch lead outside the front panel 8 On the inside of the front panel unscrew the retention nut on the torch lead s strain relief so that the
85. een 15 A and 30 A Powermax30 XP Service Manual 808150 Revision O 4 Operation Operate the Powermax30 XP The following topics explain how to begin cutting with the Powermax30 XP Connect the electrical power and gas supply Plug in the power cord 1 and connect the gas supply line 2 m Forinformation on connecting the gas supply to the power supply see Prepare the gas supply on page 29 m For information on connecting the proper plug to the power cord see Power cord considerations on page 26 m To understand which consumables to use and what cutting capacity to expect based on input voltage see Choose the consumables on page 32 m For information on electrical requirements and gas supply requirements for this system see Power Supply Setup on page 23 Powermax30 XP Service Manual 808150 Revision O 41 4 Operation Install the consumables WARNING INSTANT ON TORCHES PLASMA ARC CAN CAUSE INJURY AND BURNS The plasma arc ignites immediately when you press the torch trigger Make sure the power is OFF before changing consumables To operate the Duramax LT torch first verify 1 The power switch is in the OFF O position 2 A complete set of consumables is installed as shown in Figure 5 3 You use only the shield 4201 16 with the general purpose nozzle 4201 18 To understand the differences between the general purpose and FineCut consumables and for guidelines on selecting the right set for
86. elief fno i Route the wires for the new power cord through the strain relief from the inside of the rear panel ii Slide the strain relief nut onto the new power cord on the outside of the rear panel Because the power cord includes the ferrite core you cannot route the power cord through the strain relief from the outside of the power supply Do not remove the ferrite core from the power cord wires 2 Press the connector for the brown wire onto the pin on the upper left side of the power switch 3 Press the connector for the blue wire onto the pin on the upper right side of the power switch 4 Tighten the green yellow ground wire to the heatsink with a torque setting of 17 3 kg cm 15 inch pounds 5 Position the wires in the wire chase up the side of the panel and out of the way of the power board At the same time realign the rear panel with the power supply See Reattach the rear panel on page 97 8 Tighten the strain relief nut on the outside of the rear panel 7 Complete the following procedures a See nstall the component barrier on page 91 b See nstall the power supply cover on page 89 Reconnect the gas supply and power cord and set the power switch to ON I 104 Powermax30 XP Service Manual 808150 Revision O 6 Power Supply Component Replacement Replacing the power switch Kit number Description 428235 Kit Power switch 1 Complete the following procedures a Set the power sw
87. ers based on the conditions and work environments in your region Kit Number 428226 228561 428239 428235 428232 428233 428234 428173 228688 228106 428237 428179 428177 428181 428156 428182 428162 228109 428174 428176 128836 027055 Description Kit Current adjustment knob Kit Ground clamp Ki Work lead 4 6 m 15 feet includes ground clamp Ki Power switch Ki Control board Ki Power board CSA Kit Power board CE and CCC Ki Solenoid valve Ki Pressure switch Ki Air filter regulator with pressure switch Ki Air filter element Ki Replacement o rings for torch body Ki Duramax LT torch handle Ki Duramax LT torch handle screws Ki Torch trigger and spring Ki Spring for torch trigger Ki Torch start switch Ki Torch cap sensor switch Ki Duramax LT hand torch assembly with 4 6 m 15 foot lead Ki Duramax LT torch lead 4 6 m 15 feet Thermal grease 1 8 ounce Silicone lubricant 1 4 ounce Powermax30 XP Service Manual 808150 Revision O Reference page 186 page 186 page 186 page 188 page 188 page 188 page 188 page 190 page 190 page 190 page 190 page 193 page 193 page 193 page 193 page 193 page 193 page 193 page 193 page 193 page 195 page 195 197 8 Parts Powermax30 XP labels Kit number Descriptio
88. et plug not included 228143 Kit Power cord strain relief Remove the power cord and strain relief CSA power cords 1 Complete the following procedures a Set the power switch to OFF O disconnect the power cord from the power source and disconnect the gas supply b See Remove the power supply cover on page 88 c See Remove the component barrier on page 90 d See Detach the rear panel on page 95 2 Remove the black and white wires from the top of the power switch Figure 36 98 Powermax30 XP Service Manual 808150 Revision O 6 Power Supply Component Replacement Tahle 1 Single phase CSA power cord wires Designator Wire color L live Black N neutral White PE ground Green The power cord has a black wire and a white wire that connect to the power switch and a green ground wire that connects to the heatsink 3 Remove the screw that holds the ground wire to the heatsink A notch in the power board provides access to the screw See Figure 37 Figure 37 Powermax30 XP Service Manual 808150 Revision O 99 6 Power Supply Component Replacement 4 On the outside of the power supply loosen the strain relief nut so that the wires move freely 5 Are you replacing the strain relief Q If yes use an adjustable wrench to unscrew the retention nut on the inside of the power supply If no continue with the next step Figure 38 Inside Ou
89. etaining nut onto the strain relief Figure 99 Inside Outside 1 Strain relief nut outside the power supply 3 Front panel 2 Strain relief 4 Retaining nut inside the power supply 8 Attach the work lead to the power board at J22 using the screw and washer that you removed in step 2 Tighten to 23 0 kg cm 20 inch pounds 9 Complete the following procedures a See Reattach the front panel on page 94 b See nstall the component barrier on page 91 c See nstall the power supply cover on page 89 d Reconnect the gas supply and power cord and set the power switch to ON I 168 Powermax30 XP Service Manual 808150 Revision O 6 Power Supply Component Replacement Remove and install the ground clamp 1 2 3 10 Set the power switch to OFF O disconnect the power cord from the power source and disconnect the gas supply Slide down the black plastic sleeve on the handle of the clamp where the work lead is connected Straighten out the bent tabs that hold the work lead in place See Figure 100 Loosen the screw that connects the work lead to the clamp Remove the work lead from the clamp and discard the old clamp On the replacement clamp slide down the black plastic sleeve on the handle of the clamp where you want to connect the work lead You can attach the work lead to either of the clamp s handles Thread the work lead through the plastic sleeve you removed in the previous s
90. face to make a better connection with the work lead When you pull the torch trigger the pilot arc starts but then extinguishes before the normal 5 second timeout period The consumables torch or torch lead is not functioning correctly The gas pressure is too low The gas supply quality is poor There is a voltage imbalance on the power board The consumables are worn or damaged The torch or torch lead is damaged The gas supply line is restricted The air filter element is dirty The power board is faulty Inspect the consumables torch and lead and replace if necessary Inspect the gas supply line for restrictions or damage Inspect the air filter element and replace if necessary See Replacing the air filter bowl and air filter element on page 148 Verify that the gas supply is providing at least 4 5 bar 65 psi Perform Test 3 VBUS and voltage balance on page 78 66 Powermax30 XP Service Manual 808150 Revision O 5 Troubleshooting and System Tests Problem This may mean Possible cause s Possible solution s The cut quality is poor or the cut does not sever the metal The consumables are not functioning correctly There is a poor work lead connection The output from the power supply is too low The power board is producing low current The extension cord is not delivering sufficient power to the power supp
91. ference occurs it may be necessary to take additional precautions such as filtering of the mains supply Consideration should be given to shielding the supply cable of permanently installed cutting equipment in metallic conduit or equivalent Shielding should be electrically continuous throughout its length The shielding should be connected to the cutting mains supply so that good electrical contact is maintained between the conduit and the cutting power source enclosure SC 13 Electromagnetic Compatibility EMC Maintenance of cutting equipment The cutting equipment must be routinely maintained according to the manufacturer s recommendations All access and service doors and covers should be closed and properly fastened when the cutting equipment is in 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 c
92. fitting The Powermax30 XP contains a drain hose and two gas supply hoses that can be replaced See Figure 57 m The drain hose runs from the bottom of the air filter bowl to the base of the power supply m One gas supply hose runs from the air filter regulator to the solenoid valve m The other gas supply hose runs from the solenoid valve to the torch lead You can also replace the plastic 90 fitting that connects the gas supply hose from the solenoid valve to the gas supply fitting from the torch lead The gas supply hoses in this system use push to connect fittings Figure 56 How to use push to connect fittings Push to Connect m To connect push the hose into the fitting until it stops Pull on the hose to verify that it is secure o Hose 2 Collet 8 O ring m To release push the fitting collet toward the fitting and pull the hose away from the fitting m Powermax30 XP Service Manual 808150 Revision O 119 6 Power Supply Component Replacement Remove the drain hose gas supply hoses and 90 fitting 1 Complete the following procedures a Set the power switch to OFF O disconnect the power cord from the power source and disconnect the gas supply b See Remove the power supply cover on page 88 2 Remove one end of the drain hose from the hole in the base of the power supply 3 Remove the other end of the drain hose
93. g careful to keep the trigger spring from launching out of the handle lift the left side of the handle away from the torch Figure 107 6 While holding the spring in place slide the trigger and spring up and out of the handle Set them aside Powermax30 XP Service Manual 808150 Revision O 177 7 Torch Component Replacement 7 Compress the trigger spring into the front half of the trigger Slide the trigger and spring into place 8 Making sure that the handle does not pinch the wires align the left half of the handle with the right half Verify that the trigger pivots are both located in the trigger pivot holes See Figure 106 on page 176 9 Install the handle screws 10 Install the consumables 11 Reconnect the gas supply and power cord and set the power switch to ON I Replacing the torch body Kit Description 428178 Kit Duramax LT torch body includes o ring 1 Complete the following procedures a Set the power switch to OFF O disconnect the power cord from the power source and disconnect the gas supply b Remove all components from the torch See Remove the handle on page 173 2 Remove the screw that attaches the torch power wire to the torch body Set the nut and screw aside Figure 108 178 Powermax30 XP Service Manual 808150 Revision O 7 Torch Component Replacement 3 Use two wrenches to loosen the gas fitting that attaches the torch body to the torch l
94. g cm 7 inch pounds See Figure 28 on page 92 3 Reconnect the control board s ribbon cable to the power board 4 Tighten the strain relief nut on the torch lead and work lead 5 Reconnect the gas supply and power cord and set the power switch to ON I 94 Powermax30 XP Service Manual 808150 Revision O 6 Power Supply Component Replacement Detaching and reattaching the rear panel Several repairs are easier to make if you detach the rear panel from the power supply For instructions on replacing an old rear panel with a new one see Replacing the rear panel on page 156 Detach the rear panel 1 Set the power switch to OFF O disconnect the power cord from the power source and disconnect the gas supply 2 Loosen the power cord s strain relief nut 3 Lay the power supply on its side 4 Remove the retaining screw from the bottom of the rear panel Figure 32 1 2 3 a Fes a 1 Rear panel 3 Retaining screw 2 Snap 4 Raised rib 5 Insert needle nose pliers into the opening for one of the snaps and use the pliers to squeeze it together B Place a blade screwdriver against the raised rib next to the snap and gently turn the screwdriver to push the panel away from the base Powermax30 XP Service Manual 808150 Revision O 95 6 Power Supply Component Replacement Figure 33 a 7 Place another screwdriver or similar object i
95. g of 23 0 kg cm 20 inch pounds Figure 72 Cheats Nii J y ar VY LW YL 1 WHT wire connection stud 2 RED wire connection stud 6 Push to connect the plastic 90 fitting onto the new torch lead s brass gas supply fitting Powermax30 XP Service Manual 808150 Revision O 137 6 Power Supply Component Replacement 7 Route the orange blue and purple wire group over the center panel with the wires resting in the notch in the panel that is closest to the front of the power supply See Figure 73 on page 138 8 Press the connector into the TORCH START slot J12 on the power board See Figure 69 on page 135 Figure 73 Route the torch lead s orange blue and purple wires through this notch in the center panel 9 From the inside of the front panel tighten the retention nut onto the strain relief CAUTION Be careful not to twist the torch lead as you tighten the retention nut onto the strain relief 10 Tighten the torch lead s strain relief nut onto the strain relief as you put the front panel back in place See Reattach the front panel on page 94 11 Complete the following procedures a See nstall the power supply cover on page 89 b Reconnect the gas supply and power cord and set the power switch to ON I 138 Powermax30 XP Service Manual 808150 Revi
96. he input diode bridges D24 D30 The voltage from the diode bridge supplies the power factor correction PFC boost converter which provides a nominal 375 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 relay K1 The PFC boost converter consists of an insulated gate bipolar transistor IGBT Q1 choke and control circuit It provides a 375 VDC bus voltage when the input AC voltage is between 120 and 240 VAC The inverter consists of an IGBT Q2 the power transformer a current sense transformer and sections of the power board The inverter operates as a pulse width modulator controlled bridge circuit that is rectified by the output diode D27 The output circuitry consists of two current sensors located on the power board the pilot arc IGBT inside the D27 module and the output choke The control board s microprocessor monitors and regulates the system s operation and safety circuits The amperage adjustment knob sets the output current to the desired value between 15 A and 30 A The system compares the set point to the output current by monitoring the current sensor and adjusting the pulse width output of the inverter IGBT O2 Powermax30 XP Service Manual 808150 Revision O 55 5 T
97. he power switch to OFF O disconnect the power cord from the power source and disconnect the gas supply b See Remove the power supply cover on page 88 c See Remove the component barrier on page 90 2 Lay the power supply on its side Figure 87 1 2 3 e 8 2 Fes a 1 Rear panel 2 Snap 156 3 Retaining screw 4 Rib Powermax30 XP Service Manual 808150 Revision O 6 Power Supply Component Replacement 3 Remove the retaining screw from the bottom of the rear panel 4 Insert needle nose pliers into the opening for one of the snaps and use the pliers to squeeze it together Figure 88 lt 4 i amp E Fe MW AS O 65 4 5 Place a blade screwdriver against the raised rib next to the snap and gently turn the screwdriver to push the panel away from the base B Place another screwdriver or similar object into the opening between the panel and the base to keep the first corner of the panel from re engaging the snaps when you release the other corner Figure 89 7 Repeat step 4 and step 5 on the other corner of the panel Powermax30 XP Service Manual 808150 Revision O 157 6 Power Supply Component Replacement 8 Disconnect the ground wire from the ground wire clip near the top of the rear panel See Figure 90 9 Disconnect the 4 wires from the back of the powe
98. ickness capability can decrease Consumables life can be shortened 10 Complete the following procedures a See nstall the power supply cover on page 89 b Reconnect the gas supply and power cord and set the power switch to ON I Powermax30 XP Service Manual 808150 Revision O 145 6 Power Supply Component Replacement Replacing the air inlet fittings Kit number Description 428171 Kit Air inlet fittings CSA 428172 Kit Air inlet fittings CE CCC Each of these kits contains two fittings that are not used in the Powermax30 XP a brass coupler 015550 and a brass pipe 015618 1 Complete the following procedures a Set the power switch to OFF O disconnect the power cord from the power source and disconnect the gas supply b See Remove the power supply cover on page 88 2 CSA models Are you replacing the quick connect air fitting See Figure 78 on page 147 e If yes continue with the next step e f no remove the quick connect air fitting from the brass hex adapter Use a 5 8 inch wrench for the hex adapter and a 9 16 inch wrench for the air fitting Set the fitting aside CE CCC models Are you replacing the air fitting adapter See Figure 78 on page 147 e If yes continue with the next step e If no remove the air fitting adapter from the brass hex adapter Use a 5 8 inch wrench for the hex adapter and a 19 mm wrench for the air fitting adapter Set the air fitting adapter aside
99. ilter regulator s brass T fitting Ground wire from heatsink to air filter regulator 3 Heatsink ground clip Powermax30 XP Service Manual 808150 Revision O 129 6 Power Supply Component Replacement Replacing the solenoid valve Kit number Description 428173 Kit Solenoid valve 1 Complete the following procedures a Set the power switch to OFF O disconnect the power cord from the power source and disconnect the gas supply b See Remove the power supply cover on page 88 2 Detach the connector from J6 on the power board by pulling it straight back away from the board See Figure 63 If needed lift the top edge of the component barrier that protects the power board to better access the J6 connector Figure 63 130 Powermax30 XP Service Manual 808150 Revision O 6 Power Supply Component Replacement 3 Push to disconnect the gas supply hose from the fitting on the rear panel side of the solenoid valve See Figure 56 on page 119 4 Push to disconnect the gas supply hose from the fitting on the front panel side of the solenoid valve Figure 64 4 1 o s 3 z d a l L T L T L T CT J 1 Gas supply hose rear panel side 3 Gas supply hose front panel side 2 Solenoid valve 4 J6 wire pair 5 Remove the 2 screws that attach the solenoid valve
100. inates the voltages on the power board may be incorrect Perform the following tests at J7 on the power board See Test 2 power board voltage checks on page 76 m Test pin 5 to ground for 3 3 VDC 410 m Test pin 7 to ground for 5 VDC x 1090 m Test pin 12 to ground for 2 2 VDC x 1096 If the values you find are not within 10 of the three values listed above 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 See Replacing the control board on page 107 Otherwise replace the power board See Remove the power board on page 109 70 Powermax30 XP Service Manual 808150 Revision O Error LED 5 Troubleshooting and System Tests The number of times the Error LED blinks indicates the problem detected Each blink is a half second long and each series of blinks is separated by a 2 second pause See System tests on page 71 for detailed test procedures Number of blinks 3 Problem Faulty power board Solution Perform Test 3 VBUS and voltage balance on page 78 If any of the values are incorrect replace the power board Perform Test 2 power board voltage checks on page 76 If any of the values for pins 5 7 or 72 are incorrect remove the control board and test again If the values are correct replace the control board When performing Test 2 power board voltage checks on page 76 if the values for p
101. ing the torch body in place gently press the right side of the handle away from the torch body to remove it Figure 103 174 Powermax30 XP Service Manual 808150 Revision O 7 Torch Component Replacement 8 Slide the cap sensor switch off its mounting post See Figure 105 Figure 104 4 Start switch s mounting posts 5 Slot for the gas hose fitting s flange 1 Cap sensor switch s post hole 2 Cap sensor switch s mounting post 3 Trigger s pivot hole 6 Strain relief slot 9 Slide the start switch off the two mounting posts Figure 105 Powermax30 XP Service Manual 808150 Revision O 175 7 Torch Component Replacement Install the handle 1 Lay the right side of the handle on a flat surface with the inside facing up If replacing the handles apply the Duramax LT label to the left side of the torch handle 2 Press the cap sensor switch into its post hole and onto its mounting post See Figure 105 3 Route the cap sensor wires as shown in Figure 106 Place the connector above the start switch s posts with the wires positioned below the slot for the gas hose fitting s flange as shown 4 Press the start switch onto the two mounting posts and position the wires below the slot for the gas fitting The start switch should hold the cap sensor switch connector in place See Figure 105 and Figure 106 Figure 106 Cap sensor switch wires
102. ins 5 7 or 12 are correct but any other values are incorrect replace the power board Faulty fan or solenoid valve Perform Test 4 solenoid valve on page 80 and Test 8 fan on page 85 If the solenoid valve test and the fan test both pass replace the power board If Test 4 fails replace the solenoid valve if Test 8 fails replace the fan Inverter saturation Install new consumables in the torch If you continue to see this error code replace the power board System tests You can use either the ground clip near the top of the rear panel or the ground screw on the heatsink marked by the ground symbol on the power board for any tests that require the multimeter to be attached to ground See Figure 11 for both grounding options Figure 11 Powermax30 XP Service Manual 808150 Revision O 71 5 Troubleshooting and System Tests Nn i Ff WO ND 72 Figure 12 Input diode bridges Capacitors J17 white J16 red IGBTs J12 torch sta
103. ision O 63 5 Troubleshooting and System Tests Problem This may mean Possible cause s Possible solution s The power ON LED illuminates and the temperature LED blinks The system overheated The system is continuously drawing too much input current for too long You are operating the system on a 120 VAC input circuit while using the general purpose nozzle and shield Let the system cool for approximately 3 minutes before using it Turn down the cutting current See Adjust the gas pressure and output current on page 44 Use only the FineCut consumables when operating the system on a 120 VAC input circuit See Choose the consumables on page 32 Operate the system on a 240 VAC input circuit whenever possible Avoid stretching the arc Drag the torch on the workpiece See Edge start on a workpiece on page 50 Operate the system without using an extension cord If you must use an extension cord use a heavy conductor cord of the shortest possible length See Extension cord recommendations on page 28 The power ON LED blinks The incoming voltage is not correct The incoming voltage is below 90 VAC or above 285 VAC Perform Test 1 voltage input on page 74 The power ON LED and the torch cap LED illuminate The cap sensing circuit is open The consumables are loose incorrectly installed or missing The cap sensor switch is fau
104. itch to OFF O disconnect the power cord from the power source and disconnect the gas supply b See Remove the power supply cover on page 88 c See Remove the component barrier on page 90 2 Disconnect the ground wire from the ground wire clip near the top of the rear panel See Figure 47 3 Gently tilt the top of the rear panel away from the power supply then disconnect the 4 wires from the back of the power switch 4 Using a small blade screwdriver press down one of the tabs on the top of the power switch and push that corner of the switch out of the rear panel 5 Press down the other tab on the top of the power switch and push that corner of the switch out of the panel Make sure the first tab does not snap back into place as you release the second tab 6 Repeat the previous two steps on the bottom of the power switch to push the bottom of the switch out of the rear panel Remove the switch completely from the panel Figure 41 Ground wire clip erent X 1 3 HE 3 3 Powermax30 XP Service Manual 808150 Revision O 105 6 Power Supply Component Replacement 7 Press the new power switch into the new panel with the ON I label at the top of the switch You should hear the switch snap into place 8 Push the connectors for the two white wires that are attached to the power board at AC onto the bottom two pins of the power switch The left AC wire connects to the bottom left pi
105. kits in Power Supply Component Replacement on page 87 and Torch Component Replacement on page 171 For instructions on installing the consumables in the Duramax LT hand torch see nstall the consumables on page 42 Powermax30 XP Service Manual 808150 Revision O 185 8 Parts Power supply parts Exterior front Item Kit number Description 228096 Kit Screws for the power supply cover and handle not shown 1 428219 Kit Front panel 2 428226 Kit Current adjustment knob 3 428221 Kit Power supply cover with labels CSA 3 428222 Kit Power supply cover with labels CSA Built in America 3 428224 Kit Power supply cover with labels CE 3 428225 Kit Power supply cover with labels CCC 4 228099 Kit Handle with screws 5 228561 Kit Ground clamp 6 428239 Kit Work lead 4 6 m 15 feet with ground clamp 186 Powermax30 XP Service Manual 808150 Revision O 8 Parts Exterior rear NEMA 6 50P NEMA L6 20P a i mee ui NEMA 5 15P Item Kit number Description 1 428220 Kit Rear panel 2 228210 Kit CSA power cord with NEMA twist lock style 240 V 20 A plug 1 phase 3 0 m 10 feet 3 229132 CSA power cord extension 120 V 15 A plug adapter 4 229133 CSA power cord extension 240 V 20 A plug adapter 5 228140 Kit CE power cord 1 phase 3 0 m 10 feet plug not included 5 428231 Kit CCC power cord 1 phase 3 0 m 10 feet plug not included 6 22814
106. lty Verify that the consumables are installed correctly Perform Test 7 torch cap sensor on page 84 The power LED illuminates and the torch cap LED blinks The consumables are stuck in an open or closed position The nozzle and electrode are not touching when the torch trigger is pulled The consumables are installed incorrectly worn or damaged The torch plunger is stuck The torch or torch lead has a broken wire Verify that the consumables are installed correctly Inspect the consumables for wear and replace if necessary Perform Test 5 torch stuck open or torch stuck closed on page 81 64 Powermax30 XP Service Manual 808150 Revision O 5 Troubleshooting and System Tests Problem This may mean Possible cause s Possible solution s The gas pressure and temperature LEDs blink when the system is powered ON I ZAHN 4 The system was powered on while the plasma start signal was being sent The system was powered on with the torch trigger being pulled The start circuit is stuck closed Release the torch trigger and reset the system by turning it OFF O and then turn it ON D again Perform Test 6 plasma start on page 82 The temperature gas pressure and power ON LEDs blink and the torch cap LED illuminates xit DP LA xt INN oS ANN The inverter is saturated The inverter i
107. ly The consumables are worn or damaged The work lead is damaged or not properly connected to the workpiece The amperage adjustment knob is set too low The power board is faulty The extension cord is too long is damaged or is not capable of delivering sufficient power to the power supply Inspect the consumables and replace if necessary Inspect the work lead and replace if necessary Reposition the work lead on the workpiece Clean the workpiece surface to make a better connection with the work lead If your input circuit allows turn the amperage adjustment knob to a higher setting Operate the system without using an extension cord If you must use an extension cord use a heavy conductor cord of the shortest possible length See Extension cord recommendations on page 28 The pilot arc extinguishes when you move the plasma arc off the workpiece while still pulling the torch trigger The continuous pilot arc is not functioning correctly The power board or the control board is faulty Perform Test 2 power board voltage checks on page 76 and Test 3 VBUS and voltage balance on page 78 Powermax30 XP Service Manual 808150 Revision O 67 5 Troubleshooting and System Tests Problem This may mean Possible cause s Possible solution s The circuit breaker trips frequently while you are cutting The output from the power s
108. ly in the torch head Powermax30 XP Service Manual 808150 Revision O 81 5 Troubleshooting and System Tests 8 In either case make sure that the torch plunger moves freely in the torch head 9 If it does not replace the torch body See Replacing the torch body on page 178 If the torch parts are working properly replace the torch lead See Replacing the torch lead on page 182 10 Because torch stuck open and torch stuck closed failures can be intermittent repeat the test several times Test 6 plasma start Verify that the control board LED is receiving a valid start signal 1 Set the power switch to OFF O and disconnect the power cord from the power source 2 Remove the power supply handle and cover See Remove the power supply cover on page 88 3 Remove the component barrier See Remove the component barrier on page 90 CAUTION While testing avoid any contact with the tip of the torch WARNING ELECTRIC SHOCK CAN KILL Use extreme caution when working near live electrical circuits Dangerous voltages exist inside the power supply that can cause serious injury or death See the WARNING on page 58 before proceeding 4 Connect the electrical power and turn the power ON I 5 Look at the Start LED on the control board see Control board LEDs on page 69 for the location of the Start LED and pull the torch trigger It should illuminate whenever the trigger is pulled 6 Turn OFF O the power
109. min te 18 GA 400 10 GA 110 vs Mild steel 30 1 2 10 5 8 7 18 GA 306 10 GA 70 1 4 Stainless steel 30 31 3 8 15 1 2 9 1 8 135 1 4 45 Aluminum 30 3 8 18 1 2 9 35 3 Torch Setup FineCut consumables Use the FineCut consumables for detailed cutting on thin gauge metal The FineCut consumable set uses a FineCut nozzle and a deflector with the same electrode swirl ring and retaining cap used in the general purpose consumable set The FineCut nozzle must be installed only with the deflector not the shield Using the shield results in poor cut quality and increased power demand because the torch to work distance is too great For guidelines on cutting with 120 V input see Recommendations for cutting at 120 Von page 49 Figure 4 FineCut consumable set 9 0 00 0 O o0 5 L J ll E D 2 1 Torch 4 Nozzle 420117 2 Electrode 420120 5 Retaining cap 420114 3 Swirl ring 420211 6 Deflector 420115 36 Powermax30 XP Service Manual 808150 Revision O 120 V 25 A cutting FineCut consumables 3 Torch Setup Metric Material thickness mm Material Arc current A age tis ier en 1 101602 2 3570 Mild steel 25 Sos 6 590 7i 280 1 8390 2 2860 3 150
110. n 428215 Kit Powermax30 XP labels CSA 428216 Kit Powermax30 XP labels CSA Built in America 428217 Kit Powermax30 XP labels CE 428218 Kit Powermax30 XP labels CCC The label kits include m Consumables label m Appropriate safety labels m Front and side decals The following illustrations show the consumables label and safety labels 420116 p 420118 420114 420120 420211 FineCut 420117 Inecut 420115 PN 210240 Rev A Consumables label Plasma cutting can be injurious to operator and persons in the work area Consult manual before operating Failure to follow all these safety instructions can result in death 2 Plasma arc can injure and burn point the nozzle away 2 L from yourselt Arc starts instantly when triggered 110647 Rev B CE CCC safety label move roy or cover this label 7N nleve uire ni couv Replace if it is missing damaged or wom PN 110584 Rev D La remplacer si elle est absente endommag e ou ique us e PN 110584 Rev D CSA safety label 198 Powermax30 XP Service Manual 808150 Revision O Wiring Diagrams This section contains the following diagrams m Powermax generic timing chart m Powermax30 XP schematic Powermax30 XP Service Manual 808150 Revision O 199 9 Wiring Diagrams Powermax generic timing chart Power up Start Pilot arc Transfer Steady state Loss of start Power Aux switch closed Start LED on Pilot ar
111. n on the power switch the right AC wire connects to the bottom right pin on the power switch See Figure 42 and Figure 43 Figure 42 9 Press the connector for the black CSA or brown CE CCC wire onto the pin on the upper left side of the power switch 10 Press the connector for the white CSA or blue CE CCC wire onto the pin on the upper right side of the power switch Figure 43 Black CSA Brown CE CCC White CSA Blue CE CCC White AC left pin White AC right pin 11 Reconnect the ground wire to the ground wire clip on the rear panel 12 Complete the following procedures a See nstall the component barrier on page 91 b See nsiall the power supply cover on page 89 Reconnect the gas supply and power cord and set the power switch to ON I 106 Powermax30 XP Service Manual 808150 Revision O 6 Power Supply Component Replacement Replacing the control board Kit number Description 428232 Kit Control board 141336 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 1 Complete the following procedures a Set the power switch to OFF O disconnect the power cord from the power source and disconnect the gas supply b See Remove the component barrier on page 90 c See Remove the power su
112. n page 97 c See nstall the component barrier on page 91 d See nstall the power supply cover on page 89 e Reconnect the gas supply and power cord and set the power switch to ON I Powermax30 XP Service Manual 808150 Revision O 6 Power Supply Component Replacement Replacing the work lead and ground clamp Kit number Description 428239 Kit Work lead 4 6 m 15 feet with ground clamp 228561 Kit Ground clamp Remove and install the work lead 1 Complete the following procedures a Set the power switch to OFF O disconnect the power cord from the power source and disconnect the gas supply b See Remove the power supply cover on page 88 c See Remove the component barrier on page 90 d See Detach the front panel on page 92 2 Loosen the strain relief nut on the work lead 3 Remove and set aside the screw and washer from J22 on the power board labeled WORK LEAD that attaches the lead to the board Figure 98 1 Front panel 3 Work lead 2 Strain relief nut 4 Work lead connection to power board J22 Powermax30 XP Service Manual 808150 Revision O 167 6 Power Supply Component Replacement 4 On the inside of the front panel remove the strain relief s retaining nut 9 Pull the work lead through the hole in the front panel B Route the connector end of the new work lead through the hole in the front panel and then through the retaining nut 7 On the inside of the front panel tighten the r
113. n the pierce is complete drag the torch lightly along the workpiece to proceed with the cut Gouge a workpiece X 93 yp Essen You can use the Powermax30 XP with the general purpose consumables for light gouging applications such as the removal of spot welds and tack welds The system does not require a dedicated set of consumables or a special mode setting for gouging However do not use the FineCut consumables for gouging applications 1 Hold the torch so that the torch tip is slightly above 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 workpiece 52 Powermax30 XP Service Manual 808150 Revision O 4 Operation 3 Maintain an approximate 45 angle to the workpiece as you feed into the gouge 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 You can vary the gouge profile by varying the Q Speed of the torch over the workpiece Torch to work standoff distance Angle of the torch to the workpiece Q System s current output Varying the gouge profile Follow these recommendations to change the gouge profile as needed Increasing the speed of the torch will decrease width and decrease depth
114. na nrc c n na Fal t HR RR n cha ana ra Ra DR Dd 46 oystem operation guidelines tecti eti se ip docete d dns hceuteconssbunsunancyasstes cede ae i deca obe seat Prae tete 47 Hand toreh Operation vrsi intinne M 48 Safety Catch operation sirsiran easan anaE aa PEA Taa terea SGEE raaa rA Eaa SR A aT 48 Hand torch Cutting guideline gegessen R N AAA 49 Edge stal Ona Worp CE oaren EE 50 Pierce a WOIKDIBCB 5 a e Date du nob aaa NA A E te res acu T Pe d tgeatiayadaspeasryttvdediviecteacs 51 GOUGE a WOFKPIO CEs P at ses tatu cheats cost aa a uhatahovatiacatas at athatencn A resid count nak a 52 Common hard c tting faults ttti dett btt tit dennen debdi era ira eit ta ic nennen aeaea sad indeed 54 5 Troubleshooting and System Tests nusunsunnnnnnnnnnnnnnnnnnnnnnnnnnnnnunnnnnnnnnnnnnnnnnnnnn nenn nnnn nnmnnn nnmnnn nnn 55 THE Ory OF Operation aesa EE E E EAE dd ances E N E EE a E 55 Functional deseriptlon e en b n e mad eta c arn De dei d en da ur Rn ER ai 55 Sequence of operation anco deae atas E tete eR bebe scm din diese aie Gea ind eens 56 Troubleshooting Preparation E 57 Eee 57 Troubleshooting procedures and sequence eene tenente tenente tenente netten inte te tenente tens 57 Suum 59 Internal INSpeCtiON e 59 Initial resist
115. nlet fittings CSA 2 428172 Kit Air inlet fittings CE CCC 3 428237 Kit Air filter element 4 428246 Kit Air filter bowl 5 228688 Kit Pressure switch 6 428262 Kit Air filter retaining nut Powermax30 XP Service Manual 808150 Revision O 191 8 Parts Power supply base and magnetics Item Kit number Description 1 228139 Kit Plastic base 2 428230 Kit Magnetics assembly 192 Powermax30 XP Service Manual 808150 Revision O 8 Parts Duramax LT hand torch parts 9 we You can replace the entire hand torch and lead assembly or you can replace individual torch components Item Kit number Description 428174 Kit Duramax LT hand torch assembly with 4 6 m 15 foot lead 1 228109 Kit Torch cap sensor switch 2 428162 Kit Torch start switch 3 428178 Kit Duramax LT torch body includes o ring 4 428179 Kit Replacement o rings for torch body 5 428156 Kit Torch trigger and spring 6 428182 Kit Replacement springs for torch trigger 7 428177 Kit Duramax LT torch handle includes handle screws 8 428181 Kit Duramax LT torch replacement handle screws 9 428176 Kit Duramax LT torch lead 4 6 m 15 feet with strain relief The torch assembly includes one set of general purpose consumables QU Electrode 420120 Swirl ring 420211 Retaining cap 420114 Nozzle 420118 Shield 4201 16 D DO D Powermax30 XP Service Manual 808150 Revision O 193 8 Parts Duramax LT hand torch consumables
116. nto the opening between the panel and the base to keep the first corner of the panel from re engaging the snaps when you release the other corner Figure 34 8 Repeat step 5 and step 6 on the other corner of the panel 9 Disconnect the ground wire from the ground wire clip near the top of the rear panel See Figure 35 10 Gently pull the panel away from the power supply 96 Powermax30 XP Service Manual 808150 Revision O 6 Power Supply Component Replacement Figure 35 1 Ground wire clip 2 Rear panel Reattach the rear panel 1 Push the rear panel into the base to re engage the snaps 2 Verify the hole in the ground wire clip is aligned with the screw holes in the rear panel and the power supply See Figure 35 3 Tighten the retaining screw with a torque setting of 8 1 kg cm 7 inch pounds See Figure 32 on page 95 4 Reconnect the ground wire to the ground wire clip 9 Tighten the strain relief nut on the power cord B Reconnect the gas supply and power cord and set the power switch to ON I Powermax30 XP Service Manual 808150 Revision O 97 6 Power Supply Component Replacement Replacing the power cord and strain relief Kit number Description 228210 Kit CSA power cord with NEMA twist lock style 240 V 20 A plug 1 phase 3 0m 10 feet 228140 Kit CE power cord 1 phase 3 0 m 10 feet plug not included 428231 Kit CCC power cord 1 phase 3 0 m 10 fe
117. of 0 1 mg m m Dew point of 40 C 40 F m Oil concentration of 0 1 mg m per ISO 8573 1 Class 1 2 2 Connect the gas supply Connect the gas supply to the power supply using an inert gas hose with a 6 8 mm 1 4 inch or greater internal diameter and an industrial interchange quick disconnect coupler for CSA models or a G 1 4 BSPP threaded coupling for CE and CCC models CAUTION Some air compressors use synthetic lubricants containing esters that damage the polycarbonates used in the air filter bowl The recommended inlet pressure while gas is flowing is 5 5 6 9 bar 80 100 psi Powermax30 XP Service Manual 808150 Revision O 29 2 Power Supply Setup The air filter bowl may explode if the gas supply pressure exceeds 9 3 bar 135 psi 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 128647 available from Hypertherm distributors A three stage filtering system works as follows to clean contaminants from the gas supply Gas supply Power supply Water and particle filter Oil filter Oil vapor filter Install the filtering system between the quick disconnect coupler and the power supply 30 Powermax30 XP Service Manual 808150 Revision O Section 3 Torch Setup Introduction The Powermax30 XP includes the Duramax LT hand torch This section explains ho
118. on O 6 Power Supply Component Replacement 10 12 Align the screw holes in the plastic base with the screw holes in the metal plate on the bottom of the new magnetics assembly Attach the new magnetics to the plastic base using the six screws Align the wires from the magnetics with the notches in the center panel so that the wires do not get pinched Press the plastic base and the magnetics into the bottom of the power supply until the assembly snaps into place On the fan side of the power supply attach the ring connector for the output inductor s white wire to the stud labeled WHT using a 8 mm 5 16 inch nut driver See Figure 95 on page 164 If you removed any other wires from the WHT stud reinstall them 13 14 15 16 166 Reconnect the air filter regulator s drain hose to the hole in the bottom of the base Using the screw you removed in step 3 on page 1683 attach the ground wire to the metal base plate of the magnetics assembly with a torque setting of 17 8 kg cm 15 inch pounds See Figure 94 on page 163 On the power board side of the power supply connect the wires for the transformers and inductors on the new magnetics assembly to the power board at J13 J14 J15 J18 J19 J20 and J21 Tighten each screw to 23 0 kg cm 20 inch pounds See Figure 93 on page 163 Complete the following procedures a See Reattach the front panel on page 94 b See Reattach the rear panel o
119. ould 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 SC 14 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 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
120. pply cover on page 88 d See Detach the front panel on page 92 2 Verify the control board ribbon cable is disconnected from the power board See Figure 44 WARNING ELECTRIC SHOCK CAN KILL Stay clear of electrical wires and components while testing the new control board 3 Test the new control board before installing it a Attach control board s ribbon cable to the power board b Reconnect the power cord to the power source and turn the system ON c 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 Powermax30 XP Service Manual 808150 Revision O 107 6 Power Supply Component Replacement Figure 44 Control board ANAS Ribbon cable ATA 4 Disconnect the power cord from the power source disconnect the ribbon cable and set the new control board aside 5 Remove the amperage adjustment knob from the front of the power supply by pulling it away from the panel It does not have a set screw B Remove the 3 retaining screws from the control board and lift it out of the front panel Figure 45 VY NAT Vtt 10 4 1 Front panel 2 Ribbon cable 3 Power board 4 Control board 108 Powermax30 XP Service Manual 808150 Revision O 6 Power Supply Component Replacement 7 Slide the new control board into place and attach it to the front
121. r at d DR Fo nta re Do a nada 181 Replacing the torch ledd 2 eene ccnushcnssh tenauatenuste R dots sonst cmd rete i refor tus 182 ME LC ND 185 Power SUP PIV Moor RR 186 Exterior ront aiite lectus tir cedere re dod PLE aA ends si Eee Ee nea Enea e de naci 186 Extetiot Teal eaa ire n t es eon ictu Pa o bee bo ema eet ra ibo ipd o eben neal 187 Interior power board slde 5 cct cd eer t tenen e lr ee diode cete d sdb re n bnt eie bre ores 188 Control board and power switch nennen entente tente tenente te tentent tenente nte tenente tente tens 189 Interior fan sSlde c oen a ic cad d e ete b ih Le e E E fees D etd ae 190 Power supply base and magnetics gasss sse niente ttete treten te tente tinte onsen ttn ta tentat tates te testet te tasto tensa 192 D urariax LT hand toreh parts inire ttti rt eet rete tane terrent ni deret ne RR Ee EE Corin dna ia 193 Duramax LT hand torch consumables esee tenete tnt tnnnnentnteninittnten inte te tette parea Saaana kinan 194 AG CO SSOMY Mori rU 195 Safety Gritical PAS d T nS 196 Recommended spare parts iiie e tee ie tit a rne peni dene a Ferr ente ENE PE aKa n Fern de aaa 197 Powermax30 XP labels 5 e ted io eee Rr aen ne ere dep ciel ceni tacendo ebd d Pea Deu Ar TARE 198 9 Wiring Diagrams sisssescsssssisss siete sseieicasacusessessssbvenocvibusesedoivabncuonssvesssbuerbevansseiecsicieedesensdseuobueusuarbs 199 POWERPAK generic TIMING CHANG sar
122. r switch 10 Using a small blade screwdriver press down one of the tabs on the top of the power switch and push that corner of the switch out of the rear panel 11 Press down the other tab on the top of the power switch and push that corner of the switch out of the panel Make sure the first tab does not snap back into place as you release the second tab 12 Repeat the previous two steps on the bottom of the power switch to push the bottom of the switch out of the rear panel Remove the switch completely from the panel Figure 90 Ground wire clip 13 Disconnect the power cord from the power supply See Remove the power cord and strain relief on page 98 158 Powermax30 XP Service Manual 808150 Revision O 6 Power Supply Component Replacement Install the new rear panel 1 2 Reinstall the power cord through the new rear panel See nstall the power cord and strain relief on page 103 Push the new rear panel into the base to re engage the snaps Tighten the retaining screw Make sure that the hole in the ground clip is aligned with the screw holes in the panel and the power supply before attempting to insert the retaining screw Press the power switch into the new rear panel with the ON I label at the top of the switch You should hear the switch snap into place Push the connectors for the two white wires that are attached to the power board at AC onto the bottom two pins of the powe
123. r switch The left AC wire connects to the bottom left pin on the power switch the right AC wire connects to the bottom right pin on the power switch See Figure 91 Press the connector for the black CSA or brown CE CCC wire onto the pin on the upper left side of the power switch Press the connector for the white CSA or blue CE CCC wire onto the pin on the upper right side of the power switch Figure 91 Black CSA Brown CE CCC White CSA Blue CE CCO White AC left pin White AC right pin 8 Reconnect the ground wire to the ground wire clip on the rear panel 9 Complete the following procedures a See nstall the component barrier on page 91 b See nstall the power supply cover on page 89 c Reconnect the gas supply and power cord and set the power switch to ON I Powermax30 XP Service Manual 808150 Revision O 159 6 Power Supply Component Replacement Replacing the base Kit number Description 228139 Kit Plastic base 1 Verify that the serial number on the bottom of the old base matches the one on the new base Contact Hypertherm if the serial numbers do not match The serial number can be found on the data plate 2 Complete the following procedures a Set the power switch to OFF O disconnect the power cord from the power source and disconnect the gas supply b See Remove the power supply cover on page 88 See Remove the component barrier on p
124. r system Generator recommendations Generators used with this system should produce 240 VAC Engine drive output current 1 phase CSA CE CCC Performance arc stretch Engine drive rating 5 5 kW 30A Full 4 kW 25A Limited Adjust the cutting current as needed based on the generator rating age and condition If a fault occurs while using a generator turn OFF the system and wait approximately 60 seconds before turning it ON again Turning the power switch quickly to OFF and ON again called a quick reset may not clear the fault 28 Powermax30 XP Service Manual 808150 Revision O 2 Power Supply Setup Prepare the gas supply The gas supply can be shop compressed or cylinder compressed You must use a high pressure regulator on either type of supply and the regulator must deliver gas to the filter on the power supply at 99 1 l min at 4 7 bar 3 5 scfm at 68 psi To ensure adequate pressure to the power supply set the regulator between 5 5 and 6 9 bar 80 and 100 psi The system contains an internal filter element but additional filtration may be required depending on the quality of the gas supply If gas supply quality is poor cut speeds decrease cut quality deteriorates cutting thickness capability decreases and the life of the consumables shortens For optimal performance the gas should have a maximum m Particle size of 0 1 micron at a maximum concentration
125. rSEPRO mark of conformity meet the product safety and EMC requirements for export to the Ukraine Serbian AAA mark CE versions of Hypertherm products that include a AAA Serbian mark meet the product safety and EMC requirements for export to Serbia Powermax30 XP Service Manual 808150 Revision O 21 1 Specifications Noise levels This plasma system may exceed acceptable noise levels as defined by national and local codes Always wear proper ear protection when cutting Any noise measurements taken depend on the specific environment in which the system is used Refer to Noise can damage hearing in the Safety and Compliance Manual 80669C included with your system In addition you can find an Acoustical Noise Data Sheet for your system in the Hypertherm downloads library at https www hypertherm com 1 Click Downloads library 2 Select a product from the Product type menu 3 Select Regulatory from the Category menu 4 Select Acoustical Noise Data Sheets from the Sub Category menu IEC symbols The following symbols may appear on the power supply data plate control labels switches and LEDs Aninverter based power source Direct current DC T Volt amp curve drooping Alternating current AC characteristic Plasma torch cutting Power is ON LED o Di AC input power connection Inlet gas pressure fault LED Missing or loose consumables The terminal for the external
126. rd from the power source and then set the power switch to ON D 2 Check the resistance across the input leads Figure 6 75 kQ Black CSA Brown CE CCC 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 20 MO With the electrical power disconnected and the power switch set to OFF O all circuits should read as open The electrical value shown is 25 However this range is intended only for reference Resistance values can vary widely depending on the type of multimeter and the polarity used to measure the readings 4 Remove the consumables from the torch If you do not remove the consumables the resistance values will not read correctly 60 Powermax30 XP Service Manual 808150 Revision O 5 Troubleshooting and System Tests 5 Check the output resistance for the values shown in the following table locations on the back side of the power board J16 and J17 are labeled on the component side of the power board See Figure 7 for Measure resistance from Approximate values ground Work lead J22 to nozzle J16 red wire 100 kQ Work lead J22 to electrode J17 white wire 20 kQ Electrode J17 white wire to nozzle J16 red wire 120 kQ Work lead J22 nozzle J16 red wire and electrode J17 white wire to gt 20 MQ
127. re switch see Figure 77 a Press the black wire s connector onto the pressure switch pin that is nearest the center panel b Press the red wire s connector onto the pressure switch pin that is farthest from the center panel B Push to connect the gas supply hose to the fitting on the new air filter regulator Be careful not to kink the hose as you reconnect it 7 Using the clip you removed in step 6 on page 141 connect the ground wire to the air filter regulator s brass T fitting 8 Reconnect the air fitting CSA models or air fitting adapter CE CCC models to the brass hex adapter in the air filter regulator assembly 144 Powermax30 XP Service Manual 808150 Revision O 6 Power Supply Component Replacement Figure 77 1 Retainer nut 6 Ground wire clip 2 Brass hex adapter 7 Push to connect fitting for gas supply hose 3 Air filter regulator assembly 8 Red wire 4 Drain hose 9 Black wire 5 Brass T fitting 10 Pressure switch 9 Reconnect the gas supply and check for leaks at each fitting and hose connection point on the air filter regulator assembly CAUTION Gas supply pressures not within the specifications in the Specifications section of your system s manual can cause poor cut quality poor consumable life and operational problems If the purity level of the gas is too low or if there are leaks in the supply hoses or connections Cut speeds can decrease Cut quality can deteriorate Cutting th
128. roduct 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 TUV CE mark 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 Eurasian Customs Union CU mark CE versions of Hypertherm products that include an EAC mark of conformity meet the product safety and EMC requirements for export to Russia Belarus and Kazakhstan GOST TR mark CE versions of Hypertherm products that include a GOST TR mark of conformity meet the product safety and EMC requirements for export to the Russian Federation C Tick mark CE versions of Hypertherm products with a C Tick mark comply with the EMC regulations required for sale in Australia and New Zealand CCC mark The China Compulsory Certification CCC mark indicates that the product has been tested and found compliant with product safety regulations required for sale in China UkrSEPRO mark The CE versions of Hypertherm products that include a Uk
129. roubleshooting and System Tests Sequence of operation Power OFF O Y Connect the gas supply to the gas fitting on the power supply Connect the work lead to the workpiece Apply power at the line voltage disconnect box Set the power switch S1 to ON I Y The green power ON LED illuminates indicating the system is ready for operation All the fault LEDs should be extinguished See Troubleshooting guide on page 63 Y Set the amperage adjustment knob to the desired output current between 15 A and 30 A based on the input voltage and circuit size Y The power circuits are ready Y Position the torch on the workpiece Pull the plasma start trigger on the torch 56 The gas solenoid valve V1 opens The gas flow starts The cutting arc starts Y Dragthe torch lightly across the workpiece to make a cut The workpiece drops after the cut Release the plasma start trigger on the torch Y The arc extinguishes Gas postflow continues for 20 seconds Y The gas solenoid valve V1 closes The gas flow stops Y Setthe power switch S1 to OFF O Powermax30 XP Service Manual 808150 Revision O 5 Troubleshooting and System Tests Troubleshooting preparation The
130. rt cap sensor switch connector Snubber resistor 8 Ribbon cable connector J7 9 J6 10 J5 11 J4 12 J2 13 J1 Powermax30 XP Service Manual 808150 Revision O 5 Troubleshooting and System Tests Figure 13 d9 J J5 J4 Oe Mo Moo mo WORK LEAD BLK 1 Retaining screw 3 8 J21 2 Heatsink assembly screw 4 9 J20 3 Torch start and cap sensor J12 10 J19 4 J13 11 J18 5 J14 12 Input diode bridge screws 2 6 J15 13 IGBT screws 3 7 Work lead connector J22 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 Powermax30 XP Service Manual 808150 Revision O 73 5 Troubleshooting and System Tests Test 1 voltage input Check the incoming voltage and the line voltage to the top of the power switch S1 1 Set power switch to OFF O disconnect the power cord from the power source and disconnect the gas supply 2 Remove the power supply handle and cover See Remove the power supply cover on page 88 3 Remove the component barrier See Remove the component barrier on page 90 4 Partially pull the power switch s top two wires out from the tabs and attach the multimeter test leads to the tabs to
131. ry Figure 15 AC AC Oo n Q o o e o o o 2 10 If the power ON LED is still illuminated perform Test 2 power board voltage checks on page 76 Powermax30 XP Service Manual 808150 Revision O 75 5 Troubleshooting and System Tests Test 2 power board voltage checks 1 Set the power switch to OFF O disconnect the power cord from the power source and disconnect the gas supply 2 Remove the power supply handle and cover See Remove the power supply cover on page 88 3 Remove the component barrier See Remove the component barrier on page 90 WARNING ELECTRIC SHOCK CAN KILL Use extreme caution when working near live electrical circuits Dangerous voltages exist inside the power supply that can cause serious injury or death See the WARNING on page 58 before proceeding 4 Reconnect the electrical power and set the power switch to ON I 9 Use a multimeter to verify the voltages at the J7 pins listed in the following table to verify the power board is functioning correctly Figure 16 To test the values at pin 16 you must position the torch and power supply so that you can safely pull and release the torch trigger For ground locations see Figure 11 on page 71 If any of the values are incorrect replace the power board See Remove the power board on page 109 76 Powermax30 XP Service Manual 808150 Revision O 5 Troubleshooting and System Tests CAUTIO
132. s in an over current condition The torch was repeatedly fired with worn out consumables nstall new consumables in the torch they may be corroded or approaching end of life fyou continue to see this error replace the power board All four LEDs blink when the system is powered ON I ANANN TA ATS A major fault has occurred in the power supply The fan solenoid valve control board or power board is faulty The error LED on the control board should be blinking The number of times it blinks between pauses indicates which components to test See Control board LEDs on page 69 The power ON LED illuminates but no fault LEDs illuminate and no gas flows when you pull the torch trigger The start signal is not reaching the control board The torch or torch lead is damaged The power board is faulty The control board is faulty Inspect the torch and torch lead and replace if necessary Verify that the control board start LED illuminates when you pull the trigger If it does not perform Test 6 plasma start on page 82 Gas flows when the system is powered ON I The incoming gas pressure is too high The gas pressure from the compressor or cylinder is too high The gas solenoid valve is faulty Verify that the gas supply does not exceed 9 3 bar 135 psi and reduce the pressure if necessary Perform Test 4
133. sed on the input voltage circuit size and consumables 44 Powermax30 XP Service Manual 808150 Revision O Use only the FineCut consumables when operating the system on a 120 V input circuit Operating the system on a 120 V 15 A circuit m Set the amperage below 20 A as indicated by the gray shading around the knob the inner ring m Use only the FineCut nozzle 420117 and deflector 420115 do not use the general purpose nozzle 420118 or shield 420116 m Verify that nothing else is drawing power from the circuit Operating the system on a 120 V 20 A circuit m Set the amperage below 25 A as indicated by the blue shading around the knob the middle ring m Use only the FineCut nozzle 420117 and deflector 420115 do not use the general purpose nozzle 420118 or shield 420116 m Verify that nothing else is drawing power from the circuit Operating the system on a 240 V 20 A circuit m Set the amperage between 15 30 A m Use either the general purpose or the FineCut consumables E Do not mix the general purpose and FineCut consumables Use one set or the other See Voltage configurations on page 25 for more information Powermax30 XP Service Manual 808150 Revision O 4 Operation FineCut he 240 V 20 A AMPS H 120 V 20A 120V 15A 15 30 Gray shading 20 25 fe 240 V 20A AMPS 120 V 20A 120 V 15A 15 30 Blue shading 240 V 20A AMPS
134. should be approximately equal If they differ by more than 30 V replace the power board Figure 18 step 5 step 6 e o ABD Ee o oe Powermax30 XP Service Manual 808150 Revision O 79 5 Troubleshooting and System Tests Test 4 solenoid valve This test verifies the proper operation of the solenoid valve V1 1 Set the power switch to OFF O and disconnect the power cord from the power source 2 Remove the power supply handle and cover See Remove the power supply cover on page 88 3 Remove the component barrier See Remove the component barrier on page 90 WARNING ELECTRIC SHOCK CAN KILL Use extreme caution when working near live electrical circuits Dangerous voltages exist inside the power supply that can cause serious injury or death See the WARNING on page 58 before proceeding 4 Reconnect the electrical power 5 Place a jumper from pin 4 of J6 on the power board see Figure 12 on page 72 for location to ground see Figure 11 on page 71 Figure 19 J9 J J5 J4 ol O Oe Wo Meo Emo o 6 Turn the power ON I The valve should click 7 Measure the voltage between pin 4 of J6 and ground 8 If you do not hear the valve click and the voltage check reads 24 VDC replace the solenoid valve See Replacing the solenoid valve on page 130 80 Powermax30 XP Service Manual 808150 Revision O 5 Troubleshooting and System Tests Test 5 torch stuck open or torch
135. sii eraren pia ira Er Hener rr A EIRE PEIRIN ENEE ERE ESERE EE PERE EREE AEE AREA iE ARENE ERARE 200 Powermax30 XP schematic th tinere tertinm reir ddan ti tb fa deb id nnd al Fate doh record f el o d n ocn snos 201 Powermax30 XP Service Manual 808150 Revision O 11 Contents 12 Powermax30 XP Service Manual 808150 Revision O Introduction Hypertherm s CE marked equipment is built in compliance with standard EN60974 10 The equipment should be installed and used in accordance with the information below to achieve electromagnetic compatibility The limits required by EN60974 10 may not be adequate to completely eliminate interference when the affected equipment is in close proximity or has a high degree of sensitivity In 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 In other cases it could involve constructing an electromagnetic screen enclosing the power source and the work complete with
136. sion O 6 Power Supply Component Replacement Replacing the pressure switch Kit number Description 228688 Kit Pressure switch 1 Complete the following procedures a Set the power switch to OFF O disconnect the power cord from the power source and disconnect the gas supply b See Remove the power supply cover on page 88 2 Disconnect the ground wire that is attached to the clip on the air filter regulator s brass T fitting 3 Disconnect the red and black wires from the pins on the pressure switch 4 Use a 1 1 16 inch wrench or large adjustable wrench to remove the pressure switch from the brass elbow fitting on the air filter regulator assembly See Figure 74 on page 140 5 Apply a small drop of thread sealant to the middle threads of the new pressure switch Do not apply thread sealant to the threads at the end of the pressure switch that will be inserted into the air filter regulator assembly If applied too heavily excess amounts of thread sealant can contaminate the gas line CAUTION Never use PTFE tape on any joint preparation Use only a liquid or paste thread sealant on male threads 6 Tighten the new pressure switch into the brass elbow fitting Turn the pressure switch until its pins are horizontally aligned Verify the pressure switch is angled up at approximately 45 See Figure 74 on page 140 7 Press the black wire s connector onto the pressure switch pin that is neares
137. stall the component barrier on page 91 See nstall the power supply cover on page 89 Reconnect the gas supply and power cord and set the power switch to ON I Powermax30 XP Service Manual 808150 Revision O 161 6 Power Supply Component Replacement Replacing the magnetics assembly Kit number Description 428230 Kit Magnetics assembly Replacement transformers and inductors the magnetics for this power supply are available only as a complete assembly with the components already mounted on a metal base plate You cannot replace individual components 1 Complete the following procedures b C d e Set the power switch to OFF O disconnect the power cord from the power source and disconnect the gas supply See Remove the power supply cover on page 88 See Remove the component barrier on page 90 See Detach the front panel on page 92 See Detach the rear panel on page 95 2 From the power board side of the power supply remove the wires for the transformers and inductors See Figure 93 C 162 Remove J13 J14 and J15 located on the front panel end of the power board Remove J18 and J19 located on the rear panel end of the power board Remove J20 and J21 located on the bottom center of the power board Powermax30 XP Service Manual 808150 Revision O 6 Power Supply Component Replacement Figure 93 1 7 2 3 4 5 6 1 J13 5 J20 2 J14 6 J19 3 J15 7 J18 4 J21
138. stem Tests Control board LEDs The Powermax30 XP control board PCB1 is located inside of the front panel Figure 9 Control board Ribbon cable INTESA A3 The control board has four diagnostic LEDs m Reset This LED illuminates when a voltage reading is out of range or the Reset LED blinks m Error This LED illuminates when the gas pressure torch cap or temperature LEDs on the front of the power supply illuminate If all four LEDs on the front of the power supply are blinking the Error LED also blinks The number of blinks between pauses indicates which component may have failed m Transfer This LED illuminates when there is proper arc transfer between the torch and the workpiece and blinks during continuous pilot arc operation such as when cutting expanded metal or moving the arc off the plate and then back on m Start This LED illuminates when the power supply receives a start signal and remains illuminated during normal operation Powermax30 XP Service Manual 808150 Revision O 69 5 Troubleshooting and System Tests
139. stuck closed If the nozzle and electrode are not in contact before the torch trigger is pressed the power supply detects a torch stuck open fault If the nozzle and electrode are in contact after the torch trigger is pressed the power supply detects a torch stuck closed fault Use the following test to determine if the torch is stuck in either position 1 Set the power switch to OFF O disconnect the power cord from the power source and disconnect the gas supply 2 Remove the power supply handle and cover See Remove the power supply cover on page 88 3 Remove the component barrier See Remove the component barrier on page 90 To avoid causing a short or damage to the multimeter do not fire the torch with the multimeter connected to the power board 4 Measure the resistance from the torch lead s white wire group and red wire The resistance should read very low a closed circuit Figure 20 White wire group Red wire 5 Turn ON I the power and measure the resistance between the same points The resistance should read very high an open circuit B If the resistance reads as open the nozzle and electrode are not in contact or one of the wires in the lead is broken 7 If the resistance reads as closed the nozzle and electrode are in contact or one of the wires in the torch lead is broken Make sure that the torch plunger moves free
140. surrounding area may alleviate problems of interference Screening of the entire plasma cutting installation may be considered for special applications Safely and Compliance Attention Genuine Hypertherm parts are the factory recommended replacement parts for your Hypertherm system Any damage or injury caused by the use of other than genuine Hypertherm parts may not be covered by the Hypertherm warranty and will constitute misuse of the Hypertherm Product You are solely responsible for the safe use of the Product Hypertherm does not and cannot make any guarantee or warranty regarding the safe use of the product in your environment General Hypertherm Inc warrants that its Products shall be free from defects in materials and workmanship for the specific periods of time set forth herein and as follows if Hypertherm is notified of a defect i with respect to the plasma 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 Automation products one 1 year from its date of delivery to you with the exception of the EDGE Pro CNC E
141. t the center panel 8 Press the red wire s connector onto the pressure switch pin that is farthest from the center panel 9 Reconnect the ground wire to the clip on the brass T fitting with a torque setting of 11 5 kg cm 10 inch pounds 10 Complete the following procedures a See nstall the power supply cover on page 89 b Reconnect the gas supply and power cord and set the power switch to ON I Powermax30 XP Service Manual 808150 Revision O 139 6 Power Supply Component Replacement Figure 74 1 Air filter regulator assembly 5 Black wire 2 Brass T fitting 6 Pressure switch 3 Ground wire clip 7 Brass elbow fitting 4 Redwire 140 Powermax30 XP Service Manual 808150 Revision O 6 Power Supply Component Replacement Replacing the air filter regulator and pressure switch assembly Kit number Description 228106 Kit Air filter regulator with pressure switch Remove the air filter regulator and pressure switch assembly 1 Complete the following procedures a Set the power switch to OFF O disconnect the power cord from the power source and disconnect the gas supply b See Remove the power supply cover on page 88 2 Use 2 wrenches to remove the air fitting from the brass hex adapter that connects the fitting to the air filter regulator See Figure 75 Q CSA models Use a 9 16 inch wrench for the air fitting and a 5 8 inch wrench for the hex adapter Q CE CCC models Use a 19 mm wrench for the
142. t 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 Slightly tip the front and rear panels away from the power supply so that you can get the edges of the handle out from underneath them Remove the handle and set it and the two screws aside 4 Continue to tilt the panels outward to release the fan side of the cover from its track Then lift the cover off the power supply Figure 24 88 Powermax30 XP Service Manual 808150 Revision O 6 Power Supply Component Replacement Install the power supply cover 1 Being careful not to pinch any wires slide the cover onto the power supply Align the bottom edges with the tracks and align the slot in the top of the cover with the tab on the front panel so that the louvers in the cover are in front of the fan Figure 25 1 Cover slot 3 Tab 2 Front panel 2 Realign the front panel with the power supply 3 Realign the rear panel with the power supply making sure that the hole in the ground clip is aligned with the screw holes in both the panel and the power supply 4 Position the handle over the holes in the top of the cover and position the ends of the handle underneath the edges of the panels 5 Reinstall the two screws that attach the cover and handle with a torque setting of 23 0 kg cm 20 inch pounds B Re
143. tep and then through the slots inside the handle that act as a strain relief Line up the hole in the wire terminal with the hole in the handle of the ground clamp Insert the screw through the handle and the ring terminal on the end of the lead and fasten it with the kepnut Tighten the screw to 23 0 kg cm 20 inch pounds Fold the metal tabs over the wire to attach the wire to the handle See Figure 100 Slide the plastic sleeve over the handle of the new ground clamp Powermax30 XP Service Manual 808150 Revision O 169 6 Power Supply Component Replacement Figure 100 1 Screw through handle and work lead 3 Ring terminal 2 Kepnut 4 Strain relief tabs 170 Powermax30 XP Service Manual 808150 Revision O Section 7 Torch Component Replacement WARNING ELECTRIC SHOCK CAN KILL Disconnect electrical power before performing any maintenance See the Safety and Compliance Manual 80669C for more safety precautions Powermax30 XP Service Manual 808150 Revision O 171 7 Torch Component Replacement Disconnect the power gas supply and torch 1 Turn the plasma power supply switch to OFF O 2 Disconnect the power cord from the power source 3 Disconnect the gas supply hose from the plasma power supply Figure 101 1 Right side of the handle 9 2 Cap sensor switch 10 3 Start switch 11 4 Plunger screw 12 5 Plunger 13 6 Consumables 14 7 Torch body 15 8 Torch power wire Left side of
144. the pressure SWItCh P 139 Replacing the air filter regulator and pressure switch assembly sse entente tentenn 141 Replacing the alr iNet tttinGS E 146 Replacing the air filter bowl and air filter element sse nete tenete ntente tette te ttette tente tentat s 148 Replacing the front Panel eR 152 Replacing the rear panel icinca io Sene n undae er eme dd uate aude aaa eats 156 Replacing the base tte antt n t mire insane e rta nto da Ra E mentee dod T 160 Replacing the magnetics assembly atrak rauca tdi nuts E EAEEREN VPEA cnp aceti ord vertus E ORA LENEE EEEH 162 Replacing the work lead and ground clamp sse tentent R AR anaes tentat 167 10 Powermax30 XP Service Manual 808150 Revision O Contents 7 Torch Component Replacement s nssunennennnnunnunnnnnnunnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn nnmnnn nnmnnn nnmnnn mnnn 171 Disconnect the power gas supply and torch sese entente tete ten inte tenente tenentes 172 Replacing the handi 2 ccc d os re I de re ri asd d n EE DA HER da duas 173 Replacing the trigger assembly eee titii nimia then inima toria tania AREARE ONE dk rara KERES 177 Replacing the torek body e Ede eicit reete ides iib E A seauivensnnens 178 Replacing the Start SWwItCl cuti cai carece erret rnnt dtd di di E E 180 Replacing the cap sensor SWitOh suiit eterne tenni tecta d n Rene n ier Eea ee ae
145. torch at the edge of the workpiece Maximum cut speed is limited by the test table s maximum speed 10160 mm minute or 400 inches minute Powermax30 XP Service Manual 808150 Revision O Section 4 Operation Controls and indicators Refer to the following topics to become familiar with the controls and LED indicators on the system before you begin cutting Rear controls ON I OFF O power switch Activates the system and its control circuits Powermax30 XP Service Manual 808150 Revision O 39 4 Operation Front controls and LEDs 2 8 bar 40 psi G5 amp Power ON LED green When illuminated this LED indicates that the power switch has been set to ON I and that the safety interlocks are satisfied Gas pressure LED yellow When illuminated this LED indicates that the inlet gas pressure is below Torch cap LED yellow When illuminated this LED indicates that the consumables are loose improperly installed or missing Temperature LED yellow When illuminated this LED indicates that the system s temperature is outside the acceptable operating range Some fault conditions cause one or more of the LEDs to blink For information on what these fault conditions are and how to clear them see Troubleshooting guide on page 63 N o N a 240 V 20A AMPS 120V 20A 120V 15A 15 30 40 Amperage adjustment knob Use this knob to set the output current betw
146. torch lead moves freely See Figure 71 on page 136 9 Remove the torch lead by pulling the wires through the hole in the front panel If you are replacing the strain relief remove the strain relief from the front panel Figure 71 Outside Inside 1 Retention nut inside power supply 3 Strain relief 2 Front panel 4 Strain relief nut 136 Powermax30 XP Service Manual 808150 Revision O 6 Power Supply Component Replacement Install the torch lead and strain relief If you are replacing just the torch lead cable not the whole torch assembly refer to Replacing the torch lead on page 182 for details on how to connect the new lead to the torch 1 Are you installing a new strain relief u If yes slide the new strain relief and strain relief nut over the new torch lead and up to the hole in the front panel If no continue with the next step 2 Route the wires for the new torch lead through the hole in the front panel and then through the retention nut for the strain relief 3 Facing the fan side of the power supply slide the ring terminal for the bundle of 3 white wires over the left stud labeled WHT on the center panel 4 Slide the ring terminal for the red wire onto the stud on the right labeled RED on the center panel If you removed any other wires from the WHT and RED studs reinstall them 5 Use an 8 mm 5 16 inch nut driver to tighten the nut on each stud with a torque settin
147. trogen to cut electrically conductive metals such as mild steel stainless steel or aluminum With it you can cut thicknesses up to 15 mm 5 8 inches and pierce thicknesses up to 6 mm 1 4 inch The Powermax30 XP ships in several different configurations based on region Typically all configurations include m 1 complete set of general purpose consumables preinstalled on the Duramax LT hand torch for standard cutting Q 1 electrode Q 1 swirl ring Q 1 nozzle Q 1 retaining cap 1 shield m 1 extra general purpose nozzle m 1 extra electrode m FineCut consumables for detailed cutting Q 1 FineCut nozzle Q 1 FineCut deflector m 1 region specific air fitting Q Industrial interchange quick disconnect nipple with 1 4 NPT threads CSA models Q British Pipe Thread adapter G 1 4 BSPP with 1 4 NPT threads CE and CCC models Powermax30 XP Service Manual 808150 Revision O 17 oh Specifications m Carrying strap m Operator Manual m Safety and Compliance Manual m Quick Setup Card For details on how to select the right set of consumables for a given cutting job see Choose the consumables on page 32 Additional items may also ship with your Powermax30 XP depending on the configuration that you ordered such as instructional setup materials a carrying case leather cutting gloves or protective glasses CSA units ship with a 120 V 15 A NEMA 5 15P adapter and a 240 V 20 A NEMA 6 50P adapter that connect to the
148. tside 1 Strain relief nut outside the power supply 3 Rear panel 2 Strain relief 4 Retention nut inside the power supply B From outside of the power supply pull the wires through the strain relief and through the hole in the rear panel to remove the power cord 7 Are you replacing the strain relief Uu If yes remove the strain relief from the rear panel Q If no continue with nstall the power cord and strain relief on page 103 100 Powermax30 XP Service Manual 808150 Revision O 6 Power Supply Component Replacement CE and CCC power cords 1 Complete the following procedures a Set the power switch to OFF O disconnect the power cord from the power source and disconnect the gas supply b See Remove the power supply cover on page 88 c See Remove the component barrier on page 90 d See Detach the rear panel on page 95 CE and CCC power cords have a brown wire and a blue wire that connect to the power switch and a green yellow ground wire that connects to the heatsink 2 Remove the blue and brown wires from the power switch 3 Remove the screw that holds the green yellow ground wire to the heatsink A notch in the power board provides access to the screw Figure 39 Table 2 Single phase CE and CCC power cord wires Designator Wire color L live Brown N neutral Blue
149. upply is too high The wrong consumables are being used The power supply is not receiving enough input power The operator is stretching the arc while cutting The extension cord is not delivering sufficient power to the power supply The amperage adjustment knob is set too high for the input circuit The general purpose nozzle and shield are being used with an input circuit of 120 VAC The input circuit is not delivering sufficient power to the power supply Theoperator is holding the torch too far from the workpiece when cutting The extension cord is too long is damaged or is not capable of delivering sufficient power to the power supply Turn down the cutting current See Adjust the gas pressure and output current on page 44 Use only the FineCut consumables when operating the system on a 120 VAC input circuit See Choose the consumables on page 32 Operate the system on a 240 VAC input circuit whenever possible Avoid stretching the arc Drag the torch on the workpiece See Edge start on a workpiece on page 50 Operate the system without using an extension cord If you must use an extension cord use a heavy conductor cord of the shortest possible length See Extension cord recommendations on page 28 Verify nothing else is drawing power on the same circuit 68 Powermax30 XP Service Manual 808150 Revision O 5 Troubleshooting and Sy
150. ure 59 Lift the top edge of the component barrier and disconnect the wire pair by pulling the connector straight back away from the board Connect the new wire to the power board at J4 and route the wires through the notch in the center panel that is nearest the solenoid valve See Figure 59 Press the black wire s connector onto the pressure switch pin that is nearest the center panel Press the red wire s connector onto the pressure switch pin that is farthest from the center panel Complete the following procedures a See nstall the power supply cover on page 89 b Reconnect the gas supply and power cord and set the power switch to ON I Figure 59 i ig 1 e qm hw tol i A Solenoid valve 4 Center panel J4 connector on the power board 5 Pressure switch Pressure switch to J4 wire pair 6 Power board Powermax30 XP Service Manual 808150 Revision O 6 Power Supply Component Replacement Remove and install the ground clip wire from the heatsink to the rear panel 1 Complete the following procedures a Set the power switch to OFF O disconnect the power cord from the power source and disconnect the gas supply
151. ure varies by torch lead length 86 Powermax30 XP Service Manual 808150 Revision O Section 6 Power Supply Component Replacement WARNING 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 See the Safety and Compliance Manual 80669C for more safety precautions CAUTION Static electricity can damage circuit boards Use proper precautions when handling printed circuit boards Store PC boards in anti static containers Wear a grounded wrist strap when handling PC boards Disconnect the power and gas supply 1 Set the plasma power supply switch to OFF O 2 Disconnect the power cord from the power source 3 Disconnect the gas supply hose from the plasma power supply Powermax30 XP Service Manual 808150 Revision O 87 6 Power Supply Component Replacement Replacing the power supply cover Kit number Description 428221 Kit Power supply cover with labels CSA 428222 Kit Power supply cover with labels CSA Built in America 428224 Kit Power supply cover with labels CE 428225 Kit Power supply cover with labels CCC Remove the power supply cover 1 Set the power switch to OFF O disconnect the power cord from the power source and disconnect the gas supply 2 Remove the two screws from the handle on the top of the power supply Gently pull on the panel neares
152. use serious injury or death See the WARNING on page 58 before proceeding 5 Reconnect the electrical power and set the power switch to ON I B If the fan does not operate replace the fan See Replacing the fan on page 116 Figure 23 Because of protection features on the fan driver chip this test can trigger a fault You can disregard this fault if it occurs as a result of a fan test The purpose of the fan test is to verify that the fan is operating properly not to test the fan drive circuit Powermax30 XP Service Manual 808150 Revision O 85 5 Troubleshooting and System Tests Test 9 pressure switch Test the pressure switch to verify that the system is receiving the proper gas pressure 1 Set the power switch to OFF O disconnect the power cord from the power source and disconnect the gas supply 2 Remove the power supply handle and cover See Remove the power supply cover on page 88 3 Remove the component barrier See Remove the component barrier on page 90 4 Measure the resistance between pins 1 and 2 of J4 If there is no gas pressure it should read approximately 4 7 kQ If the gas pressure is within system tolerances as outlined in the Hypertherm system ratings on page 19 the circuit should read as closed 5 Replace the pressure switch if necessary See Replacing the pressure switch on page 139 The minimum acceptable gas press
153. ute the wires through the strain relief 2 On the inside of the rear panel slide the retention nut over the power cord wires and screw it onto the strain relief 3 Press the connector for the black wire onto the pin on the upper left side of the power switch 4 Press the connector for the white wire onto the pin on the upper right side of the power switch 5 Tighten the green ground wire to the heatsink with a torque setting of 17 8 kg cm 15 inch pounds B Position the wires in the wire chase up the side of the rear panel and out of the way of the power board At the same time realign the rear panel with the power supply See Reattach the rear panel on page 97 7 Tighten the strain relief nut on the outside of the rear panel 8 Complete the following procedures a See nstall the component barrier on page 91 b See nstall the power supply cover on page 89 Reconnect the gas supply and power cord and set the power switch to ON I Powermax30 XP Service Manual 808150 Revision O 103 6 Power Supply Component Replacement CE and CCC power cords 1 Are you installing a new strain relief u lfyes i Slide the retention nut onto the new power cord ii From the inside of the rear panel route the power cord wires through the hole in the panel ili On the outside of the rear panel slide the strain relief and strain relief nut onto the power cord iv On the inside of the rear panel screw the retention nut onto the strain r
154. ver 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 To do so risks 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 printed circuit boards 58 Powermax30 XP Service Manual 808150 Revision O 5 Troubleshooting and System Tests 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 Inspect the torch and the torch lead for damage Inspect the consumables for damage or wear Repair or replace components as necessar
155. w to set up and operate your torch To achieve optimal consumable life and cut quality follow the instructions in this manual Hand torch components 1 Handle 4 Safety catch 2 Shield shown or deflector 5 Trigger red 3 Retaining cap 6 Screws 5 Powermax30 XP Service Manual 808150 Revision O 31 3 Torch Setup Consumable life Consumable life varies based on the following factors m Thickness of the metal m Length of the average cut m Gas supply quality presence of oil moisture or other contaminants m Type of cutting piercing decreases life when compared to edge cutting m Pierce height m Consumables FineCut or general purpose Hypertherm does not recommend the use of any other consumables in the Duramax LT torch except for those listed in this section which are designed specifically for this system The use of any other consumables could adversely affect system performance Although largely dependent on the factors listed above as a general rule the consumables last approximately 1 to 2 hours of actual arc on time If the consumables life is shorter than expected or the cut quality is poor verify that you are using the correct combination of consumables See the following topic Choose the consumables Under normal conditions the nozzle wears out first See Hand torch operation on page 48 for more information about proper cutting techniques Choose the consumables WARNING INSTANT ON TO
156. y Internal inspection 1 2 3 Set power switch to OFF O disconnect the power cord from the power source and disconnect the gas supply Remove the power supply handle and cover See Remove the power supply cover on page 88 Remove the component barrier See Remove the component barrier on page 90 Inspect the inside of the power supply especially 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 components as necessary Initial resistance check All resistance values must be taken with the power cord disconnected and all internal power supply wires attached Perform the steps in nternal inspection above before continuing in this section The type of multimeter you use significantly affects the results of the tests in this section The resistance values in this manual are intended as a general reference point If resistance values indicate a problem based on the range of values provided in this section isolate the problem by removing wires attached to the resistance check points or component until the problem is found After the problem is located and repaired see Sequence of operation on page 56 to test the power supply for proper operation Powermax30 XP Service Manual 808150 Revision O 59 5 Troubleshooting and System Tests Check the power switch 1 Set power switch to OFF O disconnect the power co
157. y the use of parts that are not from Hypertherm may not be covered by the Hypertherm warranty In addition the following parts are safety critical parts that must be replaced only with genuine Hypertherm parts to maintain the warranty and system certifications including CE CSA and CCC certification L anini Item Kit number Description 1 428233 Kit Power board CSA and subcomponents 1 428234 Kit Power board CE and CCC and subcomponents 2 428230 Kit Magnetics assembly 3 228688 Kit Pressure switch 4 228106 Kit Air filter regulator with pressure switch 5 428236 Kit Fan assembly includes plenum 6 428235 Kit Power switch 196 Powermax30 XP Service Manual 808150 Revision O Item Kit number 7 228210 8 228140 8 428231 9 228143 Description 8 Parts Kit CSA power cord with NEMA twist lock style 240 V 20 A plug 1 phase 3 0 m 10 feet Kit CE power cord 1 phase 3 0 m 10 feet plug not included Kit CCC power cord 1 phase 3 0 m 10 feet plug not included Kit Power cord strain relief Recommended spare parts Hypertherm recommends that service centers keep the following spare parts on hand for repairs because these parts are critical or are usually exposed to heavy and repeated wear You may find that you need to revise or expand this list for your custom
158. your cutting applications see Choose the consumables on page 32 42 Powermax30 XP Service Manual 808150 Revision O 7 e o Oo C Q Electrode Swirl ring Nozzle general purpose Nozzle FineCut kr O N Figure 5 Powermax30 XP Service Manual 808150 Revision O 4 Operation Tighten only to finger tight 5 Retaining cap 6 Shield general purpose 7 Deflector FineCut 43 4 Operation Attach the ground clamp Attach the ground clamp to the workpiece m Verify that the ground clamp and the workpiece make good metal to metal contact m Attach the ground clamp as close as possible to the area being cut to reduce exposure to electric and magnetic fields EMF and to achieve the best possible cut quality m Donot attach the ground clamp to the portion of the workpiece that you are cutting away Power ON the system Set the ON OFF switch to the ON I position Adjust the gas pressure and output current The power ON LED and the gas pressure LED illuminate when there is insufficient gas pressure to the system Use a high pressure regulator that is capable of delivering gas to the filter on the power supply at 99 1 l min at 4 7 bar 3 5 scfm at 68 psi For more information on attaching the gas supply see Prepare the gas supply on page 29 1 Set the regulator between 5 5 and 6 9 bar BO and 100 psi 2 Turn the amperage knob to the desired output current ba

Powermax30 XP Service Manual (808150 rev 0)

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