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Hypertherm
Welding System
Powermax30 XP
Hypertherm Powermax30 XP Service Manual
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Safety information
Before operating any Hypertherm
equipment, read the separate
Safety and C
ompliance Manual
(8
06
6
9C) included
with your product for import
ant s
afety information.
4
6
Table of Contents
Table of Contents
7
Electromagnetic Compatibility (EMC
13
Assessment of Area
13
Installation and Use
13
Introduction
13
Methods of Reducing Emissions
13
Mains Supply
13
Cutting Cables
14
Earthing of the Workpiece
14
Equipotential Bonding
14
Maintenance of Cutting Equipment
14
Screening and Shielding
14
Attention
15
General
15
Warranty
15
Insurance
16
Liability Cap
16
Limitation of Liability
16
National and Local Codes
16
Patent Indemnity
16
Transfer of Rights
16
Specifications
17
Safety Information
17
System Description
17
Power Supply Dimensions
18
System Weights
18
Hypertherm System Ratings
19
Torch Dimensions
20
Torch Weight
20
Cutting Specifications
20
Symbols and Marks
21
IEC Symbols
22
Noise Levels
22
Power Supply Setup
23
Unpack the Powermax System
23
Claims
23
System Contents
24
Position the Plasma Cutting System
25
Prepare the Electrical Power
25
Voltage Configurations
25
Requirements for Grounding
26
Power Cord Considerations
26
CSA Power Cords and Plugs
26
CE and CCC Power Cords
27
Extension Cord Recommendations
28
Generator Recommendations
28
Prepare the Gas Supply
29
Connect the Gas Supply
29
Additional Gas Filtration
30
Torch Setup
31
Introduction
31
Hand Torch Components
31
Consumable Life
32
Choose the Consumables
32
Using the Cut Charts
33
General-Purpose Consumables
34
240 V / 30 a Cutting
35
Finecut Consumables
36
120 V / 25 a Cutting
37
120 V / 30 a Cutting
38
Powermax30 XP Service Manual 808150 Revision
38
Operation
39
Controls and Indicators
39
Rear Controls
39
Front Controls and Leds
40
Operate the Powermax30 XP
41
Connect the Electrical Power and Gas Supply
41
Install the Consumables
42
Adjust the Gas Pressure and Output Current
44
Attach the Ground Clamp
44
Power on the System
44
Check the Indicator Leds
46
Verify the System Is Ready
46
Understand Duty-Cycle Limitations
46
System Operation Guidelines
47
Hand Torch Operation
48
Safety Catch Operation
48
Hand Torch Cutting Guidelines
49
Edge Start on a Workpiece
50
Pierce a Workpiece
51
Gouge a Workpiece
52
Common Hand-Cutting Faults
54
Troubleshooting and System Tests
55
Theory of Operation
55
Functional Description
55
Sequence of Operation
56
Troubleshooting Preparation
57
Test Equipment
57
Troubleshooting Procedures and Sequence
57
External Inspection
59
Internal Inspection
59
Initial Resistance Check
59
Check the Power Switch
60
Power Supply Overview
62
Troubleshooting Guide
63
Control Board Leds
69
Use the Control Board Error and Reset Leds to Troubleshoot
70
System Tests
71
Test 1 - Voltage Input
74
Test 2 - Power Board Voltage Checks
76
Test 3 - VBUS and Voltage Balance
78
Test 4 - Solenoid Valve
80
Test 5 - Torch Stuck Open or Torch Stuck Closed
81
Test 6 - Plasma Start
82
Test 7 - Torch Cap-Sensor
84
Test 8 - Fan
85
Test 9 - Pressure Switch
86
Power Supply Component Replacement
87
Disconnect the Power and Gas Supply
87
Replacing the Power Supply Cover
88
Replacing the Component Barrier
90
Detaching and Reattaching the Front Panel
92
Table of Contents
93
Detaching and Reattaching the Rear Panel
95
Figure 32
95
Place Another Screwdriver or Similar Object into the Opening between the Panel and the Base to Keep the First Corner
96
Figure 33
96
Repeat Step 5 and Step 6 on the Other Corner of the Panel
96
10. Gently Pull the Panel Away from the Power Supply
96
Replacing the Power Cord and Strain Relief
98
Replacing the Power Switch
105
Replacing the Control Board
107
Replacing the Power Board
109
Replacing the Fan
116
Table of Contents
118
Default Chapter
119
Replacing the Drain Hose, Gas Supply Hoses, and 90° Fitting
119
Figure 57
121
Solenoid Valve
121
Replacing the Wire Group
123
Reconnect the Gas Supply and Power Cord, and Set the Power Switch to on (I)
124
Replacing the Solenoid Valve
130
Replacing the Torch Lead and Strain Relief
133
Replacing the Pressure Switch
139
Replacing the Air Filter/Regulator and Pressure Switch Assembly
141
Replacing the Air Inlet Fittings
146
Replacing the Air Filter Bowl and Air Filter Element
148
Replacing the Front Panel
152
Replacing the Rear Panel
156
Replacing the Base
160
Replacing the Magnetics Assembly
162
Replacing the Work Lead and Ground Clamp
167
See Install the Power Supply Cover
124
Torch Component Replacement
171
Disconnect the Power, Gas Supply, and Torch
172
Replacing the Handle
173
Replacing the Trigger Assembly
177
Replacing the Torch Body
178
Replacing the Start Switch
180
Replacing the Cap-Sensor Switch
181
Replacing the Torch Lead
182
Parts
185
Power Supply Parts
186
Exterior, Front
186
Exterior, Rear
187
Interior, Power Board Side
188
Control Board and Power Switch
189
Interior, Fan Side
190
Power Supply Base and Magnetics
192
Duramax LT Hand Torch Parts
193
Duramax LT Hand Torch Consumables
194
Accessory Parts
195
Safety-Critical Parts
196
Recommended Spare Parts
197
Powermax30 XP Labels
198
Wiring Diagrams
199
Powermax Generic Timing Chart
200
Powermax30 XP Schematic
201
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Hypertherm Powermax30 XP Specifications
General
Brand
Hypertherm
Model
Powermax30 XP
Category
Welding System
Language
English
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