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Hypertherm powermax45 Service Manual
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torch setup
3-4
powermax
45
Service Manual
T45v unshielded consumables*
* Unshielded consumables are not available for use in CE-regulated countries.
T30v (Powermax30) 30 A consumables
220713
Retaining cap
220670
Swirl ring
220669
Electrode
220717
Deflector
220718
Nozzle
220483
Retaining cap
220480
Nozzle
220478
Electrode
220479
Swirl ring
220569
Optional deflector
33
35
Table of Contents
Default Chapter
5
Safety Information
5
Table of Contents
7
Electromagnetic Compatibility (Emc)
11
Mains Supply
11
Assessment of Area
11
Maintenance of Cutting Equipment
12
Warranty
13
Patent Indemnity
14
Section 1
15
Specifications
15
System Description
16
Where to Find Information
16
Power Supply Dimensions and Weights
17
Dimensions
17
Weights
17
Power Supply Ratings
18
T45V Torch Dimensions
19
T45M Torch Dimensions
19
T45V and T45M Torch Specifications
20
Symbols and Marks
21
IEC Symbols
22
Section 2
23
Power Supply Setup
23
Unpack the Powermax45
24
Claims
24
Contents
24
Position the Power Supply
25
Prepare the Electrical Power
25
Voltage Configurations
25
Install a Line-Disconnect Switch
26
Requirements for Grounding
26
Table of Contents
26
Power Cord Considerations
26
Extension Cord Recommendations
27
Generator Recommendations
28
Prepare the Gas Supply
28
Connect the Gas Supply
29
Additional Gas Filtration
29
Section 3
32
Torch Setup Introduction
32
Consumable Life
32
Hand Torch Setup
32
Introduction
32
Choose the Consumables
33
Install the Consumables
35
Machine Torch Setup
36
Mount the Torch
36
Choose the Consumables (Cut Charts)
38
Using the Cut Charts
38
T45M Shielded Consumables
38
Align the Torch
54
Connect the Remote-Start Pendant
55
Connect a Machine Interface Cable
55
Accessing Raw Arc Voltage
57
Connect the Torch Lead
60
Operation
62
Section 4
62
Controls and Indicators
62
Front Controls and Leds
62
Rear Controls
63
Operate the Powermax45
63
Connect the Electrical Power and Gas Supply
63
Power on the System
64
Set the Mode Switch
64
Adjust the Gas Pressure
64
Check the Indicator Leds
66
Attach the Work Clamp
66
Understand Duty-Cycle Limitations
66
How to Use the Hand Torch
67
Operate the Safety Trigger
67
Hand Torch Cutting Hints
67
Start a Cut from the Edge of the Workpiece
68
Pierce a Workpiece
69
Gouge a Workpiece
70
Common Hand-Cutting Faults
72
How to Use the Machine Torch
72
Ensure the Torch and Table Are Set up Correctly
72
Understand and Optimize Cut Quality
73
To Pierce a Workpiece Using the Machine Torch
74
Common Machine-Cutting Faults
75
Section 5
77
Troubleshooting and System Tests
77
Theory of Operation
78
General
78
200-240 V CSA and 230 V Ce 1-Phase Power Supply Functional Description
78
400 V Ce 3-Phase Power Supply Functional Description
78
480 V CSA 3-Phase Power Supply Functional Description
79
Sequence of Operation
80
Troubleshooting Preparation
81
Test Equipment
81
Troubleshooting Procedures and Sequence
81
External Inspection
82
Internal Inspection
82
Initial Resistance Check
83
200-240 V CSA and 230 V Ce Power Supply Overview
84
400 V Ce Power Supply Overview
85
480 V CSA Power Supply Overview
86
Troubleshooting Guide
87
Control Board Leds
92
Use the Control Board Error and Reset Leds to Troubleshoot
93
System Tests
94
Test 1 - Voltage Input
94
Test 2 - Power Board Voltage Checks
95
Test 3 - VBUS and Voltage Balance
96
Test 4 - Solenoid Valve
100
Test 5 - Torch Stuck Open (TSO) or Torch Stuck Closed (TSC)
101
Test 6 - Plasma Start
102
Test 7 - Torch Cap Sensor
103
Test 8 - Fan
103
Test 9 - Pressure Transducer
104
Test 10 - Power Switch Trip Coil
104
Section 6
105
Component Replacement
105
Remove and Replace the Cover and Mylar ® Barrier
106
Barrier
106
Removal
106
Replacement
107
Replace the Work Lead (CSA and CE)
107
Replace the Power Cord (200-240 V CSA)
109
Replace the Power Cord (230 V CE)
110
Replace the Power Cord (400 V CE)
112
Replace the Power Cord (480 V CSA)
114
Replace the Fan
116
Replace the Gas Filter Element
117
Replace the Air Filter and Regulator
119
Replace the Control Board
120
Replace the Power Board (200-240 V CSA and 230 V CE)
121
Replace the Power Board (400 V CE and 480 V CSA)
125
Section 7
129
Parts
129
Power Supply Parts
130
Exterior
130
Interior, Power Board Side
132
Interior, Fan Side
133
Interior, Heat Sink Side
134
T45V Hand Torch Parts
135
T45V Hand Torch Consumables
136
T30V (Powermax30) 30 a Consumables
136
T45M Machine Torch Parts
137
T45M Machine Torch Consumables
138
Accessory Parts
138
Safety-Critical Parts
139
Recommended Spare Parts
140
Powermax45 Labels
141
Section 8
143
Wiring Diagrams
143
Control Board Diagram: 200-240 V CSA and 230 V CE
144
Control Board Diagram: 400 V CE and 480 V CSA
145
Power Board Wiring Diagram: 400 V CE
148
Power Board Wiring Diagram: 480 V CSA
149
Other manuals for Hypertherm powermax45
Operator's Manual
101 pages
Field Service Bulletin
26 pages
4
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Hypertherm powermax45 Specifications
General
Brand
Hypertherm
Model
powermax45
Category
Welding System
Language
English
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