Hypertherm Powermax30 Operator's Manual
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Hypertherm Powermax30 Operator's Manual

Plasma arc cutting system
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Powermax30
XP
®
Plasma Arc Cutting System
Operator Manual
808160 | Revision 3 | English

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Summary of Contents for Hypertherm Powermax30

  • Page 1 Powermax30 ® Plasma Arc Cutting System Operator Manual 808160 | Revision 3 | English...
  • Page 2 ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ Powermax, Duramax, FineCut, HyAccess, 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. © 2015 Hypertherm Inc.
  • Page 3 Powermax30 XP Operator Manual 808160 Revision 3 English June 2015 Hypertherm Inc. Hanover, NH 03755 USA www.hypertherm.com...
  • Page 4 55 11 2409 2636 Tel 55 11 2408 0462 Fax Hypertherm (S) Pte Ltd. 82 Genting Lane Media Centre Hypertherm México, S.A. de C.V. Annexe Block #A01-01 Avenida Toluca No. 444, Anexo 1, Singapore 349567, Republic of Singapore Colonia Olivar de los Padres 65 6841 2489 Tel Delegación Álvaro Obregón...
  • Page 5 WARNING! READ THE SAFETY INFORMATION Before operating or maintaining any Hypertherm equipment, read the Safety and Compliance Manual (80669C) for important safety information. You can find the Safety and Compliance Manual in the “Downloads library” at www.hypertherm.com.

  • Page 7: Table Of Contents

    Liability cap ....................................SC-13 Insurance ....................................SC-14 Transfer of rights ..................................SC-14 1 Specifications ..........................15 Safety information ..................................15 System description ..................................15 Power supply dimensions ................................16 System weights ..................................... 16 Hypertherm system ratings ................................. 17 Powermax30 XP Operator Manual 808160...
  • Page 8 120 V / 25 A cutting ..............................35 120 V / 30 A cutting ..............................36 HyAccess consumables ..............................37 Cutting at 240 V ................................37 Cutting at 120 V / 20 A .............................. 37 Ordering and replacing ............................... 37 Powermax30 XP Operator Manual 808160...
  • Page 9 Remove the old air filter element and air filter bowl ....................62 Install the new air filter element and air filter bowl ....................63 Put the power supply cover and handle back in place ..................64 Powermax30 XP Operator Manual 808160...
  • Page 10 Duramax LT hand torch parts ..............................69 Duramax LT hand torch consumables ............................. 70 General-purpose (standard) consumables ........................70 FineCut consumables ................................70 HyAccess consumables ..............................71 Accessory parts .................................... 72 Powermax30 XP labels ................................73 Powermax30 XP Operator Manual 808160...

  • Page 11: Electromagnetic Compatibility (Emc

    Electromagnetic Compatibility (EMC) Introduction Methods of reducing emissions Hypertherm’s CE-marked equipment is built in compliance with standard Mains supply EN60974-10. The equipment should be installed and used in accordance with the information below to achieve electromagnetic Cutting equipment must be connected to the mains supply according to compatibility.

  • Page 12: Screening And Shielding

    Electromagnetic Compatibility (EMC) 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.

  • Page 13: Warranty

    Hypertherm not in strict conformity herein and as follows: if Hypertherm is notified of a defect (i) with respect with Hypertherm’s specifications and in cases of designs, processes,...

  • Page 14: 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.

  • Page 15: Specifications

    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 nitrogen to cut electrically conductive metals, such as mild steel, stainless steel, or aluminum.

  • Page 16: Power Supply Dimensions

    You can order additional consumables and accessories – such as specialty consumables, a carrying strap, and a circle cutting guide – from any Hypertherm distributor. See the Parts section on page 65 for a list of spare and optional parts.

  • Page 17: Hypertherm System Ratings

    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 Operator Manual 808160...

  • Page 18: Torch Dimensions

    12 mm (1/2 inch) at 75 mm/minute (3 inches/minute)  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 the consumables on page 30. Powermax30 XP Operator Manual 808160...

  • Page 19: Symbols And Marks

    The CE versions of products that include a UkrSEPRO mark of conformity meet the product safety and EMC requirements for export to the Ukraine. Serbian AAA mark CE versions of products that include a AAA Serbian mark meet the product safety and EMC requirements for export to Serbia. Powermax30 XP Operator Manual 808160...

  • Page 20: Noise Levels

    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 http://www.hypertherm.com: 1.

  • Page 21: Power Supply Setup

    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.

  • Page 22: System Contents

    9 CSA power cord with power plug adapters 4 Safety and Compliance Manual 10 Power supply 5 Hand torch with lead 11 Carrying strap 6 Consumable kit  The specific components included with the system are subject to change over time. Powermax30 XP Operator Manual 808160...

  • Page 23: Position The Plasma System

    22.5 A – 18.8 A General-purpose or FineCut * Input voltages can be ±10% of the values in this table. See Choose the consumables on page 30 for an explanation of general-purpose (standard) and FineCut consumables. † Powermax30 XP Operator Manual 808160...

  • Page 24: Requirements For Grounding

    44.  To operate the system on a 240 V/20 A circuit, attach the female end of the 240 V/20 A (NEMA 6-50P) plug to the power supply’s NEMA twist lock-style plug. Powermax30 XP Operator Manual 808160...

  • Page 25: Ce And Ccc Power Cords

    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 Operator Manual 808160...

  • Page 26: Extension Cord Recommendations

    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. Powermax30 XP Operator Manual 808160...

  • Page 27: Prepare 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. To address these issues, use an optional air filtration system, such as the Hypertherm Eliminizer filter kit (128647). For optimal performance, the gas should have a maximum: ...

  • Page 28: Additional Gas Filtration

    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. Powermax30 XP Operator Manual 808160...

  • Page 29: Torch Setup

    Torch Setup Introduction The Powermax30 XP includes the Duramax LT hand torch. This section explains how to set up and operate your torch. To achieve optimal consumable life and cut quality, follow the instructions in this manual. Hand torch components...

  • Page 30: Consumable Life

    Type of consumable (FineCut, general-purpose, or HyAccess™)  Hypertherm does not recommend the use of any other consumables in this hand 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.
  • Page 31  Hypertherm does not recommend the use of any other consumables in this hand 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.

  • Page 32: Using The Cut Charts

    * You can order packs of nozzles or electrodes, or you can order them combined as a kit. To order a kit of 2 general-purpose (standard) nozzles with 2 electrodes, use kit number 428243. Hypertherm recommends replacing the nozzle and electrode at the same time.

  • Page 33: 240 V / 30 A Cutting

    * 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 Operator Manual 808160...

  • Page 34: Finecut Consumables

    * You can order packs of nozzles or electrodes, or you can order them combined as a kit. To order a set of 2 FineCut nozzles with 2 electrodes, use kit number 428244. Hypertherm recommends replacing the nozzle and electrode at the same time.

  • Page 35: 120 V / 25 A Cutting

    * 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 Operator Manual 808160...

  • Page 36: 120 V / 30 A Cutting

    * 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 Operator Manual 808160...

  • Page 37: Hyaccess Consumables

    If you are operating the system on a 120 V / 20 A circuit, you can use the HyAccess consumables to cut thicknesses up to 3 mm (10 GA).  Hypertherm does not recommend using the HyAccess consumables when you operate the system on a 120 V / 15 A circuit. Ordering and replacing Typically, you can expect HyAccess consumables to last about half as long as the general-purpose (standard).

  • Page 38: Powermax30 Xp Operator Manual

    3 – Torch Setup WARNING! CHANCE OF ELECTRIC SHOCK Replace the retaining cap immediately if the end of the cap becomes torn or frayed. Touching an exposed nozzle when operating the system will result in electric shock. Powermax30 XP Operator Manual 808160...

  • Page 39: Operation

    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 Operator Manual 808160...

  • Page 40: Front Controls And Leds

    Basic troubleshooting on page 58. 240 V 20 A Amperage adjustment knob – Use this knob to set the output current 120 V AMPS between 15 A and 30 A. 20 A 120 V 15 A Powermax30 XP Operator Manual 808160...

  • Page 41: Operate The Plasma System

    To understand which consumables to use and what cutting capacity to expect based on input voltage, see Choose the consumables on page 30.  For information on electrical requirements and gas supply requirements for this system, see Power Supply Setup on page 21. Powermax30 XP Operator Manual 808160...

  • Page 42: Install The Consumables

    3. You use only the general-purpose shield (420116) with the general-purpose (standard) nozzle (420118).  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 the consumables on page 30. Powermax30 XP Operator Manual 808160...
  • Page 43 4 – Operation Figure 6 Tighten only to finger tight. 1 Electrode 5 Retaining cap 2 Swirl ring 6 Shield (general-purpose) 3 Nozzle (general-purpose) 7 Deflector (FineCut) 4 Nozzle (FineCut) Powermax30 XP Operator Manual 808160...

  • Page 44: Attach The Ground Clamp

    (3.5 scfm at 68 psi). For more information on attaching the gas supply, see Prepare the gas supply on page 27. 1. For cutting, set the regulator between 5.5 and 6.9 bar (80 and 100 psi). 2. Turn the amperage knob to the desired output current based on the input voltage, circuit size, and consumables. Powermax30 XP Operator Manual 808160...

  • Page 45: Operating The System On A 120 V, 15 A Circuit

    FineCut consumables. 120 V AMPS 20 A  Do not mix the general-purpose and FineCut 120 V 15 A consumables. Use one set or the other. See Voltage configurations on page 23 for more information. Powermax30 XP Operator Manual 808160...

  • Page 46: Check The Indicator Leds

    When the duty cycle is exceeded, the system overheats, the temperature LED illuminates, the arc shuts off, and the cooling fan continues to run. To resume cutting, wait for the temperature LED to extinguish.  The fan may run during normal operation of the system. Powermax30 XP Operator Manual 808160...

  • Page 47: System Operation Guidelines

    Additional techniques to reduce the frequency of tripped circuit breakers include:  Turn down the amperage adjustment knob.  Avoid stretching the arc. Instead, drag the torch on the workpiece as explained in Edge start on a workpiece on page 50. Powermax30 XP Operator Manual 808160...

  • Page 48: Hand Torch Operation

    The hand 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. Powermax30 XP Operator Manual 808160...

  • Page 49: Hand Torch Cutting Guidelines

    For straight-line cuts, use a straight edge as a guide. To cut circles, use a template or a radius cutter attachment (a circle cutting guide). See Accessory parts on page 72 for the Hypertherm plasma cutting guide part numbers for cutting circles and making bevel cuts.

  • Page 50: Edge Start On A Workpiece

    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. Powermax30 XP Operator Manual 808160...

  • Page 51: Pierce A Workpiece

    Rolling pierce: Press the torch trigger to start the arc while still at an angle to the workpiece, then 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 Operator Manual 808160...

  • Page 52: Gouge A Workpiece

    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. Powermax30 XP Operator Manual 808160...

  • Page 53: Varying The Gouge Profile

    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. Powermax30 XP Operator Manual 808160...

  • Page 54: Common Hand-Cutting Faults

    As the workpiece heats up, more dross may form on subsequent cuts.  Worn or damaged consumables may produce intermittent dross. Powermax30 XP Operator Manual 808160...

  • Page 55: Maintenance And Troubleshooting

    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. Powermax30 XP Operator Manual 808160...
  • Page 56 Replace any damaged parts. Inspect the power cord and plug. Inspect the torch lead. Replace if damaged. Replace if damaged. Every 6 months: Clean the inside of the power supply with moisture-free compressed air or a vacuum. Powermax30 XP Operator Manual 808160...

  • Page 57: Inspect The Consumables

    O-ring and the threads. The O-ring should look shiny, but there should not be any excess or built-up lubricant. If the O-ring is cracked or worn, Torch O-ring replace it (428179). Powermax30 XP Operator Manual 808160...

  • Page 58: Basic Troubleshooting

    • 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 26. • Verify nothing else is drawing power on the same circuit. Powermax30 XP Operator Manual 808160...
  • Page 59 • Have an electrical technician check the incoming power. The input line voltage is either too high or too low (a variance greater than ±15% of the rated voltage). See Hypertherm system ratings on page 17 and Prepare the electrical power on page 23.
  • Page 60 • 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 26. • Verify nothing else is drawing power on the same circuit. Powermax30 XP Operator Manual 808160...

  • Page 61: Maintenance Procedures

    You can also use this procedure to replace the plastic retaining nut on the air filter/regulator assembly. Refer to Air filter/regulator with pressure switch assembly (interior, fan side) on page 68 for the Hypertherm kit numbers needed to order these replacement parts.

  • Page 62: Remove The Old Air Filter Element And Air Filter Bowl

    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 63. Powermax30 XP Operator Manual 808160...

  • Page 63: Install The New Air Filter Element And Air Filter Bowl

    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.  Parts life can shorten. Powermax30 XP Operator Manual 808160...

  • Page 64: Put The Power Supply Cover And Handle Back In Place

    5. Reinstall the two screws that secure the cover and handle with a torque setting of 23.0 kg-cm (20 inch-pounds). 6. Reconnect the electrical power, and turn ON the power supply. Powermax30 XP Operator Manual 808160...

  • Page 65: Parts

    Section 6 Parts Use the Hypertherm kit and part numbers in this section to order replacement parts, consumables, and accessories for your Powermax30 XP power supply and Duramax LT hand torch. For instructions on installing the air filter element and the air filter bowl in the power supply, refer to Maintenance procedures on page 61.

  • Page 66: Power Supply Parts

    Kit: Power supply cover with labels, CE 428225 Kit: Power supply cover with labels, CCC 228099 Kit: Handle with screws 228561 Kit: Ground clamp 428239 Kit: Work lead, 4.6 m (15 feet), with ground clamp Powermax30 XP Operator Manual 808160...

  • Page 67: Exterior, Rear

    CSA power cord extension: 240 V / 20 A plug adapter 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 feet) (plug not included) 228143 Kit: Power cord strain relief Powermax30 XP Operator Manual 808160...

  • Page 68: Air Filter/Regulator With Pressure Switch Assembly (Interior, Fan Side)

    6 – Parts Air filter/regulator with pressure switch assembly (interior, fan side) Item Kit number Description 428262 Kit: Air filter retaining nut 428237 Kit: Air filter element 428246 Kit: Air filter bowl (with O-ring) Powermax30 XP Operator Manual 808160...

  • Page 69: Duramax Lt Hand Torch Parts

    Kit: Duramax LT torch lead, 4.6 m (15 feet), with strain relief * The torch assembly includes one set of general-purpose (standard) consumables:  Electrode (420120)  Swirl ring (420211)  Retaining cap (420114)  Nozzle (420118)  Shield (420116) Powermax30 XP Operator Manual 808160...

  • Page 70: Duramax Lt Hand Torch Consumables

    FineCut nozzle with the shield. General-purpose (standard) consumables 420211 420120 420118 420114 420116 428243 Swirl ring Electrode Nozzle Retaining cap Shield FineCut consumables 420211 420120 420117 420114 420115 428244 Swirl ring Electrode Nozzle Retaining cap Deflector Powermax30 XP Operator Manual 808160...

  • Page 71: Hyaccess Consumables

    2 HyAccess electrodes  1 HyAccess cutting nozzle  1 HyAccess gouging nozzle  1 swirl ring  1 HyAccess retaining cap  The standard Powermax30 XP swirl ring is compatible with the HyAccess consumables. Powermax30 XP Operator Manual 808160...

  • Page 72: Accessory Parts

    Carrying case 428337 Kit: HyAccess consumables starter kit 024548 Leather torch lead cover, brown, 7.6 m (25 feet) 024877 Leather torch lead cover, black with Hypertherm logo, 7.6 m (25 feet) 127217 Shoulder strap 128647 Kit: Eliminizer air filtration 127169...

  • Page 73: Powermax30 Xp Labels

    6 – Parts Powermax30 XP labels Kit number Description 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: ...

  • Page 74: Powermax30 Xp Operator Manual

    6 – Parts Powermax30 XP Operator Manual 808160...

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