Hypertherm POWERMAX 45 Operator's Manual
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Hypertherm POWERMAX 45 Operator's Manual

Plasma arc cutting system
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Plasma arc cutting system
Operator Manual – 805780
Revision 2

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  • Page 1 Plasma arc cutting system Operator Manual – 805780 Revision 2...
  • Page 2 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:________________________________________________________________...
  • Page 3 (P/N 805780) Revision 2 – April, 2013 Hypertherm, Inc. Hanover, NH USA www.hypertherm.com © Copyright 2013 Hypertherm, Inc. All Rights Reserved Hypertherm and powermax are trademarks of Hypertherm, Inc. and may be registered in the United States and/or other countries.
  • Page 4 55 11 2409 2636 Tel Hypertherm (S) Pte Ltd. 55 11 2408 0462 Fax 82 Genting Lane Media Centre Hypertherm México, S.A. de C.V. Avenida Toluca No. 444, Anexo 1, Annexe Block #A01-01 Singapore 349567, Republic of Singapore Colonia Olivar de los Padres 65 6841 2489 Tel Delegación Álvaro Obregón...

  • Page 5: Safety Information

    Safety information Before operating any Hypertherm equipment, read the separate Safety and Compliance Manual (80669C) included with your product for important safety information.

  • Page 7: Table Of Contents

    TAble Of CONTeNTS eleCTROMAgNeTIC COMPATIbIlITy (eMC) .......................eMC-1 WARRANTy ....................................W-1 SeCTION 1 SPeCIfICATIONS System description ....................................1-2 Where to find information ..................................1-2 Power supply dimensions and weights ..............................1-3 Dimensions .......................................1-3 Weights ......................................1-3 Power supply ratings ....................................1-4 T45v torch dimensions .....................................1-5 T45m torch dimensions ....................................1-5 T45v and T45m torch specifications ..............................1-6 Symbols and marks ....................................1-7 IEC symbols ........................................1-8...
  • Page 8 Table of ConTenTs Prepare the gas supply .....................................2-6 Connect the gas supply .................................2-7 Additional gas filtration ...................................2-7 SeCTION 3 TORCH SeTUP Introduction .........................................3-2 Consumable life ......................................3-2 Hand torch setup .......................................3-2 Choose the consumables ................................3-3 Install the consumables ..................................3-5 Machine torch setup....................................3-6 Mount the torch ....................................3-6 Choose the consumables (cut charts) ............................3-8 Using the cut charts ..................................3-8...
  • Page 9 Table of ConTenTs How to use the machine torch ................................4-12 Ensure the torch and table are set up correctly ........................4-12 Understand and optimize cut quality ............................4-13 To pierce a workpiece using the machine torch ........................4-14 Common machine-cutting faults ............................... 4-15 SeCTION 5 MAINTeNANCe ANd RePAIR Perform routine maintenance ..................................5-2...
  • Page 10 Table of ConTenTs powermax Operator Manual...

  • Page 11: Electromagnetic Compatibility (Emc)

    Introduction a. Other supply cables, control cables, signaling and telephone cables; above, below and adjacent to the Hypertherm’s CE-marked equipment is built in compliance cutting equipment. with standard EN60974-10. The equipment should be installed and used in accordance with the information b.

  • Page 12: Electromagnetic Compatibility

    ELECTROMAGNETIC COMPATIBILITY earthing of the workpiece Consideration should be given to shielding the supply cable of permanently installed cutting equipment, Where the workpiece is not bonded to earth for in metallic conduit or equivalent. Shielding should electrical safety, nor connected to earth because of its be electrically continuous throughout its length.

  • Page 13: Warranty

    Products or as to Hypertherm is notified of a defect (i) with respect to the the results which may be obtained therefrom, and plasma...

  • Page 14: Patent Indemnity

    Products exceed in the aggregate the amount the use of the Hypertherm product, alone and not in paid for the Products that gave rise to such claim. combination with any other product not supplied by Hypertherm, infringes any patent of any third party.

  • Page 15: Specifications

    Section 1 SPeCIfICATIONS In this section: System description ....................................1-2 Where to find information ..................................1-2 Power supply dimensions and weights ..............................1-3 Dimensions .......................................1-3 Weights ......................................1-3 Power supply ratings ....................................1-4 T45v torch dimensions .....................................1-5 T45m torch dimensions ....................................1-5 T45v and T45m torch specifications ..............................1-6 Symbols and marks ....................................1-7 IEC symbols ........................................1-8 powermax...

  • Page 16: System Description

    Operator Manual, a Quick Setup Card, and a Setup DVD. Mechanized configurations include a remote-start pendant as well. You can order additional consumables and accessories – such as the plasma cutting guide – from any Hypertherm distributor. See the Parts section for a list of spare and optional parts.

  • Page 17: Power Supply Dimensions And Weights

    SpecificationS Power supply dimensions and weights dimensions 34.8 cm (13.7 in) 31 cm (12.19 in) 17.2 cm 42.6 cm (16.75 in) (6.75 in) Weights Power supply weights given below include the hand torch with 6.1 m (20 ft) lead, a 6.1 m (20 ft) work lead, and a 3 m (10 ft) power cord.

  • Page 18: Power Supply Ratings

    SpecificationS Power supply ratings Rated open-circuit voltage (U CSA/CE, single-phase 275 VDC (CSA/CE single-phase) CE, 3-phase 275 VDC (CE 3-phase) CSA, 3-phase 278 VDC (CSA 3-phase) Rated output current (I 20 A to 45 A Rated output voltage (U 132 VDC Duty cycle at 40° C 50% (I =45 A, U =132 V)

  • Page 19: T45V Torch Dimensions

    SpecificationS T45v torch dimensions 22.1 cm (8.72 in) 21.6 cm (8.5 in) 4.0 cm (1.58 in) 8.3 cm (3.28 in) 4.9 cm (1.91 in) 2.5 cm (1 in) T45m torch dimensions 36.5 cm (14.36 in) (30.5 cm) 2.5 cm 3.6 cm (1.43 in) outer dimension, 12 in (1 in) 3.3 cm (1.3 in) flat sides...

  • Page 20: T45V And T45M Torch Specifications

    SpecificationS T45v and T45m torch specifications Handheld cut capacity (material thickness) Recommended cut capacity (hand cutting) 12.7 mm (1/2 in) Maximum cut capacity (hand cutting or mechanized 19.1 mm (3/4 in) edge start) Severance capacity (hand cutting or mechanized edge start) 25.4 mm (1 in) Mechanized pierce capacity (material thickness) Pierce capacity (for edge starts, the capacities are the same as the handheld...

  • Page 21: Symbols And Marks

    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.

  • Page 22: Iec Symbols

    SpecificationS IeC symbols The following symbols may appear on the power supply data plate, control labels, switches, and LEDs. Power is ON Direct current (DC) Power is OFF Alternating current (AC) An inverter-based power source, either 1-phase or Plasma torch cutting 3-phase Volt/amp curve, “drooping”...

  • Page 23: Power Supply Setup

    Section 2 POWeR SUPPly SeTUP In this section: Unpack the Powermax45 ..................................2-2 Claims ........................................2-2 Contents ......................................2-2 Position the power supply..................................2-3 Prepare the electrical power ...................................2-3 Voltage configurations ..................................2-3 Install a line-disconnect switch ..............................2-4 Requirements for grounding .................................2-4 Power cord considerations ..................................2-4 Extension cord recommendations ...............................2-5 Generator recommendations ................................2-6 Prepare the gas supply .....................................2-6...

  • Page 24: Unpack The Powermax45

    •    C laims for damage during shipment – If your unit was damaged during shipment, you must file a claim with the carrier. Hypertherm will furnish you with a copy of the bill of lading upon request. If you need additional assistance, call the nearest Hypertherm office listed in the front of this manual.

  • Page 25: Position The Power Supply

    power supply setup Position the power supply Locate the Powermax45 near an appropriate 200–240 volt power receptacle for CSA or CE 1-phase power supplies, a 400 volt receptacle for 3-phase CE power supplies, or a 480 volt receptacle for 3-phase CSA power supplies. The Powermax45 has a 3 m (10-foot) power cord.

  • Page 26: Install A Line-Disconnect Switch

    Power suPPly setuP Install a line-disconnect switch Use a line-disconnect switch for each power supply so that the operator can turn off the incoming power quickly in an emergency. Locate the switch so that it is easily accessible to the operator. Installation must be performed by a licensed electrician according to national and local codes.

  • Page 27: Extension Cord Recommendations

    power supply setup extension cord recommendations Use an extension cord of an appropriate wire size for the cord length and system voltage. Use a cord that meets national and local codes. The following tables provide the recommended gauge size for various lengths and input voltages. The lengths in the tables are the length of the extension cord only;...

  • Page 28: Generator Recommendations

    Power suPPly setuP generator recommendations Generators used with the Powermax45 should satisfy the following requirements: •  1-phase, 50/60 Hz, 230/240 VAC •  3-phase, 50/60 Hz, 480 VAC •  1-phase, 50/60 Hz, 230 VAC •  3-phase, 50/60 Hz, 380/400 VAC (400 VAC recommended for best performance) engine drive output current engine Performance 1-phase 3-phase...

  • Page 29: Connect The Gas Supply

    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 shown below to clean contaminants from the gas supply.
  • Page 30 Power suPPly setuP powermax 45 Operator Manual...
  • Page 31 Section 3 TORCH SeTUP In this section: Introduction .........................................3-2 Consumable life ......................................3-2 Hand torch setup .......................................3-2 Choose the consumables ................................3-3 Install the consumables ..................................3-5 Machine torch setup....................................3-6 Mount the torch ....................................3-6 Choose the consumables (cut charts) ............................3-8 Using the cut charts ..................................3-8 T45m shielded consumables ................................3-8 Align the torch ....................................

  • Page 32: Torch Setup Introduction

    torch setup Introduction Both the T45v hand torch and the T45m machine torch are available for the Powermax45. The torch FastConnect™ system makes it easy to remove the torch for transport or to switch from one torch to the other if your applications require the use of both torches.

  • Page 33: Choose The Consumables

    Only the shield (deflector for unshielded consumables) and the nozzle are different. For the best cut quality on thin gauge stainless steel, you may prefer to reduce the amperage setting to 30 amps and use the T30v (Powermax30) 30 A consumables available from Hypertherm. T45v shielded consumables 220674...
  • Page 34 torch setup T45v unshielded consumables* 220717 220713 220670 220669 220718 Deflector Retaining cap Swirl ring Electrode Nozzle * Unshielded consumables are not available for use in CE-regulated countries. T30v (Powermax30) 30 A consumables 220569 220483 220480 220479 220478 Retaining cap Nozzle Optional deflector Swirl ring...

  • Page 35: Install The Consumables

    torch setup Install the consumables WARNINg INSTANT-ON TORCHeS PlASMA ARC CAN CAUSe INJURy ANd bURNS The plasma arc comes on im me di ate ly when the torch trigger is activated. Make sure the power is Off before changing consumables. To operate the T45v torch, it must have a complete set of consumable parts installed: a shield or deflector, retaining cap, nozzle, swirl ring and electrode.

  • Page 36: Machine Torch Setup

    torch setup Machine torch setup Consumables Positioning sleeve Gear rack Strain relief Brass strain relief Before using the T45m, you must: •    M ount the torch on your cutting table or other equipment. •    C hoose and install the consumables. •    A lign the torch. •    A ttach the torch lead to the power supply. •    S et up the power supply for remote starting with either the remote-start pendant or a machine interface cable. Mount the torch Depending on the type of cutting table you have, you may or may not need to disassemble the torch to route it through the track and mount it.
  • Page 37 torch setup Disconnect the wires for the cap-sensor switch at the connector in the middle. Gas supply line connection Cap-sensor switch’s wire connector Screw to connect the power cable to the plunger Use a #2 Phillips screwdriver and a 6 mm (1/4 inch) nut driver (or adjustable wrench) to remove the screw and nut that secure the torch’s power cable to the plunger.

  • Page 38: Choose The Consumables (Cut Charts)

    torch setup Choose the consumables (cut charts) WARNINg INSTANT-ON TORCHeS PlASMA ARC CAN CAUSe INJURy ANd bURNS The plasma arc comes on im me di ate ly when the torch trigger is activated. Make sure the power is Off before changing consumables. A complete set of shielded consumables is shipped with the T45m machine torch.
  • Page 39 torch setup T45m shielded consumables Air flowrate (lpm) Mild steel Metric Cold 165.2 Recommended Maximum Torch- Material Pierce time to-work Initial pierce Cut Speed Voltage Cut Speed Voltage current thickness delay distance height (mm/min) (mm/min) (amps) (mm) (sec) (mm) 9150 10160* 8650 10160*...
  • Page 40 torch setup T45m shielded consumables Air flowrate (scfh) Mild steel english Cold Recommended Maximum Torch- Pierce time Material to-work Initial pierce Cut Speed Voltage Cut Speed Voltage current delay thickness distance height (ipm) (ipm) (amps) (sec) (in) 0.018 in 400* (26 Ga) 0.030 in 400*...
  • Page 41 torch setup T45m shielded consumables Air flowrate ( Stainless steel Metric Cold 165.2 Recommended Maximum Torch- Material Pierce time to-work Initial pierce Cut Speed Voltage Cut Speed Voltage current thickness delay distance height (mm/min) (mm/min) (amps) (mm) (sec) (mm) 9150 10160* 8650 10160*...
  • Page 42 torch setup T45m shielded consumables Air flowrate (scfh) Stainless steel english Cold Recommended Maximum Torch- Pierce time Material to-work Initial pierce Voltage Voltage current delay Speed Speed thickness distance height (amps) (sec) (ipm) (ipm) (in) 0.018 in 400* (26 Ga) 0.030 in 400* (22 Ga)
  • Page 43 torch setup T45m shielded consumables Air flowrate (lpm) Aluminum Metric Cold 165.2 Recommended Maximum Torch- Material Pierce time to-work Initial pierce Cut Speed Voltage Cut Speed Voltage current thickness delay distance height (mm/min) (mm/min) (amps) (mm) (sec) (mm) 9150 10160* 3.8 mm 250% 8650...
  • Page 44 torch setup T45m shielded consumables Air flowrate (scfh) Aluminum english Cold Recommended Maximum Torch- Pierce time Material to-work Initial pierce Voltage Voltage current delay Speed Speed thickness distance height (amps) (sec) (ipm) (ipm) (in) 0.018 in 400* (26 Ga) 0.060 in 0.06 0.15 in 250%...
  • Page 45 torch setup T45m unshielded consumables 220717 220713 220718 220670 220669 Deflector Retaining cap Nozzle Swirl ring Electrode Mild steel Air flowrate (lpm) Metric Cold 165.2 Recommended Maximum Torch- Material Pierce time to-work Initial pierce Cut Speed Voltage Cut Speed Voltage current thickness delay...
  • Page 46 torch setup T45m unshielded consumables Air flowrate (scfh) Mild steel english Cold Recommended Maximum Torch- Pierce time Material to-work Initial pierce Voltage Voltage current delay Speed Speed thickness distance height (amps) (sec) (ipm) (ipm) (in) 0.018 in 400* (26 Ga) 0.030 in 400* (22 Ga)
  • Page 47 torch setup T45m unshielded consumables Air flowrate (lpm) Stainless steel Metric Cold 165.2 Recommended Maximum Torch- Material Pierce time to-work Initial pierce Cut Speed Voltage Cut Speed Voltage current thickness delay distance height (mm/min) (mm/min) (amps) (mm) (sec) (mm) 9144 10160* 8128 10160*...
  • Page 48 torch setup T45m unshielded consumables Air flowrate (scfh) Stainless steel english Cold Recommended Maximum Torch- Pierce time Material to-work Initial pierce Cut Speed Voltage Cut Speed Voltage current delay thickness distance height (ipm) (ipm) (amps) (sec) (in) 0.018 in 400* 400* (26 Ga) 0.030 in...
  • Page 49 torch setup T45m unshielded consumables Air flowrate (lpm) Aluminum Metric Cold 165.2 Recommended Maximum Torch- Material Pierce time to-work Initial pierce Cut Speed Voltage Cut Speed Voltage current thickness delay distance height (mm/min) (mm/min) (amps) (mm) (sec) (mm) 8900 10160* 5.0 mm 250% 8100...
  • Page 50 torch setup T45m unshielded consumables Air flowrate (scfh) Aluminum english Cold Recommended Maximum Torch- Pierce time Material to-work Initial pierce Voltage Voltage current delay Speed Speed thickness distance height (amps) (sec) (ipm) (ipm) (in) 0.018 in 400* (26 Ga) 0.060 in 0.08 0.20 in 250%...
  • Page 51 torch setup T30v (Powermax30) 30 A consumables 220569 220483 220480 220479 220478 Optional deflector Retaining cap Nozzle Swirl ring Electrode Mild steel Air flowrate (lpm) Metric 131.2 Cold 146.3 Recommended Maximum Torch- Material Pierce time to-work Initial pierce Cut Speed Voltage Cut Speed Voltage current...
  • Page 52 torch setup T30v (Powermax30) 30 A consumables Air flowrate (scfh) Mild steel english Cold Recommended Maximum Torch- Material Pierce time to-work Initial pierce Cut Speed Voltage Cut Speed Voltage current thickness delay distance height (ipm) (ipm) (amps) (in) (sec) (in) 0.018 400* (26 Ga) 0.030...
  • Page 53 torch setup T30v (Powermax30) 30 A consumables Air flowrate (scfh) Stainless steel english Cold Recommended Maximum Torch- Material Pierce time to-work Initial pierce Cut Speed Voltage Cut Speed Voltage current thickness delay distance height (ipm) (ipm) (amps) (in) (sec) (in) 0.018 400* (26 Ga) 0.030...

  • Page 54: Align The Torch

    torch setup T30v (Powermax30) 30 A consumables Air flowrate (scfh) Aluminum english Cold Recommended Maximum Torch- Material Pierce time to-work Initial pierce Cut Speed Voltage Cut Speed Voltage current thickness delay distance height (ipm) (ipm) (amps) (in) (sec) (in) 0.036 400* (20 Ga) 0.060 (16 Ga)

  • Page 55: Connect The Remote-Start Pendant

    Connect the remote-start pendant Configurations of a Powermax45 with a T45m also can include a 7.62 m / 25-foot (128650), 15.24 m / 50-foot (128651), or 22.86 m / 75-foot (128652) remote-start pendant. To use the Hypertherm remote-start pendant, plug it into the receptacle on the rear of the power supply.
  • Page 56 Verify that the connections are correct and that all live parts are enclosed and protected before operating the equipment. Note: The integration of Hypertherm equipment and customer-supplied equipment including interconnecting cords and cables, if not listed and certified as a system, is subject to inspection by local authorities at the final installation site.

  • Page 57: Accessing Raw Arc Voltage

    5 (-), 6 (+) Black (-), white (+) maximum of 7 V). Accessing raw arc voltage If you should need to access raw arc voltage, contact your Hypertherm distributor or authorized Hypertherm repair facility for assistance. WARNINg HIgH VOlTAge ANd CURReNT Connecting directly to the plasma circuit for access to raw arc voltage increases the risk of shock hazard, energy hazard, and fire hazard in the event of a single fault.

  • Page 58: Connect The Torch Lead

    torch setup Connect the torch lead The Powermax45 has a FastConnect system for connecting and disconnecting the hand and machine torches. When connecting or disconnecting a torch, first power OFF the system. To connect either torch, push the connector into receptacle on the front of the power supply.

  • Page 59: Operation

    Section 4 OPeRATION In this section: Controls and indicators ....................................4-2 Front controls and LEDs ................................4-2 Rear controls ....................................4-3 Operate the Powermax45 ..................................4-3 Connect the electrical power and gas supply ..........................4-3 Power ON the system ..................................4-4 Set the mode switch ..................................4-4 Adjust the gas pressure .................................4-4 Check the indicator LEDs ................................4-6 Attach the work clamp ...................................4-6...

  • Page 60: Controls And Indicators

    operation Controls and indicators The Powermax45 has an ON/OFF switch, an amperage adjustment knob, a pressure regulator knob, a mode switch, 4 indicator LEDs, and a gas pressure LED, which are described below. front controls and leds Pressure regulator knob Gas pressure LED and pressure bar Indicator LEDs Mode switch AMPS...

  • Page 61: Rear Controls

    operation Amperage adjustment knob Set this knob to the gas test position (fully counter-clockwise) before adjusting the gas pressure with the pressure regulator knob on the top of the power supply. Once the gas pressure is set, turn the knob clockwise to set the output amperage.

  • Page 62: Power On The System

    operation Power ON the system Set the ON/OFF switch to the ON (I) position. 200–240 V CSA / 230 V Ce 400 V Ce / 480 V CSA Set the mode switch Use the mode switch to select the type of work you will be doing: To cut expanded metal or grate (top position).
  • Page 63 operation To adjust the pressure: Turn the amperage knob counter-clockwise to the gas-test position as show below. With the amperage knob in the gas test position, pull up on the pressure regulator knob on top of the system to unlock it. Pressure regulator knob AMPS Turn the pressure regulator knob until the gas pressure LED shows a green bar in the center of the pressure bar.

  • Page 64: Check The Indicator Leds

    operation Check the indicator leds Verify that the green power ON LED on the front of the power supply is illuminated, that the gas pressure LED shows a green bar in the center of the gauge, and that none of the other LEDs are illuminated or blinking. If the temperature, torch cap sensor, or fault LEDs are illuminated or blinking, or if the power ON LED blinks, correct the fault condition before continuing.

  • Page 65: How To Use The Hand Torch

    operation How to use the hand torch WARNINg INSTANT-ON TORCHeS PlASMA ARC CAN CAUSe INJURy ANd bURNS Plasma arc comes on im me di ate ly when the torch trigger is activated. The plasma arc will cut quickly through gloves and skin. • ...

  • Page 66: Start A Cut From The Edge Of The Workpiece

    •    F or 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 the Parts section for part numbers for the Hypertherm plasma cutting guides for cutting circles and making bevel cuts. Start a cut from the edge of the workpiece 1.

  • Page 67: Pierce A Workpiece

    operation 2. Press the torch trigger to start the arc. Pause at the edge until the arc has cut completely through the workpiece. 3. Drag the nozzle lightly across the workpiece to proceed with the cut. Maintain a steady, even pace. Pierce a workpiece WARNINg SPARKS AND HOT METAL CAN INJURE EYES AND BURN SKIN. When firing the ...

  • Page 68: Gouge A Workpiece

    operation 3. Hold the torch in place while continuing to press the trigger. When sparks exit from the bottom of the workpiece, the arc has pierced the material. 4. When the pierce is complete, drag the nozzle lightly along the workpiece to proceed with the cut. gouge a workpiece WARNINg SPARKS AND HOT METAL CAN INJURE EYES AND BURN SKIN. When firing the ...
  • Page 69 operation 3. Maintain an approximate 45° angle to the workpiece as you feed into the gouge. In other words, push the plasma arc in the direction of the gouge you want to create. Keep a small distance between the torch tip and the molten metal to avoid reducing consumable life or damaging the torch.

  • Page 70: Common Hand-Cutting Faults

    operation Common hand-cutting faults The torch sputters and hisses, but does not produce an arc. The cause can be: •    T he consumables are too tight. Loosen the consumables about 1/8th of a turn and try again. Never tighten the  consumables beyond just finger-tight. The torch does not cut completely through the workpiece. The causes can be: • ...

  • Page 71: Understand And Optimize Cut Quality

    operation Understand and optimize cut quality There are several factors to consider in cut quality: •    C ut angle – The degree of angularity of the cut edge. •    D ross – The molten material that solidifies on the top or bottom of the workpiece. •    S traightness of the cut surface – The cut surface can be concave or convex. The following sections explain how these factors can affect cut quality. Cut or bevel angle • ...

  • Page 72: To Pierce A Workpiece Using The Machine Torch

    operation 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 is welded to the bottom of the cut and is difficult to remove. To reduce high-speed dross: • ...

  • Page 73: Common Machine-Cutting Faults

    operation Common machine-cutting faults The torch pilot arc will initiate, but will not transfer. Causes can be: •    T he work cables connection on the cutting table is not making good contact or the table is not properly grounded. •    T he torch-to-work distance is too great. The workpiece is not totally penetrated, and there is excessive sparking on the top of the workpiece. Causes can be: • ...
  • Page 74 operation powermax 45 Operator Manual 4-16...

  • Page 75: Maintenance And Repair

    Section 5 MAINTeNANCe ANd RePAIR In this section: Perform routine maintenance ..................................5-2 Inspect the consumables ..................................5-3 Basic troubleshooting ....................................5-4 Repairs .........................................5-6 Remove and replace the cover and Mylar barrier ........................5-6 ® Replace the work lead (CSA and CE) ............................5-7 Replace the gas filter element ..............................5-8 powermax 45 Operator Manual...

  • Page 76: Perform Routine Maintenance

    Maintenance and RepaiR Perform routine maintenance dANgeR ELECTRIC SHOCK CAN KILL disconnect electrical power before performing any maintenance. All work requiring removal of the power supply cover must be performed by a qualified technician. every use: Check the indicator lights and correct any fault conditions.

  • Page 77: Inspect The Consumables

    Maintenance and RepaiR Inspect the consumables Part Inspect Action Replace the shield if the hole is no longer The center hole for roundness. round. The gap between the shield and the Remove the shield and clean any material nozzle for accumulated debris. away.

  • Page 78: Basic Troubleshooting

    If you are unable to fix the problem by following this basic troubleshooting guide or if you need further assistance: Call your Hypertherm distributor or authorized Hypertherm repair facility. Call the nearest Hypertherm office listed in the front of this manual. Problem...
  • Page 79 ON the power supply to clear this fault. See Install the consumables in the Torch Setup section. •    I f the consumables appear to be installed correctly, the torch  may be damaged. Contact your Hypertherm distributor or authorized repair facility. The fault LED blinks.

  • Page 80: Repairs

    Maintenance and RepaiR Repairs dANgeR ELECTRIC SHOCK CAN KILL disconnect electrical power before performing any maintenance. All work requiring removal of the power supply cover must be performed by a qualified technician. Remove and replace the cover and Mylar barrier ® The first step in most maintenance and repair procedures for the Powermax45 is removing the cover and the Mylar barrier.

  • Page 81: Replace The Work Lead (Csa And Ce)

    Maintenance and RepaiR Replacement Hold the Mylar barrier so that the edge with the Three Four 3 notches is on the left and the edge with 4 notches is notches notches on the right. There is a perforation across the top, about 4.45 cm (1.75 inches) down from the top edge.

  • Page 82: Replace The Gas Filter Element

    Maintenance and RepaiR Front panel Work lead TP 19 TP 18 TP 17 192 VDC 192 VDC Strain relief Work lead connection to power board (J21) Thread the connector end of the new work lead through the front panel and fit the strain relief into the hole in the panel.
  • Page 83 Maintenance and RepaiR Unscrew the drain from the bottom of the filter. (You may want to remove the hose to make this easier.) Unscrew the filter bowl from the body and remove it. Gas supply hose Bracket Filter bowl Drain Drain hose Remove the glass filter tube by twisting it and pulling gently until it releases.
  • Page 84 Maintenance and RepaiR powermax 5-10 45 Operator Manual...

  • Page 85: Parts

    Section 6 PARTS In this section: Power supply parts ....................................6-2 T45v hand torch parts....................................6-5 T45v hand torch consumables ..............................6-6 T30v (Powermax30) 30 A consumables ...........................6-6 T45m machine torch parts ..................................6-7 T45m machine torch consumables .............................6-8 Accessory parts......................................6-8 Powermax45 labels ....................................6-9 powermax 45 Operator Manual...

  • Page 86: Power Supply Parts

    PARTS Power supply parts Item Part number description 228269 Kit: Front panel 228268 Kit: Rear panel 228270 Kit: Cover screws (not shown) 228267 Kit: Powermax45 handle and screws 228281 Kit: Power supply cover with labels, 200–240 V CSA 228283 Kit: Power supply cover with labels, CE 428076 Kit: Power supply cover with labels (Built in America), 480 V CSA 228300...
  • Page 87 Parts Power cord Receptacle for machine interface cable or remote start pendant Part number description 228278 Kit: CSA power cord, 1-phase, 200–240 V, 3 m (10 ft) 228277 Kit: CE power cord, 1-phase, 230 V, 3 m (10 ft) 228276 Kit: CE power cord, 3-phase, 400 V, 3 m (10 ft) 428077 Kit: CSA power cord, 3-phase, 480 V, 3 m (10 ft) 023206...
  • Page 88 PARTS Item Part number description 228287 Kit: Filter regulator 228302 Kit: Air filter element 228286 Kit: Fan assembly powermax 45 Operator Manual...

  • Page 89: T45V Hand Torch Parts

    Parts T45v hand torch parts The entire hand torch and lead assembly can be replaced, or individual component parts can be replaced. Part numbers starting with 088 indicate complete torch and lead assemblies. Item Part number description 088008* T45v hand torch assembly with 6.1 m (20 ft) lead 088009* T45v hand torch assembly with 15.24 m (50 ft) lead 228313...

  • Page 90: T45V Hand Torch Consumables

    PARTS T45v hand torch consumables Part number description Shielded 220669 Electrode 220670 Swirl ring 220713 Retaining cap 220671 Nozzle 220674 Shield gouging* 220675 Shield 220672 Nozzle Unshielded* 220717 Deflector 220718 Nozzle * The swirl ring, retaining cap, and electrode for these applications are the same as those for the shielded application. Unshielded consumables for the hand torch are not available in CE-regulated countries.

  • Page 91: T45M Machine Torch Parts

    Parts T45m machine torch parts 8 9 10 The entire machine torch and lead assembly can be replaced, or individual component parts can be replaced. Part numbers starting with 088 indicate complete torch and lead assemblies. Item Part number description 088010* T45m machine torch assembly with 7.62 m (25 ft) lead 088011*...

  • Page 92: T45M Machine Torch Consumables

    PARTS T45m machine torch consumables Part number description Shielded 220669 Electrode 220670 Swirl ring 220713 Retaining cap 220719 Ohmic sensing retaining cap 220671 Nozzle 220673 Shield Unshielded* 220717 Deflector 220718 Nozzle * The swirl ring, retaining cap, and electrode for the unshielded application are the same as those for the shielded application.

  • Page 93: Powermax45 Labels

    Consulter le manuel avant de faire fonctionner. Le non respect 110647 Rev. B to follow all these safety instructions can result in death. www.hypertherm.com/weee Standards, 29 CFR 1910 (http://www.osha.gov). des ces instructions de sécurité peut entraîner la mort. 1. les étincelles de coupage peuvent provoquer 1.

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