Hypertherm Powermax30 AIR Operator's Manual
Plasma arc cutting system with integrated air compressor
Hide thumbs
Also See for Powermax30 AIR:
- Service manual (223 pages) ,
- Operator's manual (98 pages) ,
- Field service bulletin (26 pages)
Related Manuals for Hypertherm Powermax30 AIR
Summary of Contents for Hypertherm Powermax30 AIR
- Page 1 Powermax30 AIR ® Plasma Arc Cutting System with Integrated Air Compressor Operator Manual 808840 | Revision 1 | English...
- Page 2 Maintenance notes: ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ Powermax 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: Operator Manual
Powermax30 AIR Operator Manual 808840 Revision 1 English February 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-14 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 AIR Operator Manual 808840... - Page 8 Hand torch components ..............................31 Consumable life .................................... 32 Consumable use ................................... 33 Using the cut charts ................................33 Consumable set ..................................34 240 V / 30 A cutting ..............................35 120 V / 20 A cutting ..............................37 Powermax30 AIR Operator Manual 808840...
- Page 9 Hand torch cutting guidelines ............................49 Recommendations for cutting at 120 V ........................49 Edge start on a workpiece ..............................50 Pierce a workpiece ................................51 Common hand-cutting faults .............................. 52 Minimizing dross ................................52 Powermax30 AIR Operator Manual 808840...
- Page 10 Exterior, front ..................................62 Exterior, rear ................................... 63 Hand torch consumables ................................64 Accessory parts .................................... 65 Power supply labels ..................................66 Consumables label ................................66 CSA warning label ................................67 CE warning label ................................... 68 Powermax30 AIR Operator Manual 808840...
-
Page 11: Electromagnetic Compatibility (Emc
Other supply cables, control cables, signaling and telephone cables; above, below and adjacent to the cutting equipment. Hypertherm’s CE-marked equipment is built in compliance with standard EN60974-10. The equipment should be b. Radio and television transmitters and receivers. installed and used in accordance with the information c. -
Page 12: Maintenance Of Cutting Equipment
Electromagnetic Compatibility (EMC) Maintenance of cutting equipment Earthing of the workpiece Where the workpiece is not bonded to earth for electrical The cutting equipment must be routinely maintained safety, nor connected to earth because of its size and according to the manufacturer’s recommendations. All position, for example, ship’s hull or building steel work, a access and service doors and covers should be closed connection bonding the workpiece to earth may reduce... -
Page 13: Warranty
Hypertherm is notified of a defect (i) with respect to the particular purpose or against infringement. The foregoing plasma power supply within a period of two (2) years from... -
Page 14: Patent Indemnity
(14) days after learning of any action or threat of action), appropriate to defend and to hold Hypertherm harmless in and Hypertherm’s obligation to defend shall be the event of any cause of action arising from the use of the conditioned upon Hypertherm’s sole control of, and the... -
Page 15: Specifications
System description The Powermax30 AIR is a 30 A handheld plasma cutting system that contains its own internal air compressor for maximum portability and ease of use. With it, you can 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 a dust cover and circle cutting guides, for example – from any Hypertherm distributor. See Parts on page 61 for a list of spare and optional parts. Power supply dimensions 333 mm (13.1 inches) -
Page 17: Hypertherm System Ratings
There may be potential difficulties in ensuring electromagnetic compatibility in those locations, due to conducted as well as radiated disturbances. † This product meets the technical requirements of IEC 61000-3-2 and IEC 61000-3-3 and is not subject to conditional connection. Powermax30 AIR Operator Manual 808840... -
Page 18: Torch Dimensions
25 mm (1.0 inch) Torch weight Air T30 torch with consumables only: 0.3 kg (0.65 pounds) Air T30 torch with consumables and 4.6 m (15 foot) lead (with strain relief): 1.0 kg (2.25 pounds) Powermax30 AIR Operator Manual 808840... -
Page 19: Cutting Specifications
120 V: When you operate the system at the maximum recommended output of 20 A, the cut capacities are: 3 mm (10 gauge) at 762 mm/minute (30 inches/minute) 6 mm (1/4 inch) at 355 mm/minute (14 inches/minute) 10 mm (3/8 inch) at 125 mm/minute (5 inches/minute) Powermax30 AIR Operator Manual 808840... -
Page 20: Iec Symbols
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 www.hypertherm.com: 1. -
Page 21: 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 AIR Operator Manual 808840... - Page 22 1 – Specifications Powermax30 AIR Operator Manual 808840...
-
Page 23: 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 24: System Contents
CSA power cord with power plug adapters Safety and Compliance Manual Power supply Air T30 torch with lead Carrying strap Consumable kit The specific components included with the system are subject to change over time. Powermax30 AIR Operator Manual 808840... -
Page 25: Position The Plasma Cutting System
Hypertherm does not recommend operating this system on a 120 V / 15 A circuit. The Hypertherm rated output is: ... -
Page 26: Powermax30 Air Operator Manual
200 V – 240 V Input current at rated output (30 A × 83 V = 2.5 kW) 16.7 A – 15.0 A Input current at arc stretch 37.5 A Voltage tolerance +10% / -10% Powermax30 AIR Operator Manual 808840... -
Page 27: Requirements For Grounding
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 AIR Operator Manual 808840... -
Page 28: Ce 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 AIR Operator Manual 808840... -
Page 29: 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 AIR Operator Manual 808840... - Page 30 2 – Power Supply Setup Powermax30 AIR Operator Manual 808840...
-
Page 31: Torch Setup
Torch Setup Introduction The Powermax30 AIR includes the Air T30 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 32: Consumable Life
For more information, see Cutting expanded metal on page 43. Hypertherm does not recommend the use of any other consumables in the Air T30 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 33: Consumable Use
The maximum cut speeds listed in the cut charts are the fastest possible speeds to cut metal without regard to cut quality. Adjust the cutting speed for your application to obtain the desired cut quality. Powermax30 AIR Operator Manual 808840... -
Page 34: Consumable Set
Retaining cap Deflector The following consumables are designed specifically for use with the Powermax30 AIR power supply and Air T30 hand torch. They cannot be used with any other Powermax system or torch. Hypertherm does not recommend operating this system on a 120 V / 15 A circuit. -
Page 35: 240 V / 30 A Cutting
* To cut material thicker than 6 mm (1/4 inch) at 240 V, start the torch at the edge of the workpiece. † Maximum cut speed is limited by the test table’s maximum speed (10,160 mm/minute or 400 inches/minute). Powermax30 AIR Operator Manual 808840... - Page 36 * To cut material thicker than 6 mm (1/4 inch) at 240 V, start the torch at the edge of the workpiece. † Maximum cut speed is limited by the test table’s maximum speed (10,160 mm/minute or 400 inches/minute). Powermax30 AIR Operator Manual 808840...
-
Page 37: 120 V / 20 A Cutting
1,245 Mild steel 3,295 2,140 1,270 Stainless steel 5,500 3,610 1,720 Aluminum 1,030 * To cut material thicker than 3 mm (10 gauge) at 120 V, start the torch at the edge of the workpiece. Powermax30 AIR Operator Manual 808840... - Page 38 18 gauge 14 gauge Stainless steel 12 gauge 1/4* 1/32 1/16 Aluminum 1/4* * To cut material thicker than 3 mm (10 gauge) at 120 V, start the torch at the edge of the workpiece. Powermax30 AIR Operator Manual 808840...
-
Page 39: Operation
Operation Controls and indicators Familiarize yourself 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 AIR Operator Manual 808840... -
Page 40: Front Panel Controls And Indicator Led Symbols
Basic troubleshooting on page 56. Amperage adjustment knob – Use this knob to set the output current between 15 A and 30 A. Powermax30 AIR Operator Manual 808840... -
Page 41: Operate The Plasma System
O-rings on the electrode and swirl ring. These consumables are designed specifically for the Powermax30 AIR power supply and Air T30 hand torch. They cannot be used with any other Powermax system or torch. Powermax30 AIR Operator Manual 808840... -
Page 42: Step 2 - Connect The Electrical Power
For information on connecting the proper plug to the power cord, see Power cord considerations on page 27. To understand what cutting capacity to expect based on input voltage, see Consumable use on page 33. For information on electrical requirements for this system, see Power Supply Setup on page 23. Powermax30 AIR Operator Manual 808840... -
Page 43: Step 3 - Adjust The Output Current
Make sure nothing else is drawing power from the circuit. Hypertherm does not recommend operating this system on a 120 V / 15 A circuit. Blue shading Operating the system on a 240 V / 20 A circuit ... -
Page 44: Step 4 - Attach The Ground Clamp
(EMF) and to achieve the best possible cut quality. Do not attach the ground clamp to the portion of the workpiece that you are cutting away. Step 5 – Power ON the system Set the ON/OFF switch to the ON (I) position. Powermax30 AIR Operator Manual 808840... -
Page 45: Step 6 - Check The Indicator Leds
When cutting, you may see a small puddle form underneath the power supply because the system automatically purges excess moisture from the internal compressor. It expels this water through a hole in the bottom of the power supply. Powermax30 AIR Operator Manual 808840... -
Page 46: Understand Duty-Cycle Limitations
Stretching the arc for prolonged periods while cutting can reduce the duty cycle. Stretching the arc requires the power supply to generate a higher voltage output, which can cause it to run hotter and overheat more quickly. Powermax30 AIR Operator Manual 808840... -
Page 47: System Operation Guidelines
When you operate the system at altitudes higher than 2,200 m (7,500 feet) above sea level, you may experience some reduction in cutting performance due to the adverse effect that altitude has on the internal air compressor. Powermax30 AIR Operator Manual 808840... -
Page 48: Hand Torch Operation
The 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 pull the red torch trigger. Powermax30 AIR Operator Manual 808840... -
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 65 for the Hypertherm plasma cutting guide part numbers for cutting circles and making bevel cuts. -
Page 50: Edge Start On A Workpiece
2. Pull 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 AIR Operator Manual 808840... -
Page 51: Pierce A Workpiece
4. Hold the torch in place while continuing to pull the trigger. When sparks exit from the bottom of the workpiece, the arc has pierced the metal. 5. When the pierce is complete, drag the torch lightly along the workpiece to proceed with the cut. Powermax30 AIR Operator Manual 808840... -
Page 52: 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 AIR Operator Manual 808840... -
Page 53: 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 AIR Operator Manual 808840... - Page 54 Replace any damaged labels. Inspect the trigger for damage. Inspect the torch body for cracks and exposed wires. Replace any damaged parts. Inspect the power cord and plug. Inspect the torch lead. Replace if damaged. Replace if damaged. Powermax30 AIR Operator Manual 808840...
-
Page 55: 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. Powermax30 AIR Operator Manual 808840... -
Page 56: Basic Troubleshooting
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 25. -
Page 57: Temperature Led Faults
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 29. Make sure nothing else is drawing power on the same circuit. Powermax30 AIR Operator Manual 808840... -
Page 58: Internal Compressor Led Faults
The internal compressor LED and the temperature LED blink alternately when the machine is powered ON. Release the trigger and restart the power supply. The system automatically disables itself when the power supply is turned on while the torch trigger is pulled. Powermax30 AIR Operator Manual 808840... -
Page 59: Torch Led Faults
LEDs blink, and the torch cap LED illuminates. Install new consumables in the torch (they may be corroded or approaching end of life). If you continue to see this error, contact your Hypertherm distributor or authorized repair facility. Powermax30 AIR Operator Manual 808840... -
Page 60: Common Cutting Issues
5 times in succession. trigger is pulled again, or • If the problem persists, inspect and replace the consumable parts if they the arc sputters and are worn or damaged. See Inspect the consumables on page 55. hisses. Powermax30 AIR Operator Manual 808840... -
Page 61: Parts
This system contains no customer serviceable parts inside the power supply or inside the hand torch. For assistance with repairing or replacing internal components: 1. Call your Hypertherm distributor or authorized Hypertherm repair facility. 2. Call the nearest Hypertherm office listed in the front of this manual. Powermax30 AIR Operator Manual 808840... -
Page 62: Power Supply Parts
6 – Parts Power supply parts Exterior, front Item Kit number Description 228267 Kit: Power supply handle (includes screws and shoulder strap clips) 428226 Kit: Current adjustment knob 228561 Kit: Ground clamp Powermax30 AIR Operator Manual 808840... -
Page 63: Exterior, Rear
CSA power cord extension: 240 V / 20 A plug adapter 229132 CSA power cord extension: 120 V / 15 A plug adapter 428392 Kit: Replacement bumpers (rubber “feet”) for bottom of power supply (4) (not shown) Powermax30 AIR Operator Manual 808840... -
Page 64: Hand Torch Consumables
Use 428350 to order a kit of 2 nozzles and 2 electrodes. These consumables are designed specifically for use with the Powermax30 AIR power supply and Air T30 hand torch. They cannot be used with any other Powermax system or torch. -
Page 65: Accessory Parts
Deluxe plasma (circle) cutting guide 127144 Dust cover 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 127169 Leather cutting gloves 127416 Protective glasses, shade 5 lens... -
Page 66: Power Supply Labels
6 – Parts Power supply labels Kit number Description 428408 Kit: Powermax30 AIR labels, CSA 428410 Kit: Powermax30 AIR labels, CSA, Built in America 428409 Kit: Powermax30 AIR labels, CE The label kits include: Consumables label Appropriate warning labels ... -
Page 67: Csa Warning Label
7. Do not remove, destroy, or cover this label. 7. Ne pas enlever, détruire ni couvrir cette étiquette. Replace if it is missing, damaged, or worn. La remplacer si elle est absente, endommagée ou usée. (PN 110673 Rev D) (PN 110673 Rev D) Powermax30 AIR Operator Manual 808840... -
Page 68: Ce Warning Label
Become trained. Only qualified personnel should operate this equipment. Use torches specified in the manual. Keep non-qualified personnel and children away. Do not remove, destroy, or cover this label. Replace if it is missing, damaged, or worn. Powermax30 AIR Operator Manual 808840...
Need help?
Do you have a question about the Powermax30 AIR and is the answer not in the manual?
Questions and answers