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Powermax30 Plasma Cutting System Service Manual

1. ASSEMBLY E je 01 12 _ mo E Ribbon cable oo Ds CDS C4 cs gt o cas Mo o LE Lu U coi 55 09 _9 EE en ME o o m Z 010 1 yy m mm mm E ie ZUD m e M czo is S O ug dd E 8 e A Umm 55 E y O O R uo o 5 R38 R39 C44 5 40 JG The control board LEDs are Start The power supply has a start signal This LED illuminates when the power supply receives a start signal and remains illuminated during normal operation Transfer This LED illuminates when there is proper arc transfer between the torch and the workpiece and will flash during continuous pilot arc operation such as when cutting expanded metal or moving the arc off the plate and then back on Error The Error LED illuminates when the gas pressure torch cap or temperature LEDs on the front of the power supply illuminate If all 4 LEDs on the front of the power supply are flashing the Error LED also flashes The numbe
2. PRESSURE SW FAN NNV DESAT 24 ING SPIEN CONTROL PWA DSP 2801 MACHINE M TIOCFM GAS SOL REAR Low Press OPEN 24v10 50A BAWABA 041953 Top Level 4 LAYER 16A 250V DPST aaa 2 35 h x 5 00 w 041950 Top Level i 7 85 hx 11 20 w TE FACING COMPONENT SIDE of POWER BD FRONT plated to 302 1983800 J of JO RESET ERROR XFR START o un 96 18 11 MES x asa 2 4 JTAGIEMULATION reup CAPOFF GASLOW RB ORS 5 CONNECTOR TSO UH LINE d COM INVUO COMPA 1010 A TE YEL YEL YEL GRN 1 7 gr INVU PWM CPLD us INVLPWM IN3 Te 26 POS 7 6 8uf 300vac X2 PA M mes 210 RIBBON Height Zone m VSS 801 CABLE IPADESAT IN7 SPiN 4x25Mhz 100Mhz 8 lt lt 0 78x 0 78 i CM Choke 16arms i gt Stayout for CM Choke Installed wo LE TEST CLIP on CE unit only Fsw 66khz
3. 3 18 powermax30 Service Manual Test 5 torch stuck open TSO Before the torch s trigger is pulled and gas starts to flow the nozzle and electrode should be closed If not the power supply will detect a TSO or torch stuck open fault Use the following test to determine if the torch is stuck open 1 Set the ON OFF switch to OFF 2 Measure the resistance from the torch lead s white wire group and red wire to the positive and negative connections on the power supply The resistance should read as closed 3 If the resistance reads as open then the nozzle and electrode are not touching or one of the wires in the torch lead is broken Make sure that the torch plunger moves freely in the torch head If it does not replace the torch head If the torch parts are working properly replace the torch lead White wire group Red wire SJ gt p powermax30 Service Manual 3 19 MAINTENANCE Test 6 plasma start Verify that the control board LED is receiving a valid start signal 1 With the power ON look at the Start LED on the control board It should illuminate whenever the trigger is pulled 2 Set the ON OFF switch to OFF O Check the resistance at the 2 torch start test points on the power board With the trigger engaged the resistance should be 10 Q or less With the trigger disengaged the circuit should read as approximately 3 kQ If this t
4. rend ER HAN KADER DE E EE ER a DEEP EE 1 5 Grounding Safety 1 5 Compressed gas equipment safety iii 1 6 Gas cylinders can explode if damaged rtt tene n n ct 1 6 Noise can damage hearilg eos itis tem ette is oet a utes ecd etude cusan s eroe ei ct etant 1 6 Pacemaker and hearing aid operation nn 1 6 A plasma arc can damage frozen pipes sise 1 6 Additional safety informali RE 1 6 WamingilabelS c e 1 7 Hypertherm Plasma Systems 1 1 8 06 SAFETY A RECOGNIZE SAFETY INFORMATION The symbols shown in this section are used to identify potential hazards When you see a safety symbol in this manual or on your machine understand the potential for personal injury and follow the related instructions to avoid the hazard FOLLOW SAFETY INSTRUCTIONS Read carefully all safety messages in this manual and safety labels on your machine Keep the safety labels on your machine in good condition Replace missing or damaged labels immediately Learn how to operate the machine and how to use the controls properly Do not let anyone operate it without instruction Keep your machine in proper working condition Unauthorized modifications to the machine may affect safety and machine service life DANGER WARNING CAUTION A s
5. na nah la ma HYPI LUIGI powermaxe lr Plasma arc cutting system Service Manual 805170 Revision 2 powermaxeur Service Manual P N 805170 Revision 2 January 2006 Hypertherm Inc Hanover NH USA www hypertherm com Copyright 2007 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 Hypertherm Inc Etna Road P O Box 5010 Hanover NH 03755 USA 603 643 3441 Tel Main Office 603 643 5352 Fax All Departments info hypertherm com Main Office Email 800 643 9878 Tel Technical Service technical service hypertherm com Technical Service Email 800 737 2978 Tel Customer Service customer service hypertherm com Customer Service Email Hypertherm Automation 5 Technology Drive Suite 300 West Lebanon NH 03784 USA 603 298 7970 Tel 603 298 7977 Fax Hypertherm Plasmatechnik GmbH Technologiepark Hanau Rodenbacher Chaussee 6 D 63457 Hanau Wolfgang Deutschland 49 6181 58 2100 Tel 49 6181 58 2134 Fax 49 6181 58 2123 Technical Service Hypertherm 5 Pte Lid No 19 Kaki Bukit Road 2 K B Warehouse Complex Singapore 417847 Republic of Singapore 65 6 841 2489 Tel 65 6 841 2490 Fax 65 6 841 2489 Technical Service Hypertherm Shanghai Trading Co Ltd Unit 1308 09 Careri Building 432 West Huai Hai Road Shanghai 200052
6. Flyback circuit Power switch S1 Control board PCB1 Inverter PFC IGBT Q1 IGBT Q2 Power board m _ PCB2 O AA PE ground S lo 4 3 gt E Input diode O bridges D24 030 L Il LES mu O E Output diode and pilot arc IGBT Work lead module D27 connection J22 3 8 powermax30 Service Manual Troubleshooting guide See System tests later in this section for detailed test procedures problem thismaymean cause sou The ON OFF power switch is set to ON but the power ON LED does not illuminate There is insufficient voltage to the control power component The power ON LED and the gas pressure LED mul There is insufficient gas pressure to the machine DO The power ON LED and the temperature LED illuminate The system has overheated The power ON LED flashes Y N The incoming voltage is not correct powermax30 Service Manual circuits or a short circuited The system has no incoming voltage or an improper incoming voltage The power board 15 faulty There is no gas attached to the system The gas supply line has a restriction or the air filter element is dirty The pressure switch 15 not reading at least 40 psi 2 8 bar on the gas supply line You have exceeded the duty cycle For more information abou
7. 1 2 Have a fire extinguisher nearby and ready to use 1 3 Do not use a drum or other closed container as a cutting table 2 Plasma arc can injure and burn point the nozzle away from yourself Arc starts instantly when triggered 2 1 Turn off power before disassembling torch 2 2 Do not grip the workpiece near the cutting path 2 3 Wear complete body protection 3 Hazardous voltage Risk of electric shock or burn 3 1 Wear insulating gloves Replace gloves when wet or damaged 3 2 Protect from shock by insulating yourself from work and ground 3 3 Disconnect power before servicing Do not touch live parts 4 Plasma fumes can be hazardous 4 1 Do not inhale fumes 4 2 Use forced ventilation or local exhaust to remove the fumes 4 3 Do not operate in closed spaces Remove fumes with ventilation 5 Arc rays can burn eyes and injure skin 5 1 Wear correct and appropriate protective equipment to protect head eyes ears hands and body Button shirt collar Protect ears from noise Use welding helmet with the correct shade of filter 6 Become trained Only qualified personnel should operate this equipment Keep non qualified personnel and children away 7 Do not remove destroy or cover this label Replace if it is missing damaged or worn PN 110584 Rev A M AVERTISSEMENT Le coupage plasma peut tre pr judiciable pour l op rateur et les personnes qui se trouvent sur les lieux de travail Consulter le manuel ava
8. HUMOS T XICOS PUEDEN CAUSAR LESIONES O MUERTE El nivel de la calidad del aire en cualquier lugar de trabajo relevante depende en variables espec ficas al sitio tales como Dise o de mesa mojada seca bajo agua La composici n del material el acabado de la superficie y la composici n de los recubrimientos Volumen que quita del material La duraci n del corte o ranura Tama o volumen del aire ventilaci n y filtraci n del lugar de trabajo Equipo de protecci n personal N mero de sistemas de soldar y cortar en la operaci n Otros procesos del lugar que pueden producir humo Si el lugar de trabajo debe cumplir reglamentos nacionales o locales solamente el monitoreo o las pruebas que se hacen en el lugar pueden determinar si el sitio est encima o debajo de los niveles permitidos Para reducir el riesgo de exposici n a humo Quite todos los recubrimientos y solventes del metal antes de cortar Use ventilaci n extractora local para quitar humo del aire No inhale el humo Use un respirador con fuente propia de aire cuando corte cualquier metal recubierto con o sospechado de contener elementos t xicos Garantice que aqu llos usando equipo de soldar o cortar al igual que aparatos de respiraci n con aire propio de aire est n capacitados y entrenados en el uso apropiado de tal equipo Nunca corte recipientes con materiales potencialmen
9. LOS RAYOS DEL ARCO PUEDEN PRODUCIR QUEMADURAS EN LOS OJOS Y EN LA PIEL Protecci n para la piel Vista ropa de protecci n para proteger la piel contra quemaduras causadas por la radiaci n ultravioleta de alta intensidad por las chispas y por el metal caliente Guantes largos zapatos de seguridad y gorro Roipa de combusti n retardada y que cubra todas las partes expuestas Pantalones sin dobladillos para impedir que recojan chispas y escorias Retire todo material combustible de los bolsillos como encendedores a butano e inclusive cerillas antes de comenzar a cortar rea de corte Prepare el rea de corte para reducir la reflexi n y la transmisi n de la luz ultravioleta Pinte las paredes y dem s superficies con colores oscuros para reducir la reflexi n Utilice pantallas o barreras protectoras para proteger a los dem s de los destellos Advierta los dem s que no debe mirarse el arco Utilice carteles o letreros SEGURIDAD DE TOMA A TIERRA Cable de trabajo La pinza del cable de trabajo debe estar bien sujetada a la pieza y hacer un buen contacto de metal a metal con ella o bien con la mesa de trabajo No conecte el cable con la parte que va a quedar separada por el corte Mesa de trabajo Conecte la mesa de trabajo a una buena toma de tierra de conformidad con los c digos el ctricos nacionales o locales apropiados Potencia primaria de entrada Aseg rese de que
10. Never lubricate cylinder valves or regulators with oil or grease Use only correct gas cylinders regulators hoses and fittings designed for the specific application Maintain all compressed gas equipment and associated parts in good condition Label and color code all gas hoses to identify the type of gas in each hose Consult applicable national or local codes GAS CYLINDERS CAN EXPLODE IF DAMAGED Gas cylinders contain gas under high pressure If damaged a cylinder can explode Handle and use compressed gas cylinders in accordance with applicable national or local codes Never use a cylinder that is not upright and secured in place Keep the protective cap in place over valve except when the cylinder is in use or connected for use Never allow electrical contact between the plasma arc and a cylinder Never expose cylinders to excessive heat sparks slag or open flame Never use a hammer wrench or other tool to open a stuck cylinder valve NOISE CAN DAMAGE HEARING Prolonged exposure to noise from cutting or gouging can damage hearing Use approved ear protection when using plasma system Warn others nearby about the noise hazard A PLASMA ARC CAN DAMAGE FROZEN PIPES Frozen pipes may be damaged or can burst if you attempt to thaw them with a plasma torch PACEMAKER AND in HEARING AID OPERATION Pacemake
11. 5 Disconnect the red and black wires from the pressure sensor 6 Disconnect the gas supply hose from the filter Pressure sensor Red and black wires Gas supply hose Nut Bracket Gas fitting Filter and p regulator iu d A Drain hose 7 Unscrew the nut that holds the air filter in the bracket Tip the bottom of the air filter away from the power supply and slide the filter out of the bracket 8 Position the new air filter in the bracket and replace the retainer nut 9 Route the drain hose through the hole in the base of the power supply 10 Press the black wire s connector onto the pin on the left side of the pressure sensor and the red wire s 11 12 13 14 connector onto the pin on the right side of the pressure sensor Connect the gas supply hose to the new filter If you are replacing the hose cut the new hose to the same length as the old hose Reconnect the gas fitting and then reconnect the gas supply to test it for leaks Being careful not to pinch any of the wires slide the cover back onto the power supply Make sure that the bottom edges are in the tracks Position the handle over the holes in the top of the cover then use the 2 screws to secure the cover Reconnect the electrical power 3 32 powermax30 Service Manual Replace the control board 1 Turn OFF the power disconnect the power cord and disconnect the gas supply 2 Remove the 2 screws from the handle on the top of
12. Un arc plasma peut endommager les tuyaux gel s ss 1a 6 CA 1 7 Section 1b SEGURIDAD Reconocimiento de informaci n de seguridad ir 1b 2 Siga las instrucciones de 1b 2 Los cortes pueden provocar incendios o explosiones ssssssseeseeeeneeeeeene eene nennen 1b 2 El choque el ctrico puede provocar la 1b 3 Electricidad est tica puede da ar tablillas de circuito 1b 3 Humos t xicos pueden causar lesiones o muerte iii 1b 4 El arco de plasma puede causar lesiones y quemaduras 1b 5 Los rayos del arco pueden producir quemaduras en los ojos y en la 1b 5 powermax30 Service Manual TABLE OF CONTENTS Seguridad de toma 1b 5 Seguridad de los equipos de gas comprimido sis 1b 6 Los cilindros de gas pueden explotar si est n 1b 6 El ruido pue
13. 1 5 Compressed gas equipment safety sise 1 6 Gas cylinders can explode if damaged iii 1 6 Noise can damage SA A ee de ieee eb ee dare e eee 1 6 Pacemaker and hearing aid operation 1 6 A plasma arc can damage frozen pipes sise 1 6 Additional safety InformatiOri ue c A E Agen Bite fn ted e e dte 1 6 Warning labels eiu AE OE eee teeta ee ead EWA 1 7 Section 1a S CURIT Identifier les consignes de s curit sienne 1a 2 Suivre les instructions de s curit issues 1 2 Le coupage peut provoquer un incendie une explosion iii 1 2 Les chocs lectriques peuvent tre fatals sise 1a 3 L lectricit statique peut endommager les cartes de circuits 2 2 22 1a 3 Les vapeurs toxiques peuvent provoquer des blessures ou la mort 1a 4 L arc plasma peut provoquer des blessures ou des 1a 5 Les rayons de l arc peuvent br ler les yeux et la peau 1 5 Mise la et la terre eiecit etai citare ROL 1 5 S curit des bouteilles de gaz comprim sienne 1a 6 Les bouteilles de gaz comprim peuvent exploser en cas de dommages sss 1a 6 Le bruit peut provoquer des probl mes auditifs sr 1a 6 Pacemakers et proth ses auditives sienne 1a 6
14. 2 4 5 METRI LL IM 2 4 ejrud 2 4 IEC SYMONS c ici 2 4 powermax30 Service Manual 2 1 SPECIFICATIONS Power supply Rated open circuit voltage 240 VDC Rated output current lo 15 1030 Rated output voltage 0 83 VDC Duty cycle at 40 C U 120 VAC See data plate on power supply for more information on duty cycle and for IEC ratings 35 30 A 83 V 60 lp 2 U2 83 V Duty cycle at 40 C Uy 200 240 100 18 A Us 83 V 50 lp 30 A 83 V 75 24 A Up 83 V 100 lp 21 A 83 V Operating temperature 14 to 104 F 10 to 40 C Storage temperature 13 to 131 F 25 to 55 C Power factor 120 V 240 V 0 99 0 97 Input voltage U Input current 1 at 120 V 26A rated output U lo max 200 240 V 15 5 13 Gas type Air Nitrogen Gas quality Clean dry oil free 99 995 pure Minimum required gas inlet flow and pressure 3 5 scfm 65 psi 99 1 l min 5 5 bar Recommended gas inlet flow and pressure 4 0 scfm 80 psi 113 3 l min 5 5 bar Dimensions and weight 20 65 Ib Weight includes the hand torch and 15 ft 4 57 m lead powermax30 Service Manual T30v torch ratings SPECIFICATION
15. 98 PACEMAKERS ET T PROTH SES AUDITIVES AN Les champs magn tiques produits par les courants haute tension peuvent affecter le fonctionnement des proth ses auditives et des pacemakers Les personnes portant ce type d appareil doivent consulter un m decin avant de s approcher d un lieu o s effectue le coupage ou le gougeage plasma Pour r duire les risques associ s aux champs magn tiques Garder loin soi et du m me c t du corps le c ble retour et le faisceau de la torche Faire passer le faisceau de la torche le plus pr s possible du c ble de retour Ne pas s enrouler le faisceau de la torche ou le cable de retour autour du corps Se tenir le plus loin possible de la source de courant Hypertherm Systemes plasma Etiquette de s curit SECURITE Cette tiquette est affich e sur la source de courant Il est important que l utilisateur et le technicien de maintenance comprennent la signification des symboles de s curit Read and follow these instructions employer safety practices and material safety data sheets Refer to ANS Z49 1 Safety in Welding Cutting and Allied Processes from American Welding Society http www aws org and OSHA Safety and Health Standards 29 CFR 1910 http www osha gov 1 Les tincelles produites par le coupage peuvent 3 3 WARNING Plasma cutting can be injurious to operator and persons in the work area Consult
16. Disconnect the electrical power and set the ON OFF switch to OFF Ease the ON OFF switch s top 2 wires out from the tabs a little ways so that you can get your test leads on the tabs to check the AC voltage Once you have your test leads in place reconnect the electrical power Leave the ON OFF switch set to OFF The voltage should equal the line voltage of the incoming circuit for example 120 V or 240 V If the AC voltage is incorrect check to see that you have power to the unit If you do have power check the power cord for damage If the power source and power cord are functioning correctly disconnect the electrical power again and reconnect the wires Reconnect the electrical power Then set the ON OFF switch to ON I and measure the AC voltage from J1 to J2 labeled AC on the power board This value should be the same as the incoming line voltage If it is not check the ON OFF switch If the AC LED is still illuminated perform test 2 to determine whether the power board or the control board is faulty Note All values can be 415 Single phase Black CSA Brown CE White CSA Blue CE PE Green CSA powermax30 Service Manual 3 15 MAINTENANCE Test 2 power board voltage checks With the power ON use a meter to verify the voltages at the J7 pins listed in the following table to be
17. Power supply parts Exterior ltem ROD Part number 228098 228097 228096 228101 108616 123868 229121 229122 228100 228099 Description Kit Labels domestic Kit Labels CE Kit Screws Kit Front panel Current adjustment knob Work lead assembly Kit Power supply cover with labels domestic Kit Power supply cover with labels CE Kit Rear panel Kit Powermax30 handle powermax30 Qty ak mh mh mk mk mk Service Manual Interior power board side PARTS Part number 1 228093 2 005605 3 228094 228102 4 228139 5 228105 228104 228103 Description Kit Control board Power rocker switch Kit Kit Kit Kit Kit Kit Power board CSA Power board CE Base Magnetic mounting base Powermax30 insulator Powermax30 wire group powermax30 Service Manual Designator Qty PCB1 1 1 PCB2 1 PCB2 1 1 1 1 1 4 3 PARTS Interior fan side 7 Item number Description Designator Qty 1 005112 Kit Pressure sensor 1 2 228108 Kit Solenoid valve V1 1 3 228095 Kit Hoses 2 4 228142 Kit CSA power cord 1 phase 8 ft 1 5 228140 Kit CE power cord 1 phase 2 5 m 6 228106 Kit Filter regulator 1 011106 Air filter element 1 7 228107 Kit Fan M1 1 4 4 powermax30 Service Manual T30v hand torch parts ltem Part number 088001 1 228112 058503 3 228109 4 228110 5 228111 6 075714 7 002244 8 228113 Desc
18. Remove GNACAD A A A ad 3 22 Replace the torch load etr I 3 24 Replace the work lui iS 3 26 Replace the power cord 3 27 Replace the power cord CE 3 28 Replace Ine us nee dt ste er ne 3 30 Replace at i gd oo ro e 3 31 Replace the air 3 32 Replace the Control D 3 33 Replace power DOG rannani EEEE WA SOG p anne ne sense rene 3 34 Replace the bi e 3 37 powermax30 Service Manual 3 1 MAINTENANCE Controls and indicators The Powermax30 has an ON OFF rocker switch an amperage adjustment knob and four indicator LEDs which are described below Front Front controls and LEDs Rear controls Power ON LED green ON I OFF power switch When illuminated this LED indicates that Activates the power supply and its control the power switch has been set at ON circuits and that the safety interlocks are satisfied Gas pressure LED yellow When illuminated this LED indicates that the gas pressure is below 40 psi 2 8 bar Correct this condition before continuing Tor
19. Service Manual Recommended spare parts Part number 108616 123868 228101 228100 005605 228093 228094 228102 228139 228105 005112 228108 228106 011106 228107 058503 228111 075714 002244 027254 128642 228109 088001 228113 027055 Description Amps adjustment knob Work cable with clamp 15 ft 4 6 m Kit Front panel Kit Rear panel Power rocker switch Kit Control board Kit Power board Kit Power board CE Kit Base Kit Magnetic mounting base Pressure sensor Kit Solenoid valve Kit Filter regulator Air filter element Kit Fan Torch o ring Kit T30v torch handle replacement T30v torch handle screws 5 required T30v torch trigger assembly with spring Replacement trigger spring T30v Kit Start switch replacement Kit T30v torch cap sensor replacement T30v hand torch assembly with 15 ft 4 6 m lead Kit T30v 15 ft 4 6 m torch lead replacement Silicone lubricant 1 4 02 tube powermax30 Service Manual Page reference 4 2 4 2 4 2 4 2 4 3 4 3 4 3 4 3 4 3 4 3 4 4 4 4 4 4 4 4 4 4 4 5 4 5 4 5 4 5 4 5 4 5 4 5 4 5 4 5 PARTS PARTS powermax30 Service Manual Section 5 WIRING DIAGRAM In this section Electrical schernmatlc ae eee es eae a eee 5 3 powermax30 Service Manual 5 1 WIRING DIAGRAM powermax30 Service Manual
20. be damaged The gas pressure is too low or the gas supply is restricted The air filter element is dirty The power board is faulty MAINTENANCE Check the gas supply to make sure that it does not exceed 135 psi 9 3 bar If necessary reduce the pressure Perform test 4 to verify that the gas solenoid valve is functioning correctly Inspect the consumables torch and lead Replace any damaged parts Verify that the gas supply is providing at least 65 psi 4 5 bar Repair any restrictions in the supply line Perform test 3 to test the voltage balance on the power board Check for loose connections at the work clamp and at the power supply Reposition the work lead on the workpiece Clean the cutting surface to ensure a better connection with the work lead Inspect the consumables torch and lead Replace any damaged parts Verify that the gas supply is providing at least 65 psi 4 5 bar Repair any restrictions in the supply line Perform test 3 to test the voltage balance on the power board MAINTENANCE Troubleshooting guide continued oem meme in The cut quality is poor or the cut does not sever the metal The pilot arc extinguishes when you move the plasma arc off the work piece while still pulling the torch s trigger The consumables need to be replaced The work lead may be damaged or not properly connected to the work piece The amps adjustme
21. been located and repaired refer to the Sequence of operation flow diagram in this section to test the power supply for proper operation Troubleshooting guide Troubleshooting tests Power OFF and disconnected External inspection Internal inspection Resistance checks 4 External inspection 1 Inspect the exterior of the power supply for damage to the cover and external components such as the power cord and plug 2 Inspect the torch and the torch lead for damage powermax30 Service Manual 3 5 MAINTENANCE DANGER ELECTRIC SHOCK CAN KILL Turn off the power and remove the input power plug from its receptacle before removing the cover from the power supply If the power supply is connected directly to a line disconnect box switch the line disconnect to OFF In the U S use a lock out tag out procedure until the service or maintenance work is complete In other countries follow appropriate national or local safety procedures Do not touch live electrical parts If power is required for servicing use extreme caution when working near live electrical circuits Dangerous voltages exist inside the power supply that can cause serious injury or death Do not attempt to repair the power board or control board Do not cut away or remove any protective conformal coating from eith
22. bruit Utiliser un masque de soudeur avec un filtre de nuance appropri e 6 Suivre une formation Seul le personnel qualifi a le droit de faire fonctionner cet quipement Le personnel non qualifi et les enfants doivent se tenir l cart 7 Ne pas enlever d truire ni couvrir cette tiquette La remplacer si elle est absente endommag e ou us e PN 110584 Rev A 1 Las chispas producidas por el corte pueden causar 3 3 Antes de trabajar en una m quina desconecte el enchufe de entrada o la potencia primaria explosiones o incendios 1 1 Mantenga los materiales inflamables lejos del lugar de 4 corte 1 2 Tenga a mano un extinguidor de incendios y aseg rese de que alguien est preparado para utilizarlo 1 3 No corte dep sitos cerrados 2 Elarco de plasma puede causar quemaduras y lesiones 2 1 Apague la fuente de energ a antes de desarmar la antorcha 2 2 No sostenga el material junto al trayecto de corte 2 3 Proteja su cuerpo completamente 3 Los electrochoques provocados por la antorcha o el cableado pueden ser fatales Prot jase del electrochoque 3 1 Col quese guantes aislantes No utilice guantes dafiados o mojados 3 2 A slese de la pieza de trabajo y de la tierra Hypertherm Sistemas plasma 4 1 4 2 5 1 La inhalaci n de los humos provenientes del rea de corte puede ser nociva para la salud Mantenga la cabeza fuera de los gases t xicos Utilice ventilaci n forzada
23. certain that the power board is functioning correctly If any of the values are incorrect replace the power board Note All values can be 10 Caution Do not use VBUS as ground Doing so could destroy the power supply Instead ground to either the ground wire clip on the rear endcap or to the heat sink as shown below ground 0 86 V 120 line voltage VACR rectified AC line voltage 1 87 V 230 line voltage BUS DC bus voltage 2 28 VDC 375 VBUS am ET NEN Start signal 3 2 VDC closed 3 0 VDC open Note To test the values at pin 16 you must have the torch and power supply positioned such that you can safely pull and release the torch s trigger Ground to the ground wire clip or to the heat sink 9 O O O O O O O O O 0 0 SZO O O O O O 000000 01 3 16 powermax30 Service Manual Test 3 VBUS and voltage balance Test the power board to ensure that the circuits are balanced Caution Do not use a multimeter with test probes which can cause a short circuit between the BUS and the heatsink Use E Z Hook leads instead 1 Turn OFF the power 2 Position the multimeter leads to measure the voltage from VBUS to 375 VDC on the power board Carefully connect the E Z Hooks to the edges of the holes in the power board so that the hook makes contact with the ring on the back side of the power board gt Note All v
24. contenu dans chaque tuyau Se r f rer aux codes locaux ou nationaux en vigueur LES BOUTEILLES DE GAZ COMPRIM PEUVENT EXPLOSER EN CAS DE DOMMAGES Les bouteilles gaz contiennent du gaz a haute pression Si une bouteille est endommag e elle peut exploser Manipuler et utiliser les bouteilles de gaz comprim conform ment aux codes locaux ou nationaux jamais utiliser une bouteille qui n est pas plac e a la verticale et bien assujettie Le capuchon de protection doit tre plac sur le robinet sauf si la bouteille est en cours d utilisation ou connect e pour utilisation viter tout prix le contact lectrique entre l arc plasma et une bouteille Ne jamais exposer des bouteilles une chaleur excessive aux tincelles aux scories ou aux flammes nues Ne jamais utiliser des marteaux des cl s ou d autres outils pour d bloquer le robinet des bouteilles LE BRUIT PEUT PROVOQUER DES PROBLEMES AUDITIFS Une exposition prolong e au bruit du coupage ou du gougeage peut provoquer des probl mes auditifs Utiliser un casque de protection homologu lors de l utilisation du syst me plasma Pr venir les personnes aux alentours des risques encourus en cas d exposition au bruit UN ARC PLASMA PEUT ENDOMMAGER LES TUYAUX GELES Les tuyaux gel s peuvent tre endommag s ou clater si l on essaie de les d geler avec une torche plasma 1a 6 11
25. deber n consultar a un m dico antes de acercarse a sitios donde se realizan operaciones de corte y ranurado por plasma Para reducir los peligros de los campos magn ticos Mantenga el cable de trabajo y la manguera de la antorcha a un lado lejos del cuerpo Dirija la manguera antorcha lo m s cerca posible del cable de trabajo No envuelva el cable de trabajo ni la manguera de la antorcha en su cuerpo Mant ngase tan lejos de la fuente de energ a como sea posible 1b 6 11 98 Hypertherm Sistemas plasma Etiqueta advertencia SEGURIDAD Esta etiqueta de advertencia se encuentra adherida a la fuente de energia Es importante que el operador y el t cnico de mantenimiento comprendan el sentido de estos s mbolos de advertencia seg n se describen El texto numerado corresponde a los cuadros numerados de la etiqueta Read and follow these instructions employer safety practices and material safety data sheets Refer to ANS 249 1 Safety in Welding Cutting and Allied Processes from American Welding Society http www aws org and OSHA Safety and Health Standards 29 CFR 1910 http www osha gov WARNING Plasma cutting can be injurious to operator and persons in the work area Consult manual before operating Failure to follow all these safety instructions can result in death 1 Cutting sparks can cause explosion or fire 1 1 Do not cut near flammables 1 2 Have a fire e
26. el alambre de toma tierra del cord n de alimentaci n est conectado al terminal de tierra en la caja del interruptor de corriente Si la instalaci n del sistema de plasma supone la conexi n del cord n de alimentaci n primaria a la fuente de energ a aseg rese de conectar correctamente el alambre de toma a tierra del cord n de alimentaci n primaria Coloque en primer lugar el alambre de toma a tierra del cord n de alimentaci n primaria en el esp rrago luego coloque cualquier otro alambre de tierra sobre el conductor de tierra del cable Ajuste firmemente la tuerca de retenci n Aseg rese de que todas las conexiones el ctricas est n firmemente realizadas para evitar sobrecalentamientos Hypertherm Sistemas plasma 1b 5 5 02 SEGURIDAD SEGURIDAD DE LOS EQUIPOS DE GAS COMPRIMIDO Nunca lubrique reguladores valvulas de cilindros con aceite grasa Utilice solamente cilindros mangueras conectores de gas correctos que hayan sido dise ados para la aplicaci n espec fica Mantenga todo el equipo de gas comprimido y las piezas relacionadas en buen estado Coloque etiquetas y c digos de color en todas las mangueras de gas para identificar el tipo de gas que conduce cada una Consulte los c digos locales o nacionales aplicables LOS CILINDROS DE GAS PUEDEN E EXPLOTAR SI ESTAN DANADOS Los cilindros de gas contienen gas ba
27. manual before operating Failure to follow all these safety instructions can result in death 1 Cutting sparks can cause explosion or fire 1 1 Do not cut near flammables 1 2 Have a fire extinguisher nearby and ready to use 1 3 Do not use a drum or other closed container as a cutting table 2 Plasma arc can injure and burn point the nozzle away from yourself Arc starts instantly when triggered 2 1 Turn off power before disassembling torch 2 2 Do not grip the workpiece near the cutting path 2 3 Wear complete body protection 3 Hazardous voltage Risk of electric shock or burn 3 1 Wear insulating gloves Replace gloves when wet or damaged 3 2 Protect from shock by insulating yourself from work and ground 3 3 Disconnect power before servicing Do not touch live parts 4 Plasma fumes can be hazardous 4 1 Do not inhale fumes 4 2 Use forced ventilation or local exhaust to remove the fumes 4 3 Do not operate in closed spaces Remove fumes with ventilation 5 Arc rays can burn eyes and injure skin 5 1 Wear correct and appropriate protective equipment to protect head eyes ears hands and body Button shirt collar Protect ears from noise Use welding helmet with the correct shade of filter 6 Become trained Only qualified personnel should operate this equipment Keep non qualified personnel and children away 7 Do not remove destroy or cover this label Replace if it is missing damaged or worn PN 110584 R
28. proc der au coupage Ne pas retirer ou peindre recouvrir les tiquettes de s curit Hypertherm Syst mes plasma Seccion 1b SEGURIDAD En esta seccion Reconocimiento de informaci n de seguridad nnne nnne nnne enn 1b 2 Siga las instrucciones de 1b 2 Los cortes pueden provocar incendios o explosiones eene nennen enne nnns 1b 2 El choque el ctrico puede provocar la muerte sitne 1b 3 Electricidad est tica puede da ar tablillas de circuito su 1b 3 Humos t xicos pueden causar lesiones o 1b 4 El arco de plasma puede causar lesiones quemaduras sess eene enne 1b 5 Los rayos del arco pueden producir quemaduras en los ojos y en la 1b 5 Seguridad de 7 1b 5 Seguridad de los equipos de gas comprimido is 1b 6 Los cilindros de gas pueden explotar si est n da ados ssssssssssssseseseseeeeee eee 1b 6 El ruido puede deteriorar la 1b 6 Operaci n de marcapasos de aud fonos sienne 1b 6 Un arco plasma puede da ar tubos congelados ssssssseee enne nnnm nnne nnns 1b
29. sido identificado como la fuente de humo t xico el material que se corta puede ser la fuente de humo o gases t xicos que vac an el ox geno El humo producido var a seg n el metal que est cort ndose Metales que pueden liberar humo t xico incluyen pero no est n limitados a acero inoxidable acero al carb n cinc galvanizado y cobre En algunos casos el metal puede estar recubierto con una sustancia que podr a liberar humos t xicos Los recubrimientos t xicos incluyen pero no est n limitados a plomo en algunas pinturas cadmio en algunas pinturas y rellenos y berilio Los gases producidos por el corte por plasma var an bas ndose en el material a cortarse y el m todo de cortar pero pueden incluir ozono xidos de nitr geno cromo hexavalente hidr geno y otras substancias si est n contenidas dentro o liberadas por el material que se corta Se debe tener cuidado de minimizar la exposici n del humo producido por cualquier proceso industrial Seg n la composici n qu mica y la concentraci n del humo al igual que otros factores tales como ventilaci n puede haber el riesgo de enfermedad f sica tal como defectos de natividad o c ncer Es la responsabilidad del due o del equipo y instalaci n el comprobar la calidad de aire en el lugar donde se est usando el equipo para garantizar que la calidad del aire en el lugar de trabajo cumpla con todas las normas y reglamentos locales y nacionales
30. sont susceptibles d en contenir S assurer que les personnes qui utilisent un mat riel de soudage ou de coupage ainsi que les dispositifs de respiration par adduction d air sont qualifi s et ont recu la formation sur la bonne utilisation d un tel mat riel Ne jamais couper les contenants dans lesquels il peut y avoir des mat riaux toxiques En premier lieu vider et nettoyer correctement le contenant Contr ler ou prouver la qualit de l air au site selon les besoins Consulter un expert local pour mettre en oeuvre un plan du site afin d assurer une qualit de l air s re 1a 4 8 06 Hypertherm Systemes plasma S CURIT Y Torches allumage instantan L arc plasma s allume imm diatement apr s que la torche Soit mise en marche L ARC PLASMA PEUT PROVOQUER DES BLESSURES OU DES BR LURES L arc plasma coupe facilement les gants et la peau Rester loign de l extr mit de la torche Ne pas tenir de m tal pr s de la trajectoire de coupe Ne jamais pointer la torche vers soi ou d autres personnes Protection des yeux Les rayons de l arc plasma produisent de puissants rayons visibles ou invisibles ultraviolets et infrarouges qui peuvent br ler les yeux et la peau Utiliser des lunettes de s curit conform ment aux codes locaux ou nationaux en vigueur Porter des lunettes de protection lunettes ou masque muni d crans lat raux et encore masque de soudure avec de
31. the control board start LED illuminates when the trigger is pulled If it does not perform test 6 to check the start signal from the power board powermax30 Service Manual Troubleshooting guide continued Gas flows when the system is powered ON When pulling the torch s trigger gas flows from the torch but the torch does not fire or fires only for a short period of time Arc goes out while cutting or intermittently will not fire When pulling the torch s trigger the pilot arc starts but then extinguishes before the normal 5 second time out period The incoming gas pressure is too high The consumables torch or torch lead are not functioning correctly the gas pressure may be too low or there is a voltage imbalance on the power board The arc lost contact with the workpiece The consumables torch or torch lead are not functioning correctly the gas pressure may be too low the air quality may be poor or there is a voltage imbalance on the power board powermax30 Service Manual The gas pressure from the compressor or cylinder may be too high The gas solenoid valve may be faulty The consumables may be worn or damaged The torch or torch lead may be damaged The gas pressure is too low or the gas supply is restricted The power board is faulty The work lead or work lead connection may be faulty The consumables may be worn or damaged The torch or torch lead may
32. the power supply Remove the Nomex barrier that protects the power board Remove and set aside the screw and washer from J22 on the power board also labeled WORK LEAD that attaches the lead to the board Either remove the front endcap or gently tilt it away from the power supply Remove the strain relief s retaining nut Pull the work lead through the hole in the endcap Front end MT Work lead ae Strain relief Work lead connection to power board J22 3 26 powermax30 Service Manual 5 Route the connector end of the new work lead through the hole in the and then through the retaining nut 6 Tighten the nut onto the strain relief to hold it in place 7 Attach the work lead to the power board at J22 using the screw and washer that you removed in step 3 The torque setting for this connection is 20 inch pounds 23 04 kg cm 8 Replace or realign the end cap 9 Being careful not to pinch any of the wires replace the Nomex barrier and slide the cover back onto the power supply Make sure that the bottom edges are in the tracks 10 Position the handle over the holes in the top of the cover then use the 2 screws to secure the cover 11 Reconnect the electrical power and the gas supply Replace the power cord CSA 1 Turn OFF the power disconnect the power cord and disconnect the gas supply 2 Remove th
33. the power supply Remove the handle and then lift the cover off the power supply Remove the Nomex barrier that protects the power board 3 Remove the front endcap or gently tilt it away from the base 4 Detach the ribbon cable from the power board Caution Static electricity can damage circuit boards Use proper precautions when handling printed circuit boards Store PC boards in anti static containers Wear a grounded wrist strap when handling PC boards Ribbon cable 5 Test the new control board before installing it by attaching its ribbon cable to the power board Reconnect the power turn the system on and verify that the Start LED on the control board is the only LED illuminated Also the fault LEDs on the front panel should be extinguished 6 Disconnect electrical power and the ribbon cable again and set aside the new control board 7 Remove the 3 retaining screws from the old control board and lift it out of the power supply 8 Screw the new control board into place with the 3 retaining screws and then attach the ribbon cable 9 Reposition the front endcap Make sure that the screw hole in the ground clip aligns with the screw holes in the endcap and the power supply 10 Being careful not to pinch any of the wires replace the Nomex barrier and slide the cover back onto the power supply Make sure that the bottom edges are in the tracks Position the handle over the holes in
34. the top of the cover then use the 2 screws to secure the cover 11 Reconnect the electrical power and the gas supply powermax30 Service Manual 3 33 MAINTENANCE Replace the power board Before beginning this procedure make sure you have the correct power board for your system The replacement kit for a CSA power board is part number 228094 The replacement kit for a CE power board is part number 228102 Although there are some technical differences between the power board for CSA power supplies and the power board for CE power supplies the procedure to replace the boards is the same 1 Turn OFF the power disconnect the power cord and disconnect the gas supply 2 Remove the 2 screws from the handle on the top of the power supply Remove the handle and then lift the cover off the power supply Remove the Nomex barrier that protects the power board Caution Static electricity can damage circuit boards Use proper precautions when handling printed circuit boards Store PC boards in anti static containers Wear a grounded wrist strap when handling PC boards 3 Detach the ribbon cable from the heatsink side of the power board See the illustration on the following page for the location of the ribbon cable and the components listed in the next steps 4 Remove the torch start and cap sensor connector at J12 on the heatsink side of the power board 5 Remove the connectors at J4 J5 and J6 on the heatsink side o
35. 13 J14 J15 J18 J19 J20 and J21 and the work lead ring terminal at J22 Torque them to 20 inch pounds 23 04 kg cm Replace the torch start and cap sensor connector at J12 and the connectors at J4 J5 and J6 Reconnect the ribbon cable from the control board to the power board Attach the red and white wires to the studs on the fan side of the board Being careful not to pinch any of the wires replace the Nomex barrier and slide the cover back onto the power supply Make sure that the bottom edges are in the tracks Position the handle over the holes in the top of the cover then use the 2 screws to secure the cover Reconnect the electrical power and the gas supply 3 36 powermax30 Service Manual Replace the base 1 Turn OFF the power disconnect the power cord and disconnect the gas supply 2 Remove the 2 screws from the handle on the top of the power supply Remove the handle and then lift the cover off the power supply Remove the Nomex barrier that protects the power board 3 Turn the power supply upside down and remove the 6 screws from the base 4 Remove the endcaps and the Nomex barrier See Remove endcap earlier in this section Screws Data plate location Holes 5 Carefully peel the data plate off the base Set it aside The data plate has your system s serial number on it so do not lose it or t
36. 6 Etiquetas c iia 1b 7 Hypertherm Sistemas plasma 1b 1 8 06 SEGURIDAD A RECONOCIMIENTO DE Mantenga su maquina en buenas condiciones de INFORMACION DE SEGURIDAD funcionamiento La realizaci n de modificaciones autorizadas a la m quina puede comprometer la Los s mbolos que se muestran en esta secci n se utilizan seguridad y la vida til de la m quina para identificar los posibles peligros Cuando vea un s mbolo de seguridad en este manual o en su m quina recuerde que existe posibilidad de que produzcan lesiones personales PELIGRO ADVERTENCIA PRECAUCION y siga las instrucciones correspondientes para evitar el peligro Las palabras PELIGRO y ADVERTENCIA se utilizan NS conjuntamente con un s mbolo de seguridad La palabra 2 SIGA LAS INSTRUCCIONES DE PELIGRO se utiliza para identificar los mayores peligros SEGURIDAD Encontrara etiquetas de seguridad con las inscripciones PELIGRO y ADVERTENCIA en su maquina junto a Lea atentamente todos los mensajes de seguridad de este peligros especificos manual y las etiquetas de seguridad en su maquina En este manual la palabra ADVERTENCIA va seguida de Mantenga las etiquetas de seguridad de su m quina en instrucciones que si no se siguen correctamente pueden buen estado Reemplace las etiquetas que se pierdan o se provocar lesiones e inclusive la muerte da en inmediatamente En este manual la palabra PRECAUCI N va seg
37. F the power 2 Check the resistance between pins 1 and 2 of J4 It should read approximately 4 7 kQ if there is no gas pressure If the gas pressure is within system tolerances the circuit should read as closed powermax30 Service Manual 3 21 MAINTENANCE DANGER ELECTRIC SHOCK CAN KILL Use extreme caution when working near live electrical circuits Dangerous voltages exist inside the power supply that can cause serious injury or death See warnings on page 3 6 before proceeding Component replacement Remove an endcap Endcaps can be removed to replace them Also some repairs are easier to make with an endcap removed 1 Turn OFF the power disconnect the power cord and disconnect the gas supply 2 Use a 2 Phillips screwdriver to remove the 2 screws from the handle on the top of the power supply Tip the endcaps back slightly so that you can get the edges of the handle out from underneath the endcaps Remove the handle and then lift the cover off the power supply M X ami 3 22 powermax30 Service Manual 3 Lay the power supply on its side or hold it upside down Each endcap has a retaining screw in the center The raised feet on the bottom of the unit have holes to provide access to the snaps that hold the endcaps in place Next to each foot is a raised rib Rear endcap Rib Rib Front endcap Snap Snap Retaining screw Retainin
38. LAX100 NP 4 J 110 HCPL 7640 _ i istne E E N5 OUTS 4 gt gt FAN 8 8 495vdc jka 01uF Y2 DRY 300vac y 2 09 5 51 REDUNDANT START OUT2 2L YpiNU PWM DRV CONTROL to MPX5700 BACK UP Er LB 0472 om Khen PRESSURE SENSOR SINK Height Zone gt NOT USED e MTG3 IGBT TEMP 13 LIFT to PFC IGBT MODULE INVERTER IGBT MODULE Hipot 3 3 3 WHT WIRE Finv 42khz Fpfc 28khz o lline Limit 37 5ams 600V 90A 90A INPUT BRIDGES att OUTPUT DIODE and PILOT ARC IGBT MODULE PFC DIODE 375vde CLAMP DIODE Ha 15 1 T H OUTPUT CURRENT SENSOR TRANSFER SENSOR ae y 0 00 2 09 mp 1 00 MAX d 12AWG UL1569 WHT 2 E27UF Zone OUT3 Me RET 630VDC 630VDC 9uF 3 630VDd 630VDC LAX100 NP our LAX100 NP ae H 2200uF 27 300vac STE 250v0c ST 8c DUE UCTANCE 4 SWNC gt gt INV IPRIM Loutput 014309 VIOLET 525 L0 410uH START L30 270uH Rdc20C ELECTRODE 19AWG 1569 RED ll RED OTE Lpfc 014307 WORK PE 98 264vac L0 350uh e 47 63hz L60 185uh Lt Rdc20C 21 5mohm HT MT MUELLER CORD THIS DRAWING AND ALL STD 148 SO Da 0 53 NEN ea HYPERTHERM CE Unit HO5VV F3G2 5 Dia 0 39 Twisted Leads Box 5010 Hanover NH 03755 5010 603 643 3441 Lleak 0 5uH Typ Lprim 0 75mH Rprim20C 4 8mohm Rsec20C 10 5mohm ELEC SCHEM PMX30 SYS p
39. OU UNE EXPLOSION AVERTISSEMENT Risque d explosion argon hydrog ne et m thane L hydrogene et le m thane sont des gaz inflammables potentiellement explosifs Conserver l cart de toute flamme les bouteilles et tuyaux contenant des m langes base d hydrog ne ou de m thane Maintenir toute flamme et tincelle l cart de la torche lors de l utilisation d un plasma d argon hydrog ne ou de m thane AVERTISSEMENT D tonation de l hydrog ne lors du coupage de l aluminium Lors du coupage de l aluminium sous l eau ou si l eau touche la partie inf rieure de la pi ce d aluminium de l hydrog ne libre peut s accumuler sous la pi ce couper et d tonner lors du coupage plasma Installer un collecteur d a ration au fond de la table eau afin d liminer les risques de d tonation de l hydrog ne Se r f rer l annexe du manuel pour plus de renseignements sur les collecteurs d a ration 1a 2 11 98 Hypertherm Systemes plasma SECURITE Le ON Toucher une pi ce lectrique sous tension peut provoquer un choc lectrique fatal ou des br lures graves La mise en fonctionnement du systeme plasma ferme un circuit lectrique entre la torche et la pi ce a couper La piece a couper et tout autre l ment en contact avec cette piece font du circuit lectrique Ne jamais toucher le corps de la torche la piece couper ou l eau de la table a eau pendant le fonctionnemen
40. PR China 86 21 5258 3330 1 Tel 86 21 5258 3332 Fax Hypertherm Branch of Hypertherm UK UC PO Box 244 Wigan Lancashire England WN8 7WU 00 800 3324 9737 Tel 00 800 4973 7329 Fax 00 800 4973 7843 Technical Service 11 21 06 France Representative office 15 Impasse des Rosiers 95610 Eragny France 00 800 3324 9737 Tel 00 800 4973 7329 Fax Hypertherm S r l Via Torino 2 20123 Milano ltalia 39 02 725 46 312 Tel 39 02 725 46 400 Fax 39 02 725 46 314 Technical Service Hypertherm Europe B V Vaartveld 9 4704 SE Roosendaal Nederland 31 165 596907 Tel 31 165 596901 Fax 31 165 596908 Tel Marketing 31 165 596900 Tel Technical Service 00 800 49 73 7843 Tel Technical Service Hypertherm Japan Ltd 801 Samty Will Building 2 40 Miyahara 1 Chome Yodogawa ku Osaka 532 0003 Japan 81 6 6170 2020 Tel 81 6 6170 2015 Fax HYPERTHERM BRASIL LTDA Avenida Doutor Renato de Andrade Maia 350 Parque Renato Maia CEP 07114 000 Guarulhos SP Brasil 55 11 6409 2636 Tel 55 11 6408 0462 Fax ELECTROMAGNETIC COMPATIBILITY EMC EMC Introduction Hypertherm s CE marked equipment is built in compliance with standard EN60974 10 The equipment should be installed and used in accordance with the information below to achieve electromagnetic compatibility The limits required by EN60974 10 may not be adequate to completely eliminate interference when the affected equipment is in close proximity or ha
41. Phillips screwdriver to remove the 2 screws from the handle on the top of the power supply Tilt the endcaps back slightly so that you can get the edges of the handle out from underneath the endcaps Remove the handle and then lift the cover off the power supply Remove the Nomex barrier that protects the power board 3 Compress the collar on the hose fitting and pull the hose from the fitting to remove the gas hose from the solenoid valve Solenoid valve Hose fitting collar Gas hose 3 24 powermax30 Service Manual 4 Carefully tilt the front endcap away the power supply The orange blue and purple wires from the torch lead are connected to the power board with a 3 pin connector at J12 Remove the connector by pulling it toward the front of the power supply TORCH o START J12 5 The white wire group and the red wire from the torch lead are secured to studs in the power supply s center panel on the fan side of the power supply Use a 5 16 inch 8 mm nut driver to remove the nuts from the studs and slide the ring terminals off the studs White wire group Red wire powermax30 Service Manual 3 25 MAINTENANCE 6 10 11 12 13 14 On the inside of the front endcap unscrew the torch lead s strain relief retaining nut so that the torch lead moves freely Remove the torch lead by pulling the wires and gas supply line through the hole in the
42. S Recommended cutting capacity Maximum cutting capacity Severance cutting capacity Weight 1 4 inch 6 mm at 30A 35 duty cycle 3 8 inch 10 mm at 30A 35 duty cycle 1 2 inch 12 mm at 30A 35 duty cycle 2 1 lbs 1 0 kg Dimensions powermax30 Service Manual 8 72 221 mm gt 8 5 216 mm _ 2 3 SPECIFICATIONS Symbols and markings S mark The 5 mark indicates that the power supply and torch are suitable for use in environments with increased hazard of electrical shock CE mark The CE mark C constitutes a manufacturer s declaration of conformity to applicable European directives and standards Only those versions of Hypertherm products with a CE mark located on or near the data plate have been tested for compliance with the European Low Voltage Directive and the European EMC Directive EMC filters needed to comply with the European EMC Directive are incorporated within versions of the power supply with a CE mark IEC symbols The following symbols may appear on the power supply data plate control labels switches and LEDs a Direct current DC ae Alternating current AC Plasma torch cutting Ja AC input power connection za The terminal for the external protective earth conductor Power is ON Power is OFF BI inverter based power source Volt amp curve drooping characteris
43. T rm 3 14 Test 1 voltage Input 3 15 Test 2 power board voltage checksum 3 16 Test 3 VBUS and voltage balance sisi 3 17 Test 4 S0l8n0id i uii teta tee tdt enacted dart cv od 3 18 Test 5 torch stuck open TSO eee eee eee eee aaa sese entm nenne nnns rennes inen rsen reset nnd nnns en nns 3 19 Test 6 plasma 5 MT 3 20 Test 7 _ ________ _ __ 3 20 TOSCO aue io een iri OA 3 21 Test 9 pressure SWITCH sets irit ed to tee octo ire deut dri een end nt dA AR Le een 3 21 vi powermax30 Service Manual TABLE OF CONTENTS Component 3 22 Remove EE 3 22 Replace the torch lead ii 3 24 Replace the work lead a tete de ieu 3 26 Replace the power cord CSA een aaa aaa aaa nenne sette tanen reset nasa sentent nnne snnt nnns 3 27 Replace the power cord 3 28 Replace the s 3 30 Replace the air filter element sise 3 31 Replace the air filter regulator seine 3 32 Replace th Control A dettes aut
44. al inspection before continuing in this section f resistance values are not close 25 to the values given in this section isolate the problem by removing wires attached to the resistance check points or component until the problem is found After the problem has been located and repaired refer to the Sequence of operation flow diagram in this section to test the power supply for proper operation 1 With the power disconnected set the ON OFF switch 51 to ON 1 2 Check the resistance across the input leads 74 5 Black CSA brown CE E M 3 Check the resistance from the input leads to ground to verify that it reads as open Note With the power disconnected and the ON OFF switch 51 set to OFF O all circuits should read as open The electrical value shown is 25 If no problems were found during the visual inspection or the initial resistance check and the power supply still does not operate correctly see the Troubleshooting guide Note The Troubleshooting guide provides most probable causes and solutions Study the system wiring diagram and understand the theory of operation before troubleshooting Before purchasing any major replacement component verify the problem with Hypertherm Technical Service or the nearest Hypertherm repair facility powermax30 Service Manual 3 7 MAINTENANCE Power supply overview
45. alues can 10 SZ Turn the power ON after you have connected the E Z Hooks The multimeter should read 375 VDC If you get a value other than 375 VDC multiply the reading by 0 00601 to convert it to millivolts Test pin 21 on J7 It should have the same value 3 Turn the power OFF and move the E Z Hooks to VBUS and 375 VDC 2 Turn the power ON after you have connected the multimeter This value should be 187 5 VDC or one half of whatever value you found in step 2 4 Turn the power OFF and move the E Z Hooks to 375 VDC and 375 VDC 2 Turn the power ON after you have connected the multimeter This value should be 187 5 VDC or one half of whatever value you found in step 2 5 The values found in steps 3 and 4 should be approximately equal If they differ by more than 30 V replace the power board Step 2 Step 3 PE Step 4 powermax30 Service Manual 3 17 MAINTENANCE Test 4 solenoid valve If gas is not flowing properly test the solenoid valve for proper operation 1 Place a jumper from pin 4 of J6 on the power board to ground You should hear the valve click PE ground 2 There is an LED on the solenoid valve that illuminates red when the torch is fired It stays illuminated until postflow stops Fire the torch and watch for the LED to illuminate 3 If you do not hear the valve click or the LED does not illuminate replace the solenoid valve Solenoid valve LED
46. ant 3 33 Replace the power DOS ds 3 34 Replace th base EE 3 37 Section 4 PARTS Power Supply E Ae eee Aa 4 2 uu T oo eee 4 2 Interior Side aote tente db ee are Du e ets 4 3 Interior due 4 4 Tay Nand torch parts cc det ete ede od pe LE cep ete aevo cox lat eve PEE dete ete Rzy c 4 5 SafetyscriticallDatts A ge re qtio nti o nia 4 6 Recommended spare parts ii aaa aaa 4 7 Section5 WIRING DIAGRAMS Electrical schemate sot A ate Bade eae o eto wi oi o 5 3 powermax30 Service Manual vii TABLE OF CONTENTS viii powermax30 Service Manual Section 1 In this section Recognize Safety INTOMMATION coccion ee 1 2 Follow safety instructions seen 1 2 Cutting can cause fire or 42 07 uses a elite hed een A derided e 1 2 Electric SHOCK IM em 1 3 Static electricity can damage circuit boards sr 1 3 Toxic fumes can cause injury or occae ee tete AA nt dr 1 4 A plasma arc can cause injury and 1 5 Arc rays can burn eyes and
47. butane lighter ultraviolet and infrared rays or matches from your pockets before cutting Lens shade Cutting area Prepare the cutting area to reduce Up to 100A No 8 No 11 Paint walls and other surfaces with dark colors to 100 200 A No 10 No 11 12 reduce reflection Use protective screens barriers to protect others Arc current fD AWS USA 150 4850 reflection and transmission of ultraviolet light 200 400 A No 12 No 13 from flash and glare Over 400 A No 14 No 14 Warn others not to watch the arc Use placards or signs GROUNDING SAFETY Input power Be sure to connect the power cord ground wire to the ground in the disconnect box Work cable Attach the work cable securely to the If installation of the plasma system involves workpiece or the work table with good metal to metal connecting the power cord to the power supply be contact Do not connect it to the piece that will fall sure to connect the power cord ground wire away when the cut is complete properly Place the power cord s ground wire on the stud first Work table Connect the work table to an earth then place any other ground wires on top of the ground in accordance with appropriate national or power cord ground Fasten the retaining nut tightly local electrical codes Tighten all electrical connections to avoid excessive heating Hypertherm Plasma Systems 1 5 5 02 COMPRESSED GAS EQUIPMENT SAFETY
48. cess Depending upon the chemical composition and concentration of the fumes as well as other factors such as ventilation there may be a risk of physical illness such as birth defects or cancer It is the responsibility of the equipment and site owner to test the air quality in the area where the equipment is used and to ensure that the air quality in the workplace meets all local and national standards and regulations TOXIC FUMES CAN CAUSE INJURY OR DEATH The air quality level in any relevant workplace depends on site specific variables such as Table design wet dry underwater Material composition surface finish and composition of coatings Volume of material removed Duration of cutting or gouging Size air volume ventilation and filtration of the work area Personal protective equipment Number of welding and cutting systems in operation Other site processes that may produce fumes If the workplace must conform to national or local regulations only monitoring or testing done at the site can determine whether the site is above or below allowable levels To reduce the risk of exposure to fumes Remove all coatings and solvents from the metal before cutting Use local exhaust ventilation to remove fumes from the air Do not inhale fumes Wear an air supplied respirator when cutting any metal coated with containing or suspected to contain toxic elements Assure that those using welding or cutt
49. ch cap LED yellow When illuminated this LED indicates that the consumables loose improperly installed or missing Temperature LED yellow When illuminated this LED indicates that the power supply s temperature is outside the acceptable operating range Amperage adjustment knob Use this knob to set the output current between 15 and 30 amps For use on a Lb Y 120 volt 15 amp circuit set it at 20 or indicated by the darker area around the knob Some fault conditions will cause one or more of the LEDs to flash For information on what these fault conditions are and how to clear them see Troubleshooting guide later in this section 3 2 powermax30 Service Manual Theory of operation General Refer to the Functional description and Sequence of operation sections below and to Section 5 Wiring diagrams Functional description AC power enters the system through the power switch S1 to the input diode bridges D24 D30 The voltage from the diode bridge supplies the power factor correction PFC boost converter which provides a nominal 375 VDC bus voltage The bus voltage then supplies voltage and current to the inverter and the flyback circuit power supply DC to DC converter on the power board PCB2 The power board provides noise suppression and spike protection A soft start is implemented via the power board resistor and relay K1 The PFC boost c
50. ct connection is not permitted the bonding should be achieved by suitable capacitances selected according to national regulations 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 increase the risk of injury for example by allowing parallel cutting current return paths which may damage the earth circuits of other equipment Further guidance is given in IEC TS 62081 Arc Welding Equipment Installation and Use Screening and shielding Selective screening and shielding of other cables and equipment in the surrounding area may alleviate problems of interference Screening of the entire plasma cutting installation may be considered for special applications 8 06 Hypertherm Plasma Systems Warning Genuine Hypertherm parts are the factory recommended replacement parts for your Hypertherm system Any damage caused by the use of other than genuine Hypertherm parts may not be covered by the Hypertherm warranty Warning You are responsible for the safe use of the Product Hypertherm does not and cannot make any guarantee or warranty regarding the safe use of the Product in your environment General Hypertherm Inc warrants that its Products shall be free from defects in materials and workmanship if Hypertherm is notified of a defect i with respect to the power supply within a pe
51. de deteriorar la audici n usine 1b 6 Operaci n de marcapasos y de aud fonos is 1b 6 Un arco plasma puede da ar tubos congelados eee 1b 6 Etiquetas de advertencia id aida 1b 7 Section 2 SPECIFICATIONS Power 5 2 2 DIMENSIONS AN Ael 2 2 Neo rige 2 3 see c Em 2 3 Symbols and MarkingS 03 a 2 4 s Marsans 2 4 at iaa 2 4 2 4 Section 3 MAINTENANCE Controls indicators RM 3 2 Front controls and LEDS viii 3 2 Rear COMMIS cnica ari NOSA 3 2 Theory Of UEM 3 3 General ai 3 3 FUNCHONAMASSEMPUON cari dd 3 3 SEQUENCE Of OPEMAtiON e 3 4 Troubleshooting preparation WA W AYO a ye ibi 3 5 PETER 3 5 Troubleshooting procedures and sequence 3 5 External iINSp CtiON em 3 5 intemal iii a 3 6 Initial resistance qM ia 3 7 Power SUPply OVOIVIS Wii AA ii 3 8 Troubleshooting guid ictericia cone 3 9 Control board LEDS cuicos inicia 3 12 Use the Error and Reset LEDs to troubleshoot aaa enne enn 3 13 System tE MERETUR L
52. e 2 screws from the handle on the top of the power supply Remove the handle and then lift the cover off the power supply Remove the Nomex barrier that protects the power board The power cord has a black wire and a white wire that connect to the power switch and a green ground wire that connects to the heatsink 3 Remove the rear endcap or gently tilt it away from the power supply 4 Carefully pull the connector for the white wire away from the power switch to disconnect it You can use needlenose pliers or a straight screwdriver to ease it off if necessary 5 Remove the black wire the same way Single phase L N White wire Black wire L NS 6 Remove the screw that holds the green wire to the heatsink A notch in the power board provides access to the screw 7 On the outside of the power supply loosen the strain relief retention nut so that the wires move freely If you will replace the strain relief use an adjustable wrench to unscrew the nut on the inside of the power supply as well powermax30 Service Manual 3 27 MAINTENANCE 8 Pull the wires through the strain relief or through the hole in the endcap to remove the old power cord 9 f you have a new strain relief slide it onto the new power cord and route the wires for the new power cord through the hole in the endcap If the old strain relief is still in place ro
53. e cancer Il incombe au propri taire du mat riel et du site de v rifier la qualit de l air dans le secteur l on utilise le mat riel et de s assurer que la qualit de l air sur les lieux de travail r pond aux normes et r glementation locales et nationales LES VAPEURS TOXIQUES PEUVENT PROVOQUER DES BLESSURES OU LA MORT Le niveau de qualit de l air dans tout lieu de travail d pend des variables propres au site comme Type de table humide s che sous l eau Composition du mat riau fini de la surface et composition des rev tements Volume de mat riau enlev Dur e du coupage ou du gougeage Dimensions volume d air ventilation et filtration de la zone de travail quipement de protection individuelle Nombre de syst mes de soudage et de coupage en fonctionnement Autres proc d s du site qui peuvent produire des vapeurs Si les lieux de travail doivent tre conformes aux r glements nationaux ou locaux seuls les contr les OU les essais effectu s au site peuvent d terminer si celui ci se situe au dessus ou au dessous des niveaux admissibles Pour r duire le risque d exposition aux vapeurs liminer tout rev tement et solvant du m tal avant le coupage Utiliser la ventilation d extraction locale pour liminer les vapeurs de l air Ne pas inhaler les vapeurs Porter un respirateur adduction d air quand on coupe des m taux rev tus d l ments toxiques ou qui en contiennent ou
54. ear it 6 Place the wooden end of a swab a stiff wire or other similar item with a 092 inch 23 cm diameter in each of the 5 holes on the power board side of the base Press each one until the clips release and you can pull the base away from the center panel 7 Position the new base over the metal plate on the bottom of the power supply so that the screw holes align Replace the 6 screws and press the data plate onto the new base 8 Replace the endcaps Make sure that the screw hole in the ground clip on the front endcap aligns with the screw holes in the endcap and the power supply 9 Being careful not to pinch any of the wires replace the Nomex barrier and slide the cover back onto the power supply Make sure that the bottom edges are in the tracks Position the handle over the holes in the top of the cover then use the 2 screws to secure the cover 10 Reconnect the electrical power and the gas supply powermax30 Service Manual 3 37 MAINTENANCE 3 38 powermax30 Service Manual Section 4 PARTS In this section Power supply palis d PER RTR CREE 4 2 EXPO tai 4 2 Interi r power board Side viii a A A da a a ii 4 3 Interior fan SidO cocninnosioiciaccctanrccrrarra rra dO ATA PP 4 4 T30v hand torch 5 ia as 4 5 EE 4 6 Recommended Spare parts A R AR A A A NRA 4 7 powermax30 Service Manual 4 1 PARTS
55. eau 5 1 Porter un bon quipement de protection pour se prot ger la t te les yeux les oreilles les mains et le corps Boutonner le col de la chemise Prot ger les oreilles contre le bruit Utiliser un masque de soudeur avec un filtre de nuance appropri e 6 Suivre une formation Seul le personnel qualifi a le droit de faire fonctionner cet quipement Le personnel non qualifi et les enfants doivent se tenir l cart 7 Ne pas enlever d truire ni couvrir cette tiquette La remplacer si elle est absente endommag e ou us e PN 110584 Rev A D brancher la prise ou la source de courant avant de provoquer une explosion ou un incendie 1 1 Pendant le coupage loigner toute mati re inflammable 1 2 Conserver un extincteur proximit et s assurer qu une personne soit pr te l utiliser 1 3 Ne jamais couper de r cipients ferm s 2 Larc plasma peut provoquer des blessures et des br lures 2 1 Couper l alimentation avant de d monter la torche 2 2 Ne pas tenir la surface couper pr s de la trajectoire de coupe 2 3 Porter des v tements de protection couvrant tout le corps 3 Un choc lectrique caus par la torche ou les cables peut tre fatal Se prot ger contre les risques de chocs lectriques 3 1 Porter des gants isolants Ne pas porter de gants mouill s ou ab m s 3 2 S isoler de la surface de travail et du sol Hypertherm Syst mes plasma 4 1 4 2 5 1 manipul
56. endcap Route the wires and the gas supply line for the new torch lead through the hole in the endcap and then through the nut for the strain relief Tighten the torch lead s strain relief retaining nut onto the strain relief Push the torch s gas supply hose approximately 65 inch 16 mm into the fitting on the bottom of the solenoid valve Slide the ring terminal for the white wire group over the left stud labeled WHT on the center panel Slide the ring terminal for the red wire onto the stud on the right labeled RED on the center panel Tighten the nut onto each stud Route the orange blue and purple wire group over the center panel with the wires resting in the notch in the panel Press the connector into the slot on the power board Being careful not to pinch any of the wires replace the Nomex barrier and slide the cover back onto the power supply Make sure that the bottom edges are in the tracks Reposition the endcap Make sure that the screw hole in the ground clip aligns with the screw holes in the endcap and the power supply Position the handle over the holes in the top of the cover then use the 2 screws to secure the cover Reconnect the electrical power and the gas supply Replace the work lead 1 2 Turn OFF the power disconnect the power cord and disconnect the gas supply Remove the 2 screws from the handle on the top of the power supply Remove the handle and then lift the cover off
57. er board To do so will risk a short circuit between the AC input circuit and the output circuit and may result in serious injury or death HOT PARTS CAN CAUSE SEVERE BURNS Allow the power supply to cool before servicing MOVING BLADES CAN CAUSE INJURY Keep hands away from moving parts STATIC ELECTRICITY CAN DAMAGE CIRCUIT BOARDS Put on a grounded wrist strap before handling PC boards Internal inspection 1 2 Set the ON OFF switch 51 to O OFF unplug the power cord and disconnect the gas supply Use a 2 Phillips head screwdriver to remove the 2 screws from the power supply s handle Tip the endcaps back slightly so that you can get the edges of the handle out from underneath the endcaps Remove the handle and then lift the cover off the power supply There is a insulating barrier between the cover and the power board Lift the barrier out of the power supply and set it aside Be certain to replace the barrier when you are finished working on the power supply Inspect the inside of the power supply especially on the side with the power board Look for broken or loose wiring connections burn and char marks damaged components and so on Repair or replace as necessary 3 6 powermax30 Service Manual Initial resistance check All resistance values must be taken with the power cord disconnected and all internal power supply wires attached Perform the steps in Intern
58. er l quipement L inhalation des vapeurs produites par le coupage peut tre dangereuse pour la sant Garder le visage l cart des vapeurs Utiliser un syst me de ventilation par aspiration ou d chappement localis pour dissiper les vapeurs Utiliser un ventilateur pour dissiper les vapeurs Les rayons de l arc peuvent br ler les yeux et provoquer des l sions de la peau Porter un casque et des lunettes de s curit Se prot ger les oreilles et porter une chemise dont le col peut tre d boutonn Porter un casque de soudure dont la protection filtrante est suffisante Porter des v tements protecteurs couvrant la totalit du corps Se former la technique du coupage et lire les instructions avant de manipuler l quipement ou de proc der au coupage Ne pas retirer ou peindre recouvrir les tiquettes de s curit 1a 7 8 99 SECURITE Etiquette de s curit Cette tiquette est affich e sur la source de courant Il est important que l utilisateur et le technicien de maintenance comprennent la signification des symboles de s curit Les num ros de la liste correspondent aux num ros des images 1a 8 8 99 Les tincelles produites par le coupage peuvent provoquer une explosion ou un incendie Pendant le coupage loigner toute mati re inflammable Conserver un ex
59. es oreilles contre le bruit Utiliser un masque de soudeur avec un filtre de nuance appropri e 6 Suivre une formation Seul le personnel qualifi a le droit de faire fonctionner cet quipement Le personnel non qualifi et les enfants doivent se tenir l cart 7 Ne pas enlever d truire ni couvrir cette tiquette La remplacer si elle est absente endommag e ou us e PN 110584 Rev A 1 Cutting sparks can cause explosion or fire 1 1 Keep flammables away from cutting 1 2 Keep a fire extinguisher nearby and have a watchperson ready to use it 1 3 Do not cut on any closed containers 2 The plasma arc can cause injury and burns 2 1 Turn off power before disassembling torch 2 2 Do not hold the material near cutting path 2 3 Wear complete body protection 3 Electric shock from torch or wiring can kill Protect yourself from electric shock 3 1 Wear insulating gloves Do not wear wet or damaged gloves 3 2 Insulate yourself from work and ground Hypertherm Plasma Systems 3 3 Disconnect input plug or power before working on machine 4 Breathing cutting fumes can be hazardous to your health 4 1 Keep your head out of the fumes 4 2 Use forced ventilation or local exhaust to remove the fumes 4 3 Use ventilating fan to remove the fumes 5 Arcrays can burn eyes and injure skin 5 1 Wear hat and safety glasses Use ear protection and button shirt collar Use welding helmet with correct shade of f
60. esa de trabajo con el cable de trabajo conectado en todo momento Antes de inspeccionar limpiar o cambiar las piezas de la antorcha desconecte la potencia primaria o desenchufe la fuente de energ a Nunca evite o descuide los bloqueos de seguridad Antes de retirar la cubierta de una fuente de energ a o del gabinete de un sistema desconecte la potencia primaria de entrada Espere 5 minutos despu s de desconectar la potencia primaria para permitir la descarga de los condensadores Nunca opere el sistema de plasma sin que las tapas de la fuente de energ a est n en su lugar Las conexiones expuestas de la fuente de energ a presentan un serio riesgo el ctrico Al hacer conexiones de entrada conecte el conductor de conexi n a tierra en primer lugar Cada sistema de plasma Hypertherm est dise ado para ser utilizado s lo con antorchas Hypertherm espec ficas No utilice antorchas diferentes que podr an recalentarse y ser peligrosas 58 lt gt Use precauciones adecuadas cuando maneje tablillas impresas de circuito ELECTRICIDAD ESTATICA PUEDE DANAR TABLILLAS DE CIRCUITO Almacene las tablillas PC en recipientes antiestaticos Use la defensa de mu eca conectada a tierra cuando maneje tablillas PC Hypertherm Sistemas plasma 1b 3 8 06 SEGURIDAD El arco plasma por si solo la fuente de calor que se uSa para cortar Segun esto aunque el arco de plasma no ha
61. est fails check the torch s start switch and the torch wires 3 Set the ON OFF switch to ON I Measure pin 16 of J7 to ground see Test 2 earlier in this section It should measure as 0 VDC for an open circuit or 3 2 VDC for a closed circuit If the values are not correct replace the power board Caution While testing avoid any contact with the tip of the torch TORCH O START 12 Test 7 torch cap sensor Test the cap sensor switch and torch leads 1 Set the ON OFF switch to OFF 2 Gently pull the front endcap away from the power supply Unplug J12 from the back side of the power board just below the torch start test points 3 Measure the resistance from the orange wire to the blue wire It should measure less than 10 If it reads as open the cap sensor switch circuit is not satisfied 4 If the torch plunger moves smoothly and the consumables are correctly installed then either the cap sensor switch is faulty or the torch lead has a broken wire Replace the faulty part 3 20 powermax30 Service Manual Test 8 fan Test the fan for proper operation Place jumper from ground to pin 3 of J5 If the fan does not operate replace the fan Ground to ground wire clip or to the heat sink Test 9 pressure switch Test the pressure switch to ensure that the system is receiving the proper gas pressure 1 Turn OF
62. ev A M AVERTISSEMENT Le coupage plasma peut tre pr judiciable pour l op rateur et les personnes qui se trouvent sur les lieux de travail Consulter le manuel avant de faire fonctionner Le non respect des ces instructions de s curit peut entra ner la mort 1 Les tincelles de coupage peuvent provoquer une explosion ou un incendie 1 1 Ne pas couper pr s des mati res inflammables 1 2 Un extincteur doit tre proximit et pr t tre utilis 1 3 Ne pas utiliser un f t ou un autre contenant ferm comme table de coupage 2 Larc plasma peut blesser et br ler loigner la buse de soi Il s allume instantan ment quand on l amorce 2 1 Couper l alimentation avant de d monter la torche 2 2 Ne pas saisir la pi ce couper de la trajectoire de coupage 2 3 Se prot ger enti rement le corps 3 Tension dangereuse Risque de choc lectrique ou de br lure 3 1 Porter des gants isolants Remplacer les gants quand ils sont humides ou endommag s 3 2 Se prot ger contre les chocs en s isolant de la pi ce et de la terre 3 3 Couper l alimentation avant l entretien Ne pas toucher les pi ces sous tension 4 Les fum es plasma peuvent tre dangereuses 4 1 Ne pas inhaler les fum es 4 2 Utiliser une ventilation forc e ou un extracteur local pour dissiper les fum es 4 3 Ne pas couper dans des espaces clos Chasser les fum es par ventilation 5 Les rayons d arc peuvent br ler les yeux et blesser la p
63. f Equipment used for calibration or measurement g Immunity of other equipment in the environment User shall ensure that other equipment being used Hypertherm Plasma Systems inthe environment is compatible This may require additional protection measures h Time of day that cutting or other activities are to be carried out The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place The surrounding area may extend beyond the boundaries of the premises Methods of reducing emissions Mains supply Cutting equipment must be connected to the mains supply according to the manufacturer s recommendations If interference occurs it may be necessary to take additional precautions such as filtering of the mains supply Consideration should be given to shielding the supply cable of permanently installed cutting equipment in metallic conduit or equivalent Shielding should be electrically continuous throughout its length The shielding should be connected to the cutting mains supply so that good electrical contact is maintained between the conduit and the cutting power source enclosure Maintenance of cutting equipment The cutting equipment must be routinely maintained according to the manufacturer s recommendations All access and service doors and covers should be closed and properly fastened when the cutting equipment is in operation The cutting e
64. f the power board 6 Remove the wires for the transformers and inductors at J13 J14 J15 J18 J19 J20 and J21 7 Remove the work lead ring terminal from J22 8 Remove the 3 retaining screws and the 4 heatsink assembly screws 9 Remove the 5 screws that attach the IGBTs to the heatsink There are holes in the power board to provide access to them 10 Remove the screw from the snubber resistor on the top of the heatsink Snubber resistor screw 3 34 powermax30 Service Manual IGBT attachment Retaining screw _ J5 and J6 screws Retaining screw Ribbon cable Heat sink assembly screw Heat sink Torch start and assembly cap sensor screw J12 J13 J14 J18 J15 ES Heat sink assembly screw Heat sink assembly screw Work lead Retaining J21 J20 J19 connector J22 screw 11 Detach the bottom 2 wires both are white from the ON OFF switch 12 Lay the unit on its side power board down and use a 5 16 inch 8 mm nut driver to remove the nuts that secure the red and the white wires that are routed underneath the board to the studs on the fan side of the unit The studs are labeled RED and WHT powermax30 Service Manual 3 35 MAINTENANCE 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 Stand up the unit again Tuck out o
65. f the way all wires that you detached Pull the board straight out from the power supply Before installing a new power board clean the heatsink with isopropyl alcohol Gently scrub away any residual thermal compound being careful not to scratch the heatsink Wipe it with a clean cloth Spread a thin layer of thermal compound 2 mil thick about the thickness of a sheet of paper on all the IGBTs Spread a layer of thermal compound 2 mil thick on the snubber resistor starting from the bottom and dragging toward the top away from the prongs It is important to avoid getting any compound on the prongs Push the red and white wires that are attached to the new power board through from the power board side of the power supply to the fan side of the power supply Line up the capacitors on the back of the power board with the holes in the power supply s center panel Push the power board straight in Reconnect the 2 white wires to the ON OFF switch Replace the 4 heatsink assembly screws and the 3 retaining screws Torque these screws to 15 inch pounds 17 28 kg cm Replace the screw you removed from the snubber resistor in step 10 Torque it to 7 inch pounds 8 06 kg cm Note Torque settings greater than 7 inch pounds 8 06 kg cm may damage the resistor Replace the 5 screws that attach the IGBTs to the heatsink The torque setting for these is 15 inch pounds 17 28 kg cm Reconnect the wires to the transformers and inductors at J
66. f this Warranty Proper disposal of Hypertherm products Hypertherm plasma cutting systems like all electronic products may contain materials or components such as printed circuit boards that cannot be discarded with ordinary waste It is your responsibility to dispose of any Hypertherm product or component part in an environmentally acceptable manner according to national and local codes In the United States check all federal state and local laws In the European Union check the EU directives national and local laws In other countries check national and local laws Register your product on line at www hypertherm com warranty htm Hypertherm Plasma Systems TABLE OF CONTENTS Electromagnetic Warranty T ii Section 1 SAFETY Recognize safety information ss tener sse trenes aaa nennen nnns 1 2 Follow safety 5 pee decine rta o ERE das 1 2 Cutting can cause fire or explosion iii 1 2 Electric shock can HERE 1 3 Static electricity can damage circuit boards se 1 3 Toxic fumes can cause injury or death sise 1 4 A plasma arc can cause injury and burns iii 1 5 Arc Can bur eyeS and WI tinea n adenda dai 1 5 Grou ding safety eter t tee ia
67. g screw 4 Remove the retaining screw from the bottom of the endcap that you will remove 5 There are snaps on both sides of each endcap that hold the endcaps in place Insert needlenose pliers into the opening for one of the snaps and use the pliers to squeeze it together 6 Place a flat blade screwdriver against the raised rib next to the snap and gently turn the screwdriver to push the endcap away from the base powermax30 Service Manual 3 23 MAINTENANCE 7 Place another screwdriver or similar object into the opening between the endcap and the base to keep the first corner of the endcap from returning to its original position when you release the other corner 8 Repeat steps 5 and 6 on the other corner of the endcap 9 If you are completely removing the endcap to replace it rather than removing it for better access to the interior of the power supply you must also disconnect the torch lead work lead and ground clip from the front endcap or the power cord and gas supply connector from the rear endcap 10 To replace the endcap push it into the base to re engage the snaps and then tighten the retaining screw On the rear endcap make sure that the hole in the ground clip is aligned with the screw holes in the endcap and the power supply before attempting to insert the retaining screw Replace the torch lead 1 Turn OFF the power disconnect the power cord and disconnect the gas supply 2 Use a 2
68. he handle and then lift the cover off the power supply 3 Remove the drain hose from the hole in the bottom of the power supply s base 4 Unscrew the nut that holds the air filter in the bracket Tip the bottom of the air filter away from the power supply 5 Unscrew the filter bowl from the body and remove it Nut Bracket Filter bowl Drain hose 6 Unscrew the element from the filter body while being careful not to allow the element to rotate 7 Screw the new element onto the filter body 8 Reattach the filter bowl 9 Reposition the air filter assembly in the bracket and replace its retainer nut 10 Route the drain hose through the hole in the base of the power supply 11 Reconnect the gas supply and check for leaks 12 Being careful not to pinch any of the wires slide the cover back onto the power supply Make sure that the bottom edges are in the tracks Position the handle over the holes in the top of the cover then use the 2 screws to secure the cover 13 Reconnect the electrical power powermax30 Service Manual 3 31 MAINTENANCE Replace the air filter and regulator 1 Turn OFF the power disconnect the power cord and disconnect the gas supply 2 Remove the 2 screws from the handle on the top of the power supply Remove the handle and then lift the cover off the power supply 3 Remove the gas fitting from the rear of the power supply 4 Remove the drain hose from the hole in the bottom of the power supply s base
69. icable European directives and standards Only those versions of Hypertherm products with a CE Marking located on or near the data plate have been tested for compliance with the European Low Voltage Directive and the European EMC Directive EMC filters needed to comply with the European EMC Directive are incorporated within versions of the power supply with a CE Marking Patent indemnity Except only in cases of products not manufactured by Hypertherm or manufactured by a person other than Hypertherm not in strict conformity with Hypertherm s specifications and in cases of designs processes formulae or combinations not developed or purported to be developed by Hypertherm Hypertherm will defend or settle at its own expense any suit or proceeding brought against you alleging that the use of the Hypertherm product alone and not in combination with any other product not supplied by Hypertherm infringes any patent of any third party You shall notify Hypertherm promptly upon learning of any action or threatened iii 8 06 WARRANTY action in connection with any such alleged infringement and Hypertherm s obligation to indemnify shall be conditioned upon Hypertherm s sole control of and the indemnified party s cooperation and assistance in the defense of the claim Limitation of liability In no event shall Hypertherm be liable to any person or entity for any incidental consequential indirect or punitive damages includi
70. ignal word DANGER or WARNING is used with a safety symbol DANGER identifies the most serious hazards DANGER and WARNING safety labels are located on your machine near specific hazards WARNING safety messages precede related instructions in this manual that may result in injury or death if not followed correctly CAUTION safety messages precede related instructions in this manual that may result in damage to equipment if not followed correctly Fire prevention Be sure the area is safe before doing any cutting Keep a fire extinguisher nearby Remove all flammables within 35 feet 10 m of the cutting area Quench hot metal or allow it to cool before handling or before letting it touch combustible materials Never cut containers with potentially flammable materials inside they must be emptied and properly cleaned first Ventilate potentially flammable atmospheres before cutting When cutting with oxygen as the plasma gas an exhaust ventilation system is required Explosion prevention Do not use the plasma system if explosive dust or vapors may be present Do not cut pressurized cylinders pipes or any closed container Do not cut containers that have held combustible materials CUTTING CAN CAUSE FIRE OR EXPLOSION WARNING Explosion Hazard Argon Hydrogen and Methane A Hydrogen and methane are flammable gases that present an explosion hazard Keep flames away from cy
71. ilter Wear complete body protection 6 Become trained and read the instructions before working on the machine or cutting 7 Do not remove or paint over cover warning labels 8 99 SAFETY s WARNING LABEL 1 Cutting sparks can cause explosion This warning label is affixed to some power supplies It is oe important that the operator and maintenance technician 1 1 Keep flammables away from cutting understand the intent of these warning symbols as described The numbered text corresponds to the numbered boxes on 1 2 Keep a fire extinguisher nearby and the label have a watchperson ready to use it 1 3 Do not cut on any closed containers 2 The plasma arc can cause injury and burns 2 1 Turn off power before disassembling torch 2 2 Do not hold the material near cutting path 2 3 Wear complete body protection 3 Electric shock from torch or wiring can kill Protect yourself from electric shock 3 1 Wear insulating gloves Do not wear wet or damaged gloves 3 2 Insulate yourself from work and ground 3 3 Disconnect input plug or power before working on machine 4 Breathing cutting fumes can be hazardous to your health 4 1 Keep your head out of the fumes 4 2 Use forced ventilation or local exhaust to remove the fumes 4 3 Use ventilating fan to remove the fumes 5 Arc rays can burn eyes and
72. ing equipment as well as air supplied respiration devices are qualified and trained in the proper use of such equipment Never cut containers with potentially toxic materials inside Empty and properly clean the container first Monitor or test the air quality at the site as needed Consult with a local expert to implement a site plan to ensure safe air quality 1 4 8 06 Hypertherm Plasma Systems SAFETY A PLASMA ARC CAN CAUSE INJURY AND BURNS Instant on torches The plasma arc will cut quickly through gloves Plasma arc comes on immediately when the torch and skin switch is activated Keep away from the torch tip Do not hold metal near the cutting path Never point the torch toward yourself or others ARC RAYS CAN BURN EYES AND SKIN Eye protection Plasma arc rays produce intense Skin protection Wear protective clothing to protect visible and invisible ultraviolet and infrared rays that against burns caused by ultraviolet light sparks and can burn eyes and skin hot metal Use eye protection in accordance with applicable Gauntlet gloves safety shoes and hat national or local codes Flame retardant clothing to cover all exposed areas Wear eye protection safety glasses or goggles with Cuffless trousers to prevent entry of sparks and side shields and a welding helmet with appropriate slag lens shading to protect your eyes from the arc s Remove any combustibles such as a
73. injure skin 5 1 Wear hat and safety glasses Use ear protection and button shirt collar Use welding helmet with correct shade of filter Wear complete body protection 6 Become trained and read the instructions before working on the machine or cutting 7 Do not remove or paint over cover warning labels 1 8 Hypertherm Plasma Systems 8 99 Section 1 SECURITE Dans cette section Identifier les consignes de s curit sise 1 2 Suivre les instructions de s curit usines 1 2 Le coupage peut provoquer un incendie ou une explosion iii 1a 2 Les chocs lectriques peuvent tre fatals iii 1a 3 L lectricit statique peut endommager les cartes de circuits imprim s 1a 3 Les vapeurs toxiques peuvent provoquer des blessures OU la mort 1a 4 L arc plasma peut provoquer des blessures ou des 1a 5 Les rayons de l arc peuvent br ler les yeux et la sie 1a 5 Mise la masse et la terre sise 1a 5 S curit des bouteilles de gaz comprim sise 1a 6 Les bouteilles de gaz comprim peuvent exploser cas de dommages 1a 6 Le bruit peut provoquer des probl mes auditifs si 1a 6 Pacemakers et proth ses auditives sise 1a 6 Un arc plasma peut endommager les tuyaux 68 1a 6 tiquettes de s curit ui icicisacessondascasssnicieassinasatoceda
74. ise replace the power board powermax30 Service Manual 3 13 MAINTENANCE Error LED The number of times the Error LED flashes indicates the problem detected Each flash is a half second long and each series of flashes is separated by a 2 second pause See System tests later in this section for detailed test procedures Number of error LED flashes Faulty control board Replace the control board Faulty power board Replace the power board Problem indicated Perform test 3 If any of the values are incorrect replace the power board Perform test 2 If any of the values for pins 5 7 or 12 are Either a faulty power board incorrect remove the control board and test again If the or a faulty control board values are correct replace the control board When performing test 2 if the values for pins 5 7 and 12 are correct but any other values are incorrect replace the power board Faulty gas solenoid valve Replace the gas solenoid valve Faulty fan Replace the fan System tests There is a ground clip near the top of the rear endcap that can be used as ground for any tests that require the multimeter to be attached to ground There is also a ground on the heat sink with access through the power board as shown in test 1 3 14 powermax30 Service Manual Test 1 voltage input Check the incoming voltage and the line voltage to the top of the power switch S1 1 2
75. jo alta presi n Un cilindro da ado puede explotar Manipule y utilice los cilindros de gas comprimido de acuerdo con los c digos locales o nacionales aplicables No use nunca un cilindro que no est de pie y bien sujeto Mantenga la tapa de protecci n en su lugar encima de la v lvula excepto cuando el cilindro se encuentre en uso o conectado para ser utilizado No permita nunca el contacto el ctrico entre el arco de plasma y un cilindro No exponga nunca los cilindros a calor excesivo chispas escorias llamas No emplee nunca martillos llaves u otro tipo de herramientas para abrir de golpe la v lvula del cilindro EL RUIDO PUEDE DETERIORAR LA AUDICI N La exposici n prolongada al ruido propio de las operaciones de corte y ranurado puede da ar la audici n Utilice un m todo de protecci n de los o dos aprobado al utilizar el sistema de plasma Advierta a las dem s personas que se encuentren en las cercan as acerca del peligro que supone el ruido excesivo UN ARCO PLASMA PUEDE 2 TUBOS CONGELADOS Se puede hacer a los tubos congelados se los puede reventar si uno trata de descongelarlos con una antorcha por plasma OPERACION DE MARCAPASOS e Y DE AUD FONOS Los campos magn ticos producidos por las elevadas corrientes pueden afectar la operaci n de marcapasos y de aud fonos Las personas que lleven marcapasos aud fonos
76. linders and hoses that contain methane or hydrogen mixtures Keep flames and sparks away from the torch when using methane or argon hydrogen plasma A When cutting aluminum underwater or with the water touching the underside of the aluminum free hydrogen gas may collect under the workpiece and detonate during plasma cutting operations Install an aeration manifold on the floor of the water table to eliminate the possibility of hydrogen detonation Refer to the Appendix section of this manual for aeration manifold details WARNING Hydrogen Detonation with Aluminum Cutting 1 2 11 98 Hypertherm Plasma Systems SAFETY Le JN Touching live electrical parts can cause a fatal shock or severe burn Operating the plasma system completes an electrical circuit between the torch and the workpiece The workpiece and anything touching the workpiece are part of the electrical circuit Never touch the torch body workpiece or the water in a water table when the plasma system is operating Electric shock prevention All Hypertherm plasma systems use high voltage in the cutting process 200 to 400 VDC are common Take the following precautions when operating this system Wear insulated gloves and boots and keep your body and clothing dry Do not stand sit or lie on or touch any wet surface when using the plasma system Insulate yourself from work and ground using dry insulating mats
77. material junto al trayecto de corte Proteja su cuerpo completamente Los electrochoques provocados por la antorcha o el cableado pueden ser fatales Prot jase del electrochoque Col quese guantes aislantes No utilice guantes da ados o mojados A slese de la pieza de trabajo y de la tierra Antes de trabajar en una m quina desconecte el enchufe de entrada o la potencia primaria La inhalaci n de los humos provenientes del rea de corte puede ser nociva para la salud Mantenga la cabeza fuera de los gases t xicos Utilice ventilaci n forzada o un sistema local de escape para eliminar los humos Utilice un ventilador para eliminar los humos Los rayos del arco pueden producir quemaduras en los ojos y en la piel Utilice un sombrero y gafas de seguridad Utilice protecci n para los o dos y abr chese el bot n del cuello de la camisa Utilice un casco de soldar con el filtro de sombreado adecuado Proteja su cuerpo completamente Antes de trabajar en la m quina o de proceder a cortar capacitese y lea las instrucciones completamente No retire las etiquetas de advertencia ni las cubra con pintura Hypertherm Sistemas plasma Section 2 SPECIFICATIONS In this section POWOr SUDDIY wawa das ria E add 2 2 DIMENSIONS 2 2 TSOV torch TAU gS 2 3 DIMENSIONS cositas 2 3 E en anses
78. minio bajo agua o con agua en contacto con el lado inferior del aluminio puede acumularse gas hidr geno bajo la pieza a cortar y detonar durante la operaci n de corte por plasma Prevenci n ante explosiones No corte en atm sferas que contengan polvo o vapores explosivos Instal de aireaci I fondo de d No corte dep sitos o tubos a presi n ni cualquier dep sito U MUNS e AESA ge agua para eliminar la posibilidad de la detonaci n del No corte dep sitos que hayan contenido materiales Consulta la Soda apendice as eee combustibles manual para conocer detalles acerca del m ltiple de aireaci n 1b 2 Hypertherm Sistemas plasma 11 98 SEGURIDAD EL CHOQUE ELECTRICO PUEDE PROVOCAR LA MUERTE El contacto directo con piezas el ctricas conectadas puede provocar un electrochoque fatal o quemaduras graves Al hacer funcionar el sistema de plasma se completa un circuito el ctrico entre la antorcha la pieza a cortar La pieza a cortar es una parte del circuito el ctrico como tambi n cualquier cosa que se encuentre en contacto con ella Nunca toque el cuerpo de la antorcha la pieza a cortar o el agua en una mesa de agua cuando el sistema de plasma se encuentre en funcionamiento Prevenci n ante el electrochoque Todos los sistemas por plasma de Hypertherm usan alto voltaje en el proceso de corte son comunes los voltajes CD de 200 a 400 Tome las sig
79. mpressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 7 CSA Standard W117 2 Code for Safety in Welding and Cutting Canadian Standards Association Standard Sales 178 Rexdale Boulevard Rexdale Ontario M9W 1R3 Canada 8 NFPA Standard 51B Cutting and Welding Processes National Fire Protection Association 470 Atlantic Avenue Boston MA 02210 9 NFPA Standard 70 1978 National Electrical Code National Fire Protection Association 470 Atlantic Avenue Boston MA 02210 10 OSHA Safety and Health Standards 29FR 1910 U S Government Printing Office Washington D C 20402 Hypertherm Plasma Systems WARNING LABEL SAFETY This warning label is affixed to some power supplies It is important that the operator and maintenance technician understand the intent of these warning symbols as described The numbered text corresponds to the numbered boxes on the label Read and follow these instructions employer safety practices and material safety data sheets Refer to ANS Z49 1 Safety in Welding Cutting and Allied Processes from American Welding Society http www aws org and OSHA Safety and Health Standards 29 CFR 1910 http www osha gov WARNING Plasma cutting can be injurious to operator and persons in the work area Consult manual before operating Failure to follow all these safety instructions can result in death 1 Cutting sparks can cause explosion or fire 1 1 Do not cut near flammables
80. ndasoagsdnianscusibindtadesanndesluesanssncesdabisadadesndanacedshdabulldssnasaeasdtadalnceniaetsae 1a 7 Hypertherm Syst mes plasma 1 1 8 06 SECURITE IDENTIFIER LES CONSIGNES DE SECURITE Les symboles indiqu s dans cette section sont utilis s pour identifier les risques ventuels Si vous trouvez un symbole de s curit que ce soit dans ce manuel ou sur l quipement soyez conscient des risques de blessures et suivez les instructions correspondantes afin d viter ces risques SUIVRE LES INSTRUCTIONS DE SECURITE Lire attentivement toutes les consignes de s curit dans le pr sent manuel et sur les tiquettes de s curit se trouvant sur la machine Les tiquettes de s curit doivent rester lisibles Remplacer imm diatement les tiquettes manquantes ou abim es Apprendre a faire fonctionner la machine et a utiliser correctement les commandes Ne laisser personne utiliser la machine sans connaitre son fonctionnement Garder la machine en bon tat Des modifications non autoris es sur la machine peuvent engendrer des probl mes de s curit et raccourcir la dur e d utilisation de l quipement DANGER AVERTISSEMENT PRECAUTION Les signaux DANGER ou AVERTISSEMENT sont utilis s avec un symbole de s curit DANGER correspondant aux risques les plus s rieux Les tiquettes de s curit DANGER et AVERTISSEMENT sont situ es sur la machine pour signaler certains dangers sp cifique
81. ner Le non respect des ces instructions de s curit peut entrainer la mort 1 Les tincelles de coupage peuvent provoquer une explosion ou un incendie 1 1 Ne pas couper pr s des mati res inflammables 1 2 Un extincteur doit tre proximit et pr t tre utilis 1 3 Ne pas utiliser un f t ou un autre contenant ferm comme table de coupage 2 l arc plasma peut blesser et br ler loigner la de soi Il s allume instantan ment quand on l amorce 2 1 Couper l alimentation avant de d monter la torche 2 2 Ne pas saisir la pi ce couper de la trajectoire de coupage 2 3 Se prot ger enti rement le corps 3 Tension dangereuse Risque de choc lectrique ou de br lure 3 1 Porter des gants isolants Remplacer les gants quand ils sont humides ou endommag s 3 2 Se prot ger contre les chocs en s isolant de la pi ce et de la terre 3 3 Couper l alimentation avant l entretien Ne pas toucher les pi ces sous tension 4 Les fum es plasma peuvent tre dangereuses 4 1 Ne pas inhaler les fum es 4 2 Utiliser une ventilation forc e ou un extracteur local pour dissiper les fum es 4 3 Ne pas couper dans des espaces clos Chasser les fum es par ventilation 5 Les rayons d arc peuvent br ler les yeux et blesser la peau 5 1 Porter un bon quipement de protection pour se prot ger la t te les yeux les oreilles les mains et le corps Boutonner le col de la chemise Prot ger les oreilles contre le
82. ng but not limited to lost profits regardless of whether such liability is based on breach of contract tort strict liability breach of warranties failure of essential purpose or otherwise and even if advised of the possibility of such damages Liability cap In no event shall Hypertherm s liability whether such liability is based on breach of contract tort strict liability breach of warranties failure of essential purpose or otherwise for any claim action suit or proceeding arising out of or relating to the use of the Products exceed in the aggregate the amount paid for the Products that gave rise to such claim 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 National and Local codes National and Local codes governing plumbing and electrical installation shall take precedent over any instructions contained in this manual In no event shall Hypertherm be liable for injury to persons or property damage by reason of any code violation or poor work practices 8 06 Transfer of rights You may transfer any remaining rights you may have hereunder only in connection with the sale of all or substantially all of your assets or capital stock to a successor in interest who agrees to be bound by all of the terms and conditions o
83. nt knob may be set too producing low current low The power board may be faulty The consumables are worn there is a poor work lead connection the output from the power supply is too low or the power board is The power board or the control board may be faulty The continuous pilot arc feature is not working Control Board LEDs The Powermax30 control board PCB1 has 4 diagnostic LEDs Ribbon cable Control board Inspect the consumables and replace if necessary Inspect the work lead for damage Reposition it and clean the work surface to ensure good contact Check the amps adjustment knob setting If your input circuit is 120 V 20 A 120 V 30 A or 240 V 20 A turn the knob to the highest setting Perform tests 2 and 3 to verify that the power board is functioning properly If the power board is faulty replace it Otherwise replace the control board powermax30 Service Manual Reset watchdog Error Transfer XFR Start P d
84. nt de faire fonctionner Le non respect des ces instructions de s curit peut entra ner la mort 1 Les tincelles de coupage peuvent provoquer une explosion ou un incendie 1 1 Ne pas couper pr s des mati res inflammables 1 2 Un extincteur doit tre proximit et pr t tre utilis 1 3 Ne pas utiliser un f t ou un autre contenant ferm comme table de coupage 2 plasma peut blesser et br ler loigner la buse de soi Il s allume instantan ment quand on l amorce 2 1 Couper l alimentation avant de d monter la torche 2 2 Ne pas saisir la pi ce couper de la trajectoire de coupage 2 3 Se prot ger enti rement le corps 3 Tension dangereuse Risque de choc lectrique ou de br lure 8 1 Porter des gants isolants Remplacer les gants quand ils sont humides ou endommag s 3 2 Se prot ger contre les chocs en s isolant de la pi ce et de la terre 3 3 Couper l alimentation avant l entretien Ne pas toucher les pi ces sous tension 4 Les fum es plasma peuvent tre dangereuses 4 1 Ne pas inhaler les fum es 4 2 Utiliser une ventilation forc e ou un extracteur local pour dissiper les fum es 4 3 Ne pas couper dans des espaces clos Chasser les fum es par ventilation 5 Les rayons d arc peuvent br ler les yeux et blesser la peau 5 1 Porter un bon quipement de protection pour se prot ger la t te les yeux les oreilles les mains et le corps Boutonner le col de la chemise Prot ger l
85. o lift the top edge of the Nomex barrier to see the connector From the top of the power supply use needlenose pliers to compress and release the 4 corner clips on the fan s plenum After you release the top clips you can tilt the plenum away from the power supply to reach the bottom 2 clips Lift the plenum off the fan casing Corner clips Top corner clips pi RE Jp Insert 1 Phillips screwdriver through the holes in the fan casing to remove the retaining screw from each corner of the fan Slide the old fan out from the power supply Slide the new fan into place Replace the 4 retaining screws Orient the fan plenum so that the wider end is at the bottom and snap it into place EU 3 30 powermax30 Service Manual 10 11 12 Attach the connector for the red and black wires on the left side of the fan to J5 on the power board Being careful not to pinch any of the wires replace the Nomex barrier and slide the cover back onto the power supply Make sure that the bottom edges are in the tracks Position the handle over the holes in the top of the cover then use the 2 screws to secure the cover Reconnect the electrical power and the gas supply Replace the air filter element 1 Turn OFF the power disconnect the power cord and disconnect the gas supply 2 Remove the 2 screws from the handle on the top of the power supply Remove t
86. o un sistema local de escape para eliminar los humos Utilice un ventilador para eliminar los humos Los rayos del arco pueden producir quemaduras en los ojos y en la piel Utilice un sombrero y gafas de seguridad Utilice protecci n para los o dos y abr chese el bot n del cuello de la camisa Utilice un casco de soldar con el filtro de sombreado adecuado Proteja su cuerpo completamente Antes de trabajar en la m quina o de proceder a cortar capac tese y lea las instrucciones completamente retire las etiquetas de advertencia ni las cubra con pintura 1b 7 8 99 SEGURIDAD Etiqueta de advertencia Esta etiqueta de advertencia se encuentra adherida a la fuente de energia Es importante que el operador y el tecnico de mantenimiento comprendan el sentido de estos simbolos de advertencia se describen El texto numerado corresponde a los cuadros numerados de la etiqueta 1b 8 8 99 Las chispas producidas por el corte pueden causar explosiones incendios Mantenga los materiales inflamables lejos del lugar de corte Tenga a mano un extinguidor de incendios y aseg rese de que alguien est preparado para utilizarlo No corte dep sitos cerrados El arco de plasma puede causar quemaduras y lesiones Apague la fuente de energ a antes de desarmar la antorcha No sostenga el
87. onverter consists of an insulated gate bipolar transistor IGBT Q1 choke and control circuit It provides a 375 VDC bus voltage when the input AC voltage is between 120 and 240 VAC The inverter consists of an IGBT Q2 the power transformer a current sense transformer and sections of the power board The inverter operates as a pulse width modulator controlled bridge circuit that is rectified by the output diode 027 The output circuitry consists of 2 current sensors located on the power board the pilot arc IGBT inside the D27 module and the output choke The control board s microprocessor monitors and regulates the system s operation and safety circuits The amps adjustment knob is used to set the output current to the desired value between 15 and 30 amps The system compares the set point to the output current by monitoring the current sensor and adjusting the pulse width output of the inverter IGBT Q2 powermax30 Service Manual 3 3 MAINTENANCE Sequence of operation Power OFF lt Connect the gas supply to the air fitting on the power supply Connect the work lead to the workpiece Apply power at the line voltage disconnect box Set the power switch 51 to OFF Set ON OFF switch 51 to ON 1 The green power ON LED illuminates indicating the system is ready for operation The gas solenoid valve V1 closes All the fault LEDs should be extinguished see The gas flo
88. open or closed position or the nozzle and electrode are not touching when the torch s trigger is pulled The system was powered on while the plasma start signal was being sent A major fault has occurred in the power supply The start signal is not reaching the control board The consumables are loose improperly installed or missing The cap sensor switch is faulty The consumables are installed incorrectly or they are worn The torch plunger is stuck The torch or lead has a broken wire The system was powered on while the torch trigger was being pulled The start circuit is stuck closed Any of the fan solenoid valve control board or power board may be faulty The torch or torch lead may be damaged The power board may be faulty The control board may be faulty Correctly install the consumables Perform test 7 to test the cap sensor switch Check the consumables for wear and replace if necessary Make sure that they are properly installed Perform test 5 and replace the torch head if necessary Release the torch trigger and turn OFF the power supply and then turn it ON again to reset the unit Perform test 6 to test the start signal The error LED on the control board should be flashing The number of times it flashes between pauses indicates which components to test See Control board LEDs in this section Inspect the torch and torch lead for damage Verify that
89. or covers big enough to prevent any physical contact with the work or ground If you must work in or near a damp area use extreme caution Provide a disconnect switch close to the power supply with properly sized fuses This switch allows the operator to turn off the power supply quickly in an emergency situation When using a water table be sure that it is correctly connected to earth ground ELECTRIC SHOCK CAN KILL Install and ground this equipment according to the instruction manual and in accordance with national and local codes Inspect the input power cord frequently for damage or cracking of the cover Replace a damaged power cord immediately Bare wiring can kill Inspect and replace any worn or damaged torch leads Do not pick up the workpiece including the waste cutoff while you cut Leave the workpiece in place or on the workbench with the work cable attached during the cutting process Before checking cleaning or changing torch parts disconnect the main power or unplug the power supply Never bypass or shortcut the safety interlocks Before removing any power supply or system enclosure cover disconnect electrical input power Wait 5 minutes after disconnecting the main power to allow capacitors to discharge Never operate the plasma system unless the power supply covers are in place Exposed power supply connections present a severe electrical hazard When making input connections attach proper grounding cond
90. quipment should not be modified in any way except for those changes and adjustments covered in the manufacturer s instructions In particular the spark gaps of arc striking and stabilizing devices should be adjusted and maintained according to the manufacturer s recommendations Cutting cables The cutting cables should be kept as short as possible and should be positioned close together running at or close to the floor level Equipotential bonding Bonding of all metallic components in the cutting installation and adjacent to it should be considered However metallic components bonded to the workpiece will increase the risk that the operator could 8 06 ELECTROMAGNETIC COMPATIBILITY EMC receive a shock by touching these metallic components and the electrode at the same time The operator should be insulated from all such bonded metallic components Earthing of workpiece Where the workpiece is not bonded to earth for electrical safety nor connected to earth because of its size and position for example ship s hull or building steelwork a connection bonding the workpiece to earth may reduce emissions in some but not all instances Care should be taken to prevent the earthing of the workpiece increasing the risk of injury to users or damage to other electrical equipment Where necessary the connection of the workpiece to earth should be made by a direct connection to the workpiece but in some countries where dire
91. r and hearing aid operation can be affected by magnetic fields from high currents Pacemaker and hearing aid wearers should consult a doctor before going near any plasma arc cutting and gouging operations To reduce magnetic field hazards Keep both the work cable and the torch lead to one side away from your body Route the torch leads as close as possible to the work cable Do not wrap or drape the torch lead or work cable around your body Keep as far away from the power supply as possible ADDITIONAL SAFETY INFORMATION 1 ANSI Standard 249 1 Safety in Welding and Cutting American Welding Society 550 LeJeune Road P O Box 351020 Miami FL 33135 2 ANSI Standard 249 2 Fire Prevention in the Use of Cutting and Welding Processes American National Standards Institute 1430 Broadway New York NY 10018 3 ANSI Standard 287 1 Safe Practices for Occupation and Educational Eye and Face Protection American National Standards Institute 1430 Broadway New York NY 10018 4 AWS F4 1 Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances American Welding Society 550 LeJeune Road P O Box 351040 Miami FL 33135 1 6 11 98 5 AWS F5 2 Recommended Safe Practices for Plasma Arc Cutting American Welding Society 550 LeJeune Road P O Box 351040 Miami FL 33135 6 CGA Pamphlet P 1 Safe Handling of Compressed Gases in Cylinders Co
92. r of flashes between pauses indicates which component may have failed Reset This LED illuminates when a voltage reading is out of range or the Reset LED flashes During normal operation the power ON LED on the front of the power supply and the Start and Transfer LEDs on the control board illuminate When a problem occurs with the system one or more of the fault LEDs on the front of the power supply and the Error LED or the Reset LED on the control board may illuminate or flash Use the control board Error and Reset LEDs to troubleshoot The Error and Reset LEDs provide information to use when troubleshooting a system failure If the LEDs on the front of the power supply are flashing look at the Error LED on the control board to determine where the fault may be Count the number of flashes and then look at the table on the following page to determine the corrective action Reset LED When the control board s Reset LED illuminates the voltages on the power board may be incorrect Perform the following tests at J7 on the power board see Test 2 power board voltage checks later in this section Test pin 5 to ground for 3 3 VDC 10 Test pin 7 to ground for 5 VDC 109 Test 12 to ground for 2 2 VDC 410 If the values you find are not within 10 of the above values detach the control board s ribbon cable and perform the tests again If you find the correct values the second time replace the control board Otherw
93. riod of two 2 years from the date of its delivery to you with the exception of Powermax Series power supplies which shall be within a period of three 3 years from the date of delivery to you and ii with respect to the torch and leads within a period of one 1 year from its date of delivery to you This warranty shall not apply to any Product which has been incorrectly installed modified or otherwise damaged Hypertherm at its sole option shall repair replace or adjust free of charge any defective Products covered by this warranty which shall be returned with Hypertherm s prior authorization which shall not be unreasonably withheld properly packed to Hypertherm s place of business in Hanover New Hampshire or to an authorized Hypertherm repair facility all costs insurance and freight prepaid Hypertherm shall not be liable for any repairs replacement or adjustments of Products covered by this warranty except those made pursuant to this paragraph or with Hypertherm s prior written consent The warranty above is exclusive and is in lieu of all other warranties express implied statutory or otherwise with respect to the Products or as to the results which may be obtained therefrom and all implied warranties or conditions of quality or of merchantability or fitness for a particular purpose or against infringement The foregoing shall constitute the sole and exclusive remedy for any breach by Hypertherm of its warran
94. ription T30v hand torch assembly with 15 ft 4 6 m lead Kit T30v torch head replacement O ring Kit Cap off sensor replacement Kit T30v torch head repair kit Kit T30v torch handle replacement Screws 4 x 1 2 SLTD Torx PAN S B Safety trigger and spring replacement Kit T30v 15 ft 4 6 m torch lead replacement Top assembly includes the following consumables 220478 220479 220483 220480 Electrode Swirl ring Retaining cap Nozzle PARTS Quantity mb mi powermax30 Service Manual PARTS Safety critical parts Genuine Hypertherm parts are the factory recommended parts for your Hypertherm system Any damage caused by the use of other than genuine Hypertherm parts may not be covered by the Hypertherm warranty In addition the parts listed below are considered safety critical parts that must be replaced only with Hypertherm parts to maintain the warranty and all system certifications including CE CSA GOST and CCC certification Part ltem number 1 228094 228102 228105 005112 228106 228107 005605 228142 228140 228143 NOOR D Description Kit Power board CSA and subcomponents Kit Power board CE and subcomponents Kit 30 A magnetics Filter regulator pressure switch Kit Filter regulator Kit Fan Rocker switch Kit Power cord 115 VAC CSA Kit Power cord CE Kit Strain relief powermax30
95. s Les messages d AVERTISSEMENT pr cedent les instructions d utilisation expliqu es dans ce manuel et signalent les risques de blessures ou de mort au cas ou ces instructions ne seraient pas suivies correctement Les messages de PRECAUTION pr c dent les instructions d utilisation contenues dans ce manuel et signalent que le mat riel risque d tre endommag si les instructions ne sont pas suivies correctement Pr vention des incendies Avant de commencer s assurer que la zone de coupage ne pr sente aucun danger Conserver un extincteur a proximit Eloigner toute matiere inflammable a une distance d au moins 10 m du poste de coupage Tremper le chaud ou le laisser refroidir avant de le manipuler ou avant de le mettre en contact avec des mat riaux combustibles Ne jamais couper des r cipients pouvant contenir des matieres inflammables avant de les avoir vid s et nettoy s correctement A rer toute atmosphere potentiellement inflammable avant d utiliser un systeme plasma Lors de l utilisation d oxyg ne comme gaz plasma un syst me de ventilation par aspiration est n cessaire Pr vention des explosions Ne pas couper en pr sence de poussi re ou de vapeurs Ne pas couper de bouteilles de tuyaux ou autres r cipients ferm s et pressuris s Ne pas couper de r cipients contenant des mati res combustibles LE COUPAGE PEUT PROVOQUER UN INCENDIE
96. s verres teint s appropri s pour prot ger les yeux des rayons ultraviolets et infrarouges de l arc Puissance des verres teint s Courant de l arc AWS U ISO 4850 Jusqu 100 A N 8 N 11 100 200 N 10 NO 11 12 200 400 A 12 N 13 Plus 400 A NO 14 NO 14 LES RAYONS DE L ARC PEUVENT BRULER LES YEUX LA PEAU Protection de la peau Porter des v tements de s curit pour se prot ger contre les br lures que peuvent causer les rayons ultraviolets les tincelles et le m tal br lant Gants crispin chaussures et casque de s curit V tements ignifuges couvrant toutes les parties expos es du corps Pantalon sans revers pour viter que des tincelles ou des scories puissent s y loger Avant le coupage retirer de ses poches tout combustible comme les briquets au butane ou les allumettes Zone de Pr parer la zone de coupage afin de r duire la r verb ration et la transmission de la lumi re ultraviolette Peindre les murs et autres surfaces de couleur sombre pour r duire la r flexion de la lumi re Utiliser des crans et autres dispositifs de protection afin de prot ger les autres personnes de la lumi re et de la r verb ration Pr venir les autres personnes de ne pas regarder Utiliser des affiches ou des panneaux MISE LA MASSE LA TERRE Cable de retour Bien fixer le cable de retour ou ma
97. s a high degree of sensitivity In such cases it may be necessary to use other measures to further reduce interference This plasma equipment is designed for use only in an industrial environment Installation and use The user is responsible for installing and using the plasma equipment according to the manufacturer s instructions If electromagnetic disturbances are detected then it shall be the responsibility of the user to resolve the situation with the technical assistance of the manufacturer In some cases this remedial action may be as simple as earthing the cutting circuit see Earthing of Workpiece other cases it could involve constructing an electromagnetic screen enclosing the power source and the work complete with associated input filters In all cases electromagnetic disturbances must be reduced to the point where they are no longer troublesome Assessment of area Before installing the equipment the user shall make an assessment of potential electromagnetic problems in the surrounding area The following shall be taken into account a Other supply cables control cables signalling and telephone cables above below and adjacent to the cutting equipment b Radio and television transmitters and receivers c Computer and other control equipment d Safety critical equipment for example guarding of industrial equipment e Health of the people around for example the use of pacemakers and hearing aids
98. s c bles de la torche qui sont us s ou endommag s Ne pas saisir la pi ce couper ni les chutes lors du coupage Laisser la pi ce couper en place ou sur la table de travail le c ble de retour connect lors du coupage Avant de v rifier de nettoyer ou de remplacer les pi ces de la torche couper l alimentation ou d brancher la prise de courant Ne jamais contourner ou court circuiter les verrouillages de s curit Avant d enlever le capot du syst me ou de la source de courant couper l alimentation lectrique Attendre ensuite 5 minutes pour que les condensateurs se d chargent Ne jamais faire fonctionner le syst me plasma sans que les capots de la source de courant ne soient en place Les raccords expos s de la source de courant sont extr mement dangereux Lors de l installation des connexions attacher tout d abord la prise de terre appropri e Chaque syst me plasma Hypertherm est concu pour tre utilis uniquement avec des torches Hypertherm sp cifiques Ne pas utiliser des torches inappropri es qui pourraient surchauffer et pr senter des risques pour la s curit 79 TAS Tv On doit prendre les pr cautions qui simposent quand on manipule les circuits imprim s Hypertherm Systemes plasma L ELECTRICITE STATIQUE PEUT ENDOMMAGER LES CARTES DE CIRCUITS IMPRIMES On doit ranger les cartes de circuits imprim s dans des contenants antistatiques On doit porter un bracelet an
99. sse la piece couper ou la table de travail de assurer un bon contact m tal m tal Ne pas fixer le c ble de retour a la de la piece qui doit se d tacher Table de travail Raccorder la table de travail la terre conform ment aux codes de s curit locaux ou nationaux appropri s Alimentation S assurer que le fil de terre du cordon d alimentation est connect la terre dans le coffret du sectionneur S il est n cessaire de brancher le cordon d alimentation la source de courant lors de l installation du syst me s assurer que le fil de terre est correctement branch Placer tout d abord le fil de terre du cordon d alimentation sur le plot de mise la terre puis placer les autres fils de terre par dessus Bien serrer l crou de retenue S assurer que toutes les connexions sont bien serr es pour viter la surchauffe Hypertherm Systemes plasma 1 5 5 02 SECURITE SECURITE DES BOUTEILLES DE GAZ COMPRIME Ne jamais lubrifier les robinets des bouteilles ou les r gulateurs avec de l huile ou de la graisse Utiliser uniquement les bouteilles r gulateurs tuyaux et accessoires appropri s et pour chaque application sp cifique Entretenir l quipement et les pi ces d quipement a gaz comprim afin de les garder en bon tat tiqueter et coder avec des couleurs tous les tuyaux de gaz afin d identifier le type de gaz
100. t du systeme plasma Pr vention des chocs lectriques Tous les systemes plasma Hypertherm utilisent des hautes tensions pour le coupage souvent de 200 400 V On doit prendre les pr cautions suivantes quand on utilise le systeme plasma Porter des bottes et des gants isolants et garder le corps et les vetements au sec Ne pas se tenir s asseoir ou se coucher sur une surface mouill e ni la toucher quand on utilise le syst me plasma S isoler de la surface de travail et du sol en utilisant des tapis isolants secs ou des couvertures assez grandes pour viter tout contact physique avec le travail ou le sol S il s av re n cessaire de travailler dans ou pr s d un endroit humide proc der avec une extr me prudence Installer un sectionneur avec fusibles appropri s proximit de la source de courant Ce dispositif permet l op rateur d arr ter rapidement la source de courant en cas d urgence En cas d utilisation d une table eau s assurer que cette derni re est correctement mise la terre LES CHOCS LECTRIQUES PEUVENT TRE FATALS Installer et mettre la terre l quipement selon les instructions du pr sent manuel et conform ment aux codes lectriques locaux et nationaux Inspecter fr quemment le cordon d alimentation primaire pour s assurer qu il n est ni endommag ni fendu Remplacer imm diatement un cordon endommag Un c ble d nud peut tuer Inspecter et remplacer le
101. t duty cycle see Section 4 of the Powermax30 Operator Manual The incoming voltage 15 below 90 VAC or above 285 VAC MAINTENANCE Check to see that the system 15 plugged into an appropriately sized circuit and that the circuit breaker has not been tripped Perform test 1 to check the incoming voltage and the power switch Ensure that the gas supply is connected correctly Check the gas supply line for restrictions or damage Check the air filter element and replace it if necessary Perform test 9 to verify that the pressure switch functions correctly Check the area around the system to make sure that the air flow is not blocked If the duty cycle has been exceeded let the system cool before using it again Perform test 8 to make sure the fan is operating correctly Perform test 1 to check the incoming line voltage MAINTENANCE Troubleshooting guide continued Problem cause The power ON LED and the torch cap LED illuminate The power ON LED illuminates and the torch cap LED flashes The gas pressure and temperature LEDs flash when the machine is powered ON All four LEDs flash when the system is powered on q Y Y OS The power ON LED illuminates and no fault LEDs illuminate but no gas flows when the torch trigger is pulled The cap sensing circuit is not satisfied The consumables are stuck in an
102. te t xicos adentro Primero vac e y limpie el recipiente adecuadamente Monitoree o compruebe la calidad del aire en el sitio como fuera necesario Consulte con un experto local para realizar un plan al sitio para garantizar la calidad de aire seguro 1b 4 8 06 Hypertherm Sistemas plasma SEGURIDAD Y Antorchas de encendido instant neo El arco de plasma se enciende inmediatamente despu s de activarse el interruptor de la antorcha EL ARCO DE PLASMA PUEDE CAUSAR LESIONES Y QUEMADURAS El arco de plasma puede cortar a trav s de guantes y de la piel con rapidez Mant ngase alejado de la punta de la antorcha No sostenga el metal junto al trayecto de corte Nunca apunte la antorcha hacia Ud mismo o hacia otras personas Protecci n para los ojos Los rayos del arco de plasma producen rayos intensos visibles e invisibles ultravioleta e infrarrojo que pueden quemar los ojos y la piel Utilice protecci n para los ojos de conformidad con los c digos locales o nacionales aplicables Col quese protectores para los ojos gafas o anteojos protectores con protectores laterales y bien un casco de soldar con lentes con sombreado adecuado para proteger sus ojos de los rayos ultravioleta e infrarrojos del arco N mero del cristal Corriente del arco AWS EE UU 150 4850 Hasta 100A No 8 No 11 100 200 A No 10 No 11 12 200 400 A No 12 No 13 Mas de 400 A No 14 No 14
103. tic Power 15 ON LED Low inlet gas pressure Missing or loose consumables Power supply is over heated powermax30 Service Manual Section 3 MAINTENANCE In this section Controls AN cde JO ta 3 2 From controls AMO lisi Dit 3 2 1 e 3 2 Theory ol operaio me RE 3 3 Generale AAA A a A DA Aaa PURE lactate eh ede ee 3 3 A DR 3 3 Sequence ot operatio Mins EE 3 4 Troubleshooting preparation sise 3 5 Test egui pmen td da 3 5 Troubleshooting procedures and sequence 3 5 External 3 5 Internal Ime lejos 3 6 Initial resistance qM 3 7 Power supp Overs o o baste ET RARAN ERATA 3 8 TROUBDIGSHOOTING 3 9 Control board LEDS accord E Or ae zpw eee 3 12 Use the Error and Reset LEDs to troubleshoot ssrin un 3 13 system LOSES sei E 3 14 NEA 3 15 Test 2 power board voltage checksum 3 16 Test 3 VBUS voltage balance iiec a dy dada idea Ea gen vides ee pe RR dev EE tenants 3 17 5 4 Ll inicien 3 18 Test 5 torchistuck open TSO usaran a i 3 19 Testo plasma Start ca dia 3 20 Test 7 torch Cap iii A A 3 20 POSE cm EE 3 21 Test 9 pressure WIICH E 3 21 Component replacement eee eee eee aaa aaa anawa rra 3 22
104. tincteur proximit et s assurer qu une personne soit pr te l utiliser Ne jamais couper de r cipients ferm s L arc plasma peut provoquer des blessures et des br lures Couper l alimentation avant de d monter la torche Ne pas tenir la surface couper pr s de la trajectoire de coupe Porter des v tements de protection couvrant tout le corps Un choc lectrique caus par la torche ou les c bles peut tre fatal Se prot ger contre les risques de chocs lectriques Porter des gants isolants Ne pas porter de gants mouill s ou abim s S isoler de la surface de travail et du sol D brancher la prise ou la source de courant avant de manipuler l quipement L inhalation des vapeurs produites par le coupage peut tre dangereuse pour la sant Garder le visage l cart des vapeurs Utiliser un syst me de ventilation par aspiration ou d chappement localis pour dissiper les vapeurs Utiliser un ventilateur pour dissiper les vapeurs Les rayons de l arc peuvent br ler les yeux et provoquer des l sions de la peau Porter un casque et des lunettes de s curit Se prot ger les oreilles et porter une chemise dont le col peut tre d boutonn Porter un casque de soudure dont la protection filtrante est suffisante Porter des v tements protecteurs couvrant la totalit du corps Se former la technique du coupage et lire les instructions avant de manipuler l quipement ou de
105. tistatique quand on manipule les cartes de circuits imprim s 1a 3 8 06 SECURITE N L arc plasma est lui m me la source de chaleur utilis e pour le coupage Par cons quent bien que Parc plasma n ait pas t reconnu comme une source de vapeurs toxiques le mat riau coup peut tre une source de vapeurs ou de gaz toxiques qui puisent Les vapeurs produites varient selon le m tal coup Les m taux qui peuvent d gager des vapeurs toxiques comprennent entre autres l acier inoxydable l acier au carbone le zinc galvanis et le cuivre Dans certains cas le m tal peut tre rev tu d une substance susceptible de d gager des vapeurs toxiques Les rev tements toxiques comprennent entre autres le plomb dans certaines peintures le cadmium dans certaines peintures et enduits et le b ryllium Les gaz produits par le coupage plasma varient selon le mat riau couper et la m thode de coupage mais ils peuvent comprendre l ozone les oxydes d azote le chrome hexavalent l hydrog ne et autres substances pr sentes dans le mat riau coup ou en manent On doit prendre les pr cautions qui s imposent pour r duire au minimum l exposition aux vapeurs produites par tout processus industriel Selon la composition chimique et la concentration des vapeurs ainsi que d autres facteurs comme la ventilation il peut y avoir un risque de maladie physique comme des malformations ou l
106. ty Distributors OEMs may offer different or additional warranties but Distributors OEMs are not authorized to give any additional warranty protection to you or make any representation to you purporting to be binding upon Hypertherm Hypertherm Plasma Systems WARRANTY Certification test marks Certified products are identified by one or more certification test marks from accredited testing laboratories The certification test marks are located on or near the data plate Each certification test mark means that the product and its safety critical components conform to the relevant national safety standards as reviewed by that testing laboratory Hypertherm places a certification test mark on its products only after that product is manufactured with safety critical components that have been authorized by the accredited testing laboratory Once the product has left the Hypertherm factory the certification test marks are invalidated if any of the following occurs The product is significantly modified in a manner that creates a hazard or non conformance Safety critical components are replaced with unauthorized spare parts Any unauthorized assembly or accessory that uses or generates a hazardous voltage is added There is any tampering with a safety circuit or other feature that is designed into the product as part of the certification CE marking constitutes a manufacturer s declaration of conformity to appl
107. uctor first Each Hypertherm plasma system is designed to be used only with specific Hypertherm torches Do not substitute other torches which could overheat and present a safety hazard Use proper precautions when handling printed circuit boards STATIC ELECTRICITY CAN DAMAGE CIRCUIT BOARDS Store PC boards in anti static containers Wear a grounded wrist strap when handling PC boards Hypertherm Plasma Systems 1 3 8 06 The plasma arc by itself is the heat source used for cutting Accordingly although the plasma arc has not been identified as a source of toxic fumes the material being cut can be a source of toxic fumes or gases that deplete oxygen Fumes produced vary depending on the metal that is cut Metals that may release toxic fumes include but are not limited to stainless steel carbon steel zinc galvanized and copper In some cases the metal may be coated with a substance that could release toxic fumes Toxic coatings include but are not limited to lead in some paints cadmium in some paints and fillers and beryllium Gases produced by plasma cutting vary based on the material to be cut and the method of cutting but may include ozone oxides of nitrogen hexavalent chromium hydrogen and other substances if such are contained in or released by the material being cut Caution should be taken to minimize exposure to fumes produced by any industrial pro
108. ue wires If you have a new strain relief slide it onto the new power cord On the inside of the endcap screw the nut onto the strain relief Press the connector for the brown wire onto the pin on the upper left side of the power switch Press the connector for the blue wire onto the pin on the upper right side of the power switch Tighten the green and yellow ground wire to the heatsink with a torque setting of 17 28 kg cm 15 inch pounds Position the wires in the wire chase up the side of the endcap and out of the way of the power board Replace or reposition the endcap Make sure that the screw hole in the ground clip aligns with the screw holes in the endcap and the power supply Tighten the strain relief retention nut on the outside of the endcap Being careful not to pinch any of the wires replace the Nomex barrier and slide the cover back onto the power supply Make sure that the bottom edges are in the tracks Position the handle over the holes in the top of the cover then use the 2 screws to secure the cover Reconnect the electrical power and the gas supply powermax30 Service Manual 3 29 MAINTENANCE Replace the fan 1 2 N Turn OFF the power disconnect the power cord and disconnect the gas supply Remove the 2 screws from the handle on the top of the power supply Remove the handle and then lift the cover off the power supply Detach the connector from J5 on the power board You may have t
109. uida de Aprenda a utilizar la m quina y a utilizar los controles de la instrucciones que si no se siguen correctamente pueden manera correcta No permita que sea utilizada por alguien provocar da os en el equipo que no conozca su funcionamiento LOS CORTES PUEDEN PROVOCAR INCENDIOS O EXPLOSIONES Prevenci n ante el fuego Aseg rese de que el rea sea segura antes de proceder a cortar Tenga a mano un extinguidor de incendios Retire todos los materiales inflamables coloc ndolos a ADVERTENCIA Peligro de explosi n Arg n Hidr geno y metano por lo menos 10 metros del rea de corte El hidr geno y el metano son gases inflamables que Remoje los metales calientes o permita que se enfrien suponen un peligro de explosi n Mantenga el fuego lejos de antes de que entren en contacto con materiales los cilindros y las mangueras que contengan mezclas de combustibles hidr geno o metano Mantenga la llama y las chispas lejos Nunca corte dep sitos que contengan materiales de la antorcha al utilizar metano o arg n hidr geno como inflamables primero es necesario vaciarlos y limpiarlos plasma debidamente Antes de realizar cortes en atm sferas potencialmente ADVERTENCIA inflamables aseg rese de ventilar bien Detonaci n de hidr geno con Al realizar cortes utilizando ox geno como gas plasma se el corte de aluminio requiere tener un sistema de ventilaci n de escape M Al cortar alu
110. uientes precauciones cuando se utiliza el equipo de plasma Use guantes y botas aislantes y mantenga el cuerpo la ropa secos No se siente se pare o se ponga sobre cualquier super ficie h meda cuando est trabajando con el equipo A slese el ctricamente de la pieza a cortar y de la tierra utilizando alfombrillas o cubiertas de aislamiento secas lo suficientemente grandes como para impedir todo contacto f sico con la pieza a cortar o con la tierra Si su nica opci n es trabajar en una rea h meda o cerca de ella sea muy cauteloso Instale un interruptor de corriente adecuado en cuanto a fusibles en una pared cercana a la fuente de energ a Este interruptor permitir al operador desconectar r pidamente la fuente de energ a en caso de emergencia Al utilizar una mesa de agua aseg rese de que sta se encuentre correctamente conectada a la toma a tierra Instale este equipo y con ctelo tierra seg n el manual de instrucciones y de conformidad con los c digos locales y nacionales Inspeccione el cord n de alimentaci n primaria con frecuencia para asegurarse de que no est da ado ni agrietado Si el cord n de alimentaci n primaria est da ado reempl celo inmediatamente Un cable pelado puede provocar la muerte Inspeccione las mangueras de la antorcha y reempl celas cuando se encuentren da adas No toque la pieza ni los recortes cuando se est cortando Deje la pieza en su lugar o sobre la m
111. ute the wires through the strain relief 10 Slide the strain relief s nut over the wires and screw it to the strain relief from the inside of the endcap 11 Press the connector for the black wire onto the pin on the upper left side of the power switch 12 Press the connector for the white wire onto the pin on the upper right side of the power switch 13 Tighten the green ground wire to the heatsink with a torque setting of 15 inch pounds 17 28 kg cm 14 Position the wires in the wire chase up the side of the endcap and out of the way of the power board Once the wires are in place tighten the strain relief s retention nut 15 Replace or reposition the endcap Make sure that the screw hole in the ground clip aligns with the screw holes in the endcap and the power supply 16 Being careful not to pinch any of the wires replace the Nomex barrier and slide the cover back onto the power supply Make sure that the bottom edges are in the tracks Position the handle over the holes in the top of the cover then use the 2 screws to secure the cover 17 Reconnect the electrical power and the gas supply Replace the power cord CE 1 Turn OFF the power disconnect the power cord and disconnect the gas supply 2 Remove the 2 screws from the handle on the top of the power supply Remove the handle and then lift the cover off the power supply Remove the Nomex barrier that protects the power board The power cord has a brown wire and a blue
112. w stops Troubleshooting guide for more information Set the amps adjustment knob to the desired output current between 15 and 30 amps based on the input voltage and circuit size The arc extinguishes Postflow continues for 20 seconds The power circuits are ready Drag the torch lightly across the workpiece to make a cut The workpiece drops after the cut Release the plasma start trigger on the hand torch Position the torch on the workpiece Pull the plasma start trigger on the torch The gas solenoid valve V1 opens The gas flow starts The cutting arc starts 3 4 powermax30 Service Manual Troubleshooting preparation The complexity of the circuits requires that service technicians have a working knowledge of inverter power supply theory In addition to being technically qualified technicians must perform all testing with safety in mind If questions or problems arise during servicing call the Hypertherm Technical Services team listed in the front of this manual Test equipment Multimeter with a variety of jumper leads including E Z Hooks Troubleshooting procedures and sequence When performing the troubleshooting procedures Read Section 1 Safety Refer to Section 5 for the system s electrical schematic Refer to Section 4 to locate power supply components and torch components After the problem has
113. wire that connect to the power switch and a green yellow ground wire that connects to the heatsink 3 Remove the rear endcap or gently tilt it away from the power supply 4 Carefully pull the connector for the blue wire away from the power switch to disconnect it You can use needlenose pliers or a straight screwdriver to ease it off if necessary 5 Remove the brown wire the same way Single phase 3 Blue wire Brown wire Green yellow a Add 3 28 powermax30 Service Manual 10 11 12 13 14 15 16 17 18 19 Remove the screw that holds the green yellow ground wire to the heatsink A notch in the power board provides access to the screw On the outside of the power supply loosen the strain relief retention nut so that the wires move freely If you are replacing the strain relief use an adjustable wrench to unscrew the nut on the inside of the power supply as well Remove the plug from the old power cord From the inside of the power supply pull the wires through the strain relief and the hole in the endcap to remove the old power cord Route the plug wires of the new power cord through the nut for the strain relief and then through the hole in the endcap Do not remove the tubular ferrite bead from the power switch end of brown and bl
114. xtinguisher nearby and ready to use 1 3 Do not use a drum or other closed container as a cutting table 2 Plasma arc can injure and burn point the nozzle away from yourself Arc starts instantly when triggered 2 1 Turn off power before disassembling torch 2 2 Do not grip the workpiece near the cutting path 2 3 Wear complete body protection 3 Hazardous voltage Risk of electric shock or burn 3 1 Wear insulating gloves Replace gloves when wet or damaged 3 2 Protect from shock by insulating yourself from work and ground 3 3 Disconnect power before servicing Do not touch live parts 4 Plasma fumes can be hazardous 4 1 Do not inhale fumes 4 2 Use forced ventilation or local exhaust to remove the fumes 4 3 Do not operate in closed spaces Remove fumes with ventilation 5 Arc rays can burn eyes and injure skin 5 1 Wear correct and appropriate protective equipment to protect head eyes ears hands and body Button shirt collar Protect ears from noise Use welding helmet with the correct shade of filter 6 Become trained Only qualified personnel should operate this equipment Keep non qualified personnel and children away 7 Do not remove destroy or cover this label Replace if it is missing damaged or worn PN 110584 Rev A T AVERTISSEMENT Le coupage plasma peut tre pr judiciable pour l op rateur et les personnes qui se trouvent sur les lieux de travail Consulter le manuel avant de faire fonction

Powermax30 Plasma Cutting System Service Manual

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