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Powermax45 Service Manual - air

1. wna 4 4 Adjust The nissan 4 4 EBEDS ite Sede 4 6 too 4 6 Understand duty cycle 4 6 How touse the hand torch one eratac ta add tad aaa a a dada wy d w 4 7 Operate the safety ther ARR R RR RANA 4 7 torch cutting hints mM 4 7 Start a cut from the edge of the workpiece sss esee cesses aaa aaa aa ta taa aaa ta aaa ata 4 8 ii powermax4s Service Manual 5 Piacoa WOPO CG 4 9 Gouge a WOrKkpICE na inz w r a Ada 4 10 BC 4 12 How to use the machine tt netten RUE p edm ai i A ERR GO an rd tr e 4 12 Ensure the torch and table are set up correctly svisino ia aa itat to tassa 4 12 Understand and optimize cut 4 13 pierce a workpiece using the machine torch 4 14 Common machine cutting faults
2. ie eben ae 5 27 E a 5 27 Test 9 pressure 5 28 Test 10 power switch trip Gol te Le tene e A e pae a 5 28 powermax45 Service Manual 5 1 TROUBLESHOOTING AND SYSTEM TESTS Theory of operation General Refer to the following functional description topics to Sequence of operation on page 5 4 and to the Wiring Diagrams section 200 240 V CSA and 230 V CE 1 phase power supply functional description AC power enters the system through the power switch S1 to the input diode bridge D48 The voltage from the diode bridge supplies the power factor correction PFC boost converter which provides a nominal 385 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 relays K1 K2 PFC boost converter consists of an insulated gate bipolar transistor IGBT 02 PFC choke and control circuit It provides a 385 VDC bus voltage when the input AC voltage is between 200 and 240 VAC The inverter consists of a dual IGBT package Q3 the power transformer a current sense transducer and the control circuit The inverter operates as a pulse width modulated half bridge c
3. 3 6 Mount the rece zzo dee ee Se ae Ne E 3 6 Choose the consumables cut GHAMMS uc c ete eene t eee acti anne tinet 3 8 Using the m 3 8 4 shieldediiconsumables nis ERR pe a daa fo d aca E 3 8 LOCI ai soe DEAD pe MUNI Dre EE 3 24 Connect the remote start pendant essent tnter tenente tente tenente 3 25 Connect a machine interface 3 25 Accessing FAW ANC er 3 27 Connect the Torchilead sore ter iii a ERE 3 30 powermax4s Service Manual 3 1 TORCH SETUP Introduction Both the T45v hand torch and the T45m machine torch are available for the Powermax45 The torch FastConnect system makes it easy to remove the torch for transport or to switch from one torch to the other if your applications require the use of both torches This section explains how to set up your torch and choose the appropriate consumables for the job Consumable life How often you will need to change the consumables on your Powermax45 will depend on a number of factors The thickness of the metal being cut The length of the average cut Whe
4. POW ER PWA 1 4 1 30 1 Leve FAN M SW1 2 REAR 22 14AWG 8 45 h x 15 00 w 202 plated to 502 GAS SOL 1 Sd 272 FACING COMPONENT SIDE BRI DELL Power board wiring 1 JH edd diagram 480 V CSA or 133 m ss 6 g v sw GAS PRES O 5 z FLYBACK E36 18 11 5 O N CIRCUITRY 18 INVU o KH 18PA 132422442 ILLE L9338MD J8 COM INVU J F 2286866692 4 4L 2 24 2 2uF PIS sls 45 eL N 12 24 zt T 43 3 45 aL 9 83 vc 449 49 670VDC INVU PWM gt 2 m 43 4 124 26 5 4 8 18REG INVL PWM S ws 42 hs RIBBON 7 eK PA ms 41 ds 81 CABLE 6 124 ins 40 1718 5 DESAT S we see 32 is 20 4a 1500v PA DESAT IN7 5 IN ai 2 INB SPI CLK 423 24 1 1 1 16 1 FLT 9 ws spi our EN 25 26 5 hs 5 942 8 450 NY 101 15 N 5 ha 1 92 MAX Ht D 1 5 24 RT 11 yo 28 CONTROL TO R hs 27 PWRELT CHASSIS GND 15 13 L285 858 1 5 12 IN14 gt GAS MICA INIS 0015 FAN 1001W CIRCUITRY y lme 235 DRV START gt ours 22 INVL PWM DRV REDUNDANTSTART S i8 ourz 21 INVU 01uF Y2 100 1W 19 out 29 PWM DRV 1 SINK MTGS 300vac 2
5. 5 11 Control Board BEDS ors tt lite Ente iet sean IEEE 5 16 Use the control board Error and Reset LEDs to troubleshoot sse tentent trente tenens 5 17 SYSTEM 1668 5 18 1 voltage Input 5 18 Test 2 power board voltage checks rettet a we ta Aa a ata 5 19 Test VBUS and voltage balance usuwana aaa 5 20 Test4 Solenoid valve etate AAAA AAA AAA OE 5 24 Test 5 torch stuck open TSO or torch stuck closed TSC 5 25 AE 5 26 I A 36n O ia Ses A A A AE GA M 5 27 5 27 9 an 5 28 Test 10 power switch trip 5 28 powermax4s Service Manual iii 5 SECTION 6 Remove and replace the cover and Mylar 6 2 sere Replacement Beplace thework lead CSA and CE isisisi eeart mei tuendae 6 3 Replace the powe
6. Solenoid valve LED 1 or J4 19 18 17 wo RO 192 VDC 192 VDC 5 24 powermaX45 Service Manual TROUBLESHOOTING AND SYSTEM TESTS Test 5 torch stuck open TSO or torch stuck closed TSC Before the torch is activated and gas starts to flow the nozzle and electrode should be in contact or touching If not the power supply will detect a TSO or torch stuck open fault If the electrode and nozzle remain closed after the torch receives a start signal the power supply will detect a TSC or torch stuck closed In either case you will have gas flow Use the following test to determine if the torch is stuck in either position 1 Turn OFF O the power 2 Measure the resistance from J17 to J19 for 200 240 V CSA and 230 CE power supplies Measure the resistance from J16 to J18 for 400 V CE and 480 V CSA power supplies The resistance should read as closed very low resistance CAUTION To avoid causing a short or damage to your meter do not fire the torch with the multimeter connected to the power board 3 Turn ON the power Set the amperage adjustment knob to gas test mode The
7. Maximum cut speed is limited by the test table s maximum speed 10160 mm min powermax4s Service Manual 3 9 TORCH SETUP T45m shielded consumables Air flowrate scth Recommended Maximum Arc Torch Pierce time current Material to work Initial pierce Cut Speed Voltage Cut Speed Voltage a eee height e W ipm W 0 018 in 26 Ga 0 030 in 22 Ga 0 036 in 20 Ga 0 060 in 16 Ga 0 036 in 20 Ga 0 060 in 16 Ga 0 075 in 14 Ga 0 105 in 12 Ga 0 135 in 10 Ga 0 188 in 3 16 in 0 250 in 1 4 in 0 375 in 3 8 in 0 500 in 1 2 in 0 625 in 5 8 in 0 750 in 3 4 in 1 000 in 1 in 360 117 400 118 340 116 400 117 250 320 400 117 225 280 Edge start recommended Maximum cut speed is limited by the test table s maximum speed 400 ipm 3 10 powermax4s Service Manual TORCH SETUP T45m shielded consumables Air flowrate ipm Stainless steel Metric Recommended Maximum Arc Material Toreh Pierce time current thickness to work mial pierce delay amps mm um height sec Cut Speed Voltage Cut Speed Voltage mm min V mm min V 0 5 9150 119 10160 123 0 8 8650 117 10160 121 250 0 9 8100 115 10160 119 1 5 3750 113 4700 118 10160 0 0 10160 0 1 9144
8. 5 5 det anand anni DOR ERO 5 5 Troubleshooting procedures and SEQUENCE 5 5 zie 5 6 intemal Inspections e nummum D IU ID ILI a 5 6 initial resistance 5 7 200 240 CSA and 230 CE power supply overview entente tnter tenente tentent entente tenente 5 8 400 powersupply Overview sanie tec eee de ee ea edna duce da e iare 5 9 480 V CSA power supply OVeIVIGW pet 5 10 AA dw 5 11 Control Board LEDS A 5 16 Use the control board Error and Reset LEDs to troubleshoot 5 17 S CECI c 5 18 I MESTUCSgm EUM 5 18 Test 2 power board voltage Checks tte rec dicite d niit rete eit dat ien 5 19 Test 3 VBUS and voltage balarice tnter tette 5 20 Test 4 solenoid i etn A 5 24 Test 5 torch stuck open TSO or torch stuck closed TSC sees tnn 5 25 Test 6 plasma Sta 5 26 7
9. tnnt eterne dA WA OWADA AWA Aa 4 15 SECTION 5 TROUBLESHOOTING AND SYSTEM TESTS Theory ad EA AE 5 2 General REPRE 5 2 200 240 V CSA and 230 V CE 1 phase power supply functional 5 2 400 V 3 phase power supply functional saseta 5 2 480 V CSA 3 phase power supply functional description esee tenente tenente tenete enn 5 3 oeg ence of operationis aieo aet ei re ea a e de d uda a i rete eda o d 5 4 Troubleshooting preparation cree ret cti citri tec tacta Eee ER 5 5 Testequipmoent suena coU enne ma en e ene ar rar Ra RS 5 5 Troubleshooting procedures and 5 5 EdemalinspECUON PEE RE 5 6 internal 5 6 RR 5 7 200 240 V CSA and 230 V CE power supply overview eese tenete tenente tenente tenente tente tenerent teens 5 8 400 V GE power supply OVEWICW oret ec Do trip ARNE haa o 5 9 480 V CSA power supply overview sese 5 10 Troubleshooting GUIAS
10. Newer 200 240 CSA and 230 V power board cp A I o j D p i d C xs 9 e TLT SEA 6 5 iw CN Pam of Description 1 Ribbon cable J7 connector 2 Heat sink assembly screw 3 J10 and J12 connectors 4 J13 connector 5 J14 connector 6 J16 connector 7 J17 connector 8 J19 connector 9 J22 connector 10 Work lead connector J21 11 Retaining screw 12 J20 connector 13 Resistor screws 4 powermax4s Service Manual 2 13 14 15 16 17 18 19 20 21 22 23 24 25 192 VDC 18 17 a Description Pressure relief vents Capacitor screws 4 J15 connector J18 connector Input bridge diode screw Newer boards have a slot here ON OFF switch wires connector J2 connector J6 connector IGBT attachment screws 3 J3 J4 and J5 connectors Older 200 240 V CSA and 230 V CE power board n MOL ER X M 3 ee TP 19 wo 192 VDG GE TP18 17 RO 192 VDC 99 Description 1 Ribbon cable J7 connector 2 Heat sink assembly screw 3 J10 and J12 connecto
11. y Gouging bottom position Use this setting to gouge metal Leaving the mode switch on this setting while cutting results in poor cut quality Adjust the gas pressure Look at the gas pressure LED If it illuminates green in the center of the pressure bar the incoming gas pressure is correct for the mode you have selected If the LED illuminates yellow either above or below the center the gas pressure needs to be adjusted powermaX45 Service Manual OPERATION To adjust the pressure 1 Turn the amperage knob counter clockwise to the gas test position as shown below 2 With the amperage knob in the gas test position pull up the pressure regulator knob on top of the system to unlock it 3 the pressure regulator knob until the gas pressure LED shows a green bar the center of the pressure bar 4 Press down on the pressure regulator knob to lock it in position 5 Turn the amperage knob to the cutting current appropriate for your application If you are using T30v Powermax30 30 A do not set the amperage knob above 30 A powermaX45 Service Manual 4 5 OPERATION Check the indicator LEDs Verify that the green power ON LED on the front of the power supply is illuminated that the gas pressure LED shows a green bar in the center of the gauge and that none of the other LEDs are illuminated or bl
12. AAA AT AO 7 6 145v pk 7 7 hand tofch co siimable ua zaw scene chi A 7 8 T30v Powermiax30 30 A corisumables t tiat ettet ted 7 8 A a RA RAY AAA Ft ire 7 9 T45m machine torch consumables 7 10 ACCOSSOLY aan Na NIU D DE INI eet E 7 10 safety critical PANTS nunci an EM 7 11 Darts ictus cease nr err terrori tais rom arr ennt rita ra alan 7 12 Powermax4b labels anite ha ice rai a ec oc De eR CU 7 13 powermax4s Service Manual 7 1 5 5 5 gt gt gt 4 Power supply parts Exterior item Part number Description Qty 228270 Kit Cover screws 1 1 228269 Kit Front panel 1 2 108616 Current adjustment knob 1 3 228300 Kit Work lead assembly 6 1 m 20 feet 1 4 228307 Kit Work lead assembly 15 24 m 50 feet 1 5 228281 Kit Power supply c
13. 4 3 Operate the Powertmax4b ai olere eco e eel e cede ead ra ac n DRE DE Dre 4 3 Connect the electrical power gas 4 3 Powe ONiitheSyStEMi itd 4 4 Set the mode SWO crcs 4 4 Adjust the gas 4 4 Check the indicator BEDS uror ore ER ed erat A RE pO Fa 4 6 Attach the Work Clamp essai da AA 4 6 Understand duty cycle limitations eese aaa a a a 4 6 Flow to use oorr EE dd 4 7 Operate ihe safety OGON eR 4 7 torch cutting 4 7 Start a Cut from the edge of the workplece intret 4 8 A 4 9 Golge a 4 10 Common hand cutting faults 4 12 How to use the machine torch eese a ded ei 4 12 Ensure the torch and table are set up correctly esse a a
14. 0 3 5080 0 4 3810 0 5 2159 0 6 1397 0 8 813 457 Edge start recommended 229 Maximum cut speed is limited by the test able s maximum speed 10160 mm min powermax4s Service Manual 3 11 TORCH SETUP T45m shielded consumables Arnona Gem Stainless steel English Recommended Maximum Arc Torch Pierce time current Material to work Initial pierce Voltage Voltage delay amps thickness height sec V z V 0 018 in 26 Ga 0 030 in 22 Ga 0 036 in 20 Ga 0 060 in 16 Ga 0 036 in 20 Ga 0 060 in 16 Ga 0 075 in 14 Ga 0 105 in 12 Ga 0 135 in 10 Ga 0 188 in 3 16 in 0 250 in 1 4 in 0 375 in 3 8 in 0 500 in 1 2 in 0 750 in 3 4 in 250 Edge start recommended Maximum cut speed is limited by the test table s maximum speed 400 ipm 3 12 powermax4s Service Manual TORCH SETUP T45m shielded consumables Air flowrate Recommended Maximum Torch to work Initial pierce distance height mm 1 2 0 0 9150 117 10160 120 Pierce time delay sec Arc Material current thickness amps mm Cut Speed Voltage Cut Speed Voltage mm min 1 5 250 8650 10160 121 0 2 1 9 5450 6860 121 10160 10160
15. 220675 220672 110672 Consumable label www hypertherm com weee CE safety label AIR 9 BAR MAX N2 135 PSI MAX 110610 REVA Maximum pressure label PN 110673 Rev D CSA safety label powermax4s Service Manual 7 13 7 14 powermaX45 Service Manual Section 8 WIRING DIAGRAMS this section Control board diagram 200 240 V CSA and 230 8 2 Control board diagram 400 V CE 480 V CSA siirius iiaa aiad 8 3 Power board wiring diagram 200 240 V CSA 230 V 8 5 Power board wiring diagram 400 V OE rete eterni itte ta crate 8 6 Power board wiring diagram 480 V 8 7 powermax4s Service Manual 8 1 WIRING DIAGRAMS Control board diagram 200 240 V CSA and 230 V CE MACHINE L FRONT RESET or ERROR R HDRFLT CODE FR START SERIAL CAPOFF TSO TSC YEL YEL DSP 2806 4x25Mhz 100Mhz 0 78 x 0 78 Stayout for TEST CLIP CPA UP NORMAL MIDDLE GOUGE DOWN Expected value 19 VACR rectified AC line 1 95 V at 230 line voltage voltage VBUS DC bus voltage 2 28 VDC at 385 VBUS 21 IPFC input current lt 0 1 VDC 200 240 and 230 V only 20 IFB output current lt 0 1 VDC ITF transfer current lt 0 1 VDC 24 V sense pin 2 2 VDC 16 Start signal 3 2 VDC c
16. ew wsze 3 6 Mount the eer PEE 3 6 Choose the consumables cut 3 8 USING the c t 3 8 T45mishielded consumables itd ir n Cu TH Ru rv e Re D d 3 8 Alignthetoreh e c 3 24 Connect the remote start 1 saseta 3 25 Connect a machine interface cable 3 25 ACCESSING raw ALC vohaga zuza aa zada ya a dO AAAA DOBA EA ad AB dY AAA 3 27 Connect the torch lead cet ei end iere c kid a T d nt wadi A A A dad 3 30 SECTION 4 OPERATION Conttols and IRdIGAtOTS dd caries neri A dO A a A in ak aea rr eR Ru 4 2 Front controls and LEDs rccte cn rade ai t Ee ata 4 2 Rear ONS m E EEUU 4 3 Operate the 45 aaa aaa 4 3 Connect the electrical power gas supply eaten 4 3 Power ON the SyStEM trente nete 4 4 Set the mode
17. nn na nah la a Plasma arc cutting system Service Manual 806110 Revision 2 Register your new Hypertherm system Register your product online at www hypertherm com registration for easier technical and warranty support You can also receive updates on new Hypertherm products and a free gift as a token of our appreciation For your records Serial number Purchase date Distributor Maintenance notes Service Manual P N 806110 Revision 2 April 2013 Hypertherm Inc Hanover NH USA www hypertherm com Copyright 2013 Hypertherm Inc All Rights Reserved Hypertherm and powermax are trademarks of Hypertherm Inc and may be registered in the United States and or other countries Hypertherm Etna Road 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 866 643 7711 Tel Return Materials Authorization 877 371 2876 Fax Return Materials Authorization return materials hypertherm com RMA email Hypertherm Plasmatechnik GmbH Technologiepark Hanau Rodenbacher Chaussee 6 D 63457 Hanau Wolfgang Deutschland 49 61
18. to CPLD J10 3 Hipot INPUT BRIDGE 100 100 Pin 5 Z GND a ER gt E INVERTER IGBT MODULE 1 15 2 START 5 95 1 8 217 J12 s 5 a A ARC VOLTAGE 5 SSA E gt lt 1 4 MR Ed z 3 16 lt 5 Finv 36khz ELEC 50 1 6 15 16 5 soov J gt 1 965 5 942 1 2 T J14 14 PIN 0 472 Ht WHT CPC REAR L OF UNIT u 1000vDC T 21 22 sz sZ 23 20 21 915 K gm ISOTOP OUTPUT DIODE AND 670vdc 1 PILOT IGBT MODULE HH 1200 111213 SRA 252627 16 13 12 d 26 a 28 14 T 10 ohm LOW INDUCTANCE 120W ISOTOP VBUS LAYOUT MTG5 MTG6 __ SSR LIFT to a a KS Hipot BLUE CAP NC 30A Tm 0 00 1 965 ORG f 1 22 MAX Ht 4 7nF 4 7nF J18 625 4 00 m NS A O zZ JUMPER MECH OUTS IN3H H OUTS IN3 H V Faso JUMPER 50 PT gt gt OUT2 jioo we 0072 TTE 5 zj OUTI 10 18AWG_RED 56K5W i 275 100K 18AWG_RED VAC s OUTPUT TRANSFER 20K_L EIECIROGE 1800uF SENSOR N W To o1uF 3 450VDC CURRENT a 18AWG WHT SENSOR 2 00K J22 Loutput 014316 NOZZLE 1 5 LO 480uH J2 2 L45 205uH J19 D AD FI O D 3 6 Rdc25C 12 5mohm 2 40 x 1 65 60 max zone V WORK 8AWG UL1028 MTW PONER KEUR 014318 Rprim25C 5 5mohm CLIP 480 50h Rsec25
19. Thread the connector end of the new work lead through the front panel and fit the strain relief into the hole in the panel Slide the nut over the work lead s connector Gently tilt the front panel away from the power supply and screw the nut onto the strain relief Attach the work lead to the power board at J21 using the screw that you removed earlier The torque setting for this connection is 23 0 kg cm 20 inch pounds Realign the front panel Replace the Mylar barrier and slide the cover back onto the power supply Position the handle over the holes in the top of the cover then secure the cover with the 2 screws Reconnect the electrical power and the gas supply powermaX45 Service Manual Replace the power cord 200 240 V CSA 1 2 L Black wire CSA White wire CSA Turn OFF the power disconnect the power cord and disconnect the gas supply Use a 2 Phillips screwdriver to remove the 2 screws from the handle on the top of the power supply Tip the end panels back slightly so that you can get the edges of the handle out from underneath them Lift the cover off the power supply Remove the Mylar barrier that protects the power board 200 240 V CSA power cord has black wire a white wire that connect to the power switch and a green ground wire that connects to the heat sink Remove the rear end panel gently tilt it away from the power supply
20. 3 Set the ON OFF switch to ON I Measure pin 16 of J7 or J8 for 400 CE and 480 V CSA power supplies to ground see Test 2 power board voltage checks on page 5 19 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 remove the consumables to avoid accidentally firing the torch J10 l O J10 is 19 TP18 TP17 we RO 192 VDC 192 VDC RE o E 5 26 powermaX45 Service Manual TROUBLESHOOTING AND SYSTEM TESTS Test 7 torch cap sensor Test the cap sensor switch and torch leads 1 Set the ON OFF switch to OFF 2 Measure the resistance between pins 1 and 2 of J10 on the power board It should measure less than 10 If it reads as open the cap sensor switch circuit is not satisfied 3 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 Test 8 fan Test the fan for proper operation Place a jumper from pin 1 of J3 to pin 1 of 14 200 240 V CSA power supplies and 230 V CE power supplies or from pin 1 of J4 to pin 1 of J5 on 400 V CE and 480 V CSA power supplies If the fan does not operat
21. 9144 250 0 1 7112 0 2 3302 0 3 2540 0 5 1067 635 Edge start recommended 254 Maximum cut speed is limited by the test table s maximum speed 10160 mm min powermax4s Service Manual 3 13 TORCH SETUP T45m shielded consumables Airfiowrate sh Aluminum English Recommended Maximum Torch Arc Pierce time Material to work Initial pierce current delay amps thickness m height sec Voltage Voltage V V 0 018 in 26 Ga 0 060 in 16 Ga 0 075 in 14 Ga 0 060 in 16 Ga 0 075 in 14 Ga 0 105 in 12 Ga 0 135 in 10 Ga 0 188 in 3 16 in 0 250 in 1 4 in 0 375 in 3 8 in 0 500 in 1 2 in 0 750 in 3 4 in 250 250 Edge start recommended Maximum cut speed is limited by the test table s maximum speed 400 ipm 3 14 powermax4s Service Manual TORCH SETUP T45m unshielded consumables CM 220717 220713 220718 220670 220669 Deflector Retaining cap Nozzle Swirl ring Electrode Mild steel Air flowrate Ipm Recommended Maximum Arc Material Torch Pierce time current thickness owo Initial pierce delay amps mm distance height sec 0 5 9150 118 10160 114 Cut Speed Voltage Cut Speed Voltage mm min 0 8 8650 118
22. Gas test mode temperature range LED 1 8 powermax4s Service Manual Section 2 POWER SUPPLY SETUP In this section Unpack the 4 2 9 QI 2 2 2 2 Position the power supply aie an ada ttd AO a a 2 3 Prepare the electrical OWEN 2 3 Mfeirre xeseW ES 2 3 install a line disconnect switch aiiis ir 2 4 Requirements for gro nding tet teen inet ia tnter eia nent 2 4 Power cord ER ORPHEO RENI ORE ERR nantes een eer 2 4 Extension cord recommendations iiis enirn tapa th tanta taies 2 5 Generator recommendations aaa tatnen stetit nsn aaa aaa 2 6 Prepare the gas 2 6 Connectthe o da 2 7 Additional gas filtrerth On sss 2 7 powermaX45 Service Manual 2 1 POWER SUPPLY SETUP Unpack the Powermax45 1 Verify that all items on your order have been received in good condition Contact your distributor if any parts are damaged or missing 2 Inspect the power supply for damage that may have occurred during shipping If there is evidence o
23. Push the power board straight in Replace the 4 heat sink assembly screws and torque them to 23 0 kg cm 20 inch pounds Replace the 3 retaining screws and the 4 resistor screws Torque these screws to 17 3 kg cm 15 inch pounds Reconnect the white wire from the ON OFF switch to J1 and the black wire to J2 Torque them to 23 0 kg cm 20 inch pounds Replace the 3 screws that attach the IGBTs and the screw that attaches the input bridge diode to the heat sink The torque setting for these is 23 0 kg cm 20 inch pounds If you replaced an older 200 240 V CSA or 230 V CE power board you will have an additional screw left over Replace the 4 capacitor screws Be sure to reattach the black wire to the left most screw Torque these screws to 23 0 kg cm 20 inch pounds Reconnect the wires to the transformers and inductors J13 J14 J15 J16 217 218 119 and 120 and the work lead ring terminal at J21 Torque them to 23 0 kg cm 20 inch pounds Replace the connectors at J10 and J12 and the connectors at J3 J4 J5 and J6 Reconnect the ribbon cable from the control board to the power board at J7 Being careful not to pinch any of the wires replace the Mylar barrier and slide the cover back onto 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 6 18 powermaX45 Service Manual
24. Tighten the strain relief s retention nut on the outside of the end panel to secure the new power cord If you are installing a plug on the new power cord use a plug that meets national and local electrical codes The plug must be connected to the power cord by a licensed electrician Being careful not to pinch any of the wires replace the Mylar barrier and slide the cover back onto 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 power cord 400 V CE 1 2 Turn OFF the power disconnect the power cord and disconnect the gas supply Use a 2 Phillips screwdriver to remove the 2 screws from the handle on the top of the power supply Tip the end panels back slightly so that you can get the edges of the handle out from underneath them Lift the cover off the power supply Remove the Mylar barrier that protects the power board The 400 V CE power cord has 3 wires brown black and gray that connect to the power switch and a green yellow ground wire that connects to the heat sink Remove the rear end panel or gently tilt it away from the power supply until you can access the screws that secure the power cord wires to the back of the power switch NOTE To remove the rear end panel you must first remove the air fitting Remove the 3 screws that secure the power cord wires to the power switch
25. including power requirements grounding power cord configurations extension cord requirements and generator recommendations see the Power Supply Setup section Handheld and machine torch consumables cut charts and torch setup information see the Torch Setup section nformation about the controls and LEDs steps for system operation and hints for improving cut quality see the Operation section Troubleshooting see the Troubleshooting and System Tests section Maintenance and repair instructions see the Component Replacement section Part numbers and ordering information for accessories consumables and replacement parts see the Parts section Wiring and timing diagrams see the Wiring Diagrams section 1 2 powermax4s Service Manual SPECIFICATIONS Power supply dimensions and weights Dimensions 34 8 cm 13 7 in 12 19 in 42 6 cm 16 75 in 17 2 cm 6 75 in Weights Power supply weights given below include the hand torch with 6 1 m 20 foot lead a 6 1 m 20 foot work lead and a 3 m 10 foot power cord CSA 200 240 power supply 16 8 kg 37 pounds CSA 480 V power supply 15 9 kg 35 pounds CE 230 V power supply 16 6 kg 36 5 pounds 400 V power supply 15 9 kg 35 pounds powermaX45 Service Manual 1 3 SPECIFICATIONS Power supply ratings Rated open circuit voltage Ug CSA CE single phase 275 VDC CSA CE single phas
26. mm height sec Cut Speed Voltage Cut Speed Voltage mm min mm min 0 5 9144 113 10160 125 0 8 8128 115 10160 128 250 0 9 1 5 10160 0 0 10160 0 1 9144 0 3 5080 0 4 3556 0 5 2032 0 6 1270 0 8 762 457 Edge start recommended Maximum cut speed is limited by the test table s maximum speed 10160 mm min powermax4s Service Manual 3 17 TORCH SETUP T45m unshielded consumables Air flowrate scfh English 360 Recommended Maximum Torch Pierce time Material to work Initial pierce current delay thickness distance height amps in sec Cut Speed Cut Speed ipm ipm 0 018 in 26 Ga 400 400 400 400 250 345 345 0 060 in 16 Ga 0 036 in 20 Ga 250 0 135 in 10 Ga 0 188 in 3 16 in 0 250 in 1 4 in 0 375 in 3 8 in 0 500 in 1 2 in 0 750 in 3 4 in Edge start recommended Maximum cut speed is limited by the test table s maximum speed 400 ipm 3 18 powermax4s Service Manual TORCH SETUP T45m unshielded consumables Air flowrate Ipm Aluminum Metric Recommended Maximum Arc Material Torch Pierce time current thickness a wore initial pierce delay amps mm distance height sec P mm 1 2 0 0 8900 122 10160
27. 10160 116 0 9 8100 117 10160 120 1 5 5800 113 7250 119 10160 10160 7620 5588 250 4318 2794 1905 1016 635 356 Edge start recommended 254 127 Maximum cut speed is limited by the test table s maximum speed 10160 mm min powermax4s Service Manual 3 15 TORCH SETUP T45m unshielded consumables Air flowrate scfh Mild steel English Recommended Maximum Arc Torch Pierce time currant Material to work Initial pierce Voltage Voltage delay amps thickness height sec V V 0 018 in 26 Ga 0 030 in 22 Ga 0 036 in 20 Ga 0 060 in 16 Ga 0 036 in 20 Ga 0 060 in 16 Ga 0 075 in 14 Ga 0 105 in 12 Ga 0 135 in 10 Ga 0 188 in 3 16 in 0 250 in 1 4 in 0 375 in 3 8 in 0 500 in 1 2 in 0 625 in 5 8 in 0 750 in 3 4 in 1 000 in 1 in 118 118 250 117 113 250 Edge start recommended Maximum cut speed is limited by the test table s maximum speed 400 ipm 3 16 powermax45 Service Manual TORCH SETUP T45m unshielded consumables Air flowrate Stainless steel Metric Recommended Maximum Arc Material Torch PEN Pierce time current thickness to work Initial pierce delay amps
28. 22 MAX Ht Hours id z gt INV IPRIM LAX100 NP JI LAX100 NP OUT1 OUT1 OUTPUT TRANSFER CURRENT SENSOR 2200uF 2200uF 400VDC 400VDC SENSOR Lpfc 014319 10 4 0 L15 1 8MH Rdc25C 80mohm POWER XFMR 014318 Lprim 1 08mH Rprim25C 4 0mohm Rsec25C 6 5mohm Lleak 0 5uH 45A 132v 10T J13 J15 275v CPA 225v Power board wiring diagram 400 V CE amp ARC VOLTAGE 50 1 5 6 JUMPER MECH 18AWG RED 18AWG RED ELECTRODE Loutput 014316 NOZZLE LO 480uH L45 205uH 2 crcs A 5 12 5 WORK 8AWG UL1028 MTW BLK MUELLER CLIP ELEC SCH 45A 400V SYSTEM 013367 SHEET1OF1 6
29. 4 Pressure relief vents Capacitor screws 4 J19 connector J17 connector Input bridge diode screw Newer boards have a slot here ON OFF switch wires J1 connector J2 connector J3 connector IGBT attachment screws 2 14 15 J6 connectors 6 23 Older 400 V CE power board Description 1 Ribbon cable J8 connector 2 Heat sink assembly screw 3 J10 and J12 connectors 4 J13 connector 5 J14 connector 6 J15 connector 7 J16 connector 8 J18 connector 9 J22 connector 10 Work lead connector J21 11 Retaining screw 12 J20 connector 6 24 Item 13 14 15 16 17 18 19 20 21 22 23 24 Description Resistor screws 4 Pressure relief vents Capacitor screws 4 J19 connector J17 connector Input bridge diode screws 2 ON OFF switch wires J1 connector J2 connector J3 connector IGBT attachment screws 2 J4 J5 and 16 connectors powermaX45 Service Manual Section 7 PARTS In this section OWE SUP DIY EE 7 2 m H 7 2 Interior power board SIG on med aoc nui nie edidit Al ATR A ATR AR che mr eR ul xr ru a Pura sania 7 4 Int rior a wwa aikido 7 5 Sde
30. CE power board you will have an additional screw left over 21 Replace the 4 capacitor screws and torque them to 23 0 kg cm 20 inch pounds Be sure to reattach the black wire to the left most screw 22 Reconnect the wires to the transformers and inductors at J13 J14 J15 J16 J17 J18 J19 and J20 and the work lead ring terminal at J21 Torque them to 23 0 kg cm 20 inch pounds 23 Replace the connectors at J10 J12 and J22 and the connectors at J4 J5 and J6 24 Reconnect the ribbon cable from the control board to the power board at J8 25 Being careful not to pinch any of the wires replace the Mylar barrier and slide the cover back onto the power supply Position the handle over the holes in the top of the cover then use the 2 screws to secure the cover 26 Reconnect the electrical power and the gas supply 6 22 powermaX45 Service Manual Newer 400 V and 480 CSA power board ms Description 1 Ribbon cable J8 connector 2 Heat sink assembly screw 3 J10 and J12 connectors 4 J13 connector 5 J14 connector 6 J15 connector 7 J16 connector 8 J18 connector 9 J22 connector 10 Work lead connector J21 11 Retaining screw 12 Ferrite CE units only 13 J20 connector powermax4s Service Manual Item 14 15 16 17 18 19 20 21 22 23 24 25 26 Description Resistor screws
31. Ib 3 54 kg 7 8 Ib 0 45 kg 1 0 Ib 2 27 kg 5 0 Ib 2 90 kg 6 4 Ib 3 85 kg 8 5 Ib powermaX45 Service Manual SPECIFICATIONS Symbols and marks Your Hypertherm product may have one or more of the following markings on or near the data plate Due to differences and conflicts in national regulations not all marks are applied to every version of a product 5 8 us mark symbol 5 mark symbol indicates that the power supply and torch are suitable for operations carried out in environments with increased hazard of electrical shock per IEC 60974 1 CSA mark Hypertherm products with a CSA mark meet the United States and Canadian regulations for product safety The products were evaluated tested and certified by CSA International Alternatively the product may have a mark by one of the other Nationally Recognized Testing Laboratories NRTL accredited in both the United States and Canada such as Underwriters Laboratories Incorporated UL or TUV CE marking The CE marking signifies the manufacturer s declaration of conformity to applicable 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 Electromagnetic Compatibility Directive EMC filters needed to comply with the European Directive are incorporated within versions of the produc
32. Pierce time current thickness initial pierce delay amps mm m height sec Cut Speed Voltage Cut Speed Voltage mm min V mm min V 0 5 8900 105 10160 98 0 8 8100 102 10160 0 9 7100 101 8900 1 5 500 4450 97 5600 1 9 3050 98 3800 2 7 2050 96 2550 3 4 1270 1650 Maximum cut speed is limited by the test table s maximum speed 10160 mm min powermax4s Service Manual 3 21 TORCH SETUP T30v Powermax30 30 A consumables Air flowrate scfh Mild steel English Recommended Maximum Torch z Arc Material gt gt Pierce time to work Initial pierce current thickness 2 delay distance height amps in in sec Cut Speed Voltage Cut Speed Voltage ipm V ipm V 500906 T30v Powermax30 30 A consumables Air flowrate Ipm Stainless steel Metric Recommended Maximum Arc Material Torch Pierce time current thickness Initial pierce delay distance height amps mm mm sec 0 5 8900 103 10160 102 Cut Speed Voltage Cut Speed Voltage mm min V mm min 0 8 8100 98 10160 100 0 9 7600 97 6850 98 1 5 500 3800 99 4800 98 1 9 2800 3450 97 2 7 1500 1900 98 3 4 1150 1400 97 M
33. Qty 1 1 m m cl ll cl o Interior heat sink side gt MMMMMMMMM FUUUUUUUUUI Item Part number 1 428065 2 228301 228426 428080 7 6 Description Qty Kit Snubber resistors Kit Capacitors 200 240 V CSA and 230 V CE Kit Capacitors 400 V CE Kit Capacitors 480 V CSA NON M ON powermax45 Service Manual T45v hand torch parts PARTS The entire hand torch and lead assembly can be replaced or individual component parts can be replaced Part numbers starting with 088 indicate complete torch and lead assemblies Part number 088008 088009 228313 075714 002244 228346 058503 228109 228315 228316 128642 O SO OI N Description T45v hand torch assembly with 6 1 m 20 feet lead T45v hand torch assembly with 15 24 m 50 feet lead Kit T45v torch handle replacement T45v torch handle screws 4 x 1 2 SLTD Torx PAN S B Safety trigger and spring replacement Kit Torch head replacement O ring Viton 0 626 x 0 070 Kit T45v torch cap sensor switch replacement Kit T45v torch lead replacement 6 1 m 20 feet Kit T45v torch lead replacement 15 24 m 50 feet Kit Start switch replacement torch assembly also includes one set of the
34. They should have the same value 3 Attach E Z Hooks to TP test point 17 and TP 18 Turn the power ON after you have connected the multimeter This value should be 335 VDC or one half of whatever value you found in step 2 Note All values can be 10 4 Turn the power OFF and move the E Z Hooks to TP 18 and TP 16 Turn the power ON after you have connected the multimeter This value should be 335 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 96 1 wo 280 VDC 280V powermax45 Service Manual 5 23 TROUBLESHOOTING AND SYSTEM TESTS Test 4 solenoid valve If gas is not flowing properly test the solenoid valve for proper operation 1 There is an LED on the solenoid valve that illuminates red when the torch is fired or when the amperage control knob is set to gas text mode It stays illuminated until postflow stops Turn the amperage knob to gas test and verify that the LED illuminates 2 Place a jumper from pin 4 of J3 J4 for 400 V CE and 480 V CSA power supplies on the power board to ground You should hear the valve click 3 If you do not hear the valve click or the LED does not illuminate and a voltage check on pin 4 of J3 or J4 reads 24 VDC replace the solenoid valve
35. and gently pull the wires out of the switch Remove the screw that holds the green yellow ground wire to the heat sink powermax4s Service Manual 6 Onthe outside of the power supply loosen the strain relief retention nut so that the wires move freely 7 the inside of the power supply pull the wires through the strain relief and the hole in the end panel to remove the old power cord 8 Ifyou are replacing the old strain relief with the new strain relief contained in the kit a Use an adjustable wrench to unscrew the strain relief nut on the inside of the power supply to remove the old strain relief b Slide the new strain relief through the hole in the rear end panel of the power supply c Secure the strain relief on the inside of the power supply using the new strain relief nut Hand tighten the nut and then over tighten slightly more 9 From the inside of the power supply route the wires of the new power cord through the strain relief in the rear end panel Do not remove the tubular ferrite bead from the power switch end of the brown black and gray wires Because the CE power cord includes the ferrite bead you cannot route the power cord through the strain relief from the outside of the power supply 10 Slide the strain relief retention nut over the wires of the new power cord and slide the retention nut forward toward the power supply powermax
36. balance Test the power board to ensure that the circuits are balanced There are three procedures below Use the first procedure if you have a 200 240 V CSA power supply or a 230 V CE power supply Use the second procedure if you have a 400 V CE power supply Use the third procedure if you have a 480 V CSA power supply For this test you can use the test point loops or you can test on the capacitor screws The test points are labeled on the back of the power board as are the voltages and positive and negative capacitor terminals CAUTION To test using the test points do not use a multimeter with test probes Use E Z Hook leads instead and attach them to the test point loops 5 20 powermaX45 Service Manual TROUBLESHOOTING AND SYSTEM TESTS Test for 200 240 V CSA and 230 V CE power supplies 1 OFF the power 2 Position the multimeter leads to measure the boosted bus voltage on the power board by attaching the test leads to TP test point 19 and TP 18 Turn on the power The multimeter should read 385 VDC If you get a value other than 385 VDC multiply the reading by 0 00601 Compare that value to a reading at pin 21 J7 They should have the same value 3 Turn the power OFF Attach the E Z Hooks to TP 19 and TP 17 Turn the power ON after you have connected the multimeter This value should be 192 5 VDC or one half of whatever value you found in step 2 Note All values can be 10 4 Turn the power OFF and move
37. 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 and that the slot in the top of the cover is aligned with the tab on the front end cap so that the louvers in the cover are in front of the fan Position the handle over the holes in the top of the cover then secure the cover with the 2 screws Replace the work lead CSA and CE 1 2 notches COMPONENT REPLACEMENT Four notches ij Tab Cover slot Turn OFF the power disconnect the power cord and disconnect the gas supply Use a 2 Phillips screwdriver to remove the 2 screws from the handle on the top of the power supply Tip the end panels back slightly so that you can get the edges of the handle out from underneath them Lift the cover off the power supply Remove the Mylar barrier that protects the power board Remove the screw from J21 also labeled work lead on the power board that attaches the lead to the board Set the screw aside Gently tilt the front panel away from the power supply From the inside of the panel unscrew the nut that secures the strain relief to the end cap powermax4s Service Manual Front panel Work lead ae TP18 17 wo RO 192 VDC E 192 VDC Strain relief Work lead connection to power board J21
38. coupler or a 1 4 NPT x G 1 4 BSPP CE units quick disconnect coupler CAUTION Synthetic lubricants containing esters that are used in some air compressors will damage polycarbonates used in the air regulator bowl 5 5 6 9 bar 80 100 psi gas supply maximum 9 3 bar or 135 psi with a flow rate of at least 165 2 l min 350 scfh The recommended flow rate and pressure is 170 at 6 2 bar 360 scfh at 90 psi Additional gas filtration When site conditions introduce moisture oil or other contaminants into the gas line use a three stage coalescing filtration system such as the Eliminizer filter kit 128647 available from Hypertherm distributors A three stage filtering system works as shown below to clean contaminants from the gas supply Water and particle filter Oil filter Oil vapor filter Gas supply Powermax45 The filtering system should be installed between the quick disconnect coupler and the power supply powermaX45 Service Manual POWER SUPPLY SETUP 2 8 powermax4s Service Manual Section 3 TORCH SETUP this section 37 Ea Cc sain 3 2 Consumable Mewa wawa asza LIS dwa GEE 3 2 miei 3 2 Choose the cra Ra do e od a Den 3 3 Iristallthe Constables recette eae iene eee hk Sc ede dee ee 3 5 Machine t rch ai RAI
39. divider provides a maximum of 7 V under open circuit conditions This is an impedance protected functional extra low voltage ELV output to prevent shock energy and fire under normal conditions at the machine interface receptacle and under single fault conditions with the machine interface wiring The voltage divider is not fault tolerant and ELV outputs do not comply with safety extra low voltage SELV requirements for direct connection to computer products Hypertherm offers several choices of machine interface cables for the Powermax45 To use the built in voltage divider that provides 50 1 arc voltage in addition to signals for arc transfer and plasma start Use kit number 228350 7 62 m 25 feet or 228351 15 24 m 50 feet for 6 wires terminated with spade connectors The following diagram shows an example of spade connectors Use part number 223048 7 62 m 25 feet or 123896 15 24 m 50 feet for a cable terminated with a D sub connector Compatible with Hypertherm s EDGE Pro Ti and Sensor PHC products powermax4s Service Manual 3 25 TORCH SETUP To use signals for arc transfer and plasma start only use either part number 023206 7 62 m 25 feet or part number 023279 15 24 m 50 feet These cables have spade connectors as shown here es Note The cover on the machine interface receptacle prevents dust and moi
40. lightly across the workpiece to proceed with the cut Maintain a steady even pace Pierce a workpiece SPARKS AND HOT METAL CAN INJURE EYES AND BURN SKIN When firing the torch at an angle sparks and hot metal will spray out from the nozzle Point the torch away from yourself and others 1 With the work clamp attached to the workpiece hold the torch at an approximate 30 angle to the workpiece with the nozzle within 1 5 mm 1 16 inch of it before firing the torch 2 Fire the torch while still at an angle to the workpiece then slowly rotate the torch to a perpendicular 90 position powermax4s Service Manual 4 9 OPERATION 3 Hold the torch in place while continuing to press the trigger When sparks exit from the bottom of the workpiece the arc has pierced the material 4 When the pierce is complete drag the nozzle lightly along the workpiece to proceed with the cut Gouge a workpiece SPARKS AND HOT METAL CAN INJURE EYES AND BURN SKIN When firing the torch at an angle sparks and hot metal will spray out from the nozzle Point the torch away from yourself and others 1 Hold the torch so that the nozzle is within 1 5 mm 1 16 inch from the workpiece before firing the torch 2 Hold the torch at a 45 angle to the workpiece with a small gap between the torch tip and the workpiece Press the trigger to obtain a pilot Transfer the arc to the workpiece 4 10 powermax4s Service Manual 3 M
41. point 17 and TP 18 Turn the power ON after you have connected the multimeter This value should be 280 VDC or one half of whatever value you found in step 2 Note All values can be 10 4 the power OFF and move the E Z Hooks to TP 18 and 16 the power ON after you have connected the multimeter This value should be 280 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 1 2a wo 280 VDC 5 22 powermaX45 Service Manual TROUBLESHOOTING AND SYSTEM TESTS Test for 480 V CSA power supplies For this test you can use the test point loops or you can test on the capacitor screws The test points are labeled on the back of the power board as are the voltages and positive and negative capacitor terminals CAUTION To test using the test points do not use a multimeter with test probes Use E Z Hook leads instead and attach them to the test point loops 1 Turn OFF the power 2 Position the multimeter leads to measure the voltage on the power board by attaching the test leads with the negative lead on TP 17 and the positive lead on TP 16 Turn on the power The multimeter should read 670 VDC If you get a value other than 670 VDC multiply the reading by 0 003 Compare that value to a reading at pin 21 on J8
42. rear mounting ring Kit T45m torch head replacement Kit T45m cap sensor switch replacement O ring Viton 0 626 x 0 070 Kit T45m torch lead replacement 7 62 m 25 feet Kit T45m torch lead replacement 10 67 m 35 feet Kit T45m torch lead replacement 15 24 m 50 feet assembly includes one set of the following consumables 220669 220670 220713 220671 220673 Electrode Swirl ring Retaining cap Nozzle Shield powermax4s Service Manual Qty A A i o A A T45m machine torch consumables Part number Description Shielded 220669 Electrode 220670 Swirl ring 220713 Retaining cap 220719 Ohmic sensing retaining cap 220671 Nozzle 220673 Shield Unshielded 220717 Deflector 220718 Nozzle The swirl ring retaining cap and electrode for the unshielded application are the same as those for the shielded application The T30v Powermax30 30 A consumables can be used on the T45m as well The part numbers are listed under 730v Powermax30 30 A consumables on page 7 8 Accessory parts Part number Description 024548 Brown leather torch sheathing 7 5 m 25 feet 024877 Black leather torch sheathing 7 5 m 25 feet 128658 Gouging heat shield 127102 Basic plasma circle cutting guide 027668 Deluxe plasma circle cutting guide 127219 Powermax45 dust cover 127217 Powermax45 shoulder strap 128647 Kit Eliminizer air filtration 127103 Face
43. resistance should read as very high resistance 4 If the resistance reads incorrectly then the nozzle and electrode are in contact or 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 5 Because TSO and TSC failures can be intermittent repeat the test several times Ferrite found on CE units only 200 240 V CSA and 230 V CE power supplies 400 V CE and 480 V CSA power supplies powermax45 Service Manual 5 25 TROUBLESHOOTING AND SYSTEM TESTS 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 torch is activated 2 Set the ON OFF switch to OFF O Check the resistance between pins 2 and 3 of J10 on the power board With the trigger or start signal engaged the resistance should be 10 or less With the trigger or start signal disengaged the circuit should read as approximately If this test fails check the torch s start switch and the torch wires NOTE If the torch will not fire after completing this test verify that J10 is connected properly that the pins are not offset and the connector is not backwards
44. 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 direct 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 in crease 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 provided in IEC 60974 9 Arc Welding Equipment Part 9 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 Compliance Information Attention Genuine Hypertherm parts are the factory recommended replacement parts for your Hypertherm system Any damage or injury caused by the use of other than genuine Hypertherm parts may not be covered by the Hypertherm warranty and will constitute misuse of the Hypertherm Product You are solely responsible for the safe use of the Product Hypertherm does not and cannot make any g
45. the E Z Hooks to TP 18 and TP 17 Turn the power ON after you have connected the multimeter This value should be 192 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 3 I I L 7 700 TP 19 s w 192 192 V n o g A Step 2 Step 4 d powermax4s Service Manual 5 21 TROUBLESHOOTING AND SYSTEM TESTS Test for 400 V CE power supplies For this test you can use the test point loops or you can test on the capacitor screws The test points are labeled on the back of the power board as are the voltages and positive and negative capacitor terminals CAUTION To test using the test points do not use a multimeter with test probes Use E Z Hook leads instead and attach them to the test point loops 1 Turn OFF the power 2 Position the multimeter leads to measure the voltage on the power board by attaching the test leads with the negative lead on TP 17 and the positive lead on TP 16 Turn on the power The multimeter should read 560 VDC If you get a value other than 560 VDC multiply the reading by 0 00601 Compare that value to a reading at pin 21 on J8 They should have the same value 3 Attach E Z Hooks to TP test
46. the end panels back slightly so that you can get the edges of the handle out from underneath them Lift the cover off the power supply Remove the Mylar 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 J7 on the heat sink side of the power board See the illustrations following this procedure for the location of the ribbon cable and the components listed in the steps that follow 4 Remove the connectors at J10 J12 and J22 on the heat sink side of the power board 5 Remove the connectors at J3 J4 and J5 on the heat sink side of the power board 6 Remove the connector for the red and black wires from the power switch at J6 from the heat sink side of the power board J6 is located about an inch down from the top edge of the board 7 Remove the wires for the transformers and inductors at J13 J14 J15 J16 J17 J18 J19 and J20 8 Remove the work lead ring terminal from J21 and the 4 capacitor screws 9 Remove the 3 retaining screws the 4 heat sink assembly screws and the 4 resistor screws 10 have an older 200 240 V CSA or 230 V CE power board that has 2 input bridge diodes and without the small slot below the heat sink assembly screw hole remove the 3 screws that attach t
47. the top or bottom of the workpiece Straightness of the cut surface The cut surface can be concave or convex The following sections explain how these factors can affect cut quality Cut or bevel angle positive cut angle or bevel results when more material is removed from the top of the cut than from the bottom negative cut angle results when more material is removed from the bottom of the cut Problem Cause Solution Negative cut angle The torch is too low Raise the torch or if you are using a torch height control increase the arc voltage Square cut Positive cut angle The torch is too high Lower the torch or if you are using a torch height control decrease the arc voltage Notes The squarest cut angle will be on the right side with respect to the forward motion of the torch The left side will always have some degree of bevel To determine whether a cut angle problem is being caused by the plasma system or the drive system make a test cut and measure the angle of each side Next rotate the torch 90 in its holder and repeat the process If the angles are the same in both tests the problem is in the drive system If a cut angle problem persists after mechanical causes have been eliminated see Ensure the torch and table are set up correctly on page 4 12 check the torch to work distance especially if the cut angles are all positive or all negative Also consider the material being cut If the meta
48. until you can access the screws that secure the power cord wires to the back of the power switch NOTE remove the rear end panel you must first remove the air fitting Remove the screws that secure the connectors for the white and black wires from the power switch to disconnect them Remove the screw that holds the green wire to the heat sink Single phase CSA PF FUUUUUUUUUvcr On the outside of the power supply loosen the power cord s strain relief retention nut so that the wires move freely If you will replace the strain relief use an adjustable wrench to unscrew the strain relief nut on the inside of the power supply to remove the old strain relief From the outside of the power supply pull the old power cord through the strain relief or through the hole in the rear end panel to remove it powermax4s Service Manual 6 5 If you replacing the old strain relief with the new strain relief contained in the kit slide the new strain relief onto the new power cord and route the wires for the new power cord through the hole in the end panel Slide the new strain relief nut over the wires and screw it to the strain relief from the inside of the end panel Hand tighten the nut and then over tighten slightly more If you are keeping the ol
49. 1 22 MAX Ht INV IPRIM 0072 100 OUT1 OUTPUT CURRENT SENSOR UNBAL y Pa 2 s INVL PWM DRV OUTPUT DIODE and PILOT ARC IGBT MODULE 1200V 60A TRANSFER SENSOR PE 200 240vac 47 63hz POWER CORD 014314 LO 300uh L75 180uh Rdc25C 10 8mohm POWER XFMR CSA 014315 CE 014331 Lprim 0 53mH Rprim25C 2 5mohm Rsec25C 5 7mohm Lleak 0 5uH typ J13 J16 45A 132v 275v 225v diagram 200 240 V CSA nd 230 VOLTAGE 50 1 50 6 JUMPER MECH 18AWG RED 18AWG RED ELECTRODE 014316 l 221 Ki LO 480uH L45 205uH c25C 12 5mohm WORK 8AWG BLK MUELLER CLIP LEC SCH 45A 230V SYSTEM 013366 SHEET 1 1 REAR 24v 1 0A 8 45 h x 13 00 w 202 plated to 302 TWEJ FACING COMPONENT SIDE OF PCB POWER PWA 141008 Top Level FAN 190CFM 01uF Y2 300vac INPUT BRIDGES PE 380 400vac 50hz CORD 4C 2 5mm HO7RN F Flyback Circuitry 4a 1500v y 5 942 8 450 1 92 MAX Ht 18REG OPCJE 100 Pin 1 b MEJ Gat Vbus Vbus INVERTER IGBT MODULE 8 2nF 1000VDC Finv 36khz y 1 965 5 942 0 472 MAX Ht OUTPUT DIODE and 560vdc PILOT ARC IGBT MODULE L3 11 12 13 25 26 27 10 ohm LOW INDUCTANCE 120W ISOTOP VBUS LAYOUT 8 2nF y 0 00 1 965 1000VDC 1
50. 121 Cut Speed Voltage Cut Speed Voltage mm min V mm min V 1 5 i 250 0 1 8100 120 10160 118 1 9 0 2 5700 121 7100 10160 10160 9144 250 0 1 6858 0 3 3175 0 3 2286 0 5 914 635 Edge start recommended 254 Maximum cut speed is limited by the test table s maximum speed 10160 mm min powermax4s Service Manual 3 19 TORCH SETUP T45m unshiel nsumabl 5m unshielded consumables Air fiowrate Aluminum English Recommended Maximum Torch Pierce time Material to work Initial pierce current delay amps thickness height sec Voltage Voltage V 0 018 in 26 Ga 0 060 in 16 Ga 0 075 in 14 Ga 0 060 in 16 Ga 0 075 in 14 Ga 0 105 in 12 Ga 0 135 in 10 Ga 0 188 in 3 16 in 0 250 in 1 4 in 0 375 in 3 8 in 0 500 in 1 2 in 0 750 in 3 4 in 250 250 Edge start recommended Maximum cut speed is limited by the test table s maximum speed 400 ipm 3 20 powermax4s Service Manual TORCH SETUP T30v Powermax30 30 A consumables 220569 220483 220480 220479 220478 Optional deflector Retaining cap Nozzle Swirl ring Electrode Mild steel Air flowrate Recommended Maximum Arc Material
51. 4s Service Manual 6 9 20 Press the connector for the brown wire into the hole the top left side of the power switch L1 and replace the screw that secures it Torque the screw to 11 5 kg cm 10 inch pounds Press the connector for the black wire into the hole on the top middle of the power switch L2 and replace the screw that secures it Torque the screw to 11 5 kg cm 10 inch pounds Press the connector for the gray wire into the hole on the top right of the power switch L3 and replace the screw that secures it Torque the screw to 11 5 kg cm 10 inch pounds Tighten the green yellow ground wire to the heat sink with a torque setting of 17 3 kg cm 15 inch pounds Position the wires in the wire chase up the side of the end panel and out of the way of the power board Replace or reposition the end panel Make sure that the screw hole in the ground clip aligns with the screw holes in the end panel and the power supply Tighten the strain relief s retention nut on the outside of the end panel to secure the new power cord If you are installing a plug on the new power cord use a plug that meets national and local electrical codes The plug must be connected to the power cord by a licensed electrician Being careful not to pinch any of the wires replace the Mylar barrier and slide the cover back onto the power supply Position the handle over the holes in the top of the cover then us
52. 81 58 2100 Tel 49 6181 58 2134 Fax 49 6181 58 2123 Technical Service Hypertherm 8 Pte Ltd 82 Genting Lane Media Centre Annexe Block 01 01 Singapore 349567 Republic of Singapore 65 6841 2489 Tel 65 6841 2490 Fax 65 6841 2489 Technical Service Hypertherm Shanghai Trading Co Ltd Unit 301 South Building 495 ShangZhong Road Shanghai 200231 PR China 86 21 60740003 Tel 86 21 60740393 Fax 07 18 12 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 4973 7843 Tel Technical Service Hypertherm Japan Lid Level 9 Edobori Center Building 2 1 1 Edobori Nishi ku Osaka 550 0002 Japan 81 66225 1183 81 66225 1184 Fax Hypertherm Brasil Lida Rua Bras Cubas 231 Jardim Maia Guarulhos SP Brasil 07115 030 55 11 2409 2636 55 11 2408 0462 Fax Hypertherm M xico S A de C V Avenida Toluca No 444 Anexo 1 Colonia Olivar de los Padres Delegaci n lvaro Obreg n M xico D F C P 01780 52 55 5681 8109 Tel 52 55 5683 2127 Fax Hypertherm Korea Branch 3904 Centum Leaders Mark B D 1514 Woo dong Haeundae gu Busan Korea 612 889 82 51 747 0358 8251 701 0358 Fax A Safety information f Before operating any Hypertherm equipment read the separate Safety and Compliance Manual 806690 included with your product for import
53. A a a a a 2 3 Voltage COMMA UP AU ONS le ERR 2 3 Install line disconnect A A da Ea Ee 2 4 Requirements for gro nding itn 2 4 powermax4s Service Manual i 5 Power cord considerations iiic x iati a add dA fad dad A add 2 4 Extension cord recommendations asc idt ania da ca hace dd a Do d e add 2 5 A 2 6 16938 SUPPLY RU a aaa 2 6 CONNECT the GAS SUPPIY id bd taa en 2 7 Additional das filtration c oe ILIA ACE ER GE UU DIL M LIE 2 7 SECTION 3 TORCH SETUP ERE TEST UL 3 2 terrenae inva cota c B RV Veg RR va n e TV e d 3 2 Hand torch wek waw uk Ra tite edd d MM MEUM MD EAM 3 2 Choose the 3 3 Install the 3 5
54. C 6 3moh MATERIAL CORD 4222 asi 22 CONTAINED THEREON IS CONSIDERED Hlor 55 c es di a 2 C mene OOOO 001020 000 Lpfc 014319 12T 10T PURPOSES WITHOUT PERMISSION 21 Great Hollow Road Hanover 03755 603 643 3441 LO 4 0MH 915 915 UNLESS OTHERWISE SPECIFIED DESCRIPTION L15 1 8MH TOLERANCES ARE NCE ELEC SCHEM 45A 480V CSA SYS Rdc25C 80mohm 2 DEC 01 A NO SCALE SHEET p ANGULAR az e 013390 1 1 1 1 PART MUST BE FREE OF BURRS AND SHARP V DRAWN BY DATE APPROVED BY DATE NW GHAMFER OR RADIUS O15 MAK S CSM 2 8 13 VG 02 13 13 8 7
55. EZ SZ NY imi Work lead connection J21 Teak points Inverter IGBT 02 Output diode and pilot arc Power board IGBT module D40 Input diode bridge D48 5 10 powermax4s Service Manual TROUBLESHOOTING AND SYSTEM TESTS Troubleshooting guide See System tests on page 5 18 for detailed test procedures It is important to note when troubleshooting a problem on the Powermax45 how the front panel LEDs operate To help diagnose transient problems an illuminated or blinking LED including the bottom bar on the gas pressure bar may continue to illuminate or blink for 10 to 20 seconds after the system is powered OFF Once the system is powered ON the LED should not illuminate or blink if the fault has been cleared Also note that there is no static gas pressure reading So the gas pressure LEDs may not indicate a low pressure situation if the gas was not connected when the system was powered ON Attempting to fire the torch without the gas connected will cause the bottom yellow gas pressure LED to blink The ON OFF power switch Check to see that the is set to ON but the power ON LED is not illuminated There is insufficient voltage to the control circuits or a short circuited power component The system has incoming voltage or an improper incoming voltage system is plugged into an appropriately sized circuit and that the circuit breaker has not been tri
56. LEDs on the front panel should be extinguished Disconnect the electrical power and the ribbon cable again and set aside the new control board Remove the 3 retaining screws from the old control board and lift it out of the power supply Screw the new control board into place with the 3 retaining screws and then attach the ribbon cable Press the amperage control knob onto the post There is a flat side on the post Ensure that the flat side of the opening in the knob aligns with the flat side on the post Reposition the front end panel Being careful not to pinch any of the wires replace the Mylar barrier and slide the cover back onto 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 powermaX45 Service Manual Replace the power board 200 240 V CSA and 230 V Before beginning this procedure make sure you have the correct power board for your system The replacement kit number for a 200 240 V CSA power board is 228261 The replacement kit number for a 230 V CE power board is 228259 The procedure below applies to the 200 240 V CSA and the 230 V CE power boards 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
57. RNING INSTANT ON TORCHES PLASMA CAN CAUSE INJURY AND BURNS The plasma arc comes on immediately when the torch trigger is activated Make sure the power is OFF before changing consumables To operate the T45v torch it must have a complete set of consumable parts installed a shield or deflector retaining cap nozzle swirl ring and electrode With the power switch in the OFF O position verify that the torch consumables are installed as shown Electrode Swirl ring gt Nozzle gt Retaining Shield or deflector gt There should be a small gap between the consumables and the torch handle Air will blow out from this gap during normal operation Note Tighten only to finger tight Overtightening will cause the torch to misfire powermax4s Service Manual 3 5 TORCH SETUP Machine torch setup Consumables Positioning sleeve Gear rack Brass strain relief Strain relief Before using the T45m you must Mount the torch on your cutting table or other equipment Choose and install the consumables Align the torch Attach the torch lead to the power supply Setup the power supply for remote starting with either the remote start pendant or a machine interface cable Mount the torch Depending on the type of cutting table you have you may or may not need to disassemble the torch to route it through the track and mount i
58. aintain approximate 45 angle to the workpiece as you feed into the gouge In other words push the plasma arc in the direction of the gouge you want to create Keep a small distance between the torch tip and the molten metal to avoid reducing consumable life or damaging the torch Changing the torch angle changes the dimensions of the gouge OPERATION Note A heat shield is available for added hand and torch protection 220049 You can vary the depth of the gouge by varying the angle of the torch to the workpiece The following tables show the gouging profile at 45 and 60 on mild steel and stainless steel Mild steel gouging profile Torch angle Speed Width Depth 254 mm min 10 ipm 7 75 mm 0 3051 inch 1 05 mm 0 0415 inch 508 mm min 20 ipm 762 mm min 80 ipm 6 50 mm 0 2550 inch 5 76 mm 0 2267 inch 2 94 mm 0 1158 inch 1 87 mm 0 0735 inch 1016 mm min 40 ipm 5 30 mm 0 2087 inch 1 31 mm 0 0517 inch 1270 mm min 50 ipm 254 mm min 10 ipm 4 73 mm 0 1863 inch 8 06 mm 0 3173 inch 1 03 mm 0 0406 inch 4 18 mm 0 1645 inch 508 mm min 20 ipm 6 15 mm 0 2423 inch 2 39 mm 0 0941 inch 762 mm min 80 ipm 6 00 mm 0 2351 inch 1 39 mm 0 0546 inch 1016 mm min 40 ipm 5 80 mm 0 2281 inch 1 21 mm 0 0476 inch 1270 mm min 50 ipm Stainless steel gouging profile Torch angle 254 mm min 10 ipm 4 61
59. an assembly Powermax45 power switch 200 240 V CSA and 230 V CE Powermax45 power switch 400 V CE and 480 V CSA CSA power cord 1 phase 200 240 3 m 10 feet not shown CE power cord 1 phase 230 V 3 m 10 feet not shown CE power cord 3 phase 400 V 3 m 10 feet not shown CSA power cord 3 phase 480 V 3 m 10 feet not shown powermax4s Service Manual 7 11 5 Recommended spare parts Hypertherm recommends that service centers keep the following spare parts on hand for repairs either because these parts are critical or because they are usually exposed to heavy and repeated wear You may find that you need to revise or expand this list for your customers based on the particular conditions for your region and working environments Page Part number Description reference 228561 Kit Ground clamp 7 2 228300 Kit Work lead assembly 6 1 m 20 feet 7 2 228266 Kit Powermax45 power switch 200 240 V CSA and 230 V CE 7 4 228288 Kit Powermax45 power switch 400 V CE and 480 V CSA 7 4 228262 Kit Control board 200 240 V CSA 230 V CE 400 V CE 7 4 428098 Kit Control board 480 V CSA 7 4 228261 Kit Power board 200 240 V CSA 7 4 428078 Kit Power board 480 V CSA 7 4 228260 Kit Power board 400 V CE 7 4 228259 Kit Power board 230 V CE 7 4 228285 Kit Solenoid valve 7 5 228287 Kit Filter and regulator 7 5 228302 Kit Air filter element 7 5 058503 O ring Viton 0 626 x 0 070 7 7 228313 Kit T45v torch ha
60. and 480 V CSA resistance across the input leads 2 5 3 Check the resistance from the input leads to ground to verify that it reads as open For all power supplies the resistance from input to ground should read as gt 20 MQ Note With the power disconnected and the ON OFF switch S1 set to OFF O all circuits should read as open The electrical values shown 25 4 Check the output resistance for the values shown in the following table 200 240 V CSA and 400 V and 480 V Measure resistance from 230 V CE power board CSA power board location location Work lead to nozzle J21 to J17 J21 to J16 100 Approximate values Work lead to electrode J21 to J19 J21 to J18 20 Electrode to nozzle J19 to J17 J18 to J16 120 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 on page 5 11 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 powermax4s Service Manual 5 7 TROUBLESHOOTING AND SYSTEM TESTS 200 240 V CSA and 230 V CE power supply overview Control b
61. and how to correct them refer to the Troubleshooting guide topic in the Troubleshooting and System Tests section Power ON LED green When illuminated this LED indicates that the power switch has been set to ON and that the safety interlocks are satisfied Gas pressure LED and pressure bar yellow green When the LED indicator in the pressure bar illuminates green and is centered in the vertical bar the gas pressure is set correctly for the mode of cutting selected with the mode switch If the pressure is too high for the selected mode the indicator in the pressure bar will be above the mid point of the bar If it is too low the indicator will be below the mid point At the highest and lowest points on the bar the indicator will illuminate yellow If the indicator is at the lowest part of the bar and is flashing then the gas pressure is less than the minimum required pressure powermaX45 Service Manual OPERATION Amperage adjustment knob Set this knob to the gas test position fully counter clockwise before adjusting the gas pressure with the pressure regulator knob on the top of the power supply Once the gas pressure is set turn the knob clockwise to set the output amperage torch will not fire when the knob is in gas test position Mode switch and LEDs The mode switch can be set in one of three positions Continuous pilot arc to cut expanded metal or grate top Non continuous pil
62. ant safety information TABLE CONTENTS ELECTROMAGNETIC COMPATIBILITY 1 WARRANTY EPA W 1 SECTION 1 SPECIFICATIONS Syst m descripti ON 1 2 Whereto find Intormation zeza aan aa 1 2 Power supply dimensions ANG WEI etit stets nest BL aa a PEJA pada AE LE 1 3 DIMENSIONS m 1 3 za ada Kota I 1 3 Power supply ratings c iei oi Aa ta dada Madan eas 1 4 torch dimensio S ddd AWA dRWAL 1 5 wa eS 1 5 T4bvand 145m torch specifications ranis raria ri tent uenerunt ad ta a way i 1 6 oymbols arid marks sx cen AE a EA RR AA PDA IL IMP LIMINE 1 7 RA ANA N 1 8 SECTION 2 POWER SUPPLY SETUP Unpack the PoWwermaxa in RA ase EA R WAWA ER AAAA A 2 2 Claims PP 2 2 Contents citi tide edid a hd aa R wh wi ada Td nad 2 2 Position the power SUPP yp asa kawasaki Wan thia A ARE AAA dn adi dn i Gi adi 2 3 Prepare the electrical pOWOr a aaa A a PA BA
63. are incorrect replace the power board 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 panel or to the heat sink as shown below Note All values can be 10 Expected value Test 200 240 V CSA or 230 V CE VACR rectified 1 95 V at 230 line J7 or J8 pin number to ground 13 line voltage voltage 21 200 240 230 V IPFC input current lt 0 1 VDC only IFB output current lt 0 1 VDC 2 2 ITF transfer current lt 0 1 VDC 2 2 Start signal 3 2 VDC closed 0 VDC open powermax4s Service Manual 0 2 5 4 12 16 VBUS DC bus 2 28 VDC at 385 VBUS voltage Expected value 400 V CE or 480 V CSA 2 7 V at 400 line voltage CE 2 016 VDC at 480 line voltage CSA 2 178 VDC at 560 VBUS CE 2 016 VDC at 670 VBUS CSA Not applicable 3 2 VDC closed 0 VDC open TROUBLESHOOTING AND SYSTEM TESTS 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 o 17 200 240V CSA 230V J8 400 V CE 480V CSA Ground to the ground wire clip or to the heat sink 80000000000 o 200000000000 L Test 3 VBUS and voltage
64. as supply 2 Use a 2 Phillips screwdriver to remove the 2 screws from the handle on the top of the power supply Gently pull on the end panel nearest the screw you are removing to keep pressure on the screw When the screw is almost out tilt the screwdriver slightly to help pull the screw out of the recessed hole 3 Tip the end panels back slightly so that you can get the edges of the handle out from underneath them Set the handle and screws aside Continue to tilt the end panels outward to release the fan side of the cover from its track Then lift the cover off the power supply 4 Remove the Mylar barrier from the power board side of the power supply The Mylar barrier is flexible and can be bent slightly for removal 6 2 powermaX45 Service Manual Replacement 1 Hold the Mylar barrier so that the edge with the 3 notches is on the left and the edge with 4 notches is on the right There is a perforation across the top about 4 45 cm 1 75 inches down from the top edge If you are replacing the Mylar barrier with a new one you will need to fold it along this perforation so that the top edge bends away from you Position the barrier so that the folded section will cover the top of the power board Slide the barrier into place with the bottom edge between the ribs on the base and the power board The notches on each side of the barrier should align with the ribs on the inside of the end caps Being
65. atibility The limits required by EN60974 10 may not be adequate to completely eliminate interference when the affected equipment is in close proximity or has a high degree of sensitivity such cases it may be necessary to use other measures to further reduce interference This cutting 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 some cases this remedial action may be as simple as earthing the cutting circuit see Earthing of the work piece In 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 Compliance Information a Other supply cables control cables signaling and telephone cables above below and adjacent to the cutting equipment b Radio and television transmitters and receivers c Computer an
66. aximum cut speed is limited by the test table s maximum speed 400 ipm or 10160 mm min 3 22 powermax4s Service Manual T30v Powermax30 30 consumables Stainless steel English TORCH SETUP Air flowrate scfh Recommended Maximum Torch to work distance in Arc current amps Material thickness in Initial pierce height Pierce time delay sec Cut Speed ipm Voltage V Cut Speed ipm Voltage V 0 018 26 Ga 0 030 22 Ga 0 036 20 Ga 0 060 16 Ga 0 075 14 Ga 0 105 12 Ga 0 135 10 Ga T30v Powermax30 30 A consumables Aluminum Metric Torch to work distance mm Arc current amps Material thickness mm Initial pierce height 350 400 Pierce time delay sec Cut Speed mm min Air flowrate Ipm Cut Speed mm min 0 5 0 8 0 9 1 5 1 9 500 8100 10160 6100 7650 4800 6100 3700 4550 2400 Maximum cut speed is limited by the test table s maximum speed 400 ipm 10160 mm min powermax4s Service Manual 3050 3 23 TORCH SETUP T30v Powermax30 30 A consumables Air flowrate scfh Aluminum English Recommended Maximum Arc Material Torch Pierce time to work Initial pierce Cut Speed Voltage Cut Speed Voltage current thic
67. before performing any tests Test 1 voltage input Check the incoming voltage and the line voltage to the top of the power switch S1 1 Disconnect the electrical power and set the ON OFF switch to OFF O 2 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 3 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 4 With the electrical power connected set the ON OFF switch to ON I and measure the AC voltage from J1 to 12 labeled on the power board This value should be the same as the incoming line voltage If it is not check the ON OFF switch 5 lf the power ON LED is still illuminated perform Test 2 power board voltage checks on page 5 19 to determine whether the power board or the control board is faulty Note All values can be 15 5 18 powermax4s Service Manual TROUBLESHOOTING AND SYSTEM TESTS Single phase L Black CSA Brown CE White CSA Blue CE PE Green CSA Green yellow CE Test 2 power board voltage checks Three phase CE Three phase CSA With the power ON use a meter to verify the voltages at the J7 pins JB on 400 V CE and 480 V CSA power supplies listed in the following table to be certain that the power board is functioning correctly If any of the values
68. ck open or torch stuck closed situation power supply is too cold You have exceeded the duty cycle For more information about duty cycle see the Operation section incoming voltage is either too high or too low a variance greater than 15 of the rated voltage consumables are loose improperly installed or missing cap sensor switch is faulty consumables are installed incorrectly they are worn or were removed while the power supply is ON torch plunger is stuck The torch or lead has a broken wire Allow the power supply to warm up if it has been extremely cold 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 fan on page 5 27 to make sure the fan is operating correctly Perform Test 1 voltage input on page 5 18 to check the incoming line voltage Correctly install the consumables Perform Test 7 torch cap sensor on page 5 27 to test the cap sensor switch Check the consumables for wear and replace if necessary Make sure they are properly installed Verify that they are finger tight Try loosening them 1 8th of a turn and restarting the power supply Perform Test 5 torch stuck open TSO or torch stuck closed TSC on page 5 25 and replace the torch h
69. consumables listed on the next page powermax4s Service Manual Qty 1 1 T45v hand consumables Part number Shielded 220669 220670 220713 220671 220674 Gouging 220675 220672 Unshielded 220717 220718 Description Electrode Swirl ring Retaining cap Nozzle Shield Shield Nozzle Deflector Nozzle The swirl ring retaining cap and electrode for these applications are the same as those for the shielded application Unshielded consumables for the hand torch are not available in CE regulated countries T30v Powermax30 30 consumables Part number 220569 220483 220480 220479 220478 Description Deflector Retaining cap Nozzle Swirl ring Electrode powermax4s Service Manual 45 machine torch parts PARTS The entire machine torch and lead assembly can be replaced or individual component parts can be replaced Part numbers starting with 088 indicate complete torch and lead assemblies Part number 088010 088011 088012 228228 228229 228322 228323 228320 228321 058503 228317 228318 228319 JS OO A ON Description T45m machine torch assembly with 7 62 m 25 feet lead T45m machine torch assembly with 10 67 m 35 feet lead T45m machine torch assembly with 15 24 m 50 feet lead Kit T45m positioning sleeve Kit T45m removable gear rack Kit T45m front mounting ring Kit T45m
70. cover off the power supply Remove the Mylar barrier that protects the power board The 230 V CE power cord has a brown wire and a blue wire that connect to the power switch and a green yellow ground wire that connects to the heat sink Remove the rear end panel or gently tilt it away from the power supply until you can access the screws that secure the power cord wires to the back of the power switch NOTE To remove the rear end panel you must first remove the air fitting Remove the screws that secure the connectors for the blue and brown wires from the power switch to disconnect them Remove the screw that holds the green yellow wire to the heat sink powermax4s Service Manual L 10 11 Single phase CE e Blus wire CE Green yellow On the outside of the power supply loosen the power cord s strain relief retention nut so that the wires move freely From the inside of the power supply pull the wires through the strain relief and the hole in the rear end panel to remove the old power cord If you are replacing the old strain relief with the new strain relief contained in the kit a Use an adjustable wrench to unscrew the strain relief nut on the inside of the power supply to remove the old strain relief b Slide the new strain relie
71. d 230 V aa Replace the power Gord 400 V A Replace the power cord 480 V Replace the dE ni e duit rane tartan ancien Replace the gas filter element e Replace the air filter and regulator siisii riisiin Replace the control ssa waza A a Replace the power board 200 240 V CSA and 230 V CE Replace the power board 400 V CE and 480 V CSA powermax4s Service Manual 6 1 DANGER ELECTRIC SHOCK CAN KILL Disconnect electrical power before performing any maintenance work requiring removal of the power supply cover must be performed by a qualified technician Remove and replace the cover and Mylar barrier The first step in most maintenance and repair procedures for the Powermax45 is removing the cover and the Mylar barrier To protect your power supply it is important to replace both items properly when the maintenance is complete Removal 1 Turn OFF the power disconnect the power cord and disconnect the g
72. d other control equioment 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 f Equipment used for calibration or measurement 9 Immunity of other equipment in the environment User shall ensure that other equipment being used in the 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 EMC 1 7 10 ELECTROMAGNETIC COMPATIBILITY 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 equipmen
73. d strain relief in place route the wires for the new power cord through the strain relief Screw the connector for the black wire onto the pin on the upper left side of the power switch with a torque setting of 23 0 kg cm 20 inch pounds Screw the connector for the white wire onto the pin on the upper right side of the power switch with a torque setting of 23 0 kg cm 20 inch pounds Tighten the green ground wire to the heat sink with a torque setting of 17 3 kg cm 15 inch pounds Position the wires in the wire chase up the side of the end panel and out of the way of the power board Replace or reposition the end panel Make sure that the screw hole in the ground clip aligns with the screw holes in the end panel and the power supply Tighten the strain relief s retention nut on the outside of the end panel to secure the new power cord Being careful not to pinch any of the wires replace the Mylar barrier and slide the cover back onto 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 power cord 230 V CE 1 2 Turn OFF the power disconnect the power cord and disconnect the gas supply Use a 2 Phillips screwdriver to remove the 2 screws from the handle on the top of the power supply Tip the end panels back slightly so that you can get the edges of the handle out from underneath them Lift the
74. e CE 3 phase 275 VDC CE 3 phase CSA 3 phase 278 VDC CSA 3 phase Rated output current 20Ato45A Rated output voltage Us 132 VDC Duty cycle at 40 50 1 245 132 V 60 1 41 A U 132 V See data plate on power supply for more information on 100 1 732 A 0 132 V duty cycle Operating temperature 10 to 40 14 to 104 Storage temperature 25 to 55 13 to 131 Power factor 200 240 V CSA 230 V CE 1 phase 0 99 400 V CE 3 phase 0 94 480 V CSA 3 phase 0 93 Input voltage U Input current l4 at 200 240 VAC 34 28 A 200 240 V CSA rated output Us 15 230 VAC 30 A 230 V CE 400 VAC 10 A 400 See Voltage configurations in the Power Supply Setup 480 VAC 8 5 A 480 V CSA section for more information Gas type Air Nitrogen Gas quality Clean dry oil free per ISO 99 995 pure 8573 1 Class 1 2 2 Recommended gas inlet flow and pressure 170 l min at 6 2 bar 360 scfh at 90 psi Equipment complies with IEC 61000 3 12 Equipment complies with IEC 61000 3 12 provided that the short circuit power S is greater than or equal to 692 KVA at the interface point between the user s supply and the public system It is the responsibility of the installer or user of the equipment to ensure by consultation with the distribution network operator if necessary that the equipment is connected only to a supp
75. e replace the fan NOTE Testing the fan can trigger a fault due to protection features on the fan driver chip You can disregard this fault if it occurs as a result of a fan test The purpose of the fan test is to ensure the fan is operating properly not to test the fan drive circuit J3 and J4 J4 and J5 19 18 wo RO 192 VDC 192 VDC Ferrite found on CE units only 200 240 V CSA and 230 V CE 400 V CE and 480 V CSA power supplies power supplies powermax4s Service Manual 5 27 TROUBLESHOOTING AND SYSTEM TESTS Test 9 pressure transducer Test the pressure transducer to ensure that the system is receiving the proper gas pressure 1 ONthe power 2 Check the voltage between pins 1 and 2 of J5 for 200 240 V CSA and 230 V CE power supplies or pins 1 and 2 of J6 for 400 V CE and 480 V CSA power supplies It should read approximately 0 2 V if there is no gas pressure If the gas pressure is within system tolerances the circuit should read approximately 3 3 The minimum acceptable gas pressure varies by torch type torch lead length and mode switch setting as shown in the following table Handheld 6 1 m 20 feet 3 45 bar 50 psi 3 45 bar 50 psi 1 72 bar 25 psi Handheld 15 24 m 50 feet 3 80 bar 55 psi 3 80 bar 55 psi 2 07 bar 30 psi Mechanized 7 62 m 25 feet 3 45 bar 50 psi 3 45 bar 50 psi 1 72 bar 25 psi Mechanized 10 7 m 35 f
76. e meaning associated with each set of flashes Number of error Faulty control board Replace the control board Faulty power board Replace the power board Faulty gas solenoid valve Replace the gas solenoid valve Faulty fan Replace the fan Machine motion relay fault Replace the power board Perform Test 3 VBUS and voltage balance on page 5 20 If any of the values are incorrect replace the power board Perform Test 2 power board voltage checks on page 5 19 If any of the values for pins 5 7 12 are incorrect Either a faulty power board 3 remove the control board and test again If the values are or a faulty control board 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 powermax4s Service Manual 5 17 TROUBLESHOOTING AND SYSTEM TESTS System tests There is a ground clip near the top of the rear end cap 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 next to the power board and below the power switch Ground wire clip Voltages of up to 50 VDC continue to be present on the DC bus for at least 30 seconds after disconnecting the input power Allow bus voltages to dissipate
77. e metal being cut is too thick The wrong consumables are being used gouging consumables are installed instead of cutting consumables for example You are moving the torch too quickly or too slowly The arc sputters and consumables life is shorter than expected The cause can be Moisture in the gas supply The gas pressure is too low How to use the machine torch Since the Powermax45 and the T45m can be used with a wide variety of cutting tables track burners pipe bevelers and such you will need to refer to the manufacturer s instructions for specifics on operating the machine torch in your configuration However the information in the following sections can help you optimize cut quality and maximize consumable life Ensure the torch and table are set up correctly Usea square to align the torch at right angles to the workpiece The torch may travel more smoothly if you clean check and tune the rails and drive system on the cutting table Unsteady machine motion can cause a regular wavy pattern on the cut surface Ensure that the torch does not touch the workpiece during cutting Contact with the workpiece can damage the shield and nozzle and affect the cut surface 4 12 powermax45 Service Manual OPERATION Understand and optimize cut quality There are several factors to consider in cut quality Cut angle The degree of angularity of the cut edge Dross The molten material that solidifies on
78. e the 2 screws to secure the cover Reconnect the electrical power and the gas supply Replace the power cord 480 V CSA 1 2 Turn OFF the power disconnect the power cord and disconnect the gas supply Use a 2 Phillips screwdriver to remove the 2 screws from the handle on the top of the power supply Tip the end panels back slightly so that you can get the edges of the handle out from underneath them Lift the cover off the power supply Remove the Mylar barrier that protects the power board The 480 V CSA power cord has 3 wires black white and red that connect to the power switch and a green ground wire that connects to the heat sink Remove the rear end panel or gently tilt it away from the power supply until you can access the screws that secure the power cord wires to the back of the power switch NOTE To remove the rear end panel you must first remove the air fitting Remove the 3 screws that secure the power cord wires to the power switch and gently pull the wires out of the switch Remove the screw that holds the green ground wire to the heat sink 6 10 powermaX45 Service Manual Three phase CSA Due 6 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 strain relief nut on the inside of the power supp
79. ead if necessary powermaX45 Service Manual The power ON LED is illuminated or is blinking and the fault LED is blinking x The power ON LED is illuminated and the fault LED and the temperature LED alternately flash when the system is powered ON OSO The power ON LED is illuminated and no fault LEDs are illuminated but no gas flows when the torch trigger is pulled Gas flows when the system The incoming gas pressure is too high or the system is is powered ON A major fault has occurred in the power supply The system was powered on while the plasma start signal was being sent The start signal is not reaching the control board in gas test mode powermax4s Service Manual TROUBLESHOOTING AND SYSTEM TESTS Any of the fan solenoid valve control board or power board may be faulty The system was powered on while the torch trigger was being pulled or the trigger was activated too soon after the system was powered on The start circuit is stuck closed The torch or torch lead may be damaged The power board may be faulty The control board may be faulty Verify that the mode switch is not set to gas test mode The gas pressure from the compressor or cylinder may be too high The gas solenoid valve may be faulty The error LED on the control board should be flashing The number of times it flashes between pauses indicat
80. eet 3 45 bar 55 psi 3 45 bar 50 psi 1 72 bar 25 psi Mechanized 15 25 m 50 feet 3 80 bar 55 psi 3 80 bar 55 psi 2 07 bar 30 psi Test 10 power switch trip coil 200 240 V CSA and the 230 V CE power supplies have over voltage protection on the power switch in the form of a mechanical trip coil If voltage provided by the incoming circuit is greater than the maximum voltage the trip coil will switch OFF the power supply If the power supply appears to be shutting down unexpectedly test the power switch 1 With the power switch in the OFF position disconnect the electrical power 2 Move the power switch to the ON position If the switch stays in position the trip coil mechanism is functioning properly If it does not stay in the ON position replace the power switch 5 28 powermax4s Service Manual Section 6 COMPONENT REPLACEMENT this section Remove and replace the cover and Mylar barrier aid A AAA wie dE O AO A AE Replace the work lead CSA and CE assess aaa dian Replace the power Cord 200 240 Replace the power Cor
81. er Reconnect the electrical power and the gas supply powermaX45 Service Manual Replace the air filter and regulator 1 2 10 11 12 Turn OFF the power disconnect the power cord disconnect the gas supply Use a 2 Phillips screwdriver to remove the 2 screws from the handle on the top of the power supply Tip the end panels back slightly so that you can get the edges of the handle out from underneath them Lift the cover off the power supply Remove the gas fitting from the rear of the power supply Remove the drain hose from the hole in the bottom of the power supply s base Disconnect the gas supply hose from the filter Gas supply hose Bracket p d Gas fitting Filter and regulator OO OT 1 NEZ NS MI Drain hose 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 Position the new gas filter in the bracket and replace the retainer nut Route the drain hose through the hole in the base of the power supply 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 supp
82. er supplies The Powermax45 has a 3 m 10 foot power cord Allow at least 0 25 m 10 inches of space around the power supply for proper ventilation Prepare the electrical power The maximum output voltage will vary based on your input voltage and the circuit s amperage Because the current draw varies during startup slow blow fuses are recommended as shown in the following chart Slow blow fuses can withstand currents up to 10 times the rated value for short periods of time Voltage configurations The following chart shows the maximum rated output for typical combinations of input voltage and amperage Acceptable input voltages can be 10 of the values given below CAUTION Protect the circuit with appropriately sized time delay slow blow fuses and a line disconnect switch Input Pea Recommended Input voltage Rated output current at slow blow fuse during arc 6 kw output size stretch 200 240 VAC 1 45A 132V 34 28A 55 45A 200 240 VAC 1 45A 132V 34 28A 55 45A 35or50 A CE 400 VAC 45 A 132 V 15 5 A 15 or 20 A CE CCC Use the higher amperage fuse for applications that require a long arc stretch powermax4s Service Manual 2 3 POWER SUPPLY SETUP Install a line disconnect switch Use a line disconnect switch for each power supply so that the operator can turn off the incoming power quickly in an emergency Locate the switch so that it is easily accessible to the operator Installation must be perfor
83. ermax45 uses air or nitrogen to cut electrically conductive metals such as mild or stainless steel or aluminum With it you can cut thicknesses up to 25 4 mm 1 inch and pierce thicknesses up to 9 5 mm 3 8 inch The standard Powermax45 includes one complete set of the consumables needed for cutting shield retaining cap swirl ring nozzle electrode 2 spare electrodes 2 spare nozzles gouging consumables handheld configurations only a quick disconnect air fitting 1 4 NPT on CSA units and 1 4 NPT x G 1 4 BSPP on CE units a consumables box a shoulder strap an Operator Manual a Quick Setup Card and a Setup DVD Mechanized configurations include a remote start pendant as well You can order additional consumables and accessories such as the plasma cutting guide from any Hypertherm distributor See the Parts section for a list of spare and optional parts The power cords on the 200 240 V CSA power supplies are shipped with 50 A 250 V plug NEMA 6 50P on the power cord The CE units and the 480 V CSA units are shipped without a plug on the power cord See Prepare the electrical power in the Power Supply Setup section for more information Where to find information System specifications such as size weight detailed electrical specifications and cut speeds can be found in this section For information on Safety information see the Safety and Compliance Manual for detailed safety information Setup requirements
84. ervicing 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 either 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 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 Internal inspection 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 Gently pull on the end panel nearest the screw you are removing to keep pressure on the screw When the screw is almost out tilt the screwdriver slightly to help pull the screw out of the recessed hole 3 the end panels back slightly so that you can get the edges of the handle out from underneath them Set the handle and screws aside Continue to til
85. es as a pulse width modulated half bridge circuit driving an isolation transformer The secondary of the isolation transformer is rectified by the output bridge D40 The output circuitry consists of 2 current sense transducers located on the power board the pilot arc IGBT inside the D40 module and the output choke The control board s digital signal processor DSP monitors and regulates the system s operation and safety circuits The amperage adjustment knob is used to set the output current to the desired value between 20 and 45 amps The system compares the set point to the output current by monitoring the current sense transducers and adjusting the pulse width output of the inverter IGBT Q2 powermax45 Service Manual 5 3 TROUBLESHOOTING AND SYSTEM TESTS Sequence of operation Power OFF Connect the gas supply to the air fitting on the power supply Connect the work lead to workpiece Plug in the power supply make sure incoming power is ON if using line disconnect box Set the ON OFF switch S1 to ON green power ON LED illuminates indicating the system is ready for operation All the fault LEDs should be extinguished see the Troubleshooting guide on page 5 11 for more information Set the mode switch to the desired mode for cutting or gouging Turn the amperage adjustment knob to the gas test position The gas solenoid valve V1 opens to purge the system and to all
86. es which components to test See Control Board LEDs on page 5 16 Release the torch trigger and turn OFF the power supply and then turn it ON again to reset the unit Be sure to allow time for the soft start circuit to be satisfied Perform Test 6 plasma start on page 5 26 to test the start signal Ensure that the gas is connected gas pressure LED will illuminate yellow after the torch is activated Inspect the torch and torch lead for damage Verify that the control board start LED illuminates when the trigger is pulled If it does not perform Test 6 plasma start on page 5 26 to check the start signal from the power board Check the gas supply to make sure that it does not exceed 9 3 bar 135 psi If necessary reduce the pressure Perform Test 4 solenoid valve on page 5 24 to verify that the gas solenoid valve is functioning correctly TROUBLESHOOTING AND SYSTEM TESTS 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 or the pilot arc starts but extinguishes before the normal 5 second time out period Arc goes out while cutting or intermittently will not fire The cut quality is poor or the cut does not sever the metal The consumables torch or torch lead are not functioning correctly the gas pressure may be too low or too high the air quality may be poor or
87. f damage refer to Claims below All communications regarding this equipment must include the model number and the serial number located on the bottom of the power supply 3 Before you set up and operate this Hypertherm system read the Safety and Compliance Manual Claims Claims for damage during shipment If your unit was damaged during shipment you must file a claim with the carrier Hypertherm will furnish you with a copy of the bill of lading upon request If you need additional assistance call the nearest Hypertherm office listed in the front of this manual Claims for defective or missing merchandise If any component is missing or defective contact your Hypertherm distributor If you need additional assistance call the nearest Hypertherm office listed in the front of this manual Contents Verify the items in the box against the illustration Operator Manual N Quick Setup Card 200 240V CSA plug included 230V CE cx plug not included Registration Card Setup DVD e 400V CE 480V CSA plug not included Box with extra consumables Remote start pendant optional Shoulder strap CE jp 2 2 powermax4s Service Manual POWER SUPPLY SETUP Position the power supply Locate the Powermax45 near an appropriate 200 240 volt power receptacle for CSA or CE 1 phase power supplies a 400 volt receptacle for 3 phase CE power supplies or a 480 volt receptacle for 3 phase CSA pow
88. f through the hole in the rear end panel of the power supply c Secure the strain relief on the inside of the power supply using the new strain relief nut Hand tighten the nut and then over tighten slightly more From the inside of the power supply route the wires of the new power cord through the strain relief in the rear end panel Do not remove the tubular ferrite bead from the power switch end of the brown and blue wires Because the CE power cord includes the ferrite bead you cannot route the power cord through the strain relief from the outside of the power supply Slide the strain relief retention nut over the wires of the new power cord and slide the retention nut forward toward the power supply Screw the connector for the brown wire onto the pin on the upper left side of the power switch with a torque setting of 23 0 kg cm 20 inch pounds powermax4s Service Manual 6 7 Screw the connector for the blue wire onto the the upper right side of the power switch with a torque setting of 23 0 kg cm 20 inch pounds Tighten the green yellow ground wire to the heat sink with a torque setting of 17 3 kg 15 inch pounds Position the wires in the wire chase up the side of the end panel and out of the way of the power board Replace or reposition the end panel Make sure that the screw hole in the ground clip aligns with the screw holes in the end panel and the power supply
89. hat secure the 3 white wires from the bottom of the ON OFF switch to the power board 11 Stand up the unit again Tuck out of the way all the wires that you detached 12 Pull the board straight out from the power supply 13 Before installing a new power board clean the heat sink with isopropyl alcohol Gently scrub away any residual thermal compound being careful not to scratch the heat sink Wipe it with a clean cloth powermax4s Service Manual 6 21 14 Spread a thin layer of thermal compound included the parts kit 2 mm thick about the thickness of a sheet of paper on all the IGBTs and the input bridge diode NOTE Remix the compound if the material separates 15 Line up the holes for the capacitor screws with the capacitors the pressure relief vents should be visible from the two notches in the power board 16 Push the power board straight in 17 Replace the 4 heat sink assembly screws and torque them to 23 0 kg cm 20 inch pounds 18 Replace the 3 retaining screws and the 4 resistor screws Torque these screws to 17 3 kg 15 inch pounds 19 Reconnect the white wires from the ON OFF switch to J1 J2 and J3 Torque them to 23 0 kg cm 20 inch pounds 20 Replace the 2 screws that attach the IGBTs and the screw that attaches the input bridge diode to the heat sink The torque setting for these screws is 23 0 kg cm 20 inch pounds If you replaced an older 400 V
90. he IGBTs and the 2 screws that attach the input bridge diodes to the heat sink There are holes in the power board to provide access to them If you have a newer 200 240 V CSA or 230 V CE power board that has a single input bridge diode and has a small slot below the heat sink assembly screw hole remove the 3 screws that attach the IGBTs and the screw that attaches the input bridge diode to the heat sink There are holes in the power board to provide access to them 11 Remove the screw at J1 that secures the white wire and the screw at J2 that secures the black wire from the ON OFF switch to the power board 12 Stand up the unit again Tuck out of the way all the wires that you detached 13 Pull the board straight out from the power supply powermax4s Service Manual 6 17 20 21 22 23 24 25 26 27 Before installing a new power board clean the heat sink with isopropyl alcohol Gently scrub away residual thermal compound being careful not to scratch the heat sink Wipe it with a clean cloth Spread a thin layer of thermal compound included in the parts kit 2 mm thick about the thickness of a sheet of paper on all the IGBTs and the input bridge diode NOTE Remix the compound if the material separates Line up the holes for the capacitor screws with the capacitors the pressure relief vents should be visible from the two notches in the power board
91. he drain hose from the drain in the bottom of the power supply s base Compress the hose fitting s collar on the gas supply hose and pull the gas hose from the fitting Unscrew the nut that holds the filter in the bracket Tip the bottom of the filter away from the power supply Unscrew the drain from the bottom of the filter You may want to remove the hose to make this easier powermax4s Service Manual 6 13 7 Unscrew the filter bowl from the body and remove it Gas supply hose Bracket Filter bowl Drain Drain hose Remove the glass filter tube by twisting it and pulling gently until it releases Unscrew the element from the filter body while being careful not to allow the element to rotate Screw the new element to the filter body Place the glass filter tube inside the filter bowl and screw the drain onto the bottom of the filter bowl Reattach the hose if you removed it earlier Reattach the filter bowl to the filter body making sure that the drain and drain hose point toward the front edge of the fan Reposition the filter assembly in the bracket and replace its retainer nut Reconnect the gas supply hose and press the drain hose onto the in the bottom of the power supply Reconnect the gas supply and check for leaks Slide the cover back onto the power supply Position the handle over the holes in the top of the cover then use the 2 screws to secure the cov
92. he length needed to go between the power supply and the CNC or other equipment plus an additional 45 72 cm 18 inches 1 On the end of the cable that will be attached to the power supply strip the outer jacket 11 43 cm 4 5 inches Cut 6 35 cm 2 5 inches off of wire 2 so that wire 1 is 11 43 cm 4 5 inches long and wire 2 is 5 08 cm 2 inches long Then strip 1 27 cm 0 5 inches of wire insulation off of each wire 2 Crimp a 8 insulated ring on the end of wire 1 and a 10 insulated ring on the end of wire 2 3 Use a 2 Phillips screwdriver to remove the 2 screws from the handle on the top of the power supply Tip the end panels back slightly so that you can get the edges of the handle out from underneath them Lift the cover off the power supply Remove the Mylar barrier that protects the power board powermax4s Service Manual 3 27 TORCH SETUP 4 Separate the rear panel from the Powermax45 by removing the screw from the bottom and backing the end panel away from the base so that there is enough room to drill out the access point without risk of hitting the interior components Rear end panel Access point GEE 5 Use a drill with a 19 32 inch drill bit to drill out the access point on the rear panel 6 Route the cable through the strain relief and tighten it down so that 45 72 cm 18 inches of insulated wire is on the side of the strain
93. herm of its warranty 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 9 10 WARRANTY 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 have the right to 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 action in connection with any such alleged infringement and in any event no longer than fourteen 14 days after learning of any action or threat of action and Hypertherm s obligation to defend 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 direct indirect punitive or exemplary damages incl
94. hile cutting make sure that sparks exit from the bottom of the workpiece The sparks should be lagging slightly behind the torch as you cut 15 30 angle from vertical f sparks are spraying up from the workpiece move the torch more slowly or set the output current higher powermaX45 Service Manual 4 7 OPERATION Hold the torch nozzle perpendicular to the workpiece so that the nozzle is at a 90 angle to the cutting surface and watch the arc as it cuts along the line f you fire the torch unnecessarily you shorten the life of the nozzle and electrode Pulling or dragging the torch along the cut is easier than pushing it For straight line cuts use a straight edge as a guide To cut circles use a template or a radius cutter attachment a circle cutting guide See the Parts section for part numbers for the Hypertherm plasma cutting guides for cutting circles and making bevel cuts Start a cut from the edge of the workpiece W 1 With the work clamp attached to the workpiece hold the torch nozzle perpendicular 90 to the edge of the workpiece If you are using the shielded consumables no standoff is needed With unshielded consumables maintain an approximate 2 mm 0 08 inch standoff 4 8 powermaX45 Service Manual OPERATION 2 Press the torch trigger to start the arc Pause at the edge until the arc has cut completely through the workpiece 3 Drag the nozzle
95. inking If the temperature torch cap sensor or fault LEDs are illuminated or blinking or if the power ON LED blinks correct the fault condition before continuing See the Troubleshooting guide topic in the Troubleshooting and System Tests section for more information The work clamp must be attached to the workpiece while you are cutting Attach the work clamp Note If you are using the Powermax45 with a cutting table you can ground it through the table instead of using the work clamp See your table manufacturer s instructions for more information Ensure that the work clamp and the workpiece make good metal to metal contact For the best cut quality attach the work clamp as close as possible to the area being cut Do not attach the work clamp to the portion of the workpiece to be cut away Work clamp When the power ON LED is illuminated none of the other LEDs are illuminated or blinking the gas pressure LED indicates pressure is in the correct range the amperage knob is set and the work clamp is attached the system is ready for use Understand duty cycle limitations The duty cycle is the amount of time in minutes that a plasma arc can remain on within a 10 minute period when operating at an ambient temperature of 40 C 104 F With a Powermax45 At 45 A the arc can remain on for 5 minutes out of 10 minutes without causing the unit to overheat 50 duty cycle At 41 A the arc can remain on for 6 minutes o
96. ipment Multimeter with a variety of jumper leads including E Z Hooks Troubleshooting procedures and sequence When performing the troubleshooting procedures Read the Safety and Compliance Manual for detailed safety information Refer to the Wiring Diagrams section for the system s electrical schematic Refer to the Component Replacement section for part replacement procedures Refer to the Parts section to locate power supply components and torch components After the problem has been located and repaired refer to the Sequence of operation flow diagram on page 5 4 to test the power supply for proper operation Power OFF and disconnected x J External inspection Internal inspection y Resistance checks Y Power S m y Troubleshooting guide Troubleshooting tests powermax4s Service Manual 5 5 TROUBLESHOOTING AND SYSTEM TESTS 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 O 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 s
97. ircuit driving an isolation transformer The secondary of the isolation transformer is rectified by the output bridge D38 The output circuitry consists of 2 current sense transducers located on the power board the pilot arc IGBT inside the D38 module and the output choke The control board s digital signal processor DSP monitors and regulates the system s operation and safety circuits The amperage adjustment knob is used to set the output current to the desired value between 20 and 45 amps The system compares the set point to the output current by monitoring the current sense transducers and adjusting the pulse width output of the inverter IGBTs A trip coil on the power switch provides over voltage protection 400 V CE 3 phase power supply functional description AC power enters the system through the power switch S1 to the input diode bridge D48 The voltage from the diode bridge supplies the power factor correction PFC choke which provides a nominal 560 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 relays K2 The inverter consists of a dual IGBT package Q2 the power transformer a current sense transducer and the control circuit The inverter operates as a pulse width mod
98. kness dista ce height delay ipm W ipm V amps in in 9 sec P 0 036 400 105 20 0 060 16 Ga 103 WI 500 103 0 105 12 Ga 198 0 135 10 191 Maximum cut speed is limited by the test table s maximum speed 400 ipm Align the torch Mount the machine torch perpendicular to the workpiece in order to get a vertical cut Use a square to align the torch at 0 and 90 3 24 powermax4s Service Manual TORCH SETUP Connect the remote start pendant Configurations of a Powermax45 with a T45m also can include a 7 62 m 25 foot 128650 15 24 m 50 foot 128651 or 22 86 m 75 foot 128652 remote start pendant To use the Hypertherm remote start pendant plug it into the receptacle on the rear of the power supply Note remote start pendant is for use only with a machine torch It will not operate if a hand torch is installed Receptacle for the remote start pendant or a machine interface cable Connect a machine interface cable The Powermax45 is equipped with a factory installed voltage divider that is designed to be safely connected without tools The built in voltage divider provides a 50 1 arc voltage A receptacle on the rear of the power supply provides access to the 50 1 arc voltage and signals for arc transfer and plasma start CAUTION The factory installed internal voltage
99. l is magnetized or hardened you are more likely to experience cut angle problems Dross Some amount of dross will always be present when cutting with air plasma However you can minimize the amount and type of dross by adjusting your system correctly for your application Dross appears on the top edge of both pieces of the plate when the torch is too low or voltage is too high if using a torch height control Adjust the torch or the voltage in small increments 5 volts or less until the dross is reduced Low speed dross forms when the torch s cutting speed is too slow and the arc shoots ahead It forms as a heavy bubbly deposit at the bottom of the cut and can be removed easily Increase the speed to reduce this type of dross powermax4s Service Manual 4 13 OPERATION High speed dross forms when the cutting speed is too fast and the arc lags behind It forms as a thin linear bead of solid metal attached very close to the cut It is welded to the bottom of the cut and is difficult to remove To reduce high speed dross Decrease the cutting speed Decrease arc voltage to decrease the torch to work distance Notes Dross is more likely to form on warm or hot metal than on cool metal For example the first cut in a series of cuts will likely produce the least dross As the workpiece heats up more dross may form on subsequent cuts Dross is more likely to form on mild steel than on stainless steel or aluminum Worn or damaged con
100. losed E 0 VDC open 8 2 powermax4s Service Manual WIRING DIAGRAMS Control board diagram 400 V CE and 480 V CSA MACHINE L FRONT IRESET or ERROR HDRFLT CODE START SERIAL CAPOFF1 FAULTI AC 1 TSO TSC L H LINE vEL YEL Y GRN AMPS1 DSP 2806 4x25Mhz 100Mhz 0 78 x 0 78 Stayout for TEST CLIP UP NORMAL MIDDLE ON GOUGE DOWN Expected value 2 7 V at 400 line voltage CE 2 178 VDC at 560 VBUS CE ONE 2 016 VDC at 670 VBUS CSA 16 Start sianal 3 2 VDC closed VDC open powermax4s Service Manual 8 3 WIRING DIAGRAMS 8 4 powermaX45 Service Manual REAR 50A 250V with 32v TRIP COIL OAWG POWER PWA 230V CSA 141005 Top Level 230V CE 141046 Top Level 8 45 h x 13 00 w 2 2 plated to 2 FACING COMPONENT SIDE OF PCB FAN 190CFM 24v 1 0A GAS SOL PRESSURE 24v 0 13A SENSOR Power board wiring Y Cap 300vac D29 50A lt 1600V 8 2uF 8 2uF 630VDC 630VDC 8 2uF 630VDC 2 40 x 1 65 1 60 max zone PFC IGBT MODULE 130A Fpfc 24khz lline Limit 58arms PFC 4 60A 600 3 2 CLAMP DIODE 60A 600V d av 27K 3W 5600uF 250VDC 30A 003192 240VAC 30A 003192 240VAC LOW INDUCTANCE VBUS LAYOUT 5600uF 250VDC 16 gt IPFC DRVFLT 9 5 942 8 450 E 1 92 MAX Ht 1m oid y 1 965 5 942 0 472 MAX Ht y 0 00 1 965
101. ly to remove the old strain relief 7 From the outside of the power supply pull the wires through the strain relief and the hole in the end panel to remove the old power cord 8 If you are replacing the old strain relief with the new strain relief contained in the kit slide the new strain relief onto the new power cord and route the wires for the new power cord through the hole in the end panel Slide the new strain relief nut over the wires and screw it to the strain relief from the inside of the end panel Hand tighten the nut and then over tighten slightly more If you are keeping the old strain relief in place route the wires for the new power cord through the strain relief 9 Press the connector for the black wire into the hole on the top left side of the power switch L1 and replace the screw that secures it Torque the screw to 11 5 kg cm 10 inch pounds 10 Press the connector for the white wire into the hole on the top middle of the power switch L2 and replace the screw that secures it Torque the screw to 11 5 kg cm 10 inch pounds 11 Press the connector for the red wire into the hole on the top right of the power switch L3 and replace the screw that secures it Torque the screw to 11 5 kg cm 10 inch pounds powermax4s Service Manual 6 11 Tighten the green ground wire to the heat sink with a torque setting of 17 3 kg cm 15 inch pounds Position the wires in the wire cha
102. ly to test it for leaks Being careful not to pinch any of the wires slide the cover back onto 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 powermax4s Service Manual 6 15 Replace the control board 1 2 Turn OFF the power disconnect the power cord and disconnect the gas supply Use a 2 Phillips screwdriver to remove the 2 screws from the handle on the top of the power supply Tip the end panels back slightly so that you can get the edges of the handle out from underneath them Lift the cover off the power supply Remove the Mylar barrier that protects the power board Remove the amperage control knob by pulling it straight out from the end panel Remove the front end panel or gently tilt it away from the base Detach the ribbon cable from the power board at J7 200 240 V CSA 230 V or J8 400 V CE and 480 V CSA 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 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
103. ly with a short circuit power S greater than or equal to 692 KVA 1 4 powermax4s Service Manual SPECIFICATIONS T45v torch dimensions 22 1 8 72 gt gt 21 6 cm 8 5 in 36 5 cm 14 36 in cL TH 30 5 cm 12 in 3 6 cm 1 43 in outer dimension 3 3 cm 1 3 in flat sides 33 0 cm 13 in powermaX45 Service Manual 1 5 SPECIFICATIONS T45v and T45m torch specifications Handheld cut capacity material thickness Recommended cut capacity hand cutting 12 7 mm 1 2 inch Maximum cut capacity hand cutting or mechanized edge start 19 1 mm 3 4 inch Severance capacity hand cutting or mechanized edge start 25 4 mm 1 inch Mechanized pierce capacity material thickness Pierce capacity for edge starts the capacities are the same as the handheld capacities Recommended cut speed on mild steel 6 35 mm 1 4 inch 9 53 mm 3 8 inch 12 7 mm 1 2 inch 19 1 mm 3 4 inch 25 4 mm 1 inch Gouging capacity Metal removal rate on mild steel Weight 9 5 mm 3 8 inch 1524 mm min 60 ipm 813 mm min 32 ipm 508 mm min 20 ipm 203 mm min 8 ipm 102 mm min 4 ipm 2 8 kg hr 6 2 lbs hr T45v torch only T45v with 6 1 m 20 foot lead T45v with 15 24 m 50 foot lead T45m torch only T45m with 7 62 m 25 foot lead T45m with 10 7 m 35 foot lead T45m with 15 24 m 50 foot lead 0 27 kg 0 6 Ib 1 55 kg 3 4
104. med by a licensed electrician according to national and local codes The interrupt level of the switch must be equal to or exceed the continuous rating of the fuses In addition the switch should Isolate the electrical equipment and disconnect all live conductors from the incoming supply voltage when in the OFF position Have one OFF and one ON position that are clearly marked with O OFF and I ON Have an external operating handle that can be locked in the OFF position Contain a power operated mechanism that serves as an emergency stop Have slow blow fuses installed as recommended in the table on the previous page Requirements for grounding To ensure personal safety proper operation and to reduce electromagnetic interference EMI the Powermax45 must be properly grounded The power supply must be grounded through the power cord according to national and local electrical codes Single phase service must be of the 3 wire type with a green or green yellow wire for the protective earth ground and must comply with national and local requirements Do not use a 2 wire service Three phase service must be of the 4 wire type with a green or green yellow wire for the protective earth ground and must comply with national and local requirements Refer to the Safety and Compliance Manual for more information Power cord considerations Powermax45 power supplies are shipped with CSA and CE power cord configurations The power cords on
105. mm 0 1816 inch 6 37 mm 0 2508 inch 0 73 mm 0 0289 inch 3 05 mm 0 1200 inch 508 mm min 20 ipm 5 74 mm 0 2258 inch 1 96 mm 0 0772 inch 762 mm min 80 ipm 5 28 mm 0 2077 inch 1 09 mm 0 0428 inch 1016 mm min 40 ipm 4 83 mm 0 1901 inch 1 73 mm 0 0680 inch 1270 mm min 50 ipm 254 mm min 10 ipm 4 42 mm 0 1739 inch 6 55 mm 0 2580 inch 1 47 mm 0 0580 inch 5 92 mm 0 2330 inch 508 mm min 20 ipm 6 42 mm 0 2526 inch 2 01 mm 0 0792 inch 762 mm min 80 ipm 5 92 mm 0 2329 inch 1 45 mm 0 0569 inch 1016 mm min 40 ipm 5 36 mm 0 2110 inch 1 10 mm 0 0432 inch 1270 mm min 50 ipm powermaX45 Service Manual 5 09 mm 0 2003 inch 0 82 mm 0 0322 inch OPERATION Common hand cutting faults The torch sputters and hisses but does not produce an arc The cause can be The consumables are too tight Loosen the consumables about 1 8th of a turn and try again Never tighten the consumables beyond just finger tight The torch does not cut completely through the workpiece The causes can be The cut speed is too fast The consumables are worn The metal being cut is too thick Gouging consumables are installed instead of cutting consumables The work clamp is not attached properly to the workpiece The gas pressure or gas flow rate is too low Cut quality is poor The causes can be Th
106. mum Sia T za Control board ue no m p A Ribbon cable m in Ara 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 The control board LEDs are 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 whenever there is a fault in the system If the Fault LED on the front panel flashes and the Error LED on the control board also flashes there is a major fault in the system The number of flashes between pauses indicates which component may have failed Reset This LED illuminates when the reset circuit is active or the watchdog circuit fires 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 LEDs on the front of the power supply and the Error LED or the Reset LED on the control board may illuminate or flash 5 16 powermaX45 Ser
107. ndle replacement 7 7 075714 T45v torch handle screws 5 required 7 7 002244 T45v torch trigger assembly with spring 7 7 228109 Kit T45v torch cap sensor switch replacement 7 7 088008 T45v hand torch assembly with 6 1 m 20 feet lead 7 7 088009 T45v hand torch assembly with 15 24 m 50 feet lead 7 7 228315 Kit T45v torch lead replacement 6 1 m 20 feet 7 7 228316 Kit T45v torch lead replacement 15 24 m 50 feet 7 7 088010 T45m machine torch assembly with 7 62 m 25 feet lead 7 9 088012 T45m machine torch assembly with 15 24 m 50 feet lead 7 9 228228 Kit T45m positioning sleeve 7 9 228229 Kit T45m removable gear rack 7 9 228322 Kit T45m front mounting ring 7 9 228323 Kit T45m rear mounting ring 7 9 228321 Kit T45m cap sensor switch replacement 7 9 228317 Kit T45m torch lead replacement 7 62 m 25 feet 7 9 228319 Kit T45m torch lead replacement 15 24 m 50 feet 7 9 7 12 powermax4s Service Manual Powermax45 labels Part number Description 228272 Kit Powermax45 labels CE 228264 Kit Powermax45 labels 200 240 V CSA 428075 Kit Powermax45 labels Built in America 480 V CSA The label kits include the consumable label appropriate safety labels as well as front and side decals The consumable and safety labels are pictured below Data pl T45v CONSUMABLE PARTS Plaque signaletique _ Pieces Consommables T45v lt j a 220717 220718 X l i Oe 220674 220713 220671 220670 220669
108. o a successor in interest who agrees to be bound by all of the terms and conditions of this Warranty Within thirty 30 days before any such transfer occurs you agree to notify in writing Hypertherm which reserves the right of approval Should you fail timely to notify Hypertherm and seek its approval as set forth herein the Warranty set forth herein shall be null and void and you will have no further recourse against Hypertherm under the Warranty or otherwise Compliance Information Section 1 SPECIFICATIONS In this section SysiemiAeSCIPHUONU PP Where to find information Power supply dimensions weights nnne ien tette 1 3 DIMENSIONS tdeo ie ope dr W a R AO A AE e i hsc ea AAAA nti aen 1 3 WGN NS Ln 1 3 Power supply Rp BAR LR MD DIDI MID AM 1 4 aocielnie tp 1 5 TA5Mm t rch dimensio S uwaza zzz EE RA titt cni io WEW nd GA RE RR Eu ad c 1 5 T4by and 45m torch specifications ni i Li e ER drin a n e d Ft Ed 1 6 yiueezaoduriccme D M 1 7 SymBOlS Z R PEIPER 1 8 powermaX45 Service Manual 1 1 SPECIFICATIONS System description The Powermax45 is a highly portable 45 amp handheld and mechanized plasma cutting system appropriate for a wide range of applications The Pow
109. oard 1 Flyback circuit PE ground Power board PCB2 Power switch 51 9 mou o NEN IA ie Fe d 4 NEN oo __ 7 TP 19 TP18 wo RO Gi R 192 VDC 192 D 9 9 i Inverter IGBT Work lead connection J21 Test points PFC IGBT Q2 Newer power board Output diode and pilot arc Input diode bridge IGBT module 038 D48 Older power board Input diode bridges D29 D39 5 8 powermaX45 Service Manual TROUBLESHOOTING AND SYSTEM TESTS 400 V CE power supply overview PE ground Control board 1 Flyback circuit Power switch 81 Power board PCB2 CARY _ lt M Work lead connection 121 Test points Inverter IGBT Q2 Output diode and pilot arc Newer power board IGBT module D40 Input diode bridge D48 Older power board Input diode bridges D28 D38 powermax45 Service Manual 5 9 TROUBLESHOOTING AND SYSTEM TESTS 480 V CSA power supply overview PE ground Control board 1 Flyback circuit Power switch S1 eee coco A J 2 et 7960 TP16 A TP17 o wo 18 7280 280 VDC B e ENAS le C
110. on the work lead on the workpiece Clean the cutting surface to ensure a better connection with the work lead 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 200 V 34 A 240 V 28 A 400 V 10 A 480 V 8 5 A turn the knob to the highest setting powermax4s Service Manual TROUBLESHOOTING AND SYSTEM TESTS rosin The pilot arc extinguishes The continuous pilot mode switch may be Verify that the mode when you move the plasma feature is not working set incorrectly switch is set to continuous arc off the work piece while still pulling the torch s trigger The power board or the pilot arc control board may be Perform Test 2 power faulty board voltage checks on page 5 19 and Test 3 VBUS and voltage balance on page 5 20 to verify that the power board is functioning properly If the power board is faulty replace it Otherwise replace the control board powermax45 Service Manual 5 15 TROUBLESHOOTING AND SYSTEM TESTS Control Board LEDs Powermax45 control board 1 has 4 diagnostic LEDs Start Transfer XFR Error Reset watchdog 2 EEN 2 ota 2 z EN
111. ot arc to cut metal plate middle Gouging bottom After you change the mode switch verify that the gas pressure is still set correctly Different modes of cutting require different pressure settings Rear controls 200 240 V CSA 230 V CE 400 V 480 V CSA ON D OFF O power switch Activates the power supply and its control circuits Operate the Powermax45 Follow the steps below to begin cutting or gouging with the Powermax45 Connect the electrical power and gas supply Plug in the power cord and connect the gas supply line For more information about the electrical requirements and the gas supply requirements of the Powermax45 see the Power Supply Setup section powermaX45 Service Manual OPERATION Power ON the system Set the ON OFF switch to the ON position 200 240 V CSA 230 V 400 V CE 480 V CSA Set the mode switch Use the mode switch to select the type of work you will be doing To cut expanded metal or grate top position Use this setting to cut metal root Bi with holes in it or for any job requiring a continuous pilot arc Leaving the mode cud switch on this setting when cutting standard metal plate will result in reduced NS consumable life TD To cut metal plate middle position Use this setting to cut metal up to 25 4 E 1 inch thick or pierce metal up to 12 7 mm 1 2 inch thick gt
112. over with labels 200 240 V CSA 1 6 228283 Kit Power supply cover with labels CE 1 7 428076 Kit Power supply cover with labels Built in America 480 V CSA 1 8 228268 Kit Rear panel 1 9 228267 Kit Powermax45 handle and screws 1 10 228282 Kit FastConnect replacement power supply half 1 11 228561 Kit Ground clamp 1 7 2 powermaX45 Service Manual Power Receptacle for machine interface cable or remote start pendant Part number Description 228278 Kit CSA power cord 1 phase 200 240 V 3 m 10 feet 228277 Kit CE power cord 1 phase 230 V 3 m 10 feet 228276 Kit CE power cord 3 phase 400 V 3 m 10 feet 428077 Kit CSA power cord 3 phase 480 V 3 m 10 feet 023206 Machine interface cable start plasma arc transfer and ground 7 62 m 25 feet 023279 Machine interface cable start plasma arc transfer and ground 15 24 m 50 feet 123966 Powermax45 machine interface cable start plasma arc transfer 50 1 voltage divider and ground 7 62 m 25 feet spade connectors 123967 Powermax45 machine interface cable start plasma arc transfer 50 1 voltage divider and ground 15 24 m 50 feet spade connectors 223048 Machine interface cable start plasma arc transfer 50 1 voltage divider and ground 7 62 m 25 feet D sub connector with screws 123896 Machine interface cable start plasma arc transfer 50 1 voltage divider and ground 15 24 m 50 feet D sub connector with scre
113. ow the gas pressure to be set Verify that the gas pressure LED illuminates green and is centered in the pressure bar Set the amperage adjustment knob to the desired output current between 20 and 45 amps based on the thickness of the metal to be cut Set the power switch 51 to OFF O gas solenoid valve V1 closes The gas flow stops arc extinguishes Gas continues to flow for 20 seconds Drag the torch lightly across the workpiece to make a cut workpiece drops after the cut Release the plasma start trigger on the hand torch or the remote start switch for the machine torch gas solenoid valve V1 opens The gas flow starts cutting arc starts Position the torch on the workpiece Pull the plasma start trigger on the hand torch or press the remote start switch for the machine torch gas solenoid valve V1 closes The gas flow stops power circuits are ready powermaX45 Service Manual TROUBLESHOOTING AND SYSTEM TESTS 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 equ
114. pe 3 26 powermax4s Service Manual SETUP Refer to the following table when connecting the Powermax45 to a torch height controller or with a machine interface cable Signal Type Notes Connector External cable sockets wires Normally open Start start plasma Input 18 VDC open circuit voltage at START 3 4 Green black terminals Requires dry contact closure to activate Normally open Dry contact closure when the arc transfers Transfer start machine motion Output 120 A maximum at the machine 1214 Ren PAOR interface relay or switching device supplied by the customer Ground Ground 13 Voltage divider Output Divided arc signal of 50 1 provides a 5 6 Black white maximum of 7 V Accessing raw arc voltage Connecting a cable to the Powermax45 power board to bypass the voltage divider and access raw arc voltage must be done by a qualified service technician WARNING HIGH VOLTAGE AND CURRENT Connecting directly to the plasma circuit for access to raw arc voltage increases the risk of shock hazard energy hazard and fire hazard in the event of a single fault The output voltage and the output current of the circuit are specified on the data plate To access raw arc voltage on a Powermax45 you will need kit number 228352 and an 18 AWG 2 wire non shielded cable similar to OLFLEX 190 601802 in t
115. pped power board is faulty Perform Test 1 voltage input on page 5 18 to check the incoming voltage and the power switch The power ON LED is illuminated the fault LED is illuminated and the bottom LED on the gas pressure bar is illuminated yellow and is blinking There is insufficient gas pressure to the machine There is no gas attached to the system Ensure that the gas supply is connected correctly gas supply line has a restriction or the air filter element is dirty Check the gas supply line for restrictions or damage Check the air filter element and replace it if necessary The reading at the pressure transducer is below the minimum acceptable gas pressure Perform Test 9 pressure transducer on page 5 28 to verify that the pressure transducer functions correctly powermax4s Service Manual TROUBLESHOOTING AND SYSTEM TESTS poom emayman Jee The power ON LED is illuminated and the yellow temperature LED is illuminated The power ON LED is blinking The power ON LED is illuminated and the torch cap LED is illuminated The power ON LED is illuminated and the torch cap LED blinks W The internal system temperature is either over or under its operating range approximately 30 C to 80 The incoming voltage is not correct The cap sensing circuit is not satisfied This indicates either a torch stu
116. r power quality whether from phase converters or incoming line power This warranty shall not apply to any product which has been incorrectly installed modified or otherwise damaged Compliance Information WARRANTY Hypertherm provides repair replacement or adjustment of the Product as the sole and exclusive remedy if and only if the warranty set forth herein properly is invoked and applies 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 pre paid by the customer Hypertherm shall not be liable for any repairs replacement or adjustments of Products covered by this warranty except those made pursuant to this paragraph and with Hypertherm s prior written consent The warranty set forth 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 Hypert
117. r Cord 200 240 6 5 Replace the power Cord 230 VCE esrara ienai E ERR E E R R AAAA E IRER 6 6 Replace the power cord 400 V 6 8 Replace the power cord 480 V CSA senpacie n R R R ERE 6 10 A 6 12 Replace the gas filter elemerit tit ett treten iii dt 6 13 Replace thezair filter and regulator i eet da ed 6 15 Replace the control board eese entente tente tentent tente tenente tete tenente tente senten te tente tentent tente tenente nte tenentes 6 16 Replace the power board 200 240 V CSA and 230 V 6 17 Replace the power board 400 V CE and 480 6 21 SECTION 7 PARTS Powetsupplypatrts acai eat ata aita hah date Dt erit Exterior Interior power board side Interior Tati Side nh ter testi Interior heat sink side T45v hand torch par
118. rc stretch at 45 A cutting current Good stretch at 30 A cutting current Notes Based on the generator rating age and condition adjust the cutting current as needed If a fault occurs while using a generator turning the power switch quickly to OFF and then to ON again sometimes called a quick reset may not clear the fault Instead turn the power supply off and wait 30 to 45 seconds before turning it on again Prepare the gas supply The gas supply for the Powermax45 can be shop compressed or cylinder compressed A high pressure regulator must be used on either type of supply and must capable of delivering gas to the filter on the power supply at 170 l min at 6 2 bar 360 scfh at 90 psi Do not allow the gas supply pressure to exceed 9 3 bar 135 psi The filter bowl may explode if this pressure is exceeded If gas supply quality is poor cut speeds decrease cut quality deteriorates cutting thickness capability decreases and the life for consumables shortens For optimum performance the gas should have a maximum particle size of 0 1 micron at a maximum concentration of 0 1 mg m3 a maximum dew point of 40 C 40 and a maximum oil concentration of 0 1 mg m per ISO 8573 1 Class 1 2 2 2 6 powermax4s Service Manual POWER SUPPLY SETUP Connect the gas supply Connect the gas supply to the power supply using an inert gas hose with a 9 5 mm 3 8 inch internal diameter and a 1 4 NPT quick disconnect
119. rcuit boards Store PC boards in anti static containers Wear a grounded wrist strap when handling PC boards 3 Detach the ribbon cable from J8 on the heat sink side of the power board See the illustrations following this procedure for the location of the ribbon cable and the components listed in the steps that follow 4 Remove the connectors at J10 J12 and J22 on the heat sink side of the power board 5 Remove the connectors at 14 J5 and J6 on the heat sink side of the power board 6 Remove the wires for the transformers and inductors at J13 J14 J15 J16 J17 J18 J19 and J20 7 Remove the work lead ring terminal from J21 and the 4 capacitor screws 8 Remove the 3 retaining screws the 4 resistor screws and the 4 heat sink assembly screws 9 Ifyou have an older 400 V CE power board that has 2 input bridge diodes and without the small slot below the heat sink assembly screw hole remove the 2 screws that attach the IGBTs and the 2 screws that attach the input bridge diodes to the heat sink There are holes in the power board to provide access to them If you have a newer 400 V CE or 480 V CSA power board that has a single input bridge diode and has a small slot below the heat sink assembly screw hole remove the 2 screws that attach the IGBTs and the screw that attaches the input bridge diode to the heat sink There are holes in the power board to provide access to them 10 Remove the screws at J1 12 and J3 t
120. relief that will go inside the power supply 7 Thread the 45 72 cm 18 inches of wire through the hole you drilled in the rear panel and fit the strain relief into the hole If necessary drill out any remaining rough spots so that the strain relief fits snugly 8 Tighten the strain relief nut on the inside of the rear panel to hold the strain relief in place 9 Find the grommet closest to the rear panel and at the bottom of the center panel Route the 2 wires through the grommet to the power board side of the power supply Rear panel pulled slightly away from the base Grommet in center panel 3 28 powermax45 Service Manual TORCH SETUP 10 Route the wires along the base of the unit and behind the cables connected to the power board 11 Remove the work lead connector screw at J21 and the white wire connector screw at J19 J18 for 400 V CE and 480 V CSA power supplies 12 Connect wire 1 to J19 J18 for 400 V CE and 480 V CSA power supplies with the ring connector for wire 1 closest to the power board and the connector for the white wire closest to the head of the screw the ring connector for wire 1 upside down so that the slight bend in the ring connector base creates a little space between the wire and the board Tighten the screw to 23 0 kg cm 20 inch pounds 13 Connect wire 2 to J21 This time put the connector for the work lead closest to the power board and put the ring connector for
121. rs 4 J13 connector 5 J14 connector 6 J16 connector 7 J17 connector 8 J19 connector 9 J22 connector 10 Work lead connector J21 11 Retaining screw 12 J20 connector 6 20 9 9 Item 13 14 15 16 17 18 19 20 21 22 23 24 15 Description Resistor screws 4 Pressure relief vents Capacitor screws 4 J15 connector J18 connector Input bridge diode screws 2 ON OFF switch wires J1 connector J2 connector J6 connector IGBT attachment screws 3 J3 J4 and J5 connectors powermaX45 Service Manual Replace the power board 400 V and 480 CSA Before beginning this procedure make sure you have the correct power board for your system The kit number for a 400 V CE power board is 228260 The kit number for a 480 V CSA power board is 428078 These power boards have a small slot immediately below the heat sink assembly screw hole and a single input bridge diode 1 Turn OFF the power disconnect the power cord and disconnect the gas supply 2 Usea 2 Phillips screwdriver to remove the 2 screws from the handle on the top of the power supply Tip the end panels back slightly so that you can get the edges of the handle out from underneath them Lift the cover off the power supply Remove the Mylar barrier that protects the power board CAUTION Static electricity can damage circuit boards Use proper precautions when handling printed ci
122. se up the side of the end panel and out of the way of the power board Replace or reposition the end panel Make sure that the screw hole in the ground clip aligns with the screw holes in the end panel and the power supply Tighten the strain relief s retention nut on the outside of the end panel to secure the new power cord If you are installing a plug on the new power cord use a plug that meets national and local electrical codes The plug must be connected to the power cord by a licensed electrician Being careful not to pinch any of the wires replace the Mylar barrier and slide the cover back onto 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 fan 1 2 Turn OFF the power disconnect the power cord and disconnect the gas supply Use a 2 Phillips screwdriver to remove the 2 screws from the handle on the top of the power supply Tip the end panels back slightly so that you can get the edges of the handle out from underneath them Lift the cover off the power supply Detach the connector from J4 200 240 V CSA and 230 V or J5 400 V CE and 480 V CSA on the power board You may have to lift the top edge of the Mylar 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
123. shield shade 8 lens 127239 Face shield shade 6 lens 127105 Replacement lens for face shield shade 8 127243 Replacement lens for face shield shade 6 127169 Leather cutting gloves 128650 Remote start pendant for machine torch 7 62 m 25 feet 128651 Remote start pendant for machine torch 15 24 m 50 feet 128652 Remote start pendant for machine torch 22 86 m 75 feet 7 10 powermax4s Service Manual Safety critical parts 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 Item Partnumber Description 1 228261 Kit 228260 Kit 228259 Kit 428078 Kit 2 228265 Kit 228273 Kit 228263 Kit 428079 Kit 3 228287 Kit 4 228286 Kit 5 228266 Kit 228288 Kit 228278 Kit 228277 Kit 228276 Kit 428077 Kit Power board 200 240 V CSA and subcomponents Power board 400 V CE and subcomponents Power board 230 V CE and subcomponents Power board 480 V CSA and subcomponents Magnetics assembly 200 240 V CSA Magnetics assembly 230 V CE Magnetics assembly 400 V CE Magnetics assembly 480 V CSA Filter and regulator F
124. sture from damaging the receptacle when not in use This cover should be replaced if damaged or lost 127204 Installation of the machine interface cable must be performed by a qualified service technician To install a machine interface cable 1 Turn OFF the power and disconnect the power cord 2 Remove the machine interface receptacle s cover from the rear of the power supply 3 Connect the Hypertherm machine interface cable to the power supply 4 f you are using a cable with a D sub connector on the other end plug it into the appropriate pin connector on the torch height controller or CNC Secure it with the screws on the D sub connector If you are using a cable with wires and spade connectors on the other end terminate the machine interface cable inside the electrical enclosure of listed and certified torch height controllers or CNC controllers to prevent operator access to the connections after installation Verify that the connections are correct and that all live parts are enclosed and protected before operating the equipment Note The integration of Hypertherm equipment and customer supplied equipment including interconnecting cords and cables if not listed and certified as a system is subject to inspection by local authorities at the final installation site The connector sockets for each type of signal available through the machine interface cable are shown below The table on page 3 27 provides details about each signal ty
125. sumables may produce intermittent dross Straightness of the cut surface A typical plasma cut surface is slightly concave The cut surface may become more concave or convex Correct torch height is required to keep the cut surface acceptably close to straight Worn consumables also affect the straightness of the cut q A strongly concave cut surface occurs when the torch to work distance is too low Increase the torch to work distance to straighten the cut surface A convex cut surface occurs when the torch to work distance is too great or the cutting current is too high First try lowering the torch then reduce the cutting current To pierce a workpiece using the machine torch As with the hand torch you can start a cut with the machine torch at the edge of the workpiece or by piercing the workpiece Piercing will result in a shorter consumable life than with edge starts The cut charts include a column for the height at which the torch should be when starting a pierce For the Powermax45 the pierce height is generally 2 5 times the torch cutting height Refer to the cut charts for specifics The pierce delay must be sufficiently long that the arc can pierce the material before the torch moves but not so long that the arc wanders while trying to find the edge of a large hole When piercing maximum thicknesses the ring of dross that forms during the pierce may become high enough to contact the torch when the torch begins to mo
126. t If your cutting table s track is large enough for you to thread the torch through it without removing the torch body from the lead do so and then attach the torch to the lifter per the manufacturer s instructions Note The T45m can be mounted on a wide variety of X Y tables track burners pipe bevelers and other equipment Install the torch per the manufacturer s instructions and following the instructions below for disassembly if necessary If you need to disassemble the torch follow these steps 1 Disconnect the torch lead from the power supply and remove the consumables from the torch 2 Remove the gear rack from the positioning sleeve by removing the 2 black screws that secure it to the positioning sleeve Remove the 6 screws 3 at each end that secure the positioning sleeve to the brass strain relief ring and to the torch body Slide the positioning sleeve off the torch 3 6 powermax4s Service Manual 3 8 9 TORCH SETUP Disconnect the wires for the cap sensor switch at the connector in the middle Gas supply line connection Cap sensor switch s wire connector Screw to connect the power cable to the plunger Use a 2 Phillips screwdriver and a 6 mm 1 4 inch nut driver or adjustable wrench to remove the screw and nut that secure the torch s power cable to the plunger Turn the plunger if necessary to gain access to the screw Use 6 mm 1 4 inch and 10 mm 3 8 inch or adjustable wrenches to loosen the n
127. t 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 equipment should not be modified in any way except as set forth in and in accordance with the manufacturer s written instructions For example 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 receive a shock by touching these metallic components and the electrode nozzle for laser heads at the same time The operator should be insulated from all such bonded metallic components EMC 2 7 10 Earthing of the 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 steel work 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
128. t the end panels outward to release the fan side of the cover from its track Then lift the cover off the power supply 5 6 powermaX45 Service Manual TROUBLESHOOTING AND SYSTEM TESTS 4 Remove the Mylar barrier from the power board side of the power supply Be certain to replace the barrier when you are finished working on the power supply 5 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 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 nternal inspection on page 5 6 before continuing in this section 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 on page 5 4 to test the power supply for proper operation 1 With the power disconnected and the torch removed from the power supply set the ON OFF switch S1 to ON 2 Check the resistance across the input leads the leads are identified with printed on the power board 200 240 CSA and 230 CE resistance across the input leads 75 400 V CE
129. t with a CE marking GOST TR mark CE versions of Hypertherm products that include a GOST TR mark of conformity meet the product safety and EMC requirements for export to the Russian Federation C Tick mark CE versions of Hypertherm products with a C Tick mark comply with the EMC regulations required for sale in Australia and New Zealand CCC mark The China Compulsory Certification CCC mark indicates that the product has been tested and found compliant with product safety regulations required for sale in China UkrSEPRO mark CE versions of Hypertherm products that include a UkrSEPRO mark of conformity meet the product safety and EMC requirements for export to the Ukraine powermaX45 Service Manual 1 7 SPECIFICATIONS IEC symbols The following symbols may appear on the power supply data plate control labels switches and LEDs Direct current DC 1 LA 7 0 DIL An inverter based power source either 1 phase or 3 phase Plasma torch cutting O Power is OFF Alternating current AC um Volt amp curve drooping Plate metal cutting characteristic Expanded metal cutting Powar is ON 7N y System fault LED Hm km De AG tiu Inlet gas pressure fault LED B The terminal for the external Missing or loose consumables protective earth conductor LED Power supply is out of
130. the 200 240 V CSA power supplies are shipped with a 50 amp 250 V plug 6 50P on the power cord The CE power supplies and the 480 V CSA power supplies are shipped without a plug on the power cord Obtain the correct plug for your unit 230 V CE 400 V CE or 480 V CSA and location and it installed by a licensed electrician powermax4s Service Manual POWER SUPPLY SETUP Extension cord recommendations Use an extension cord of an appropriate wire size for the cord length and system voltage Use a cord that meets national and local codes The following tables provide the recommended gauge size for various lengths and input voltages The lengths in the tables are the length of the extension cord only they do not include the power supply s power cord Metric Input voltage ew 380 400 480 English Input voltage POR PO nre ERY ZO D 480 VAC 3 12 AWG 12 AWG 12 AWG 10 AWG 10 AWG powermax4s Service Manual 2 5 POWER SUPPLY SETUP Generator recommendations Generators used with the Powermax45 should satisfy the following requirements CSA 1 phase 50 60 Hz 230 240 3 phase 50 60 Hz 480 CE 1 phase 50 60 Hz 230 VAC 3 phase 50 60 Hz 380 400 VAC 400 VAC recommended for best performance Engine Performance drive rating 1 phase 3 phase 3 phase arc stretch Good arc stretch at 45 A cutting current Limited a
131. the T45m Using the cut charts The following sections provide illustrations of the consumable sets and cut charts for each set Maximum cut speeds are the fastest speeds possible to cut material without regard to cut quality Recommended cut speeds are a good starting point for finding the best quality cut best angle least dross and best cut surface finish You will need to adjust the speeds for your application and your table to obtain the desired cut quality When cutting thin metal 3 mm 10 Ga or thinner you may achieve a higher cut quality by using the T30v Powermax30 30 A consumables and cut charts T45m shielded consumables ma 220673 220713 220671 220670 220669 Shield Retaining cap Nozzle Swirl ring Electrode or 220719 Ohmic sensing retaining cap The cut charts for these consumables are shown on the following pages 3 8 powermax4s Service Manual TORCH SETUP T45m shielded consumables Air flowrate Recommended Maximum Arc Material Torch Pierce time current thickness To Work Initial pierce delay amps mm boy height sec Cut Speed Voltage Cut Speed Voltage mm min 0 5 9150 117 10160 118 0 8 8650 116 10160 117 250 0 9 8100 10160 117 1 5 5650 7100 10160 10160 9144 6096 250 4445 2794 1905 Edge start recommended
132. ther you are doing machine or hand cutting The air quality presence of oil moisture or other contaminants Whether you are piercing the metal or starting cuts from the edge Proper torch to work distance when gouging or cutting with unshielded consumables Proper pierce height Which consumables you are using The T30v Powermax30 30 amp consumables will have a shorter life when used on the T45v However they provide optimum cut quality for certain applications Under normal conditions the electrode will wear out first during machine cutting and the nozzle will wear out first when hand cutting A good rule of thumb is that a set of consumables will last approximately 1 to 2 hours of actual arc on time for hand cutting depending on these factors For cutting with a machine torch consumables may last up to 3 to 5 hours You will find more information about proper cutting techniques in the Operation section Hand torch setup Safety trigger 3 2 powermax4s Service Manual TORCH SETUP Choose the consumables The Powermax45 with the T45v handheld torch comes with a full set of consumables for cutting installed on the torch spare electrodes and nozzles in the consumables box and consumables for gouging in the consumables box In non CE regulated countries you can also purchase unshielded consumables that are useful for certain applications With shielded consumables you drag the torch tip along the metal to c
133. there is a voltage imbalance on the power board The arc lost contact with the workpiece consumables worn there is a poor work lead connection the output from the power supply is too low or the power board is producing low current The consumables may be worn or damaged torch or torch lead may be damaged gas pressure is too high or too low or the gas supply is restricted gas filter element is dirty power board is faulty work lead or work lead connection may be faulty material being cut may require the use of continuous pilot arc mode The consumables need to be replaced work lead may be damaged or not properly connected to the work piece The amps adjustment knob may be set too low power board may be faulty Inspect the consumables torch and lead Replace any damaged parts Verify that the gas supply is providing at least 4 5 bar 65 psi and does not exceed 9 3 bar 135 psi Repair any restrictions in the supply line Replace the gas filter element if dirty Perform Test VBUS and voltage balance on page 5 20 to test the voltage balance on the power board If you are cutting expanded metal grate or any metal with holes set the mode switch to continuous pilot arc mode Check for loose connections at the work clamp and at the power supply Repositi
134. 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 Insert a 1 Phillips screwdriver through the holes in the fan casing to remove the retaining screw from each corner of the fan Corner clips Top corner clips powermaX45 Service Manual 10 11 12 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 0000 97 9 Attach the connector for the red and black wires on the left side of the fan to 4 200 240 V CSA and 230 V CE or J5 400 V CE and 480 V CSA on the power board 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 and the gas supply Replace the gas filter element 1 2 Turn OFF the power disconnect the power cord and disconnect the gas supply Use a 2 Phillips screwdriver to remove the 2 screws from the handle on the top of the power supply Tip the end panels back slightly so that you can get the edges of the handle out from underneath them Lift the cover off the power supply Remove t
135. ts tente A ctii race nu ena ev ev enn de en e ate se P e T4by h nd torchi eoriSumiableSs a cm tet e merde Ira soap tod eiecit sir ie e A ruso t e e 7 8 T30v Powermax30 30 A consumables 7 8 Tabimiriachine torch alten cene ai tiet rernm rr tot iter E EE RE re Ea Rc Foe Rost RR T45m machine torch consumables Accessory S safety onical Pal St zau RRC Recommended Spare parts enean PPowermnaxub labels 6 E IM ear eas SECTION 8 WIRING DIAGRAMS Control board diagram 200 240 V CSA and 230 Control board diagram 400 CE and 480 V CA inne eme n treten taire tio tiere tni perpe enit bete che tnl Power board wiring diagram 200 240 V CSA and 230 V CE Power board wiring diagram 400 tentata nette enhn tes rel aes sn as Power board wiring diagram 480 V iv powermax4s Service Manual ELECTROMAGNETIC COMPATIBILITY 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 comp
136. tutta A 4 12 Understand and optimize cut quality toc ied alan ded A d de as 4 13 To pierce a workpiece using the machine torch aaa aaa 4 14 Common machine cutting faults ess sesenta tst a E aa ta a a aa 4 15 powermaX45 Service Manual 4 1 OPERATION Controls and indicators The Powermax45 has an ON OFF switch an amperage adjustment knob a pressure regulator knob a mode switch 4 indicator LEDs and a gas pressure LED which are described below Front controls and LEDs Co Amperage adjustment knob Gas pressure LED and pressure bar Mode switch Temperature LED yellow When illuminated this LED indicates that the power supply temperature is outside the acceptable range Torch cap sensor LED yellow When illuminated this LED indicates that the consumables are loose improperly installed or missing For information on the possible fault conditions refer to the Troubleshooting guide topic in the Troubleshooting and System Tests section If this LED illuminates the power must be turned OFF the consumables installed properly and the system turned ON again to reset it Fault LED yellow When illuminated this LED indicates that there is a fault with the power supply Some fault conditions will cause one or more of the LEDs to blink For information on what these fault conditions are
137. uarantee 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 for the specific periods of time set forth herein and as follows if Hypertherm is notified of a defect i with respect to the plasma power supply within a period of two 2 years from the date of its delivery to you with the exception of Powermax brand 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 and with respect to torch lifter assemblies within a period of one 1 year from its date of delivery to you and with respect to Automation products one 1 year from its date of delivery to you with the exception of the EDGE Pro CNC and ArcGlide THC which shall be within a period of two 2 years from the date of delivery to you and iii with respect to Hylntensity fiber laser components within a period of two 2 years from the date of its delivery to you with the exception of laser heads and beam delivery cables which shall be within a period of one 1 year from its date of delivery to you This warranty shall not apply to any Powermax brand power supplies that have been used with phase converters In addition Hypertherm does not warranty systems that have been damaged as a result of poo
138. uding but not limited to lost profits regardless of whether such liability is based on breach of contract tort strict liability breach of warranty failure of essential purpose or otherwise and even if advised of the possibility of such damages National and local codes National and local codes governing plumbing and electrical installation shall take precedence 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 9 10 Liability cap In no event shall Hypertherm s liability if any 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 whether in court arbitration regulatory proceeding or otherwise 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 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 t
139. ulated half bridge circuit driving an isolation transformer The secondary of the isolation transformer is rectified by the output bridge D40 The output circuitry consists of 2 current sense transducers located on the power board the pilot arc IGBT inside the D40 module and the output choke The control board s digital signal processor DSP monitors and regulates the system s operation and safety circuits The amperage adjustment knob is used to set the output current to the desired value between 20 and 45 amps The system compares the set point to the output current by monitoring the current sense transducers and adjusting the pulse width output of the inverter IGBT Q2 5 2 powermaX45 Service Manual TROUBLESHOOTING AND SYSTEM TESTS 480 V CSA 3 phase power supply functional description AC power enters the system through the power switch S1 to the input diode bridge D48 The voltage from the diode bridge supplies the power factor correction PFC choke which provides a nominal 670 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 relays K2 The inverter consists of a dual IGBT package Q2 the power transformer a current sense transducer and the control circuit The inverter operat
140. ut With unshielded consumables you must keep the torch a small distance about 2 mm 0 08 inch away from the metal Unshielded consumables generally have a shorter life than shielded consumables however you may find that visibility and accessibility are better for some applications Consumables for hand cutting are shown below Notice that the retaining cap swirl ring and electrode are the same for shielded unshielded and gouging applications Only the shield deflector for unshielded consumables and the nozzle are different For the best cut quality on thin gauge stainless steel you may prefer to reduce the amperage setting to 30 amps and use the T30v Powermax30 30 A consumables available from Hypertherm T45v shielded consumables C D 220674 220713 220671 220670 220669 Shield Retaining cap Nozzle Swirl ring Electrode T45v gouging consumables 220675 220713 220672 220670 220669 Shield Retaining cap Nozzle Swirl ring Electrode powermax4s Service Manual 3 3 TORCH SETUP T45v unshielded consumables mm 220717 220713 220718 220670 220669 Deflector Retaining cap Nozzle Swirl ring Electrode Unshielded consumables are not available for use in CE regulated countries T30v Powermax30 30 A consumables 220569 220483 220480 220479 220478 Optional deflector Retaining cap Nozzle Swirl ring Electrode 3 4 powermax4s Service Manual TORCH SETUP Install the consumables WA
141. ut of 10 60 At 32 the arc can remain on for 10 minutes out of 10 100 If the power supply overheats because the duty cycle is exceeded the temperature LED will illuminate the arc will shut off and the cooling fan will continue to run To resume cutting wait for the temperature LED to extinguish 4 6 powermax4s Service Manual OPERATION The next section explains how to operate the hand torch To use the machine torch see How to use the machine torch on page 4 12 How to use the hand torch WARNING INSTANT ON TORCHES PLASMA CAN CAUSE INJURY AND BURNS Plasma arc comes on immediately when the torch trigger is activated The plasma arc will cut quickly through gloves and skin Keep away from the torch tip Do not hold the workpiece and keep your hands clear of the cutting path Never point the torch toward yourself or others Operate the safety trigger The T45v is equipped with a safety trigger to prevent accidental firings When you are ready to cut with the torch flip the yellow safety trigger forward toward the torch head and press the red torch trigger as show below Hand torch cutting hints With shielded consumables drag the nozzle lightly along the workpiece to maintain a steady cut With unshielded consumables maintain an approximate 2 mm 0 08 inch distance between the tip of the torch and the workpiece This is between 1 6 3 2 mm or between 1 16th and 1 8th of an inch W
142. ut that secures the gas supply line to the torch lead Set the torch body aside Note Cover the end of the gas line on the torch lead with tape to keep dirt and other contaminants from getting in the gas line when you route the lead through the track Route the torch lead through the cutting table s track Reattach the torch s power cable to the torch plunger using the screw and nut Rotate the plunger so that the screw does not interfere with the cap sensor switch Reconnect the gas line to the torch lead Press the two halves of the cap sensor switch s wire connector together 10 Slide the positioning sleeve over the torch body and check the alignment of the screw holes Replace the three screws at each end 11 If you will be using the gear rack re attach it with the 2 black screws you removed earlier 12 Attach the torch to the lifter per the manufacturer s instructions powermax4s Service Manual 3 7 TORCH SETUP Choose the consumables cut charts WARNING INSTANT ON TORCHES PLASMA ARC CAN CAUSE INJURY AND BURNS The plasma arc comes on immediately when the torch trigger is activated Make sure the power is OFF before changing consumables A complete set of shielded consumables is shipped with the T45m machine torch In addition an ohmic sensing retaining cap is available for use with the T45m shielded consumables Unshielded consumables and the T30v Powermax30 30 A consumables are also available for use with
143. ve after the pierce is complete 4 14 powermaX45 Service Manual OPERATION Common machine cutting faults The torch pilot arc will initiate but will not transfer Causes can be The work cables connection on the cutting table is not making good contact or the table is not properly grounded The torch to work distance is too great The workpiece is not totally penetrated and there is excessive sparking on the top of the workpiece Causes can be The work cable s connection on the cutting table is not making good contact or the table is not properly grounded The amperage is set too low the cut charts in the Torch Setup section for more information The cut speed is too high See the cut charts in the Torch Setup section for more information The consumables are worn and need to be replaced The metal being cut exceeds the maximum capacity See 745 and 145m torch specifications in the Specifications section Dross forms on the bottom of the cut Causes can be The cutting speed is not correct See the cut charts in the Torch Setup section for more information The amperage is set too low See the cut charts in the Torch Setup section for more information The consumables are worn and need to be changed The cut angle is not square Causes can be The direction of the torch travel is incorrect The high quality cut is always on the right with respect to the forward motion of the torch The distance bet
144. vice Manual TROUBLESHOOTING AND SYSTEM TESTS 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 below 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 200 240 V CSA power supplies and 230 V CE power supplies or J8 on 400 V and 480 V CSA power supplies the pin numbers are the same for all power supplies on the power board see Test 2 power board checks on page 5 19 Test pin 25 to ground for 3 3 VDC 10 Test pin 24 to ground for 5 VDC 10 Test pin 12 to ground for 2 2 VDC 10 If the values you find are not within X 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 Otherwise replace the power board 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 on page 5 18 for detailed test procedures The following table shows th
145. ween the torch and the workpiece is not correct The cutting speed is not correct See the cut charts in the Torch Setup section for more information The consumables are worn and need to be replaced The consumable life is shortened Causes can be The arc current arc voltage travel speed and other variables are not set as specified in the cut charts Firing the arc in the air beginning or ending the cut off of the plate surface Starting at the edge is acceptable as long as the arc makes contact with the workpiece when started Starting a pierce with an incorrect torch height For the Powermax45 the pierce height is generally 2 5 times the torch cutting height Refer to the cut charts for specifics powermaX45 Service Manual 4 15 OPERATION 4 16 powermaX45 Service Manual Section 5 TROUBLESHOOTING AND SYSTEM TESTS this section ORNE RANI 5 2 ECC RR 5 2 200 240 V CSA and 230 CE 1 phase power supply functional description seen 5 2 400 V CE 3 phase power supply functional description aaa aaa aaa A 5 2 480 V CSA 3 phase power supply functional description sese 5 3 Sequence of 5 4 Troubleshooting preparatloh crine tnnt
146. wire 2 closest to the head of the screw Torque the screw to 23 0 kg cm 20 inch pounds J19 or J18 white wire TP 19 TP18 17 wo RO 192 VDC 192 VDC J21 work lead 14 Replace the rear panel and secure it with the screw Replace the Mylar barrier in front of the power board Replace the cover 15 Connect the other end of the cable to the equipment according to the manufacturer s instructions NOTE The integration of Hypertherm equipment and customer supplied equipment including interconnecting cords and cables if not listed and certified as a system is subject to inspection by local authorities at the final installation site powermax4s Service Manual 3 29 TORCH SETUP Connect the torch lead The Powermax45 has a FastConnect system for connecting and disconnecting the hand and machine torches When connecting or disconnecting a torch first power OFF the system To connect either torch push the connector into receptacle on the front of the power supply To remove the torch press the red button on the connector and pull the connector out of the receptacle Red button 3 30 powermax4s Service Manual Section 4 OPERATION In this section Controls and IndiCalors nu rere tt wi ORO RAE RA E I 4 2 Front controls and Adware Reni 4 2 Rear
147. ws powermaX45 Service Manual 7 3 Interior power board side 19 18 17 wo RO 192 VDC 192 VDC DAMO Part number Description Designator Qty 1 228262 Kit Control board 200 240 V CSA 230 V 400 V CE PCB1 1 428098 Kit Control board 480 V CSA PCB1 1 2 228266 Kit Powermax45 power switch 200 240 V CSA and 230 V 1 3 228288 Kit Powermax45 power switch 400 V CE and 480 V CSA 1 4 228261 Kit Power board 200 240 V CSA PCB2 1 5 428078 Kit Power board 480 V CSA PCB2 1 6 228260 Kit Power board 400 V CE PCB2 1 7 228259 Kit Power board 230 V CE PCB2 1 8 228258 Kit Base 1 9 228265 Kit Magnetics assembly 200 240 V CSA 1 10 228273 Magnetics assembly 230 V CE 1 11 228263 Kit Magnetics assembly 400 V CE 1 12 428079 Kit Magnetics assembly 480 V CSA 1 228279 Kit Powermax45 insulator not shown 1 228290 Kit Powermax45 wire group not shown 1 7 4 powermaX45 Service Manual Interior fan side Part Item number 228284 228285 015337 015551 015511 228287 228302 228286 Jo OI p PARTS c LE Description Kit Pressure sensor cable Kit Solenoid valve Quick disconnect 1 4 NPT stainless nipple 1 4 brass coupling 1 4 X 2 brass nipple Kit Filter and regulator Kit Air filter element Kit Fan assembly powermaX45 Service Manual Designator

Powermax45 Service Manual - air

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