Hypertherm Manual Family Service Manual (SM)

Powermax30®AIR

Plasma Arc Cutting System with Integrated Air Compressor

Service Manual

808850|Revision4|English

Powermax and Hypertherm are trademarks of Hypertherm, Inc. and may be registered in the United States and other countries. All other trademarks are the property of their respective holders.

Environmental stewardship is one of Hypertherm’s core values, and it is critical to our success and our customers’ success. We are striving to reduce the environmental impact of everything we do. For more information:www.hypertherm.com/environment.

Powermax30 AIR

Service Manual

808850

Revision 4

English

March 2022

Hypertherm, Inc.

Hanover, NH 03755 USA

www.hypertherm.com

Hypertherm, Inc.

21 Great Hollow Road, P.O. Box 5010 Hanover, NH 03755 USA 603-643-3441 Tel (Main Office) 603-643-5352 Fax (All Departments) info@hypertherm.com (Main Office)

800-643-9878 Tel (Technical Service)

technical.service@hypertherm.com (Technical Service)

800-737-2978 Tel (Customer Service)

customer.service@hypertherm.com (Customer Service)

Hypertherm México, S.A. de C.V.

52 55 5681 8109 Tel 52 55 5681 7978 Tel soporte.tecnico@hypertherm.com (Technical Service)

Hypertherm Plasmatechnik GmbH

Sophie-Scholl-Platz 5 63452 Hanau Germany 00 800 33 24 97 37 Tel 00 800 49 73 73 29 Fax

31 (0) 165 596900 Tel (Technical Service) 00 800 4973 7843 Tel (Technical Service)

technicalservice.emeia@hypertherm.com (Technical Service)

Hypertherm (Singapore) Pte Ltd.

Solaris @ Kallang 164 164 Kallang Way #03-13 Singapore 349248, Republic of Singapore 65 6841 2489 Tel 65 6841 2490 Fax marketing.asia@hypertherm.com (Marketing) techsupportapac@hypertherm.com (Technical Service)

Hypertherm Japan Ltd.

Level 9, Edobori Center Building 2-1-1 Edobori, Nishi-ku Osaka 550-0002 Japan 81 6 6225 1183 Tel 81 6 6225 1184 Fax htjapan.info@hypertherm.com (Main Office) techsupportapac@hypertherm.com (Technical Service)

Hypertherm Europe B.V.

Vaartveld 9, 4704 SE Roosendaal, Nederland 31 165 596907 Tel 31 165 596901 Fax 31 165 596908 Tel (Marketing)

31 (0) 165 596900 Tel (Technical Service) 00 800 4973 7843 Tel (Technical Service)

technicalservice.emeia@hypertherm.com (Technical Service)

Hypertherm (Shanghai) Trading Co., Ltd.

B301, 495 ShangZhong Road Shanghai, 200231 PR China 86-21-80231122 Tel 86-21-80231120 Fax

86-21-80231128 Tel (Technical Service)

techsupport.china@hypertherm.com (Technical Service)

South America & Central America: Hypertherm Brasil Ltda.

Rua Bras Cubas, 231 – Jardim Maia Guarulhos, SP – Brasil CEP 07115-030 55 11 2409 2636 Tel tecnico.sa@hypertherm.com (Technical Service)

Hypertherm Korea Branch

#3904. APEC-ro 17. Heaundae-gu. Busan. Korea 48060 82 (0)51 747 0358 Tel 82 (0)51 701 0358 Fax marketing.korea@hypertherm.com (Marketing) techsupportapac@hypertherm.com (Technical Service)

Hypertherm Pty Limited

GPO Box 4836 Sydney NSW 2001, Australia 61 7 3103 1695 Tel 61 7 3219 9010 Fax au.sales@hypertherm.com (Main Office) techsupportapac@hypertherm.com (Technical Service)

Hypertherm (India) Thermal Cutting Pvt. Ltd

A-18 / B-1 Extension, Mohan Co-Operative Industrial Estate, Mathura Road, New Delhi 110044, India 91-11-40521201/ 2/ 3 Tel 91-11 40521204 Fax htindia.info@hypertherm.com (Main Office) technicalservice.emeia@hypertherm.com (Technical Service)

For training and education resources, go to the Hypertherm Cutting Institute (HCI) online at

www.hypertherm.com/hci.

ENGLISH

WARNING! Before operating any Hypertherm equipment, read the safety instructions in your product’s manual, the Safety and Compliance Manual (80669C),

Waterjet Safety and Compliance Manual (80943C), and Radio Frequency Warning Manual (80945C). Failure to follow safety instructions can result in personal injury

or in damage to equipment. Copies of the manuals can come with the product in electronic and printed formats.

Electronic copies are also on our website. Many manuals are available in multiple languages at www.hypertherm.com/docs.

FR (FRANÇAIS/FRENCH)

AVERTISSEMENT! Avant d’utiliser tout équipement Hypertherm, lire les consignes de sécurité dumanuel de votre produit, duManuel de sécurité et de conformité (80669C), du Manuel de sécurité et de conformité du jet d’eau (80943C) et du Manuel d'avertissement relatif aux radiofréqunces (80945C).

Les exemplaires des manuels qui accompagnent le produit peuvent être sous forme électronique ou papier. Les manuels sous forme électronique se trouvent également sur notre site Internet. Plusieurs manuels sont offerts en plusieurs langues à www.hypertherm.com/docs.

BG (БЪЛГAPCКИ/BULGARIAN)

ПРЕДУПРЕЖДЕНИЕ! Преди да работите с което и да е оборудване Hypertherm, прочетете инструкциите за безопасност в ръководството на вашия продукт, „Инструкция за безопасност и съответствие“ (80669C), „Инструкция за безопасност и съответствие на Waterjet“ (80943С) и „Инструкция за предупреждение за радиочестота“ (80945С).

Продуктът може да е съпроводен от копия на ръководствата в електронен и в печатен формат. Тези в електронен формат са достъпни също на уебсайта ни. Много ръководства са налице на няколко езика на адрес www.hypertherm.com/docs.

CS (ČESKY/CZECH)

VAROVÁNÍ! Před uvedením jakéhokoli zařízení Hypertherm do provozu si přečtěte bezpečnostní pokyny v příručce k produktu a v Manuálu pro bezpečnost

a dodržování předpisů (80669C), Manuálu pro bezpečnost a dodržování předpisů při řezání vodním paprskem (80943C) a Manuálu varování ohledně rádiových frekvencí (80945C).

Kopie příruček mohou být součástí dodávky produktu, a to v elektronické i tištěné formě. Elektronické kopie jsou k dispozici i na našich webových stránkách. Mnoho příruček je k dispozici v různých jazycích na stránce www.hypertherm.com/docs.

DA (DANSK/DANISH)

ADVARSEL! Inden Hypertherm udstyr tages i brug skal sikkerhedsinstruktionerne i produktets manual og i Manual om sikkerhed og overholdelse af krav (80669C), Manual om sikkerhed og overholdelse af krav for vandstråleskæring (80943C), og Manual om radiofrekvensadvarsel (80945C), gennemlæses.

Kopier af manualerne kan leveres med produktet i elektronisk og trykt format. Elektroniske kopier findes også på vores hjemmeside. Mange manualer er tilgængelige på flere sprog på www.hypertherm.com/docs.

DE (DEUTSCH/GERMAN)

WARNUNG! Bevor Sie ein Hypertherm-Gerät in Betrieb nehmen, lesen Sie bitte die Sicherheitsanweisungen in Ihrer Bedienungsanleitung, das Handbuch für Sicherheit

und Übereinstimmung (80669C), das Handbuch für Sicherheit und Compliance bei Wasserstrahl-Schneidanlagen (80943C) und das Handbuch für HochfrequenzWarnung (80945C).

Bedienungsanleitungen und Handbücher können dem Gerät in elektronischer Form oder als Druckversion beiliegen. In elektronischer Form liegen sie auch auf unserer Website vor. Viele Handbücher stehen in verschiedenen Sprachen auf

www.hypertherm.com/docs zur Verfügung.

ES (ESPAÑOL/SPANISH)

¡ADVERTENCIA! Antes de operar cualquier equipo Hypertherm, lea las instrucciones de seguridad del manual de su producto, del Manual de seguridad

y cumplimiento (80669C), del Manual de seguridad y cumplimiento en corte con chorro de agua (80943C) y del Manual de advertencias de radiofrecuencia

(80945C). El producto puede incluir copias de los manuales en formato digital e impreso.

Las copias digitales también están en nuestra página web. Hay diversos manuales disponibles en varios idiomas en www.hypertherm.com/docs.

ET (EESTI/ESTONIAN)

HOIATUS! Enne Hyperthermi mis tahes seadme kasutamist lugege läbi toote kasutusjuhendis olevad ohutusjuhised ning Ohutus- ja vastavusjuhend (80669C), Veejoa ohutuse ja vastavuse juhend (80943C) ja Raadiosageduse hoiatusjuhend (80945C). Ohutusjuhiste eiramine võib põhjustada vigastusi ja kahjustada seadmeid.

Juhiste koopiad võivad tootega kaasas olla elektrooniliselt või trükituna. Elektroonilised koopiad on saadaval ka meie veebilehel. Paljud kasutusjuhendid on erinevates keeltes saadaval veebilehel www.hypertherm.com/docs.

FI (SUOMI/FINNISH)

VAROITUS! Ennen minkään Hypertherm-laitteen käyttöä lue tuotteen käyttöoppaassa olevat turvallisuusohjeet, turvallisuuden ja vaatimustenmukaisuuden

käsikirja (80669C), vesileikkauksen turvallisuuden ja vaatimustenmukaisuuden käsikirja (80943C) ja radiotaajuusvaroitusten käsikirja (80945C).

Käyttöoppaiden kopiot voivat olla tuotteen mukana sähköisessä ja tulostetussa muodossa. Sähköiset kopiot ovat myös verkkosivustollamme. Monet käyttöoppaat ovat myös saatavissa useilla kielillä www.hypertherm.com/docs.

GR (ΕΛΛΗΝΙΚΆ/GREEK)

ΠΡΟΕΙΔΟΠΟΙΗΣΗ! Πριν θέσετε σε λειτουργία οποιονδήποτε εξοπλισμό της Hypertherm, διαβάστε τις οδηγίες ασφαλείας στο εγχειρίδιο του προϊόντος και στο

εγχειρίδιο ασφάλειας και συμμόρφωσης (80669C), στο εγχειρίδιο ασφάλειας και συμμόρφωσης του waterjet (80943C) και στο εγχειρίδιο προειδοποιήσεων για τις ραδιοσυχνότητες (80945C).

Το προϊόν μπορεί να συνοδεύεται από αντίγραφα των εγχειριδίων σε ηλεκτρονική και έντυπη μορφή. Τα ηλεκτρονικά αντίγραφα υπάρχουν επίσης στον ιστότοπό μας. Πολλά εγχειρίδια είναι διαθέσιμα σε διάφορες γλώσσες στο

www.hypertherm.com/docs.

HU (MAGYAR/HUNGARIAN)

VIGYÁZAT! Mielőtt bármilyen Hypertherm berendezést üzemeltetne, olvassa el a biztonsági információkat a termék kézikönyvében, a Biztonsági

és szabálykövetési kézikönyvben (80669C), a Vízsugaras biztonsági és szabálykövetési kézikönyvben (80943C) és a Rádiófrekvenciás figyelmeztetéseket tartalmazó kézikönyvben (80945C).

A termékhez a kézikönyv példányai elektronikus és nyomtatott formában is mellékelve lehetnek. Az elektronikus példányok webhelyünkön is megtalálhatók. Számos kézikönyv áll rendelkezésre több nyelven a www.hypertherm.com/docs weboldalon.

ID (BAHASA INDONESIA/INDONESIAN)

PERINGATAN! Sebelum mengoperasikan peralatan Hypertherm, bacalah petunjuk keselamatan dalam manual produk Anda, Manual Keselamatan dan Kepatuhan (80669C), Manual Keselamatan dan Kepatuhan Jet Air (80943C), dan Manual Peringatan Frekuensi Radio (80945C). Kegagalan mengikuti petunjuk keselamatan dapat menyebabkan cedera pribadi atau kerusakan pada peralatan.

Produk mungkin disertai salinan manual atau petunjuk dalam format elektronik maupun cetak. Salinan elektronik juga tersedia di situs web kami. Berbagai manual tersedia dalam beberapa bahasa di www.hypertherm.com/docs.

IT (ITALIANO/ITALIAN)

AVVERTENZA! Prima di usare un’attrezzatura Hypertherm, leggere le istruzioni sulla sicurezza nel manuale del prodotto, nel Manuale sulla sicurezza e la conformità (80669C), nel Manuale sulla sicurezza e la conformità Waterjet (80943C) e nel Manuale di avvertenze sulla radiofrequenza(80945C).

Copie del manuale possono accompagnare il prodotto in formato cartaceo o elettronico. Le copie elettroniche sono disponibili anche sul nostro sito web. Molti manuali sono disponibili in diverse lingue all’indirizzo www.hypertherm.com/docs.

JA (日本語/JAPANESE)

警告 ! Hypertherm 機器を操作する前に、この製品説明書にある安全情報、「安全とコンプライアンスマニュアル」 (80669C) 、「ウォータージェットの安全とコンプライアンス」 (80943C)、「高周波警告」 (80945C) をお読みください。

説明書のコピーは、電子フォーマット、または印刷物として製品に同梱されています。電子コピーは当社ウェブサイトにも掲載されています。説明書の多くは www.hypertherm.com/docs にて複数の言語でご用意しています。

KO (한국어 /KOREAN)

경고! Hypertherm 장비를 사용하기 전에 제품 설명서와 안전 및 규정 준수 설명서(80669C), 워터젯 안전 및 규정 준수 설명서(80943C) 그리고 무선 주파수 경고 설명서(80945C)에 나와 있는 안전 지침을 읽으십시오.

전자 형식과 인쇄된 형식으로 설명서 사본이 제품과 함께 제공될 수 있습니다. 전자 사본도 Hypertherm 웹사이트에서 보실 수 있으며 설명서 사본은

www.hypertherm.com/docs 에서 여러 언어로 제공됩니다.

NE (NEDERLANDS/DUTCH)

WAARSCHUWING! Lees voordat u Hypertherm-apparatuur gebruikt de veiligheidsinstructies in de producthandleiding, in de Veiligheids-

en nalevingshandleiding (80669C) in de Veiligheids- en nalevingshandleiding voor waterstralen (80943C) en in de Waarschuwingshandleiding radiofrequentie

(80945C). De handleidingen kunnen in elektronische en gedrukte vorm met het product worden

meegeleverd. Elektronische versies zijn ook beschikbaar op onze website. Veel handleidingen zijn in meerdere talen beschikbaar via www.hypertherm.com/docs.

NO (NORSK/NORWEGIAN)

ADVARSEL! Før du bruker noe Hypertherm-utstyr, må du lese sikkerhetsinstruksjonene i produktets håndbok, håndboken om sikkerhet og samsvar (80669C), håndboken om vannjet sikkerhet og samsvar (80943C), og håndboken om radiofrekvensadvarsler (80945C).

Eksemplarer av håndbøkene kan følge med produktet i elektronisk og trykt form. Elektroniske eksemplarer finnes også på nettstedet vårt. Mange håndbøker er tilgjengelig i flere språk på www.hypertherm.com/docs.

SV (SVENSKA/SWEDISH)

VARNING! Läs häftet säkerhetsinformationen i din produkts säkerhets- och efterlevnadsmanual (80669C), säkerhets- och efterlevnadsmanualen för Waterjet

(80943C) och varningsmanualen för radiofrekvenser (80945C) för viktig säkerhetsinformation innan du använder eller underhåller Hypertherm-utrustning.

Kopior av manualerna kan medfölja produkten i elektroniskt och tryckt format. Elektroniska kopior finns också på vår webbplats. Många manualer finns på flera språk på www.hypertherm.com/docs.

PL (POLSKI/POLISH)

OSTRZEŻENIE! Przed rozpoczęciem obsługi jakiegokolwiek systemu firmy Hypertherm należy się zapoznać z instrukcjami bezpieczeństwa zamieszczonymi w podręczniku produktu, w podręczniku bezpieczeństwa i zgodności (80669C), podręczniku bezpieczeństwa i zgodności systemów strumienia wody (80943C) oraz podręczniku z ostrzeżeniem o częstotliwości radiowej (80945C).

Do produktu mogą być dołączone podręczniki użytkownika wformie elektronicznej idrukowanej. Kopie elektroniczne znajdują się również wnaszej witrynie internetowej. Wiele podręczników jest dostępnych wróżnych językach pod adresem

www.hypertherm.com/docs.

PT (PORTUGUÊS/PORTUGUESE)

ADVERTÊNCIA! Antes de operar qualquer equipamento Hypertherm, leia as instruções de segurança no manual do seu produto, no Manual

de Segurança e de Conformidade (80669C), no Manual de Segurança e de Conformidade do Waterjet (80943C) e no Manual de Advertência de radiofrequência (80945C).

Cópias dos manuais podem vir com o produto nos formatos eletrônico e impresso. Cópias eletrônicas também são encontradas em nosso website. Muitos manuais estão disponíveis em vários idiomas em www.hypertherm.com/docs.

RO (ROMÂNĂ/ROMANIAN)

AVERTIZARE! Înainte de utilizarea oricărui echipament Hypertherm, citiți instrucțiunile de siguranță din manualul produsului, manualul de siguranță și conformitate (80669C), manualul de siguranță și conformitate Waterjet (80943C) și din manualul de avertizare privind radiofrecvența (80945C).

Produsul poate fi însoțit de copii ale manualelor în format tipărit și electronic. Exemplarele electronice sunt disponibile și pe site-ul nostru web. Numeroase manuale sunt disponibile în mai mult limbi la adresa:

www.hypertherm.com/docs.

RU (PУССКИЙ/RUSSIAN)

БЕРЕГИСЬ! Перед работой с любым оборудованием Hypertherm ознакомьтесь с инструкциями по безопасности, представленными в руководстве, которое поставляется вместе с продуктом, в Руководстве по безопасности и

соответствию (80669С), в Руководстве по безопасности и соответствию для водоструйной резки (80943C) и Руководстве по предупреждению о радиочастотном излучении (80945С).

Копии руководств, которые поставляются вместе с продуктом, могут быть представлены в электронном и бумажном виде. Электронные копии также доступны на нашем веб-сайте. Целый ряд руководств доступны на нескольких языках по ссылке www.hypertherm.com/docs.

SK (S LOVENČINA/SLOVAK)

VÝSTRAHA! Pred použitím akéhokoľvek zariadenia od spoločnosti Hypertherm si prečítajte bezpečnostné pokyny v návode na obsluhu vášho zariadenia a v Manuáli

o bezpečnosti a súlade s normami (80669C), Manuáli o bezpečnosti a súlade snormami pre systém rezania vodou (80943C) avManuáli sinformáciami orádiofrekvencii (80945C).

Návod na obsluhu sa dodáva spolu sproduktom velektronickej atlačenej podobe. Jeho elektronický formát je dostupný aj na našej webovej stránke. Mnohé znávodov na obsluhu sú dostupné vo viacjazyčnej mutácii na stránke

www.hypertherm.com/docs.

TH (ภาษาไทย/THAI)

คําเตือน! กอนการใชงานอุปกรณของ Hypertherm ทั้งหมด โปรดอานคําแนะนําดานความ ปลอดภัยในคูมือการใชสินคา คูมือดานความปลอดภัยและการปฏิบัติตาม (80669C), คูมือ ดานความปลอดภัยและการปฏิบัติตามสําหรับการใชหัวตัดระบบวอเตอรเจ็ต (80943C) และ คูมือคําเตือนเกี่ยวกับความถี่วิทยุ (80945C) การไมปฏิบัติตามคําแนะนําดานความ ปลอดภัยอาจสงผลใหเกิดการบาดเจ็บหรือเกิดความเสียหายตออุปกรณ

สําเนาคูมือทั้งในรูปแบบอิเล็กทรอนิกสและแบบสิ่งพิมพจะถูกแนบมาพรอมกับ ผลิตภัณฑ สําเนาคูมือในรูปแ ๆ ในหลากหลายภาษานั้นยังมีใหบริการบนเว็บไซต www.hypertherm.com/docs ของเราอีกดวย

TR (TÜRKÇE/TURKISH)

UYARI! Bir Hypertherm ekipmanını çalıştırmadan önce, ürününüzün kullanım kılavuzunda, Güvenlik ve Uyumluluk Kılavuzu’nda (80669C), Su Jeti Güvenlik ve Uyumluluk Kılavuzu’nda (80943C) ve Radyo Frekansı Uyarısı Kılavuzu’nda (80945C) yer alan güvenlik talimatlarını okuyun.

Kılavuzların kopyaları, elektronik ve basılı formatta ürünle birlikte verilebilir. Elektronik kopyalar web sitemizde de yer alır. Kılavuzların birçoğu www.hypertherm.com/docs adresinde birçok dilde mevcuttur.

VI (TIẾNG VIỆT/VIETNAMESE)

CẢNH BÁO! Trước khi vận hành bất kỳ thiết bị Hypertherm nào, hãy đọc các hướng dẫn an toàn trong hướng dẫn sử dụng sản phẩm của bạn,

và Tuân thủ dẫn Cảnh báo Tần số Vô tuyến

có thể dẫn đến thương tích cá nhân hoặc hư hỏng thiết bị. Bản sao của sổ tay có thể đi kèm với sản phẩm ở định dạng điện tử và in. Bản

điện tử cũng có trên trang web của chúng tôi. Nhiều sổ tay có sẵn bằng nhiều ngôn ngữ tại www.hypertherm.com/docs.

ZH-CN (简体中文 /CHINESE SIMPLIFIED)

警告！在操作任何海宝设备之前，请阅读产品手册、《安全和法规遵守手册》 (80669C)、《水射流安全和法规遵守手册》 (80943C) 以及《射频警告手册》 (80945C) 中的安全操作说明。

随产品提供的手册可提供电子版和印刷版两种格式。电子版本同时也在我们的网站上提供。很多手册有多种语言版本，详见 www.hypertherm.com/docs.

ZH-TW (繁體中文/CHINESE TRADITIONAL)

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（80943C），以及《無線電頻率警示訊號手冊》（80945C）。

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(80669C),

บบอิเล็กทรอนิกสของผลิตภัณฑและสําเนาคูมือตาง

Sổ tay An toàn và Tuân thủ Tia nước

(80945C). Không tuân thủ các hướng dẫn an toàn

(80943C), và

Sổ tay An toàn

Hướng

SL (S LOVENŠČINA/SLOVENIAN)

OPOZORILO! Pred uporabo katerekoli Hyperthermove opreme preberite varnostna navodila v priročniku vašega izdelka, v Priročniku za varnost in skladnost (80669C), v Priročniku za varnost in skladnost sistemov rezanja z vodnim curkom (80943C) in v Priročniku Opozorilo o radijskih frekvencah (80945C).

Izvodi priročnikov so lahko izdelku priloženi v elektronski in tiskani obliki. Elektronski izvodi so na voljo tudi na našem spletnem mestu. Številni priročniki so na voljo v različnih jezikih na naslovu www.hypertherm.com/docs.

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UPOZORENJE! Pre rukovanja bilo kojom Hyperthermovom opremom pročitajte uputstva o bezbednosti u svom priručniku za proizvod, Priručniku o bezbednosti

i usaglašenosti (80669C), Priručniku o bezbednosti i usaglašenosti Waterjet tehnologije (80943C) i Priručniku sa upozorenjem o radio-frekvenciji (80945C).

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Electromagnetic Compatibility (EMC) ............................................................................ SC-13

Introduction ..............................................................................................................................................................................SC-13

Installation and use .................................................................................................................................................................SC-13

Assessment of area ................................................................................................................................................................SC-13

Methods of reducing emissions ..........................................................................................................................................SC-13

Mains supply ....................................................................................................................................................................SC-13

Maintenance of cutting equipment .....................................................................................................................................SC-13

Cutting cables .........................................................................................................................................................................SC-13

Equipotential bonding ....................................................................................................................................................SC-13

Earthing of the workpiece .............................................................................................................................................SC-14

Screening and shielding .......................................................................................................................................................SC-14

Warranty ..................................................................................................................................SC-15

Attention ....................................................................................................................................................................................SC-15

General .....................................................................................................................................................................................SC-15

Patent indemnity .....................................................................................................................................................................SC-15

Limitation of liability ................................................................................................................................................................SC-15

National and local codes .......................................................................................................................................................SC-15

Liability cap ..............................................................................................................................................................................SC-16

Insurance ..................................................................................................................................................................................SC-16

Transfer of rights .....................................................................................................................................................................SC-16

Waterjet product warranty coverage .................................................................................................................................SC-16

Product ..............................................................................................................................................................................SC-16

Parts coverage .................................................................................................................................................................SC-16

1 Specifications .............................................................................................................................. 17

Safety information ......................................................................................................................................................................... 17

System description ....................................................................................................................................................................... 17

Powermax30 AIR Service Manual 808850 7

Contents

Power supply dimensions ........................................................................................................................................................... 18

System weights ............................................................................................................................................................................. 18

Hypertherm system ratings ........................................................................................................................................................ 19

Disconnect the internal compressor ................................................................................................................................ 20

Torch dimensions ......................................................................................................................................................................... 21

Torch weight .................................................................................................................................................................................. 21

Cutting specifications .................................................................................................................................................................. 22

IEC symbols ................................................................................................................................................................................... 23

Noise levels .................................................................................................................................................................................... 23

Critical raw materials ................................................................................................................................................................... 23

Symbols and marks ...................................................................................................................................................................... 24

2 Power Supply Setup .................................................................................................................. 25

Unpack the plasma system ........................................................................................................................................................ 25

Claims ...................................................................................................................................................................................... 25

System contents ........................................................................................................................................................................... 26

Position the plasma cutting system .......................................................................................................................................... 27

Prepare the electrical power ...................................................................................................................................................... 27

Voltage configurations ......................................................................................................................................................... 27

Requirements for grounding .............................................................................................................................................. 29

Power cord considerations ........................................................................................................................................................ 29

CSA power cords and plugs ............................................................................................................................................. 29

CE and CCC power cords ................................................................................................................................................ 30

Install a plug on the power cord ................................................................................................................................ 30

Extension cord recommendations ..................................................................................................................................... 31

Generator recommendations ............................................................................................................................................. 31

3 Torch Setup .................................................................................................................................. 33

Introduction .................................................................................................................................................................................... 33

Hand torch components ..................................................................................................................................................... 33

Consumable life ............................................................................................................................................................................ 34

Consumable use ........................................................................................................................................................................... 35

Using the cut charts ............................................................................................................................................................. 35

Consumable set .................................................................................................................................................................... 36

240 V / 30 A cutting .................................................................................................................................................... 37

120 V / 20 A cutting .................................................................................................................................................... 39

4 Operation ...................................................................................................................................... 41

Controls and indicators ............................................................................................................................................................... 41

Rear controls ......................................................................................................................................................................... 41

Front panel controls and indicator LED symbols .......................................................................................................... 42

8 Powermax30 AIR Service Manual 808850

Contents

Operate the plasma system ....................................................................................................................................................... 43

Step 1 – Install the consumables ..................................................................................................................................... 43

Step 2 – Connect the electrical power ........................................................................................................................... 44

Step 3 – Adjust the output current ................................................................................................................................... 45

Operating the system on a 120 V / 20 A circuit ................................................................................................... 45

Operating the system on a 240 V / 20 A circuit ................................................................................................... 45

Decrease output current for lower-rated power plugs ......................................................................................... 45

Cutting expanded metal .............................................................................................................................................. 45

Step 4 – Attach the ground clamp ................................................................................................................................... 46

Step 5 – Power ON the system ........................................................................................................................................ 46

Step 6 – Check the indicator LEDs ................................................................................................................................. 46

Step 7 – Make sure the system is ready, and start cutting ........................................................................................ 47

What to expect during and after cutting ................................................................................................................................. 47

Water at the torch nozzle .................................................................................................................................................... 47

Postflow .................................................................................................................................................................................. 47

Internal compressor and fan activity ................................................................................................................................. 47

Water under the power supply .......................................................................................................................................... 47

Understand duty-cycle limitations ............................................................................................................................................. 48

System operation guidelines ...................................................................................................................................................... 49

Hand torch operation ................................................................................................................................................................... 50

Safety catch operation ......................................................................................................................................................... 50

Hand torch cutting guidelines ............................................................................................................................................ 51

Recommendations for cutting at 120 V ................................................................................................................... 51

Edge start on a workpiece .................................................................................................................................................. 52

Pierce a workpiece ............................................................................................................................................................... 53

Common hand-cutting faults .............................................................................................................................................. 54

Minimizing dross ............................................................................................................................................................ 54

5 Troubleshooting and System Tests ....................................................................................... 55

Theory of operation ...................................................................................................................................................................... 55

Functional description ......................................................................................................................................................... 55

Sequence of operation ........................................................................................................................................................ 56

Troubleshooting preparation ...................................................................................................................................................... 57

Test equipment ...................................................................................................................................................................... 58

Troubleshooting procedures and sequence ................................................................................................................... 58

External inspection ................................................................................................................................................................ 59

Internal inspection ................................................................................................................................................................. 59

Initial resistance check ........................................................................................................................................................ 59

Check the power switch ............................................................................................................................................. 60

Power supply overview ................................................................................................................................................................ 62

Troubleshooting guide ................................................................................................................................................................. 63

Powermax30 AIR Service Manual 808850 9

Contents

Power LED faults .................................................................................................................................................................. 63

Temperature LED faults ....................................................................................................................................................... 65

Internal compressor LED faults ......................................................................................................................................... 66

Torch cap LED faults ........................................................................................................................................................... 68

Common cutting issues ...................................................................................................................................................... 69

Control board LEDs ..................................................................................................................................................................... 73

Use the control board Reset and Error LEDs to troubleshoot ................................................................................... 74

Reset LED ...................................................................................................................................................................... 74

Error LED ........................................................................................................................................................................ 75

System tests .................................................................................................................................................................................. 75

Test 1 – voltage input .......................................................................................................................................................... 80

Test 2 – power board voltage checks ............................................................................................................................. 82

Test 3 – VBUS and voltage balance on power board ................................................................................................. 84

Test 4 – solenoid valve ........................................................................................................................................................ 87

Test 5 – torch stuck open or torch stuck closed .......................................................................................................... 88

Test 6 – plasma start ........................................................................................................................................................... 90

Test 7 – torch cap-sensor .................................................................................................................................................. 92

Test 8 – fan ............................................................................................................................................................................ 93

Test 9 – internal compressor, compressor-driver board, and power board ........................................................... 94

Test 9a – Check the diagnostic LED (D5) on the compressor-driver board ................................................. 94

Test 9b – Check the internal compressor .............................................................................................................. 95

Test 9c – Check the compressor-driver board ..................................................................................................... 96

Test 9d – Check the power board ........................................................................................................................... 98

Test 10 – check air pressure ............................................................................................................................................. 99

Tools required ................................................................................................................................................................ 99

Troubleshooting steps ................................................................................................................................................. 99

6 Power Supply Component Replacement ........................................................................... 103

Replace the power supply cover ............................................................................................................................................ 104

Replace the component barrier ............................................................................................................................................... 106

Detach and reattach the front panel ...................................................................................................................................... 108

Detach and reattach the rear panel ........................................................................................................................................ 110

Replace the power cord and strain relief .............................................................................................................................. 113

Replace the power switch ........................................................................................................................................................ 122

Replace the control board ........................................................................................................................................................ 124

Replace the compressor-driver board ................................................................................................................................... 127

Replace the power board ......................................................................................................................................................... 133

Replace the drain hose, gas supply hoses, and 90° fitting .............................................................................................. 140

Replace the wire group ............................................................................................................................................................. 144

Replace the solenoid valve ....................................................................................................................................................... 149

Replace the torch lead and strain relief ................................................................................................................................. 151

10 Powermax30 AIR Service Manual 808850

Contents

Replace the air filter assembly ................................................................................................................................................. 155

Replace the air filter bowl and air filter element ................................................................................................................... 158

Replace the fan ........................................................................................................................................................................... 162

Replace the heat exchange coil .............................................................................................................................................. 164

Replace the internal compressor ............................................................................................................................................ 167

Replace the air inlet filter in the internal compressor ......................................................................................................... 172

Replace the front panel ............................................................................................................................................................. 173

Replace the rear panel .............................................................................................................................................................. 176

Replace the base ........................................................................................................................................................................ 180

Replace the magnetics assembly ........................................................................................................................................... 182

Replace the work lead and ground clamp ............................................................................................................................ 187

7 Torch Component Replacement .......................................................................................... 191

Torch components ..................................................................................................................................................................... 192

Replace the handle .................................................................................................................................................................... 193

Replace the trigger assembly .................................................................................................................................................. 197

Replace the torch body ............................................................................................................................................................. 199

Replace the start switch ........................................................................................................................................................... 201

Replace the cap-sensor switch ............................................................................................................................................... 202

Replace the torch lead .............................................................................................................................................................. 203

8 Parts ............................................................................................................................................. 207

Power supply parts ..................................................................................................................................................................... 208

Exterior, front ........................................................................................................................................................................ 208

Exterior, rear ......................................................................................................................................................................... 209

Interior, power board side ................................................................................................................................................. 210

Interior, control board and power switch ...................................................................................................................... 211

Interior, fan assembly ......................................................................................................................................................... 212

Interior, pneumatics (fan side) .......................................................................................................................................... 213

Interior, wires ........................................................................................................................................................................ 214

Power supply base and magnetics ................................................................................................................................. 215

Hand torch parts ......................................................................................................................................................................... 216

Hand torch consumables .......................................................................................................................................................... 217

Accessory parts .......................................................................................................................................................................... 218

Safety-critical parts .................................................................................................................................................................... 219

Recommended spare parts ...................................................................................................................................................... 221

Power supply labels ................................................................................................................................................................... 222

Consumables label ............................................................................................................................................................. 222

CSA warning label .............................................................................................................................................................. 223

CE/CCC warning label ..................................................................................................................................................... 224

Powermax30 AIR Service Manual 808850 11

Contents

9 Wiring Diagrams ....................................................................................................................... 225

Process flow for troubleshooting internal compressor and temperature fault LEDs .................................................. 226

Timing chart for torch start ....................................................................................................................................................... 227

Powermax30 AIR schematic .................................................................................................................................................... 228

12 Powermax30 AIR Service Manual 808850

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 compatibility.

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. In 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. In some cases this remedial action may be as simple as earthing the cutting circuit, see Earthing of the workpiece. 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.

Methods of reducing emissions

Mains supply

Cutting equipment must be connected to the mains supply according to the manufacturer’s recommendations. If interference occurs, it may be necessary to take additional precautions such as filtering of the mains supply.

Consideration should be given to shielding the supply cable of permanently installed cutting equipment, in metallic conduit or equivalent. Shielding should be electrically continuous throughout its length. The shielding should be connected to the cutting mains supply so that good electrical contact is maintained between the conduit and the cutting power source enclosure.

Maintenance of cutting equipment

The cutting equipment must be routinely maintained according to the manufacturer’s recommendations. All access and service doors and covers should be closed and properly fastened when the cutting equipment is in operation. The cutting 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

Assessment of area

Before installing the equipment, the user shall make an assessment of potential electromagnetic problems in the surrounding area. The following shall be taken into account:

a. Other supply cables, control cables, signaling and telephone

cables; above, below and adjacent to the cutting equipment.

b. Radio and television transmitters and receivers. c. Computer and other control equipment. d. Safety critical equipment, for example guarding of industrial

equipment.

e. Health of the people around, for example the use of

pacemakers and hearing aids.

f. Equipment used for calibration or measurement.

g. 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.

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.

Safety and compliance SC-13

Electromagnetic Compatibility (EMC)

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 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 increase the risk of injury, for example, by allowing parallel cutting current return paths which may damage the earth circuits of other equipment. Further guidance is 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.

SC-14 Safety and compliance

Warranty

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 guarantee or warranty regarding the safe use of the product in your environment.

General

Hypertherm, Inc. warrants that its Products shall be free from defects in materials and workmanship 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, with the exception of the HPRXD short torch with integrated lead, which shall be within a period of six (6) months from the 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 Connect CNC, EDGE Connect T CNC, EDGE Connect TC CNC, EDGE Pro CNC, EDGE Pro Ti CNC, MicroEDGE 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 HyIntensity 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.

All third-party engines, engine accessories, alternators, and alternator accessories are covered by the respective manufacturers’ warranties and not covered by this warranty.

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 poor 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.

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 Hypertherm 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.

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 (including 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. Hypertherm shall not be liable for any losses to Distributor based on down time, lost production or lost profits. It is the intention of the Distributor and Hypertherm that this provision be construed by a court as being the broadest limitation of liability consistent with applicable law.

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.

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.

Safety and compliance SC-15

Warranty

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 to 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.

Waterjet product warranty coverage

Product Parts coverage

HyPrecision pumps 27 months from the ship date, or 24 months

from the date of proven installation, or 4,000 hours, whichever occurs first

PowerDredge abrasive removal system

EcoSift abrasive recycling system

Abrasive metering devices

On/off valve air actuators

Diamond orifices 600 hours of use with the use of a thimble

Consumable parts are not covered by this warranty. Consumable parts include, but are not limited to, high-pressure water seals, check valves, cylinders, bleed-down valves, low-pressure seals, high-pressure tubing, low- and high-pressure water filters and abrasive collection bags. All third-party pumps, pump accessories, hoppers, hopper accessories, dryer boxes, dryer box accessories and plumbing accessories are covered by the respective manufacturers’ warranties and not covered by this warranty.

15 months from the ship date or 12 months from the date of proven installation, whichever occurs first

filter and compliance with Hypertherm’s water quality requirements

SC-16 Safety and compliance

Section 1

Specifications

Safety information

Before operating any Hypertherm equipment, read the separate Safety and Compliance Manual (80669C) Controls and indicators on page 41 your product for important safety information.

System description

The Powermax30 AIR is a 30 A handheld plasma cutting system that contains its own internal air compressor for maximum portability and ease of use. With it, you can cut electrically conductive metals – such as mild steel, stainless steel, or aluminum – of thicknesses up to 10 mm (3/8 inches). You can also pierce thicknesses up to 6 mm (1/4 inch).

The Powermax30 AIR ships in several different configurations, based on region. Typically all configurations include:

 1 complete set of consumables (preinstalled on the Air T30 hand torch):

 1 electrode

 1 swirl ring

 1 nozzle

 1 retaining cap

 1 deflector

 1 extra nozzle

 1 extra electrode

 Carrying strap

 Operator Manual

 Safety and Compliance Manual

 Quick Setup Card

Powermax30 AIR Service Manual 808850 17

1 – Specifications

420 mm

(16.5 inches)

195 mm

(7.7 inches)

333 mm

(13.1 inches)

295 mm

(11.6 inches)

CSA units ship with a 120 V / 15 A (NEMA 5-15P) adapter and a 240 V / 20 A (NEMA 6-50P) adapter that connect to the NEMA twist lock-style 240 V / 20 A (NEMA L6-20P) plug wired to the power supply. CE and CCC units ship without a plug on the power cord. See Power cord considerations on page 29 for more information.

You can order additional consumables and accessories – such as a dust cover and circle cutting guides, for example – from any Hypertherm distributor. See Parts on page 207 for a list of spare and optional parts.

Power supply dimensions

System weights

The following system weights include the hand torch with 4.6m (15foot) torch lead, a 4.6m (15foot) work lead with ground clamp, and a 3.0 m (10 foot) power cord:

 CSA systems: 13.5 kg (29.8 pounds)

 CE and CCC systems: 13.4 kg (29.5 pounds)

18 Powermax30 AIR Service Manual 808850

1 – Specifications

Hypertherm system ratings

Rated open circuit voltage (U0)256VDC

Output characteristic* Drooping

Rated output current (I

Rated output voltage (U

Rated output voltage (U U

= 200 VAC – 240 VAC

Duty cycle at 40°C, U

)15A to 30A

) at U1= 120 VAC 83 VDC

) at

= 120 VAC

20% (I2=30A, U2=83V)

83 VDC

(See data plate on power supply’s rear panel for more information on duty cycle and for IEC ratings.)

Duty cycle at 40°C, U

= 200 VAC – 240 VAC

35% (I2=30A, U2=83V)

(See data plate on power supply’s rear panel for more information on duty cycle and for IEC ratings.)

Operating temperature -10°C to 40°C (14°F to 104°F)

Storage temperature -25°C to 55°C (-13°F to 131°F)

Power factor (120 V – 240 V) 0.99 – 0.97

Idle state power consumption 14W

Power source efficiency at rated maximum

86%

output power**

EMC classification CISPR 11 (CE models only)

Input voltage (U output (U

2MAX

†

)/ Input current (I1) at rated

, I

)

2MAX

120 V, 1-phase, 50/60 Hz, 28.7 A

200 V – 240 V, 1-phase, 50/60 Hz, 16.7 A – 15.0 A

Class A

††

(See Voltage configurations on page 27 for more information.)

Gas type Air

* Defined as a plot of output voltage versus output current.

** Power source efficiency consumption measured in a laboratory setting with internal compressor disconnected.

Refer to Disconnect the internal compressor on page 20 for details about disconnecting the air compressor.

† WARNING: This Class A equipment is not intended for use in residential locations where the electrical power is provided by the

public low.voltage supply system. There may be potential difficulties in ensuring electromagnetic compatibility in those locations, due to conducted as well as radiated disturbances.

‡ This product meets the technical requirements of IEC 61000-3-2 and IEC 61000-3-3 and is not subject to conditional

connection.

Powermax30 AIR Service Manual 808850 19

1 – Specifications

Disconnect the internal compressor

WARNING!

HOT SURFACE CAN CAUSE INJURY

Allow the internal compressor to cool before touching it. The surface of the compressor can become very hot during use and can cause serious

injury if it comes in contact with skin.

To do a test of power source efficiency at the rated maximum output power, it is necessary to disconnect the Powermax30 AIR internal compressor. To disconnect the internal air compressor, complete the following steps:

1. Set the power switch to OFF (O), and disconnect the power cord from the power source.

2. Remove the power supply cover.

 See Remove the power supply cover on page 104.

3. Detach the rear panel cover.

 See Detach the rear panel on page 110.

4. Remove the J2 connector from the compressor-driver board.

20 Powermax30 AIR Service Manual 808850

Torch dimensions

25 mm

(1.0 inch)

51 mm (2.0 inches)

230 mm (9.0 inches)

45 mm (1.8 inches)

86 mm (3.4 inches)

75°

1 – Specifications

Torch weight

 Air T30 torch with consumables only: 0.3 kg (0.65 pounds)

 Air T30 torch with consumables and 4.6 m (15 foot) lead (with strain relief): 1.0 kg (2.25 pounds)

Powermax30 AIR Service Manual 808850 21

1 – Specifications

Cutting specifications

240 V

Recommended cut capacity* 8 mm (5/16 inch) at a minimum of 500 mm/minute (20 inches/minute)

10 mm (3/8 inch) at a minimum of 250 mm/minute (10 inches/minute)

Severance cut capacity 16 mm (5/8 inch) at a minimum of 125 mm/minute (5 inches/minute)

* When you operate this system at altitudes higher than 2,200 m (7,500 feet) above sea level, you may experience some reduction

in cutting performance due to the adverse effect that altitude has on air compressors.

120 V

When you operate the system at the maximum recommended output of 20 A, the cut capacities are:

 3 mm (10 gauge) at 762 mm/minute (30 inches/minute)

 6 mm (1/4 inch) at 355 mm/minute (14 inches/minute)

 10 mm (3/8 inch) at 125 mm/minute (5 inches/minute)

22 Powermax30 AIR Service Manual 808850

1 – Specifications

Direct current (DC)

Alternating current (AC)

Plasma torch cutting

AC input power connection

The terminal for the external protective (earth) conductor

I Power is ON

O Power is OFF

An inverter-based power source

Volt/amp curve, “drooping” characteristic

Power is ON (LED)

Internal air compressor fault (LED)

Missing or loose consumables (LED)

Power supply is overheated (LED)

IEC symbols

The following symbols may appear on the power supply data plate, control labels, switches, and LEDs.

Noise levels

This plasma system can make more than the permitted acoustical noise levels as defined by national and local codes. Always put on correct ear protection when cutting or gouging. Any acoustical noise measurements taken are related to

the specific environment in which the system is used. Refer to Noise can damage hearing in the Safety and Compliance Manual (80669C).

In addition, you can find an Acoustical Noise Data Sheet for your system at www.hypertherm.com/docs box, enter data sheet.

Critical raw materials

Critical raw material Components that contain more than 1 gram

Antimony Torch leads

Borate All printed circuit boards

Magnesium Heatsinks, metal covers

Silicon metal Heatsinks, metal covers, compressor (Powermax30 AIR only)

Powermax30 AIR Service Manual 808850 23

. In the search

1 – Specifications

Symbols and marks

Your product may have one or more of the following marks on or near the data plate. Because of differences and conflicts in national regulations, not all marks are applied to every version of a product.

S mark

The S mark indicates that the power supply and torch are suitable for operations carried out in environments with increased hazard of electrical shock according to IEC 60974-1.

CSA mark

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 UL or TÜV.

CE mark

The CE marking signifies the manufacturer’s declaration of conformity to applicable European directives and standards. Only those versions of products with a CE marking located on or near the data plate comply with European Directives. Applicable directives may include the European Low Voltage Directive, the European Electromagnetic Compatibility (EMC) Directive, the Radio Equipment Directive (RED), and the Restriction of Hazardous Substances (RoHS) Directive. See the European CE Declaration of Conformity for details.

Eurasian Customs Union (CU) mark

CE versions of products that include an EAC mark of conformity meet the product safety and EMC requirements for export to Russia, Belarus, and Kazakhstan.

GOST-TR mark

CE versions of products that include a GOST-TR mark of conformity meet the product safety and EMC requirements for export to the Russian Federation.

RCM mark

CE versions of products with an RCM mark comply with the EMC and safety 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

The CE versions of products that include a UkrSEPRO mark of conformity meet the product safety and EMC requirements for export to the Ukraine.

Serbian AAA mark

CE versions of products that include a AAA Serbian mark meet the product safety and EMC requirements for export to Serbia.

RoHS mark

The RoHS mark indicates that the product meets the requirements of the European Restriction of Hazardous Substances (RoHS) Directive.

24 Powermax30 AIR Service Manual 808850

Section 2

Power Supply Setup

Unpack the plasma system

1. Make sure that you received all items on your order in good condition. Contact your distributor if any parts are damaged or missing. (See System contents on page 26.)

2. Inspect the system for damage that may have occurred during shipment. If you find evidence of damage, see Claims, below. All communications regarding this equipment must include the model number and the serial number located on the rear panel of the power supply.

3. Before you set up and operate this system, read the separate Safety and Compliance Manual (80669C) included with your system for important safety information.

Claims

 Claims for damage during shipment – If your unit was damaged during shipment, file a claim with the carrier. You

can contact Hypertherm for a copy of the bill of lading. If you need additional assistance, call the nearest Hypertherm office listed in the front of this manual.

 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.

Powermax30 AIR Service Manual 808850 25

2 – Power Supply Setup

Operator Manual

Quick Setup Card

Registration card

Safety and Compliance Manual

Air T30 torch with lead

Consumable kit

Ground clamp and work lead

CE/CCC power cord (no power plug included)

CSA power cord with power plug adapters

Power supply

Carrying strap

System contents

The following illustration shows the components typically included with all system configurations.

The specific components included with the system are subject to change over time.



26 Powermax30 AIR Service Manual 808850

2 – Power Supply Setup

Position the plasma cutting system

 Position the plasma system near an appropriate power receptacle. The system has a 3.0 m (10 foot) power cord.

 Allow at least 0.25 m (10 inches) of space around the power supply for proper ventilation.

 When positioning the plasma system, be aware that excess moisture from the internal compressor exits through a

hole in the base, underneath the power supply. You may see a small puddle form under the power supply as you operate the system.

 Place the power supply on a stable, level surface before using. The power supply can tip over if set at an angle

greater than 10 degrees.

 Do not place the power supply on its side. Doing so can prevent proper air circulation needed to cool internal

components. It can also divert air away from the torch and prevent it from working properly.

 Be aware that when you operate this system at altitudes higher than 2,200 m (7,500 feet) above sea level, you may

experience some reduction in cutting performance due to the adverse effect that altitude has on air compressors.

 Do not use the system in rain or snow.

WARNING!

CHANCE OF ELECTRIC SHOCK

Never cut under water or submerge the torch in water. Electric shock can cause serious injury.

Prepare the electrical power

The system’s maximum output voltage varies based on the input voltage and the circuit’s amperage.

Additional factors must be considered when you are operating the system at an input power of 120 V, as tripped circuit breakers can result under some conditions. For more information, see System operation guidelines on page 49 and Troubleshooting guide on page 63.

Voltage configurations

The system automatically adjusts for proper operation at the current input voltage without requiring you to perform any switching or rewiring. However, you must make sure that an appropriate set of consumables is properly installed in the torch and the amperage adjustment knob is set to an appropriate output current. For more information, see Step 1 – Install the consumables on page 43 and Step 3 – Adjust the output current on page 45.

The following tables show the maximum rated output for typical combinations of input voltage and amperage. The output setting you need to use depends on the thickness of the metal and is limited by the input power to your system.

Hypertherm does not recommend operating this system on a 120 V / 15 A circuit.



The Hypertherm rated output is:

 15 A – 30 A maximum output current

 83 VDC maximum rated output voltage

 2.5 kW cutting power

Powermax30 AIR Service Manual 808850 27

2 – Power Supply Setup

Determine the plasma system’s cutting power in watts by multiplying its maximum output amperage by its maximum rated output voltage:

30 A × 83 VDC = 2,490 W (or 2.5 kW).

CAUTION!

A circuit capable of 120V/20A or 240V/20A is required for proper operation. Protect the circuit with appropriately sized slow-blow (time-delay) fuses or circuit breakers.

Table1 – 120V/20A

Input voltage 120 V

Input current at rated output (19A×83V=1.6kW) 19.2A

Input current at arc stretch 37.5 A

Voltage tolerance +20% / -15%

Table2 – 120V/30A

Input voltage 120 V

Input current at rated output (30 A × 83 V = 2.5 kW) 28.7 A

Input current at arc stretch 37.5 A

Voltage tolerance +20% / -15%

Table3 – 200V – 240V/16A

Input voltage 200 V – 240 V

Input current at rated output (28A×83V=2.3kW) 15.8A–13.4A

Input current at arc stretch 37.5 A

Voltage tolerance +20% / -15%

Table4 – 200V – 240V/20A

Input voltage 200 V – 240 V

Input current at rated output (30 A × 83 V = 2.5 kW) 16.7 A – 15.0 A

Input current at arc stretch 37.5 A

Voltage tolerance +20% / -15%

28 Powermax30 AIR Service Manual 808850

2 – Power Supply Setup

Requirements for grounding

Properly ground the system as follows to ensure personal safety and proper operation, and to reduce electromagnetic interference (EMI):

 The system must be grounded through the power cord according to national and local electrical codes.

 Single-phase service must be of the three-wire type with a green (CSA) or green/yellow (CE/CCC) wire for the

protective earth ground and must comply with national and local requirements. Do not use a two-wire service.

 Refer to the Safety and Compliance Manual (80669C) for more information.

Power cord considerations

This system ships with a CSA or CE, or CCC power cord configuration. See Exterior, rear on page 209 for part number information.

CSA power cords and plugs

CSA configurations include the following plug and adapters.

 The power cord is equipped with a NEMA twist

lock-style plug (NEMA L6-20P) appropriate for use on a 240 V / 20 A circuit with a NEMA twist lock-style outlet.

 To operate the system on a lower amperage circuit,

attach the female end of the 120 V / 15 A (NEMA 5-15P) plug adapter to the power supply’s NEMA twist lock-style plug.

Do not set the amperage adjustment knob above



20 A, or you may trip the circuit breaker. See Step 3 – Adjust the output current on page 45.

 To operate the system on a 240 V / 20 A circuit, attach

the female end of the 240 V / 20 A (NEMA 6-50P) plug to the power supply’s NEMA twist lock-style plug.

Powermax30 AIR Service Manual 808850 29

2 – Power Supply Setup

Cord grip

Outer shell

To line 1 terminal (brown)

220 V (CCC) or 230 V (CE) plug

To line 2 terminal (blue)

To ground terminal (green/yellow)

CE and CCC power cords

CE and CCC configurations ship without a plug on the power cord. To operate at 220 V (CCC) or 230 V (CE), obtain the correct plug for your unit and location and have it installed by a licensed electrician.

Install a plug on the power cord

1. Strip back the cord insulation to separate wires 3, 5, and 6.

2. Remove each wire’s insulation to allow good contact with the plug terminals.

3. Make the connections.

4. Reinstall the outer shell and cord grip, and tighten the cord grip’s screws until snug. Do not overtighten.

30 Powermax30 AIR Service Manual 808850

2 – Power Supply Setup

Extension cord recommendations

Use an extension cord of an appropriate wire gauge for the cord length and system voltage. Use a cord that meets national and local codes.

Input voltage Phase

Recommended cord gauge size Length

120 VAC 1 4 mm

240 VAC 1 2 mm

Extension cords can cause the machine to receive less input voltage than the output of



the circuit. This can limit the operation of your system.

Generator recommendations

Generators used with this system should produce 240 VAC.

Engine drive rating

5.5kW 30A Full

4kW 25A Limited

Adjust the cutting current as needed based on the generator rating, age, and condition.



Engine drive output current

1-phase (CSA/CE/CCC)

(12 AWG) Up to 16 m (53 feet)

(14 AWG) Up to 40.5 m (133 feet)

Performance (arc stretch)

If a fault occurs while using a generator, turn OFF the system and wait approximately



60 seconds before turning it ON again. Turning the power switch quickly to OFF and ON again (called a “quick reset”) may not clear the fault.

Powermax30 AIR Service Manual 808850 31

2 – Power Supply Setup

32 Powermax30 AIR Service Manual 808850

Section 3

Handle

Deflector

Retaining cap

Safety catch

Trigger (red)

Screws (5)

Torch Setup

Introduction

The Powermax30 AIR includes the Air T30 hand torch. This section explains how to set up and operate your torch. To achieve optimal consumable life and cut quality, follow the instructions in this manual.

Hand torch components

Powermax30 AIR Service Manual 808850 33

3 – Torch Setup

Consumable life

Consumable life varies based on the following factors:

 Thickness of the metal.

 Length of the average cut.

 Type of cutting (piercing decreases life when compared to edge cutting).

 Pierce height (stretching the arc).

 Whether you are cutting solid metal or expanded metal. Cutting expanded metal wears out consumables more

quickly. For more information, see Cutting expanded metal on page 45.

Hypertherm does not recommend the use of any other consumables in the Air T30 torch



except for those listed in this section, which are designed specifically for this system. The use of any other consumables could adversely affect system performance.

Although largely dependent on the factors listed above, as a general rule, the consumables last approximately 1 to 2 hours of actual “arc on” time.

If the consumables’ life is shorter than expected or the cut quality is poor, make sure that you are using the correct consumables and that they are properly installed. (See the following topic, Consumable use.) Under normal conditions, the nozzle wears out first.

For optimal cutting performance, always replace the nozzle and the electrode together.



See Hand torch operation on page 50 for more information about proper cutting techniques.

34 Powermax30 AIR Service Manual 808850

3 – Torch Setup

Consumable use

WARNING!

INSTANT-ON TORCHES

PLASMA ARC CAN CAUSE INJURY AND BURNS

The plasma arc ignites immediately when you pull the torch trigger. Make sure the power is OFF before changing consumables.

The hand torch ships with a complete set of consumables installed. The consumables are designed for a broad range of cutting applications.

The amperage output setting you need to use depends on the thickness of the metal you are planning to cut and is limited by the input power to your system. See Voltage configurations on page 27.

Do not use any other consumables in the Air T30 torch except for those listed in this



section, which are designed specifically for this system. The use of any other consumables could adversely affect system performance.

Using the cut charts

Use the following cut charts to guide you in selecting the cutting current (amperage) based on the thickness and type of the metal you need to cut.

The maximum cut speeds listed in the cut charts are the fastest possible speeds to cut metal without regard to cut quality. Adjust the cutting speed for your application to obtain the desired cut quality.

Powermax30 AIR Service Manual 808850 35

3 – Torch Setup

54321 6

To rc h

Electrode

Swirl ring

Nozzle

Retaining cap

Deflector

Consumable set

A complete set of consumables includes:

 Electrode

 Swirl ring

 Nozzle

 Retaining cap

 Deflector

Hypertherm does not recommend operating this system on a 120 V / 15 A circuit.



The following consumables are designed specifically for use with the Powermax30 AIR power supply and Air T30 hand torch. They cannot be used with any other Powermax system or torch.

36 Powermax30 AIR Service Manual 808850

Metric

3 – Torch Setup

240V/30A cutting

Material thickness (mm) Material Arc current (A)

1 2 5,145 3 2,545 4 1,450 5 1,155

7* 570

Mild steel 30

9* 400 11* 280 13* 215 16* 125

1 2 3,290 3 1,970 4 1,260 5 980

Stainless steel 30 7* 535 9* 310

11* 215 13* 170

1 2 6,630 3 3,585 4 2,370 5 1,770

Aluminum 30 7* 575 9* 435

11* 245 13* 135

Maximum cut speed

(mm/minute)

10,160

†

* To cut material thicker than 6 mm (1/4 inch) at 240 V, start the torch at the edge of the workpiece. † Maximum cut speed is limited by the test table’s maximum speed (10,160 mm/minute or 400 inches/minute).

Powermax30 AIR Service Manual 808850 37

3 – Torch Setup

English

Material thickness

(gauge/inches)

Material Arc current (A)

Maximum cut speed

18 gauge 14 gauge 214 12 gauge 130 10 g auge 64

1/4 30

Mild steel 30

5/16* 22

3/8* 13 1/2* 9

5/8* 5 18 gauge 14 gauge 135 10 g auge 56

1/4 24

Stainless steel 30

3/8* 10

1/2* 7

1/32 1/16 306

1/8 111 1/4 38

Aluminum 30

3/8* 13

1/2* 6

(inches/minute)

395

370

†

400

38 Powermax30 AIR Service Manual 808850

Metric

3 – Torch Setup

120 V / 20 A cutting

Material thickness (mm) Material Arc current (A)

1 2 2,420

3 1,245 4* 680 6* 400 8* 235

10* 90

2 2,140

3 1,270 4* 965 5* 660 7* 150

2 3,610

3 1,720 4* 1,030 5* 740 7* 165

Mild steel 20

Stainless steel 20

Aluminum 20

Maximum cut speed

(mm/minute)

6,540

3,295

5,500

* To cut material thicker than 3 mm (10 gauge) at 120 V, start the torch at the edge of the workpiece.

Powermax30 AIR Service Manual 808850 39

3 – Torch Setup

English

Material thickness

(gauge/inches)

18 gauge 14 gauge 10 0 10 g auge 30

1/4* 14

3/8* 5 18 gauge 14 gauge 89 12 gauge 54

1/4* 10

1/32 1/16 170

1/8 49

1/4* 14

* To cut material thicker than 3 mm (10 gauge) at 120 V, start the torch at the edge of the workpiece.

Material Arc current (A)

Mild steel 20

Stainless steel 20

Aluminum 20

Maximum cut speed

(inches/minute)

220

120

231

40 Powermax30 AIR Service Manual 808850

Controls and indicators

Familiarize yourself with the controls and LED indicators on the system before you begin cutting.

Rear controls

Section 4

Operation

ON (I) / OFF (O) power switch

Activates the system and its control circuits.

Powermax30 AIR Service Manual 808850 41

4 – Operation

Front panel controls and indicator LED symbols

Power ON LED (green) – When illuminated, this LED indicates that the power switch has been set to ON (I)

and that the safety interlocks are satisfied.

Internal compressor LED (yellow) – When illuminated, this LED indicates a possible issue with the internal air compressor.

Torch cap LED (yellow) – When illuminated, this LED indicates that the consumables are loose, improperly installed, or missing.

Temperature LED (yellow) – When illuminated, this LED indicates that the system’s temperature is outside the acceptable operating range.

Some fault conditions cause multiple LEDs to illuminate or blink at the same time. For



information on what these fault conditions are and how to clear them, see Troubleshooting guide on page 63.

Amperage adjustment knob – Use this knob to set the output current between 15 A and 30 A.

42 Powermax30 AIR Service Manual 808850

Operate the plasma system

Tighten only to finger tight.

234

The following topics explain how to begin cutting with the plasma system.

Step 1 – Install the consumables

WARNING!

INSTANT-ON TORCHES

PLASMA ARC CAN CAUSE INJURY AND BURNS

The plasma arc ignites immediately when you pull the torch trigger. Make sure the power is OFF (O) before changing consumables.

Before operating the plasma system and hand torch, first make sure:

1. The power switch on the power

supply is in the OFF (O) position.

4–Operation

2. A complete set of consumables is installed on the hand torch as shown:

Electrode

Swirl ring

Nozzle

Retaining cap

Deflector*

* Install the deflector by snapping it

securely into place on the retaining cap.

Do not apply grease or



other lubricants to the O-rings on the electrode and swirl ring.

These consumables are designed specifically for the Powermax30 AIR power supply and



Air T30 hand torch. They cannot be used with any other Powermax system or torch.

Powermax30 AIR Service Manual 808850 43

4 – Operation

Step 2 – Connect the electrical power

Plug in the power cord.

Step 3 – Adjust the output current

The power ON LED illuminates when the system is powered ON and ready to operate.

If any of the other LEDs illuminate or blink, do not try to cut – a fault has occurred. Refer to Internal compressor LED faults on page 66 for a list of troubleshooting steps to follow.

When the system is ready to cut, turn the amperage knob to the desired output current based on the input voltage and circuit size.

Operating the system on a 120 V / 20 A circuit

 Set the amperage below 20 A, as indicated by the

blue shading around the knob (the thick inner ring).

 Make sure nothing else is drawing power from the

circuit.

Hypertherm does not recommend operating this



system on a 120 V / 15 A circuit.

Operating the system on a 240 V / 20 A circuit

 Set the amperage between 15 – 30 A.

Decrease output current for lower-rated power plugs

If you are operating the system using a lower-rated power plug or service, turn down the output current to avoid tripping the circuit breaker.

For example, to operate the system on a 230 V / 16 A circuit, set the amperage below 28 A.

See Voltage configurations on page 27 for more information.



Cutting expanded metal

Use the consumables that come with the torch to cut expanded metal. (Expanded metal has a slotted or mesh pattern.) The system does not require a dedicated mode for cutting expanded metal.

Cutting expanded metal wears out consumables more quickly because it requires a continuous pilot arc. A pilot arc occurs when the torch is fired but the plasma arc is not in contact with the workpiece.

For best results, operate on a higher rated circuit (240 V / 20 A).

Powermax30 AIR Service Manual 808850 45

4 – Operation

Step 4 – Attach the ground clamp

Attach the ground clamp to the workpiece.

 Make sure the ground clamp and the workpiece make good metal-to-metal contact.

 Attach the ground clamp as close as possible to the area being cut to reduce exposure to electric and magnetic

fields (EMF) and to achieve the best possible cut quality.

 Do not attach the ground clamp to the portion of the workpiece that you are cutting away.

Step 5 – Power ON the system

Set the ON/OFF switch to the ON (I) position.

Step 6 – Check the indicator LEDs

Make sure the green power ON LED on the front of the power supply is illuminated and that none of the other LEDs are illuminated or blinking.

If the temperature, torch cap sensor, or internal compressor LEDs illuminate or blink, or if the power ON LED blinks, this indicates a fault. Correct the fault condition before continuing. See Troubleshooting guide on page 63 for more information.

46 Powermax30 AIR Service Manual 808850

4–Operation

Step 7 – Make sure the system is ready, and start cutting

When the power ON LED illuminates, none of the other LEDs illuminate or blink, and the amperage knob is set, the system is ready for use.

What to expect during and after cutting

Water at the torch nozzle

 A small amount of moisture at the torch nozzle is normal for this system, particularly in very humid environments. It

should not prevent the torch from firing or degrade cut quality or performance.

Postflow

 After you complete a cut and release the torch trigger, air continues to flow from the torch in order to cool the

consumables. This is referred to as postflow.

 The length of postflow depends on how long the torch fired a sustained arc:

Length of time arc was sustained Length of postflow

0–5seconds 5seconds

> 5 – 21 seconds 10 seconds

> 21 – 135 seconds 15 seconds

> 135 seconds 20 seconds

Internal compressor and fan activity

 The internal compressor runs while you are cutting, and it continues to run during postflow.

 The fan inside the power supply runs for 7 minutes after postflow. It also runs intermittently during cutting.

Water under the power supply

 When cutting, you may see a small puddle form underneath the power supply because the system automatically

purges excess moisture from the internal compressor. It expels this water through a hole in the bottom of the power supply.

Powermax30 AIR Service Manual 808850 47

4 – Operation

Understand duty-cycle limitations

The duty cycle is the percentage of time out of 10 minutes that a plasma arc can remain on when operating at an ambient temperature of 40°C (104°F).

 35% duty cycle at 240 V / 30 A: With input power of 240 V and the output current set to 30 A, the arc can remain

on for 3.5 minutes out of 10 minutes without causing the unit to overheat.

 20% duty cycle at 120 V / 30 A*: With input power of 120 V and the output current set to 30 A, the arc can

remain on for 2.0 minutes out of 10 minutes without causing the unit to overheat.

* Although the duty cycle is rated for 30 A output, the recommended output current for 120 V circuits is 20 A or less. Operating the

system at 30 A on 120 V input can result in frequent tripped circuit breakers.

When you exceed the duty cycle and the system overheats, one of the following conditions occurs:

 The temperature LED illuminates, the arc shuts off, and the cooling fan continues to run. To resume cutting, wait for

the temperature LED to extinguish.

 The internal compressor LED and the temperature LED both illuminate. Allow the power supply to cool for 4 minutes

before using it again. If the problem persists, see Internal compressor LED faults on page 66 for more troubleshooting tips.

When either condition occurs, leave the system on to allow the fan to cool the power



supply. The fan runs for 7 minutes after postflow.

Stretching the arc for prolonged periods while cutting can reduce the duty cycle. Stretching the arc requires the power supply to generate a higher voltage output, which can cause it to run hotter and overheat more quickly.

48 Powermax30 AIR Service Manual 808850

4–Operation

System operation guidelines

 To achieve the highest level of performance:

 Operate the system at an input power of 240 VAC whenever possible.

 Do not operate the system on a 120 V / 15 A circuit.

 Avoid using an extension cord whenever possible.

If you must use an extension cord, use a heavy conductor cord of the shortest possible



length. See Extension cord recommendations on page 31.

 If you are operating your system on a 120 V / 20 A circuit, do not set the amperage higher than 20 A. See Voltage

configurations on page 27.

 For best results when operating your system on a 120 V / 20 A circuit:

 Do not connect anything else that will draw power from the same circuit.

 Be aware that extension cords can reduce the voltage to the machine from what is output by the circuit. This

reduction in power can impair cutting performance and increase the probability of tripping the circuit breaker.

 Cutting a thicker workpiece requires a higher amperage setting. It is preferable to operate on a higher rated circuit

(240 V / 30 A) when cutting thicker metal. See Voltage configurations on page 27.

 Additional techniques to reduce the frequency of tripped circuit breakers include:

 Turn down the amperage adjustment knob.

 Avoid stretching the arc. Instead, drag the torch on the workpiece as explained in Edge start on a workpiece on

page 52.

 When you operate the system at altitudes higher than 2,200 m (7,500 feet) above sea level, you may experience

some reduction in cutting performance due to the adverse effect that altitude has on the internal air compressor.

Powermax30 AIR Service Manual 808850 49

4 – Operation

Hand torch operation

WARNING!

INSTANT-ON TORCHES

PLASMA ARC CAN CAUSE INJURY AND BURNS

Plasma arc ignites immediately when you pull the torch trigger. The plasma arc cuts quickly through gloves and skin.

Keep hands, clothes, and objects 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.

WARNING!

SPARKS AND HOT METAL

CAN INJURE EYES AND BURN SKIN

Always wear proper protective equipment including gloves and eye protection, and point the torch away from yourself and others. Sparks and hot molten metal spray out from the nozzle.

Safety catch operation

The torch is equipped with a safety catch to prevent accidental firings. When you are ready to cut with the torch, flip the safety catch forward (toward the torch head) and pull the red torch trigger.

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4–Operation

Hand torch cutting guidelines

 Drag the torch tip lightly on the workpiece to maintain a steady cut speed.

With drag-cutting, it is normal to experience the torch sticking slightly to the workpiece.



 While cutting, make sure that sparks exit from the bottom of the workpiece. The sparks should lag slightly behind the

torch as you cut (15°–30° angle from vertical).

 If sparks spray up, you are not cutting all the way through the workpiece. Move the torch more slowly, or, if possible,

increase the output current.

 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.

 Pulling the torch toward you along the cut is easier than pushing it or moving from side-to-side.

 For straight-line cuts, use a straight edge as a guide. To cut circles, use a template or a radius cutter attachment (a

circle cutting guide). See Accessory parts on page 218 for the Hypertherm plasma cutting guide part numbers for cutting circles and making bevel cuts.

 If you fire the torch unnecessarily, you shorten the life of the nozzle and electrode.

Recommendations for cutting at 120 V

 Do not operate the system on a 15 A circuit.

 Do not use an extension cord.

 Make sure nothing else is drawing power from the circuit.

 Turn down the current adjustment knob to avoid tripping the breaker.

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4 – Operation

Edge start on a workpiece

When cutting material up to 10 mm (3/8 inch) thick, start the torch at the edge of the workpiece to prolong consumable life.

1. With the ground clamp attached to the workpiece, hold the torch perpendicular (90°) to the workpiece and on the edge.

2. Pull the torch trigger to start the arc. You may need to pause at the edge until the arc has cut completely through the workpiece.

3. Drag the torch lightly across the workpiece to proceed with the cut. Maintain a steady, even pace.

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4–Operation

30° – 45° for rolling pierce

Pierce a workpiece

When cutting material up to 6 mm (1/4 inch) thick, use piercing to cut an interior feature. Piercing shortens the life of the deflector and the nozzle.

The type of pierce to perform depends on the thickness of the metal:

 Straight pierce – For cutting mild or stainless steel that is thinner than 3 mm (10 gauge).  Rolling pierce – For cutting mild or stainless steel that is 3 mm (10 gauge) or thicker.

1. Attach the ground clamp to the workpiece.

2. Straight pierce: Hold the torch perpendicular (90°)

to the workpiece with the torch tip just above the workpiece.

Rolling pierce: Hold the torch at an approximate 30° – 45° angle to the workpiece with the torch tip within 1.5 mm (1/16 inch) of it before firing the torch.

3. Straight pierce: Pull the torch trigger to start the

arc. Rolling pierce: Pull the torch trigger to start the arc

while still at an angle to the workpiece, then rotate the torch to the perpendicular (90°) position.

4. Hold the torch in place while continuing to pull the trigger. When sparks exit from the bottom of the workpiece, the arc has pierced the metal.

5. When the pierce is complete, drag the torch lightly along the workpiece to proceed with the cut.

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4 – Operation

Common hand-cutting faults

For more information on faults, see Troubleshooting guide on page 63.

 The torch sputters and hisses, but does not produce an arc. The cause can be:

 Overtightened consumables

 The torch does not cut completely through the workpiece. The causes can be:

 Cut speed is too fast

 Worn consumables

 Metal being cut is too thick for the selected amperage

 Installation of the wrong consumables

 Poor electrical contact between the ground clamp and the workpiece

 Cut quality is poor. The causes can be:

 Metal being cut is too thick for the selected amperage

 Installation of the wrong consumables

 Cut speed is too fast or too slow

 Worn or damaged consumables

 The arc sputters and consumables life is shorter than expected. The causes can be:

 Incorrect installation of the consumables

 Installation of the wrong consumables

 Moisture in the consumables or in the air supply within the system

Minimizing dross

Dross is the molten metal that solidifies on the workpiece. Some amount of dross is always present when cutting with air plasma. However, you can control the amount and type of dross by adjusting your system correctly for your application.

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 is usually easy to remove. Increase your speed to reduce this type of dross.

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 forms to the bottom of the cut and is often more difficult to remove. Decrease your speed to reduce this type of dross.

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 is likely to produce the least dross. As the workpiece heats up, more dross may form on subsequent cuts.

Worn or damaged consumables may produce intermittent dross.



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Section 5

Troubleshooting and System Tests

Theory of operation

Functional description

AC power enters the system through the power switch (S1) to the input diode bridges (D24, D30). The voltage from the diode bridges supplies the power factor correction (PFC) boost converter, which provides a nominal 375 VDC bus voltage. The bus voltage then supplies voltage and current to the inverter, the flyback circuit power supply (DC to DC converter) on the power board (PCB2), and the compressor-driver board (DC to DC converter). The power board provides noise suppression and spike protection. A “soft start” is implemented via the power board resistor and relay (K1).

The compressor-driver board (PCB3) converts 375 VDC bus voltage from the power board to nominal 15 VDC through a DC to DC converter. The compressor-driver board supplies 15 VDC to power the internal air compressor.

The PFC boost converter consists of an insulated gate bipolar transistor IGBT (Q1), choke, and control circuit. It provides a 375 VDC bus voltage when the input AC voltage is between 120 and 240 VAC.

The inverter consists of an IGBT (Q2), the power transformer, a current-sense transformer, and sections of the power board. The inverter operates as a pulse-width modulator-controlled bridge circuit that is rectified by the output diode (D27).

The output circuitry consists of two current sensors located on the power board, the pilot arc IGBT (inside the D27 module), and the output choke.

The control board’s microprocessor monitors and regulates the system’s operation and safety circuits. The amperage adjustment knob sets the output current to the desired value between 15 A and 30 A. The system compares the set-point to the output current by monitoring the current sensor and adjusting the pulse-width output of the inverter IGBT (Q2).

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5 – Troubleshooting and System Tests

Power OFF (O)

• Connect the work lead to the workpiece.

• Plug in the power cord. Apply power at the line-voltage disconnect box, if applicable.

• Set the power switch (S1) to ON (I).

• The green power ON LED illuminates, indicating the system is ready for operation.

• All the fault LEDs should be extinguished. See Troubleshooting guide on page 63.

• Set the amperage adjustment knob to the desired output current (between 15 A and 30 A) based on the input voltage and circuit size.

• The power circuits are ready.

• Position the torch on the workpiece.

• Pull the plasma start trigger on the torch.

• The fan and the internal compressor turn on.

• The gas solenoid valve (V1) opens.

• The gas flow starts.

• The cutting arc starts.

• Drag the torch lightly across the workpiece to make a cut.

• The workpiece drops after the cut.

• Release the plasma start trigger on the torch.

• The arc extinguishes.

• Gas postflow continues for 5–20 seconds. See Postflow on page 47.

• The fan continues to run for 7 minutes.

• The internal compressor shuts off.

• The gas solenoid valve (V1) closes.

• The gas flow stops.

• Set the power switch (S1) to OFF (O).

Sequence of operation

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5 – 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.

WARNING!

ELECTRIC SHOCK CAN KILL Turn OFF (O) the power and disconnect the electrical power 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! Do not touch the tip of the nozzle when the system is powered ON (I)! If power is required for servicing, use extreme caution when working near live electrical circuits. Dangerous voltages exist inside the power supply that can cause serious injury or death.

Do not attempt to repair the power board, control board, or compressor-driver board. Do not cut away or remove any protective conformal coating from these boards. To do so risks 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 printed circuit boards.

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5 – Troubleshooting and System Tests

Test equipment

 Multimeter with a variety of test leads. Most power boards

contain test points with a diameter of 2.25 mm (0.09 inches) that

accept miniature banana plugs (for example, Pamona

2945 plugs). Earlier-style power boards contain larger test point openings that require the use of test hooks. See page 84.

 Air pressure test gauge (kit 428643) to troubleshoot

pressure-related issues.

Troubleshooting procedures and sequence

When performing the troubleshooting procedures, refer to:

 Safety and Compliance Manual (80669C) for detailed safety information.

 Powermax30 AIR schematic on page 228 for the system’s electrical schematic.

 Power Supply Component Replacement on page 103 or Torch Component Replacement on page 191 for

replacement procedures.

 Parts on page 207 for power supply components and torch components.

Power OFF (O) and disconnected

External inspection

Internal inspection

Initial resistance check

Power ON (I)

Troubleshooting guide

System tests

After the problem has been located and repaired, refer to Sequence of operation on page 56 to test the power supply for proper operation.

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5 – Troubleshooting and System Tests

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.

3. Inspect the consumables for damage or wear.

4. Repair or replace components as necessary.

Internal inspection

1. Set the power switch to OFF (O), and disconnect the power cord from the power source.

2. Remove the power supply handle and cover. See Remove the power supply cover on page 104.

3. Remove the component barrier. See Remove the component barrier on page 106.

4. Inspect the inside of the power supply:

 Power board side: Look for broken or loose wiring connections, burn and char marks, damaged components,

and so on.

 Fan side: Check for leaks and loose connections at each pneumatic (air) connection point on the internal

compressor, air filter, and solenoid valve.

5. Repair or replace components 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 Internal inspection (above) before continuing in this section.

 The type of multimeter you use significantly affects the results of the tests in this section. The resistance values in this

manual are intended as a general reference point.

 If resistance values indicate a problem based on the range of values provided 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 is located and repaired, see Sequence of operation on page 56 to test the power supply for proper

operation.

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5 – Troubleshooting and System Tests

75 kΩ

Black (CSA)

Brown (CE/CCC)

Check the power switch

1. Set the power switch to OFF (O), disconnect the power cord from the power source, and then set the power switch to ON (I).

2. Check the resistance across the input leads. The resistance should read as approximately 75 kΩ.

3. Check the resistance from the input leads to ground to make sure it reads as open. For all power supplies, the resistance from input to ground should read as > 20 MΩ.

With the electrical power disconnected



and the power switch set to OFF (O), all circuits should read as open.

The electrical value shown is ±25%. However, this range is intended only for reference. Resistance values can vary widely depending on the type of multimeter and the polarity used to measure the readings.

4. Remove the consumables from the torch. If you do not remove the consumables, the resistance values will not read correctly.

5. Check the output resistance for the values shown in the following table.

J16 and J17 are labeled on the component side of the power board. See Figure 1 for



locations on the back side of the power board.

Measure resistance from (with consumables removed) Approximate values

Work lead (J22) to nozzle (J16, red wire) 100 kΩ

Work lead (J22) to electrode (J17, white wire) 20 kΩ

Electrode (J17, white wire) to nozzle (J16, red wire) 120 kΩ

Work lead (J22), nozzle (J16, red wire), and electrode (J17, white wire) to ground

>20MΩ

60 Powermax30 AIR Service Manual 808850

Figure 1

WORK LEAD (BLK)

AC AC

TORCH START

BLK

TORCH START

J22

WORK LEAD (BLK)

J16, red

J17, white

5 – Troubleshooting and System Tests

6. If you do not find any problems during the visual inspection or the initial resistance check, and the power supply is still not operating correctly, see Troubleshooting guide on page 63.

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5 – Troubleshooting and System Tests

WORK LEAD (BLK)

AC AC

TORCH START

BLK

TORCH START

Output diode and pilot arc IGBT module (D27)

Work lead connection (J22)

Input diode bridges (D24, D30)

PE (ground)

Power board (PCB2)

Power switch (S1)

PFC IGBT (Q1)

Flyback circuit

Inverter IGBT (Q2)

Control board (PCB1)

Power supply overview

Figure 2 – Power board side of power supply

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5 – Troubleshooting and System Tests

Troubleshooting guide

This guide provides the most common causes and solutions.

 Before troubleshooting, study the Powermax30 AIR schematic on page 228 and understand the Theory of operation

on page 55.

 Before purchasing any major replacement component, verify the problem with Hypertherm Technical Service or the

nearest Hypertherm repair facility listed in the front of this manual.

 See System tests on page 75 for detailed test procedures.

Power LED faults

The ON/OFF power switch is set to ON (I), but the power ON LED does not illuminate.

Possible causes Possible solutions

 The system has no incoming voltage or an

improper incoming voltage.

 The power cord, power switch, or power

board is faulty.

 Make sure the electrical power is connected

to an appropriately sized circuit.

 Make sure the system did not trip the circuit

breaker.

 Perform Test 1 – voltage input on page 80.

The power ON LED illuminates, but no fault LEDs illuminate, and no gas flows when you pull the torch trigger.

Possible causes Possible solutions

 The start signal is not reaching the control

board due to:

 Damaged torch or torch lead

 Faulty power board

 Faulty control board

 Inspect the torch and torch lead, and

replace if necessary.

 Make sure the control board start LED

illuminates when you pull the torch trigger. If it does not, perform Test 6 – plasma start on page 90.

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5 – Troubleshooting and System Tests

The power ON LED blinks.

Possible cause Possible solution

 The incoming voltage is below 90 VAC or

 Perform Test 1 – voltage input on page 80.

above 285 VAC.

All four LEDs blink when the system is powered ON.

Possible causes Possible solutions

 A major fault has occurred in the power

supply. For example, the fan, solenoid valve, control board, or power board may be faulty.

 The error LED on the control board should

be blinking. The number of times it blinks between pauses indicates which components to test. See Control board LEDs on page 73.

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Temperature LED faults

The temperature LED illuminates while the machine is powered ON.

Possible causes Possible solutions

 The system overheated because the duty

cycle was exceeded.

 The system is too cold to operate. The

ambient temperature is too low.

 Let the system cool before using it. Leave

the system on to allow the fan to cool the power supply. The fan runs for 7 minutes after postflow. See Understand duty-cycle limitations on page 48.

 Perform Te st 8 – f a n on page 93.

 Let the system warm up before using it. The

operating temperature range for this system is -10°C (14°F) to 40°C (104°F).

The temperature LED blinks while the machine is powered ON.

Possible causes Possible solutions

This fault occurs when the system continuously draws too much input current for too long. The fault protects the power switch and power cord from damage caused by overheating. This fault most often

Let the system cool for 3 minutes before using it. Leave the system on to allow the fan to cool the power supply.

To prevent the fault from occurring:

occurs when:

 You are operating the system on a 120 VAC

 Operate the system on a 240 VAC input

circuit whenever possible.

input circuit and the cutting current is set above 20 A.

 Turn down the cutting current. See

Step 3 – Adjust the output current on

 You are operating the system on a

page 45.

120 V / 15 A circuit.

 You are operating the system on a 120 VAC

input circuit and are frequently stretching the

 If you do operate the system on a120 VAC

input circuit, use a 20 A circuit and set the cutting current below 20 A.

arc while cutting.

 You are using an extension cord that is too

long.

The maximum length for an extension cord on a 120 VAC input circuit is 16 m (53 feet). The maximum length for an extension cord on a 240 VAC input circuit is 40.5 m (133 feet).

 Avoid stretching the arc. Drag the torch on

the workpiece. See Edge start on a workpiece on page 52.

 Operate the system without using an

extension cord. If you must use an extension cord, use a heavy conductor cord of the shortest possible length. See Extension cord recommendations on page 31.

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5 – Troubleshooting and System Tests

Internal compressor LED faults

The internal compressor LED never illuminates by itself. It always illuminates with the



temperature LED.

The internal compressor LED and the temperature LED illuminate while the machine is powered ON and the torch trigger is pulled.

Possible causes Possible solutions

 The internal compressor overheated and

turned off. You may have exceeded the duty cycle for the system. See Understand duty-cycle limitations on page 48.

 Environmental conditions or worn

consumables are adversely affecting the power supply’s performance.

1. Allow the power supply to cool for 4 minutes. Leave the system on to allow the fan to cool the power supply. Then try to produce an arc by pulling the torch trigger.

When the internal compressor overheats, the compressor turns off, and the compressor and temperature LEDs remain illuminated for 4 minutes.

The system does not prevent you from firing the torch before the 4 minutes elapses. However, if you begin cutting before the compressor has time to fully cool down, the same fault is likely to occur again.

If the fault LEDs persist, continue with the following troubleshooting steps in the order listed.

2. Make sure the louvers in the cover are not blocked. Blocking the louvers in the cover can prevent proper air circulation needed to cool internal components.

3. Place the power supply right-side up on a level surface. Do NOT lay the power supply on its side. Laying the power supply on its side can cause the air filter to divert air away from the torch.

4. Inspect and replace the consumables if they are worn or damaged. Always replace the nozzle and electrode together.

5. Was the system stored in temperatures below freezing? If so, ice might have formed in the air-flow system inside the power supply. Move the power supply to a warmer location to allow the ice to melt.

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The internal compressor LED and the temperature LED illuminate while the machine is powered ON and the torch trigger is pulled.

Possible causes Possible solutions

 The air inlet filter on the internal compressor

is completely clogged.

For the compressor’s air inlet filter to

6. Replace the compressor’s air inlet filter. See

Replace the air inlet filter in the internal compressor on page 172.

trigger this LED fault, the filter would have to be so blocked that no air can flow through it.

 One of the following internal components is

faulty and needs to be replaced:

 Internal compressor

 Compressor-driver board

 Power board

7. Systematically check the internal compressor, the compressor-driver board, and the power board to determine which component needs to be replaced. Perform Test 9 – internal compressor, compressor-driver board, and power board on page 94.

The internal compressor LED and the temperature LED blink alternately when the machine is powered ON.

Possible causes Possible solutions

 The system was powered on with the torch

trigger being pulled.

 The start circuit is stuck closed.

 Release the torch trigger and reset the

system by turning it OFF (O) and then turning it ON (I) again. The system automatically disables itself when the power supply is turned on while the torch trigger is pulled.

 Perform Test 6 – plasma start on page 90.

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5 – Troubleshooting and System Tests

Torch cap LED faults

The torch cap LED illuminates while the machine is powered ON.

Possible causes Possible solutions

 The cap-sensing circuit is open due to:

 The consumables are loose,

incorrectly installed, or missing.

 The cap-sensor switch, torch

 Make sure the consumables are installed

correctly.

 Perform Test 7 – torch cap-sensor on

page 92.

lead, or torch body is faulty.

The torch cap LED blinks while the machine is powered ON.

Possible causes Possible solutions

 The consumables are stuck in an open or

closed position because they are installed incorrectly, worn, or damaged.

 The nozzle and electrode are not touching

when the torch trigger is pulled. The torch plunger is stuck.

 The torch or torch lead has a broken or

short-circuited wire.

 Inspect the torch lead. If it is twisted or

kinked, straighten it out and try to fire the torch again.

 Make sure the consumables are installed

correctly. See Step 1 – Install the consumables on page 43.

 Inspect the consumables for wear, and

replace if necessary. Always replace the nozzle and electrode together.

 Perform Test 5 – torch stuck open or torch

stuck closed on page 88.

The internal compressor, temperature, and power ON LEDs blink, and the torch cap LED illuminates.

Possible causes Possible solutions

 The torch was repeatedly fired with worn out

consumables.

 The inverter is saturated (is in an

over-current condition).

 Install new consumables in the torch (they

may be corroded or approaching end of life).

 If you continue to see this error, replace the

power board. See Replace the power board on page 133.

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Common cutting issues

Problem Possible causes Possible solutions

When you pull the torch trigger:

• Gas flows from the torch, but the torch does not fire or fires only for a short period of time.

• The pilot arc starts but then extinguishes before the normal 5-second timeout period.

The arc goes out during cutting or intermittently will not fire.

The pilot arc extinguishes when you move the plasma arc off the workpiece while still pulling the torch trigger.

• The consumables are worn or damaged.

• The torch or torch lead is damaged.

• The air filter element is dirty.

• There is a voltage imbalance on the power board. The power board may be faulty.

• The work lead connection is poor. The work lead may be damaged or not properly connected to the workpiece.

• The consumables are worn or damaged.

• The system is connected to a generator and is running on low input voltage (for example, less than 100 V ).

• The continuous pilot arc is not functioning correctly. The power board may be faulty.

• Inspect the consumables, torch, and torch lead, and replace if necessary.

• Inspect the air filter element, and replace if necessary. See Replace the air filter bowl and air filter element on page 158.

•Perform Test 3 – VBUS and voltage balance on power board on page 84.

• Inspect for loose connections at the ground clamp and at the power supply, and repair if necessary.

• Reposition the work lead on the workpiece.

• Clean the cutting surface to make a better connection with the work lead.

• Inspect the consumables and replace if necessary.

• If you use a generator, make sure it is properly rated for this system. See Generator recommendations on page 31.

•Perform Test 2 – power bo ard v ol tag e

checks on page 82 and Test 3 – VBUS and voltage balance on power board on page 84.

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5 – Troubleshooting and System Tests

Problem Possible causes Possible solutions

Moisture exits the torch nozzle.

• A small amount of moisture at

the torch nozzle is normal for this system, particularly in very

humid environments.

• A larger amount of moisture at the torch nozzle may indicate that the air filter is not properly removing moisture from the system.

• A small amount of moisture should not prevent the torch from firing or degrade cut quality or performance.

• In case of excess moisture, examine the air filter inside the power supply. It

is normal to see water in the filter bowl. The filter purges water

when the water level in the bowl is high enough to engage the float mechanism. If the water level in the filter bowl is approximately half full (or more), the air filter may not be purging water properly.

• Make sure the drain hose connected to the bottom of the air filter bowl is not twisted or clogged.

• Water purged from the air filter exits through a hole in bottom of the of the power supply. Make sure this hole is not blocked.

• Replace the air filter bowl. See

Replace the air filter bowl and air filter element on page 158.

• If the problem persists, replace the whole air filter assembly. See Replace the air filter assembly on page 155.

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5 – Troubleshooting and System Tests

Problem Possible causes Possible solutions

The arc blows out but re-ignites when the torch trigger is pulled again, or the arc sputters and hisses.

• Too much moisture is present in the consumables.

• The consumables are worn or damaged.

• Inspect the consumables for signs of

excess moisture. A small amount of

moisture at the torch nozzle is normal for this system and should not prevent the torch from firing. If excess moisture is

present, fire the torch approximately 5 times in succession. Fire the torch in the air, not on the workpiece.

• If the problem persists and excess moisture is not an issue, inspect and replace the consumable parts if they are worn or damaged.

• If firing the torch does not clear out the excess moisture, examine the air filter inside the power supply. It is

normal to see water in the filter bowl. The filter purges water when

the water level in the bowl is high enough to engage the float mechanism. If the water level in the filter bowl is approximately half full (or more), the air filter may not be purging water properly.

• Make sure the drain hose connected to the bottom of the air filter bowl is not twisted or clogged.

• Water purged from the air filter exits through a hole in bottom of the of the power supply. Make sure this hole is not blocked.

• Replace the air filter bowl. See

Replace the air filter bowl and air filter element on page 158.

• If the problem persists, replace the whole air filter assembly. See Replace the air filter assembly on page 155.

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5 – Troubleshooting and System Tests

Problem Possible causes Possible solutions

The cut quality is poor, or the cut does not sever the metal.

• The consumables are worn or damaged.

• The work lead connection is poor. The work lead may be damaged or not properly connected to the workpiece.

• The amperage adjustment knob is set too low.

• The air pressure to the torch is too low.

• The power board is producing low current and may be faulty.

• The extension cord is too long, is damaged, or is not capable of delivering sufficient power to the power supply.

• Inspect the consumables and replace if necessary.

• Reposition the work lead on the workpiece.

• Clean the workpiece surface to make a better connection with the work lead.

• Inspect the work lead and replace if necessary.

• If your input circuit is capable, turn the amperage adjustment knob to a higher setting.

• Check the gas supply line for leaks or defective parts. Perform Test 10 – check air pressure on page 99.

•Perform Test 2 – power bo ard v ol tag e

checks on page 82 and Test 3 – VBUS and voltage balance on power board on page 84.

• Operate the system without using an extension cord. If you must use an extension cord, use a heavy conductor cord of the shortest possible length. See Extension cord recommendations on page 31.

The circuit breaker trips frequently while you are cutting.

• The amperage adjustment knob is set too high for the input circuit.

• The wrong consumables are being used.

• The input circuit is not delivering sufficient power to the power supply.

• The operator is stretching the arc by holding the torch too far from the workpiece when cutting.

• The extension cord is too long, is damaged, or is not capable of delivering sufficient power to the power supply.

• Turn down the cutting current. See Step 3 – Adjust the output current on page 45.

• Make sure the correct consumables are installed for this power supply and torch. See Consumable use on page 35.

• Operate the system on a 240 VAC input circuit whenever possible.

• Avoid stretching the arc. Drag the torch on the workpiece. See Edge start on a workpiece on page 52.

• Operate the system without using an extension cord. If you must use an extension cord, use a heavy conductor cord of the shortest possible length. See Extension cord recommendations on page 31.

• Make sure nothing else is drawing power on the same circuit.

72 Powermax30 AIR Service Manual 808850

Control board LEDs

Control board

Ribbon cable

The control board (PCB1) is located inside of the front panel.

Figure 3

5 – Troubleshooting and System Tests

The control board has four diagnostic LEDs:

 Reset – This LED illuminates when certain voltage readings to the power board are out of range. See Reset LED on

page 74.

 Error – This LED illuminates when the internal compressor, torch cap, or temperature LEDs on the front of the power

supply illuminate. If all four LEDs on the front of the power supply are blinking, the Error LED also blinks. The number of blinks between pauses indicates which component may have failed.

 Transfer – This LED illuminates when there is proper arc transfer between the torch and the workpiece, and blinks

during continuous pilot arc operation (such as when cutting expanded metal or moving the arc off the plate and then back on).

 Start – This LED illuminates when the power supply receives a start signal and remains illuminated during normal

operation.

Powermax30 AIR Service Manual 808850 73

5 – Troubleshooting and System Tests

Reset

Error

Transfer (XFR)

Start

Ribbon cable

Figure 4

During normal operation, the power-ON LED on the front of the power supply and the Start and Transfer LEDs on the control board illuminate. When a problem occurs with the system, one or more of the fault LEDs on the front of the power supply and the Error LED or the Reset LED on the control board may illuminate or blink.

Use the control board Reset and Error LEDs to troubleshoot

The Reset and Error LEDs provide information to use when troubleshooting a system failure. If the LEDs on the front of the power supply are blinking, count the number of times the Error LED blinks. Then, look at Ta ble 5 on page 75 to determine the corrective action.

Reset LED

When the control board’s Reset LED illuminates, the voltages on the power board may be incorrect. Perform the following tests at J7 on the power board. See Test 2 – power board voltage checks on page 82.

 Test pin 5 to ground for 3.3 VDC (±10%).

 Test pin 7 to ground for 5 VDC (±10%).

 Test pin 12 to ground for 2.2 VDC (±10%).

If the values you find are not within ±10% of the three values listed above, 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. See Replace the control board on page 124 or Replace the power board on page 133.

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5 – Troubleshooting and System Tests

Error LED

The number of times the Error LED blinks indicates the problem detected. Each blink is a half-second long, and each series of blinks is separated by a 2-second pause. See System tests (below) for detailed test procedures.

Table 5

Number of blinks

3 Faulty power board or

4 Faulty fan, solenoid valve, or

6 Inverter saturation • Install new consumables in the torch. If you continue to see this error

Problem Solution

•Perform Test 3 – VBUS and voltage balance on power board on

control board

power board

page 84. If any of the values are incorrect, replace the power board.

•Perform Test 2 – power board voltage checks on page 82. If any of the values for pins 5, 7, or 12 are incorrect, remove the control board and test again. If the values are correct, replace the control board.

• If the values for pins 5, 7, or 12 are correct when you perform Test 2 – power board voltage checks on page 82 but any other values from Test 2 are incorrect, replace the power board.

•Perform Test 4 – solenoid valve on page 87 and Test 8 – fan on page 93. If the solenoid valve test and the fan test both pass, replace the power board. If Test 4 fails, replace the solenoid valve; if Test 8 fails, replace the fan.

code, replace the power board.

System tests

You can use either the ground clip near the top of the rear panel or the ground screw on the heatsink (marked by the ground symbol on the power board) for any tests that require the multimeter to be attached to ground.

Figure 5 – Grounding options

Powermax30 AIR Service Manual 808850 75

5 – Troubleshooting and System Tests

WORK LEAD (BLK)

AC AC

TORCH START

BLK

TORCH START

8 9

Retaining screw (2)

Heatsink assembly screw (4)

Torch start and cap-sensor (J12)

J13

J14

J15

Work lead connector (J22)

J21

J20

J19

J18

Input diode bridge screws (2)

IGBT screws (3)

Figure 6 – Back of the power board

76 Powermax30 AIR Service Manual 808850

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 before performing any tests.

WARNING!

5 – Troubleshooting and System Tests

5 5 5

Input diode bridges

Capacitors

J17 (white)

J16 (red)

IGBTs

J12 (torch-start, cap-sensor switch connector)

Snubber resistor

Ribbon cable connector (J7) from control board

375 VDC bus voltage to compressor-driver board

Figure 7 – Component side of the power board

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5 – Troubleshooting and System Tests

Compressor-driver board

MOSFET

Diode

Figure 8 – Back of the compressor-driver board

78 Powermax30 AIR Service Manual 808850

5 – Troubleshooting and System Tests

Retaining screw (3)

Diagnostic LED (D5)

Figure 9 – Component side of the compressor-driver board

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5 – Troubleshooting and System Tests

Test 1 – voltage input

Check the incoming voltage and the line voltage to the top of the power switch (S1).

1. Set power switch to OFF (O), and disconnect the power cord from the power source.

2. Remove the power supply handle and cover. See Remove the power supply cover on page 104.

3. Remove the component barrier. See Remove the component barrier on page 106.

4. Partially pull the power switch’s top two wires out from the tabs and attach the multimeter test leads to the tabs to

check the AC voltage. See Figure 10 on page 81.

WARNING!

ELECTRIC SHOCK CAN KILL

Use extreme caution when working near live electrical circuits. Dangerous voltages exist inside the power supply that can cause serious injury or death.

See the WARNING! on page 57 before proceeding.

5. Once you have the test leads in place, leave the power switch set to OFF (O), and reconnect the electrical power.

The voltage should equal the line voltage of the incoming circuit, for example 120 V or 240 V.

All values can be ±15%.



80 Powermax30 AIR Service Manual 808850

Figure 10

WORK LEAD (BLK)

AC AC

TORCH START

BLK

TORCH START

J1, J2 (AC)

5 – Troubleshooting and System Tests

Single phase power supplies

Designator CSA wire colors CE/CCC wire colors

L (live) Black Brown

N (neutral) White Blue

PE (ground) Green Green/yellow

6. If the AC voltage is incorrect, make sure you have power to the unit. If you do have power, inspect the power cord for damage, and replace if necessary. See Replace the power cord and strain relief on page 113.

7. If the power source and power cord are functioning correctly, disconnect the power cord again and reconnect the two wires to the power switch.

8. Reconnect the electrical power and set the power switch to ON (I).

9. Measure the AC voltage from J1 to J2 (labeled “AC” on the back of the power board). This value should be the same

as the incoming line voltage. If it is not, check the power switch and replace if necessary. See Replace the power switch on page 122.

Figure 11

10. If the power-ON LED is still illuminated, perform Test 2 – power board voltage checks on page 82.

Powermax30 AIR Service Manual 808850 81

5 – Troubleshooting and System Tests

WORK LEAD (BLK)

AC AC

TORCH START

BLK

TORCH START

Test 2 – power board voltage checks

1. Set the power switch to OFF (O), and disconnect the power cord from the power source.

2. Remove the power supply handle and cover. See Remove the power supply cover on page 104.

3. Remove the component barrier. See Remove the component barrier on page 106.

WARNING!

ELECTRIC SHOCK CAN KILL

Use extreme caution when working near live electrical circuits. Dangerous voltages exist inside the power supply that can cause serious injury or death.

See the WARNING! on page 57 before proceeding.

4. Reconnect the electrical power and set the power switch to ON (I).

5. Use a multimeter to verify the voltages at the J7 pins listed in Ta bl e 6 on page 83 to make sure the power board

(PCB2) is functioning correctly. If any of the values are incorrect, replace the power board. See Replace the power board on page 133.

Figure 12

To test the values at pin 16, you must position the torch and power supply so that you can



safely pull and release the torch trigger. For ground locations, see Figure 5 on page 75.

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5 – Troubleshooting and System Tests

CAUTION!

Do not use -VBUS (test point W) as ground. Doing so could destroy the power supply. Instead ground to either the ground wire clip on the rear panel or to the heatsink. See Figure 5 on page 75.

Table 6

J7 pin number to

ground

19 VACR (rectified AC line voltage) 0.86 V at 120 line voltage

21 VBUS (DC bus voltage) 2.28 VDC at 375 VBUS

18 IPFC (input current) <0.1 VDC

20 IFB (output current) <0.1 VDC

22 ITF (transfer current) <0.1 VDC

5 3.3 VDC 3.3 VDC ±10%

7 5 VDC 5 VDC ±10%

12 24 V sense pin 2.2 VDC ±10%

16 Start signal 3.2 VDC closed

All values can be ±10%.



Test Expected value

1.87 V at 230 line voltage

0 VDC open

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5 – Troubleshooting and System Tests

Test 3 – VBUS and voltage balance on power board

Test the power board (PCB2) to make sure the circuits are balanced. The test points are labeled on the back of the power board, as are the voltages and positive and negative capacitor terminals. See Figure 13 on page 86 for locations of test points.

1. Set the power switch to OFF (O), and disconnect the power cord from the power source.

2. Remove the power supply handle and cover. See Remove the power supply cover on page 104.

3. Remove the component barrier. See Remove the component barrier on page 106.)

WARNING!

ELECTRIC SHOCK CAN KILL

Use extreme caution when working near live electrical circuits. Dangerous voltages exist inside the power supply that can cause serious injury or death.

See the WARNING! on page 57 before proceeding.

4. Reconnect the electrical power.

5. Use Tabl e 7 to identify how to attach to the test points on the power board based on the power board design in your

system. The test points are labeled R, W, and B on all power boards.

CAUTION!

Use only the test point types identified in Table 7. Follow the instructions in this procedure to correctly attach to the test point openings in the power board.

Do not use a multimeter with standard test leads for this test. This can cause a short-circuit between the BUS and the heatsink.

Do not use -VBUS (test point W) as ground. Doing so could destroy the power supply.

84 Powermax30 AIR Service Manual 808850

Table7–Identify test point type on power board

5 – Troubleshooting and System Tests

Current power board design

(CSA models: revision E and later)

(CE/CCC models: revision D and later)

Prior power board design

(CSA models: revision D and earlier)

(CE/CCC models: revision C and earlier)

Each test point lined with copper ring No metal ring around test points

Use miniature banana plugs*

(Pamona

2945 plugs or similar) Use test hooks

* If miniature banana plugs are not available, use small test clips that you can attach to the copper contacts in the test point

openings on the power board.

6. Measure the voltage from W to R. See Figure 13. a. Position the banana plugs or test hooks at W and R on the power board. b. Turn the power ON (I).

c. The multimeter should read 375 VDC.

If you get a value other than 375 VDC, multiply the reading by 0.00601 to convert it to millivolts. Test pin 21 on J7. See Test 2 – power board voltage checks on page 82. If the values match, it is a normal reading.

7. Measure the voltage from W to B. a. Turn the power OFF (O). b. Move the banana plugs or test hooks to W and B. c. Turn the power ON (I).

d. This value should be 187.5 VDC or one-half of the value found in step 6.

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5 – Troubleshooting and System Tests

WORK LEAD (BLK)

BLK

TORCH START

AC AC

step 8

step 7

step 6

8. Measure the voltage from R to B. a. Turn the power OFF (O). b. Move the banana plugs or test hooks to R and B.

c. Turn the power ON (I).

d. This value should be 187.5 VDC or one-half of the value found in step 6.

9. The values found in step 7 and step 8 should be approximately equal. If they differ by more than 30 V, replace the

power board.

Figure 13

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5 – Troubleshooting and System Tests

Test 4 – solenoid valve

This test verifies the proper operation of the solenoid valve (V1).

1. Set the power switch to OFF (O), and disconnect the power cord from the power source.

2. Remove the power supply handle and cover. See Remove the power supply cover on page 104.

3. Remove the component barrier. See Remove the component barrier on page 106.

WARNING!

ELECTRIC SHOCK CAN KILL

Use extreme caution when working near live electrical circuits. Dangerous voltages exist inside the power supply that can cause serious injury or death.

See the WARNING! on page 57 before proceeding.

4. Reconnect the electrical power.

5. Place a jumper from pin 2 of J6 (black wire) on the power board to ground. See Figure 5 on page 75 for grounding

options.

Figure 14

6. Turn the power ON (I). The valve should click.

7. Remove the valve’s connector from J6 on the power board.

8. Measure the voltage between pin 1 of J6 (red wire) and ground.

9. If you do not hear the valve click and the voltage check reads 24 VDC, replace the solenoid valve. See Replace the

solenoid valve on page 149.

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5 – Troubleshooting and System Tests

Test 5 – torch stuck open or torch stuck closed

If the nozzle and electrode are not in contact before the torch trigger is pulled, the power supply detects a “torch stuck open” fault. If the nozzle and electrode remain in contact after the torch trigger is pulled, the power supply detects a “torch stuck closed” fault.

Use the following test to determine if the torch is stuck in either position.

1. Set the power switch to OFF (O), and disconnect the power cord from the power source.

2. Remove the power supply handle and cover. See Remove the power supply cover on page 104.

3. Remove the component barrier. See Remove the component barrier on page 106.

4. Measure the resistance between the torch lead’s white wire group and red wire . The resistance should read

very low, a closed circuit.

 If the resistance reads as open with the power OFF, the nozzle and electrode are not in contact, or one of the

wires in the lead is broken. Make sure that the torch plunger moves freely in the torch head.

Figure 15

The front panel is hidden in this figure to better show the torch lead and wires.



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5 – Troubleshooting and System Tests

CAUTION!

To avoid causing a short or damage to the multimeter, do not fire the torch with the multimeter connected to the torch lead’s white wire group and red wire while the system is powered ON.

5. Turn ON (I) the power. With the system idle, quickly tap the torch trigger to force gas flow without firing an arc. Is gas

flowing?

 If yes, the gas will flow for 5 seconds before shutting off. While the gas is flowing, measure the resistance

between the torch lead’s white wire group and red wire . The resistance should read very high – an open circuit – when gas is flowing.

If the resistance reads as very low (closed circuit) with the gas flowing, the nozzle and electrode are in contact or a short-circuit occurred in one of the wires in the torch lead. Continue with step 6.

 If no, the solenoid valve may be faulty. Perform Test 4 – solenoid valve on page 87.

6. Does the torch plunger move freely in the torch head?

 If yes, replace the torch lead. See Replace the torch lead on page 203.

 If no, replace the torch body. See Replace the torch body on page 199.

7. Because “torch stuck open” and “torch stuck closed” failures can be intermittent, repeat the test several times.

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5 – Troubleshooting and System Tests

Test 6 – plasma start

Use this test to make sure the control board LED is receiving a valid start signal.

1. Set the power switch to OFF (O), and disconnect the power cord from the power source.

2. Remove the power supply handle and cover. See Remove the power supply cover on page 104.

3. Remove the component barrier. See Remove the component barrier on page 106.

WARNING!

While testing, do not touch the nozzle at the end of the torch. Dangerous voltages can cause serious injury.

WARNING!

ELECTRIC SHOCK CAN KILL

Use extreme caution when working near live electrical circuits. Dangerous voltages exist inside the power supply that can cause serious injury or death.

See the WARNING! on page 57 before proceeding.

4. Reconnect the electrical power and turn the power ON (I).

5. Quickly tap the torch trigger to force gas flow without firing an arc, and watch the Start LED on the control board.

The Start LED should illuminate whenever the trigger is pulled. See Control board LEDs on page 73 for the location of the Start LED.

6. Turn OFF (O) the power.

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5 – Troubleshooting and System Tests

WORK LEAD (BLK)

AC AC

TORCH START

BLK

TORCH START

7. Check the resistance at the 2 torch-start test points on the power board. See Figure 16.

a. With the trigger pulled, the resistance should read 10 Ω or less.

b. With the trigger released, the circuit should read approximately 3 kΩ.

Figure 16

8. If this test fails, check the torch start switch and the torch wires. Replace if necessary. See Replace the start switch

on page 201 or Replace the torch lead and strain relief on page 151.

9. Turn ON (I) the power.

10. Measure pin 16 of J7 to ground. See Test 2 – power board voltage checks on page 82.

a. With the trigger pulled, it should measure as 0 VDC for an open circuit.

b. With the trigger released, it should measure 3.2 VDC for a closed circuit.

11 . Are the values correct?

 If yes, replace the control board. See Replace the control board on page 124.

 If no, replace the power board. See Replace the power board on page 133.

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5 – Troubleshooting and System Tests

Push tab toward plug

Test 7 – torch cap-sensor

Test the torch cap-sensor switch and torch leads.

1. Set the power switch to OFF (O), and disconnect the power cord from the power source.

2. Remove the power supply handle and cover. See Remove the power supply cover on page 104.

3. Remove the component barrier. See Remove the component barrier on page 106.

4. Detach the front panel. See Detach the front panel on page 108.

5. Disconnect the cap-sensor connector at J12 on the heatsink side of the power board by pushing the tab on the

connector toward the plug and pulling the plug out.

Figure 17

6. Measure the resistance from the blue wire (pin 1)

to the orange wire (pin 2) . It should measure less than 10 Ω. If it measures high resistance, the cap-sensor switch circuit is open.

7. Make sure the torch plunger moves smoothly. If it does not, replace the torch body. See Replace the torch body on page 199.

8. Make sure the consumables are correctly installed. Adjust the consumables if necessary.

9. If the torch parts mentioned in step 7 and step 8 are working properly, the cap-sensor switch is faulty or the torch lead has a broken wire. Replace the faulty part. See Replace the cap-sensor switch on page 202 or Replace the torch lead and strain relief on page 151.

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5 – Troubleshooting and System Tests

Test 8 – fan

Test the fan (M1) for proper operation.

1. Set the power switch to OFF (O), and disconnect the power cord from the power source.

2. Remove the power supply handle and cover. See Remove the power supply cover on page 104.

3. Remove the component barrier. See Remove the component barrier on page 106.

4. Place a jumper from ground (see Figure 5 on page 75 for grounding options) to pin 3 of J5 (black wire, see

Figure 18).

WARNING!

ELECTRIC SHOCK CAN KILL

Use extreme caution when working near live electrical circuits. Dangerous voltages exist inside the power supply that can cause serious injury or death.

See the WARNING! on page 57 before proceeding.

5. Reconnect the electrical power and set the power switch to ON (I).

6. If the fan does not operate, replace the fan. See Replace the fan on page 162.

Figure 18

Because of protection features on the fan driver chip, this test can trigger a fault. You can



disregard this fault if it occurs as a result of a fan test. The purpose of the fan test is to verify that the fan is operating properly, not to test the fan drive circuit.

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5 – Troubleshooting and System Tests

Test 9 – internal compressor, compressor-driver board, and power board

If the internal compressor fault LED and temperature fault LED both illuminate, the root cause may be:

 Faulty internal compressor

 Faulty compressor-driver board (PCB3)

 Faulty power board (PCB2)

Use this test to systematically check each of these 3 components to determine which one needs to be replaced.

For a high-level overview of this procedure, see Process flow for troubleshooting internal



compressor and temperature fault LEDs on page 226.

Turn OFF the power and remove the cover

1. Set the power switch to OFF (O), and disconnect the power cord from the power source.

2. Remove the power supply handle and cover. See Remove the power supply cover on page 104.

3. Remove the component barrier. See Remove the component barrier on page 106.)

WARNING!

ELECTRIC SHOCK CAN KILL

Use extreme caution when working near live electrical circuits. Dangerous voltages exist inside the power supply that can cause serious injury or death.

See the WARNING! on page 57 before proceeding.

Test 9a – Check the diagnostic LED (D5) on the compressor-driver board

4. Reconnect the power cord, and set the power switch to ON (I).

5. Quickly tap the torch trigger to force gas flow

without firing an arc, then watch the green diagnostic LED (D5) on the compressor-driver board. Does the LED illuminate while the torch is being fired?

a. If yes, check the internal compressor. Skip to

step 10.

b. If no, continue with the next step.

The D5 diagnostic LED indicates whether or not



there is 15 VDC output from the compressor-driver board to the internal compressor.

6. Set the power switch to OFF (O).

94 Powermax30 AIR Service Manual 808850

7. Remove the J2 connector from the

234

compressor-driver board.

8. Set the power switch to ON (I).

9. Quickly tap the torch trigger, then watch the green

diagnostic LED (D5) on the compressor-driver board. Does the LED illuminate while the torch is being fired?

a. If yes, check the internal compressor. Continue

with the next step.

b. If no, check the compressor-driver board. Skip to step 16.

Test 9b – Check the internal compressor

5 – Troubleshooting and System Tests

WARNING!

While testing, do not touch the nozzle at the end of the torch. Dangerous voltages can cause serious injury.

WARNING!

HOT SURFACE CAN CAUSE INJURY

Allow the internal compressor to cool before touching it. The surface of the compressor can become very hot during use and can cause serious

injury if it comes in contact with skin.

10. Set the power switch to OFF (O).

11 . On the fan side of the power supply, pull back the clip on the right side of the solenoid valve, and work the valve free

from that clip . Carefully tilt the top of the valve towards you until you can see the gas shut-off override button . See Figure 19.

12. Connect the internal compressor to an external 12 VDC power source (for example, a car battery).

13. Hold down the gas shut-off override button on top of the solenoid valve, then quickly tap the torch trigger. Is the

compressor running, and is air blowing from the torch?

a. If yes, check the compressor-driver board. Continue with the next step.

b. If no, replace the internal compressor. See Replace the internal compressor on page 167. Be sure to push

the solenoid valve back into place between both clips from the center panel.

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5 – Troubleshooting and System Tests

Figure 19

14. Push the solenoid valve back into place between both clips from the center panel.

15. Make sure both of the solenoid valve’s gas supply hoses are connected securely to their fittings.

Test 9c – Check the compressor-driver board

16. Set the power switch to OFF (O).

17. Remove the white cap from the top of the J3 connector on the compressor-driver board. See Figure 20 on

page 97.

You may need to unplug the J3 connector in order to remove the white cap. If you do, plug



the connector back in before continuing with the next step.

WARNING!

ELECTRIC SHOCK CAN KILL

Use extreme caution when working near live electrical circuits. Dangerous voltages exist inside the power supply that can cause serious injury or death.

See the WARNING! on page 57 before proceeding.

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5 – Troubleshooting and System Tests

18. Set the power switch to ON (I).

19. Check VBUS on the red and black wires on the J3 connector (pin 1 and pin 4) . Is VBUS present (nominal

375 VDC bus voltage)?

a. If yes, check the compressor-enable voltage on the compressor-driver board. Skip to step 21.

b. If no, remove the J2 connector from the compressor-driver board. Continue with the next step.

20. Repeat the previous step to check VBUS with J2 disconnected. Is VBUS present (nominal 375 VDC bus voltage)?

a. If yes, check the compressor-enable voltage on the compressor-driver board. Continue with the next step.

b. If no, check the power board. Skip to step 23.

21. Quickly tap the torch trigger, then check the compressor-enable voltage on the J1 connector on the

compressor-driver board. (The J1 connector may look different from the one shown in Figure 20.) Is compressor-enable voltage present (3 VDC)?

a. If yes, replace the compressor-driver board. See Replace the compressor-driver board on page 127.

b. If no, check the twisted pair wires that connect the compressor-driver board to the power board. Continue with

the next step.

22. Quickly tap the torch trigger, then check the compressor-enable voltage on the J9 connector on the power board.

(The J9 connector may look different from the one shown in Figure 20.) Is compressor-enable voltage present (3 VDC)?

a. If yes, replace the J1-to-J9 twisted pair wires. See Replace the wire group on page 144.

b. If no, check the power board. Continue with the next step.

Figure 20

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5 – Troubleshooting and System Tests

Test 9d – Check the power board

23. Set the power switch to OFF (O).

24. Remove the J1 and J3 connectors from the compressor-driver board. This isolates the power board.

25. Set the power switch to ON (I).

26. Check VBUS on the power board (nominal 375 VDC bus voltage) .

27. Quickly tap the torch trigger, then check compressor-enable voltage at J9 on the power board (3 VDC) .

Figure 21

28. Are VBUS and compressor-enable voltage present on the power board?

a. If VBUS and compressor-enable voltage are both present on the power board, replace the

compressor-driver board. See Replace the compressor-driver board on page 127.

b. If neither VBUS nor compressor-enable voltage are present on the power board, replace the power board.

See Replace the power board on page 133.

c. If VBUS or compressor-enable voltage is present on the power board but the other is not, replace the power

board. See Replace the power board on page 133.

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5 – Troubleshooting and System Tests

Kit 428643

Torch O-ring

Test 10 – check air pressure

Use this test to determine if low air pressure is affecting system performance.

Tools required

 Air pressure test gauge kit (428643)

 Leak detector solution (for example, Snoop

a mixture of gentle soap and water

 Silicone lubricant (027055)

 Multimeter

 Assorted Phillips

and TORX® screwdrivers

Troubleshooting steps

1. Set the power switch to OFF (O), and disconnect

the power cord from the power source.

2. Check the O-ring on the torch head.

) or

 If the torch O-ring is dry, apply a thin film of silicone lubricant (027055) on

the O-ring and the threads. The O-ring should look shiny, but there should not be any excess or built-up lubricant.

 If the O-ring is cracked or worn, replace it (428179).

3. Install new consumables. Make sure they are the correct consumables for this system and torch and that they are installed correctly. See page 43.

4. Remove the power supply handle and cover. See page 104.

5. Make sure the heat exchange coil is fully seated in the 90° fitting on

the air filter.

6. Make sure the 90° fitting is fully seated on the brass gas supply fitting from the torch lead.

7. Examine the 2 gas supply hoses that connect to the solenoid valve. Make sure the hoses are fully seated in each 90° fitting. If the hoses are kinked or damaged, replace them. See page 140.

Powermax30 AIR Service Manual 808850 99

5 – Troubleshooting and System Tests

224

8. Connect the air pressure test gauge kit (428643) inside the power supply as shown in Figure 22:

a. From the fan side of the power supply, push-to-release the 90° fitting from the torch lead gas supply fitting.

b. Push-to-connect the 90° fitting onto the short tube of the pressure test gauge assembly .

c. Push-to-connect the 90° fitting from the pressure test gauge onto the torch lead gas supply fitting.

Figure 22 – Pressure test gauge connected to power supply

WARNING!

ELECTRIC SHOCK CAN KILL

Use extreme caution when working near live electrical circuits. Dangerous voltages exist inside the power supply that can cause serious injury or death.

While testing, do not touch the nozzle at the end of the torch. Dangerous voltages can cause serious injury.

See the WARN ING! on page 57 before proceeding.

9. Reconnect the power cord, and set the power switch to ON (I).

10. Set the cutting current (amperage) as follows:

 22 A for 120 V electrical service

 30 A for 240 V electrical service

100 Powermax30 AIR Service Manual 808850

Hypertherm Manual Family Service Manual (SM)

Specifications and Main Features

Frequently Asked Questions

User Manual

Contents

Electromagnetic Compatibility (EMC)

Introduction

Installation and use

Methods of reducing emissions

Mains supply

Maintenance of cutting equipment

Cutting cables

Assessment of area

Equipotential bonding

Earthing of the workpiece

Screening and shielding

Warranty

Attention

General

Patent indemnity

Limitation of liability

National and local codes

Liability cap

Insurance

Transfer of rights

Waterjet product warranty coverage

Product Parts coverage

Specifications

Safety information

System description

Power supply dimensions

System weights

Hypertherm system ratings

Disconnect the internal compressor

Torch dimensions

Torch weight

Cutting specifications

IEC symbols

Noise levels

Critical raw materials

Symbols and marks

Power Supply Setup

Unpack the plasma system

Claims

System contents

Position the plasma cutting system

Prepare the electrical power

Voltage configurations

Requirements for grounding

Power cord considerations

CSA power cords and plugs

CE and CCC power cords

Install a plug on the power cord

Extension cord recommendations

Generator recommendations

Torch Setup

Introduction

Hand torch components

Consumable life

Consumable use

Using the cut charts

Consumable set

240V/30A cutting

120 V / 20 A cutting

Controls and indicators

Rear controls

Operation

Front panel controls and indicator LED symbols

Operate the plasma system

Step 1 – Install the consumables

Step 2 – Connect the electrical power

Step 3 – Adjust the output current

Operating the system on a 120 V / 20 A circuit

Operating the system on a 240 V / 20 A circuit

Decrease output current for lower-rated power plugs

Cutting expanded metal

Step 4 – Attach the ground clamp

Step 5 – Power ON the system

Step 6 – Check the indicator LEDs

Step 7 – Make sure the system is ready, and start cutting