Hypertherm Powermax30 Troubleshooting

Plasma arc cutting system

Operator Manual – 805160 Revision 2

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powermax30

Operator Manual

(P/N 805160)

Revision 2 – November 2009

Hypertherm, Inc.

Hanover, NH USA

www.hypertherm.com

email:info@hypertherm.com

Hypertherm and Powermax are trademarks of Hypertherm, Inc.

and may be registered in the United States and/or other countries.

7/1/09

Hypertherm, Inc.

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

800-643-9878 Tel (Technical Service)

technical.service@hypertherm.com (Technical Service Email) 800-737-2978 Tel (Customer Service) customer.service@hypertherm.com (Customer Service Email)

Hypertherm Automation

5 Technology Drive, Suite 300 West Lebanon, NH 03784 USA 603-298-7970 Tel 603-298-7977 Fax

Hypertherm Plasmatechnik GmbH

Technologiepark Hanau Rodenbacher Chaussee 6 D-63457 Hanau-Wolfgang, Deutschland 49 6181 58 2100 Tel 49 6181 58 2134 Fax

49 6181 58 2123 (Technical Service)

Hypertherm (S) Pte Ltd.

82 Genting Lane Media Centre Annexe Block #A01-01 Singapore 349567, Republic of Singapore 65 6841 2489 Tel 65 6841 2490 Fax

65 6841 2489 (Technical Service)

Hypertherm (Shanghai) Trading Co., Ltd.

Unit A, 5th Floor, Careri Building 432 West Huai Hai Road Shanghai, 200052 PR China 86-21 5258 3330/1 Tel 86-21 5258 3332 Fax

Hypertherm Europe B.V.

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

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

Hypertherm Japan Ltd.

801 Samty Will Building 2-40 Miyahara 1-Chome, Yodogawa-ku, Osaka 532-0003, Japan 81 6 6170 2020 Tel 81 6 6170 2015 Fax

Hypertherm Brasil Ltda.

Avenida Doutor Renato de

Andrade Maia 350 Parque Renato Maia CEP 07114-000 Guarulhos, SP Brasil 55 11 2409 2636 Tel 55 11 2408 0462 Fax

Hypertherm México, S.A. de C.V.

Avenida Toluca No. 444, Anexo 1, Colonia Olivar de los Padres Delegación Álvaro Obregón México, D.F. C.P. 01780 52 55 5681 8109 Tel 52 55 5683 2127 Fax

ELECTROMAGNETIC COMPATIBILITY (EMC)

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Hypertherm i

EMC Introduction

Hypertherm’s CE-marked equipment is built in compliance with standard EN60974-10. The equipment should be in stalled and used in accordance with the information be low to achieve elec tro mag net ic com pat i bil i ty.

The limits required by EN60974-10 may not be adequate to com plete ly eliminate in ter fer ence when the affected equip ment is in close proximity or has a high degree of sen si tivity. In such cases it may be nec es sary to use other mea sures to further re duce interference.

This cutting equipment is designed for use only in an in dus tri al environment.

Installation and use

The user is responsible for installing and using the plasma equipment according to the manufacturer’s instructions. If elec tro mag net ic disturbances are de tect ed then it shall be the respon si bil i ty of the user to re solve the situation with the technical as sis tance of the man u fac tur er. In some cases this remedial action may be as sim ple as earthing the cutting circuit, see Earthing of Workpiece. In other cas es it could involve constructing an electromag net ic screen enclosing the pow er source and the work complete with associated input filters. In all cases elec tro mag net ic disturbanc es must be reduced to the point where they are no longer trou ble some.

Assessment of area

Before installing the equipment the user shall make an assessment of po ten tial electro magnet ic problems in the sur round ing area. The following shall be taken into account:

a. Other supply cables, control cables,

signalling and telephone ca bles; above, below and adjacent to the cutting equipment.

b. Radio and television transmitters and

receivers. c. Computer and other control equip ment. d. Safety critical equipment, for example

guarding of industrial equipment. e. Health of the people around, for example the

use of pacemakers and hear ing 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

com pat i ble. This may require ad di tion al

protection measures. h. Time of day that cutting or other ac tiv i ties

are to be carried out.

The size of the sur round ing area to be con sidered will depend on the structure of the building and other activities that are tak ing place. The surrounding area may ex tend beyond the bound aries of the pre mises.

Methods of reducing emissions

Mains supply

Cutting equipment must be con nect ed to the mains supply according to the man u fac tur er’s recom men da tions. If in ter fer ence occurs, it may be necessary to take addi tional precautions such as fil ter ing of the mains supply. Consideration should be given to shield ing the supply cable of per ma nent ly installed cutting equip ment, in metallic conduit or equiv a lent. Shielding should be elec tri cal ly continuous through out its length. The shielding should be con nect ed to the cutting mains supply so that good electrical contact is maintained between the conduit and the cutting pow er source enclosure.

ELECTROMAGNETIC COMPATIBILITY (EMC)

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ii Hypertherm

Maintenance of cutting equipment

The cutting equipment must be rou tine ly maintained according to the man u fac tur er’s recom men da tions. All ac cess and service doors and covers should be closed and properly fastened when the cutting equip ment is in operation. The cutting equipment should not be modified in any way except for those chang es and ad just ments covered in the manufac tur er’s instructions. In par tic u lar, the spark gaps of arc striking and sta bi liz ing devices should be adjusted and maintained according to the manu fac tur er’s recommendations.

Cutting cables

The cutting cables should be kept as short as possible and should be po si tioned 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 com po nents bonded to the workpiece will increase the risk that the op er a tor could receive a shock by touch ing these metallic compo nents and the electrode (nozzle for laser heads) at the same time. The op er a tor should be in su lat ed from all such bonded metallic components.

Earthing of workpiece

Where the workpiece is not bonded to earth for electrical safety, nor connected to earth because of its size and position, for ex am ple, ship’s hull or building steel work, a con nec tion bonding the work piece to earth may reduce emis sions in some, but not all instances. Care should be taken to prevent the earthing of the work piece increasing the risk of injury to users, or damage to other elec tri cal equip ment. Where necessary, the con nec tion of the

workpiece to earth should be made by a direct connection to the work piece, but in some countries where direct connection is not permitted, the bonding should be achieved by suit able capacitances se lect ed 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 com pe tent to assess whether the chang es will in crease the risk of injury, for example, by al low ing parallel cutting cur rent return paths which may damage the earth cir cuits of other equipment. Further guid ance is given in IEC/ TS 62081 Arc Welding Equip ment Installation and Use.

Screening and shielding

Selective screening and shielding of other cables and equipment in the surrounding area may alleviate problems of in ter fer ence. Screening of the entire plas ma cutting installation may be con sid ered for special applications.

WARRANTY

Hypertherm iii

4-08

Attention

Genuine Hypertherm parts are the factoryrecommended replacement parts for your Hypertherm system. Any damage caused by the use of other than genuine Hypertherm parts may not be covered by the Hypertherm warranty.

You are responsible for the safe use of the Product. Hypertherm does not and cannot make any guarantee or warranty regarding the safe use of the Product in your environment.

General

Hypertherm, Inc. warrants that its Products shall be free from defects in materials and workman ship, if Hypertherm is notified of a defect (i) with respect to the power supply within a period of two (2) years from the date of its delivery to you, with the exception of Powermax brand power supplies, which shall be within a period of three (3) years from the date of delivery to you, and (ii) with respect to the torch and leads within a period of one (1) year from its date of delivery to you, and with respect to torch lifter assemblies within a period of one (1) year from its date of delivery to you, and with respect to laser heads within a period of one (1) year from its date of delivery to you. This warranty shall not apply to any Powermax brand power supplies that have been used with phase converters. In addition, Hypertherm does not warranty systems that have been damaged as a result of 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. 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. Hypertherm shall not be liable for any repairs, replacement, or adjustments of Products covered by this war ranty, except those made pursuant to this paragraph or with Hypertherm’s prior written consent. The warranty above is

exclusive and is in lieu of all other warranties, express, implied, statutory, or otherwise with respect to the Products or as to the results which may be obtained therefrom, and all implied war ranties 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.

Certification test marks

Certified products are identified by one or more certification test marks from accredited testing laboratories. The certification test marks are located on or near the data plate. Each certification test mark means that the product and its safety-critical components conform to the relevant national safety standards as reviewed by that testing laboratory. Hypertherm places a certification test mark on its products only after that product is manufactured with safety-critical components that have been authorized by the accredited testing laboratory.

Once the product has left the Hypertherm factory, the certification test marks are invalidated if any of the following occurs:

• The product is significantly modified in a manner that creates a hazard or non-conformance.

• Safety-critical components are replaced with unauthorized spare parts.

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iv Hypertherm

• Any unauthorized assembly or accessory that uses or generates a hazardous voltage is added.

• There is any tampering with a safety circuit or other feature that is designed into the product as part of the certification.

CE marking constitutes a manufacturer’s declaration of conformity to applicable European directives and standards. Only those versions of Hypertherm products with a CE Marking located on or near the data plate have been tested for compliance with the European Low Voltage Directive and the European EMC Directive. EMC filters needed to comply with the European EMC Directive are incorporated within versions of the power supply with a CE Marking.

Differences in National Standards

Differences in standards include, but are not limited to:

• Voltages

• Plug and cord ratings

• Language requirements

• Electromagnetic compatibility requirements

These differences in national standards may make it impossible or impractical for all certification test marks to be placed on the same version of a product. For example, the CSA versions of Hypertherm’s products do not comply with European EMC requirements and they do not have a CE marking on the data plate.

Countries that require CE marking or have compulsory EMC regulations must use CE versions of Hypertherm products with the CE marking on the data plate. These include:

• Australia

• New Zealand

• Countries in the European Union

• Russia

It is important that the product and its certification test mark be suitable for the enduse installation site. When Hypertherm products are shipped to one country for export to another country, the product must be configured and certified properly for the enduse site.

Higher-level systems

When a system integrator adds additional equipment; such as cutting tables, motor drives, motion controllers or robots; to a Hypertherm plasma cutting system, the combined system may be considered a higher-level system. A higher-level system with hazardous moving parts may constitute industrial machinery or robotic equipment, in which case the OEM or end-use customer may be subject to additional regulations and standards than those relevant to the plasma cutting system as manufactured by Hypertherm.

It is the responsibility of the end-use customer and the OEM to perform a risk assessment for the higher-level system and to provide protection against hazardous moving parts. Unless the higher-level system is certified when the OEM incorporates Hypertherm products into it, the installation also may be subject to approval by local authorities. Seek advice from legal counsel and local regulatory experts if uncertain about compliance.

External interconnecting cables between component parts of the higher level system must be suitable for contaminants and movement as required by the final end-use installation site. When the external inter connecting cables are subject to oil, dust, or water contaminants, hard usage ratings may be required. When external interconnecting cables are subject to continuous movement, constant flexing ratings may be required. It is the responsibility of the end-use customer or the OEM to ensure the cables are suitable for the application. Since there are differences in the

TABLE OF CONTENTS

Electromagnetic compatibility................................................................................................................................i

Warranty....................................................................................................................................................................iii

Section 1 Safety

Recognize safety information ...........................................................................................................................1-2

Follow safety instructions..................................................................................................................................1-2

Cutting can cause fire or explosion ................................................................................................................1-2

Electric shock can kill.........................................................................................................................................1-3

Static electricity can damage circuit boards ................................................................................................1-3

Toxic fumes can cause injury or death............................................................................................................1-4

A plasma arc can cause injury and burns......................................................................................................1-5

Arc rays can burn eyes and skin......................................................................................................................1-5

Grounding safety.................................................................................................................................................1-6

Compressed gas equipment safety................................................................................................................1-6

Gas cylinders can explode if damaged..........................................................................................................1-6

Noise can damage hearing ...............................................................................................................................1-7

Pacemaker and hearing aid operation............................................................................................................1-7

A plasma arc can damage frozen pipes.........................................................................................................1-7

Additional safety information.............................................................................................................................1-7

Warning labels.....................................................................................................................................................1-8

Section 1a Sécurité

Identifier les consignes de sécurité..............................................................................................................1a-2

Suivre les instructions de sécurité................................................................................................................1a-2

Danger Avertissement Précaution..............................................................................................................1a-2

Le coupage peut provoquer un incendie ou une explosion....................................................................1a-2

Les chocs électriques peuvent être fatals ..................................................................................................1a-3

Le coupage peut produire des vapeurs toxiques......................................................................................1a-3

L’arc plasma peut provoquer des blessures ou des brûlures.................................................................1a-4

Les rayons de l’arc peuvent brûler les yeux et la peau.............................................................................1a-4

Mise à la masse et à la terre...........................................................................................................................1a-4

Sécurité des bouteilles de gaz comprimé...................................................................................................1a-5

Les bouteilles de gaz comprimé peuvent exploser en cas de dommages..........................................1a-5

Le bruit peut provoquer des problèmes auditifs........................................................................................1a-5

Pacemakers et prothèses auditives..............................................................................................................1a-5

Un arc plasma peut endommager les tuyaux gelés ..................................................................................1a-5

Étiquette de sécurité........................................................................................................................................1a-6

Section 1b Seguridad

Reconocimiento de información de seguridad..........................................................................................1b-2

Siga las instrucciones de seguridad............................................................................................................1b-2

Los cortes pueden provocar incendios o explosiones ............................................................................1b-2

El choque eléctrico puede provocar la muerte..........................................................................................1b-3

Electricidad estática puede dañar tablillas de circuito ............................................................................1b-3

Humos tóxicos pueden causar lesiones o muerte....................................................................................1b-4

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TABLE OF CONTENTS

El arco de plasma puede causar lesiones y quemaduras.......................................................................1b-5

Los rayos del arco pueden producir quemaduras en los ojos y en la piel..........................................1b-5

Seguridad de toma a tierra.............................................................................................................................1b-6

Seguridad de los equipos de gas comprimido..........................................................................................1b-6

Los cilindros de gas pueden explotar si están dañados .........................................................................1b-6

El ruido puede deteriorar la audición ...........................................................................................................1b-7

Operación de marcapasos y de audífonos.................................................................................................1b-7

Un arco plasma puede dañar tubos congelados ......................................................................................1b-7

Etiquetas de advertencia ................................................................................................................................1b-8

Section 2 Specifications

System description.............................................................................................................................................2-2

Power supply dimensions and weight ..........................................................................................................2-2

Power supply ratings..........................................................................................................................................2-3

Torch dimensions ................................................................................................................................................2-4

T30v torch ratings...............................................................................................................................................2-4

Symbols and markings.......................................................................................................................................2-5

mark......................................................................................................................................................2-5

CE mark ......................................................................................................................................................2-5

IEC symbols...............................................................................................................................................2-5

Section 3 Setup

Unpack the Powermax30..................................................................................................................................3-2

Claims .........................................................................................................................................................3-2

Contents.....................................................................................................................................................3-2

Position the power supply.................................................................................................................................3-3

Voltage configurations .......................................................................................................................................3-3

Requirements for grounding.............................................................................................................................3-3

Power cord considerations...............................................................................................................................3-4

Power cord and plugs for CSA power supplies ...............................................................................3-4

Power cord for CE power supplies......................................................................................................3-5

Extension cord recommendations ........................................................................................................3-6

Generator recommendations.................................................................................................................3-6

Gas supply............................................................................................................................................................3-7

Connection.................................................................................................................................................3-7

Additional gas filtration............................................................................................................................3-8

Section 4 Operation

Controls and indicators .....................................................................................................................................4-2

Front controls and LEDs.........................................................................................................................4-2

Rear controls .............................................................................................................................................4-2

Install the consumables .....................................................................................................................................4-3

Attach the work clamp.......................................................................................................................................4-4

Power ON the system........................................................................................................................................4-4

Hand torch operation .........................................................................................................................................4-6

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TABLE OF CONTENTS

Safety trigger operation ..........................................................................................................................4-6

Hand torch cutting hints..........................................................................................................................4-7

To start a cut from the edge of the workpiece...................................................................................4-8

To pierce a workpiece..............................................................................................................................4-9

Cut chart.............................................................................................................................................................4-10

Duty cycle and overheating............................................................................................................................4-11

Common cutting faults....................................................................................................................................4-11

Section 5 Maintenance and parts

Routine maintenance..........................................................................................................................................5-2

Inspect the consumables ..................................................................................................................................5-3

Basic troubleshooting........................................................................................................................................5-4

Repairs...................................................................................................................................................................5-7

Remove and replace the cover and Nomex® barrier.......................................................................5-7

Remove an endcap ..................................................................................................................................5-9

Disconnect the torch lead....................................................................................................................5-11

Replace the work lead ..........................................................................................................................5-13

Replace the power cord (CSA)..........................................................................................................5-15

Replace the power cord (CE) .............................................................................................................5-17

Replace the air filter element...............................................................................................................5-19

Replacement and accessory parts...............................................................................................................5-20

Power cords and adapters...................................................................................................................5-20

Accessory parts......................................................................................................................................5-20

T30v hand torch assembly ..................................................................................................................5-21

Consumables..........................................................................................................................................5-21

Filter regulator.........................................................................................................................................5-22

Work clamp.............................................................................................................................................5-22

Powermax30 labels ...............................................................................................................................5-23

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viii powermax30 Operator Manual

Hypertherm 1-1

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Section 1

SAFETY

In this section: