Hypertherm Powermax30 Service Manual
Powermax30®XP
Plasma Arc Cutting System
Service Manual
808150 | Revision 1 | English
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© 2014 Hypertherm Inc.
Powermax30 XP
Service Manual
808150
Revision 1
English
March 2014
Hypertherm Inc.
Hanover, NH 03755 USA
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)
866-643-7711 Tel (Return Materials Authorization)
877-371-2876 Fax (Return Materials Authorization)
return.materials@hypertherm.com (RMA email)
Hypertherm Plasmatechnik GmbH
Technologiepark Hanau
Rodenbacher Chaussee 6
D-63457 Hanau-Wolfgang, Deutschland
49 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 301, South Building
495 ShangZhong Road
Shanghai, 200231
PR China
86-21-60740003 Tel
86-21-60740393 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.
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
Hypertherm Brasil Ltda.
Rua Bras Cubas, 231 – Jardim Maia
Guarulhos, SP - Brasil
CEP 07115-030
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
Hypertherm Korea Branch
#3904 Centum Leaders Mark B/D,
1514 Woo-dong, Haeundae-gu, Busan
Korea, 612-889
82 51 747 0358 Tel
82 51 701 0358 Fax
Safety information
Before operating any Hypertherm equipment, read the separate Safety and Compliance Manual (80669C) included
with your product for important safety information.
Contents
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-14
Cutting cables .........................................................................................................................................................................SC-14
Equipotential bonding ....................................................................................................................................................SC-14
Earthing of the workpiece .............................................................................................................................................SC-14
Screening and shielding .......................................................................................................................................................SC-14
Warranty .................................................................................................................................. SC-15
Attention ....................................................................................................................................................................................SC-15
General .....................................................................................................................................................................................SC-15
Patent indemnity .....................................................................................................................................................................SC-16
Limitation of liability ................................................................................................................................................................SC-16
National and local codes .......................................................................................................................................................SC-16
Liability cap ..............................................................................................................................................................................SC-16
Insurance ..................................................................................................................................................................................SC-16
Transfer of rights .....................................................................................................................................................................SC-16
1 Specifications .............................................................................................................................. 17
Safety information ......................................................................................................................................................................... 17
System description ....................................................................................................................................................................... 17
Power supply dimensions ........................................................................................................................................................... 18
System weights ............................................................................................................................................................................. 18
Hypertherm system ratings ......................................................................................................................................................... 19
Powermax30 XP Service Manual 808150 Revision 1 7
Contents
Torch dimensions ......................................................................................................................................................................... 20
Torch weight .................................................................................................................................................................................. 20
Cutting specifications .................................................................................................................................................................. 20
Symbols and marks ...................................................................................................................................................................... 21
Noise levels ............................................................................................................................................................................ 22
IEC symbols ........................................................................................................................................................................... 22
2 Power Supply Setup .................................................................................................................. 23
Unpack the Powermax system .................................................................................................................................................. 23
Claims ...................................................................................................................................................................................... 23
System contents ........................................................................................................................................................................... 24
Position the plasma cutting system .......................................................................................................................................... 25
Prepare the electrical power ...................................................................................................................................................... 25
Voltage configurations ......................................................................................................................................................... 25
Requirements for grounding .............................................................................................................................................. 26
Power cord considerations ........................................................................................................................................................ 26
CSA power cords and plugs ............................................................................................................................................. 26
CE and CCC power cords ................................................................................................................................................ 27
Extension cord recommendations ..................................................................................................................................... 28
Generator recommendations ............................................................................................................................................. 28
Prepare the gas supply ............................................................................................................................................................... 29
Connect the gas supply ...................................................................................................................................................... 29
Additional gas filtration ........................................................................................................................................................ 30
3 Torch Setup .................................................................................................................................. 31
Introduction .................................................................................................................................................................................... 31
Hand torch components ..................................................................................................................................................... 31
Consumable life ............................................................................................................................................................................ 32
Choose the consumables ........................................................................................................................................................... 32
Using the cut charts ............................................................................................................................................................. 33
General-purpose (standard) consumables ..................................................................................................................... 34
240 V / 30 A cutting .................................................................................................................................................... 35
FineCut consumables .......................................................................................................................................................... 36
120 V / 25 A cutting .................................................................................................................................................... 37
120 V / 30 A cutting .................................................................................................................................................... 38
8 Powermax30 XP Service Manual 808150 Revision 1
Contents
4 Operation ...................................................................................................................................... 39
Controls and indicators ............................................................................................................................................................... 39
Rear controls .......................................................................................................................................................................... 39
Front controls and LEDs ..................................................................................................................................................... 40
Operate the Powermax30 XP .................................................................................................................................................... 41
Connect the electrical power and gas supply ............................................................................................................... 41
Install the consumables ............................................................................................................................................................... 42
Attach the ground clamp ..................................................................................................................................................... 44
Power ON the system ......................................................................................................................................................... 44
Adjust the gas pressure and output current ................................................................................................................... 44
Operating the system on a 120 V, 15 A circuit ..................................................................................................... 45
Operating the system on a 120 V, 20 A circuit ..................................................................................................... 45
Operating the system on a 240 V, 20 A circuit ..................................................................................................... 45
Check the indicator LEDs ................................................................................................................................................... 46
Verify the system is ready ................................................................................................................................................... 46
Understand duty-cycle limitations ............................................................................................................................................. 46
System operation guidelines ...................................................................................................................................................... 47
Hand torch operation ................................................................................................................................................................... 48
Safety catch operation ......................................................................................................................................................... 48
Hand torch cutting guidelines ............................................................................................................................................ 49
Recommendations for cutting at 120 V ................................................................................................................... 49
Edge start on a workpiece .................................................................................................................................................. 50
Pierce a workpiece ............................................................................................................................................................... 51
Gouge a workpiece .............................................................................................................................................................. 52
Varying the gouge profile ............................................................................................................................................ 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 ...................................................................................................................................................................... 57
Troubleshooting procedures and sequence ................................................................................................................... 57
External inspection ................................................................................................................................................................ 59
Internal inspection ................................................................................................................................................................. 59
Initial resistance check ................................................................................................................................................................ 59
Check the power switch ..................................................................................................................................................... 60
Power supply overview ................................................................................................................................................................ 62
Troubleshooting guide ................................................................................................................................................................. 63
Powermax30 XP Service Manual 808150 Revision 1 9
Contents
Control board LEDs ..................................................................................................................................................................... 69
Use the control board Error and Reset LEDs to troubleshoot ................................................................................... 70
Reset LED ...................................................................................................................................................................... 70
Error LED ........................................................................................................................................................................ 71
System tests .................................................................................................................................................................................. 71
Test 1 – voltage input .......................................................................................................................................................... 74
Test 2 – power board voltage checks ............................................................................................................................. 76
Test 3 – VBUS and voltage balance ................................................................................................................................ 78
Test 4 – solenoid valve ........................................................................................................................................................ 80
Test 5 – torch stuck open or torch stuck closed .......................................................................................................... 81
Test 6 – plasma start ........................................................................................................................................................... 82
Test 7 – torch cap-sensor .................................................................................................................................................. 84
Test 8 – fan ............................................................................................................................................................................ 85
Test 9 – pressure switch .................................................................................................................................................... 86
6 Power Supply Component Replacement ............................................................................. 87
Disconnect the power and gas supply .................................................................................................................................... 87
Replacing the power supply cover ........................................................................................................................................... 88
Replacing the component barrier ............................................................................................................................................. 90
Detaching and reattaching the front panel ............................................................................................................................. 92
Detaching and reattaching the rear panel .............................................................................................................................. 95
Replacing the power cord and strain relief ............................................................................................................................. 98
Replacing the power switch .................................................................................................................................................... 105
Replacing the control board .................................................................................................................................................... 107
Replacing the power board ...................................................................................................................................................... 109
Replacing the fan ........................................................................................................................................................................ 116
Replacing the drain hose, gas supply hoses, and 90° fitting ........................................................................................... 119
Replacing the wire group ......................................................................................................................................................... 123
Replacing the solenoid valve ................................................................................................................................................... 130
Replacing the torch lead and strain relief ............................................................................................................................. 133
Replacing the pressure switch ................................................................................................................................................ 139
Replacing the air filter/regulator and pressure switch assembly ..................................................................................... 141
Replacing the air inlet fittings .................................................................................................................................................. 146
Replacing the air filter bowl and air filter element ............................................................................................................... 148
Replacing the front panel .......................................................................................................................................................... 152
Replacing the rear panel ........................................................................................................................................................... 156
Replacing the base .................................................................................................................................................................... 160
Replacing the magnetics assembly ........................................................................................................................................ 162
Replacing the work lead and ground clamp ......................................................................................................................... 167
10 Powermax30 XP Service Manual 808150 Revision 1
Contents
7 Torch Component Replacement .......................................................................................... 171
Disconnect the power, gas supply, and torch ..................................................................................................................... 172
Replacing the handle ................................................................................................................................................................. 173
Replacing the trigger assembly ............................................................................................................................................... 177
Replacing the torch body .......................................................................................................................................................... 178
Replacing the start switch ........................................................................................................................................................ 180
Replacing the cap-sensor switch ........................................................................................................................................... 181
Replacing the torch lead ........................................................................................................................................................... 182
8 Parts ............................................................................................................................................. 185
Power supply parts ..................................................................................................................................................................... 186
Exterior, front ........................................................................................................................................................................ 186
Exterior, rear ......................................................................................................................................................................... 187
Interior, power board side ................................................................................................................................................. 188
Control board and power switch .................................................................................................................................... 189
Interior, fan side ................................................................................................................................................................... 190
Air filter/regulator with pressure switch assembly ............................................................................................... 191
Power supply base and magnetics ................................................................................................................................. 192
Duramax LT hand torch parts ................................................................................................................................................... 193
Duramax LT hand torch consumables ................................................................................................................................... 194
General-purpose (standard) consumables ................................................................................................................... 194
FineCut consumables ........................................................................................................................................................ 194
Accessory parts .......................................................................................................................................................................... 195
Safety-critical parts .................................................................................................................................................................... 196
Recommended spare parts ...................................................................................................................................................... 197
Powermax30 XP labels ............................................................................................................................................................. 198
9 Wiring Diagrams ....................................................................................................................... 199
Powermax generic timing chart ............................................................................................................................................... 200
Powermax30 XP schematic ..................................................................................................................................................... 201
Powermax30 XP Service Manual 808150 Revision 1 11
Contents
12 Powermax30 XP Service Manual 808150 Revision 1
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 work piece. In other
cases, it could involve constructing an electromagnetic
screen enclosing the power source and the work
complete with associated input filters. In all cases,
electromagnetic disturbances must be reduced to the
point where they are no longer troublesome.
Assessment of area
Before installing the equipment, the user shall make an
assessment of potential electromagnetic problems in the
surrounding area. The following shall be taken into
account:
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.
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.
Safety and Compliance SC-13
Electromagnetic Compatibility (EMC)
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
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.
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 in crease the risk of
injury, for example, by allowing parallel cutting current
return paths which may damage the earth circuits of other
equipment. Further guidance is provided in IEC 60974-9,
Arc Welding Equipment, Part 9: Installation and Use.
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.
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, and with
respect to torch lifter assemblies within a period of one (1)
year from its date of delivery to you, and with respect to
Automation products one (1) year from its date of delivery
to you, with the exception of the EDGE Pro CNC,
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.
Hypertherm provides repair, replacement or adjustment of
the Product as the sole and exclusive remedy, if and only if
the warranty set forth herein properly is invoked and
applies. Hypertherm, at its sole option, shall repair,
replace, or adjust, free of charge, any defective Products
covered by this warranty which shall be returned with
Hypertherm’s prior authorization (which shall not be
unreasonably withheld), properly packed, to Hypertherm’s
place of business in Hanover, New Hampshire, or to an
authorized Hypertherm repair facility, all costs, insurance
and freight pre paid by the customer. Hypertherm shall not
be liable for any repairs, replacement, or adjustments of
Products covered by this warranty, except those made
pursuant to this paragraph and with Hypertherm’s prior
written consent.
The warranty set forth above is exclusive and is in lieu of all
other warranties, express, implied, statutory, or otherwise
with respect to the Products or as to the results which
may be obtained therefrom, and all implied warranties or
conditions of quality or of merchantability or fitness for a
particular purpose or against infringement. The foregoing
shall constitute the sole and exclusive remedy for any
breach by 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.
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.
Safety and Compliance SC-15
Warranty
Patent indemnity
Except only in cases of products not manufactured by
Hypertherm or manufactured by a person other than
Hypertherm not in strict conformity with Hypertherm’s
specifications and in cases of designs, processes,
formulae, or combinations not developed or purported to
be developed by Hypertherm, Hypertherm will have the
right to defend or settle, at its own expense, any suit or
proceeding brought against you alleging that the use of
the Hypertherm product, alone and not in combination
with any other product not supplied by Hypertherm,
infringes any patent of any third party. You shall notify
Hypertherm promptly upon learning of any action or
threatened action in connection with any such alleged
infringement (and in any event no longer than fourteen
(14) days after learning of any action or threat of action),
and Hypertherm’s obligation to defend shall be
conditioned upon Hypertherm’s sole control of, and the
indemnified party’s cooperation and assistance in, the
defense of the claim.
Limitation of liability
In no event shall Hypertherm be liable to any
person or entity for any incidental, consequential
direct, indirect, punitive or exemplary damages
(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.
National and local codes
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.
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.
SC-16 Safety and Compliance
Section 1
Specifications
Safety information
Before operating any Hypertherm equipment, read the separate Safety and Compliance Manual (80669C) included with
your product for important safety information.
System description
The Powermax30 XP is a highly portable, 30 A, handheld plasma cutting system appropriate for a wide range of
applications. It uses air or nitrogen to cut electrically conductive metals, such as mild steel, stainless steel, or aluminum.
With it you can cut thicknesses up to 15 mm (5/8 inches) and pierce thicknesses up to 6 mm (1/4 inch).
The Powermax30 XP ships in several different configurations, based on region. Typically all configurations include:
1 complete set of general-purpose (standard) consumables (preinstalled on the Duramax
standard cutting:
™
LT hand torch) for
1 electrode
1 swirl ring
1 nozzle
1 retaining cap
1 shield
1 extra general-purpose nozzle
1 extra electrode
FineCut
1 FineCut nozzle
1 FineCut deflector
1 region-specific air fitting:
Industrial interchange quick-disconnect nipple with 1/4 NPT threads (CSA models)
British Pipe Thread adapter G-1/4 BSPP with 1/4 NPT threads (CE and CCC models)
®
consumables for detailed cutting:
Powermax30 XP Service Manual 808150 Revision 1 17
1 – Specifications
356 mm
(14 inches)
140 mm
(5.5 inches)
292 mm
(11.5 inches)
254 mm
(10 inches)
Carrying strap
Operator Manual
Safety and Compliance Manual
Quick Setup Card
For details on how to select the right set of consumables for a given cutting job, see
Choose the consumables on page 32.
Additional items may also ship with your Powermax30 XP depending on the configuration that you ordered, such as
instructional setup materials, a carrying case, leather cutting gloves, or protective glasses.
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 26 for more information.
You can order additional consumables and accessories – such as the carrying case, carrying strap, and a circle cutting
guide – from any Hypertherm distributor. See the Parts section on page 185 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: 9.7 kg (21.4 pounds)
CE and CCC systems: 9.5 kg (21.0 pounds)
18 Powermax30 XP Service Manual 808150 Revision 1
1 – Specifications
Hypertherm system ratings
Rated open circuit voltage (U0)256VDC
Rated output current (I
Rated output voltage (U
Rated output voltage (U
= 200 – 240 VAC
U
1
Duty cycle at 40°C, U
(See data plate on power supply for more
information on duty cycle and for IEC ratings.)
Duty cycle at 40°C, U
(See data plate on power supply for more
information on duty cycle and for IEC ratings.)
)15A to 30A
2
) at U1= 120 VAC 83 VDC
2
) at
2
= 120 VAC
1
= 200 – 240 VAC
1
20% (I2=30A, U2=83V)
60% (I
100% (I
35% (I2=30A, U2=125V)
60% (I
100% (I
125 VDC
=17A, U2=83V)
2
=15A, U2= 83 V)
2
=23A, U2=125V)
2
=18A, U2= 125 V)
2
Operating temperature -10° to 40° C (14° to 104° F)
Storage temperature -25° to 55° C (-13° to 131° F)
Power factor (120 V – 240 V) 0.99 – 0.97
Input voltage (U
output (U
2MAX
, I
)/ Input current (I1) at rated
1
)
2MAX
200 – 240 V, 1-phase, 50/60 Hz, 22.5 – 18.8 A
120 V, 1-phase, 50/60 Hz, 25 A
(See Voltage configurations on page 25 for
more information.)
Gas type Air Nitrogen
Gas quality Clean, dry, oil-free 99.995% pure
Minimum required gas inlet flow and pressure 99.1 l/min at 4.7 bar (3.5 scfm at 68 psi)
Recommended gas inlet flow and pressure 113.3 l/min at 5.5 bar (4.0 scfm at 80 psi)
Maximum gas inlet pressure 9.3 bar (135 psi)
Powermax30 XP Service Manual 808150 Revision 1 19
1 – Specifications
25 mm
(1.0 inch)
48 mm (1.9 inches)
230 mm (9.0 inches)
45 mm
(1.8 inches)
83 mm
(3.3 inches)
75°
Torch dimensions
Torch weight
Duramax LT torch with general-purpose (standard) consumables only 0.3 kg (0.75 pounds)
Duramax LT torch with general-purpose (standard) consumables and 4.6m (15foot)
lead (with strain relief)
1.1kg (2.35pounds)
Cutting specifications
240 V (with general-purpose [standard] consumables)
Recommended cut capacity 9 mm (3/8 inch) at 500 mm/minute (20 inches/minute)
12 mm (1/2 inch) at 250 mm/minute (10 inches/minute)
Severance cut capacity 15 mm (5/8 inch) at 125 mm/minute (5 inches/minute)
120 V: Use the FineCut nozzle and deflector for cutting on 120 V input circuits. When you operate the system at the
maximum recommended output of 25 A, the cut capacities are:
6 mm (1/4 inch) at 480 mm/minute (19 inches/minute)
9 mm (3/8 inch) at 200 mm/minute (8 inches/minute)
12 mm (1/2 inch) at 75 mm/minute (3 inches/minute)
To understand the differences between the general-purpose and FineCut consumables,
and for guidelines on selecting the right set for your cutting applications, see Choose
the consumables on page 32.
20 Powermax30 XP Service Manual 808150 Revision 1
1 – Specifications
s
Symbols and marks
Your Hypertherm product may have one or more of the following markings on or near the data plate. Due to differences
and conflicts in national regulations, not all marks are applied to every version of a product.
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
Hypertherm products with a CSA mark meet the United States and Canadian regulations for product
safety. The products were evaluated, tested, and certified by CSA-International. Alternatively, the product
may have a mark by one of the other Nationally Recognized Testing Laboratories (NRTL) accredited in
both the United States and Canada, such as Underwriters Laboratories, Incorporated (UL) or TÜV.
CE mark
The CE marking signifies the manufacturer’s declaration of conformity to applicable European directives
and standards. Only those versions of Hypertherm products with a CE marking located on or near the
data plate have been tested for compliance with the European Low Voltage Directive and the European
Electromagnetic Compatibility (EMC) Directive. EMC filters needed to comply with the European
EMC Directive are incorporated within versions of the product with a CE marking.
Eurasian Customs Union (CU) mark
CE versions of Hypertherm 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 Hypertherm products that include a GOST-TR mark of conformity meet the product safety
and EMC requirements for export to the Russian Federation.
C-Tick mark
CE versions of Hypertherm products with a C-Tick mark comply with the EMC regulations required for
sale in Australia and New Zealand.
CCC mark
The China Compulsory Certification (CCC) mark indicates that the product has been tested and found
compliant with product safety regulations required for sale in China.
UkrSEPRO mark
The CE versions of Hypertherm 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 Hypertherm products that include a AAA Serbian mark meet the product safety and EMC
requirements for export to Serbia.
Powermax30 XP Service Manual 808150 Revision 1 21
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)
Inlet gas pressure fault (LED)
Missing or loose consumables
(LED)
Power supply is overheated
(LED)
f
1
f
2
1~
AC
AC
Noise levels
This plasma system may exceed acceptable noise levels as defined by national and local codes. Always wear proper ear
protection when cutting. Any noise measurements taken depend on the specific environment in which the system is used.
Refer to Noise can damage hearing in the Safety and Compliance Manual (80669C) included with your system.
In addition, you can find an Acoustical Noise Data Sheet for your system in the Hypertherm downloads library at
https://www.hypertherm.com
:
1. Click “Downloads library.”
2. Select a product from the “Product type” menu.
3. Select “Regulatory” from the “Category” menu.
4. Select “Acoustical Noise Data Sheets” from the “Sub Category” menu.
IEC symbols
The following symbols may appear on the power supply data plate, control labels, switches, and LEDs.
22 Powermax30 XP Service Manual 808150 Revision 1
Section 2
Power Supply Setup
Unpack the Powermax system
1. Verify 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 24.)
2. Inspect the system for damage that may have occurred during shipment. If you find evidence of damage, refer to
Claims. All communications regarding this equipment must include the model number and the serial number located
on the bottom of the power supply.
3. Before you set up and operate this Hypertherm system, read the 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 XP Service Manual 808150 Revision 1 23
2 – Power Supply Setup
1
2
3
4
5
6
7
8
11
9
10
1
Operator Manual
2
Quick Setup Card
3
Registration card
4
Safety and Compliance Manual
5
Duramax LT torch with lead
6
Consumable kit
7
Ground clamp and work lead
8
CE/CCC power cord (no power plug included)
9
CSA power cord with power plug adapters
10
Power supply
11
Carrying strap
System contents
The following illustration shows the components typically included with all system configurations. Additional
components – such as setup instructions, a carrying case and protective glasses and gloves – may also be included with
your system, depending on the configuration you ordered.
The specific components included with the system are subject to change over time.
24 Powermax30 XP Service Manual 808150 Revision 1
2 – Power Supply Setup
Position the plasma cutting system
Position the Powermax30 XP 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.
Place the power supply on a stable, level surface before using.
Do not use the system in rain or snow.
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 47 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 set the amperage adjustment knob to an appropriate output current and verify
that an appropriate set of consumables is properly installed in the torch. For more information, see Adjust the gas
pressure and output current on page 44 and Install the consumables on page 42.
The following table shows 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.
Input voltage circuit* Rated output
Input current at rated
output
kVA
Recommended
consumables
†
120 V, 15 A 20 A, 83 V 16.4 A 2.0 FineCut
120 V, 20 A 25 A, 83 V 20.5 A 2.5 FineCut
120 V, 30 A 30 A, 83 V 25 A 3.0 FineCut
200 – 240 V, 20 A 30 A, 125 V 22.5 – 18.8 A 4.5 General-purpose or FineCut
* Input voltages can be ±10% of the values in this table.
†
See Choose the consumables on page 32 for an explanation of general-purpose (standard) and FineCut consumables.
CAUTION!
A circuit capable of 20 A/120 V or 20 A/240 V is required for proper operation. Protect the circuit with
appropriately sized slow-blow (time-delay) fuses or circuit breakers.
Powermax30 XP Service Manual 808150 Revision 1 25
2 – Power Supply Setup
Requirements for grounding
Properly ground the system as follows to ensure personal safety, 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, CE, or CCC power cord configuration. See Exterior, rear on page 187 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 Adjust
the gas pressure and output current on page 44.
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.
26 Powermax30 XP Service Manual 808150 Revision 1
2 – Power Supply Setup
1
2
3
4
5
6
1
Cord grip
2
Outer shell
3
To line 1 terminal (brown)
4
220 V (CCC) or 230 V (CE) plug
5
To line 2 terminal (blue)
6
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.
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.
Powermax30 XP Service Manual 808150 Revision 1 27
2 – Power Supply Setup
A
1
1
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)
2
(12 AWG) Up to 16 m (53 feet)
2
(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.
28 Powermax30 XP Service Manual 808150 Revision 1
2 – Power Supply Setup
The recommended inlet pressure while gas is flowing is
5.5 – 6.9 bar (80 – 100 psi).
Prepare the gas supply
The gas supply can be shop-compressed or cylinder-compressed.You must use a high-pressure regulator on either type
of supply, and the regulator must deliver gas to the filter on the power supply at 99.1 l/min at 4.7 bar (3.5 scfm at 68 psi).
To ensure adequate pressure to the power supply, set the regulator between 5.5 and 6.9 bar (80 and 100 psi).
The system contains an internal filter element, but additional filtration may be required depending on the quality of the gas
supply. If gas supply quality is poor, cut speeds decrease, cut quality deteriorates, cutting thickness capability decreases,
and the life of the consumables shortens. For optimal performance, the gas should have a maximum:
Particle size of 0.1 micron at a maximum concentration of 0.1 mg/m
Dew point of -40° C (-40° F)
Oil concentration of 0.1 mg/m
3
(per ISO 8573-1 Class 1.2.2)
Connect the gas supply
Connect the gas supply to the power supply using an inert gas hose with a 6.3 mm (1/4 inch) or greater internal diameter
and an industrial interchange quick-disconnect coupler (for CSA models) or a G-1/4 BSPP threaded coupling (for CE
and CCC models).
3
CAUTION!
Some air compressors use synthetic lubricants containing esters that damage the polycarbonates
used in the air filter bowl.
Powermax30 XP Service Manual 808150 Revision 1 29
2 – Power Supply Setup
Gas supply Power supply
Oil vapor filterOil filterWater and particle filter
WARNING!
The air filter bowl may explode if the gas supply pressure exceeds 9.3 bar (135 psi).
Additional gas filtration
When site conditions introduce moisture, oil, or other contaminants into the gas line, use a three-stage coalescing
filtration system, such as the Eliminizer filter kit (128647) available from Hypertherm distributors. A three-stage filtering
system works as follows to clean contaminants from the gas supply.
Install the filtering system between the quick-disconnect coupler and the power supply.
30 Powermax30 XP Service Manual 808150 Revision 1
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