Plasma Arc Cutting System with Integrated Air Compressor
Operator Manual
808840|Revision 1|English
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Installation and use .................................................................................................................................................................SC-11
Assessment of area ................................................................................................................................................................SC-11
Methods of reducing emissions ..........................................................................................................................................SC-11
Maintenance of cutting equipment .....................................................................................................................................SC-12
Earthing of the workpiece .............................................................................................................................................SC-12
Screening and shielding .......................................................................................................................................................SC-12
General .....................................................................................................................................................................................SC-13
Limitation of liability ................................................................................................................................................................SC-14
National and local codes .......................................................................................................................................................SC-14
Liability cap ..............................................................................................................................................................................SC-14
Transfer of rights .....................................................................................................................................................................SC-14
Safety information ......................................................................................................................................................................... 15
System description ....................................................................................................................................................................... 15
Power supply dimensions ........................................................................................................................................................... 16
System weights ............................................................................................................................................................................. 16
Hypertherm system ratings ......................................................................................................................................................... 17
Symbols and marks ...................................................................................................................................................................... 21
Unpack the plasma system ........................................................................................................................................................ 23
System contents ........................................................................................................................................................................... 24
Position the plasma cutting system .......................................................................................................................................... 25
Prepare the electrical power ...................................................................................................................................................... 25
Voltage configurations ......................................................................................................................................................... 25
Requirements for grounding .............................................................................................................................................. 27
Power cord considerations ........................................................................................................................................................ 27
CSA power cords and plugs ............................................................................................................................................. 27
CE power cords .................................................................................................................................................................... 28
Install a plug on the power cord ................................................................................................................................ 28
Hand torch components ..................................................................................................................................................... 31
Consumable life ............................................................................................................................................................................ 32
Consumable use ........................................................................................................................................................................... 33
Using the cut charts ............................................................................................................................................................. 33
Consumable set .................................................................................................................................................................... 34
240 V / 30 A cutting .................................................................................................................................................... 35
120 V / 20 A cutting .................................................................................................................................................... 37
Controls and indicators ............................................................................................................................................................... 39
Front panel controls and indicator LED symbols ........................................................................................................... 40
Operate the plasma system ....................................................................................................................................................... 41
Step 1 – Install the consumables ..................................................................................................................................... 41
Step 2 – Connect the electrical power ........................................................................................................................... 42
Step 3 – Adjust the output current ................................................................................................................................... 43
Operating the system on a 120 V / 20 A circuit ................................................................................................... 43
Operating the system on a 240 V / 20 A circuit ................................................................................................... 43
Decrease output current for lower-rated power plugs ......................................................................................... 43
Cutting expanded metal .............................................................................................................................................. 43
Step 4 – Attach the ground clamp ................................................................................................................................... 44
Step 5 – Power ON the system ........................................................................................................................................ 44
Step 6 – Check the indicator LEDs ................................................................................................................................. 45
Step 7 – Make sure the system is ready, and start cutting ........................................................................................ 45
What to expect during and after cutting ................................................................................................................................. 45
Internal compressor and fan activity ................................................................................................................................. 45
Water under the power supply .......................................................................................................................................... 45
System operation guidelines ...................................................................................................................................................... 47
Hand torch operation ................................................................................................................................................................... 48
Hand torch cutting guidelines ............................................................................................................................................ 49
Recommendations for cutting at 120 V ................................................................................................................... 49
Edge start on a workpiece .................................................................................................................................................. 50
Pierce a workpiece ............................................................................................................................................................... 51
Common hand-cutting faults .............................................................................................................................................. 52
Inspect the consumables ............................................................................................................................................................ 55
Power LED faults .................................................................................................................................................................. 56
Temperature LED faults ....................................................................................................................................................... 57
Internal compressor LED faults ......................................................................................................................................... 58
Torch LED faults ................................................................................................................................................................... 59
Common cutting issues ...................................................................................................................................................... 60
Power supply parts ...................................................................................................................................................................... 62
Exterior, front .......................................................................................................................................................................... 62
Hand torch consumables ............................................................................................................................................................ 64
Accessory parts ............................................................................................................................................................................ 65
Power supply labels ..................................................................................................................................................................... 66
CE warning label ................................................................................................................................................................... 68
10Powermax30 AIROperator Manual808840
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 ComplianceSC-11
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-12Safety 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 prepaid 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 ComplianceSC-13
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-14Safety 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 AIR is a 30 A handheld plasma cutting system that contains its own internal air compressor for
maximum portability and ease of use. With it, you can cut electrically conductive metals – such as mild steel, stainless
steel, or aluminum – of thicknesses up to 10 mm (3/8 inches). You can also pierce thicknesses up to 6 mm (1/4 inch).
The Powermax30 AIR ships in several different configurations, based on region. Typically all configurations include:
1 complete set of consumables (preinstalled on the Air T30 hand torch):
1 electrode
1 swirl ring
1 nozzle
1 retaining cap
1 deflector
1 extra nozzle
1 extra electrode
Carrying strap
Operator Manual
Safety and Compliance Manual
Quick Setup Card
Powermax30 AIROperator Manual80884015
1 – Specifications
420 mm
(16.5 inches)
195 mm
(7.7 inches)
333 mm
(13.1 inches)
295 mm
(11.6 inches)
CSA units ship with a 120 V / 15 A (NEMA 5-15P) adapter and a 240 V / 20 A (NEMA 6-50P) adapter that connect to
the NEMA twist lock-style 240 V / 20 A (NEMA L6-20P) plug wired to the power supply. CE units ship without a plug on
the power cord. See Power cord considerations on page 27 for more information.
You can order additional consumables and accessories – such as a dust cover and circle cutting guides, for example –
from any Hypertherm distributor. See Parts on page 61 for a list of spare and optional parts.
Power supply dimensions
System weights
The following system weights include the hand torch with 4.6m (15foot) torch lead, a 4.6m (15foot) work lead with
ground clamp, and a 3.0 m (10 foot) power cord:
CSA systems: 13.5 kg (29.8 pounds)
CE systems: 13.4 kg (29.5 pounds)
16Powermax30 AIROperator Manual808840
1 – Specifications
Hypertherm system ratings
Rated open circuit voltage (U0)256VDC
Output characteristic*Drooping
Rated output current (I
Rated output voltage (U
Rated output voltage (U
U
= 200 VAC – 240 VAC
1
Duty cycle at 40°C, U
)15A to 30A
2
) at U1= 120 VAC83 VDC
2
) at
2
= 120 VAC
1
20% (I2=30A, U2=83V)
83 VDC
(See data plate on power supply’s rear panel for
more information on duty cycle and for
IEC ratings.)
Duty cycle at 40°C, U
= 200 VAC – 240 VAC
1
35% (I2=30A, U2=83V)
(See data plate on power supply’s rear panel for
more information on duty cycle and for
IEC ratings.)
Operating temperature-10°C to 40°C (14°F to 104°F)
Storage temperature -25°C to 55°C (-13°F to 131°F)
Power factor (120 V – 240 V)0.99 – 0.97
EMC classification CISPR 11
Class A
(CE models only)**
Input voltage (U
output (U
2MAX
)/ Input current (I1) at rated
1
, I
)
2MAX
120 V, 1-phase, 50/60 Hz, 28.7 A
200 V – 240 V, 1-phase, 50/60 Hz, 16.7 A – 15.0 A
†
(See Voltage configurations on page 25 for
more information.)
Gas typeAir
* Defined as a plot of output voltage versus output current.
** WARNING: This Class A equipment is not intended for use in residential locations where the electrical power is provided by the
public low.voltage supply system. There may be potential difficulties in ensuring electromagnetic compatibility in those locations,
due to conducted as well as radiated disturbances.
† This product meets the technical requirements of IEC 61000-3-2 and IEC 61000-3-3 and is not subject to conditional
connection.
Powermax30 AIROperator Manual80884017
1 – Specifications
25 mm
(1.0 inch)
51 mm (2.0 inches)
230 mm (9.0 inches)
45 mm
(1.8 inches)
86 mm
(3.4 inches)
75°
Torch dimensions
Torch weight
Air T30 torch with consumables only: 0.3 kg (0.65 pounds)
Air T30 torch with consumables and 4.6 m (15 foot) lead (with strain relief): 1.0 kg (2.25 pounds)
18Powermax30 AIROperator Manual808840
1 – Specifications
Cutting specifications
240 V
Recommended cut capacity*8 mm (5/16 inch) at a minimum of 500 mm/minute (20 inches/minute)
10 mm (3/8 inch) at a minimum of 250 mm/minute (10 inches/minute)
Severance cut capacity16 mm (5/8 inch) at a minimum of 125 mm/minute (5 inches/minute)
* When you operate this system at altitudes higher than 2,200 m (7,500 feet) above sea level, you may experience some reduction
in cutting performance due to the adverse effect that altitude has on air compressors.
120 V: When you operate the system at the maximum recommended output of 20 A, the cut capacities are:
3mm (10gauge) at 762mm/minute (30inches/minute)
6 mm (1/4 inch) at 355 mm/minute (14 inches/minute)
10 mm (3/8 inch) at 125 mm/minute (5 inches/minute)
Powermax30 AIROperator Manual80884019
1 – Specifications
Direct current (DC)
Alternating current (AC)
Plasma torch cutting
AC input power connection
The terminal for the external
protective (earth) conductor
IPower is ON
OPower is OFF
An inverter-based power
source
Volt/amp curve, “drooping”
characteristic
Power is ON (LED)
Internal air compressor fault
(LED)
Missing or loose consumables
(LED)
Power supply is overheated
(LED)
f
1
f
2
1~
AC
IEC symbols
The following symbols may appear on the power supply data plate, control labels, switches, and LEDs.
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
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.
20Powermax30 AIROperator Manual808840
1 – Specifications
s
Symbols and marks
Your 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
Products with a CSA mark meet the United States and Canadian regulations for product safety. The products
were evaluated, tested, and certified by CSA-International. Alternatively, the product may have a mark by one
of the other Nationally Recognized Testing Laboratories (NRTL) accredited in both the United States and
Canada, such as UL or TÜV.
CE mark
The CE marking signifies the manufacturer’s declaration of conformity to applicable European directives and
standards. Only those versions of products with a CE marking located on or near the data plate 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 products that include an EAC mark of conformity meet the product safety and EMC
requirements for export to Russia, Belarus, and Kazakhstan.
GOST-TR mark
CE versions of products that include a GOST-TR mark of conformity meet the product safety and EMC
requirements for export to the Russian Federation.
C-Tick mark
CE versions of 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 products that include a UkrSEPRO mark of conformity meet the product safety and EMC
requirements for export to the Ukraine.
Serbian AAA mark
CE versions of products that include a AAA Serbian mark meet the product safety and EMC requirements for
export to Serbia.
Powermax30 AIROperator Manual80884021
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