Hypertherm Powermax30 XP Operator Manual
Powermax30®XP
Plasma Arc Cutting System
Operator Manual
808160|Revision3|English
Register your new Hypertherm system
Register your product online at www.hypertherm.com/registration for easier technical
and warranty support. You can also receive updates on new Hypertherm products and a free
gift as a token of our appreciation.
For your records
Serial number:________________________________________________________________
Purchase date: _______________________________________________________________
Distributor: __________________________________________________________________
____________________________________________________________________________
____________________________________________________________________________
Maintenance notes:
____________________________________________________________________________
____________________________________________________________________________
____________________________________________________________________________
____________________________________________________________________________
____________________________________________________________________________
____________________________________________________________________________
Powermax, Duramax, FineCut, HyAccess, and Hypertherm are trademarks of Hypertherm Inc. and may be registered in the United
States and other countries. All other trademarks are the property of their respective holders.
© 2015 Hypertherm Inc.
Powermax30 XP
Operator Manual
808160
Revision 3
English
June 2015
Hypertherm Inc.
Hanover, NH 03755 USA
www.hypertherm.com
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
WARNING!
READ THE SAFETY INFORMATION
Before operating or maintaining any Hypertherm equipment, read the
Safety and Compliance Manual (80669C) for important safety information.
You can find the Safety and Compliance Manual in the “Downloads library”
at www.hypertherm.com
.
Contents
Electromagnetic Compatibility (EMC) ............................................................................ SC-11
Introduction ..............................................................................................................................................................................SC-11
Installation and use .................................................................................................................................................................SC-11
Assessment of area ................................................................................................................................................................SC-11
Methods of reducing emissions ..........................................................................................................................................SC-11
Mains supply ....................................................................................................................................................................SC-11
Maintenance of cutting equipment .....................................................................................................................................SC-11
Cutting cables .........................................................................................................................................................................SC-11
Equipotential bonding ....................................................................................................................................................SC-11
Earthing of the workpiece .............................................................................................................................................SC-11
Screening and shielding .......................................................................................................................................................SC-12
Warranty .................................................................................................................................. SC-13
Attention ....................................................................................................................................................................................SC-13
General .....................................................................................................................................................................................SC-13
Patent indemnity .....................................................................................................................................................................SC-13
Limitation of liability ................................................................................................................................................................SC-13
National and local codes .......................................................................................................................................................SC-13
Liability cap ..............................................................................................................................................................................SC-13
Insurance ..................................................................................................................................................................................SC-14
Transfer of rights .....................................................................................................................................................................SC-14
1 Specifications .............................................................................................................................. 15
Safety information ......................................................................................................................................................................... 15
System description ....................................................................................................................................................................... 15
Power supply dimensions ........................................................................................................................................................... 16
System weights ............................................................................................................................................................................. 16
Hypertherm system ratings ......................................................................................................................................................... 17
Powermax30 XP Operator Manual 808160 7
Contents
Torch dimensions ......................................................................................................................................................................... 18
Torch weight .................................................................................................................................................................................. 18
Cutting specifications .................................................................................................................................................................. 18
Symbols and marks ...................................................................................................................................................................... 19
Noise levels ............................................................................................................................................................................ 20
IEC symbols ........................................................................................................................................................................... 20
2 Power Supply Setup .................................................................................................................. 21
Unpack the plasma system ........................................................................................................................................................ 21
Claims ...................................................................................................................................................................................... 21
System contents ........................................................................................................................................................................... 22
Position the plasma system ........................................................................................................................................................ 23
Prepare the electrical power ...................................................................................................................................................... 23
Voltage configurations ......................................................................................................................................................... 23
Requirements for grounding .............................................................................................................................................. 24
Power cord considerations ........................................................................................................................................................ 24
CSA power cords and plugs ............................................................................................................................................. 24
CE and CCC power cords ................................................................................................................................................ 25
Extension cord recommendations ..................................................................................................................................... 26
Generator recommendations ............................................................................................................................................. 26
Prepare the gas supply ............................................................................................................................................................... 27
Connect the gas supply ...................................................................................................................................................... 27
Additional gas filtration ........................................................................................................................................................ 28
3 Torch Setup .................................................................................................................................. 29
Introduction .................................................................................................................................................................................... 29
Hand torch components ..................................................................................................................................................... 29
Consumable life ............................................................................................................................................................................ 30
Choose the consumables ........................................................................................................................................................... 30
Using the cut charts ............................................................................................................................................................. 32
General-purpose (standard) consumables ..................................................................................................................... 32
240 V / 30 A cutting .................................................................................................................................................... 33
FineCut consumables .......................................................................................................................................................... 34
120 V / 25 A cutting .................................................................................................................................................... 35
120 V / 30 A cutting .................................................................................................................................................... 36
HyAccess consumables ...................................................................................................................................................... 37
Cutting at 240 V ........................................................................................................................................................... 37
Cutting at 120 V / 20 A .............................................................................................................................................. 37
Ordering and replacing ............................................................................................................................................... 37
8 Powermax30 XP Operator Manual 808160
Contents
4 Operation ...................................................................................................................................... 39
Controls and indicators ............................................................................................................................................................... 39
Rear controls .......................................................................................................................................................................... 39
Front controls and LEDs ..................................................................................................................................................... 40
Operate the plasma system ....................................................................................................................................................... 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 Maintenance and Troubleshooting ....................................................................................... 55
Perform routine maintenance ..................................................................................................................................................... 55
Inspect the consumables ............................................................................................................................................................ 57
Basic troubleshooting .......................................................................................................................................................... 58
Maintenance procedures ............................................................................................................................................................ 61
Replace the air filter element and air filter bowl ............................................................................................................. 61
Remove the power supply cover and handle ......................................................................................................... 61
Remove the old air filter element and air filter bowl .............................................................................................. 62
Install the new air filter element and air filter bowl ................................................................................................ 63
Put the power supply cover and handle back in place ........................................................................................ 64
Powermax30 XP Operator Manual 808160 9
Contents
6 Parts ............................................................................................................................................... 65
Power supply parts ...................................................................................................................................................................... 66
Exterior, front .......................................................................................................................................................................... 66
Exterior, rear ........................................................................................................................................................................... 67
Air filter/regulator with pressure switch assembly (interior, fan side) ....................................................................... 68
Duramax LT hand torch parts .................................................................................................................................................... 69
Duramax LT hand torch consumables ..................................................................................................................................... 70
General-purpose (standard) consumables ..................................................................................................................... 70
FineCut consumables .......................................................................................................................................................... 70
HyAccess consumables ...................................................................................................................................................... 71
Accessory parts ............................................................................................................................................................................ 72
Powermax30 XP labels ............................................................................................................................................................... 73
10 Powermax30 XP Operator Manual 808160
Electromagnetic Compatibility (EMC)
Introduction
Hypertherm’s CE-marked equipment is built in compliance with standard
EN60974-10. The equipment should be installed and used in
accordance with the information below to achieve electromagnetic
compatibility.
The limits required by EN60974-10 may not be adequate to completely
eliminate interference when the affected equipment is in close proximity
or has a high degree of sensitivity. In such cases it may be necessary to
use other measures to further reduce interference.
This cutting equipment is designed for use only in an industrial
environment.
Installation and use
The user is responsible for installing and using the plasma equipment
according to the manufacturer’s instructions.
If electromagnetic disturbances are detected then it shall be the
responsibility of the user to resolve the situation with the technical
assistance of the manufacturer. In some cases this remedial action may
be as simple as earthing the cutting circuit, see Earthing of the
workpiece. In other cases, it could involve constructing an
electromagnetic screen enclosing the power source and the work
complete with associated input filters. In all cases, electromagnetic
disturbances must be reduced to the point where they are no longer
troublesome.
Methods of reducing emissions
Mains supply
Cutting equipment must be connected to the mains supply according to
the manufacturer’s recommendations. If interference occurs, it may be
necessary to take additional precautions such as filtering of the mains
supply.
Consideration should be given to shielding the supply cable of
permanently installed cutting equipment, in metallic conduit or
equivalent. Shielding should be electrically continuous throughout its
length. The shielding should be connected to the cutting mains supply so
that good electrical contact is maintained between the conduit and the
cutting power source enclosure.
Maintenance of cutting equipment
The cutting equipment must be routinely maintained according to the
manufacturer’s recommendations. All access and service doors and
covers should be closed and properly fastened when the cutting
equipment is in operation. The cutting equipment should not be modified
in any way, except as set forth in and in accordance with the
manufacturer’s written instructions. For example, the spark gaps of arc
striking and stabilizing devices should be adjusted and maintained
according to the manufacturer’s recommendations.
Cutting cables
Assessment of area
Before installing the equipment, the user shall make an assessment of
potential electromagnetic problems in the surrounding area. The
following shall be taken into account:
a. Other supply cables, control cables, signaling and telephone
cables; above, below and adjacent to the cutting equipment.
b. Radio and television transmitters and receivers.
c. Computer and other control equipment.
d. Safety critical equipment, for example guarding of industrial
equipment.
e. Health of the people around, for example the use of pacemakers
and hearing aids.
f. Equipment used for calibration or measurement.
g. Immunity of other equipment in the environment. User shall
ensure that other equipment being used in the environment is
compatible. This may require additional protection measures.
h. Time of day that cutting or other activities are to be carried out.
The size of the surrounding area to be considered will depend on the
structure of the building and other activities that are taking place. The
surrounding area may extend beyond the boundaries of the premises.
The cutting cables should be kept as short as possible and should be
positioned close together, running at or close to the floor level.
Equipotential bonding
Bonding of all metallic components in the cutting installation and
adjacent to it should be considered.
However, metallic components bonded to the workpiece will increase
the risk that the operator could receive a shock by touching these
metallic components and the electrode (nozzle for laser heads) at the
same time.
The operator should be insulated from all such bonded metallic
components.
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.
Safety and Compliance SC-11
Electromagnetic Compatibility (EMC)
Note: The cutting circuit may or may not be earthed for safety reasons.
Changing the earthing arrangements should only be authorized by a
person who is competent to assess whether the changes will in crease
the risk of injury, for example, by allowing parallel cutting current return
paths which may damage the earth circuits of other equipment. Further
guidance is provided in IEC 60974-9, Arc Welding Equipment, Part 9:
Installation and Use.
Screening and shielding
Selective screening and shielding of other cables and equipment in the
surrounding area may alleviate problems of interference. Screening of the
entire plasma cutting installation may be considered for special
applications.
SC-12 Safety and Compliance
Warranty
Attention
Genuine Hypertherm parts are the factory-recommended replacement
parts for your Hypertherm system. Any damage or injury caused by the
use of other than genuine Hypertherm parts may not be covered by the
Hypertherm warranty, and will constitute misuse of the Hypertherm
Product.
You are solely responsible for the safe use of the Product. Hypertherm
does not and cannot make any guarantee or warranty regarding the safe
use of the product in your environment.
General
Hypertherm Inc. warrants that its Products shall be free from defects in
materials and workmanship for the specific periods of time set forth
herein and as follows: if Hypertherm is notified of a defect (i) with respect
to the plasma power supply within a period of two (2) years from the date
of its delivery to you, with the exception of Powermax brand power
supplies, which shall be within a period of three (3) years from the date of
delivery to you, and (ii) with respect to the torch and leads within a period
of one (1) year from its date of delivery to you, with the exception of the
HPRXD short torch with integrated lead, which shall be within a period of
six (6) months from the date of delivery to you, and with respect to torch
lifter assemblies within a period of one (1) year from its date of delivery to
you, and with respect to Automation products one (1) year from its date
of delivery to you, with the exception of the EDGE 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.
This warranty shall not apply to any Powermax brand power supplies that
have been used with phase converters. In addition, Hypertherm does not
warranty systems that have been damaged as a result of poor power
quality, whether from phase converters or incoming line power. This
warranty shall not apply to any product which has been incorrectly
installed, modified, or otherwise damaged.
Hypertherm 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.
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
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.
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.
Safety and Compliance SC-13
Warranty
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.
SC-14 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 16 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 Operator Manual 808160 15
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 30.
Additional items may also ship with your system 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 24 for more information.
You can order additional consumables and accessories – such as specialty consumables, a carrying strap, and a circle
cutting guide – from any Hypertherm distributor. See the Parts section on page 65 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)
16 Powermax30 XP Operator Manual 808160
1 – Specifications
Hypertherm system ratings
Rated open circuit voltage (U0)256VDC
Rated output current (I
Rated output voltage (U
Rated output voltage (U
U
= 200 – 240 VAC
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
)/ Input current (I1) at rated
1
, I
)
2MAX
120 V, 1-phase, 50/60 Hz, 25 A
200 – 240 V, 1-phase, 50/60 Hz, 22.5 – 18.8 A
(See Voltage configurations on page 23 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 Operator Manual 808160 17
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
Hand torch with general-purpose (standard) consumables only 0.3 kg (0.75 pounds)
Hand torch with general-purpose (standard) consumables and 4.6 m (15 foot) lead (with
strain relief)
1.1 kg (2.35 pounds)
Cutting specifications
240 V (with general-purpose [standard] consumables)
Recommended cut capacity 10 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 16 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)
10 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 30.
18 Powermax30 XP Operator Manual 808160
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 XP Operator Manual 808160 19
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
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
http://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.
20 Powermax30 XP Operator Manual 808160
Section 2
Power Supply Setup
Unpack the plasma 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 22.)
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 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 Operator Manual 808160 21
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 Hand 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.
22 Powermax30 XP Operator Manual 808160
2 – Power Supply Setup
Position the plasma system
Position the plasma system near an appropriate power receptacle. The system has a 3.0 m (10 foot) power cord.
Allow at least 0.25 m (10 inches) of space around the power supply for proper ventilation.
Place the power supply on a stable, level surface before using. To avoid toppling, do not set the power supply on an
incline greater than 10 degrees.
Do not use the system in rain or snow.
WARNING!
Never cut under water or submerge the torch in water.
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 Basic
troubleshooting on page 58.
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
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 V – 240 V, 20 A 30 A, 125 V 22.5 A – 18.8 A 4.5 General-purpose or FineCut
Recommended
consumables
†
* Input voltages can be ±10% of the values in this table.
†
See Choose the consumables on page 30 for an explanation of general-purpose (standard) and FineCut consumables.
Powermax30 XP Operator Manual 808160 23
Loading...