Hypertherm Powermax45 Service Manual

45
Plasma arc cutting system
Service Manual – 806110 Revision 2
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Service Manual
45
(P/N 806110)
Revision 2 – April, 2013
Hypertherm, Inc.
Hanover, NH USA
www.hypertherm.com
© Copyright 2013 Hypertherm, Inc.
All Rights Reserved
Hypertherm and powermax are trademarks of Hypertherm, Inc.
and may be registered in the United States and/or other countries.
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
07/18/12
Safety information
Before operating any Hypertherm equipment, read the separate Safety and Compliance Manual (80669C) included with your product for important safety information.

TABLE OF CONTENTS

ELECTROMAGNETIC COMPATIBILITY EMC .......................................................................................................EMC1
WARRANTY ............................................................................................................................................................................ W1
SECTION 1
SPECIFICATIONS
System description ....................................................................................................................................................................................1-2
Where to find information ........................................................................................................................................................................1-2
Power supply dimensions and weights ................................................................................................................................................1-3
Dimensions .......................................................................................................................................................................................1-3
Weights .............................................................................................................................................................................................1-3
Power supply ratings .................................................................................................................................................................................1-4
T45v torch dimensions .............................................................................................................................................................................1-5
T45m torch dimensions ............................................................................................................................................................................1-5
T45v and T45m torch specifications .....................................................................................................................................................1-6
Symbols and marks ...................................................................................................................................................................................1-7
IEC symbols ................................................................................................................................................................................................1-8
SECTION 2
POWER SUPPLY SETUP
Unpack the Powermax45 .........................................................................................................................................................................2-2
Claims ................................................................................................................................................................................................2-2
Contents ............................................................................................................................................................................................2-2
Position the power supply........................................................................................................................................................................2-3
Prepare the electrical power ...................................................................................................................................................................2-3
Voltage configurations ....................................................................................................................................................................2-3
Install a line-disconnect switch ....................................................................................................................................................2-4
Requirements for grounding .........................................................................................................................................................2-4
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Table of ConTenTs
Power cord considerations ......................................................................................................................................................................2-4
Extension cord recommendations ...............................................................................................................................................2-5
Generator recommendations ........................................................................................................................................................2-6
Prepare the gas supply .............................................................................................................................................................................2-6
Connect the gas supply .................................................................................................................................................................2-7
Additional gas filtration ...................................................................................................................................................................2-7
SECTION 3
TORCH SETUP
Introduction .................................................................................................................................................................................................3-2
Consumable life ..........................................................................................................................................................................................3-2
Hand torch setup .......................................................................................................................................................................................3-2
Choose the consumables ..............................................................................................................................................................3-3
Install the consumables ..................................................................................................................................................................3-5
Machine torch setup..................................................................................................................................................................................3-6
Mount the torch ................................................................................................................................................................................3-6
Choose the consumables (cut charts) .......................................................................................................................................3-8
Using the cut charts ........................................................................................................................................................................3-8
T45m shielded consumables ........................................................................................................................................................3-8
Align the torch ............................................................................................................................................................................... 3-24
Connect the remote-start pendant ...........................................................................................................................................3-25
Connect a machine interface cable .........................................................................................................................................3-25
Accessing raw arc voltage ......................................................................................................................................................... 3-27
Connect the torch lead .......................................................................................................................................................................... 3-30
SECTION 4
OPERATION
Controls and indicators ............................................................................................................................................................................4-2
Front controls and LEDs ................................................................................................................................................................4-2
Rear controls ....................................................................................................................................................................................4-3
Operate the Powermax45 ........................................................................................................................................................................4-3
Connect the electrical power and gas supply ..........................................................................................................................4-3
Power ON the system ....................................................................................................................................................................4-4
Set the mode switch .......................................................................................................................................................................4-4
Adjust the gas pressure .................................................................................................................................................................4-4
Check the indicator LEDs .............................................................................................................................................................4-6
Attach the work clamp ...................................................................................................................................................................4-6
Understand duty-cycle limitations ..........................................................................................................................................................4-6
How to use the hand torch ......................................................................................................................................................................4-7
Operate the safety trigger .............................................................................................................................................................4-7
Hand torch cutting hints ................................................................................................................................................................4-7
Start a cut from the edge of the workpiece...............................................................................................................................4-8
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Service Manual
Table of ConTenTs
Pierce a workpiece ..........................................................................................................................................................................4-9
Gouge a workpiece .....................................................................................................................................................................4-10
Common hand-cutting faults ..................................................................................................................................................... 4-12
How to use the machine torch .............................................................................................................................................................4-12
Ensure the torch and table are set up correctly .................................................................................................................... 4-12
Understand and optimize cut quality ........................................................................................................................................4-13
To pierce a workpiece using the machine torch ................................................................................................................... 4-14
Common machine-cutting faults ............................................................................................................................................... 4-15
SECTION 5
TROUBLESHOOTING AND SYSTEM TESTS
Theory of operation ....................................................................................................................................................................................5-2
General ..............................................................................................................................................................................................5-2
200–240V CSA and 230V CE 1-phase power supply functional description..............................................................5-2
400V CE 3-phase power supply functional description .......................................................................................................5-2
480V CSA 3-phase power supply functional description ....................................................................................................5-3
Sequence of operation ...................................................................................................................................................................5-4
Troubleshooting preparation ...................................................................................................................................................................5-5
Test equipment ................................................................................................................................................................................5-5
Troubleshooting procedures and sequence .............................................................................................................................5-5
External inspection ..........................................................................................................................................................................5-6
Internal inspection ...........................................................................................................................................................................5-6
Initial resistance check ..............................................................................................................................................................................5-7
200–240V CSA and 230V CE power supply overview ................................................................................................................5-8
400V CE power supply overview .........................................................................................................................................................5-9
480V CSA power supply overview ...................................................................................................................................................5-10
Troubleshooting guide ........................................................................................................................................................................... 5-11
Control Board LEDs ............................................................................................................................................................................... 5-16
Use the control board Error and Reset LEDs to troubleshoot ...........................................................................................5-17
System tests.............................................................................................................................................................................................5-18
Test 1 – voltage input ..................................................................................................................................................................5-18
Test 2 – power board voltage checks ..................................................................................................................................... 5-19
Test 3 – VBUS and voltage balance .......................................................................................................................................5-20
Test 4 – solenoid valve ...............................................................................................................................................................5-24
Test 5 – torch stuck open (TSO) or torch stuck closed (TSC) ........................................................................................5-25
Test 6 – plasma start ................................................................................................................................................................... 5-26
Test 7 – torch cap sensor .......................................................................................................................................................... 5-27
Test 8 – fan ....................................................................................................................................................................................5-27
Test 9 – pressure transducer .................................................................................................................................................... 5-28
Test 10 – power switch trip coil ............................................................................................................................................... 5-28
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Table of ConTenTs
SECTION 6
COMPONENT REPLACEMENT
Remove and replace the cover and Mylar® barrier .............................................................................................................................6-2
Removal .............................................................................................................................................................................................6-2
Replacement .....................................................................................................................................................................................6-3
Replace the work lead (CSA and CE) ..................................................................................................................................................6-3
Replace the power cord (200–240V CSA) .......................................................................................................................................6-5
Replace the power cord (230V CE) ....................................................................................................................................................6-6
Replace the power cord (400V CE) ....................................................................................................................................................6-8
Replace the power cord (480V CSA) .............................................................................................................................................. 6-10
Replace the fan .......................................................................................................................................................................................6-12
Replace the gas filter element .............................................................................................................................................................6-13
Replace the air filter and regulator ...................................................................................................................................................... 6-15
Replace the control board .................................................................................................................................................................... 6-16
Replace the power board (200–240V CSA and 230V CE) ......................................................................................................6-17
Replace the power board (400V CE and 480V CSA) ................................................................................................................ 6-21
SECTION 7
PARTS
Power supply parts ....................................................................................................................................................................................7-2
Exterior ...............................................................................................................................................................................................7-2
Interior, power board side .............................................................................................................................................................7-4
Interior, fan side ...............................................................................................................................................................................7-5
Interior, heat sink side .....................................................................................................................................................................7-6
T45v hand torch parts...............................................................................................................................................................................7-7
T45v hand torch consumables .....................................................................................................................................................7-8
T30v (Powermax30) 30A consumables ...................................................................................................................................7-8
T45m machine torch parts .......................................................................................................................................................................7-9
T45m machine torch consumables .......................................................................................................................................... 7-10
Accessory parts.......................................................................................................................................................................................7-10
Safety-critical parts.................................................................................................................................................................................7-11
Recommended spare parts .................................................................................................................................................................. 7-12
Powermax45 labels ................................................................................................................................................................................ 7-13
SECTION 8
WIRING DIAGRAMS
Control board diagram: 200–240V CSA and 230V CE ...............................................................................................................8-2
Control board diagram: 400V CE and 480V CSA ..........................................................................................................................8-3
Power board wiring diagram: 200–240VCSA and 230VCE .....................................................................................................8-5
Power board wiring diagram: 400VCE ..............................................................................................................................................8-6
Power board wiring diagram: 480VCSA ...........................................................................................................................................8-7
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Service Manual
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.
Compliance Information EMC-1
7/ 10
ELECTROMAGNETIC COMPATIBILITY
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
The cutting cables should be kept as short as possible and should be positioned close together, running at or close to the floor level.
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 Equip ment, Part 9: Installation and Use.
Screening and shielding
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.
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.
EMC-2 Compliance Information
7/ 10

WARRANTY

Attention
Genuine Hypertherm parts are the factory­recommended 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 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.
Compliance Information W-1
9/10
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.
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
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.
W-2 Compliance Information
9/10

Section 1

SPECIFICATIONS

In this section:
System description ....................................................................................................................................................................................1-2
Where to find information ........................................................................................................................................................................1-2
Power supply dimensions and weights ................................................................................................................................................1-3
Dimensions .......................................................................................................................................................................................1-3
Weights .............................................................................................................................................................................................1-3
Power supply ratings .................................................................................................................................................................................1-4
T45v torch dimensions .............................................................................................................................................................................1-5
T45m torch dimensions ............................................................................................................................................................................1-5
T45v and T45m torch specifications .....................................................................................................................................................1-6
Symbols and marks ...................................................................................................................................................................................1-7
IEC symbols ................................................................................................................................................................................................1-8
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SpecificationS

System description

The Powermax45 is a highly portable, 45-amp, handheld and mechanized plasma cutting system appropriate for a wide range of applications. The Powermax45 uses air or nitrogen to cut electrically conductive metals, such as mild or stainless steel or aluminum. With it, you can cut thicknesses up to 25.4mm (1inch) and pierce thicknesses up to
9.5mm (3/8inch).
The standard Powermax45 includes one complete set of the consumables needed for cutting (shield, retaining cap, swirl ring, nozzle, electrode), 2spare electrodes, 2spare nozzles, gouging consumables (handheld configurations only), a quick-disconnect air fitting (1/4NPT on CSA units and 1/4NPT x G-1/4BSPP on CE units), a consumables box, a shoulder strap, an Operator Manual, a Quick Setup Card, and a Setup DVD. Mechanized configurations include a remote-start pendant as well.
You can order additional consumables and accessories – such as the plasma cutting guide – from any Hypertherm distributor. See the Parts section for a list of spare and optional parts.
The power cords on the 200–240V CSA power supplies are shipped with a 50A, 250V plug (NEMA6-50P) on the power cord. The CE units and the 480V CSA units are shipped without a plug on the power cord. See Prepare the electrical power in the Power Supply Setup section for more information.

Where to find information

System specifications, such as size, weight, detailed electrical specifications, and cut speeds can be found in this section. For information on:
• Safety information – see the Safety and Compliance Manual for detailed safety information.
• Setup requirements, including power requirements, grounding, power cord configurations, extension cord
requirements, and generator recommendations – see the Power Supply Setup section.
• Handheld and machine torch consumables, cut charts, and torch setup information – see the Torch Setup section.
• Information about the controls and LEDs, steps for system operation, and hints for improving cut quality – see the
Operation section.
• Troubleshooting – see the Troubleshooting and System Tests section.
• Maintenance and repair instructions – see the Component Replacement section.
• Part numbers and ordering information for accessories, consumables, and replacement parts – see the Parts
section.
• Wiring and timing diagrams – see the Wiring Diagrams section.
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Service Manual

Power supply dimensions and weights

Dimensions
34.8 cm (13.7 in)
31 cm
(12.19 in)
SpecificationS
42.6 cm
(16.75 in)
17.2 cm (6.75 in)
Weights
Power supply weights given below include the hand torch with 6.1m (20foot) lead, a 6.1m (20foot) work lead, and a 3m (10foot) power cord.
• CSA 200–240V power supply: 16.8 kg (37 pounds)
• CSA 480V power supply: 15.9 kg (35 pounds)
• CE 230V power supply: 16.6 kg (36.5 pounds)
• CE 400V power supply: 15.9 kg (35 pounds)
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SpecificationS

Power supply ratings

Rated open-circuit voltage (U0)
CSA/CE, single-phase CE, 3-phase CSA, 3-phase
275VDC (CSA/CE single-phase)
275VDC (CE 3-phase)
278VDC (CSA 3-phase)
Rated output current (I2) 20 A to 45 A
Rated output voltage (U
Duty cycle at 40° C
(See data plate on power supply for moreinformation on dutycycle.)
) 132VDC
2
50% (I
=45 A, U2=132V)
2
60% (I2=41 A, U2=132V)
100% (I2=32 A, U2=132V)
Operating temperature -10° to 40° C (14° to 104° F)
Storage temperature -25° to 55° C (-13° to 131° F)
Power factor
200–240V CSA, 230V CE, 1-phase 400V CE, 3-phase 480V CSA, 3-phase
Input voltage (U ratedoutput(U
) / Input current (I1) at
1
,I
2MAX
)
2MAX
(See Voltage configurations in the Power Supply Setup section for more information.)
200–240VAC / 34–28 A (200–240V CSA)
230VAC / 30 A (230V CE)*
400VAC / 10 A (400V CE)**
480VAC / 8.5A (480V CSA)
0.99
0.94
0.93
Gas type Air Nitrogen
Gas quality Clean, dry, oil-free per ISO
99.995% pure
8573-1 Class 1.2.2
Recommended gas inlet flow and pressure 170 l/min at 6.2 bar (360 scfh at 90 psi)
* Equipment complies with IEC 61000-3-12.
** Equipment complies with IEC 61000-3-12 provided that the short-circuit power S
is greater than or equal to
sc
692KVA at the interface point between the user’s supply and the public system. It is the responsibility of the installer or user of the equipment to ensure, by consultation with the distribution network operator if necessary, that the equipment is connected only to a supply with a short-circuit power Ssc greater than or equal to 692 KVA.
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Service Manual

T45v torch dimensions

8.3 cm
(3.28 in)
2.5 cm (1 in)
SpecificationS
22.1 cm (8.72 in)
21.6 cm (8.5 in)
4.0 cm (1.58 in)
4.9 cm (1.91 in)

T45m torch dimensions

2.5 cm (1 in)
36.5 cm
(14.36 in)
(30.5 cm)
12 in
33.0 cm (13 in)
3.6 cm (1.43 in) outer dimension,
3.3 cm (1.3 in) flat sides
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SpecificationS

T45v and T45m torch specifications

Handheld cut capacity (material thickness)
Recommended cut capacity (hand cutting) 12.7 mm (1/2 inch)
Maximum cut capacity (hand cutting or mechanized edgestart)
Severance capacity (hand cutting or mechanized edgestart) 25.4 mm (1 inch)
Mechanized pierce capacity (material thickness)
Pierce capacity (for edge starts, the capacities are the same as the handheld capacities)
Recommended cut speed (on mild steel)
6.35 mm (1/4 inch) 1524 mm/min (60 ipm)
9.53 mm (3/8 inch) 813 mm/min (32 ipm)
12.7 mm (1/2 inch) 508 mm/min (20 ipm)
19.1 mm (3/4 inch) 203 mm/min (8 ipm)
25.4 mm (1 inch) 102 mm/min (4 ipm)
Gouging capacity
Metal removal rate on mild steel 2.8 kg/hr (6.2 lbs/hr)
Weight
T45v torch only 0.27 kg (0.6 lb)
19.1 mm (3/4 inch)
9.5 mm (3/8 inch)
T45v with 6.1 m (20 foot) lead 1.55 kg (3.4 lb)
T45v with 15.24 m (50 foot) lead 3.54 kg (7.8 lb)
T45m torch only 0.45 kg (1.0 lb)
T45m with 7.62 m (25 foot) lead 2.27 kg (5.0 lb)
T45m with 10.7 m (35 foot) lead 2.90 kg (6.4 lb)
T45m with 15.24 m (50 foot) lead 3.85 kg (8.5 lb)
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Service Manual
SpecificationS

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 symbol
The S mark symbol indicates that the power supply and torch are suit able for operations carried out in environments with in creased hazard of elec tri cal shock per 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 marking
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.
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
CE versions of Hypertherm products that include a UkrSEPRO mark of conformity meet the product safety and EMC requirements for export to the Ukraine.
powermax
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Service Manual 1-7
SpecificationS

IEC symbols

The following symbols may appear on the power supply data plate, control labels, switches, and LEDs.
Direct current (DC)
Alternating current (AC)
Plasma torch cutting
Plate metal cutting
Expanded metal cutting
Gouging
AC input power connection
The terminal for the external protective (earth) conductor
l
O
1~
f
1
f
2
AC
Power is ON
Power is OFF
An inverter-based power source, either 1-phase or 3-phase
Volt/amp curve, “drooping” characteristic
Power is ON (LED)
System fault (LED)
Inlet gas pressure fault (LED)
Missing or loose consumables (LED)
Power supply is out of
Gas test mode
temperature range (LED)
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Service Manual

Section 2

POWER SUPPLY SETUP

In this section:
Unpack the Powermax45 .........................................................................................................................................................................2-2
Claims ................................................................................................................................................................................................2-2
Contents ............................................................................................................................................................................................2-2
Position the power supply........................................................................................................................................................................2-3
Prepare the electrical power ...................................................................................................................................................................2-3
Voltage configurations ....................................................................................................................................................................2-3
Install a line-disconnect switch ....................................................................................................................................................2-4
Requirements for grounding .........................................................................................................................................................2-4
Power cord considerations ......................................................................................................................................................................2-4
Extension cord recommendations ...............................................................................................................................................2-5
Generator recommendations ........................................................................................................................................................2-6
Prepare the gas supply .............................................................................................................................................................................2-6
Connect the gas supply .................................................................................................................................................................2-7
Additional gas filtration ...................................................................................................................................................................2-7
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Service Manual 2-1
Power suPPly setuP

Unpack the Powermax45

1. Verify that all items on your order have been received in good condition. Contact your distributor if any parts are damaged or missing.
2. Inspect the power supply for damage that may have occurred during shipping. If there is evidence of damage, refer to Claims, below. 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 Safety and Compliance Manual.
Claims
• Claims for damage during shipment – If your unit was damaged during shipment, youmust file a claim
with the carrier. Hypertherm will furnish you with a copy of the bill oflading upon request. 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.
Contents
Verify the items in the box against the illustration.
Operator Manual
Quick Setup Card
Registration Card
Setup DVD
or
200–240V (CSA) (plug included)
230V (CE) (plug not included)
400V (CE) 480V (CSA) (plug not included)
Box with extra consumables
Remote-start pendant (optional) Shoulder strap
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Service Manual
power supply setup

Position the power supply

Locate the Powermax45 near an appropriate 200–240volt power receptacle for CSA or CE 1-phase power supplies, a 400volt receptacle for 3-phase CE power supplies, or a 480volt receptacle for 3-phase CSA power supplies. The Powermax45 has a 3m (10-foot) power cord. Allow at least 0.25m (10inches) of space around the power supply for proper ventilation.

Prepare the electrical power

The maximum output voltage will vary based on your input voltage and the circuit’s amperage. Because the current draw varies during startup, slow-blow fuses are recommended as shown in the following chart. Slow-blow fuses can withstand currents up to 10times the rated value for short periods of time.
Voltage configurations
The following chart shows the maximum rated output for typical combinations of input voltage and amperage. Acceptable input voltages can be ±10% of the values given below.
CAUTION
Protect the circuit with appropriately sized time-delay (slow-blow) fuses and a line-disconnect switch.
Input
Model Input voltage Phase Rated output
200–240 VAC 1 45 A, 132V 34–28A 55–45A 50 A
CSA
CE
CE/CCC
* Use the higher amperage fuse for applications that require a long arc stretch.
208VAC 1 45 A, 132V 33 A 54.5 A 50 A
480VAC 3 45 A, 132V 8.5A 12A 15 or 20*A
200–240 VAC 1 45 A, 132V 34–28A 55–45A 35 or 50*A
400VAC 3 45 A, 132V 10 A 15.5 A 15 or 20*A
220VAC 1 45 A, 132V 31 A 53 A 35 or 50*A
380VAC 3 45 A, 132V 11 A 14 A 15 A
current at
6kw output
Input
current
during arc
stretch
Recommended slow-blow fuse
size
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Service Manual 2-3
Power suPPly setuP
Install a line-disconnect switch
Use a line-disconnect switch for each power supply so that the operator can turn off the incoming power quickly in an emergency. Locate the switch so that it is easily accessible to the operator. Installation must be performed by a licensed electrician according to national and local codes. The interrupt level of the switch must be equal to or exceed the continuous rating of the fuses. In addition, the switch should:
• Isolate the electrical equipment and disconnect all live conductors from the incoming supply voltage when in the OFF position.
• Have one OFF and one ON position that are clearly marked with O (OFF) and I (ON).
• Have an external operating handle that can be locked in the OFF position.
• Contain a power-operated mechanism that serves as an emergency stop.
• Have slow-blow fuses installed as recommended in the table on the previous page.
Requirements for grounding
To ensure personal safety, proper operation, and to reduce electromagnetic interference (EMI), the Powermax45 must be properly grounded:
• The power supply must be grounded through the power cord according to national and local electrical codes.
• Single-phase service must be of the 3-wire type with a green or green/yellow wire for the protective earth ground
and must comply with national and local requirements. Do not use a 2-wire service.
• Three-phase service must be of the 4-wire type with a green or green/yellow wire for the protective earth ground and must comply with national and local requirements.
• Refer to the Safety and Compliance Manual for more information.

Power cord considerations

Powermax45 power supplies are shipped with CSA and CE power cord configurations.
The power cords on the 200–240V CSA power supplies are shipped with a 50 amp, 250V plug (NEMA 6-50P) on the power cord.
The CE power supplies and the 480V CSA power supplies are shipped without a plug on the power cord. Obtain the correct plug for your unit (230V CE, 400V CE, or 480V CSA) and location and have it installed by a licensed electrician.
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Service Manual
power supply setup
Extension cord recommendations
Use an extension cord of an appropriate wire size for the cord length and system voltage. Usea cord that meets national and local codes.
The following tables provide the recommended gauge size for various lengths and input voltages. The lengths in the tables are the length of the extension cord only; they do not include the power supply’s power cord.
Metric
Input voltage Phase < 3 m 3–7.5 m 7.5–15 m 15–30 m 30 –45 m
208VAC 1 10 mm
220VAC
200–240VAC
380VAC
400VAC
480VAC
1
1
3
3
3
10 mm
10 mm
4 mm
4 mm
4 mm
2
10 mm
2
10 mm
2
10 mm
2
2
2
4 mm
4 mm
4 mm
2
2
2
2
2
2
10 mm
10 mm
10 mm
4 mm
4 mm
4 mm
2
2
2
2
2
2
16 mm
16 mm
16 mm
6 mm
6 mm
6 mm
2
2
2
2
2
2
25 mm
25 mm
25 mm
6 mm
6 mm
6 mm
2
2
2
2
2
2
English
Input voltage Phase < 10 feet 10–25 feet 25–50 feet 50–100 feet 100–150 feet
208VAC 1 8 AWG 8 AWG 8 AWG 6 AWG 4 AWG
220VAC 1 8 AWG 8 AWG 8 AWG 6 AWG 4 AWG
200–240VAC 1 8 AWG 8 AWG 8 AWG 6 AWG 4 AWG
380VAC 3 12 AWG 12 AWG 12 AWG 10 AWG 10 AWG
400VAC 3 12 AWG 12 AWG 12 AWG 10 AWG 10 AWG
480VAC 3 12 AWG 12 AWG 12 AWG 10 AWG 10 AWG
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Service Manual 2-5
Power suPPly setuP
Generator recommendations
Generators used with the Powermax45 should satisfy the following requirements:
CSA
• 1-phase, 50/60Hz, 230/240VAC
• 3-phase, 50/60Hz, 480VAC
CE
• 1-phase, 50/60Hz, 230VAC
• 3-phase, 50/60Hz, 380/400VAC (400VAC recommended for best performance)
Engine drive outputcurrent
Engine
driverating
8 KW 33 A 11.5A 10A Good arc stretch at 45A cutting current
1-phase
(CSA/CE)
3-phase
(CE)
3-phase
(CSA)
Performance
(arc stretch)
6 KW 25 A 9A 7A
Notes: Based on the generator rating, age, and condition, adjust the cutting current as needed.
If a fault occurs while using a generator, turning the power switch quickly to OFF and then to ON again (sometimes called a “quick reset”) may not clear the fault. Instead, turn the power supply off and wait 30 to 45seconds before turning it on again.
Limited arc stretch at 45A cutting current
Good arc stretch at 30A cutting current

Prepare the gas supply

The gas supply for the Powermax45 can be shop-compressed or cylinder-compressed.A high-pressure regulator must be used on either type of supply and must be capable of delivering gas to the filter on the power supply at 170l/min at
6.2bar (360scfhat90psi).
WARNING
Do not allow the gas supply pressure to exceed 9.3 bar (135 psi). The filter bowl may explode if this pressure is exceeded.
If gas supply quality is poor, cut speeds decrease, cut quality deteriorates, cutting thickness capability decreases, and the life for consumables shortens. For optimum performance, the gas should have a maximum particle size of 0.1micron at a maximum concentration of 0.1mg/m3, a maximum dew point of -40°C (-40°F), and a maximum oil concentration of
0.1mg/m3 (per ISO8573-1 Class1.2.2).
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Connect the gas supply
Connect the gas supply to the power supply using an inert gas hose with a 9.5mm (3/8 inch) internal diameter and a 1/4NPT quick-disconnect coupler or a 1/4NPTxG-1/4 BSPP (CE units) quick-disconnect coupler.
CAUTION
Synthetic lubricants containing esters that are used in some air compressors will damage polycarbonates used in the air regulator bowl.
5.5 – 6.9 bar (80 – 100 psi) gas supply (maximum 9.3 bar or 135 psi) with a flow rate of at least 165.2 l/min (350 scfh). The recommended flow rate and pressure is 170 l/min at 6.2 bar (360scfh at 90 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 shown below toclean contaminants from the gas supply.
Oil vapor filter
Powermax45
Gas supply
Water and particle filter
Oil filter
The filtering system should be installed between the quick-disconnect coupler and the power supply.
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Power suPPly setuP
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Service Manual

Section 3

TORCH SETUP

In this section:
Introduction .................................................................................................................................................................................................3-2
Consumable life ..........................................................................................................................................................................................3-2
Hand torch setup .......................................................................................................................................................................................3-2
Choose the consumables ..............................................................................................................................................................3-3
Install the consumables ..................................................................................................................................................................3-5
Machine torch setup..................................................................................................................................................................................3-6
Mount the torch ................................................................................................................................................................................3-6
Choose the consumables (cut charts) .......................................................................................................................................3-8
Using the cut charts ........................................................................................................................................................................3-8
T45m shielded consumables ........................................................................................................................................................3-8
Align the torch ............................................................................................................................................................................... 3-24
Connect the remote-start pendant ...........................................................................................................................................3-25
Connect a machine interface cable .........................................................................................................................................3-25
Accessing raw arc voltage ......................................................................................................................................................... 3-27
Connect the torch lead .......................................................................................................................................................................... 3-30
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Service Manual 3-1
torch setup

Introduction

Both the T45v hand torch and the T45m machine torch are available for the Powermax45. The torch FastConnect™ system makes it easy to remove the torch for transport or to switch from one torch to the other if your applications require the use of both torches.
This section explains how to set up your torch and choose the appropriate consumables for the job.

Consumable life

How often you will need to change the consumables on your Powermax45 will depend on a number of factors:
• The thickness of the metal being cut.
• The length of the average cut.
• Whether you are doing machine or hand cutting.
• The air quality (presence of oil, moisture, or other contaminants).
• Whether you are piercing the metal or starting cuts from the edge.
• Proper torch-to-work distance when gouging or cutting with unshielded consumables.
• Proper pierce height.
• Which consumables you are using. The T30v (Powermax30) 30 amp consumables will have a shorter life when
used on the T45v. However, they provide optimum cut quality for certain applications.
Under normal conditions, the electrode will wear out first during machine cutting, and the nozzle will wear out first when hand cutting.
A good rule of thumb is that a set of consumables will last approximately 1to2hours of actual “arc on” time for hand cutting, depending on these factors. For cutting with a machine torch, consumables may last up to 3to5hours.
You will find more information about proper cutting techniques in the Operation section.

Hand torch setup

Consumables
Safety trigger
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Service Manual
torch setup
Choose the consumables
The Powermax45 with the T45v handheld torch comes with a full set of consumables for cutting installed on the torch, spare electrodes and nozzles in the consumables box, and consumables for gouging in the consumables box. In non­CE-regulated countries, you can also purchase unshielded consumables that are useful for certain applications.
With shielded consumables, you drag the torch tip along the metal to cut. With unshielded consumables, you must keep the torch a small distance, about 2mm (0.08inch), away from the metal. Unshielded consumables generally have a shorter life than shielded consumables; however, you may find that visibility and accessibility are better for some applications.
Consumables for hand cutting are shown below. Notice that the retaining cap, swirl ring, and electrode are the same for shielded, unshielded, and gouging applications. Only the shield (deflector for unshielded consumables) and the nozzle are different.
For the best cut quality on thin gauge stainless steel, you may prefer to reduce the amperage setting to 30amps and use the T30v (Powermax30) 30A consumables available from Hypertherm.
T45v shielded consumables
220674
Shield
220713
Retaining cap
T45v gouging consumables
220675
Shield
220713
Retaining cap
220671
Nozzle
220672
Nozzle
220670
Swirl ring
220670
Swirl ring
220669
Electrode
220669
Electrode
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Service Manual 3-3
torch setup
T45v unshielded consumables*
220717
Deflector
220713
Retaining cap
220718
Nozzle
220670
Swirl ring
* Unshielded consumables are not available for use in CE-regulated countries.
T30v (Powermax30) 30 A consumables
220569
Optional deflector
220483
Retaining cap
220480
Nozzle
220479
Swirl ring
220669
Electrode
220478
Electrode
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Service Manual
Install the consumables
torch setup
WARNING
INSTANTON TORCHES
PLASMA ARC CAN CAUSE INJURY AND BURNS
I
O
The plasma arc comes on im me di ate ly when the torch trigger is activated. Makesure the power is OFF before changing consumables.
To operate the T45v torch, it must have a complete set of consumable parts installed: a shield or deflector, retaining cap, nozzle, swirl ring and electrode.
With the power switch in the OFF (O) position, verify that the torch consumables are installed as shown.
Electrode
Swirl ring
Nozzle
Retaining cap
Shield or deflector
Note: Tighten only to finger-tight. Overtightening
will cause the torch to misfire.
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Service Manual 3-5
There should be a small gap
between the consumables and the
torch handle. Air will blow out from
this gap during normal operation.
torch setup

Machine torch setup

Consumables
Before using the T45m, you must:
• Mount the torch on your cutting table or other equipment.
• Choose and install the consumables.
• Align the torch.
• Attach the torch lead to the power supply.
• Set up the power supply for remote starting with either the remote-start pendant or a machine interface cable.
Positioning sleeve
Gear rack
Brass strain relief
Strain relief
Mount the torch
Depending on the type of cutting table you have, you may or may not need to disassemble the torch to route it through the track and mount it. If your cutting table’s track is large enough for you to thread the torch through it without removing the torch body from the lead, do so and then attach the torch to the lifter per the manufacturer’s instructions.
Note: The T45m can be mounted on a wide variety of X-Y tables, track burners, pipe bevelers, and other equipment.
Install the torch per the manufacturer’s instructions and following the instructions below for disassembly if necessary.
If you need to disassemble the torch, follow these steps:
1. Disconnect the torch lead from the power supply and remove the consumables from the torch.
2. Remove the gear rack from the positioning sleeve by removing the 2black screws that secure it to the positioning sleeve. Remove the 6screws (3 at each end) that secure the positioning sleeve to the brass strain relief ring and to the torch body. Slide the positioning sleeve off the torch.
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3. Disconnect the wires for the cap-sensor switch at the connector in the middle.
Gas supply line connection
torch setup
Screw to connect the power cable to the plunger
4. Use a #2Phillips screwdriver and a 6mm (1/4inch) nut driver (or adjustable wrench) to remove the screw and nut
that secure the torch’s power cable to the plunger. (Turn the plunger if necessary to gain access to the screw.)
5. Use 6mm (1/4inch) and 10mm (3/8inch) or adjustable wrenches to loosen the nut that secures the gas supply
line to the torch lead. Set the torch body aside.
Note: Cover the end of the gas line on the torch lead with tape to keep dirt and other contaminants from getting
in the gas line when you route the lead through the track.
6. Route the torch lead through the cutting table’s track.
7. Reattach the torch’s power cable to the torch plunger using the screw and nut. Rotate the plunger so that the screw
does not interfere with the cap-sensor switch.
8. Reconnect the gas line to the torch lead.
9. Press the two halves of the cap-sensor switch’s wire connector together.
10. Slide the positioning sleeve over the torch body and check the alignment of the screw holes. Replace the three
screws at each end.
Cap-sensor switch’s wireconnector
11. If you will be using the gear rack, re-attach it with the 2 black screws you removed earlier.
12. Attach the torch to the lifter per the manufacturer’s instructions.
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Service Manual 3-7
torch setup
Choose the consumables (cut charts)
PLASMA ARC CAN CAUSE INJURY AND BURNS
WARNING
INSTANTON TORCHES
I
O
The plasma arc comes on im me di ate ly when the torch trigger is activated. Make sure the power is OFF before changing consumables.
A complete set of shielded consumables is shipped with the T45m machine torch. In addition, an ohmic sensing retaining cap is available for use with the T45m shielded consumables. Unshielded consumables and the T30v (Powermax30) 30A consumables are also available for use with the T45m.
Using the cut charts
The following sections provide illustrations of the consumable sets and cut charts for each set. Maximum cut speeds are the fastest speeds possible to cut material without regard to cut quality. Recommended cut speeds are a good starting point for finding the best quality cut (best angle, least dross, and best cut surface finish). You will need to adjust the speeds for your application and your table to obtain the desired cut quality.
When cutting thin metal (3mm/10Ga or thinner), you may achieve a higher cut quality by using the T30v (Powermax30) 30A consumables and cut charts.
T45m shielded consumables
220673
Shield
220713
Retaining cap
or
220719
Ohmic sensing retaining cap
220671
Nozzle
220670
Swirl ring
220669
Electrode
The cut charts for these consumables are shown on the following pages.
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torch setup
T45m shielded consumables
Mild steel Metric
Arc
current
(amps)
30
Material
thickness
(mm)
0.5
0.8 8650 116 10160* 117
0.9 8100 115 10160* 117
1.5 0.2 5650 111 7100 115
0.9
1.5 8890 116 10160* 115
1.9 0.1 7100 117 9144 115
2.7 0.3 4800 117 6096 115
3.4 0.4 3550 117 4445 115
Torch-
to-work
distance
(mm)
1.5 3.8 mm 250%
Initial pierce
height
3.8 mm 250%
Pierce time
delay
(sec)
0.0
0.0
Air flowrate (lpm)
Hot 151
Cold 165.2
Recommended Maximum
Cut Speed
(mm/min)
9150 117 10160* 118
9652 115 10160* 112
Voltage
(V)
Cut Speed
(mm/min)
Voltage
(V)
4.8 0.5 2150 118 2794 115
45
6.4 0.6 1500 120 1905 116
9.5 0.9 510 122 101 6 116
12.7
15.9 280 138 356 127
19.1 200 140 254 131
25.4 10 0 146 127 142
*Maximum cut speed is limited by the test table’s maximum speed (10160 mm/min).
1.5
Edge start recommended
510 132 635 125
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Service Manual 3-9
torch setup
T45m shielded consumables
Mild steel English
Arc
current
(amps)
30
45
Material
thickness
0.018 in (26 Ga)
0.030 in (22 Ga)
0.036 in (20 Ga)
0.060 in (16 Ga)
0.036 in (20 Ga)
0.060 in (16 Ga)
0.075 in (14 Ga)
0.105 in (12 Ga)
0.135 in (10 Ga)
0.188 in
(3/16 in)
0.250 in (1/4 in)
0.375 in (3/8 in)
0.500 in (1/2 in)
0.625 in (5/8 in)
0.750 in (3/4 in)
1.000 in
(1 in)
Torch-
to-work
distance
(in)
0.06 0.15 in 250%
0.06
Initial pierce
height
0.15 in 250%
Edge start recommended
Air flowrate (scfh)
Hot 320
Cold 360
Recommended Maximum
Pierce time
delay
(sec)
0.0
0.2 225 111 280 115
0.0
0.1 280 117 360 115
0.3 190 117 240 115
0.4 140 117 175 115
0.5 85 118 110 115
0.6 60 120 75 116
0.9 32 122 40 116
Cut Speed
(ipm)
360 117 400* 118
340 116 400* 117
320 115 400* 117
380 115 400* 112
350 116 400* 115
20 132 25 125
11 138 14 127
8 140 10 131
4 146 5 142
Voltage
(V)
Cut Speed
(ipm)
Voltage
(V)
*Maximum cut speed is limited by the test table’s maximum speed (400 ipm).
3-10 powermax
45
Service Manual
torch setup
T45m shielded consumables
Stainless steel Metric
Arc
current
(amps)
30
45
Material
thickness
(mm)
0.5
0.8 8650 117 10160* 121
0.9 8100 115 10160* 119
1.5 0.2 3750 113 4700 118
0.9
1.5 8100 112 10160* 125
1.9 0.1 7100 118 9144 115
2.7 0.3 4050 118 5080 116
3.4 0.4 3050 121 3 810 118
4.8 0.5 1780 122 2159 118
Torch-
to-work
distance
(mm)
1.5 3.8 mm 250%
1.5
Initial pierce
height
3.8 mm 250%
Pierce time
delay
(sec)
0.0
0.0
Air flowrate (lpm)
Hot 151
Cold 165.2
Recommended Maximum
Cut Speed
(mm/min)
9150 119 10160* 123
7600 112 10160* 10 9
Voltage
(V)
Cut Speed
(mm/min)
Voltage
(V)
6.4 0.6 1100 124 1397 120
9.5 0.8 760 126 813 121
12.7 Edge start recommended
19.1 175 136 229 131
*Maximum cut speed is limited by the test able’s maximum speed (10160 mm/min).
350 132 457 128
powermax
45
Service Manual 3-11
torch setup
T45m shielded consumables
Stainless steel English
Arc
current
(amps)
30
45
Material
thickness
0.018 in (26 Ga)
0.030 in (22 Ga)
0.036 in (20 Ga)
0.060 in (16 Ga)
0.036 in (20 Ga)
0.060 in (16 Ga)
0.075 in (14 Ga)
0.105 in (12 Ga)
0.135 in
(10 Ga)
0.188 in
(3/16 in)
0.250 in
(1/4 in)
0.375 in
(3/8 in)
0.500 in
(1/2 in)
0.750 in
(3/4 in)
Torch-
to-work
distance
0.06 0.15 in 250%
0.06
(in)
Initial pierce
height
0.15 in 250%
Edge start recommended
Air flowrate (scfh)
Hot 320
Cold 360
Recommended Maximum
Pierce time
delay
(sec)
0.0
0.2 145 111 185 118
0.0
0.1 280 117 360 115
0.3 160 117 200 116
0.4 120 117 150 118
0.5 70 118 85 118
0.6 44 120 55 120
0.8 30 122 32 121
Cut
Speed
(ipm)
360 117 400* 123
340 116 400* 121
320 115 400* 119
300 115 400* 10 9
320 116 400* 125
14 132 18 128
7 140 9 131
Voltage
(V)
Cut
Speed
(ipm)
Voltage
(V)
*Maximum cut speed is limited by the test table’s maximum speed (400 ipm).
3-12 powermax
45
Service Manual
torch setup
T45m shielded consumables
Aluminum Metric
Arc
current
(amps)
30
45
Material
thickness
(mm)
1.2
1.5
1.9 5450 118 6860 121
1.5
1.9 8650 117 1016 0 116
2.7 7100 120 9144 119
3.4 0.1 5600 122 7112 120
4.8 0.2 2550 123 3302 120
Torch-
to-work
distance
(mm)
1.5 3.8 mm 250%
1.5
Initial pierce
height
3.8 mm 250%
Air flowrate (lpm)
Hot 151
Cold 165.2
Recommended Maximum
Pierce time
delay
(sec)
0.0 9150 117 10160* 120
0.2
0.0
Cut Speed
(mm/min)
8650 118 10160* 121
9150 116 10160* 114
Voltage
(V)
Cut Speed
(mm/min)
Voltage
(V)
6.4 0.3 2050 123 2540 120
9.5 0.5 840 130 10 67 125
12.7 Edge start recommended
19.1 200 143 254 138
*Maximum cut speed is limited by the test table’s maximum speed (10160 mm/min).
510 134 635 130
powermax
45
Service Manual 3-13
torch setup
T45m shielded consumables
Aluminum English
Arc
current
(amps)
30
45
Material
thickness
0.018 in (26 Ga)
0.060 in (16 Ga)
0.075 in (14 Ga)
0.060 in (16 Ga)
0.075 in (14 Ga)
0.105 in (12 Ga)
0.135 in
(10 Ga)
0.188 in
(3/16 in)
0.250 in
(1/4 in)
0.375 in
(3/8 in)
0.500 in
(1/2 in)
0.750 in
(3/4 in)
Torch-
to-work
distance
(in)
0.06 0.15 in 250%
0.06
Initial pierce
height
0.15 in 250%
Edge start recommended
Air flowrate (scfh)
Hot 320
Cold 360
Recommended Maximum
Pierce time
delay
(sec)
0.0 360 117 400* 120
0.2
0.0
0.1 220 122 280 120
0.2 100 123 130 120
0.3 80 123 10 0 120
0.5 33 130 42 125
Cut
Speed
(ipm)
340 118 400* 121
215 118 270 121
360 116 400* 114
340 117 400* 116
280 120 360 119
20 134 25 130
8 143 10 138
Voltage
(V)
Cut
Speed
(ipm)
Voltage
(V)
*Maximum cut speed is limited by the test table’s maximum speed (400 ipm).
3-14 powermax
45
Service Manual
T45m unshielded consumables
torch setup
220717
Deflector
Mild steel Metric
Arc
current
(amps)
30
45
220713
Retaining cap
Material
thickness
(mm)
0.5
0.8 8650 118 10160* 116
0.9 8100 117 10160* 120
1.5 0.2 5800 113 7250 119
0.9
1.5 8900 114 10160* 113
1.9 6100 114 7620 114
2.7 0.3 4450 116 5588 114
3.4 0.4 3400 118 4318 116
4.8 0.4 2150 118 2794 116
6.4 0.5 1500 118 1905 118
9.5 0.7 810 120 101 6 118
12.7
15.9 280 132 356 126
19.1 200 138 254 132
25.4 10 0 145 127 140
Torch-
to-work
distance
(mm)
2.0 5.0 mm 250%
2.0
220718
Nozzle
Initial pierce
height
5.0 mm 250%
Edge start recommended
220670
Swirl ring
Pierce time
delay
(sec)
0.0
0.0
220669
Electrode
Air flowrate (lpm)
Hot 151
Cold 165.2
Recommended Maximum
Cut Speed
(mm/min)
9150 118 10160* 114
9650 118 10160* 110
510 130 635 124
Voltage
(V)
Cut Speed
(mm/min)
Voltage
(V)
*Maximum cut speed is limited by the test table’s maximum speed (10160 mm/min).
powermax
45
Service Manual 3-15
torch setup
T45m unshielded consumables
Mild steel English
Arc
current
(amps)
30
45
Material
thickness
0.018 in
(26 Ga)
0.030 in (22 Ga)
0.036 in (20 Ga)
0.060 in (16 Ga)
0.036 in (20 Ga)
0.060 in (16 Ga)
0.075 in (14 Ga)
0.105 in (12 Ga)
0.135 in
(10 Ga)
0.188 in
(3/16 in)
0.250 in
(1/4 in)
0.375 in
(3/8 in)
0.500 in
(1/2 in)
0.625 in
(5/8 in)
0.750 in
(3/4 in)
1.000 in
(1 in)
Torch-
to-work
distance
(in)
0.08 0.2 in 250%
0.08
Initial pierce
height
0.2 in 250%
Edge start recommended
Air flowrate (scfh)
Hot 320
Cold 360
Recommended Maximum
Pierce time
delay
(sec)
0.0
0.2 225 113 285 119
0.0
0.3 175 116 220 114
0.4 135 118 170 116
0.4 85 118 110 116
0.5 60 118 75 118
0.7 32 120 40 118
Cut
Speed
(ipm)
360 118 400* 114
340 118 400* 116
320 117 400* 120
380 118 400* 1 10
350 114 400* 113
240 114 300 114
20 130 25 124
11 132 14 126
8 138 10 132
4 145 5 140
Voltage
(V)
Cut
Speed
(ipm)
Voltage
(V)
*Maximum cut speed is limited by the test table’s maximum speed (400 ipm).
3-16 powermax
45
Service Manual
torch setup
T45m unshielded consumables
Stainless steel Metric
Arc
current
(amps)
30
45
Material
thickness
(mm)
0.5
0.8 8128 115 10160* 128
0.9 7000 114 9000 125
1.5 0.2 3650 112 4800 118
0.9
1.5 8100 115 10160* 113
1.9 0.1 7112 116 9144 114
2.7 0.3 4100 118 5080 116
3.4 0.4 2800 120 3556 118
4.8 0.5 1650 120 2032 118
Torch-
to-work
distance
(mm)
2.0 5.0 mm 250%
2.0
Initial pierce
height
5.0 mm 250%
Pierce time
delay
(sec)
0.0
0.0
Air flowrate (lpm)
Hot 151
Cold 165.2
Recommended Maximum
Cut Speed
(mm/min)
9144 113 10160* 125
8900 112 10160* 110
Voltage
(V)
Cut Speed
(mm/min)
Voltage
(V)
6.4 0.6 1010 121 1270 118
9.5 0.8 610 125 762 120
12.7 Edge start recommended
19.1 175 133 229 138
*Maximum cut speed is limited by the test table’s maximum speed (10160 mm/min).
355 130 457 126
powermax
45
Service Manual 3-17
torch setup
T45m unshielded consumables
Stainless steel English
Arc
current
(amps)
30
45
Material
thickness
0.018 in (26 Ga)
0.030 in (22 Ga)
0.036 in (20 Ga)
0.060 in (16 Ga)
0.036 in (20 Ga)
0.060 in (16 Ga)
0.075 in (14 Ga)
0.105 in (12 Ga)
0.135 in (10 Ga)
0.188 in
(3/16 in)
0.250 in
(1/4 in)
0.375 in
(3/8 in)
0.500 in
(1/2 in)
0.750 in
(3/4 in)
Torch-
to-work
distance
(in)
0.08 0.2 in 250%
0.08
Initial pierce
height
0.2 in 250%
Edge start recommended
Pierce time
Air flowrate (scfh)
Hot 320
Cold 360
Recommended Maximum
delay
(sec)
0.0
0.2 145 112 180 118
0.0
0.1 280 116 360 114
0.3 160 118 200 116
0.4 110 120 140 118
0.5 64 120 80 118
0.6 40 121 50 118
0.8 24 125 30 120
Cut Speed
(ipm)
400* 113 400* 125
400* 115 400* 128
345 114 345 125
350 112 400* 110
320 115 400* 113
14 130 18 126
7 133 9 138
Voltage
(V)
Cut Speed
(ipm)
Voltage
(V)
*Maximum cut speed is limited by the test table’s maximum speed (400 ipm).
3-18 powermax
45
Service Manual
torch setup
T45m unshielded consumables
Aluminum Metric
Arc
current
(amps)
30
45
Material
thickness
(mm)
1.2
1.5 0.1 8100 120 10160* 118
1.9 0.2 5700 121 7100 119
1.5
1.9 8100 120 10160* 116
2.7 7200 122 9144 118
3.4 0.1 5500 123 6858 118
4.8 0.3 2540 123 3175 118
Torch-
to-work
distance
(mm)
2.0 5.0 mm 250%
2.0
Initial pierce
height
5.0 mm 250%
Air flowrate (lpm)
Hot 151
Cold 165.2
Recommended Maximum
Pierce time
delay
(sec)
0.0 8900 122 10160* 121
0.0
Cut Speed
(mm/min)
8900 120 10160* 116
Voltage
(V)
Cut Speed
(mm/min)
Voltage
(V)
6.4 0.3 1820 128 2286 124
9.5 0.5 710 130 914 124
12.7 Edge start recommended
19.1 200 148 254 143
*Maximum cut speed is limited by the test table’s maximum speed (10160 mm/min).
510 131 635 125
powermax
45
Service Manual 3-19
torch setup
T45m unshielded consumables
Aluminum English
Arc
current
(amps)
30
45
Material
thickness
0.018 in (26 Ga)
0.060 in (16 Ga)
0.075 in (14 Ga)
0.060 in (16 Ga)
0.075 in (14 Ga)
0.105 in (12 Ga)
0.135 in
(10 Ga)
0.188 in
(3/16 in)
0.250 in
(1/4 in)
0.375 in
(3/8 in)
0.500 in
(1/2 in)
0.750 in
(3/4 in)
Torch-
to-work
distance
(in)
0.08 0.20 in 250%
0.08
Initial pierce
height
0.20 in 250%
Edge start recommended
Air flowrate (scfh)
Hot 320
Cold 360
Recommended Maximum
Pierce time
delay
(sec)
0.0 350 122 400* 121
0.1 320 120 400* 118
0.2 225 121 280 119
0.0
0.1 215 123 270 118
0.3 100 123 125 118
0.3 72 128 90 124
0.5 28 130 36 124
Cut
Speed
(ipm)
350 120 400* 116
320 120 400* 116
285 122 360 118
20 131 25 125
8 148 10 143
Voltage
(V)
Cut
Speed
(ipm)
Voltage
(V)
*Maximum cut speed is limited by the test table’s maximum speed (400 ipm).
3-20 powermax
45
Service Manual
T30v (Powermax30) 30A consumables
torch setup
220569
Optional deflector
Mild steel Metric
Arc
current
(amps)
30
220483
Retaining cap
Material
thickness
(mm)
0.5
0.8 8100 10 2 10160* 103
0.9 7100 101 8900 10 0
1.5 0.2 4450 97 5600 100
1.9
Torch-
to-work
distance
(mm)
0.5 2.5 mm 500%
220480
Nozzle
Initial pierce
height
220479
Swirl ring
Pierce time
delay
(sec)
0.0
220478
Electrode
Air flowrate (lpm)
Hot 131.2
Cold 146.3
Recommended Maximum
Cut Speed
(mm/min)
8900 10 5 10160* 98
3050 98 3800 97
Voltage
(V)
Cut Speed
(mm/min)
Voltage
(V)
2.7 2050 96 2550 96
3.4 1270 10 0 1650 101
*Maximum cut speed is limited by the test table’s maximum speed (10160 mm/min).
powermax
45
Service Manual 3-21
0.4
torch setup
T30v (Powermax30) 30A consumables
Mild steel English
Arc
current
(amps)
30
Material
thickness
(in)
0.018
(26 Ga)
0.030
(22 Ga)
0.036
(20 Ga)
0.060
(16 Ga)
0.075
(14 Ga)
0.105
(12 Ga)
0.135
(10 Ga)
Torch-
to-work
distance
(in)
0.02 0.1 in 500%
Initial pierce
height
Air flowrate (scfh)
Hot 280
Cold 3 10
Recommended Maximum
Pierce time
delay
(sec)
0.0
0.2 175 97 220 10 0
0.4
Cut Speed
(ipm)
350 105 400* 98
320 102 400* 103
280 101 350 10 0
120 98 150 97
80 96 100 96
50 10 0 65 101
Voltage
(V)
Cut Speed
(ipm)
Voltage
(V)
T30v (Powermax30) 30A consumables
Stainless steel Metric
Recommended Maximum
Arc
current
(amps)
30
*Maximum cut speed is limited by the test table’s maximum speed (400 ipm or 10160 mm/min).
Material
thickness
(mm)
0.5
0.8 8100 98 10160* 100
0.9 7600 97 6850 98
1.5 0.2 3800 99 4800 98
1.9
2.7 1500 101 1900 98
3.4 1150 10 2 1400 97
Torch-
to-work
distance
(mm)
0.5 2.5 mm 500%
Initial pierce
height
Pierce time
delay
(sec)
0.0
0.4
Cut Speed
(mm/min)
8900 10 3 10160* 102
2800 101 3450 97
Voltage
(V)
Air flowrate (lpm)
Hot 131.2
Cold 146.3
Cut Speed
(mm/min)
Voltage
(V)
3-22 powermax
45
Service Manual
torch setup
T30v (Powermax30) 30A consumables
Stainless steel English
Arc
current
(amps)
30
Material
thickness
(in)
0.018
(26 Ga)
0.030
(22 Ga)
0.036
(20 Ga)
0.060
(16 Ga)
0.075
(14 Ga)
0.105
(12 Ga)
0.135
(10 Ga)
Torch-
to-work
distance
(in)
0.02 0.1 in 500%
Initial pierce
height
Air flowrate (scfh)
Hot 280
Cold 3 10
Recommended Maximum
Pierce time
delay
(sec)
0.0
0.2 150 99 190 98
0.4
Cut Speed
(ipm)
350 103 400* 10 2
320 98 400* 10 0
300 97 380 98
110 101 135 97
60 101 75 98
45 102 55 97
Voltage
(V)
Cut Speed
(ipm)
Voltage
(V)
T30v (Powermax30) 30A consumables
Aluminum Metric
Recommended Maximum
Arc
current
(amps)
30
*Maximum cut speed is limited by the test table’s maximum speed (400 ipm or 10160 mm/min).
Material
thickness
(mm)
0.5
0.8 6100 10 4 7650 103
0.9 4800 10 4 6100 103
1.5
1.9 2400 101 3050 101
Torch-
to-work
distance
(mm)
0.5 2.5 mm 500%
Initial pierce
height
Pierce time
delay
(sec)
0.0
0.2
Cut Speed
(mm/min)
8100 107 10160* 105
3700 10 3 4550 103
Voltage
(V)
Air flowrate (lpm)
Hot 131.2
Cold 146.3
Cut Speed
(mm/min)
Voltage
(V)
powermax
45
Service Manual 3-23
torch setup
T30v (Powermax30) 30A consumables
Aluminum English
Arc
current
(amps)
30
*Maximum cut speed is limited by the test table’s maximum speed (400 ipm).
Material
thickness
(in)
0.036
(20 Ga)
0.060
(16 Ga)
0.075
(14 Ga)
0.105
(12 Ga)
0.135
(10 Ga)
Torch-
to-work
distance
(in)
0.02 0.10 in 500%
Initial pierce
height
Pierce time
delay
(sec)
0.0
0.2
Air flowrate (scfh)
Hot 280
Cold 3 10
Recommended Maximum
Cut Speed
(ipm)
320 107 400* 105
240 104 300 10 3
190 104 240 10 3
145 103 180 10 3
95 101 120 101
Voltage
(V)
Cut Speed
(ipm)
Voltage
(V)
Align the torch
Mount the machine torch perpendicular to the workpiece in order to get a vertical cut. Use a square to align the torch at 0° and 90°.
Torch
90°
3-24 powermax
45
Service Manual
torch setup
Connect the remote-start pendant
Configurations of a Powermax45 with a T45m also can include a 7.62m/25-foot (128650), 15.24m/50-foot (128651), or 22.86m/75-foot (128652) remote-start pendant. To use the Hypertherm remote-start pendant, plug it into the receptacle on the rear of the power supply.
Note: The remote-start pendant is for use only with a machine torch. It will not operate if a hand torch is installed.
Receptacle for the remote-startpendant or a machineinterfacecable.
Connect a machine interface cable
The Powermax45 is equipped with a factory-installed voltage divider that is designed to be safely connected without tools. The built-in voltage divider provides a 50:1 arc voltage. A receptacle on the rear of the power supply provides access to the 50:1 arc voltage and signals for arc transfer and plasma start.
CAUTION
The factory-installed internal voltage divider provides a maximum of 7V under open circuit conditions. This is an impedance-protected functional extra low voltage (ELV) output to prevent shock, energy, and fire under normal conditions at the machine interface receptacle and under single fault conditions with the machine interface wiring. The voltage divider is not fault tolerant and ELV outputs do not comply with safety extra low voltage (SELV) requirements for direct connection to computer products.
Hypertherm offers several choices of machine interface cables for the Powermax45:
• To use the built-in voltage divider that provides a 50:1 arc voltage in addition to signals for arc transfer and plasma start:
— Use kit number 228350 (7.62m, 25feet) or 228351 (15.24m, 50feet) for 6wires terminated with spade
connectors. (The following diagram shows an example of spade connectors.)
— Use part number 223048 (7.62m, 25feet) or 123896 (15.24m, 50feet) for a cable terminated with a
D-sub connector. (Compatible with Hypertherm’s EDGE®ProTi and Sensor™PHC products.)
powermax
45
Service Manual 3-25
torch setup
• To use signals for arc transfer and plasma start only, use either part number 023206 (7.62m, 25feet) or part number 023279 (15.24m, 50feet). These cables have spade connectors as shown here:
Note: The cover on the machine interface receptacle prevents dust and moisture from damaging the receptacle
when not in use. This cover should be replaced if damaged or lost (127204).
Installation of the machine interface cable must be performed by a qualified service technician. To install a machine interface cable:
1. Turn OFF the power and disconnect the power cord.
2. Remove the machine interface receptacle’s cover from the rear of the power supply.
3. Connect the Hypertherm machine interface cable to the power supply.
4. If you are using a cable with a D-sub connector on the other end, plug it into the appropriate pin connector on the torch height controller or CNC. Secure it with the screws on the D-sub connector.
If you are using a cable with wires and spade connectors on the other end, terminate the machine interface cable inside the electrical enclosure of listed and certified torch height controllers or CNC controllers to prevent operator access to the connections after installation. Verify that the connections are correct and that all live parts are enclosed and protected before operating the equipment.
Note: The integration of Hypertherm equipment and customer-supplied equipment including interconnecting
cords and cables, if not listed and certified as a system, is subject to inspection by local authorities at the final installation site.
The connector sockets for each type of signal available through the machine interface cable are shown below. The table on page 3-27 provides details about each signal type.
6
3
14
5
4
12
13
3-26 powermax
45
Service Manual
torch setup
Refer to the following table when connecting the Powermax45 to a torch height controller or CNC with a machine interface cable.
Signal Type Notes
Normally open.
Start (start plasma) Input
Transfer (startmachinemotion)
Ground Ground 13
Voltage divider Output
Output
18VDC open circuit voltage at START terminals. Requires dry contact closure to activate.
Normally open. Dry contact closure when the arc transfers.
120VAC/1A maximum at the machine interface relay or switching device (supplied by the customer).
Divided arc signal of 50:1 (provides a maximum of 7V).
Connector sockets
3, 4 Green, black
12, 14 Red, black
5(-), 6(+) Black(-), white(+)
External cable wires
Accessing raw arc voltage
Connecting a cable to the Powermax45 power board to bypass the voltage divider and access raw arc voltage must be done by a qualified service technician.
WARNING
HIGH VOLTAGE AND CURRENT
Connecting directly to the plasma circuit for access to raw arc voltage increases the risk of shock hazard, energy hazard, and fire hazard in the event of a single fault. The output voltage and the output current of the circuit are specified on the data plate.
To access raw arc voltage on a Powermax45, you will need kit number 228352 and an 18 AWG, 2 wire, non-shielded cable similar to OLFLEX equipment plus an additional 45.72cm (18 inches).
1. On the end of the cable that will be attached to the power supply, strip the outer jacket 11.43cm (4.5 inches). Cut
6.35cm (2.5 inches) off of wire2 so that wire1 is 11.43cm (4.5inches) long and wire2 is 5.08cm (2inches) long. Then strip 1.27cm (0.5 inches) of wire insulation off of each wire.
2. Crimp a #8insulated ring on the end of wire1 and a #10insulated ring on the end of wire2.
3. Use a #2 Phillips screwdriver to remove the 2 screws from the handle on the top of the power supply. Tip the end
panels back slightly so that you can get the edges of the handle out from underneath them. Lift the cover off the power supply. Remove the Mylar barrier that protects the power board.
®
190 (601802) in the length needed to go between the power supply and the CNC or other
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Service Manual 3-27
torch setup
4. Separate the rear panel from the Powermax45 by removing the screw from the bottom and backing the end panel away from the base so that there is enough room to drill out the access point without risk of hitting the interior components.
Rear end panel
Access point
5. Use a drill with a 19/32inch drill bit to drill out the access point on the rear panel.
6. Route the cable through the strain relief and tighten it down so that 45.72cm (18inches) of insulated wire is on the side of the strain relief that will go inside the power supply.
7. Thread the 45.72cm (18inches) of wire through the hole you drilled in the rear panel and fit the strain relief into the hole. If necessary, drill out any remaining rough spots so that the strain relief fits snugly.
8. Tighten the strain relief nut on the inside of the rear panel to hold the strain relief in place.
9. Find the grommet closest to the rear panel and at the bottom of the center panel. Route the 2wires through the grommet to the power board side of the power supply.
Rear panel pulled slightly
away from the base
Grommet in center panel
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torch setup
10. Route the wires along the base of the unit and behind the cables connected to the power board.
11. Remove the work lead connector screw at J21 and the white wire connector screw at J19 (J18 for 400V CE and
480V CSA power supplies).
12. Connect wire1 to J19 (J18 for 400V CE and 480V CSA power supplies) with the ring connector for wire1
closest to the power board and the connector for the white wire closest to the head of the screw. Turn the ring connector for wire1 upside down so that the slight bend in the ring connector base creates a little space between the wire and the board. Tighten the screw to 23.0kgcm (20 inch-pounds).
13. Connect wire2 to J21. This time, put the connector for the work lead closest to the power board and put the ring
connector for wire2 closest to the head of the screw. Torque the screw to 23.0kgcm (20 inch-pounds).
J19 or J18
(white wire)
192 VDC
TP 19
TP 18
192 VDC
TP 17
R
B
-
+
W
-
+
J21 (work lead)
14. Replace the rear panel and secure it with the screw. Replace the Mylar barrier in front of the power board. Replace
the cover.
15. Connect the other end of the cable to the equipment according to the manufacturer’s instructions.
NOTE: The integration of Hypertherm equipment and customer-supplied equipment including interconnecting
cords and cables, if not listed and certified as a system, is subject to inspection by local authorities at the final installation site.
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torch setup

Connect the torch lead

The Powermax45 has a FastConnect system for connecting and disconnecting the hand and machine torches. When connecting or disconnecting a torch, first power OFF the system. To connect either torch, push the connector into receptacle on the front of the power supply.
To remove the torch, press the red button on the connector and pull the connector out of the receptacle.
Red button
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Service Manual

Section 4

OPERATION

In this section:
Controls and indicators ............................................................................................................................................................................4-2
Front controls and LEDs ................................................................................................................................................................4-2
Rear controls ....................................................................................................................................................................................4-3
Operate the Powermax45 ........................................................................................................................................................................4-3
Connect the electrical power and gas supply ..........................................................................................................................4-3
Power ON the system ....................................................................................................................................................................4-4
Set the mode switch .......................................................................................................................................................................4-4
Adjust the gas pressure .................................................................................................................................................................4-4
Check the indicator LEDs .............................................................................................................................................................4-6
Attach the work clamp ...................................................................................................................................................................4-6
Understand duty-cycle limitations ..........................................................................................................................................................4-6
How to use the hand torch ......................................................................................................................................................................4-7
Operate the safety trigger .............................................................................................................................................................4-7
Hand torch cutting hints ................................................................................................................................................................4-7
Start a cut from the edge of the workpiece ..............................................................................................................................4-8
Pierce a workpiece ..........................................................................................................................................................................4-9
Gouge a workpiece ..................................................................................................................................................................... 4-10
Common hand-cutting faults ..................................................................................................................................................... 4-12
How to use the machine torch .............................................................................................................................................................4-12
Ensure the torch and table are set up correctly .................................................................................................................... 4-12
Understand and optimize cut quality ........................................................................................................................................4-13
To pierce a workpiece using the machine torch .................................................................................................................... 4-14
Common machine-cutting faults ............................................................................................................................................... 4-15
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Service Manual 4-1
operation

Controls and indicators

The Powermax45 has an ON/OFF switch, an amperage adjustment knob, a pressure regulator knob, a mode switch, 4indicator LEDs, and a gas pressure LED, which are described below.
Front controls and LEDs
Pressure regulator knob
Gas pressure LED and pressure bar
Indicator LEDs
Amperage adjustment knob
30
20
AMPS
40
45
Mode switch
AC
Temperature LED (yellow)
When illuminated, this LED indicates that the power supply temperature is outside the acceptable range.
Torch cap sensor LED (yellow)
When illuminated, this LED indicates that the consumables are loose, improperly installed, or missing. For information on the possible fault conditions, refer to the Troubleshooting guide topic in the Troubleshooting and System Tests section. If this LED illuminates, the power must be turned OFF, the consumables installed properly, and the system turned ON again to reset it.
Fault LED (yellow)
When illuminated, this LED indicates that there is a fault with the power supply. Some fault conditions will cause one or more of the LEDs to blink. For information on what these fault conditions are and how to correct them, refer to the Troubleshooting guide topic in the Troubleshooting and System Tests section.
Power ON LED (green)
When illuminated, this LED indicates that the power switch has been set to I (ON) and that the safety interlocks are satisfied.
Gas pressure LED and pressure bar (yellow/green)
When the LED indicator in the pressure bar illuminates green and is centered in the vertical bar, the gas pressure is set correctly for the mode of cutting selected with the mode switch. If the pressure is too high for the selected mode, the indicator in the pressure bar will be above the mid-point of the bar. If it is too low, the indicator will be below the mid-point. At the highest and lowest points on the bar, the indicator will illuminate yellow.
If the indicator is at the lowest part of the bar and is flashing, then the gas pressure is less than the minimum required pressure.
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Amperage adjustment knob
40
Set this knob to the gas test position (fully counter-clockwise) before adjusting the gas pressure with the pressure regulator knob on the top of the power supply. Once the gas pressure is set, turn the knob
45
clockwise to set the output amperage. The torch will not fire when the knob is in gas-test position.
Mode switch and LEDs
The mode switch can be set in one of three positions:
• Continuous pilot arc to cut expanded metal or grate (top).
• Non-continuous pilot arc to cut metal plate (middle).
• Gouging (bottom).
After you change the mode switch, verify that the gas pressure is still set correctly. Different modes of cutting require different pressure settings.
Rear controls
200–240V CSA / 230V CE 400V CE / 480V CSA
I
I
O
O
operation
ON (I)/OFF (O) power switch Activates the power supply and its control circuits.

Operate the Powermax45

Follow the steps below to begin cutting or gouging with the Powermax45.
Connect the electrical power and gas supply
Plug in the power cord and connect the gas supply line. For more information about the electrical requirements and the gas supply requirements of the Powermax45, see the Power Supply Setup section.
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Service Manual 4-3
operation
Power ON the system
Set the ON/OFF switch to the ON (I) position.
I
I
O
200–240V CSA / 230V CE 400V CE / 480V CSA
Set the mode switch
Use the mode switch to select the type of work you will be doing:
To cut expanded metal or grate (top position). Use this setting to cut metal with holes in it or for any job requiring a continuous pilot arc. Leaving the mode switch on this setting when cutting standard metal plate will result in reduced consumable life.
To cut metal plate (middle position). Use this setting to cut metal up to 25.4mm (1-inch) thick or pierce metal up to 12.7mm (1/2-inch) thick.
O
I
O
Gouging (bottom position). Use this setting to gouge metal. Leaving the mode switch on this setting while cutting results in poor cut quality.
Adjust the gas pressure
Look at the gas pressure LED. If it illuminates green in the center of the pressure bar, the incoming gas pressure is correct for the mode you have selected. If the LED illuminates yellow, either above or below the center, the gas pressure needs to be adjusted.
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To adjust the pressure:
1. Turn the amperage knob counter-clockwise to the gas-test position as shown below.
30
40
45
2. With the amperage knob in the gas test position, pull up on the pressure regulator knob on top of the system to unlock it.
Pressure regulator knob
30
20
40
AMPS
45
3. Turn the pressure regulator knob until the gas pressure LED shows a green bar in the center of the pressure bar.
4. Press down on the pressure regulator knob to lock it in position.
5. Turn the amperage knob to the cutting current appropriate for your application. If you are using T30v (Powermax30) 30A consumables, do not set the amperage knob above 30A.
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Service Manual 4-5
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Check the indicator LEDs
Verify that the green power ON LED on the front of the power supply is illuminated, that the gas pressure LED shows a green bar in the center of the gauge, and that none of the other LEDs are illuminated or blinking. If the temperature, torch cap sensor, or fault LEDs are illuminated or blinking, or if the power ON LED blinks, correct the fault condition before continuing. See the Troubleshooting guide topic in the Troubleshooting and System Tests section for more information.
Attach the work clamp
The work clamp must be attached to the workpiece while you are cutting.
Note: If you are using the Powermax45 with a cutting table, you can ground it through the table instead of using
the work clamp. See your table manufacturer’s instructions for more information.
• Ensure that the work clamp and the workpiece make good metal-to-metal contact.
• For the best cut quality, attach the work clamp as close as possible to the area being cut.
• Donot attach the work clamp to the portion of the workpiece to be cut away.
Work clamp
When the power ON LED is illuminated, none of the other LEDs are illuminated or blinking, the gas pressure LED indicates pressure is in the correct range, the amperage knob is set, and the work clamp is attached, the system is ready for use.

Understand duty-cycle limitations

The duty cycle is the amount of time, in minutes, that a plasma arc can remain on within a 10-minute period when operating at an ambient temperature of 40°C (104°F). With a Powermax45:
• At 45A, the arc can remain on for 5minutes out of 10minutes without causing the unit to overheat (50%duty cycle).
• At 41A, the arc can remain on for 6minutes out of 10 (60%).
• At 32A, the arc can remain on for 10minutes out of 10 (100%).
If the power supply overheats because the duty cycle is exceeded, the temperature LED will illuminate, the arc will shut off, and the cooling fan will continue to run. To resume cutting, wait for the temperature LED to extinguish.
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The next section explains how to operate the hand torch. To use the machine torch, see How to use the machine torch on page 4-12.

How to use the hand torch

WARNING
INSTANTON TORCHES
PLASMA ARC CAN CAUSE INJURY AND BURNS
Plasma arc comes on im me di ate ly when the torch trigger is activated. The plasma arc will cut quickly through gloves and skin.
•   Keep away from the torch tip.
•   Do not hold the workpiece and keep your hands clear of the cutting path.
•   Never point the torch toward yourself or others.
Operate the safety trigger
The T45v is equipped with a safety trigger to prevent accidental firings. When you are ready to cut with the torch, flip the yellow safety trigger forward (toward the torch head) and press the red torch trigger as show below.
1
2
3
Hand torch cutting hints
• With shielded consumables, drag the nozzle lightly along the workpiece to maintain a steady cut. With unshielded consumables, maintain an approximate 2mm (0.08-inch) distance between the tip of the torch and the workpiece. (This is between 1.6–3.2mm, or between 1/16th and 1/8th of an inch.)
• While cutting, make sure that sparks exit from the bottom of the workpiece. The sparks should be lagging slightly behind the torch as you cut (15°–30° angle from vertical).
• If sparks are spraying up from the workpiece, move the torch more slowly, or set the output current higher.
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Service Manual 4-7
operation
• Hold the torch nozzle perpendicular to the workpiece so that the nozzle is at a 90°angle to the cutting surface, and watch the arc as it cuts along the line.
• If you fire the torch unnecessarily, you shorten the life of the nozzle and electrode.
• Pulling, or dragging, the torch along the cut is easier than pushing it.
• For straight-line cuts, use a straight edge as a guide. To cut circles, use a template or a radius cutter attachment (a circle cutting guide). See the Parts section for part numbers for the Hypertherm plasma cutting guides for cutting circles and making bevel cuts.
Start a cut from the edge of the workpiece
1. With the work clamp attached to the workpiece, hold the torch nozzle perpendicular (90°) to the edge of the workpiece. If you are using the shielded consumables, no standoff is needed. With unshielded consumables, maintain an approximate 2mm (0.08-inch) standoff.
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Service Manual
2. Press the torch trigger to start the arc. Pause at the edge until the arc has cut completely through the workpiece.
3. Drag the nozzle lightly across the workpiece to proceed with the cut. Maintain a steady, even pace.
operation
Pierce a workpiece
WARNING
SPARKS AND HOT METAL CAN INJURE EYES AND BURN SKIN. When firing the 
torch at an angle, sparks and hot metal will spray out from the nozzle. Point the torch away from yourself and others.
1. With the work clamp attached to the workpiece, hold the torch at an approximate 30° angle to the workpiece with the nozzle within 1.5mm (1/16 inch) of it before firing the torch.
2. Fire the torch while still at an angle to the workpiece, then slowly rotate the torch to a perpendicular (90°) position.
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Service Manual 4-9
operation
3. Hold the torch in place while continuing to press the trigger. When sparks exit from the bottom of the workpiece, the arc has pierced the material.
4. When the pierce is complete, dragthe nozzle lightly along the workpiece to proceed with the cut.
Gouge a workpiece
WARNING
SPARKS AND HOT METAL CAN INJURE EYES AND BURN SKIN. When firing the 
torch at an angle, sparks and hot metal will spray out from the nozzle. Point the torch away from yourself and others.
1. Hold the torch so that the nozzle is within 1.5mm (1/16 inch) from the workpiece before firing the torch.
2. Hold the torch at a 45° angle to the workpiece with a small gap between the torch tip and the workpiece. Press the trigger to obtain a pilot arc. Transfer the arc to the workpiece.
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Service Manual
3. Maintain an approximate 45° angle to the workpiece as you feed into the gouge.
In other words, push the plasma arc in the direction of the gouge you want to create. Keep a small distance between the torch tip and the molten metal to avoid reducing consumable life or damaging the torch.
operation
Changing the torch angle changes the dimensions of the gouge.
Di rec tion of travel
Note: A heat shield is available for added hand and torch protection (220049).
You can vary the depth of the gouge by varying the angle of the torch to the workpiece. The following tables show the gouging profile at 45° and 60° on mild steel and stainless steel.
Mild steel gouging profile
Torch angle Speed Width Depth
254 mm/min (10 ipm) 7.75 mm (0.3051 inch) 1.05 mm (0.0415 inch) 508 mm/min (20 ipm) 6.50 mm (0.2550 inch) 2.94 mm (0.1158 inch)
45°
60°
762 mm/min (30 ipm) 5.76 mm (0.2267 inch) 1.87 mm (0.0735 inch) 1016 mm/min (40 ipm) 5.30 mm (0.2087 inch) 1.31 mm (0.0517 inch) 1270 mm/min (50 ipm) 4.73 mm (0.1863 inch) 1.03 mm (0.0406 inch)
254 mm/min (10 ipm) 8.06 mm (0.3173 inch) 4.18 mm (0.1645 inch)
508 mm/min (20 ipm) 6.15 mm (0.2423 inch) 2.39 mm (0.0941 inch)
762 mm/min (30 ipm) 6.00 mm (0.2351 inch) 1.39 mm (0.0546 inch) 1016 mm/min (40 ipm) 5.80 mm (0.2281 inch) 1.21 mm (0.0476 inch) 1270 mm/min (50 ipm) 4.61 mm (0.1816 inch) 0.73 mm (0.0289 inch)
45°
Stainless steel gouging profile
Torch angle Speed Width Depth
254 mm/min (10 ipm) 6.37 mm (0.2508 inch) 3.05 mm (0.1200 inch)
508 mm/min (20 ipm) 5.74 mm (0.2258 inch) 1.96 mm (0.0772 inch)
45°
60°
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Service Manual 4-11
762 mm/min (30 ipm) 5.28 mm (0.2077 inch) 1.09 mm (0.0428 inch) 1016 mm/min (40 ipm) 4.83 mm (0.1901 inch) 1.73 mm (0.0680 inch) 1270 mm/min (50 ipm) 4.42 mm (0.1739 inch) 1.47 mm (0.0580 inch)
254 mm/min (10 ipm) 6.55 mm (0.2580 inch) 5.92 mm (0.2330 inch)
508 mm/min (20 ipm) 6.42 mm (0.2526 inch) 2.01 mm (0.0792 inch)
762 mm/min (30 ipm) 5.92 mm (0.2329 inch) 1.45 mm (0.0569 inch) 1016 mm/min (40 ipm) 5.36 mm (0.2110 inch) 1.10 mm (0.0432 inch) 1270 mm/min (50 ipm) 5.09 mm (0.2003 inch) 0.82 mm (0.0322 inch)
operation
Common hand-cutting faults
The torch sputters and hisses, but does not produce an arc. The cause can be:
• The consumables are too tight. Loosen the consumables about 1/8th of a turn and try again. Never tighten the consumables beyond just finger-tight.
The torch does not cut completely through the workpiece. The causes can be:
• The cut speed is too fast.
• The consumables are worn.
• The metal being cut is too thick.
• Gouging consumables are installed instead of cutting consumables.
• The work clamp is not attached properly to the workpiece.
• The gas pressure or gas flow rate is too low.
Cut quality is poor. The causes can be:
• The metal being cut is too thick.
• The wrong consumables are being used (gouging consumables are installed instead of cutting consumables, for
example).
• You are moving the torch too quickly or too slowly.
The arc sputters and consumables life is shorter than expected. The cause can be:
• Moisture in the gas supply.
• The gas pressure is too low.

How to use the machine torch

Since the Powermax45 and the T45m can be used with a wide variety of cutting tables, track burners, pipe bevelers, and such, you will need to refer to the manufacturer’s instructions for specifics on operating the machine torch in your configuration. However, the information in the following sections can help you optimize cut quality and maximize consumable life.
Ensure the torch and table are set up correctly
• Use a square to align the torch at right angles to the workpiece.
• The torch may travel more smoothly if you clean, check, and “tune” the rails and drive system on the cutting table.
Unsteady machine motion can cause a regular, wavy pattern on the cut surface.
• Ensure that the torch does not touch the workpiece during cutting. Contact with the workpiece can damage the shield and nozzle and affect the cut surface.
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Understand and optimize cut quality
There are several factors to consider in cut quality:
• Cut angle – The degree of angularity of the cut edge.
• Dross – The molten material that solidifies on the top or bottom of the workpiece.
• Straightness of the cut surface – The cut surface can be concave or convex.
The following sections explain how these factors can affect cut quality.
Cut or bevel angle
• A positive cut angle, or bevel, results when more material is removed from the top of the cut than from the bottom.
• A negative cut angle results when more material is removed from the bottom of the cut.
Problem
Negative cut angle
Square cut
Positive cut angle
Notes: The squarest cut angle will be on the right side with respect to the forward motion of the torch. The left side
will always have some degree of bevel.
To determine whether a cut-angle problem is being caused by the plasma system or the drive system, make a test cut and measure the angle of each side. Next, rotate the torch 90° in its holder and repeat the process. If the angles are the same in both tests, the problem is in the drive system.
If a cut-angle problem persists after “mechanical causes” have been eliminated (see Ensure the torch and table are set
up correctly on page 4-12), check the torch-to-work distance, especially if the cut angles are all positive or all negative.
Also consider the material being cut. If the metal is magnetized or hardened, you are more likely to experience cut angle problems.
Dross
Some amount of dross will always be present when cutting with air plasma. However, you can minimize the amount and type of dross by adjusting your system correctly for your application.
Cause
The torch is too low.
The torch is too high.
Solution
Raise the torch; or if you are using a torch height control, increase the arc voltage.
Lower the torch; or if you are using a torch height control, decrease the arc voltage.
Dross appears on the top edge of both pieces of the plate when the torch is too low (or voltage is too high if using a torch height control). Adjust the torch or the voltage in small increments (5 volts or less) until the dross is reduced.
Low-speed dross forms when the torch’s cutting speed is too slow and the arc shoots ahead. It forms as a heavy, bubbly deposit at the bottom of the cut and can be removed easily. Increase the speed to reduce this type of dross.
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Service Manual 4-13
operation
High-speed dross forms when the cutting speed is too fast and the arc lags behind. It forms as a thin, linear bead of solid metal attached very close to the cut. It is welded to the bottom of the cut and is difficult to remove. To reduce high-speed dross:
• Decrease the cutting speed.
• Decrease arc voltage to decrease the torch-to-work distance.
Notes: Dross is more likely to form on warm or hot metal than on cool metal. For example, the first
cut in a series of cuts will likely produce the least dross. As the workpiece heats up, more dross may form on subsequent cuts.
Dross is more likely to form on mild steel than on stainless steel or aluminum.
Worn or damaged consumables may produce intermittent dross.
Straightness of the cut surface
A typical plasma cut surface is slightly concave.
The cut surface may become more concave or convex. Correct torch height is required to keep the cut surface
acceptably close to straight. Worn consumables also affect the straightness of the cut.
A strongly concave cut surface occurs when the torch-to-work distance is too low. Increase the torch-to-work distance to straighten the cut surface.
A convex cut surface occurs when the torch-to-work distance is too great or the cutting current is too high. First, try lowering the torch, then reduce the cutting current.
To pierce a workpiece using the machine torch
As with the hand torch, you can start a cut with the machine torch at the edge of the workpiece or by piercing the workpiece. Piercing will result in a shorter consumable life than with edge starts.
The cut charts include a column for the height at which the torch should be when starting a pierce. For the Powermax45, the pierce height is generally 2.5 times the torch cutting height. Refer to the cut charts for specifics.
The pierce delay must be sufficiently long that the arc can pierce the material before the torch moves, but not so long that the arc “wanders” while trying to find the edge of a large hole.
When piercing maximum thicknesses, the ring of dross that forms during the pierce may become high enough to contact the torch when the torch begins to move after the pierce is complete.
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Common machine-cutting faults
The torch pilot arc will initiate, but will not transfer. Causes can be:
• The work cables connection on the cutting table is not making good contact or the table is not properly grounded.
• The torch-to-work distance is too great.
The workpiece is not totally penetrated, and there is excessive sparking on the top of the workpiece. Causes can be:
• The work cable’s connection on the cutting table is not making good contact or the table is not properly grounded.
• The amperage is set too low. See the cut charts in the Torch Setup section for more information.
• The cut speed is too high. See the cut charts in the Torch Setup section for more information.
• The consumables are worn and need to be replaced.
• The metal being cut exceeds the maximum capacity. See T45v and T45m torch specifications in the Specifications
section.
Dross forms on the bottom of the cut. Causes can be:
• The cutting speed is not correct. See the cut charts in the Torch Setup section for more information.
• The amperage is set too low. See the cut charts in the Torch Setup section for more information.
• The consumables are worn and need to be changed.
The cut angle is not square. Causes can be:
• The direction of the torch travel is incorrect. The high-quality cut is always on the right with respect to the forward motion of the torch.
• The distance between the torch and the workpiece is not correct.
• The cutting speed is not correct. See the cut charts in the Torch Setup section for more information.
• The consumables are worn and need to be replaced.
The consumable life is shortened. Causes can be:
• The arc current, arc voltage, travel speed, and other variables are not set as specified in the cut charts.
• Firing the arc in the air (beginning or ending the cut off of the plate surface). Starting at the edge is acceptable as
long as the arc makes contact with the workpiece when started.
• Starting a pierce with an incorrect torch height. For the Powermax45, the pierce height is generally 2.5times the
torch cutting height. Refer to the cut charts for specifics.
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Service Manual 4-15
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Section 5

TROUBLESHOOTING AND SYSTEM TESTS

In this section:
Theory of operation ....................................................................................................................................................................................5-2
General ..............................................................................................................................................................................................5-2
200–240V CSA and 230V CE 1-phase power supply functional description .............................................................5-2
400V CE 3-phase power supply functional description .......................................................................................................5-2
480V CSA 3-phase power supply functional description ...................................................................................................5-3
Sequence of operation ...................................................................................................................................................................5-4
Troubleshooting preparation ....................................................................................................................................................................5-5
Test equipment .................................................................................................................................................................................5-5
Troubleshooting procedures and sequence..............................................................................................................................5-5
External inspection ..........................................................................................................................................................................5-6
Internal inspection ...........................................................................................................................................................................5-6
Initial resistance check ..............................................................................................................................................................................5-7
200–240V CSA and 230V CE power supply overview ................................................................................................................5-8
400V CE power supply overview .........................................................................................................................................................5-9
480V CSA power supply overview ................................................................................................................................................... 5-10
Troubleshooting guide ...........................................................................................................................................................................5-11
Control Board LEDs............................................................................................................................................................................... 5-16
Use the control board Error and Reset LEDs to troubleshoot .......................................................................................... 5-17
System tests.............................................................................................................................................................................................5-18
Test 1 – voltage input .................................................................................................................................................................. 5-18
Test 2 – power board voltage checks .....................................................................................................................................5-19
Test 3 – VBUS and voltage balance ....................................................................................................................................... 5-20
Test 4 – solenoid valve ................................................................................................................................................................ 5-24
Test 5 – torch stuck open (TSO) or torch stuck closed (TSC) .........................................................................................5-25
Test 6 – plasma start ................................................................................................................................................................... 5-26
Test 7 – torch cap sensor ........................................................................................................................................................... 5-27
Test 8 – fan .................................................................................................................................................................................... 5-27
Test 9 – pressure transducer ..................................................................................................................................................... 5-28
Test 10 – power switch trip coil ................................................................................................................................................ 5-28
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Theory of operation

General
Refer to the following functional description topics, to Sequence of operation on page 5-4, and to the Wiring Diagrams section.
200–240V CSA and 230V CE 1-phase power supply functional description
AC power enters the system through the power switch (S1) to the input diode bridge (D48). The voltage from the diode bridge supplies the power factor correction (PFC) boost converter, which provides a nominal 385VDC bus voltage. The bus voltage then supplies voltage and current to the inverter and the flyback circuit power supply (DC to DC converter) on the power board (PCB2). The power board provides noise suppression and spike protection. A “soft start” is implemented via the power board resistor and relays (K1, K2).
The PFC boost converter consists of an insulated gate bipolar transistor (IGBT Q2), PFC choke, and control circuit. Itprovides a 385VDC bus voltage when the input AC voltage is between 200 and 240VAC.
The inverter consists of a dual IGBT package (Q3), the power transformer, a current sense transducer, and the control circuit. The inverter operates as a pulse-width modulated half-bridge circuit driving an isolation transformer. The secondary of the isolation transformer is rectified by the output bridge (D38).
The output circuitry consists of 2 current sense transducers located on the power board, the pilot arc IGBT (inside the D38module), and the output choke.
The control board’s digital signal processor (DSP) monitors and regulates the system’s operation and safety circuits. The amperage adjustment knob is used to set the output current to the desired value between 20 and 45 amps. The system compares the set-point to the output current by monitoring the current sense transducers and adjusting the pulse-width output of the inverter IGBTs (Q3). A trip coil on the power switch provides over-voltage protection.
400V CE 3-phase power supply functional description
AC power enters the system through the power switch (S1) to the input diode bridge (D48). The voltage from the diode bridge supplies the power factor correction (PFC) choke, which provides a nominal 560VDC bus voltage. The bus voltage then supplies voltage and current to the inverter and the flyback circuit power supply (DC to DC converter) on the power board (PCB2). The power board provides noise suppression and spike protection. A “soft start” is implemented via the power board resistor and relays (K2).
The inverter consists of a dual IGBT package (Q2), the power transformer, a current sense transducer, and the control circuit. The inverter operates as a pulse-width modulated half-bridge circuit driving an isolation transformer. The secondary of the isolation transformer is rectified by the output bridge (D40).
The output circuitry consists of 2 current sense transducers located on the power board, the pilot arc IGBT (inside the D40module), and the output choke.
The control board’s digital signal processor(DSP) monitors and regulates the system’s operation and safety circuits. The amperage adjustment knob is used to set the output current to the desired value between 20 and 45amps. The system compares the set-point to the output current by monitoring the current sense transducers and adjusting the pulse-width output of the inverter IGBT(Q2).
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480V CSA 3-phase power supply functional description
AC power enters the system through the power switch (S1) to the input diode bridge (D48). The voltage from the diode bridge supplies the power factor correction (PFC) choke, which provides a nominal 670VDC bus voltage. The bus voltage then supplies voltage and current to the inverter and the flyback circuit power supply (DC to DC converter) on the power board (PCB2). The power board provides noise suppression and spike protection. A “soft start” is implemented via the power board resistor and relays (K2).
The inverter consists of a dual IGBT package (Q2), the power transformer, a current sense transducer, and the control circuit. The inverter operates as a pulse-width modulated half-bridge circuit driving an isolation transformer. The secondary of the isolation transformer is rectified by the output bridge (D40).
The output circuitry consists of 2 current sense transducers located on the power board, the pilot arc IGBT (inside the D40module), and the output choke.
The control board’s digital signal processor (DSP) monitors and regulates the system’s operation and safety circuits. The amperage adjustment knob is used to set the output current to the desired value between 20 and 45 amps. The system compares the set-point to the output current by monitoring the current sense transducers and adjusting the pulse-width output of the inverter IGBT (Q2).
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Sequence of operation
Power OFF
•Connect the gas supply to the air fitting on the power supply.
•Connect the work lead to the workpiece.
•Plug in the power supply and make sure incoming power is ON if using a
line-disconnect box.
•Set the ON/OFF switch(S1) to ON(I).
•The green power ON LED illuminates, indicating the system is ready for
operation.
•All the fault LEDs should be extinguished (see the Troubleshooting guide on page 5-11 for more information).
•Set the mode switch to the desired mode for cutting or gouging.
•Set the power switch(S1) to OFF(O).
•The gas solenoid valve(V1) closes.
•The gas flow stops.
•The arc extinguishes.
•Gas continues to flow for 20seconds.
•Drag the torch lightly across the workpiece to
make a cut.
•The workpiece drops after the cut.
•Release the plasma start trigger on the hand
torch or the remote start switch for the machine torch.
•Turn the amperage adjustment knob to the gas test position.
•The gas solenoid valve(V1) opens to purge the system and to allow the
gas pressure to be set.
•Verify that the gas pressure LED illuminates green and is centered in the pressure bar.
•Set the amperage adjustment knob to the desired output current (between 20 and 45amps) based on the thickness of the metal to be cut.
•The gas solenoid valve(V1) opens.
•The gas flow starts.
•The cutting arc starts.
•Position the torch on the workpiece.
•Pull the plasma start trigger on the hand torch
or press the remote start switch for the machine torch.
•The gas solenoid valve(V1) closes.
•The gas flow stops.
•The power circuits are ready.
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Troubleshooting preparation

The complexity of the circuits requires that service technicians have a working knowledge of inverter power supply theory. In addition to being technically qualified, technicians must perform all testing with safety in mind.
If questions or problems arise during servicing, call the Hypertherm Technical Services team listed in the front of this manual.
Test equipment
• Multimeter with a variety of jumper leads, including E-ZHooks®.
Troubleshooting procedures and sequence
When performing the troubleshooting procedures,
• Read the Safety and Compliance Manual for detailed safety information;
• Refer to the Wiring Diagrams section for the system’s electrical schematic;
• Refer to the Component Replacement section for part replacement procedures;
• Refer to the Parts section to locate power supply components and torch components.
After the problem has been located and repaired, refer to the Sequence of operation flow diagram on page 5-4 to test the power supply for proper operation.
Power OFF and disconnected
External inspection
Internal inspection
Resistance checks
Power ON
Troubleshooting guide
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ELECTRIC SHOCK CAN KILL
•   Turn off the power and remove the input power plug from its receptacle before 
removing the cover from the power supply. If the power supply is connected directly to a line disconnect box, switch the line disconnect to OFF(O). In the U.S., use a “lock­out / tag-out” procedure until the service or maintenance work is complete. In other countries, follow appropriate national or local safety procedures.
•   Do not touch live electrical parts! If power is required for servicing, use extreme caution 
when working near live electrical circuits. Dangerous voltages exist inside the power supply that can cause serious injury or death.
•   Do not attempt to repair the power board or control board. Do not cut away or remove 
any protective conformal coating from either board. To do so will risk a short circuit between the AC input circuit and the output circuit and may result in serious injury or death.
DANGER
HOT PARTS CAN CAUSE SEVERE BURNS
•  Allow the power supply to cool before servicing.
MOVING BLADES CAN CAUSE INJURY
•   Keep hands away from moving parts.
STATIC ELECTRICITY CAN DAMAGE CIRCUIT BOARDS
•   Put on a grounded wrist strap before handling PC boards.
External inspection
1. Inspect the exterior of the power supply for damage to the cover and external components, such as the power
cord and plug.
2. Inspect the torch and the torch lead for damage.
Internal inspection
1. Turn OFF the power, disconnect the power cord, and disconnect the gas supply.
2. Use a #2Phillips screwdriver to remove the 2 screws from the handle on the top of the power supply. Gently pull
on the end panel nearest the screw you are removing to keep pressure on the screw. When the screw is almost out, tilt the screwdriver slightly to help pull the screw out of the recessed hole.
3. Tip the end panels back slightly so that you can get the edges of the handle out from underneath them. Set the
handle and screws aside. Continue to tilt the end panels outward to release the fan side of the cover from its track. Then lift the cover off the power supply.
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4. Remove the Mylar barrier from the power board side of the power supply. Be certain to replace the barrier when you are finished working on the power supply.
5. Inspect the inside of the power supply, especially on the side with the power board. Look for broken or loose wiring connections, burn and char marks, damaged components, and so on. Repair or replace as necessary.

Initial resistance check

All resistance values must be taken with the power cord disconnected and all internal power supply wires attached. Perform the steps in Internal inspection on page 5-6 before continuing in this section.
• If resistance values are not close (±25%) to the values given in this section, isolate the problem by removing wires attached to the resistance check points or component until the problem is found.
• After the problem has been located and repaired, refer to the Sequence of operation flow diagram on page 5-4 to test the power supply for proper operation.
1. With the power disconnected and the torch removed from the power supply, set the ON/OFF switch(S1) to ON(I).
2. Check the resistance across the input leads (the leads are identified with “AC” printed on the power board).
• 200–240V CSA and 230V CE: resistance across the input leads = 75kΩ.
• 400V CE and 480V CSA: resistance across the input leads = 2.5MΩ.
3. Check the resistance from the input leads to ground to verify that it reads as open. For all power supplies, the resistance from input to ground should read as > 20MΩ.
Note: With the power disconnected and the ON/OFF switch(S1) set to OFF(O), all circuits should read
asopen.
The electrical values shown are ±25%.
4. Check the output resistance for the values shown in the following table.
200–240V CSA and
Measure resistance from
Work lead to nozzle J21 to J17 J21 to J16 100 kΩ
Work lead to electrode J21 to J19 J21 to J18 20 kΩ
Electrode to nozzle J19 to J17 J18 to J16 120 kΩ
Output to ground > 20 MΩ
If no problems were found during the visual inspection or the initial resistance check, and the power supply still does not operate correctly, see the Troubleshooting guide on page 5-11.
230V CE power board
location
400V CE and 480V
CSA power board
location
Approximate
values
Note: The Troubleshooting guide provides most probable causes and solutions. Study the system wiring diagram
and understand the theory of operation before troubleshooting. Before purchasing any major replacement component, verify the problem with Hypertherm Technical Service or the nearest Hypertherm repair facility.
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200–240V CSA and 230V CE power supply overview
Control board (PCB1)
Flyback circuit
TP 19
W
192 VDC
+
PE (ground)
Power switch (S1)Power board (PCB2)
TP 18
TP 17
R
192 VDC
-
B
-
+
Inverter IGBT
Work lead connection (J21)
(Q3)
Test points
PFC IGBT (Q2)
Newer power board
Output diode and pilot arc
IGBT module (D38)
Input diode bridge
(D48)
Older power board
Input diode bridges
(D29, D39)
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400V CE power supply overview
Control board (PCB1)
Power board (PCB2)
Flyback circuit
TroubleshooTing and sysTem TesTs
PE (ground)
Power switch (S1)
Work lead connection (J21)
Output diode and pilot arc
IGBT module (D40)
Inverter IGBT (Q2)
TP17
W
~280 VDC
+
TP16
R
TP18
-
~280 VDC
Test points
B
-
+
Newer power board
Input diode bridge
(D48)
Older power board
Input diode bridges
(D28, D38)
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480V CSA power supply overview
Control board (PCB1)
Power board (PCB2)
Flyback circuit
PE (ground)
Power switch (S1)
Work lead connection (J21)
Output diode and pilot arc
IGBT module (D40)
Inverter IGBT (Q2)
TP17
W
~280 VDC
+
TP16
R
TP18
~280 VDC
-
Test points
B
-
+
Power board
Input diode bridge
(D48)
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Troubleshooting guide

See System tests on page 5-18 for detailed test procedures.
It is important to note, when troubleshooting a problem on the Powermax45, how the front panel LEDs operate. To help diagnose transient problems, an illuminated or blinking LED, including the bottom bar on the gas pressure bar, may continue to illuminate or blink for 10to 20seconds after the system is poweredOFF. Once the system is poweredON, the LED should not illuminate or blink if the fault has been cleared.
Also, note that there is no static gas pressure reading. So the gas pressure LEDs may not indicate a low pressure situation if the gas was not connected when the system was powered ON. Attempting to fire the torch without the gas connected will cause the bottom yellow gas pressure LED to blink.
Problem This may mean Cause Solution
The ON/OFF power switch is set to ON(I), but the power ON LED is not illuminated.
The power ON LED is illuminated, the fault LED is illuminated, and the bottom LED on the gas pressure bar is illuminated yellow and is blinking.
AC
There is insufficient voltage to the control circuits or a short-circuited power component.
There is insufficient gas pressure to the machine.
•The system has no incoming voltage or an improper incoming voltage.
•The power board is faulty.
•There is no gas attached
to the system.
•The gas supply line has a restriction or the air filter element is dirty.
•The reading at the pressure transducer is below the minimum acceptable gas pressure.
•Check to see that the system is plugged into an appropriately-sized circuit and that the circuit breaker has not been tripped.
•Perform Test 1 – voltage input on page 5-18
to check the incoming voltage and the power switch.
•Ensure that the gas supply is connected correctly.
•Check the gas supply line for restrictions or damage.
•Check the air filter element and replace it if necessary.
•Perform Test 9 – pressure transducer on page 5-28
to verify that the pressure transducer functions correctly.
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Problem This may mean Cause Solution
The power ON LED is illuminated and the yellow temperature LED is illuminated.
AC
The power ON LED is blinking.
The power ON LED is illuminated and the torch cap LED is illuminated.
AC
The internal system temperature is either over or under its operating range (approximately -30°C to 80°C).
The incoming voltage is not correct.
The cap-sensing circuit is not satisfied.
•The power supply is too cold.
•You have exceeded the duty cycle. (For more information about duty cycle, see the Operation section.)
•The incoming voltage is either too high or too low (a variance greater than ±15% of the rated voltage).
•The consumables are loose, improperly installed, or missing.
•The cap-sensor switch is faulty.
•Allow the power supply to warm up if it has been extremely cold.
•Check the area around the system to make sure that the air flow is not blocked.
•If the duty cycle has been exceeded, let the system cool before using it again.
•Perform Test 8 – fan on page 5-27 to make sure the fan is operating correctly.
•Perform Test 1 – voltage input on page 5-18 to
check the incoming line voltage.
•Correctly install the consumables.
•Perform Test 7 – torch cap sensor on page 5-27
to test the cap-sensor switch.
The power ON LED is illuminated and the torch cap LED blinks.
AC
This indicates either a “torch stuck open” or “torch stuck closed” situation.
•The consumables are installed incorrectly, they are worn, or were removed while the power supply is ON.
•The torch plunger is stuck.
•The torch or lead has a
broken wire.
•Check the consumables for wear and replace if necessary.
•Make sure they are properly installed.
•Verify that they are finger-tight. Try loosening them 1/8th of a turn and restarting the power supply.
•Perform Test 5 – torch stuck open (TSO) or torch stuck closed (TSC)
on page 5-25 and replace the torch head ifnecessary.
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Problem This may mean Cause Solution
The power ON LED is illuminated or is blinking and the fault LED is blinking.
AC
The power ON LED is illuminated and the fault LED and the temperature LED alternately flash when the system is powered ON.
AC
The power ON LED is illuminated and no fault LEDs are illuminated, but no gas flows when the torch trigger is pulled.
AC
A major fault has occurred in the power supply.
The system was powered on while the plasma start signal was being sent.
The start signal is not reaching the control board.
•Any of the fan, solenoid valve, control board, or power board may be faulty.
•The system was powered on while the torch trigger was being pulled or the trigger was activated too soon after the system was powered on.
•The start circuit is stuck closed.
•The torch or torch lead may be damaged.
•The power board may be faulty.
•The control board may be faulty.
•The error LED on the control board should be flashing. The number of times it flashes between pauses indicates which components to test. See Control Board LEDs on page 5-16.
•Release the torch trigger and turn OFF the power supply and then turn it ON again to reset the unit. Be sure to allow time for the soft start circuit to be satisfied.
•Perform Test 6 – plasma start on page 5-26 to test
the start signal.
•Ensure that the gas is connected (gas pressure LED will illuminate yellow after the torch is activated).
•Inspect the torch and torch lead for damage.
•Verify that the control board start LED illuminates when the trigger is pulled. If it does not, perform Test 6 – plasma start on page 5-26 to check the start signal from the power board.
Gas flows when the system is powered ON.
AC
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The incoming gas pressure is too high or the system is in gas test mode.
•Verify that the mode switch is not set to gas test mode.
•The gas pressure from the compressor or cylinder may be too high.
•The gas solenoid valve may be faulty.
•Check the gas supply to make sure that it does not exceed 9.3bar (135psi). If necessary, reduce the pressure.
•Perform Test 4 – solenoid valve on page 5-24 to
verify that the gas solenoid valve is functioning correctly.
TroubleshooTing and sysTem TesTs
Problem This may mean Cause Solution
When pulling the torch’s trigger, gas flows from the torch, but the torch does not fire or fires only for a short period of time, or the pilot arc starts but extinguishes before the normal 5-second time-out period.
Arc goes out while cuttingor intermittently willnot fire.
The consumables, torch, or torch lead are not functioning correctly, the gas pressure may be too low or too high, the air quality may be poor, or there is a voltage imbalance on the power board.
The arc lost contact with the workpiece.
•The consumables may be worn or damaged.
•The torch or torch lead may be damaged.
•The gas pressure is too high or too low or the gas supply is restricted.
•The gas filter element is dirty.
•The power board is faulty.
•The work lead or work
lead connection may be faulty.
•The material being cut may require the use of continuous pilot arc mode.
•Inspect the consumables, torch, and lead. Replace any damaged parts.
•Verify that the gas supply is providing at least
4.5bar (65psi) and does not exceed 9.3bar (135psi).
•Repair any restrictions in the supply line.
•Replace the gas filter element if dirty.
•Perform Test 3 – VBUS and voltage balance on
page 5-20 to test the voltage balance on the power board.
•If you are cutting expanded metal, grate, or any metal with holes, set the mode switch to continuous pilot arc mode.
•Check for loose connections at the work clamp and at the power supply.
•Reposition the work lead on the workpiece.
•Clean the cutting surface to ensure a better connection with the work lead.
The cut quality is poor orthe cut does not sever the metal.
The consumables are worn, there is a poor work lead connection, the output from the power supply is too low, or the power board is producing low current.
•The consumables need to be replaced.
•The work lead may be damaged or not properly connected to the work piece.
•The amps adjustment knob may be set too low.
•The power board may be faulty.
•Inspect the consumables and replace if necessary.
•Inspect the work lead for damage. Reposition it and clean the work surface to ensure good contact.
•Check the amps adjustment knob setting. If your input circuit is 200V, 34A; 240V, 28A; 400V, 10A; or 480V, 8.5A, turn the knob to the highest setting.
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Problem This may mean Cause Solution
The pilot arc extinguishes when you move the plasma arc off the work piece while still pulling the torch’s trigger.
The continuous pilot arc feature is not working.
•The mode switch may be set incorrectly.
•The power board or the control board may be faulty.
•Verify that the mode switch is set to continuous pilot arc.
•Perform Test 2 – power board voltage checks on page 5-19 andTest 3 – VBUS and voltage balance on page 5-20 to
verify that the power board is functioning properly. If the power board is faulty, replace it. Otherwise, replace the control board.
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Control Board LEDs

The Powermax45 control board (PCB1) has 4 diagnostic LEDs.
Start
Transfer (XFR)
Error
Reset/watchdog
Control board
Ribbon cable
The control board LEDs are:
• Start – The power supply has a start signal. This LED illuminates when the power supply receives a start signal and remains illuminated during normal operation.
• Transfer – This LED illuminates when there is proper arc transfer between the torch and the workpiece, and will flash
during continuous pilot arc operation (such as when cutting expanded metal or moving the arc off the plate and then back on).
• Error – The Error LED illuminates whenever there is a fault in the system. If the Fault LED on the front panel flashes and the Error LED on the control board also flashes, there is a major fault in the system. The number of
flashes between pauses indicates which component may have failed.
• Reset – This LED illuminates when the reset circuit is active or the watchdog circuit fires.
During normal operation, the power ON LED on the front of the power supply and the Start and Transfer LEDs on the control board illuminate. When a problem occurs with the system, one or more of the LEDs on the front of the power supply and the Error LED or the Reset LED on the control board may illuminate or flash.
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Use the control board Error and Reset LEDs to troubleshoot
The Error and Reset LEDs provide information to use when troubleshooting a system failure. If the LEDs on the front of the power supply are flashing, look at the Error LED on the control board to determine where the fault may be. Count the number of flashes and then look at the table below to determine the corrective action.
Reset LED
When the control board’s Reset LED illuminates, the voltages on the power board may be incorrect. Perform the following tests at J7 on 200–240V CSA power supplies and 230V CE power supplies or J8 on 400V CE and 480V CSA power supplies (the pin numbers are the same for all power supplies) on the power board (see Test 2 – power board voltage checks on page 5-19):
• Test pin 25 to ground for 3.3VDC (±10%).
• Test pin 24 to ground for 5VDC (±10%).
• Test pin 12 to ground for 2.2VDC (±10%).
If the values you find are not within ±10% of the above values, detach the control board’s ribbon cable and perform the tests again. If you find the correct values the second time, replace the control board. Otherwise, replace the power board.
Error LED
The number of times the Error LED flashes indicates the problem detected. Each flash is a half-second long and each series of flashes is separated by a 2-second pause. See System tests on page 5-18 for detailed test procedures.
The following table shows the meaning associated with each set of flashes.
Number of error LED flashes
1 Faulty control board Replace the control board.
2 Faulty power board Replace the power board.
3
4 Faulty gas solenoid valve Replace the gas solenoid valve.
Problem indicated Solution
•Perform Test 3 – VBUS and voltage balance on page 5-20. If any of the values are incorrect, replace the power board.
•Perform Test 2 – power board voltage checks on page
Either a faulty power board or a faulty control board
5-19. If any of the values for pins 5, 7, or 12 are incorrect, remove the control board and test again. If the values are correct, replace the control board.
•When performing test 2, if the values for pins 5, 7, and 12 are correct, but any other values are incorrect, replace the power board.
5 Faulty fan Replace the fan.
6 Machine motion relay fault Replace the power board.
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System tests

There is a ground clip near the top of the rear end cap that can be used as ground for any tests that require the multimeter to be attached to ground. There is also a ground on the heat sink with access next to the power board and below the power switch.
Ground wire clip
WARNING
Voltages of up to 50VDC continue to be present on the DC bus for at least 30 seconds after disconnecting the input power. Allow bus voltages to dissipate before performing any tests.
Test 1 – voltage input
Check the incoming voltage and the line voltage to the top of the power switch (S1).
1. Disconnect the electrical power and set the ON/OFF switch to OFF (O).
2. Once you have your test leads in place, reconnect the electrical power. Leave the ON/OFF switch set to OFF. The voltage should equal the line voltage of the incoming circuit.
3. If the AC voltage is incorrect, check to see that you have power to the unit. If you do have power, check the power cord for damage.
4. With the electrical power connected, set the ON/OFF switch to ON (I), and measure the AC voltage from J1 to J2 (labeled “AC” on the power board). This value should be the same as the incoming line voltage. If it is not, check the ON/OFF switch.
5. If the power ON LED is still illuminated, perform Test 2 – power board voltage checks on page 5-19 to determine whether the power board or the control board is faulty.
Note: All values can be ±15%.
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Single phase Three phase (CE) Three phase (CSA)
Black (CSA)
L
Brown (CE)
White (CSA)
N
Blue (CE)
Green (CSA)
PE
Green/yellow (CE)
L1 Brown L1 Black
L2 Black L2 White
L3 Gray L3 Red
PE Green/yellow PE Green
Test 2 – power board voltage checks
With the power ON, use a meter to verify the voltages at the J7 pins (J8 on 400V CE and 480V CSA power supplies) listed in the following table to be certain that the power board is functioning correctly. If any of the values are incorrect, replace the power board.
CAUTION
Do not use -VBUS as ground – doing so could destroy the power supply. Instead ground to either the ground wire clip on the rear panel or to the heat sink as shown below.
Note: All values can be ±10%.
J7 or J8 pin number to
ground
19
21
18
(200–240 and 230V
only)
20 IFB (output current) < 0.1VDC < 0.1VDC
22 ITF (transfer current) < 0.1VDC < 0.1VDC
25 3.3VDC 3.3VDC ±5% 3.3VDC ±5%
24 5VDC 5VDC ±5% 5VDC ±5%
Expected value
Test
VACR (rectified AC line voltage)
VBUS (DC bus voltage)
IPFC (input current) < 0.1VDC Not applicable
(200–240V CSA or
230V CE)
1.95V at 230 line voltage
2.28VDC at 385VBUS
2.7V at 400 line voltage (CE)
2.016VDC at 480 line voltage (CSA)
2.178VDC at 560VBUS (CE)
2.016VDC at 670VBUS (CSA)
Expected value
(400V CE or 480V CSA)
12 24V sense pin 2.2VDC 2.2VDC
16 Start signal
powermax
3.2VDC closed 0VDC open
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Service Manual 5-19
3.2VDC closed 0VDC open
TroubleshooTing and sysTem TesTs
J7 (200–240V CSA / 230V CE) J8 (400 V CE / 480V CSA)
1
2
25
26
Note: To test the values at pin 16, you must have the torch and power supply positioned such that you can safely pull
and release the torch’s trigger.
Ground to the ground wire clip or to the heat sink
TP 19
TP 18
TP 17
W
R
192 VDC
+
B
192 VDC
-
+
-
Test 3 – VBUS and voltage balance
Test the power board to ensure that the circuits are balanced. There are three procedures below. Use the first procedure if you have a 200–240V CSA power supply or a 230V CE power supply. Use the second procedure if you have a 400VCE power supply. Use the third procedure if you have a 480V CSA power supply.
For this test, you can use the test point loops or you can test on the capacitor screws. The test points are labeled on the back of the power board, as are the voltages and positive and negative capacitor terminals.
CAUTION
To test using the test points, do not use a multimeter with test probes. Use E-Z Hook leads instead and attach them to the test point loops.
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Service Manual
TroubleshooTing and sysTem TesTs
TP 19
W
-
+
-
+
TP 18
R
TP 17
B
192 VDC
192 VDC
Test for 200–240V CSA and 230V CE power supplies
1. Turn OFF the power.
2. Position the multimeter leads to measure the boosted bus voltage on the power board by attaching the test leads to TP (test point)19 and TP18. Turn on the power. The multimeter should read 385VDC. If you get a value other than 385VDC, multiply the reading by 0.00601. Compare that value to a reading at pin 21 on J7. They should have the same value.
3. Turn the power OFF. Attach the E-ZHooks to TP19 and TP17. Turn the power ON after you have connected the multimeter. This value should be 192.5VDC or one-half of whatever value you found in step2.
Note: All values can be ±10%.
4. Turn the power OFF and move the E-Z Hooks to TP18 and TP17. Turn the power ON after you have connected the multimeter. This value should be 192.5VDC or one-half of whatever value you found in step2.
5. The values found in steps3 and4 should be approximately equal. If they differ by more than 30V, replace the power board.
Step 3
powermax
TP 19
TP 18
W
192 VDC
+
Step 2
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Service Manual 5-21
Step 4
TP 17
R
B
192 VDC
-
+
-
TroubleshooTing and sysTem TesTs
TP17
W
+
-
+
-
TP18
B
TP16
R
~280 VDC
~280 VDC
Test for 400V CE power supplies
For this test, you can use the test point loops or you can test on the capacitor screws. The test points are labeled on the back of the power board, as are the voltages and positive and negative capacitor terminals.
CAUTION
To test using the test points, do not use a multimeter with test probes. Use E-Z Hook leads instead and attach them to the test point loops.
1. Turn OFF the power.
2. Position the multimeter leads to measure the voltage on the power board by attaching the test leads with the negative lead on TP 17 and the positive lead on TP 16. Turn on the power. The multimeter should read 560VDC. If you get a value other than 560VDC, multiply the reading by 0.00601. Compare that value to a reading at pin 21 on J8. They should have the same value.
3. Attach E-Z Hooks to TP (test point)17 and TP18. Turn the power ON after you have connected the multimeter. This value should be 280VDC or one-half of whatever value you found in step2.
Note: All values can be ±10%.
4. Turn the power OFF and move the E-Z Hooks to TP18 and TP16. Turn the power ON after you have connected the multimeter. This value should be 280VDC or one-half of whatever value you found in step2.
5. The values found in steps3 and4 should be approximately equal. If they differ by more than 30V, replace the power board.
Step 2
Step 3
TP17
W
~280 VDC
-
+
Step 4
5-22 powermax
TP16
R TP18
B
~280 VDC
-
+
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Service Manual
TroubleshooTing and sysTem TesTs
TP17
W
+
-
+
-
TP18
B
TP16
R
~280 VDC
~280 VDC
Test for 480V CSA power supplies
For this test, you can use the test point loops or you can test on the capacitor screws. The test points are labeled on the back of the power board, as are the voltages and positive and negative capacitor terminals.
CAUTION
To test using the test points, do not use a multimeter with test probes. Use E-Z Hook leads instead and attach them to the test point loops.
1. Turn OFF the power.
2. Position the multimeter leads to measure the voltage on the power board by attaching the test leads with the negative lead on TP17 and the positive lead on TP16. Turn on the power. The multimeter should read 670VDC. If you get a value other than 670VDC, multiply the reading by 0.003. Compare that value to a reading at pin21 on J8. They should have the same value.
3. Attach E-Z Hooks to TP (test point)17 and TP18. Turn the power ON after you have connected the multimeter. This value should be 335VDC or one-half of whatever value you found in step2.
Note: All values can be ±10%.
4. Turn the power OFF and move the E-Z Hooks to TP18 and TP16. Turn the power ON after you have connected the multimeter. This value should be 335VDC or one-half of whatever value you found in step2.
5. The values found in steps3 and4 should be approximately equal. If they differ by more than 30V, replace the power board.
Step 2
Step 3
powermax
TP16
~280 VDC
R
TP18
B
-
+
Step 4
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Service Manual 5-23
TP17
W
~280 VDC
-
+
TroubleshooTing and sysTem TesTs
Test 4 – solenoid valve
If gas is not flowing properly, test the solenoid valve for proper operation.
1. There is an LED on the solenoid valve that illuminates red when the torch is fired or when the amperage control knob is set to gas text mode. It stays illuminated until postflow stops. Turn the amperage knob to gas test and verify that the LED illuminates.
2. Place a jumper from pin4 of J3 (J4 for 400V CE and 480V CSA power supplies) on the power board to ground. You should hear the valve click.
3. If you do not hear the valve click or the LED does not illuminate and a voltage check on pin4 of J3 (or J4) reads 24VDC, replace the solenoid valve.
Solenoid valve LED
J3 or J4
PE (ground)
TP 19
TP 18
192 VDC
TP 17
R
B
-
+
192 VDC
W
-
+
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Service Manual
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