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Hypertherm powermax30 air Service Manual

Plasma arc cutting system with integrated air compressor
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Powermax30 AIR
®
Plasma Arc Cutting System with Integrated Air Compressor
Service Manual
808850 | Revision 0 | English

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Summary of Contents for Hypertherm powermax30 air

  • Page 1 Powermax30 AIR ® Plasma Arc Cutting System with Integrated Air Compressor Service Manual 808850 | Revision 0 | English...
  • Page 2 Maintenance notes: ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ Powermax and Hypertherm are trademarks of Hypertherm Inc. and may be registered in the United States and other countries. All other trademarks are the property of their respective holders. © 2015 Hypertherm Inc.

  • Page 3: Service Manual

    Powermax30 AIR Service Manual 808850 Revision 0 English March 2015 Hypertherm Inc. Hanover, NH 03755 USA www.hypertherm.com...
  • Page 4 55 11 2409 2636 Tel 55 11 2408 0462 Fax Hypertherm (S) Pte Ltd. 82 Genting Lane Media Centre Hypertherm México, S.A. de C.V. Annexe Block #A01-01 Avenida Toluca No. 444, Anexo 1, Singapore 349567, Republic of Singapore Colonia Olivar de los Padres 65 6841 2489 Tel Delegación Álvaro Obregón...
  • Page 5 WARNING! READ THE SAFETY INFORMATION Before operating or maintaining any Hypertherm equipment, read the Safety and Compliance Manual (80669C) for important safety information. You can find the Safety and Compliance Manual in the “Downloads library” at www.hypertherm.com.

  • Page 7: Table Of Contents

    Liability cap ....................................SC-15 Insurance ....................................SC-16 Transfer of rights ..................................SC-16 1 Specifications ..........................17 Safety information ..................................17 System description ..................................17 Power supply dimensions ................................18 System weights ..................................... 18 Hypertherm system ratings ................................. 19 Powermax30 AIR Service Manual 808850...
  • Page 8 Hand torch components ..............................33 Consumable life .................................... 34 Consumable use ................................... 35 Using the cut charts ................................35 Consumable set ..................................36 240 V / 30 A cutting ..............................37 120 V / 20 A cutting ..............................39 Powermax30 AIR Service Manual 808850...
  • Page 9 Hand torch cutting guidelines ............................51 Recommendations for cutting at 120 V ........................51 Edge start on a workpiece ..............................52 Pierce a workpiece ................................53 Common hand-cutting faults .............................. 54 Minimizing dross ................................54 Powermax30 AIR Service Manual 808850...
  • Page 10 Test 9a – Check the diagnostic LED (D5) on the compressor-driver board ..........91 Test 9b – Check the internal compressor ......................92 Test 9c – Check the compressor-driver board ..................... 93 Test 9d – Check the power board ........................... 95 Powermax30 AIR Service Manual 808850...
  • Page 11 Replace the handle ..................................187 Replace the trigger assembly ..............................191 Replace the torch body ................................193 Replace the start switch ................................195 Replace the cap-sensor switch ............................... 196 Replace the torch lead ................................197 Powermax30 AIR Service Manual 808850...
  • Page 12 CSA warning label ................................217 CE warning label ................................. 218 9 Wiring Diagrams ........................219 Process flow for troubleshooting internal compressor and temperature fault LEDs ..........220 Timing chart for torch start ............................... 221 Powermax30 AIR schematic ..............................222 Powermax30 AIR Service Manual 808850...

  • Page 13: Electromagnetic Compatibility (Emc

    Electromagnetic Compatibility (EMC) Introduction Methods of reducing emissions Hypertherm’s CE-marked equipment is built in compliance with standard Mains supply EN60974-10. The equipment should be installed and used in accordance with the information below to achieve electromagnetic Cutting equipment must be connected to the mains supply according to compatibility.

  • Page 14: Screening And Shielding

    Electromagnetic Compatibility (EMC) Note: The cutting circuit may or may not be earthed for safety reasons. Changing the earthing arrangements should only be authorized by a person who is competent to assess whether the changes will in crease the risk of injury, for example, by allowing parallel cutting current return paths which may damage the earth circuits of other equipment.

  • Page 15: Warranty

    Hypertherm not in strict conformity herein and as follows: if Hypertherm is notified of a defect (i) with respect with Hypertherm’s specifications and in cases of designs, processes,...

  • Page 16: 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.

  • Page 17: Specifications

    System description The Powermax30 AIR is a 30 A handheld plasma cutting system that contains its own internal air compressor for maximum portability and ease of use. With it, you can cut electrically conductive metals – such as mild steel, stainless steel, or aluminum –...

  • Page 18: Power Supply Dimensions

    You can order additional consumables and accessories – such as a dust cover and circle cutting guides, for example – from any Hypertherm distributor. See Parts on page 201 for a list of spare and optional parts. Power supply dimensions 333 mm (13.1 inches)

  • Page 19: Hypertherm System Ratings

    There may be potential difficulties in ensuring electromagnetic compatibility in those locations, due to conducted as well as radiated disturbances. † This product meets the technical requirements of IEC 61000-3-2 and IEC 61000-3-3 and is not subject to conditional connection. Powermax30 AIR Service Manual 808850...

  • Page 20: Torch Dimensions

    25 mm (1.0 inch) Torch weight  Air T30 torch with consumables only: 0.3 kg (0.65 pounds)  Air T30 torch with consumables and 4.6 m (15 foot) lead (with strain relief): 1.0 kg (2.25 pounds) Powermax30 AIR Service Manual 808850...

  • Page 21: Cutting Specifications

    120 V: When you operate the system at the maximum recommended output of 20 A, the cut capacities are:  3 mm (10 gauge) at 762 mm/minute (30 inches/minute)  6 mm (1/4 inch) at 355 mm/minute (14 inches/minute)  10 mm (3/8 inch) at 125 mm/minute (5 inches/minute) Powermax30 AIR Service Manual 808850...

  • Page 22: Iec Symbols

    Any noise measurements taken depend on the specific environment in which the system is used. Refer to Noise can damage hearing in the Safety and Compliance Manual (80669C) included with your system. In addition, you can find an Acoustical Noise Data Sheet for your system in the Hypertherm downloads library at www.hypertherm.com: 1.

  • Page 23: Symbols And Marks

    The CE versions of products that include a UkrSEPRO mark of conformity meet the product safety and EMC requirements for export to the Ukraine. Serbian AAA mark CE versions of products that include a AAA Serbian mark meet the product safety and EMC requirements for export to Serbia. Powermax30 AIR Service Manual 808850...
  • Page 24 1 – Specifications Powermax30 AIR Service Manual 808850...

  • Page 25: Power Supply Setup

    Claims for damage during shipment – If your unit was damaged during shipment, file a claim with the carrier. You can contact Hypertherm for a copy of the bill of lading. If you need additional assistance, call the nearest Hypertherm office listed in the front of this manual.

  • Page 26: System Contents

    CSA power cord with power plug adapters Safety and Compliance Manual Power supply Air T30 torch with lead Carrying strap Consumable kit  The specific components included with the system are subject to change over time. Powermax30 AIR Service Manual 808850...

  • Page 27: Position The Plasma Cutting System

     Hypertherm does not recommend operating this system on a 120 V / 15 A circuit. The Hypertherm rated output is: ...
  • Page 28 200 V – 240 V Input current at rated output (30 A × 83 V = 2.5 kW) 16.7 A – 15.0 A Input current at arc stretch 37.5 A Voltage tolerance +10% / -10% Powermax30 AIR Service Manual 808850...

  • Page 29: Requirements For Grounding

     To operate the system on a 240 V / 20 A circuit, attach the female end of the 240 V / 20 A (NEMA 6-50P) plug to the power supply’s NEMA twist lock-style plug. Powermax30 AIR Service Manual 808850...

  • Page 30: Ce Power Cords

    2. Remove each wire’s insulation to allow good contact with the plug terminals. 3. Make the connections. 4. Reinstall the outer shell and cord grip, and tighten the cord grip’s screws until snug. Do not overtighten. Powermax30 AIR Service Manual 808850...

  • Page 31: Extension Cord Recommendations

    If a fault occurs while using a generator, turn OFF the system and wait approximately 60 seconds before turning it ON again. Turning the power switch quickly to OFF and ON again (called a “quick reset”) may not clear the fault. Powermax30 AIR Service Manual 808850...
  • Page 32 2 – Power Supply Setup Powermax30 AIR Service Manual 808850...

  • Page 33: Torch Setup

    Torch Setup Introduction The Powermax30 AIR includes the Air T30 hand torch. This section explains how to set up and operate your torch. To achieve optimal consumable life and cut quality, follow the instructions in this manual. Hand torch components...

  • Page 34: Consumable Life

    For more information, see Cutting expanded metal on page 45.  Hypertherm does not recommend the use of any other consumables in the Air T30 torch except for those listed in this section, which are designed specifically for this system. The use of any other consumables could adversely affect system performance.

  • Page 35: Consumable Use

    The maximum cut speeds listed in the cut charts are the fastest possible speeds to cut metal without regard to cut quality. Adjust the cutting speed for your application to obtain the desired cut quality. Powermax30 AIR Service Manual 808850...

  • Page 36: Consumable Set

    Retaining cap  Deflector The following consumables are designed specifically for use with the Powermax30 AIR power supply and Air T30 hand torch. They cannot be used with any other Powermax system or torch.  Hypertherm does not recommend operating this system on a 120 V / 15 A circuit.

  • Page 37: 240 V / 30 A Cutting

    * To cut material thicker than 6 mm (1/4 inch) at 240 V, start the torch at the edge of the workpiece. † Maximum cut speed is limited by the test table’s maximum speed (10,160 mm/minute or 400 inches/minute). Powermax30 AIR Service Manual 808850...
  • Page 38 * To cut material thicker than 6 mm (1/4 inch) at 240 V, start the torch at the edge of the workpiece. † Maximum cut speed is limited by the test table’s maximum speed (10,160 mm/minute or 400 inches/minute). Powermax30 AIR Service Manual 808850...

  • Page 39: 120 V / 20 A Cutting

    1,245 Mild steel 3,295 2,140 1,270 Stainless steel 5,500 3,610 1,720 Aluminum 1,030 * To cut material thicker than 3 mm (10 gauge) at 120 V, start the torch at the edge of the workpiece. Powermax30 AIR Service Manual 808850...

  • Page 40: Powermax30 Air Service Manual

    18 gauge 14 gauge Stainless steel 12 gauge 1/4* 1/32 1/16 Aluminum 1/4* * To cut material thicker than 3 mm (10 gauge) at 120 V, start the torch at the edge of the workpiece. Powermax30 AIR Service Manual 808850...

  • Page 41: Operation

    Operation Controls and indicators Familiarize yourself with the controls and LED indicators on the system before you begin cutting. Rear controls ON (I) / OFF (O) power switch Activates the system and its control circuits. Powermax30 AIR Service Manual 808850...

  • Page 42: Front Panel Controls And Indicator Led Symbols

    Troubleshooting guide on page 63. Amperage adjustment knob – Use this knob to set the output current between 15 A and 30 A. Powermax30 AIR Service Manual 808850...

  • Page 43: Operate The Plasma System

    O-rings on the electrode and swirl ring.  These consumables are designed specifically for the Powermax30 AIR power supply and Air T30 hand torch. They cannot be used with any other Powermax system or torch. Powermax30 AIR Service Manual 808850...

  • Page 44: Step 2 - Connect The Electrical Power

    For information on connecting the proper plug to the power cord, see Power cord considerations on page 29.  To understand what cutting capacity to expect based on input voltage, see Consumable use on page 35.  For information on electrical requirements for this system, see Power Supply Setup on page 25. Powermax30 AIR Service Manual 808850...

  • Page 45: Step 3 - Adjust The Output Current

     Make sure nothing else is drawing power from the circuit.  Hypertherm does not recommend operating this system on a 120 V / 15 A circuit. Blue shading Operating the system on a 240 V / 20 A circuit ...

  • Page 46: Step 4 - Attach The Ground Clamp

    (EMF) and to achieve the best possible cut quality.  Do not attach the ground clamp to the portion of the workpiece that you are cutting away. Step 5 – Power ON the system Set the ON/OFF switch to the ON (I) position. Powermax30 AIR Service Manual 808850...

  • Page 47: Step 6 - Check The Indicator Leds

    When cutting, you may see a small puddle form underneath the power supply because the system automatically purges excess moisture from the internal compressor. It expels this water through a hole in the bottom of the power supply. Powermax30 AIR Service Manual 808850...

  • Page 48: Understand Duty-Cycle Limitations

    Stretching the arc for prolonged periods while cutting can reduce the duty cycle. Stretching the arc requires the power supply to generate a higher voltage output, which can cause it to run hotter and overheat more quickly. Powermax30 AIR Service Manual 808850...

  • Page 49: System Operation Guidelines

    When you operate the system at altitudes higher than 2,200 m (7,500 feet) above sea level, you may experience some reduction in cutting performance due to the adverse effect that altitude has on the internal air compressor. Powermax30 AIR Service Manual 808850...

  • Page 50: Hand Torch Operation

    The torch is equipped with a safety catch to prevent accidental firings. When you are ready to cut with the torch, flip the safety catch forward (toward the torch head) and pull the red torch trigger. Powermax30 AIR Service Manual 808850...

  • Page 51: Hand Torch Cutting Guidelines

    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 Accessory parts on page 212 for the Hypertherm plasma cutting guide part numbers for cutting circles and making bevel cuts.

  • Page 52: Edge Start On A Workpiece

    2. Pull the torch trigger to start the arc. You may need to pause at the edge until the arc has cut completely through the workpiece. 3. Drag the torch lightly across the workpiece to proceed with the cut. Maintain a steady, even pace. Powermax30 AIR Service Manual 808850...

  • Page 53: Pierce A Workpiece

    4. Hold the torch in place while continuing to pull the trigger. When sparks exit from the bottom of the workpiece, the arc has pierced the metal. 5. When the pierce is complete, drag the torch lightly along the workpiece to proceed with the cut. Powermax30 AIR Service Manual 808850...

  • Page 54: Common Hand-Cutting Faults

    As the workpiece heats up, more dross may form on subsequent cuts.  Worn or damaged consumables may produce intermittent dross. Powermax30 AIR Service Manual 808850...

  • Page 55: Troubleshooting And System Tests

    15 A and 30 A. The system compares the set-point to the output current by monitoring the current sensor and adjusting the pulse-width output of the inverter IGBT (Q2). Powermax30 AIR Service Manual 808850...

  • Page 56: Sequence Of Operation

    • The power circuits are ready. • The gas flow stops. • Position the torch on the workpiece. • Set the power switch (S1) to OFF (O). • Pull the plasma start trigger on the torch. Powermax30 AIR Service Manual 808850...

  • Page 57: 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.

  • Page 58: Test Equipment

     Safety and Compliance Manual (80669C) for detailed safety information.  Powermax30 AIR schematic on page 222 for the system’s electrical schematic.  Power Supply Component Replacement on page 97 or Torch Component Replacement on page 185 for replacement procedures.

  • Page 59: External Inspection

     After the problem is located and repaired, see Sequence of operation on page 56 to test the power supply for proper operation. Powermax30 AIR Service Manual 808850...

  • Page 60: Check The Power Switch

    Work lead (J22) to electrode (J17, white wire) 20 kΩ Electrode (J17, white wire) to nozzle (J16, red wire) 120 kΩ Work lead (J22), nozzle (J16, red wire), and electrode (J17, white wire) to > 20 MΩ ground Powermax30 AIR Service Manual 808850...
  • Page 61 WORK LEAD (BLK) 6. If you do not find any problems during the visual inspection or the initial resistance check, and the power supply is still not operating correctly, see Troubleshooting guide on page 63. Powermax30 AIR Service Manual 808850...

  • Page 62: Power Supply Overview

    Output diode and pilot arc IGBT module (D27) Power switch (S1) Work lead connection (J22) PFC IGBT (Q1) Input diode bridges (D24, D30) Flyback circuit PE (ground) Inverter IGBT (Q2) Power board (PCB2) Control board (PCB1) Powermax30 AIR Service Manual 808850...

  • Page 63: Troubleshooting Guide

    Troubleshooting guide This guide provides the most common causes and solutions.  Before troubleshooting, study the Powermax30 AIR schematic on page 222 and understand the Theory of operation on page 55.  Before purchasing any major replacement component, verify the problem with Hypertherm Technical Service or the nearest Hypertherm repair facility listed in the front of this manual.
  • Page 64 For example, the fan, solenoid valve, be blinking. The number of times it blinks control board, or power board may be faulty. between pauses indicates which components to test. See Control board LEDs on page 71. Powermax30 AIR Service Manual 808850...

  • Page 65: Temperature Led Faults

    (53 feet). The maximum length for an cord, use a heavy conductor cord of the extension cord on a 240 VAC input shortest possible length. See Extension circuit is 40.5 m (133 feet). cord recommendations on page 31. Powermax30 AIR Service Manual 808850...

  • Page 66: Internal Compressor Led Faults

    5. Was the system stored in temperatures below freezing? If so, ice might have formed in the air-flow system inside the power supply. Move the power supply to a warmer location to allow the ice to melt. Powermax30 AIR Service Manual 808850...
  • Page 67 ON (I) again. The system  The start circuit is stuck closed. automatically disables itself when the power supply is turned on while the torch trigger is pulled.  Perform Test 6 – plasma start on page 87. Powermax30 AIR Service Manual 808850...

  • Page 68: Torch Cap Led Faults

     The inverter is saturated (is in an  If you continue to see this error, replace the power board. See Replace the power board over-current condition). on page 126. Powermax30 AIR Service Manual 808850...

  • Page 69: Common Cutting Issues

    Fire the torch in the air, damaged. sputters and hisses. not on the workpiece. • If the problem persists, inspect and replace the consumable parts if they are worn or damaged. Powermax30 AIR Service Manual 808850...
  • Page 70 If you must use an extension cord, use a heavy conductor cord of the shortest possible length. See Extension cord recommendations on page 31. • Make sure nothing else is drawing power on the same circuit. Powermax30 AIR Service Manual 808850...

  • Page 71: Control Board Leds

    (such as when cutting expanded metal or moving the arc off the plate and then back on).  Start – This LED illuminates when the power supply receives a start signal and remains illuminated during normal operation. Powermax30 AIR Service Manual 808850...

  • Page 72: Use The Control Board Rest And Error Leds To Troubleshoot

    If you find the correct values the second time, replace the control board. Otherwise, replace the power board. See Replace the control board on page 118 or Replace the power board on page 126. Powermax30 AIR Service Manual 808850...

  • Page 73: Error Led

    You can use either the ground clip near the top of the rear panel or the ground screw on the heatsink (marked by the ground symbol on the power board) for any tests that require the multimeter to be attached to ground. Figure 5 – Grounding options Powermax30 AIR Service Manual 808850...
  • Page 74 Work lead connector (J22) 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. Powermax30 AIR Service Manual 808850...
  • Page 75 Figure 7 – Component side of the power board Input diode bridges Ribbon cable connector (J7) from control board Capacitors J17 (white) J16 (red) IGBTs 375 VDC bus voltage to compressor-driver board J12 (torch-start, cap-sensor switch connector) Snubber resistor Powermax30 AIR Service Manual 808850...
  • Page 76 5 – Troubleshooting and System Tests Figure 8 – Back of the compressor-driver board Compressor-driver board Diode MOSFET Powermax30 AIR Service Manual 808850...
  • Page 77 5 – Troubleshooting and System Tests Figure 9 – Component side of the compressor-driver board Retaining screw (3) Diagnostic LED (D5) Powermax30 AIR Service Manual 808850...

  • Page 78: Test 1 - Voltage Input

    5. Once you have the test leads in place, leave the power switch set to OFF (O), and reconnect the electrical power. The voltage should equal the line voltage of the incoming circuit, for example 120 V or 240 V.  All values can be ±15%. Powermax30 AIR Service Manual 808850...
  • Page 79 If it is not, check the power switch and replace if necessary. See Replace the power switch on page 116. Figure 11 10. If the power-ON LED is still illuminated, perform Test 2 – power board voltage checks on page 80. Powermax30 AIR Service Manual 808850...

  • Page 80: Test 2 - Power Board Voltage Checks

    To test the values at pin 16, you must position the torch and power supply so that you can safely pull and release the torch trigger. For ground locations, see Figure 5 on page 73. Powermax30 AIR Service Manual 808850...
  • Page 81 ITF (transfer current) < 0.1 VDC 3.3 VDC 3.3 VDC ±10% 5 VDC 5 VDC ±10% 24 V sense pin 2.2 VDC ±10% Start signal 3.2 VDC closed 0 VDC open  All values can be ±10%. Powermax30 AIR Service Manual 808850...

  • Page 82: Test 3 - Vbus And Voltage Balance On Power Board

    5. For each of the following 3 steps, carefully connect the test hooks to the edges of the holes in the power board so that the hook makes contact with the ring on the back side of the power board. Powermax30 AIR Service Manual 808850...
  • Page 83 9. The values found in step 7 and step 8 should be approximately equal. If they differ by more than 30 V, replace the power board. Figure 13 step 6 step 7 TORCH START step 8 WORK LEAD (BLK) Powermax30 AIR Service Manual 808850...

  • Page 84: Test 4 - Solenoid Valve

    7. Measure the voltage between pin 1 of J6 and ground. 8. If you do not hear the valve click and the voltage check reads 24 VDC, replace the solenoid valve. See Replace the solenoid valve on page 142. Powermax30 AIR Service Manual 808850...

  • Page 85: Test 5 - Torch Stuck Open Or Torch Stuck Closed

    Make sure that the torch plunger moves freely in the torch head. Figure 15  The front panel is hidden in this figure to better show the torch lead and wires. Powermax30 AIR Service Manual 808850...
  • Page 86 If yes, replace the torch lead. See Replace the torch lead on page 197.  If no, replace the torch body. See Replace the torch body on page 193. 7. Because “torch stuck open” and “torch stuck closed” failures can be intermittent, repeat the test several times. Powermax30 AIR Service Manual 808850...

  • Page 87: Test 6 - Plasma Start

    5. Quickly tap the torch trigger to force gas flow without firing an arc, and watch the Start LED on the control board. The Start LED should illuminate whenever the trigger is pulled. See Control board LEDs on page 71 for the location of the Start LED. 6. Turn OFF (O) the power. Powermax30 AIR Service Manual 808850...
  • Page 88 11. Are the values correct?  If yes, replace the control board. See Replace the control board on page 118.  If no, replace the power board. See Replace the power board on page 126. Powermax30 AIR Service Manual 808850...

  • Page 89: Test 7 - Torch Cap-Sensor

    Replace the faulty part. See Replace the cap-sensor switch on page 196 or Replace the torch lead and strain relief on page 144. Powermax30 AIR Service Manual 808850...

  • Page 90: Test 8 - Fan

    The purpose of the fan test is to verify that the fan is operating properly, not to test the fan drive circuit. Powermax30 AIR Service Manual 808850...

  • Page 91: Test 9 - Internal Compressor, Compressor-Driver Board, And Power Board

    If no, continue with the next step.  The D5 diagnostic LED indicates whether or not there is 15 VDC output from the compressor-driver board to the internal compressor. 6. Set the power switch to OFF (O). Powermax30 AIR Service Manual 808850...

  • Page 92: Test 9B - Check The Internal Compressor

    If yes, check the compressor-driver board. Continue with the next step. b. If no, replace the internal compressor. See Replace the internal compressor on page 160. Be sure to push the solenoid valve back into place between both clips from the center panel. Powermax30 AIR Service Manual 808850...

  • Page 93: Test 9C - Check The Compressor-Driver Board

    ELECTRIC SHOCK CAN KILL Use extreme caution when working near live electrical circuits. Dangerous voltages exist inside the power supply that can cause serious injury or death. See the WARNING! on page 57 before proceeding. Powermax30 AIR Service Manual 808850...
  • Page 94 Is compressor-enable voltage present (3 VDC)? a. If yes, replace the J1-to-J9 twisted pair wires. See Replace the wire group on page 137. b. If no, check the power board. Continue with the next step. Figure 20 Powermax30 AIR Service Manual 808850...

  • Page 95: Test 9D - Check The Power Board

    See Replace the power board on page 126. c. If VBUS or compressor-enable voltage is present on the power board but the other is not, replace the power board. See Replace the power board on page 126. Powermax30 AIR Service Manual 808850...

  • Page 96: Powermax30 Air Service Manual

    5 – Troubleshooting and System Tests Powermax30 AIR Service Manual 808850...

  • Page 97: Power Supply Component Replacement

    See the Safety and Compliance Manual (80669C) for more safety precautions. CAUTION! Static electricity can damage circuit boards. Use proper precautions when handling printed circuit boards. Store PC boards in anti-static containers. Wear a grounded wrist strap when handling PC boards. Powermax30 AIR Service Manual 808850...

  • Page 98: Replace The Power Supply Cover

    Remove the handle, and set it and the two screws aside. 4. Continue to tilt the panels outward to release the fan side of the cover from its track. Then lift the cover off the power supply. Figure 22 Powermax30 AIR Service Manual 808850...
  • Page 99 5. Install the 2 screws that attach the cover and handle. Tighten the screws to 23.0 kg∙cm (20 inch·pounds). 6. Reconnect the power cord, and set the power switch to ON (I). Powermax30 AIR Service Manual 808850...

  • Page 100: Replace The Component Barrier

    2. Remove the power supply cover. See Remove the power supply cover on page 98. 3. Remove the component barrier from the power board side of the power supply. The barrier is flexible and can be bent slightly for removal. Figure 24 Powermax30 AIR Service Manual 808850...
  • Page 101  The barrier will not fit in the same track as the power supply cover. 3. Put the power supply cover back in place. See Install the power supply cover on page 99. Figure 25 Powermax30 AIR Service Manual 808850...

  • Page 102: Detach And Reattach The Front Panel

     In Figure 27, the center panel is hidden in the image on the left. 9. Gently pull the panel away from the power supply. Powermax30 AIR Service Manual 808850...
  • Page 103 3. Reconnect the control board’s ribbon cable to the power board at J7. Make sure the latches are folded up to hold the connector in place. 4. Tighten the strain relief nuts on the torch lead and work lead. 5. Put the power supply cover back in place. See Install the power supply cover on page 99. Powermax30 AIR Service Manual 808850...

  • Page 104: Detach And Reattach The Rear Panel

    2. Remove the power supply cover. See Remove the power supply cover on page 98. 3. Loosen the power cord’s strain relief nut 4. Lay the power supply on its side. 5. Remove the retaining screw from the bottom of the rear panel Figure 28 Powermax30 AIR Service Manual 808850...
  • Page 105 8. Disconnect the ground wire from the ground wire clip near the top of the rear panel . See Figure 29. 9. Gently pull the panel away from the power supply. Figure 29 Powermax30 AIR Service Manual 808850...
  • Page 106 5. Reconnect the ground wire to the ground wire clip. 6. Tighten the strain relief nut on the power cord. 7. Put the power supply cover back in place. See Install the power supply cover on page 99. Powermax30 AIR Service Manual 808850...

  • Page 107: Replace The Power Cord And Strain Relief

    Set the power switch to OFF (O), and disconnect the power cord from the power source. b. See Remove the power supply cover on page 98. c. See Remove the component barrier on page 100. d. See Detach the rear panel on page 104. Powermax30 AIR Service Manual 808850...
  • Page 108 Black N (neutral) White PE (ground) Green  The power cord has a black wire and a white wire that connect to the power switch and a green ground wire that connects to the heatsink. Powermax30 AIR Service Manual 808850...
  • Page 109 6 – Power Supply Component Replacement 3. Remove the screw that holds the ground wire to the heatsink. A notch in the power board provides access to the screw. See Figure 32. Figure 32 Powermax30 AIR Service Manual 808850...
  • Page 110 If yes, use an adjustable wrench to unscrew the retention nut on the inside of the power supply. Remove the strain relief from the rear panel.  If no, continue with Install the power cord and strain relief on page 114. Figure 33 Inside Outside Powermax30 AIR Service Manual 808850...
  • Page 111 2. Remove the blue and brown wires from the power switch. Figure 34 – Single-phase CE power cord wires Designator Wire color L (live) Brown N (neutral) Blue PE (ground) Green/yellow Powermax30 AIR Service Manual 808850...
  • Page 112 6 – Power Supply Component Replacement 3. Remove the screw that holds the green/yellow ground wire to the heatsink. A notch in the power board provides access to the screw. Figure 35 Powermax30 AIR Service Manual 808850...
  • Page 113 If yes, use an adjustable wrench to unscrew the retention nut on the inside of the power supply. Remove the strain relief from the rear panel.  If no, continue with Install the power cord and strain relief on page 114. Figure 36 Inside Outside Powermax30 AIR Service Manual 808850...
  • Page 114 8. Complete the following procedures: a. See Install the component barrier on page 101. b. See Install the power supply cover on page 99. c. Reconnect the power cord, and set the power switch to ON (I). Powermax30 AIR Service Manual 808850...
  • Page 115 8. Complete the following procedures: a. See Install the component barrier on page 101. b. See Install the power supply cover on page 99. c. Reconnect the power cord, and set the power switch to ON (I). Powermax30 AIR Service Manual 808850...

  • Page 116: Replace The Power Switch

    5. Repeat the previous two steps on the top of the power switch to push the top of the switch out of the rear panel. Remove the switch completely from the panel. Figure 37 Powermax30 AIR Service Manual 808850...
  • Page 117 5. Complete the following procedures: a. See Install the component barrier on page 101. b. See Install the power supply cover on page 99. c. Reconnect the power cord, and set the power switch to ON (I). Powermax30 AIR Service Manual 808850...

  • Page 118: Replace The Control Board

    ON (I). c. Make sure the Start LED on the control board is the only LED illuminated. Also, the fault LEDs on the front panel should be extinguished. See Control board LEDs on page 71. Powermax30 AIR Service Manual 808850...
  • Page 119 5. Remove the amperage adjustment knob from the front of the power supply by pulling it away from the front panel (It does not have a set screw.) 6. Remove the 3 retaining screws from the control board. Lift the board out of the front panel. Figure 41 Powermax30 AIR Service Manual 808850...
  • Page 120 See Reattach the front panel on page 103. b. See Install the component barrier on page 101. c. See Install the power supply cover on page 99. d. Reconnect the power cord, and set the power switch to ON (I). Powermax30 AIR Service Manual 808850...

  • Page 121: Replace The Compressor-Driver Board

    Do not remove the screw.  A quarter turn to a half turn on the screw should loosen it enough for you to remove the compressor-driver board. Powermax30 AIR Service Manual 808850...
  • Page 122 7. Repeat the previous step to detach the MOSFET from its thermal strip. 8. Make sure the MOSFET and diode are fully detached from the heatsink. Lift the compressor-driver board out of the power supply. Powermax30 AIR Service Manual 808850...
  • Page 123 If the ends of the strips are tucked down between the heatsink and center panel, firmly grip both corners of the strip and pull up to remove it from the power supply. Figure 44 Powermax30 AIR Service Manual 808850...
  • Page 124 4. Make sure the thermal strips line up with the grooves where the clips attach to the heatsink. The thermal strips need to reach – or extend slightly beyond – the line shown in Figure 46. Figure 46 Powermax30 AIR Service Manual 808850...
  • Page 125 11. Complete the following procedures: a. See Install the component barrier on page 101. b. See Install the power supply cover on page 99. c. Reconnect the power cord, and set the power switch to ON (I). Powermax30 AIR Service Manual 808850...

  • Page 126: Replace The Power Board

    3. Remove the TORCH START connector (J12) on the component side of the power board by pushing the tab on the connector toward the plug and pulling the plug out. Figure 47 Push tab toward plug Powermax30 AIR Service Manual 808850...
  • Page 127 4. Remove the connectors at J5, J6, and J9 on the component side of the power board. 5. Remove the J3 connector from the compressor-driver board. Figure 48 Input diode bridges J7 (ribbon cable connector) Capacitors IGBTs J12 (TORCH START connector) Snubber resistor J3 (connects to compressor-driver board) Powermax30 AIR Service Manual 808850...
  • Page 128 TORCH START TORCH START WORK LEAD (BLK) Ferrite on CE power supplies only Retaining screws (2) Heatsink assembly screws (4) J12 (TORCH START connector) Input diode bridge screws (2) IGBT screws (3) J22 (work lead) Powermax30 AIR Service Manual 808850...
  • Page 129 Red (“RED”) Grommet 15. From the power board side of the power supply, push the wires that you disconnected down and out of the way. 16. Pull the power board straight out from the power supply. Powermax30 AIR Service Manual 808850...
  • Page 130 Start from the end closest to the power board and drag away from the prongs. c. Spread an even layer of thermal grease 0.051 mm (0.002 inch) thick on the bottom of the snubber resistor. Figure 52 Snubber resistor Thermal grease applied Thermal grease applied Capacitors Powermax30 AIR Service Manual 808850...
  • Page 131 10. Replace the 3 screws that attach the IGBTs to the heatsink and the 2 screws that attach the input diode bridges to the heatsink. Tighten the screws to 23.0 kg∙cm (20 inch∙pounds). 11. Replace the 2 retaining screws. Tighten the screws to 17.3 kg∙cm (15 inch∙pounds). Powermax30 AIR Service Manual 808850...
  • Page 132 See Reattach the front panel on page 103. b. See Install the component barrier on page 101. c. See Install the power supply cover on page 99. d. Reconnect the power cord, and set the power switch to ON (I). Powermax30 AIR Service Manual 808850...

  • Page 133: Replace The Drain Hose, Gas Supply Hoses, And 90° Fitting

    To connect, push the hose into the fitting until it stops. Pull on the hose to verify that it is secure. Hose Collet O-ring  To release, push the fitting collet toward the fitting, and pull the hose away from the fitting. Powermax30 AIR Service Manual 808850...
  • Page 134 Push-to-release the plastic 90° fitting from the torch lead’s brass gas supply fitting inside the front panel of the power supply. c. Push-to-release the gas supply hose from the top of the plastic 90° fitting. Powermax30 AIR Service Manual 808850...
  • Page 135 7 90° fitting on solenoid valve (right side) 4 90° fitting on solenoid valve (left side)  The fan and the front panel are hidden in Figure 54 to better show the hoses and fittings. Powermax30 AIR Service Manual 808850...
  • Page 136 Cutting thickness capability can decrease.  Consumables life can be shortened. 6. Complete the following procedures: a. See Install the power supply cover on page 99. b. Reconnect the power cord, and set the power switch to ON (I). Powermax30 AIR Service Manual 808850...

  • Page 137: Replace The Wire Group

    6. Route the wires along the top of the center panel. Use the notches provided , as shown in Figure 56. 7. Connect the other end of the new twisted pair wires to J1 on the compressor-driver board. Powermax30 AIR Service Manual 808850...
  • Page 138 8. Complete the following procedures: a. See Install the component barrier on page 101. b. See Install the power supply cover on page 99. c. Reconnect the power cord, and set the power switch to ON (I). Figure 56 Powermax30 AIR Service Manual 808850...
  • Page 139 5. Press the connector on the other end of the wire onto the rear panel’s ground clip. 6. Complete the following procedures: a. See Install the power supply cover on page 99. b. Reconnect the power cord, and set the power switch to ON (I). Figure 57 Powermax30 AIR Service Manual 808850...
  • Page 140 7. Complete the following procedures: a. See Install the component barrier on page 101. b. See Install the power supply cover on page 99. c. Reconnect the power cord, and set the power switch to ON (I). Powermax30 AIR Service Manual 808850...
  • Page 141 6 – Power Supply Component Replacement Figure 58 1 Ground wire attached to heatsink 3 Grommet in center panel 2 Ground wire attached to magnetics assembly’s metal base plate Powermax30 AIR Service Manual 808850...

  • Page 142: Replace The Solenoid Valve

    (See How to use push-to-connect fittings on page 133.) 6. Push-to-release the gas supply hose from the fitting on the right side of the solenoid valve. Figure 59 Powermax30 AIR Service Manual 808850...
  • Page 143 ON (I). CAUTION! If there are leaks in the gas supply hoses or connections:  Cut speeds can decrease.  Cut quality can deteriorate.  Cutting thickness capability can decrease.  Consumables life can be shortened. Powermax30 AIR Service Manual 808850...

  • Page 144: Replace The Torch Lead And Strain Relief

    2. Locate the 3-pin connector at the TORCH START slot (J12) on the power board (on the side facing the heatsink) where the orange, blue, and purple wires from the torch lead connect. Figure 60 TORCH START TORCH START WORK LEAD (BLK) Powermax30 AIR Service Manual 808850...
  • Page 145 6. Use an 8 mm (5/16 inch) nut driver to remove the nuts from the studs, and slide the ring terminals off the studs. 7. Loosen the strain relief nut on the torch lead outside the front panel. Figure 62 Powermax30 AIR Service Manual 808850...
  • Page 146 3. From the inside of the front panel, tighten the retention nut onto the strain relief. CAUTION! Be careful not to twist the torch lead as you tighten the retention nut onto the strain relief. Powermax30 AIR Service Manual 808850...
  • Page 147 See Reattach the front panel on page 103. 11. Complete the following procedures: a. See Install the power supply cover on page 99. b. Reconnect the power cord, and set the power switch to ON (I). Powermax30 AIR Service Manual 808850...

  • Page 148: Replace The Air Filter Assembly

    If you need better access to the air filter, remove the fan plenum . Use a pair of needlenose pliers to compress and release the plenum’s top 2 corner clips first before working the bottom 2 clips free from the fan casing. Figure 64 Powermax30 AIR Service Manual 808850...
  • Page 149 7. Push the other end of the drain hose into the hole in the bottom of the power supply. The hole is underneath the fan. Figure 65 Powermax30 AIR Service Manual 808850...
  • Page 150 Cutting thickness capability can decrease.  Consumables life can be shortened. 9. Complete the following procedures: a. See Install the power supply cover on page 99. b. Reconnect the power cord, and set the power switch to ON (I). Powermax30 AIR Service Manual 808850...

  • Page 151: Replace The Air Filter Bowl And Air Filter Element

    2 clips free from the fan casing. 3. Hold the top of the air filter assembly steady with one hand. With your other hand, unscrew the air filter bowl remove it. Figure 66 Powermax30 AIR Service Manual 808850...
  • Page 152 3. Clean the filter bowl before installing it by wiping away any oil, dirt, or other contaminants. Make sure the O-ring on the bowl is not cracked or damaged. See Figure 68 on page 153. Powermax30 AIR Service Manual 808850...
  • Page 153 7. Make sure the other end of the drain hose is pressed securely in the hole in the base of the power supply. Figure 68 8. Put the fan plenum back in place, if you removed it earlier. Powermax30 AIR Service Manual 808850...
  • Page 154 Cutting thickness capability can decrease.  Parts life can shorten. 10. Complete the following procedures: a. See Install the power supply cover on page 99. b. Reconnect the power cord, and set the power switch to ON (I). Powermax30 AIR Service Manual 808850...

  • Page 155: Replace The Fan

    Be careful not to apply too much pressure to any of the clips as you detach the plenum from the fan. 5. Remove the retaining screw from each corner of the fan. Slide the fan out of the power supply. Figure 69 Powermax30 AIR Service Manual 808850...
  • Page 156 6. Attach the connector for the red-and-black wires to J5 on the power board. Figure 70 7. Complete the following procedures: a. See Install the power supply cover on page 99. b. Reconnect the power cord, and set the power switch to ON (I). Powermax30 AIR Service Manual 808850...

  • Page 157: Replace The Heat Exchange Coil

    If the exhaust fitting on the internal compressor is in good condition, leave it in place. If the fitting needs to be replaced, use an 11 mm (7/16 inch) wrench to remove it. Figure 71 Powermax30 AIR Service Manual 808850...
  • Page 158 Figure 72. 4. Push-to-connect the left end of the coil into the exhaust fitting on the internal compressor. (See How to use push-to-connect fittings on page 133.) Figure 72 Powermax30 AIR Service Manual 808850...
  • Page 159 8. Complete the following procedures: a. See Install the fan on page 156. b. See Install the power supply cover on page 99. c. Reconnect the power cord, and set the power switch to ON (I). Powermax30 AIR Service Manual 808850...

  • Page 160: Replace The Internal Compressor

    It is normal to see water in the drain hose and in the air filter bowl. Remove any water that spills inside the power supply before operating the system again. 3. Remove the J2 connector from the compressor-driver board. Remove the J2 wires from the notches in the center panel. Powermax30 AIR Service Manual 808850...
  • Page 161 4. Use an 8 mm (5/16 inch) wrench to remove the hex nuts from the 3 retaining screws that secure the internal compressor to the base of the power supply. 5. Remove the metal washer from each retaining screw. Figure 73 Powermax30 AIR Service Manual 808850...
  • Page 162 8. Lift the internal compressor until it is free of the third retaining screw (the one in the middle of the power supply). Remove the internal compressor from the power supply. Figure 74 9. Check the 3 retaining screws in the power supply. If brass sleeves were left behind on any of the screws, remove the sleeves. Powermax30 AIR Service Manual 808850...
  • Page 163 2. Orient the internal compressor so it is perpendicular to the power supply. Slide the internal compressor’s bracket over the retaining screw in the middle of the power supply’s base, as shown in Figure 76. Figure 76 Powermax30 AIR Service Manual 808850...
  • Page 164 See Install the fan on page 156. c. See Reattach the rear panel on page 106. d. See Install the power supply cover on page 99. e. Reconnect the power cord, and set the power switch to ON (I). Powermax30 AIR Service Manual 808850...

  • Page 165: Replace The Air Inlet Filter In The Internal Compressor

    Tighten the filter assembly only to finger-tight. 2. Complete the following procedures: a. See Install the power supply cover on page 99. b. Reconnect the power cord, and set the power switch to ON (I). Powermax30 AIR Service Manual 808850...

  • Page 166: Replace The Front Panel

    See Remove the power supply cover on page 98. c. See Remove the component barrier on page 100. 2. Lay the power supply on its side. 3. Remove the retaining screw from the bottom of the front panel Figure 77 Powermax30 AIR Service Manual 808850...
  • Page 167 Figure 78 7. Remove the amperage adjustment knob from the front of the power supply by pulling it away from the front panel. (It does not have a set screw.) Set the knob aside. Powermax30 AIR Service Manual 808850...
  • Page 168 8. Complete the following procedures: a. See Install the component barrier on page 101. b. See Install the power supply cover on page 99. c. Reconnect the power cord, and set the power switch to ON (I). Powermax30 AIR Service Manual 808850...

  • Page 169: Replace The Rear Panel

    Reattach the rear panel on page 106. 1. Make sure that the serial number on the existing rear panel matches the one on the new rear panel. Contact Hypertherm if the serial numbers do not match. The serial number can be found on the data plate.
  • Page 170 11. Repeat the previous two steps on the top of the power switch to push the top of the switch out of the rear panel. Remove the switch completely from the panel. Figure 81 12. Disconnect the power cord from the power supply. See Remove the power cord and strain relief on page 107. Powermax30 AIR Service Manual 808850...
  • Page 171 6. Press the power switch into the new rear panel with the ON (I) label at the top of the switch. You should hear the switch snap into place. Figure 82 Powermax30 AIR Service Manual 808850...
  • Page 172 12. Complete the following procedures: a. See Install the component barrier on page 101. b. See Install the power supply cover on page 99. c. Reconnect the power cord, and set the power switch to ON (I). Powermax30 AIR Service Manual 808850...

  • Page 173: Replace The Base

    5. Place the end of a stiff wire or other similar item with a 0.23 cm (0.092-inch) diameter in each of the 6 holes the power board side of the base. Press each one until the clips release and you can pull the base away from the center panel. Powermax30 AIR Service Manual 808850...
  • Page 174 See Reattach the front panel on page 103. f. See Install the component barrier on page 101. g. See Install the power supply cover on page 99. h. Reconnect the power cord, and set the power switch to ON (I). Powermax30 AIR Service Manual 808850...

  • Page 175: Replace The Magnetics Assembly

    Remove J18 and J19, located on the rear panel end of the power board. c. Remove J20 and J21, located on the bottom center of the power board. Figure 86 TORCH START TORCH START WORK LEAD (BLK) Ferrite on CE power supplies only Powermax30 AIR Service Manual 808850...
  • Page 176 5. Use an 8 mm (5/16 inch) nut driver to remove the nut that attaches the ring terminal for the output inductor’s white wire to the stud labeled “WHT” Figure 87 Powermax30 AIR Service Manual 808850...
  • Page 177 Press each one in until the clips release and you can pull the base and the attached magnetics away from the center panel. 8. Remove the 6 screws that hold the magnetics’ metal mounting plate in place. Remove the plate and the magnetics. Figure 88 Powermax30 AIR Service Manual 808850...
  • Page 178 “WHT” stud. 6. Using the screw you removed in step 3 on page 176, attach the ground wire to the metal base plate of the magnetics assembly. Tighten the screw to 17.3 kg∙cm (15 inch∙pounds). Powermax30 AIR Service Manual 808850...
  • Page 179 See Reattach the front panel on page 103. f. See Install the component barrier on page 101. g. See Install the power supply cover on page 99. h. Reconnect the power cord, and set the power switch to ON (I). Powermax30 AIR Service Manual 808850...

  • Page 180: Replace The Work Lead And Ground Clamp

    See Detach the front panel on page 102. 2. Loosen the strain relief nut on the work lead 3. Remove and set aside the screw and washer from J22 on the power board (labeled “WORK LEAD”). Figure 90 Powermax30 AIR Service Manual 808850...
  • Page 181 See Reattach the front panel on page 103. b. See Install the component barrier on page 101. c. See Install the power supply cover on page 99. d. Reconnect the power cord, and set the power switch to ON (I). Powermax30 AIR Service Manual 808850...
  • Page 182 Tighten the screw to 34.6 kg∙cm (30 inch∙pounds). 10. Fold the metal tabs over the wire to attach the wire to the handle. See Figure 92. 11. Slide the plastic sleeve over the handle of the new ground clamp. Powermax30 AIR Service Manual 808850...
  • Page 183 6 – Power Supply Component Replacement Figure 92 Powermax30 AIR Service Manual 808850...
  • Page 184 6 – Power Supply Component Replacement Powermax30 AIR Service Manual 808850...

  • Page 185: Torch Component Replacement

    Section 7 Torch Component Replacement WARNING! ELECTRIC SHOCK CAN KILL Disconnect electrical power before performing any maintenance. See the Safety and Compliance Manual (80669C) for more safety precautions. Powermax30 AIR Service Manual 808850...

  • Page 186: Torch Components

    Right side of the handle Left side of the handle Cap-sensor switch Screws (5) Start switch Trigger assembly Plunger screw Trigger spring Plunger Gas hose fitting’s flange Consumables Strain relief Torch body Cap-sensor wire connector Torch power wire Powermax30 AIR Service Manual 808850...

  • Page 187: Replace The Handle

    Wear eye protection, as the trigger spring can launch out of the handle. 5. Being careful to keep the trigger spring from launching out of the handle, carefully pry the left side of the handle away from the torch. Powermax30 AIR Service Manual 808850...
  • Page 188 7. The torch body fits snugly into the right side of the handle. While holding the torch body in place, gently press the right side of the handle away from the torch body to remove it. Figure 95 Powermax30 AIR Service Manual 808850...
  • Page 189 Cap-sensor switch’s post hole Start switch’s mounting posts Cap-sensor switch’s mounting post Slot for the gas hose fitting’s flange Trigger’s pivot hole Strain relief slot 9. Slide the start switch off the 2 mounting posts. Figure 97 Powermax30 AIR Service Manual 808850...
  • Page 190 8. Being careful that the handle does not pinch the wires, align the left half of the handle with the right half. Make sure the trigger pivots are both located in the trigger pivot holes. See Figure 98. Powermax30 AIR Service Manual 808850...

  • Page 191: Replace The Trigger Assembly

    Wear eye protection, as the trigger spring can launch out of the handle. 5. Being careful to keep the trigger spring from launching out of the handle, carefully pry the left side of the handle away from the torch. Powermax30 AIR Service Manual 808850...
  • Page 192 9. Install the handle screws. 10. Pull the trigger to make sure it is positioned correctly in the torch handle 11. Install the consumables. 12. Reconnect the power cord, and set the power switch to ON (I). Powermax30 AIR Service Manual 808850...

  • Page 193: Replace The Torch Body

    4. Use two wrenches to loosen the gas fitting that attaches the torch body to the torch lead. CAUTION! Always use two wrenches to properly loosen and tighten the hex nuts and bolts mentioned in these procedures. Powermax30 AIR Service Manual 808850...
  • Page 194 8. Complete the following procedures: a. Install all of the torch components that you removed. See Install the handle on page 190. b. Reconnect the power cord, and set the power switch to ON (I). Powermax30 AIR Service Manual 808850...

  • Page 195: Replace The Start Switch

    4. Complete the following procedures: Start switch a. Install all of the torch components that you removed. See Install the handle on page 190. b. Reconnect the power cord, and set the power switch to ON (I). Powermax30 AIR Service Manual 808850...

  • Page 196: Replace The Cap-Sensor Switch

    4. Complete the following procedures: Cap-sensor switch a. Install all of the torch components that you removed. See Install the handle on page 190. b. Reconnect the power cord, and set the power switch to ON (I). Powermax30 AIR Service Manual 808850...

  • Page 197: Replace The Torch Lead

    3. Remove the screw that attaches the torch power wire to the torch body. Set the nut and screw aside. 4. Peel off the tape that attaches the torch power wire to the torch body. Figure 104 Peel tape to remove Powermax30 AIR Service Manual 808850...
  • Page 198 Figure 106.  The tape holds the power wire in place and prevents the wire from getting pinched. Do not pull the wire too tight when you attach it to the gas tube. Figure 106 Powermax30 AIR Service Manual 808850...
  • Page 199 10. Complete the following procedures: a. Install all of the torch components that you removed. See Install the handle on page 190. b. Reconnect the power cord, and set the power switch to ON (I). Powermax30 AIR Service Manual 808850...
  • Page 200 7 – Torch Component Replacement Powermax30 AIR Service Manual 808850...

  • Page 201: Parts

    Power Supply Component Replacement on page 97  Torch Component Replacement on page 185  For instructions on installing the consumables in the hand torch, see Step 1 – Install the consumables on page 43. Powermax30 AIR Service Manual 808850...

  • Page 202: Power Supply Parts

    Kit: Power supply cover with labels, CE 428226 Kit: Current adjustment knob 428389 Kit: Front panel (does not include current adjustment knob) 428388 Kit: Work lead, 4.6 m (15 feet), with ground clamp 228561 Kit: Ground clamp Powermax30 AIR Service Manual 808850...

  • Page 203: Exterior, Rear

    3.0 m (10 feet) (strain relief not included) 428390 Kit: CE power cord, 1-phase, 3.0 m (10 feet) (plug and strain relief not included) 228143 Kit: Power cord strain relief 428391 Kit: Rear panel (includes data plate and consumables label) Powermax30 AIR Service Manual 808850...

  • Page 204: Interior, Power Board Side

    Replacement clip and screws for snubber resistor on power board  Replacement clips and screws for MOSFET and diode on compressor-driver board 428411 Kit: Replacement hex nut standoffs (5) for mounting power board to heatsink (not shown) Powermax30 AIR Service Manual 808850...

  • Page 205: Interior, Control Board And Power Switch

    8 – Parts Interior, control board and power switch Item Kit number Description Designator 428404 Kit: Control board (141365) PCB1 428235 Kit: Power switch Powermax30 AIR Service Manual 808850...

  • Page 206: Interior, Fan Assembly

    8 – Parts Interior, fan assembly Item Kit number Description Designator 428236 Kit: Fan assembly with plenum Powermax30 AIR Service Manual 808850...

  • Page 207: Interior, Pneumatics (Fan Side)

    Kit: Air filter bowl (includes air filter element, O-ring, and drain hose) 428374 Kit: Solenoid valve (includes gas hoses and elbow fittings) 8, 9 428373 Kit: Drain hose, 2 gas supply hoses, elbow fitting 428238 Kit: Replacement elbow fitting for torch lead Powermax30 AIR Service Manual 808850...

  • Page 208: Interior, Wires

     Ground clip wire from rear panel to center panel (green)  Ground wire from heatsink to magnetics assembly (green) 428413 Kit: Replacement hex nut standoff (5) for attaching ground clip wire to center panel Powermax30 AIR Service Manual 808850...

  • Page 209: Power Supply Base And Magnetics

    Description 428399 Kit: Plastic base (includes rubber bumpers, or “feet”) 428392 Kit: Replacement bumpers (“feet”) for bottom of plastic base (4) (not shown) 428400 Kit: Magnetics assembly 428407 Kit: Replacement grommet for center panel (5) Powermax30 AIR Service Manual 808850...

  • Page 210: Hand Torch Parts

    † kit 428350. This kit contains 2 nozzles and 2 electrodes.  Swirl ring (420133) Replace the nozzle and electrode at the same time.  Nozzle (420134) †  Retaining cap (420135)  Deflector (420399) Powermax30 AIR Service Manual 808850...

  • Page 211: Hand Torch Consumables

    Use 428350 to order a kit of 2 nozzles and 2 electrodes.  These consumables are designed specifically for use with the Powermax30 AIR power supply and Air T30 hand torch. They cannot be used with any other Powermax system or torch.

  • Page 212: Accessory Parts

    Deluxe plasma (circle) cutting guide 127144 Dust cover 024548 Leather torch lead cover, brown, 7.6 m (25 feet) 024877 Leather torch lead cover, black with Hypertherm logo, 7.6 m (25 feet) 127217 Shoulder strap 127169 Leather cutting gloves 127416 Protective glasses, shade 5 lens...

  • Page 213: Safety-Critical Parts

    Genuine Hypertherm parts are factory-recommended parts for your Hypertherm system. Any damage caused by the use of parts that are not from Hypertherm may not be covered by the Hypertherm warranty. In addition, the following parts are safety-critical parts that must be replaced only with genuine Hypertherm parts to maintain the warranty and system certifications, including CE and CSA certification.
  • Page 214 428400 Kit: Magnetics assembly 228210 Kit: CSA power cord with NEMA twist lock-style 240 V/20 A plug, 1-phase, 3.0 m (10 feet) 428390 Kit: CE power cord, 1-phase, 3.0 m (10 feet) (plug not included) Powermax30 AIR Service Manual 808850...

  • Page 215: Recommended Spare Parts

    Recommended spare parts Hypertherm recommends that service centers keep the following spare parts on hand for repairs because these parts are critical or are usually exposed to heavy and repeated wear. You may find that you need to revise or expand this list for your customers, based on the conditions and work environments in your region.

  • Page 216: Power Supply Labels

    8 – Parts Power supply labels Kit number Description 428408 Kit: Powermax30 AIR labels, CSA 428410 Kit: Powermax30 AIR labels, CSA, Built in America 428409 Kit: Powermax30 AIR labels, CE The label kits include:  Consumables label  Appropriate warning labels ...

  • Page 217: Csa Warning Label

    7. Do not remove, destroy, or cover this label. 7. Ne pas enlever, détruire ni couvrir cette étiquette. Replace if it is missing, damaged, or worn. La remplacer si elle est absente, endommagée ou usée. (PN 110673 Rev D) (PN 110673 Rev D) Powermax30 AIR Service Manual 808850...

  • Page 218: Ce Warning Label

    Become trained. Only qualified personnel should operate this equipment. Use torches specified in the manual. Keep non-qualified personnel and children away. Do not remove, destroy, or cover this label. Replace if it is missing, damaged, or worn. Powermax30 AIR Service Manual 808850...

  • Page 219: Wiring Diagrams

    Section 9 Wiring Diagrams This section contains the following diagrams:  Process flow for troubleshooting internal compressor and temperature fault LEDs  Timing chart for torch start  Powermax30 AIR schematic Powermax30 AIR Service Manual 808850...

  • Page 220: Process Flow For Troubleshooting Internal Compressor And Temperature Fault Leds

    9 – Wiring Diagrams Process flow for troubleshooting internal compressor and temperature fault LEDs after tapping torch trigger after tapping torch trigger after tapping torch trigger after tapping torch trigger Powermax30 AIR Service Manual 808850...

  • Page 221: Timing Chart For Torch Start

    Internal compressor ON/OFF Pilot arc IGBT ON/OFF Postflow Gas solenoid ON/OFF (5–20 seconds) Pilot arc current = 15 A User-set current Inverter output ON/OFF Control board Transfer LED ON/OFF Transfer threshold: 1.6 A (system is cutting) Powermax30 AIR Service Manual 808850...

  • Page 222: Powermax30 Air Schematic

    9 – Wiring Diagrams Powermax30 AIR schematic 013393 Rev A SHEET 1 of 2 Powermax30 AIR Service Manual 808850...

  • Page 223: Powermax30 Air Service Manual

    9 – Wiring Diagrams 013393 Rev A SHEET 2 of 2 Powermax30 AIR Service Manual 808850...

Table of Contents