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Hypertherm Powermax30 XP Service Manual

Plasma arc cutting system
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Powermax30
XP
®
Plasma Arc Cutting System
Service Manual
808150 | Revision 0 | English

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Summary of Contents for Hypertherm Powermax30 XP

  • Page 1 Powermax30 ® Plasma Arc Cutting System Service Manual 808150 | Revision 0 | English...
  • Page 2 ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ Powermax, Duramax, FineCut, 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. © 2014 Hypertherm Inc.

  • Page 3: Service Manual

    Powermax30 XP Service Manual 808150 Revision 0 English February 2014 Hypertherm Inc. Hanover, NH 03755 USA...
  • 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 Safety information Before operating any Hypertherm equipment, read the separate Safety and Compliance Manual (80669C) included with your product for important safety information.

  • Page 7: Table Of Contents

    Liability cap ....................................SC-16 Insurance ....................................SC-16 Transfer of rights ..................................SC-16 1 Specifications ..........................17 Safety information ..................................17 System description ..................................17 Power supply dimensions ................................18 System weights ..................................... 18 Hypertherm system ratings ................................. 19 Powermax30 XP Service Manual 808150 Revision 0...
  • Page 8 Using the cut charts ................................33 General-purpose consumables ............................34 240 V / 30 A cutting ................................35 FineCut consumables ................................36 120 V / 25 A cutting ................................37 120 V / 30 A cutting ................................38 Powermax30 XP Service Manual 808150 Revision 0...
  • Page 9 Initial resistance check ................................59 Check the power switch ..............................60 Power supply overview ................................62 Troubleshooting guide ................................. 63 Control board LEDs ..................................69 Use the control board Error and Reset LEDs to troubleshoot ................... 70 Powermax30 XP Service Manual 808150 Revision 0...
  • Page 10 Replacing the air filter bowl and air filter element ....................... 148 Replacing the front panel ................................152 Replacing the rear panel ................................156 Replacing the base ..................................160 Replacing the magnetics assembly ............................162 Replacing the work lead and ground clamp ......................... 167 Powermax30 XP Service Manual 808150 Revision 0...
  • Page 11 Accessory parts ..................................195 Safety-critical parts ..................................196 Recommended spare parts ..............................197 Powermax30 XP labels ................................198 9 Wiring Diagrams ........................199 Powermax generic timing chart ............................... 200 Powermax30 XP schematic ..............................201 Powermax30 XP Service Manual 808150 Revision 0...
  • Page 12 Contents Powermax30 XP Service Manual 808150 Revision 0...

  • Page 13: Electromagnetic Compatibility (Emc

    Other supply cables, control cables, signaling and telephone cables; above, below and adjacent to the cutting equipment. Hypertherm’s CE-marked equipment is built in compliance with standard EN60974-10. The equipment should be b. Radio and television transmitters and receivers. installed and used in accordance with the information c.

  • Page 14: Maintenance Of Cutting Equipment

    Electromagnetic Compatibility (EMC) Maintenance of cutting equipment Earthing of the workpiece Where the workpiece is not bonded to earth for electrical The cutting equipment must be routinely maintained safety, nor connected to earth because of its size and according to the manufacturer’s recommendations. All position, for example, ship’s hull or building steel work, a access and service doors and covers should be closed connection bonding the workpiece to earth may reduce...

  • Page 15: Warranty

    Hypertherm is notified of a defect (i) with respect to the particular purpose or against infringement. The foregoing plasma power supply within a period of two (2) years from...

  • Page 16: Patent Indemnity

    (14) days after learning of any action or threat of action), appropriate to defend and to hold Hypertherm harmless in and Hypertherm’s obligation to defend shall be the event of any cause of action arising from the use of the conditioned upon Hypertherm’s sole control of, and the...

  • Page 17: Specifications

    System description The Powermax30 XP is a highly portable, 30 A, handheld plasma cutting system appropriate for a wide range of applications. It uses air or nitrogen to cut electrically conductive metals, such as mild steel, stainless steel, or aluminum.

  • Page 18: Power Supply Dimensions

    You can order additional consumables and accessories – such as the carrying case, carrying strap, and a circle cutting guide – from any Hypertherm distributor. See the Parts section on page 185 for a list of spare and optional parts.

  • Page 19: Hypertherm System Ratings

    99.1 l/min at 4.7 bar (3.5 scfm at 68 psi) Recommended gas inlet flow and pressure 113.3 l/min at 5.5 bar (4.0 scfm at 80 psi) Maximum gas inlet pressure 9.3 bar (135 psi) Powermax30 XP Service Manual 808150 Revision 0...

  • Page 20: Torch Dimensions

    12 mm (1/2 inch) at 75 mm/minute (3 inches/minute)  To understand the differences between the general-purpose and FineCut consumables, and for guidelines on selecting the right set for your cutting applications, see Choose the consumables on page 32. Powermax30 XP Service Manual 808150 Revision 0...

  • Page 21: Symbols And Marks

    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.

  • Page 22: Noise Levels

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

  • Page 23: 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 24: System Contents

    CSA power cord with power plug adaptors Safety and Compliance Manual Power supply Duramax LT torch with lead Carrying strap Consumable kit  The specific components included with the system are subject to change over time. Powermax30 XP Service Manual 808150 Revision 0...

  • Page 25: Position The Plasma Cutting System

    Position the plasma cutting system  Position the Powermax30 XP near an appropriate power receptacle. The system has a 3.0 m (10 foot) power cord.  Allow at least 0.25 m (10 inches) of space around the power supply for proper ventilation.

  • Page 26: Requirements For Grounding

    44.  To operate the system on a 240 V/20 A circuit, attach the female end of the 240 V/20 A (NEMA 6-50P) plug to the power supply’s NEMA twist lock-style plug. Powermax30 XP Service Manual 808150 Revision 0...

  • Page 27: Ce And Ccc 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 XP Service Manual 808150 Revision 0...

  • Page 28: 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 XP Service Manual 808150 Revision 0...

  • Page 29: Prepare The Gas Supply

    Some air compressors use synthetic lubricants containing esters that damage the polycarbonates used in the air filter bowl. The recommended inlet pressure while gas is flowing is 5.5 – 6.9 bar (80 – 100 psi). Powermax30 XP Service Manual 808150 Revision 0...

  • Page 30: Additional Gas Filtration

    When site conditions introduce moisture, oil, or other contaminants into the gas line, use a three-stage coalescing filtration system, such as the Eliminizer filter kit (128647) available from Hypertherm distributors. A three-stage filtering system works as follows to clean contaminants from the gas supply.

  • Page 31: Torch Setup

    Torch Setup Introduction The Powermax30 XP includes the Duramax LT 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 32: Consumable Life

    Consumables (FineCut or general-purpose)  Hypertherm does not recommend the use of any other consumables in the Duramax LT 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 33: Using The Cut Charts

     Hypertherm does not recommend the use of any other consumables in the Duramax LT torch except for those listed in this section, which are designed specifically for this system.

  • Page 34: General-Purpose Consumables

    Cutting at 120 V with the general-purpose consumables is not recommended. Figure 3 – General-purpose consumable set Torch Nozzle (420118) Electrode (420120) Retaining cap (420114) Swirl ring (420211) Shield (420116) Powermax30 XP Service Manual 808150 Revision 0...

  • Page 35: 240 V / 30 A Cutting

    To cut material thicker than 6 mm (1/4 inch), start the torch at the edge of the workpiece. Maximum cut speed is limited by the test table’s maximum speed (10160 mm/minute or 400 inches/minute). Powermax30 XP Service Manual 808150 Revision 0...

  • Page 36: Finecut Consumables

    For guidelines on cutting with 120 V input, see Recommendations for cutting at 120 V on page 49. Figure 4 – FineCut consumable set Torch Nozzle (420117) Electrode (420120) Retaining cap (420114) Swirl ring (420211) Deflector (420115) Powermax30 XP Service Manual 808150 Revision 0...

  • Page 37: 120 V / 25 A Cutting

    To cut material thicker than 6 mm (1/4 inch), start the torch at the edge of the workpiece. Maximum cut speed is limited by the test table’s maximum speed (10160 mm/minute or 400 inches/minute). Powermax30 XP Service Manual 808150 Revision 0...

  • Page 38: 120 V / 30 A Cutting

    To cut material thicker than 6 mm (1/4 inch), start the torch at the edge of the workpiece. Maximum cut speed is limited by the test table’s maximum speed (10160 mm/minute or 400 inches/minute). Powermax30 XP Service Manual 808150 Revision 0...

  • Page 39: Operation

    Refer to the following topics to become familiar 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 XP Service Manual 808150 Revision 0...

  • Page 40: Front Controls And Leds

    Troubleshooting guide on page 63. 240 V 20 A Amperage adjustment knob – Use this knob to set the output current 120 V AMPS between 15 A and 30 A. 20 A 120 V 15 A Powermax30 XP Service Manual 808150 Revision 0...

  • Page 41: Operate The Powermax30 Xp

    4 – Operation Operate the Powermax30 XP The following topics explain how to begin cutting with the Powermax30 XP. Connect the electrical power and gas supply Plug in the power cord and connect the gas supply line  For information on connecting the gas supply to the power supply, see Prepare the gas supply on page 29.

  • Page 42: Install The Consumables

    3. You use only the shield (420116) with the general-purpose nozzle (420118).  To understand the differences between the general-purpose and FineCut consumables, and for guidelines on selecting the right set for your cutting applications, see Choose the consumables on page 32. Powermax30 XP Service Manual 808150 Revision 0...
  • Page 43 4 – Operation Figure 5 Tighten only to finger tight. 1 Electrode 5 Retaining cap 2 Swirl ring 6 Shield (general-purpose) 3 Nozzle (general-purpose) 7 Deflector (FineCut) 4 Nozzle (FineCut) Powermax30 XP Service Manual 808150 Revision 0...

  • Page 44: Attach The Ground Clamp

    (3.5 scfm at 68 psi). For more information on attaching the gas supply, see Prepare the gas supply on page 29. 1. Set the regulator between 5.5 and 6.9 bar (80 and 100 psi). 2. Turn the amperage knob to the desired output current based on the input voltage, circuit size, and consumables. Powermax30 XP Service Manual 808150 Revision 0...
  • Page 45 120 V AMPS 20 A  Do not mix the general-purpose and FineCut 120 V 15 A consumables. Use one set or the other. See Voltage configurations on page 25 for more information. Powermax30 XP Service Manual 808150 Revision 0...

  • Page 46: Check The Indicator Leds

    When the duty cycle is exceeded, the system overheats, the temperature LED illuminates, the arc shuts off, and the cooling fan continues to run. To resume cutting, wait for the temperature LED to extinguish.  The fan may run during normal operation of the system. Powermax30 XP Service Manual 808150 Revision 0...

  • Page 47: System Operation Guidelines

    Additional techniques to reduce the frequency of tripped circuit breakers include:  Turn down the amperage adjustment knob.  Avoid stretching the arc. Instead, drag the torch on the workpiece as explained in Edge start on a workpiece on page 50. Powermax30 XP Service Manual 808150 Revision 0...

  • Page 48: Hand Torch Operation

    The Duramax LT 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 press the red torch trigger. Powermax30 XP Service Manual 808150 Revision 0...

  • Page 49: 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 195 for the Hypertherm plasma cutting guide part numbers for cutting circles and making bevel cuts.

  • Page 50: Edge Start On A Workpiece

    2. Press 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 XP Service Manual 808150 Revision 0...

  • Page 51: Pierce A Workpiece

    If the metal is thinner than 6 mm (1/4 inch), use piercing to cut an interior feature. Piercing shortens the life of the consumables. The type of pierce to perform depends on the thickness of the metal. Hypertherm recommends: ...

  • Page 52: Gouge A Workpiece

    5. When the pierce is complete, drag the torch lightly along the workpiece to proceed with the cut. Gouge a workpiece You can use the Powermax30 XP with the general-purpose consumables for light gouging applications, such as the removal of spot welds and tack welds.
  • Page 53 Decreasing the angle of the torch (less vertical) will increase width and decrease depth.  Increasing the current of the power supply will increase width and increase depth.  Decreasing the current of the power supply will decrease width and decrease depth. Powermax30 XP Service Manual 808150 Revision 0...

  • 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 XP Service Manual 808150 Revision 0...

  • 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 XP Service Manual 808150 Revision 0...

  • Page 56: Sequence Of Operation

    • Set the power switch (S1) to OFF (O). • The power circuits are ready. • Position the torch on the workpiece. • Pull the plasma start trigger on the torch. Powermax30 XP Service Manual 808150 Revision 0...

  • 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 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 printed circuit boards. Powermax30 XP Service Manual 808150 Revision 0...

  • 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 XP Service Manual 808150 Revision 0...

  • Page 60: Check The Power Switch

    4. Remove the consumables from the torch. If you do not remove the consumables, the resistance values will not read correctly. Powermax30 XP Service Manual 808150 Revision 0...
  • 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 XP Service Manual 808150 Revision 0...

  • 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 XP Service Manual 808150 Revision 0...

  • Page 63: Troubleshooting Guide

    5 – Troubleshooting and System Tests Troubleshooting guide This guide provides the most probable causes and solutions. Study the Powermax30 XP schematic on page 201 and understand the Theory of operation on page 55 before troubleshooting. 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 • Perform Test 5 – torch stuck touching when the • The torch or torch lead open or torch stuck closed on torch trigger is pulled. has a broken wire. page 81. Powermax30 XP Service Manual 808150 Revision 0...
  • Page 65 9.3 bar (135 psi), cylinder is too high. and reduce the pressure if necessary. • The gas solenoid valve is faulty. • Perform Test 4 – solenoid valve on page 80. Powermax30 XP Service Manual 808150 Revision 0...
  • Page 66 • The power board is imbalance on the • Verify that the gas supply is faulty. power board. providing at least 4.5 bar (65 psi). • Perform Test 3 – VBUS and voltage balance on page 78. Powermax30 XP Service Manual 808150 Revision 0...
  • Page 67 Test 3 – VBUS and voltage still pulling the torch balance on page 78. trigger. Powermax30 XP Service Manual 808150 Revision 0...
  • Page 68 See Extension cord power to the power recommendations on page 28. supply. • Verify nothing else is drawing power on the same circuit. Powermax30 XP Service Manual 808150 Revision 0...

  • Page 69: Control Board Leds

    5 – Troubleshooting and System Tests Control board LEDs The Powermax30 XP control board (PCB1) is located inside of the front panel. Figure 9 Control board Ribbon cable The control board has four diagnostic LEDs:  Reset – This LED illuminates when a voltage reading is out of range or the Reset LED blinks.

  • Page 70: Use The Control Board Error And Reset Leds To Troubleshoot

    If you find the correct values the second time, replace the control board. (See Replacing the control board on page 107.) Otherwise, replace the power board. (See Remove the power board on page 109.) Powermax30 XP Service Manual 808150 Revision 0...

  • Page 71: System Tests

    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. See Figure 11 for both grounding options. Figure 11 Powermax30 XP Service Manual 808150 Revision 0...
  • Page 72 5 – Troubleshooting and System Tests Figure 12 Input diode bridges Ribbon cable connector (J7) Capacitors J17 (white) J16 (red) IGBTs J12 (torch-start, cap-sensor switch connector) Snubber resistor Powermax30 XP Service Manual 808150 Revision 0...
  • Page 73 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 XP Service Manual 808150 Revision 0...

  • Page 74: 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 XP Service Manual 808150 Revision 0...
  • Page 75 If it is not, check the power switch and replace if necessary. Figure 15 10. If the power-ON LED is still illuminated, perform Test 2 – power board voltage checks on page 76. Powermax30 XP Service Manual 808150 Revision 0...

  • Page 76: Test 2 - Power Board Voltage Checks

    For ground locations, see Figure 11 on page 71. If any of the values are incorrect, replace the power board. (See Remove the power board on page 109.) Powermax30 XP Service Manual 808150 Revision 0...
  • Page 77 < 0.1 VDC 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 Start signal 3.2 VDC closed 0 VDC open Powermax30 XP Service Manual 808150 Revision 0...

  • Page 78: Test 3 - Vbus And Voltage Balance

    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. Figure 17 Powermax30 XP Service Manual 808150 Revision 0...
  • Page 79 8. The values found in step 6 and step 7 should be approximately equal. If they differ by more than 30 V, replace the power board. Figure 18 step 5 step 6 step 7 Powermax30 XP Service Manual 808150 Revision 0...

  • Page 80: Test 4 - Solenoid Valve

    7. Measure the voltage between pin 4 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 Replacing the solenoid valve on page 130.) Powermax30 XP Service Manual 808150 Revision 0...

  • Page 81: Test 5 - Torch Stuck Open Or Torch Stuck Closed

    7. If the resistance reads as closed, the nozzle and electrode are in contact or one of the wires in the torch lead is broken. Make sure that the torch plunger moves freely in the torch head. Powermax30 XP Service Manual 808150 Revision 0...

  • Page 82: Test 6 - Plasma Start

    With the trigger pulled, the resistance should 10 Ω or less. b. With the trigger released, the circuit should read approximately 3 kΩ. 8. If this test fails, check the torch start-switch and the torch wires. Powermax30 XP Service Manual 808150 Revision 0...
  • Page 83 With the trigger released, it should measure 3.2 VDC for a closed circuit. 11. If the values are not correct, replace the power board. (See Remove the power board on page 109.) Powermax30 XP Service Manual 808150 Revision 0...

  • Page 84: Test 7 - Torch Cap-Sensor

    9. If the torch parts mentioned in step 7 and step 8 are working properly, the cap-sensor switch is faulty or the torch lead has a broken wire. Replace the faulty part. (See Replacing the cap-sensor switch on page 181 or Replacing the torch lead on page 182.) Powermax30 XP Service Manual 808150 Revision 0...

  • Page 85: 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 XP Service Manual 808150 Revision 0...

  • Page 86: Test 9 - Pressure Switch

    4. Measure the resistance between pins 1 and 2 of J4. If there is no gas pressure, it should read approximately 4.7 kΩ. If the gas pressure is within system tolerances as outlined in the Hypertherm system ratings on page 19, the circuit should read as closed.

  • Page 87: Power Supply Component Replacement

    Disconnect the power and gas supply 1. Set the plasma power supply switch to OFF (O). 2. Disconnect the power cord from the power source. 3. Disconnect the gas supply hose from the plasma power supply. Powermax30 XP Service Manual 808150 Revision 0...

  • Page 88: Replacing 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 24 Powermax30 XP Service Manual 808150 Revision 0...
  • Page 89 5. Reinstall the two screws that attach the cover and handle with a torque setting of 23.0 kg-cm (20 inch-pounds). 6. Reconnect the gas supply and power cord, and set the power switch to ON (I). Powermax30 XP Service Manual 808150 Revision 0...

  • Page 90: Replacing The Component Barrier

    1. Set the power switch to OFF (O), disconnect the power cord from the power source, and disconnect the gas supply. 2. 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 26 Component barrier Powermax30 XP Service Manual 808150 Revision 0...
  • Page 91 5. Reconnect the gas supply and power cord, and set the power switch to ON (I). Figure 27 Component barrier edge with long cutout and Track two notches Rear panel Front panel Component barrier edge with three notches Powermax30 XP Service Manual 808150 Revision 0...

  • Page 92: Detaching And Reattaching The Front Panel

    5. Insert needle nose pliers into the opening for one of the snaps, and use the pliers to squeeze it together. 6. Place a blade screwdriver against the raised rib next to the snap, and gently turn the screwdriver to push the panel away from the base. Powermax30 XP Service Manual 808150 Revision 0...
  • Page 93 9. Disconnect the control panel ribbon cable from the power board by folding the latches back.  In Figure 31, the center panel is hidden in the image on the left. 10. Gently pull the panel away from the power supply. Powermax30 XP Service Manual 808150 Revision 0...
  • Page 94 3. Reconnect the control board’s ribbon cable to the power board. 4. Tighten the strain relief nut on the torch lead and work lead. 5. Reconnect the gas supply and power cord, and set the power switch to ON (I). Powermax30 XP Service Manual 808150 Revision 0...

  • Page 95: Detaching And Reattaching The Rear Panel

    5. Insert needle nose pliers into the opening for one of the snaps and use the pliers to squeeze it together. 6. Place a blade screwdriver against the raised rib next to the snap and gently turn the screwdriver to push the panel away from the base. Powermax30 XP Service Manual 808150 Revision 0...

  • Page 96: Place Another Screwdriver Or Similar Object Into The Opening Between The Panel And The Base To Keep The First Corner

    8. Repeat step 5 and step 6 on the other corner of the panel. 9. Disconnect the ground wire from the ground wire clip near the top of the rear panel. (See Figure 35.) 10. Gently pull the panel away from the power supply. Powermax30 XP Service Manual 808150 Revision 0...
  • Page 97 4. Reconnect the ground wire to the ground wire clip. 5. Tighten the strain relief nut on the power cord. 6. Reconnect the gas supply and power cord, and set the power switch to ON (I). Powermax30 XP Service Manual 808150 Revision 0...

  • Page 98: Replacing The Power Cord And Strain Relief

    See Remove the component barrier on page 90. d. See Detach the rear panel on page 95. 2. Remove the black and white wires from the top of the power switch. Figure 36 Powermax30 XP Service Manual 808150 Revision 0...
  • Page 99 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 37.) Figure 37 Powermax30 XP Service Manual 808150 Revision 0...
  • Page 100 7. Are you replacing the strain relief?  If yes, remove the strain relief from the rear panel.  If no, continue with Install the power cord and strain relief on page 103. Powermax30 XP Service Manual 808150 Revision 0...
  • Page 101 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 39 Table 2 – Single-phase CE and CCC power cord wires Designator Wire color L (live) Brown N (neutral) Blue PE (ground) Green/yellow Powermax30 XP Service Manual 808150 Revision 0...
  • Page 102 8. Are you replacing the strain relief?  If yes, remove the strain relief from the rear panel.  If no, continue with Install the power cord and strain relief on page 103. Powermax30 XP Service Manual 808150 Revision 0...
  • Page 103 See Install the component barrier on page 91. b. See Install the power supply cover on page 89. c. Reconnect the gas supply and power cord, and set the power switch to ON (I). Powermax30 XP Service Manual 808150 Revision 0...
  • Page 104 See Install the component barrier on page 91. b. See Install the power supply cover on page 89. c. Reconnect the gas supply and power cord, and set the power switch to ON (I). Powermax30 XP Service Manual 808150 Revision 0...

  • Page 105: Replacing The Power Switch

    6. Repeat the previous two steps on the bottom of the power switch to push the bottom of the switch out of the rear panel. Remove the switch completely from the panel. Figure 41 Ground wire clip Powermax30 XP Service Manual 808150 Revision 0...
  • Page 106 See Install the component barrier on page 91. b. See Install the power supply cover on page 89. c. Reconnect the gas supply and power cord, and set the power switch to ON (I). Powermax30 XP Service Manual 808150 Revision 0...

  • Page 107: Replacing The Control Board

    Reconnect the power cord to the power source, and turn the system ON. c. Verify that the Start LED on the control board is the only LED illuminated. Also, the fault LEDs on the front panel should be extinguished. Powermax30 XP Service Manual 808150 Revision 0...
  • Page 108 6. Remove the 3 retaining screws from the control board, and lift it out of the front panel. Figure 45 Front panel Power board Ribbon cable Control board Powermax30 XP Service Manual 808150 Revision 0...

  • Page 109: Replacing The Power Board

    2. Remove the TORCH START connector (J12) on the component side of the power board (see Figure 47 on page 110) by pushing the tab on the connector toward the plug and pulling the plug out. Figure 46 Push tab toward connector. Powermax30 XP Service Manual 808150 Revision 0...
  • Page 110 3. Remove the connectors at J4, J5, and J6 on the component side of the power board. (See Figure 47.) Figure 47 Input diode bridges Ribbon cable connector (J7) Capacitors IGBTs Connector TORCH START (J12) Snubber resistor Powermax30 XP Service Manual 808150 Revision 0...
  • Page 111 Holes in the power board provide access to the 2 input diode bridge screws. Figure 48 TORCH START WORK LEAD (BLK) Retaining screws (3) Heatsink assembly screws (4) Connector TORCH START (J12) Input diode bridge screws (2) IGBT screws (3) Work lead connector (J22) Powermax30 XP Service Manual 808150 Revision 0...
  • Page 112 12. From the power board side of the power supply, push the wires that you disconnected down and out of the way. 13. Pull the board straight out from the power supply and set it aside. Powermax30 XP Service Manual 808150 Revision 0...
  • Page 113 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. (See Figure 51.) Figure 51 Snubber resistor Capacitors Thermal grease Powermax30 XP Service Manual 808150 Revision 0...
  • Page 114 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 these screws to 17.3 kg-cm (15 inch-pounds). Powermax30 XP Service Manual 808150 Revision 0...
  • Page 115 See Install the component barrier on page 91. c. See Install the power supply cover on page 89. d. Reconnect the gas supply and power cord, and set the power switch to ON (I). Powermax30 XP Service Manual 808150 Revision 0...

  • Page 116: Replacing The Fan

    CAUTION! Be careful not to apply too much pressure to any of the clips as you detach the plenum from the fan. Powermax30 XP Service Manual 808150 Revision 0...
  • Page 117 9. Route the fan’s red-and-black wires through the notch in the top of the center panel that is nearest the solenoid valve. (See Figure 55.) 10. Attach the connector for the red-and-black wires to J5 on the power board. (See Figure 53 on page 116.) Powermax30 XP Service Manual 808150 Revision 0...
  • Page 118 11. Complete the following procedures: a. See Install the power supply cover on page 89. b. Reconnect the gas supply and power cord, and set the power switch to ON (I). Powermax30 XP Service Manual 808150 Revision 0...

  • Page 119: Replacing The Drain Hose, Gas Supply Hoses, And 90° Fitting

    228095 Kit: Hoses: drain hose, two gas supply hoses, elbow fitting The Powermax30 XP contains a drain hose and two gas supply hoses that can be replaced. (See Figure 57.)  The drain hose runs from the bottom of the air filter bowl to the base of the power supply.
  • Page 120 Push-to-disconnect the plastic 90° fitting from the torch lead’s brass gas supply fitting inside the front panel of the power supply. c. Push-to-disconnect the gas supply hose from the top of the plastic 90° fitting. Powermax30 XP Service Manual 808150 Revision 0...

  • Page 121: Figure 57

    Brass “T” fitting Plastic 90° fitting for torch lead Air filter bowl Gas supply hose from solenoid valve to torch lead Fitting Solenoid valve Drain hose Gas supply hose from air filter/regulator to solenoid valve Powermax30 XP Service Manual 808150 Revision 0...
  • Page 122 Push-to-connect the other end of the new hose into the fitting on the rear-panel side of the solenoid valve.  This kit contains 1 extra gas supply hose not used in the Powermax30 XP system. 4. Install the new gas supply hose and the plastic 90° fitting that connect the solenoid valve to the torch lead: a.

  • Page 123: Replacing The Wire Group

    Description 228103 Kit: Wire group: pressure switch wire pair, 3 ground wires The wire group kit for the Powermax30 XP includes the following 4 wires: Figure 58 Pressure switch to J4 wire pair (red/black) Ground wire from heatsink to magnetics assembly...

  • Page 124: See Install The Power Supply Cover

    Reconnect the gas supply and power cord, and set the power switch to ON (I). Figure 59 Solenoid valve Center panel J4 connector on the power board Pressure switch Pressure switch to J4 wire pair Power board Powermax30 XP Service Manual 808150 Revision 0...
  • Page 125 Reconnect the gas supply and power cord, and set the power switch to ON (I). Figure 60 Ground clip wire from heatsink to rear panel Rear panel ground clip Rear panel Heatsink Powermax30 XP Service Manual 808150 Revision 0...
  • Page 126 17.3 kg-cm (15 inch-pounds). 7. Complete the following procedures: a. See Install the power supply cover on page 89. b. Reconnect the gas supply and power cord, and set the power switch to ON (I). Powermax30 XP Service Manual 808150 Revision 0...
  • Page 127 6 – Power Supply Component Replacement Figure 61 Pressure switch Heatsink Screw on the metal base plate of the magnetics Ground wire from heatsink to magnetics assembly assembly that attaches the ground wire Center panel Powermax30 XP Service Manual 808150 Revision 0...
  • Page 128 (10 inch-pounds). (See Figure 62.) 7. Complete the following procedures: a. See Install the power supply cover on page 89. b. Reconnect the gas supply and power cord, and set the power switch to ON (I). Powermax30 XP Service Manual 808150 Revision 0...
  • Page 129 6 – Power Supply Component Replacement Figure 62 Rear panel Center panel Ground clip on air filter/regulator’s brass “T” fitting Ground wire from heatsink to air filter/regulator ground clip Heatsink Powermax30 XP Service Manual 808150 Revision 0...

  • Page 130: Replacing The Solenoid Valve

    2. Detach the connector from J6 on the power board by pulling it straight back away from the board. (See Figure 63.)  If needed, lift the top edge of the component barrier that protects the power board to better access the J6 connector. Figure 63 Powermax30 XP Service Manual 808150 Revision 0...
  • Page 131 6. Orient the new solenoid valve so that the pink-and-gray J6 wire pair is on the rear-panel side of the valve. Figure 65 (Rear panel) (Front panel) Push-to-connect fitting Solenoid valve bracket Pink-and-gray J6 wire pair Powermax30 XP Service Manual 808150 Revision 0...
  • Page 132 Consumables life can be shortened. 12. Complete the following procedures: a. See Install the power supply cover on page 89. b. Reconnect the gas supply and power cord, and set the power switch to ON (I). Powermax30 XP Service Manual 808150 Revision 0...

  • Page 133: Replacing The Torch Lead And Strain Relief

    2. Push-to-disconnect the plastic 90° fitting from the torch lead’s brass gas supply fitting inside the front panel of the power supply. (See Figure 56 on page 119.) Figure 67 Torch lead Front panel (hidden) Plastic 90° fitting connected to brass gas supply fitting Powermax30 XP Service Manual 808150 Revision 0...
  • Page 134 3. 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 68 TORCH START slot (J12) Front panel Powermax30 XP Service Manual 808150 Revision 0...
  • Page 135 (on the fan side of the power supply). 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. Figure 70 Red wire White wire group Powermax30 XP Service Manual 808150 Revision 0...
  • Page 136 9. Remove the torch lead by pulling the wires through the hole in the front panel. If you are replacing the strain relief, remove the strain relief from the front panel. Figure 71 Outside Inside Retention nut (inside power supply) Strain relief Front panel Strain relief nut Powermax30 XP Service Manual 808150 Revision 0...
  • Page 137 5. Use an 8 mm (5/16 inch) nut driver to tighten the nut on each stud with a torque setting of 23.0 kg-cm (20 inch-pounds). Figure 72 WHT wire connection stud RED wire connection stud 6. Push-to-connect the plastic 90° fitting onto the new torch lead’s brass gas supply fitting. Powermax30 XP Service Manual 808150 Revision 0...
  • Page 138 94. 11. Complete the following procedures: a. See Install the power supply cover on page 89. b. Reconnect the gas supply and power cord, and set the power switch to ON (I). Powermax30 XP Service Manual 808150 Revision 0...

  • Page 139: Replacing The Pressure Switch

    9. Reconnect the ground wire to the clip on the brass “T” fitting with a torque setting of 11.5 kg-cm (10 inch-pounds). 10. Complete the following procedures: a. See Install the power supply cover on page 89. b. Reconnect the gas supply and power cord, and set the power switch to ON (I). Powermax30 XP Service Manual 808150 Revision 0...
  • Page 140 6 – Power Supply Component Replacement Figure 74 Air filter/regulator assembly Black wire Brass “T” fitting Pressure switch Ground wire clip Brass elbow fitting Red wire Powermax30 XP Service Manual 808150 Revision 0...

  • Page 141: Replacing The Air Filter/Regulator And Pressure Switch Assembly

    5. Push-to-disconnect the gas supply hose from the air filter/regulator’s brass “T” fitting. (See Figure 56 on page 119.) 6. Disconnect the ground wire that is attached to the clip on the air filter/regulator’s brass “T” fitting. Set the clip aside. Powermax30 XP Service Manual 808150 Revision 0...
  • Page 142 6 – Power Supply Component Replacement Figure 75 Air fitting (CSA) or air fitting adapter (CE/CCC) Red and black pressure switch wires Air filter/regulator Pressure switch Drain hose Ground wire clip on the “T” fitting Gas supply hose Powermax30 XP Service Manual 808150 Revision 0...
  • Page 143 Gently tilt the top of the rear panel away from the power supply as you remove the assembly, if needed. Figure 76 Retainer nut Air filter/regulator Center panel bracket Powermax30 XP Service Manual 808150 Revision 0...
  • Page 144 6 – Power Supply Component Replacement Install the air filter/regulator and pressure switch assembly  This kit contains two fittings that are not used in the Powermax30 XP: a brass coupler (015550) and a brass pipe (015618). CAUTION! The regulator is pre-set at the factory. Do not adjust this setting.
  • Page 145 Consumables life can be shortened. 10. Complete the following procedures: a. See Install the power supply cover on page 89. b. Reconnect the gas supply and power cord, and set the power switch to ON (I). Powermax30 XP Service Manual 808150 Revision 0...

  • Page 146: Replacing The Air Inlet Fittings

    428172 Kit: Air inlet fittings, CE/CCC  Each of these kits contains two fittings that are not used in the Powermax30 XP: a brass coupler (015550) and a brass pipe (015618). 1. Complete the following procedures: a. Set the power switch to OFF (O), disconnect the power cord from the power source, and disconnect the gas supply.
  • Page 147 Air filter/regulator 8. Complete the following procedures: a. See Install the power supply cover on page 89. b. Reconnect the gas supply and power cord, and set the power switch to ON (I). Powermax30 XP Service Manual 808150 Revision 0...

  • Page 148: Replacing The Air Filter Bowl And Air Filter Element

    4. Unscrew the plastic retainer nut that holds the air filter/regulator in the bracket on the center panel. 5. Tilt the bottom of the air filter/regulator assembly towards you with one hand. 6. With your other hand, unscrew the air filter bowl to remove it from the air filter/regulator assembly. Powermax30 XP Service Manual 808150 Revision 0...
  • Page 149 6 – Power Supply Component Replacement Figure 79 1 Plastic retainer nut (red) 4 Air filter bowl 2 Center panel bracket 5 Brass fitting 3 Air filter/regulator 6 Drain hose Powermax30 XP Service Manual 808150 Revision 0...
  • Page 150 Hand-tighten the retainer nut plus a quarter turn.  Do not overtighten the retainer nut. 6. Route the drain hose through the hole in the base of the power supply. Powermax30 XP Service Manual 808150 Revision 0...
  • Page 151 If the purity level of the gas is too low, or if there are leaks in the supply hoses or connections:  Cut speeds can decrease.  Cut quality can deteriorate.  Cutting thickness capability can decrease.  Consumables life can be shortened. Powermax30 XP Service Manual 808150 Revision 0...

  • Page 152: Replacing The Front Panel

    See Remove the component barrier on page 90. 2. Lay the power supply on its side. 3. Remove the retaining screw from the bottom of the front panel. Figure 82 Retaining screw Snap Front panel Powermax30 XP Service Manual 808150 Revision 0...
  • Page 153 6. Place another screwdriver or similar object into the opening between the panel and the base to keep the first corner of the panel from re-engaging the snaps when you release the other corner. Figure 84 7. Repeat step 4 and step 5 on the other corner of the panel. Powermax30 XP Service Manual 808150 Revision 0...
  • Page 154 8. Disconnect the control panel ribbon cable from the power board by folding the latches back.  In Figure 85, the center panel is hidden in the image on the left. Figure 85 Latches Ribbon cable Control board Power board Powermax30 XP Service Manual 808150 Revision 0...
  • Page 155 See Install the component barrier on page 91. b. See Install the power supply cover on page 89. c. Reconnect the gas supply and power cord, and set the power switch to ON (I). Powermax30 XP Service Manual 808150 Revision 0...

  • Page 156: Replacing The Rear Panel

    See Remove the power supply cover on page 88. c. See Remove the component barrier on page 90. 2. Lay the power supply on its side. Figure 87 Rear panel Retaining screw Snap Powermax30 XP Service Manual 808150 Revision 0...
  • Page 157 6. Place another screwdriver or similar object into the opening between the panel and the base to keep the first corner of the panel from re-engaging the snaps when you release the other corner. Figure 89 7. Repeat step 4 and step 5 on the other corner of the panel. Powermax30 XP Service Manual 808150 Revision 0...
  • Page 158 Remove the switch completely from the panel. Figure 90 Ground wire clip 13. Disconnect the power cord from the power supply. See Remove the power cord and strain relief on page 98. Powermax30 XP Service Manual 808150 Revision 0...
  • Page 159 See Install the component barrier on page 91. b. See Install the power supply cover on page 89. c. Reconnect the gas supply and power cord, and set the power switch to ON (I). Powermax30 XP Service Manual 808150 Revision 0...

  • Page 160: Replacing The Base

    Kit: Plastic base 1. Verify that the serial number on the bottom of the old base matches the one on the new base. Contact Hypertherm if the serial numbers do not match. The serial number can be found on the data plate.
  • Page 161 See Install the component barrier on page 91. d. See Install the power supply cover on page 89. e. Reconnect the gas supply and power cord, and set the power switch to ON (I). Powermax30 XP Service Manual 808150 Revision 0...

  • Page 162: Replacing The Magnetics Assembly

    Remove J13, J14, and J15, located on the front panel end of the power board. b. 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. Powermax30 XP Service Manual 808150 Revision 0...
  • Page 163 6 – Power Supply Component Replacement Figure 93 3. On the fan side of the power supply, remove the ground wire screw from the base of the magnetics assembly. Figure 94 Ground wire screw Powermax30 XP Service Manual 808150 Revision 0...
  • Page 164 5. Use a 8 mm (5/16 inch) nut driver to remove the nut that attaches the ring connector for the output inductor’s white wire to the stud labeled “WHT. ” Figure 95 Drain hose White wire stud (“WHT”) Output inductor Powermax30 XP Service Manual 808150 Revision 0...
  • Page 165 Figure 96 Holes 7. Remove the six screws that hold the magnetics’ metal mounting plate in place. Remove the plate and the magnetics. Figure 97 Powermax30 XP Service Manual 808150 Revision 0...
  • Page 166 See Install the component barrier on page 91. d. See Install the power supply cover on page 89. e. Reconnect the gas supply and power cord, and set the power switch to ON (I). Powermax30 XP Service Manual 808150 Revision 0...

  • Page 167: Replacing The Work Lead And Ground Clamp

    3. Remove and set aside the screw and washer from J22 on the power board (labeled “WORK LEAD”) that attaches the lead to the board. Figure 98 Front panel Work lead Strain relief nut Work lead connection to power board (J22) Powermax30 XP Service Manual 808150 Revision 0...
  • Page 168 See Install the component barrier on page 91. c. See Install the power supply cover on page 89. d. Reconnect the gas supply and power cord, and set the power switch to ON (I). Powermax30 XP Service Manual 808150 Revision 0...
  • Page 169 23.0 kg-cm (20 inch-pounds). 10. Fold the metal tabs over the wire to attach the wire to the handle. See Figure 100. 11. Slide the plastic sleeve over the handle of the new ground clamp. Powermax30 XP Service Manual 808150 Revision 0...
  • Page 170 6 – Power Supply Component Replacement Figure 100 Screw through handle and work lead Ring terminal Kepnut Strain relief tabs Powermax30 XP Service Manual 808150 Revision 0...

  • Page 171: 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 XP Service Manual 808150 Revision 0...

  • Page 172: Disconnect The Power, Gas Supply, And Torch

    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 XP Service Manual 808150 Revision 0...

  • Page 173: Replacing 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, lift the left side of the handle away from the torch. Powermax30 XP Service Manual 808150 Revision 0...
  • Page 174 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 103 Powermax30 XP Service Manual 808150 Revision 0...
  • Page 175 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 two mounting posts. Figure 105 Powermax30 XP Service Manual 808150 Revision 0...
  • Page 176 Verify that the trigger pivots are both located in the trigger pivot holes. (See Figure 106.) 9. Install the handle screws. 10. Install the consumables. 11. Reconnect the gas supply and power cord, and set the power switch to ON (I). Powermax30 XP Service Manual 808150 Revision 0...

  • Page 177: Replacing The Trigger Assembly

    5. Being careful to keep the trigger spring from launching out of the handle, lift the left side of the handle away from the torch. Figure 107 6. While holding the spring in place, slide the trigger and spring up and out of the handle. Set them aside. Powermax30 XP Service Manual 808150 Revision 0...

  • Page 178: Replacing The Torch Body

    Remove all components from the torch. See Remove the handle on page 173. 2. Remove the screw that attaches the torch power wire to the torch body. Set the nut and screw aside. Figure 108 Powermax30 XP Service Manual 808150 Revision 0...
  • Page 179 Install all of the torch components that you removed. See Install the handle on page 176. b. Reconnect the gas supply and power cord, and set the power switch to ON (I). Powermax30 XP Service Manual 808150 Revision 0...

  • Page 180: Replacing The Start Switch

    Install all of the torch components that you removed. See Install the handle on page 176. b. Reconnect the gas supply and power cord, and set the power switch to ON (I). Powermax30 XP Service Manual 808150 Revision 0...

  • Page 181: Replacing The Cap-Sensor Switch

    Install all of the torch components that you removed. See Install the handle on page 176. b. Reconnect the gas supply and power cord, and set the power switch to ON (I). Powermax30 XP Service Manual 808150 Revision 0...

  • Page 182: Replacing The Torch Lead

    4. Use 2 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 XP Service Manual 808150 Revision 0...
  • Page 183 Install all of the torch components that you removed. See Install the handle on page 176. b. Reconnect the gas supply and power cord, and set the power switch to ON (I). Powermax30 XP Service Manual 808150 Revision 0...
  • Page 184 7 – Torch Component Replacement Powermax30 XP Service Manual 808150 Revision 0...

  • Page 185: Parts

    Section 8 Parts Use the Hypertherm kit numbers in this section to order replacement parts, consumables, and accessories for your Powermax30 XP power supply and Duramax LT hand torch. You can find procedures explaining how to install these kits in Power Supply Component Replacement on page 87 and Torch Component Replacement on page 171.

  • Page 186: Power Supply Parts

    Kit: Power supply cover with labels, CE 428225 Kit: Power supply cover with labels, CCC 228099 Kit: Handle with screws 228561 Kit: Ground clamp 428239 Kit: Work lead, 4.6 m (15 feet), with ground clamp Powermax30 XP Service Manual 808150 Revision 0...

  • Page 187: Exterior, Rear

    CSA power cord extension: 240 V / 20 A plug adapter 228140 Kit: CE power cord, 1-phase, 3.0 m (10 feet) (plug not included) 428231 Kit: CCC power cord, 1-phase, 3.0 m (10 feet) (plug not included) 228143 Kit: Power cord strain relief Powermax30 XP Service Manual 808150 Revision 0...

  • Page 188: Interior, Power Board Side

    8 – Parts Interior, power board side Item Kit number Description Designator 228104 Kit: Component barrier 428233 Kit: Power board, CSA (141304) PCB2 428234 Kit: Power board, CE and CCC (141309) PCB2 Powermax30 XP Service Manual 808150 Revision 0...

  • Page 189: Control Board And Power Switch

    8 – Parts Control board and power switch Item Kit number Description Designator 428232 Kit: Control board (141336) PCB1 428235 Kit: Power switch Powermax30 XP Service Manual 808150 Revision 0...

  • Page 190: Interior, Fan Side

    Kit: Hoses: drain hose, two gas supply hoses, elbow fitting 428238 Kit: Replacement elbow fittings 428173 Kit: Solenoid valve 428236 Kit: Fan assembly with plenum 228103 Kit: Wire group: pressure switch wire pair, 3 ground wires Powermax30 XP Service Manual 808150 Revision 0...
  • Page 191 Kit: Air filter/regulator with pressure switch assembly 428171 Kit: Air inlet fittings, CSA 428172 Kit: Air inlet fittings, CE/CCC 428237 Kit: Air filter element 428246 Kit: Air filter bowl 228688 Kit: Pressure switch 428262 Kit: Air filter retaining nut Powermax30 XP Service Manual 808150 Revision 0...

  • Page 192: Power Supply Base And Magnetics

    8 – Parts Power supply base and magnetics Item Kit number Description 228139 Kit: Plastic base 428230 Kit: Magnetics assembly Powermax30 XP Service Manual 808150 Revision 0...

  • Page 193: Duramax Lt Hand Torch Parts

    Kit: Duramax LT torch lead, 4.6 m (15 feet), with strain relief * The torch assembly includes one set of general-purpose consumables:  Electrode (420120)  Swirl ring (420211)  Retaining cap (420114)  Nozzle (420118)  Shield (420116) Powermax30 XP Service Manual 808150 Revision 0...

  • Page 194: Duramax Lt Hand Torch Consumables

    Use the same electrode, swirl ring, and retaining cap for both general-purpose and FineCut applications. Do not use the general-purpose nozzle with the deflector; do not use the FineCut nozzle with the shield. Powermax30 XP Service Manual 808150 Revision 0...

  • Page 195: Accessory Parts

    Dust cover 127410 Carrying case 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 128647 Kit: Eliminizer air filtration 127169 Leather cutting gloves...

  • Page 196: 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, CSA, and CCC certification.

  • Page 197: 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 198: Powermax30 Xp Labels

    8 – Parts Powermax30 XP labels Kit number Description 428215 Kit: Powermax30 XP labels, CSA 428216 Kit: Powermax30 XP labels, CSA, Built in America 428217 Kit: Powermax30 XP labels, CE 428218 Kit: Powermax30 XP labels, CCC The label kits include: ...

  • Page 199: Wiring Diagrams

    Wiring Diagrams This section contains the following diagrams:  Powermax generic timing chart  Powermax30 XP schematic Powermax30 XP Service Manual 808150 Revision 0...

  • Page 200: Powermax Generic Timing Chart

    Maximum 5 seconds Pilot arc IGBT gated Post flow Gas control device LED on User set current Transfer PA current Pilot arc current Inverter output on Transfer threshold: 1.6 A Transfer relay and LED on Powermax30 XP Service Manual 808150 Revision 0...

  • Page 201: Powermax30 Xp Schematic

    9 – Wiring Diagrams Powermax30 XP schematic Powermax30 XP Service Manual 808150 Revision 0...

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