Hypertherm Powermax30 AIR Plasma Cutter Manuals

Manuals and User Guides for Hypertherm Powermax30 AIR Plasma Cutter. We have 11 Hypertherm Powermax30 AIR Plasma Cutter manuals available for free PDF download: Service Manual, Operator's Manual, Field Service Bulletin, Manual

Hypertherm Powermax30 AIR Service Manual (223 pages)

Plasma Arc Cutting System with Integrated Air Compressor

Brand: Hypertherm | Category: Welding System | Size: 12 MB

Table of Contents
7
Electromagnetic Compatibility (EMC

13
- Introduction
  13
- Installation and Use
  13
- Assessment of Area
  13
- Methods of Reducing Emissions
  13
  - Mains Supply
    13
- Maintenance of Cutting Equipment
  13
- Cutting Cables
  13
  - Earthing of the Workpiece
    13
  - Equipotential Bonding
    13
- Screening and Shielding
  14
Warranty

15
- Attention
  15
- General
  15
- Patent Indemnity
  15
- Limitation of Liability
  15
- National and Local Codes
  15
- Liability Cap
  15
- Insurance
  16
- Transfer of Rights
  16
1 Specifications

17
- Safety Information
  17
- System Description
  17
- Power Supply Dimensions
  18
- System Weights
  18
- Hypertherm System Ratings
  19
- Torch Dimensions
  20
- Torch Weight
  20
- Cutting Specifications
  21
- IEC Symbols
  22
- Noise Levels
  22
- Symbols and Marks
  23
2 Power Supply Setup

25
- Unpack the Plasma System
  25
  - Claims
    25
- System Contents
  26
- Position the Plasma Cutting System
  27
- Prepare the Electrical Power
  27
  - Voltage Configurations
    27
  - Requirements for Grounding
    29
- Power Cord Considerations
  29
  - CSA Power Cords and Plugs
    29
  - CE Power Cords
    30
    
    Install a Plug on the Power Cord
    30
    
    Extension Cord Recommendations
    31
    
    Generator Recommendations
    31
3 Torch Setup

33
- Introduction
  33
  - 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
    40
4 Operation

41
- Controls and Indicators
  41
5 Troubleshooting and System Tests

55
- Theory of Operation
  55
  - Functional Description
    55
  - Sequence of Operation
    56
- Troubleshooting Preparation
  57
  - Test Equipment
    58
  - Troubleshooting Procedures and Sequence
    58
  - External Inspection
    59
  - Internal Inspection
    59
  - Initial Resistance Check
    59
    
    Check the Power Switch
    60
- Power Supply Overview
  62
- Troubleshooting Guide
  63
  - Power LED Faults
    63
  - Temperature LED Faults
    65
  - Internal Compressor LED Faults
    66
  - Torch Cap LED Faults
    68
  - Common Cutting Issues
    69
- Control Board Leds
  71
  - Use the Control Board Rest and Error Leds to Troubleshoot
    72
    
    Reset LED
    72
    
    Error LED
    73
- System Tests
  73
6 Power Supply Component Replacement

97
- Replace the Power Supply Cover
  98
- Replace the Component Barrier
  100
- Detach and Reattach the Front Panel
  102
- Detach and Reattach the Rear Panel
  104
- Replace the Power Cord and Strain Relief
  107
- Replace the Power Switch
  116
- Replace the Control Board
  118
- Replace the Compressor-Driver Board
  121
- Replace the Power Board
  126
- Replace the Drain Hose, Gas Supply Hoses, and 90° Fitting
  133
- Replace the Wire Group
  137
- Replace the Solenoid Valve
  142
- Replace the Torch Lead and Strain Relief
  144
- Replace the Air Filter Assembly
  148
- Replace the Air Filter Bowl and Air Filter Element
  151
- Replace the Fan
  155
- Replace the Heat Exchange Coil
  157
- Replace the Internal Compressor
  160
- Replace the Air Inlet Filter in the Internal Compressor
  165
- Replace the Front Panel
  166
- Replace the Rear Panel
  169
- Replace the Base
  173
- Replace the Magnetics Assembly
  175
- Replace the Work Lead and Ground Clamp
  180
7 Torch Component Replacement

185
- Torch Components
  186
- 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
8 Parts

201
- Power Supply Parts
  202
  - Exterior, Front
    202
  - Exterior, Rear
    203
  - Interior, Power Board Side
    204
  - Interior, Control Board and Power Switch
    205
  - Interior, Fan Assembly
    206
  - Interior, Pneumatics (Fan Side)
    207
  - Interior, Wires
    208
  - Power Supply Base and Magnetics
    209
- Hand Torch Parts
  210
- Hand Torch Consumables
  211
- Accessory Parts
  212
- Safety-Critical Parts
  213
- Recommended Spare Parts
  215
- Power Supply Labels
  216
  - Consumables Label
    216
  - CSA Warning Label
    217
  - CE Warning Label
    218
9 Wiring Diagrams

219

Hypertherm Powermax30 AIR Service Manual (201 pages)

Plasma Arc Cutting System

Brand: Hypertherm | Category: Welding System | Size: 15 MB

Table of Contents

7
- Electromagnetic Compatibility (EMC
  
  13
  - Assessment of Area
    13
  - Installation and Use
    13
  - Introduction
    13
  - Methods of Reducing Emissions
    13
    
    Mains Supply
    13
  - Cutting Cables
    14
    
    Earthing of the Workpiece
    14
    
    Equipotential Bonding
    14
  - Maintenance of Cutting Equipment
    14
  - Screening and Shielding
    14
  - Attention
    15
  - General
    15
- Warranty
  
  15
  - Insurance
    16
  - Liability Cap
    16
  - Limitation of Liability
    16
  - National and Local Codes
    16
  - Patent Indemnity
    16
  - Transfer of Rights
    16
- Specifications
  
  17
  - Safety Information
    17
  - System Description
    17
  - Power Supply Dimensions
    18
  - System Weights
    18
  - Hypertherm System Ratings
    19
  - Torch Dimensions
    20
  - Torch Weight
    20
  - Cutting Specifications
    20
  - Symbols and Marks
    21
    
    IEC Symbols
    22
    
    Noise Levels
    22
- Power Supply Setup
  
  23
  - Unpack the Powermax System
    23
    
    Claims
    23
  - System Contents
    24
  - Position the Plasma Cutting System
    25
  - Prepare the Electrical Power
    25
    
    Voltage Configurations
    25
    
    Requirements for Grounding
    26
  - Power Cord Considerations
    26
    
    CSA Power Cords and Plugs
    26
    
    CE and CCC Power Cords
    27
    
    Extension Cord Recommendations
    28
    
    Generator Recommendations
    28
  - Prepare the Gas Supply
    29
    
    Connect the Gas Supply
    29
    
    Additional Gas Filtration
    30
- Torch Setup
  
  31
  - Introduction
    31
    
    Hand Torch Components
    31
  - Consumable Life
    32
  - Choose the Consumables
    32
    
    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
    38
- Operation
  
  39
  - Controls and Indicators
    39
    
    Rear Controls
    39
    
    Front Controls and Leds
    40
  - Operate the Powermax30 XP
    41
    
    Connect the Electrical Power and Gas Supply
    41
  - Install the Consumables
    42
    
    Adjust the Gas Pressure and Output Current
    44
    
    Attach the Ground Clamp
    44
    
    Power on the System
    44
    
    Check the Indicator Leds
    46
    
    Verify the System Is Ready
    46
  - Understand Duty-Cycle Limitations
    46
  - System Operation Guidelines
    47
  - Hand Torch Operation
    48
    
    Safety Catch Operation
    48
    
    Hand Torch Cutting Guidelines
    49
    
    Edge Start on a Workpiece
    50
    
    Pierce a Workpiece
    51
    
    Gouge a Workpiece
    52
    
    Common Hand-Cutting Faults
    54
- Troubleshooting and System Tests
  
  55
  - Theory of Operation
    55
    
    Functional Description
    55
    
    Sequence of Operation
    56
  - Troubleshooting Preparation
    57
    
    Test Equipment
    57
    
    Troubleshooting Procedures and Sequence
    57
    
    External Inspection
    59
    
    Internal Inspection
    59
  - 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
  - System Tests
    71
    
    Test 1 - Voltage Input
    74
    
    Test 2 - Power Board Voltage Checks
    76
    
    Test 3 - VBUS and Voltage Balance
    78
    
    Test 4 - Solenoid Valve
    80
    
    Test 5 - Torch Stuck Open or Torch Stuck Closed
    81
    
    Test 6 - Plasma Start
    82
    
    Test 7 - Torch Cap-Sensor
    84
    
    Test 8 - Fan
    85
    
    Test 9 - Pressure Switch
    86
- Power Supply Component Replacement
  
  87
Table of Contents

93
Table of Contents

118
- Replacing the Drain Hose, Gas Supply Hoses, and 90° Fitting
  119
- Figure 57
  121
- Solenoid Valve
  121
- Replacing the Wire Group
  123
- Reconnect the Gas Supply and Power Cord, and Set the Power Switch to on (I)
  124
- See Install the Power Supply Cover
  124
- Torch Component Replacement
  
  171
  - Disconnect the Power, Gas Supply, and Torch
    172
  - Replacing the Handle
    173
  - Replacing the Trigger Assembly
    177
  - Replacing the Torch Body
    178
  - Replacing the Start Switch
    180
  - Replacing the Cap-Sensor Switch
    181
  - Replacing the Torch Lead
    182
- Parts
  
  185
  - Power Supply Parts
    186
    
    Exterior, Front
    186
    
    Exterior, Rear
    187
    
    Interior, Power Board Side
    188
    
    Control Board and Power Switch
    189
    
    Interior, Fan Side
    190
    
    Power Supply Base and Magnetics
    192
  - Duramax LT Hand Torch Parts
    193
  - Duramax LT Hand Torch Consumables
    194
  - Accessory Parts
    195
  - Safety-Critical Parts
    196
  - Recommended Spare Parts
    197
  - Powermax30 XP Labels
    198
- Wiring Diagrams
  
  199
  - Powermax Generic Timing Chart
    200
  - Powermax30 XP Schematic
    201

Hypertherm Powermax30 AIR Operator's Manual (98 pages)

Plasma arc cutting system

Brand: Hypertherm | Category: Welding System | Size: 5 MB

Hypertherm Powermax30 AIR Operator's Manual (74 pages)

Plasma Arc Cutting System

Brand: Hypertherm | Category: Cutter | Size: 2 MB

Table of Contents
7
Electromagnetic Compatibility (EMC

11
- Assessment of Area
  11
- Cutting Cables
  11
  - Equipotential Bonding
    11
  - Earthing of the Workpiece
    11
- Installation and Use
  11
- Introduction
  11
- Maintenance of Cutting Equipment
  11
- Methods of Reducing Emissions
  11
  - Mains Supply
    11
- Screening and Shielding
  12
- Attention
  13
- General
  13
- Liability Cap
  13
- Limitation of Liability
  13
- National and Local Codes
  13
- Patent Indemnity
  13
Warranty

13
- Insurance
  14
- Transfer of Rights
  14
Specifications

15
- Safety Information
  15
- System Description
  15
- Power Supply Dimensions
  16
- System Weights
  16
- Hypertherm System Ratings
  17
- Torch Dimensions
  18
- Torch Weight
  18
- Cutting Specifications
  18
- Symbols and Marks
  19
  - Noise Levels
    20
  - IEC Symbols
    20
Power Supply Setup

21
- Unpack the Plasma System
  21
  - Claims
    21
- System Contents
  22
- Position the Plasma System
  23
- Prepare the Electrical Power
  23
  - Voltage Configurations
    23
  - Requirements for Grounding
    24
- Power Cord Considerations
  24
  - CSA Power Cords and Plugs
    24
  - CE and CCC Power Cords
    25
  - Extension Cord Recommendations
    26
  - Generator Recommendations
    26
- Prepare the Gas Supply
  27
  - Connect the Gas Supply
    27
  - Additional Gas Filtration
    28
Torch Setup

29
- Introduction
  29
  - Hand Torch Components
    29
- Consumable Life
  30
- Choose the Consumables
  30
  - Using the Cut Charts
    32
  - General-Purpose (Standard) Consumables
    32
    
    240 V / 30 a Cutting
    33
  - Finecut Consumables
    34
    
    120 V / 25 a Cutting
    35
    
    120 V / 30 a Cutting
    36
  - Hyaccess Consumables
    37
    
    Cutting at 240 V
    37
    
    Cutting at 120 V / 20 a
    37
    
    Ordering and Replacing
    37
    
    Powermax30 XP Operator Manual
    38
Operation

39
- Controls and Indicators
  39
  - Rear Controls
    39
  - Front Controls and Leds
    40
- Operate the Plasma System
  41
  - Connect the Electrical Power and Gas Supply
    41
- Install the Consumables
  42
- Understand Duty-Cycle Limitations
  46
- System Operation Guidelines
  47
- Hand Torch Operation
  48
  - Safety Catch Operation
    48
  - Hand Torch Cutting Guidelines
    49
    
    Recommendations for Cutting at 120 V
    49
  - Edge Start on a Workpiece
    50
  - Pierce a Workpiece
    51
  - Gouge a Workpiece
    52
    
    Varying the Gouge Profile
    53
  - Common Hand-Cutting Faults
    54
    
    Minimizing Dross
    54
Maintenance and Troubleshooting

55
Parts

65
- Power Supply Parts
  66
- Duramax LT Hand Torch Parts
  69
- Duramax LT Hand Torch Consumables
  70
- Accessory Parts
  72
- Powermax30 XP Labels
  73
- Powermax30 XP Operator Manual
  74

Hypertherm Powermax30 AIR Operator's Manual (68 pages)

Plasma Arc Cutting System with Integrated Air Compressor

Brand: Hypertherm | Category: Welding System | Size: 2 MB

Table of Contents
7
Electromagnetic Compatibility (EMC

11
- Introduction
  11
- Installation and Use
  11
- Assessment of Area
  11
- Methods of Reducing Emissions
  11
  - Mains Supply
    11
- Maintenance of Cutting Equipment
  12
- Cutting Cables
  12
  - Equipotential Bonding
    12
  - Earthing of the Workpiece
    12
- Screening and Shielding
  12
Warranty

13
- Attention
  13
- General
  13
- Patent Indemnity
  14
- Limitation of Liability
  14
- National and Local Codes
  14
- Liability Cap
  14
- Insurance
  14
- Transfer of Rights
  14
1 Specifications

15
- Safety Information
  15
- System Description
  15
- Power Supply Dimensions
  16
- System Weights
  16
- Hypertherm System Ratings
  17
- Torch Dimensions
  18
- Torch Weight
  18
- Cutting Specifications
  19
- IEC Symbols
  20
- Noise Levels
  20
- Symbols and Marks
  21
2 Power Supply Setup

23
- Unpack the Plasma System
  23
  - Claims
    23
- System Contents
  24
- Position the Plasma Cutting System
  25
- Prepare the Electrical Power
  25
- Power Cord Considerations
  27
  - CSA Power Cords and Plugs
    27
  - CE Power Cords
    28
    
    Install a Plug on the Power Cord
    28
  - Extension Cord Recommendations
    29
  - Generator Recommendations
    29
3 Torch Setup

31
- Introduction
  31
  - Hand Torch Components
    31
- Consumable Life
  32
- Consumable Use
  33
  - Using the Cut Charts
    33
  - Consumable Set
    34
    
    240 V / 30 a Cutting
    35
    
    120 V / 20 a Cutting
    37
    
    Powermax30 AIR Operator Manual
    37
4 Operation

39
5 Maintenance and Troubleshooting

53
- Perform Routine Maintenance
  53
- Inspect the Consumables
  55
- Basic Troubleshooting
  56
  - Power LED Faults
    56
  - Temperature LED Faults
    57
  - Internal Compressor LED Faults
    58
  - Torch LED Faults
    59
  - Common Cutting Issues
    60
  - Troubleshooting
    60
6 Parts

61
- Power Supply Parts
  62
  - Exterior, Front
    62
  - Exterior, Rear
    63
- Hand Torch Consumables
  64
- Accessory Parts
  65
- Power Supply Labels
  66
  - Consumables Label
    66
  - CSA Warning Label
    67
  - CE Warning Label
    68

Hypertherm Powermax30 AIR Field Service Bulletin (26 pages)

Power Cord Replacement

Brand: Hypertherm | Category: Welding System | Size: 1 MB

Hypertherm Powermax30 AIR Field Service Bulletin (18 pages)

Air Filter/Regulator and Pressure Switch Replacement

Brand: Hypertherm | Category: Welding System | Size: 1 MB

Hypertherm Powermax30 AIR Manual (14 pages)

Optional Oil Removal Air Filter Kit and Element Replacement

Brand: Hypertherm | Category: Cutter | Size: 0 MB

Hypertherm Powermax30 AIR Field Service Bulletin (10 pages)

Component Barrier Replacement

Brand: Hypertherm | Category: Welding System | Size: 0 MB

Hypertherm Powermax30 AIR Field Service Bulletin (10 pages)

Ground Clamp Replacement

Brand: Hypertherm | Category: Welding System | Size: 0 MB

Hypertherm Powermax30 AIR Operator's Manual (4 pages)

Brand: Hypertherm | Category: Welding System | Size: 0 MB

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Table of Contents

Electromagnetic Compatibility (EMC

Warranty

1 Specifications

2 Power Supply Setup

3 Torch Setup

4 Operation

5 Troubleshooting and System Tests

6 Power Supply Component Replacement

7 Torch Component Replacement

8 Parts

9 Wiring Diagrams

Table of Contents

Table of Contents

Electromagnetic Compatibility (EMC

Warranty

Specifications

Power Supply Setup

Torch Setup

Operation

Troubleshooting and System Tests

Power Supply Component Replacement

Table of Contents

Table of Contents

Torch Component Replacement

Parts

Wiring Diagrams

Table of Contents

Table of Contents

Electromagnetic Compatibility (EMC

Warranty

Specifications

Power Supply Setup

Torch Setup

Operation

Maintenance and Troubleshooting

Parts

Table of Contents

Electromagnetic Compatibility (EMC

Warranty

1 Specifications

2 Power Supply Setup

3 Torch Setup

4 Operation

5 Maintenance and Troubleshooting

6 Parts

Table of Contents

Table of Contents

Table of Contents

Table of Contents

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