Hypertherm Powermax45 XP Manuals

Manuals and User Guides for Hypertherm Powermax45 XP. We have 17 Hypertherm Powermax45 XP manuals available for free PDF download: Operator's Manual, Service Manual, Field Service Bulletin, Manual, Quick Setup

Hypertherm Powermax45 XP Operator's Manual (174 pages)

Plasma Arc Cutting System

Brand: Hypertherm | Category: Welding System | Size: 9.51 MB

Table of Contents
8
Electromagnetic Compatibility (EMC)

15
- Earthing of the Workpiece
  16
Warranty

17
- Waterjet Product Warranty Coverage
  18
  - Product
    18
  - Parts Coverage
    18
- Liability Cap
  18
Installation and Setup

19
- System Contents
  20
  - What to Do if Components Are Missing or Damaged
    21
  - Hypertherm Plasma Power Supply Ratings
    21
  - Cutting Specifications
    22
    
    Pierce Capacity
    22
    
    Recommended Cut Capacity - Handheld
    22
    
    Gouge Capacity
    23
    
    Maximum Cut Speeds (Mild Steel)
    23
    
    Noise Levels
    23
  - Position the Plasma Power Supply
    24
    
    Power Supply Dimensions and Weight
    26
    
    Work Lead Weights
    26
  - Connect to Electrical Power
    27
    
    Install a Line-Disconnect Switch
    27
    
    Requirements for Grounding
    28
    
    The System's Rated Output (Cutting Power)
    28
    
    Voltage Configurations
    28
    
    CCC 220 V (1-Phase)
    29
    
    CE 230 V (1-Phase)
    29
    
    CSA 208 V (1-Phase)
    29
    
    CSA/CE/CCC 200 V - 240 V (1-Phase)
    29
    
    CCC 380 V (3-Phase)
    30
    
    CE 400 V (3-Phase)
    30
    
    CSA 480 V (3-Phase)
    30
    
    Decrease Output Current and Arc Stretch for Lower Rated Electrical Service
    31
    
    Example: 230 V Input on 20 a Electrical Service
    31
  - Prepare the Power Cord
    32
    
    1-Phase (200 V - 240 V)
    32
    
    3-Phase (380 V / 400 V)
    32
    
    3-Phase (480 V)
    32
    
    CE/CCC Systems
    32
    
    CSA Systems
    32
    
    Extension Cord Recommendations
    33
    
    Generator Recommendations
    33
  - Connect the Gas Supply
    34
    
    Gas Supply Source
    35
    
    High-Pressure Gas Cylinders
    36
    
    Cutting
    37
    
    Gas Flow Rates
    37
    
    Minimum Inlet Pressure (While Gas Is Flowing)
    37
    
    Maximum Control Gouging (26 - 45 A)
    38
    
    Precision Gouging / Marking (10 - 25 A)
    38
    
    Additional Gas Filtration
    39
Operation

41
- Controls and Indicators
  41
Cut with the Hand Torch

59
- Hand Torch Components, Dimensions, Weights
  60
  - Components
    60
  - Dimensions
    60
    
    75° Hand Torch
    60
    
    Weights
    61
  - Choose the Consumables
    61
    
    Finecut Consumables
    62
    
    Hyaccess Cutting Consumables
    62
    
    Shielded Drag-Cutting Consumables
    62
    
    Specialty Consumables
    62
    
    Copperplus™ Electrode
    63
  - Consumable Life
    63
  - Prepare to Fire the Torch
    65
  - Hand Torch Cutting Guidelines
    66
  - Start a Cut from the Edge of the Workpiece
    67
  - Pierce a Workpiece
    68
Gouge with the Hand Torch and Machine Torch

71
- Gouging Processes
  71
  - Maximum Control Gouging
    72
    
    Maximum Control Gouging Consumables (26 - 45 A)
    72
    
    Precision Gouging
    72
    
    Precision Gouging Consumables (10 - 25 A)
    72
    
    Hyaccess Gouging Consumables
    73
    
    Specialty Consumables
    73
  - How to Control the Gouge Profile
    74
  - Gouge with the Hand Torch
    75
    
    Remove Spot Welds
    76
    
    Tips
    76
    
    Procedure
    77
  - Gouge with the Machine Torch
    80
    
    Maximum Control Gouging Consumables (45 A)
    81
    
    Typical Gouge Profiles
    81
    
    Precision Gouging Consumables (10 A)
    83
  - Troubleshooting Tips for Gouging
    84
Set up the Machine Torch

87
- Machine Torch Components, Dimensions, Weights
  88
  - Components
    88
  - Dimensions
    88
  - Weights
    89
  - Mount the Torch
    89
    
    Remove the Gear Rack
    89
    
    Disassemble the Machine Torch
    90
    
    Assemble the Machine Torch
    92
  - Align the Torch
    94
Configure Controls for Mechanized Cutting

95
- Machine Torch Setup Overview
  95
Cut with the Machine Torch

105
- Choose the Consumables
  105
  - Mechanized Shielded Consumables
    106
  - Mechanized Shielded Consumables with Ohmic Retaining Cap
    106
  - Finecut Shielded Consumables with Ohmic Retaining Cap
    107
  - Finecut Unshielded Consumables
    107
  - Consumable Life
    107
  - Understand and Optimize Cut Quality
    108
    
    Cut or Bevel Angle
    108
    
    Dross
    109
    
    Pierce a Workpiece Using the Machine Torch
    110
    
    Pierce Delay
    110
    
    Pierce Height
    110
    
    Pierce Maximum Thickness
    110
    
    Cut Stainless Steel with F5
    111
- Guidelines for Marking
  
  113
  - Marking Consumables (10 - 25 A)
    113
  - Process Gas: Air Versus Argon
    114
    
    How the System Handles Postflow for Marking
    114
    
    Marking Samples
    115
    
    Types of Marking
    115
    
    Marking, Scoring, and Dimpling Profiles
    117
    
    Marking Process Guidelines
    118
    
    Cornering Guidelines
    119
    
    Marking Troubleshooting Tips
    119
    
    Common Marking Problems and Solutions
    120
- Cut Charts and Marking Charts
  
  121
Troubleshooting Guide

135
- Common Cutting Issues
  136
  - Hand Cutting Issues
    137
  - Mechanized Cutting Issues
    138
  - Check the Gas Pressure
    140
  - Check the Gas Quality
    141
  - Cold Restarts and Quick Restarts
    142
    
    Perform a Cold Restart
    142
    
    Perform a Quick Restart
    142
    
    Fault Leds and Fault Codes
    143
    
    Gas Pressure Fault LED
    147
    
    Torch Cap Fault LED
    148
    
    Enter Gas Test Mode
    149
    
    Generator Considerations
    149
    
    Run a Gas Test
    149
    
    Exit Gas Test Mode
    150
    
    While Gas Test Mode Is Active
    150
Routine Maintenance

151
- Inspect the System and Torch
  151
  - Every Use
    152
  - Every Consumable Change or Weekly (Whichever Is more Frequent)
    152
  - Every 3 Months
    153
  - Inspect the Consumables
    154
  - Replace the Air Filter Bowl and Filter Element
    155
Replacement Parts and Accessories

159
- Plasma Supply Exterior, Front
  160
- Plasma Supply Exterior, Rear
  161
- Machine Interface (CPC) and Serial Interface Upgrade Kits
  162
  - External Cables for Machine Interface Port and Serial Port
    163
  - 75° Hand Torch Replacement Parts
    164
  - 15° Hand Torch Replacement Parts
    165
  - Machine Torch Replacement Parts
    166
  - Accessory Parts
    168
  - Powermax45 XP Labels
    169
    
    Consumable Labels and Fault Codes Label
    169
    
    CSA Warning Label
    170
    
    CE/CCC Warning Label
    171
  - Data Plate
    172
  - Symbols and Marks
    173
    
    IEC Symbols
    174

Hypertherm Powermax45 XP Service Manual (149 pages)

Plasma arc cutting system

Brand: Hypertherm | Category: Welding System | Size: 17.46 MB

Safety Information
5
Table of Contents
7
Electromagnetic Compatibility (Emc)

11
- Mains Supply
  11
- Assessment of Area
  11
- Maintenance of Cutting Equipment
  12
Warranty

13
- Patent Indemnity
  14
Section 1

15
Specifications

15
- System Description
  16
- Where to Find Information
  16
- Power Supply Dimensions and Weights
  17
  - Dimensions
    17
  - Weights
    17
- Power Supply Ratings
  18
- T45V Torch Dimensions
  19
- T45M Torch Dimensions
  19
- T45V and T45M Torch Specifications
  20
- Symbols and Marks
  21
- IEC Symbols
  22
Section 2

23
Power Supply Setup

23
- Unpack the Powermax45
  24
  - Claims
    24
  - Contents
    24
- Position the Power Supply
  25
- Prepare the Electrical Power
  25
Table of Contents

26
- Power Cord Considerations
  26
  - Extension Cord Recommendations
    27
  - Generator Recommendations
    28
- Prepare the Gas Supply
  28
  - Connect the Gas Supply
    29
  - Additional Gas Filtration
    29
Section 3

32
Torch Setup Introduction

32
- Consumable Life
  32
- Hand Torch Setup
  32
  - Introduction
    32
  - Choose the Consumables
    33
  - Install the Consumables
    35
- Machine Torch Setup
  36
  - Mount the Torch
    36
  - Choose the Consumables (Cut Charts)
    38
  - Using the Cut Charts
    38
  - T45M Shielded Consumables
    38
  - Align the Torch
    54
  - Connect the Remote-Start Pendant
    55
  - Connect a Machine Interface Cable
    55
  - Accessing Raw Arc Voltage
    57
- Connect the Torch Lead
  60
Operation

62
Section 4

62
- Controls and Indicators
  62
  - Front Controls and Leds
    62
  - Rear Controls
    63
- Operate the Powermax45
  63
  - Connect the Electrical Power and Gas Supply
    63
  - Power on the System
    64
  - Set the Mode Switch
    64
  - Adjust the Gas Pressure
    64
  - Check the Indicator Leds
    66
  - Attach the Work Clamp
    66
- Understand Duty-Cycle Limitations
  66
- How to Use the Hand Torch
  67
  - Operate the Safety Trigger
    67
  - Hand Torch Cutting Hints
    67
  - Start a Cut from the Edge of the Workpiece
    68
  - Pierce a Workpiece
    69
  - Gouge a Workpiece
    70
  - Common Hand-Cutting Faults
    72
- How to Use the Machine Torch
  72
Section 5

77
Troubleshooting and System Tests

77
Section 6

105
Component Replacement

105
- Remove and Replace the Cover and Mylar ® Barrier
  106
  - Barrier
    106
  - Removal
    106
  - Replacement
    107
- Replace the Work Lead (CSA and CE)
  107
- Replace the Power Cord (200-240 V CSA)
  109
- Replace the Power Cord (230 V CE)
  110
- Replace the Power Cord (400 V CE)
  112
- Replace the Power Cord (480 V CSA)
  114
- Replace the Fan
  116
- Replace the Gas Filter Element
  117
- Replace the Air Filter and Regulator
  119
- Replace the Control Board
  120
- Replace the Power Board (200-240 V CSA and 230 V CE)
  121
- Replace the Power Board (400 V CE and 480 V CSA)
  125
Section 7

129
Parts

129
- Power Supply Parts
  130
  - Exterior
    130
  - Interior, Power Board Side
    132
  - Interior, Fan Side
    133
  - Interior, Heat Sink Side
    134
- T45V Hand Torch Parts
  135
  - T45V Hand Torch Consumables
    136
  - T30V (Powermax30) 30 a Consumables
    136
- T45M Machine Torch Parts
  137
  - T45M Machine Torch Consumables
    138
- Accessory Parts
  138
- Safety-Critical Parts
  139
- Recommended Spare Parts
  140
- Powermax45 Labels
  141
Section 8

143
Wiring Diagrams

143

Hypertherm Powermax45 XP Operator's Manual (101 pages)

plasma arc cutting system

Brand: Hypertherm | Category: Cutter | Size: 6.14 MB

Electromagnetic Compatibility
4
Warranty
6
- Safety Information
  9
- Table of Contents
  10
- Where To Find Information 1
  14
System Description
15
Where to Find Information
15
Power Supply Dimensions and Weights
16
- Dimensions
  16
- Weights
  16
Power Supply Ratings
17
T45V Torch Dimensions
18
T45M Torch Dimensions
18
T45V and T45M Torch Specifications
19
Symbols and Markings
20
- IEC Symbols
  21
- Unpack The Powermax45 2
  22
Unpack the Powermax45
23
- Claims
  23
- Contents
  23
Position the Power Supply
24
Prepare the Electrical Power
24
Power Cord Considerations
26
- Extension Cord Recommendations
  26
- Generator Recommendations
  28
Prepare the Gas Supply
28
- Connect the Gas Supply
  29
- Additional Gas Filtration
  29
- Introduction 3
  30
Introduction
31
Consumable Life
31
Hand Torch Setup
32
- Choose the Consumables
  32
- Install the Consumables
  34
Machine Torch Setup
35
- Mount the Torch
  35
- Choose the Consumables (Cut Charts)
  37
- Align the Torch
  55
- Connect the Remote-Start Pendant
  55
- Connect a Machine Interface Cable
  56
Connect the Torch Lead
59
Controls And Indicators 4
60
Controls and Indicators
61
- Front Controls and Leds
  61
- Rear Controls
  62
Operate the Powermax45
63
- Connect the Electrical Power and Gas Supply
  63
- Turn on the System
  63
- Set the Mode Switch
  64
- Adjust the Gas Pressure
  64
- Check the Indicator Leds
  65
- Attach the Work Clamp
  66
Understand Duty-Cycle Limitations
66
How to Use the Hand Torch
67
- Operate the Safety Trigger
  67
- Hand Torch Cutting Hints
  68
- Start a Cut from the Edge of the Workpiece
  69
- Pierce a Workpiece
  70
- Gouge a Workpiece
  71
- Common Hand-Cutting Faults
  73
How to Use the Machine Torch
74
Perform Routine Maintenance
81
Inspect the Consumables
82
Basic Troubleshooting
83
Repairs 5
84
Powermax 45 Operator Manual
87
Repairs
87
Power Supply Parts
93
T45V Hand Torch Parts
96
- T45V Hand Torch Consumables
  97
- T30V (Powermax30) 30 a Consumables
  97
T45M Machine Torch Parts
98
- T45M Machine Torch Consumables
  99
Accessory Parts
99
Powermax45 Labels
99

Hypertherm Powermax45 XP Field Service Bulletin (30 pages)

Machine Interface Receptacle with Voltage Divider PCB

Brand: Hypertherm | Category: Industrial Equipment | Size: 4.37 MB

Hypertherm Powermax45 XP Field Service Bulletin (30 pages)

Port with Voltage Divider Board

Brand: Hypertherm | Category: Recording Equipment | Size: 4.27 MB

Hypertherm Powermax45 XP Field Service Bulletin (26 pages)

Snubber Resistor Replacement Kit

Brand: Hypertherm | Category: Welding System | Size: 1.58 MB

Hypertherm Powermax45 XP Field Service Bulletin (17 pages)

Cutters Machine Interface Cable Kit

Brand: Hypertherm | Category: Welding System | Size: 0.8 MB

Hypertherm Powermax45 XP Field Service Bulletin (18 pages)

Raw Arc Voltage Kit

Brand: Hypertherm | Category: Welding System | Size: 2.6 MB

Hypertherm Powermax45 XP Field Service Bulletin (18 pages)

Install The RS-485 Serial Interface Port

Brand: Hypertherm | Category: Welding System | Size: 2.83 MB

Hypertherm Powermax45 XP Manual (14 pages)

Optional Oil Removal Air Filter Kit and Element Replacement

Brand: Hypertherm | Category: Cutter | Size: 0.43 MB

Hypertherm Powermax45 XP Field Service Bulletin (16 pages)

Machine Interface Cable Kit

Brand: Hypertherm | Category: Recording Equipment | Size: 0.94 MB

Hypertherm Powermax45 XP Field Service Bulletin (14 pages)

Power Switch Replacement Kit

Brand: Hypertherm | Category: Welding System | Size: 1.16 MB

Hypertherm Powermax45 XP Field Service Bulletin (10 pages)

Plastic Base Replacement

Brand: Hypertherm | Category: Welding System | Size: 0.47 MB

Hypertherm Powermax45 XP Field Service Bulletin (10 pages)

Capacitor Replacement Kit

Brand: Hypertherm | Category: Welding System | Size: 0.46 MB

Hypertherm Powermax45 XP Field Service Bulletin (10 pages)

Ground Clamp Replacement

Brand: Hypertherm | Category: Welding System | Size: 0.19 MB

Hypertherm Powermax45 XP Field Service Bulletin (6 pages)

Control Board Replacement Kit

Brand: Hypertherm | Category: Controller | Size: 0.41 MB

Hypertherm Powermax45 XP Quick Setup (4 pages)

Quick setup for hand torch operation

Brand: Hypertherm | Category: Welding System | Size: 0.53 MB

Hypertherm Categories

Welding System Cutter Flashlight Industrial Equipment Controller

More Hypertherm Manuals

Hypertherm Powermax45 XP Manuals

Table of Contents

Electromagnetic Compatibility (EMC)

Warranty

Installation and Setup

Operation

Cut with the Hand Torch

Gouge with the Hand Torch and Machine Torch

Set up the Machine Torch

Configure Controls for Mechanized Cutting

Cut with the Machine Torch

Guidelines for Marking

Cut Charts and Marking Charts

Troubleshooting Guide

Routine Maintenance

Replacement Parts and Accessories

Table of Contents

Electromagnetic Compatibility (Emc)

Warranty

Section 1

Specifications

Section 2

Power Supply Setup

Table of Contents

Section 3

Torch Setup Introduction

Operation

Section 4

Section 5

Troubleshooting and System Tests

Section 6

Component Replacement

Section 7

Parts

Section 8

Wiring Diagrams

Table of Contents

Table of Contents

Table of Contents

Table of Contents

Related Products

Hypertherm Categories