COV_OM_805160.
COV_OM_805160.qxp:COV_OM_805160 10/7/09 12:40 PM Page 2 Register your new Hypertherm system Register your product on-line at www.hypertherm.com/registration for easier technical and warranty support. You can also receive updates on new Hypertherm products and a free gift as a token of our appreciation.
PMX30_OM_TP.qxp:PMX30_OM_TP 10/7/09 12:42 PM Page 1 powermax30 Operator Manual (P/N 805160) Revision 2 – November 2009 Hypertherm, Inc. Hanover, NH USA www.hypertherm.com email:info@hypertherm.com © Copyright 2009 Hypertherm, Inc. All Rights Reserved Hypertherm and Powermax are trademarks of Hypertherm, Inc. and may be registered in the United States and/or other countries.
PMX30_OM_TP.qxp:PMX30_OM_TP 10/7/09 12:43 PM Page 2 Hypertherm, Inc. Etna Road, P.O. Box 5010 Hanover, NH 03755 USA 603-643-3441 Tel (Main Office) 603-643-5352 Fax (All Departments) info@hypertherm.com (Main Office Email) 800-643-9878 Tel (Technical Service) technical.service@hypertherm.com (Technical Service Email) 800-737-2978 Tel (Customer Service) customer.service@hypertherm.
PMX30_OM_FM.qxp:PMX30_OM_FM 10/7/09 12:43 PM Page i ELECTROMAGNETIC COMPATIBILITY (EMC) EMC Introduction Hypertherm’s CE-marked equipment is built in compliance with standard EN60974-10. The equipment should be installed and used in accordance with the information below to achieve electromagnetic compatibility. The limits required by EN60974-10 may not be adequate to completely eliminate interference when the affected equipment is in close proximity or has a high degree of sensitivity.
PMX30_OM_FM.qxp:PMX30_OM_FM 10/7/09 12:43 PM Page ii ELECTROMAGNETIC COMPATIBILITY (EMC) Maintenance of cutting equipment The cutting equipment must be routinely maintained according to the manufacturer’s recommendations. All access and service doors and covers should be closed and properly fastened when the cutting equipment is in operation. The cutting equipment should not be modified in any way except for those changes and adjustments covered in the manufacturer’s instructions.
PMX30_OM_FM.qxp:PMX30_OM_FM 10/7/09 12:43 PM Page iii WARRANTY Attention Genuine Hypertherm parts are the factoryrecommended replacement parts for your Hypertherm system. Any damage caused by the use of other than genuine Hypertherm parts may not be covered by the Hypertherm warranty. You are responsible for the safe use of the Product. Hypertherm does not and cannot make any guarantee or warranty regarding the safe use of the Product in your environment. General Hypertherm, Inc.
PMX30_OM_FM.qxp:PMX30_OM_FM 10/7/09 12:43 PM Page iv WARRANTY • Any unauthorized assembly or accessory that uses or generates a hazardous voltage is added. • There is any tampering with a safety circuit or other feature that is designed into the product as part of the certification. CE marking constitutes a manufacturer’s declaration of conformity to applicable European directives and standards.
PMX30_OM_FM.qxp:PMX30_OM_FM 10/7/09 12:43 PM Page v TABLE OF CONTENTS Electromagnetic compatibility................................................................................................................................i Warranty....................................................................................................................................................................iii Section 1 Safety Recognize safety information .........................................................
PMX30_OM_FM.qxp:PMX30_OM_FM 10/7/09 12:43 PM Page vi TABLE OF CONTENTS El arco de plasma puede causar lesiones y quemaduras.......................................................................1b-5 Los rayos del arco pueden producir quemaduras en los ojos y en la piel ..........................................1b-5 Seguridad de toma a tierra.............................................................................................................................
PMX30_OM_FM.qxp:PMX30_OM_FM 10/7/09 12:43 PM Page vii TABLE OF CONTENTS Safety trigger operation ..........................................................................................................................4-6 Hand torch cutting hints..........................................................................................................................4-7 To start a cut from the edge of the workpiece...................................................................................
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Section 1 SAFETY In this section: Recognize safety information ...........................................................................................................................1-2 Follow safety instructions..................................................................................................................................1-2 Cutting can cause fire or explosion ................................................................................................................
SAFETY RECOGNIZE SAFETY INFORMATION The symbols shown in this section are used to identify potential hazards. When you see a safety symbol in this manual or on your machine, understand the potential for personal injury, and follow the related instructions to avoid the hazard. FOLLOW SAFETY INSTRUCTIONS Read carefully all safety messages in this manual and safety labels on your machine. • Keep the safety labels on your machine in good condition. Replace missing or damaged labels immediately.
SAFETY ELECTRIC SHOCK CAN KILL Touching live electrical parts can cause a fatal shock or severe burn. • Operating the plasma system completes an electrical circuit between the torch and the workpiece. The workpiece and anything touching the workpiece are part of the electrical circuit. • Never touch the torch body, workpiece or the water in a water table when the plasma system is operating.
SAFETY TOXIC FUMES CAN CAUSE INJURY OR DEATH The plasma arc by itself is the heat source used for cutting. Accordingly, although the plasma arc has not been identified as a source of toxic fumes, the material being cut can be a source of toxic fumes or gases that deplete oxygen. Fumes produced vary depending on the metal that is cut. Metals that may release toxic fumes include, but are not limited to, stainless steel, carbon steel, zinc (galvanized), and copper.
SAFETY A PLASMA ARC CAN CAUSE INJURY AND BURNS Instant-On Torches Plasma arc comes on immediately when the torch switch is activated. The plasma arc will cut quickly through gloves and skin. • Keep away from the torch tip. • Do not hold metal near the cutting path. • Never point the torch toward yourself or others. ARC RAYS CAN BURN EYES AND SKIN Eye Protection Plasma arc rays produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin.
SAFETY GROUNDING SAFETY Work Cable Attach the work cable securely to the workpiece or the work table with good metal-to-metal contact. Do not connect it to the piece that will fall away when the cut is complete. Work Table Connect the work table to an earth ground, in accordance with appropriate national or local electrical codes. Input Power • Be sure to connect the power cord ground wire to the ground in the disconnect box.
SAFETY NOISE CAN DAMAGE HEARING Prolonged exposure to noise from cutting or gouging can damage hearing. • Use approved ear protection when using plasma system. • Warn others nearby about the noise hazard. PACEMAKER AND HEARING AID OPERATION Pacemaker and hearing aid operation can be affected by magnetic fields from high currents. Pacemaker and hearing aid wearers should consult a doctor before going near any plasma arc cutting and gouging operations.
SAFETY SYMBOLS AND MARKINGS Your Hypertherm product may have one or more of the following markings on or near the data plate. Due to differences and conflicts in national regulations, not all marks are applied to every version of a product. S mark symbol The S mark symbol indicates that the power supply and torch are suitable for operations carried out in environments with increased hazard of electrical shock per IEC 60974-1.
SAFETY WARNING LABEL This warning label is affixed to some power supplies. It is important that the operator and maintenance technician understand the intent of these warning symbols as described. The numbered text corresponds to the numbered boxes on the label. Read and follow these instructions, employer safety practices, and material safety data sheets. Refer to ANS Z49.1, “Safety in Welding, Cutting and Allied Processes” from American Welding Society (http://www.aws.
SAFETY WARNING LABEL 1. This warning label is affixed to some power supplies. It is important that the operator and maintenance technician understand the intent of these warning symbols as described. The numbered text corresponds to the numbered boxes on the label. 1.1 1.2 1.3 2. 2.1 2.2 2.3 3. 3.1 3.2 3.3 4. www.hypertherm.com/weee 1-10 11/08 110647 Rev. A Cutting sparks can cause explosion or fire. Do not cut near flammables. Have a fire extinguisher nearby and ready to use.
SAFETY DRY DUST COLLECTION INFORMATION At some sites, dry dust can represent a potential explosion hazard. The U.S. National Fire Protection Association’s 2007 edition of NFPA standard 68, “Explosion Protection by Deflagration Venting,” provides requirements for the design, location, installation, maintenance, and use of devices and systems to vent combustion gases and pressures after any deflagration event.
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Section 1a SÉCURITÉ Dans cette section : Identifier les consignes de sécurité ..............................................................................................................1a-2 Suivre les instructions de sécurité ................................................................................................................1a-2 Le coupage peut provoquer un incendie ou une explosion ....................................................................
SÉCURITÉ IDENTIFIER LES CONSIGNES DE SÉCURITÉ DANGER AVERTISSEMENT ATTENTION Hypertherm adopte les lignes directrices de l’American National Standards Institute relativement aux termes, aux symboles et à la signalisation de sécurité. Les signaux DANGER ou AVERTISSEMENT sont utilisés avec un symbole de sécurité, DANGER correspondant aux risques les plus sérieux.
SÉCURITÉ LES CHOCS ÉLECTRIQUES PEUVENT ÊTRE FATALS Toucher une pièce électrique sous tension peut provoquer un choc électrique fatal ou des brûlures graves. • La mise en fonctionnement du système plasma ferme un circuit électrique entre la torche et la pièce à couper. La pièce à couper et tout autre élément en contact avec cette pièce font partie du circuit électrique. • Ne jamais toucher le corps de la torche, la pièce à couper ou l’eau de la table à eau pendant le fonctionnement du système plasma.
SÉCURITÉ LES VAPEURS TOXIQUES PEUVENT PROVOQUER DES BLESSURES OU LA MORT L’arc plasma est lui-même la source de chaleur utilisée pour le coupage. Par conséquent, bien que l’arc plasma n’ait pas été reconnu comme une source de vapeurs toxiques, le matériau coupé peut être une source de vapeurs ou de gaz toxiques qui épuisent l’oxygène. Les vapeurs produites varient selon le métal coupé.
SÉCURITÉ L’ARC PLASMA PEUT PROVOQUER DES BLESSURES OU DES BRÛLURES Torches à allumage instantané L’arc plasma s’allume immédiatement après que la torche soit mise en marche. L’arc plasma coupe facilement les gants et la peau. • Rester éloigné de l’extrémité de la torche. • Ne pas tenir de métal près de la trajectoire de coupe. • Ne jamais pointer la torche vers soi ou d’autres personnes.
SÉCURITÉ MISE À LA MASSE ET À LA TERRE Câble de retour Bien fixer le câble de retour (ou de masse) à la pièce à couper ou à la table de travail de façon à assurer un bon contact métal-métal. Ne pas fixer le câble de retour à la partie de la pièce qui doit se détacher. Table de travail Raccorder la table de travail à la terre, conformément aux codes de sécurité locaux ou nationaux appropriés.
SÉCURITÉ LE BRUIT PEUT PROVOQUER DES PROBLÈMES AUDITIFS Une exposition prolongée au bruit du coupage ou du gougeage peut provoquer des problèmes auditifs. • Utiliser un casque de protection homologué lors de l’utilisation du système plasma. • Prévenir les personnes aux alentours des risques encourus en cas d’exposition au bruit. UN ARC PLASMA PEUT ENDOMMAGER LES TUYAUX GELÉS Les tuyaux gelés peuvent être endommagés ou éclater si l'on essaie de les dégeler avec une torche plasma.
SÉCURITÉ SYMBOLES ET MARQUAGE Votre produit Hypertherm peut comporter une ou plusieurs des marques suivantes sur sa plaque signalétique ou à proximité. En raison des différends et des conflits relatifs aux règlements nationaux, toutes les marques ne sont pas appliquées à chaque version d’un produit. Symbole marque S Le symbole de marque S indique que la source de courant et la torche conviennent pour les travaux effectués dans les milieux à risque accru de choc électrique selon l’IEC 60974-1.
SÉCURITÉ ÉTIQUETTE DE SÉCURITÉ Cette étiquette est affichée sur la source de courant. Il est important que l’utilisateur et le technicien de maintenance comprennent la signification des symboles de sécurité. Les numéros de la liste correspondent aux numéros des images. Read and follow these instructions, employer safety practices, and material safety data sheets. Refer to ANS Z49.1, “Safety in Welding, Cutting and Allied Processes” from American Welding Society (http://www.aws.
SÉCURITÉ 1. ÉTIQUETTE DE SÉCURITÉ Cette étiquette est affichée sur la source de courant. Il est important que l’utilisateur et le technicien de maintenance comprennent la signification des symboles de sécurité. Les numéros de la liste correspondent aux numéros des images. 1.1 1.2 1.3 2. 2.1 2.2 2.3 3. 3.1 3.2 3.3 4. 4.1 4.2 4.3 5. 5.1 www.hypertherm.com/weee 110647 Rev. A 6. 7. 1a-10 11/08 Les étincelles de coupage peuvent provoquer une explosion ou un incendie.
SÉCURITÉ INFORMATION SUR LE DÉPOUSSIÉRAGE À certains endroits, la poussière peut représenter un risque d’explosion potentiel. À certains endroits, la poussière peut représenter un risque d’explosion potentiel. La norme NFPA 68 de la National Fire Protection Association des É.-U.
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Seccíon 1b SEGURIDAD En esta sección: Reconocimiento de información de seguridad ..........................................................................................1b-2 Siga las instrucciones de seguridad ............................................................................................................1b-2 Los cortes pueden provocar incendios o explosiones ............................................................................1b-2 El choque eléctrico puede provocar la muerte..........
SEGURIDAD RECONOCIMIENTO DE INFORMACIÓN DE SEGURIDAD Los símbolos que se muestran en esta sección se utilizan para identificar los posibles peligros. Cuando vea un símbolo de seguridad en este manual o en su máquina, recuerde que existe la posibilidad de que se produzcan lesiones personales y siga las instrucciones correspondientes para evitar el peligro. SIGA LAS INSTRUCCIONES DE SEGURIDAD Lea atentamente todos los mensajes de seguridad de este manual y las etiquetas de seguridad en su máquina.
SEGURIDAD EL CHOQUE ELÉCTRICO PUEDE PROVOCAR LA MUERTE El contacto directo con piezas eléctricas conectadas puede provocar un electrochoque fatal o quemaduras graves. • Al hacer funcionar el sistema de plasma, se completa un circuito eléctrico entre la antorcha y la pieza a cortar. La pieza a cortar es una parte del circuito eléctrico, como también cualquier cosa que se encuentre en contacto con ella.
SEGURIDAD HUMOS TÓXICOS PUEDEN CAUSAR LESIONES O MUERTE El arco plasma es por si solo la fuente de calor que se usa para cortar. Según esto, aunque el arco de plasma no ha sido identificado como la fuente de humo tóxico, el material que se corta puede ser la fuente de humo o gases tóxicos que vacían el oxígeno. El humo producido varía según el metal que está cortándose.
SEGURIDAD EL ARCO DE PLASMA PUEDE CAUSAR LESIONES Y QUEMADURAS Antorchas de encendido instantáneo El arco de plasma se enciende inmediatamente después de activarse el interruptor de la antorcha. El arco de plasma puede cortar a través de guantes y de la piel con rapidez. • Manténgase alejado de la punta de la antorcha. • No sostenga el metal junto al trayecto de corte. • Nunca apunte la antorcha hacia Ud. mismo o hacia otras personas.
SEGURIDAD SEGURIDAD DE TOMA A TIERRA Cable de trabajo La pinza del cable de trabajo debe estar bien sujetada a la pieza y hacer un buen contacto de metal a metal con ella o bien con la mesa de trabajo. No conecte el cable con la parte que va a quedar separada por el corte. Mesa de trabajo Conecte la mesa de trabajo a una buena toma de tierra, de conformidad con los códigos eléctricos nacionales o locales apropiados.
SEGURIDAD EL RUIDO PUEDE DETERIORAR LA AUDICIÓN La exposición prolongada al ruido propio de las operaciones de corte y ranurado puede dañar la audición. • Utilice un método de protección de los oídos aprobado al utilizar el sistema de plasma. • Advierta a las demás personas que se encuentren en las cercanías acerca del peligro que supone el ruido excesivo.
SEGURIDAD SÍMBOLOS Y MARCAS Su producto de Hypertherm puede tener una o más de las marcas que siguen en, o cerca de la placa de datos. Debido a diferencias y conflictos en reglamentos nacionales, no todas las marcas se aplican a toda versión del producto. Símbolo de marca S El símbolo de marca S indica que la fuente de energía y antorcha son aptas para operaciones que se llevan a cabo en entornos con peligro aumentado de choque o descarga eléctrica según IEC 60974-1.
SEGURIDAD ETIQUETA DE ADVERTENCIA Esta etiqueta de advertencia se encuentra adherida a la fuente de energía. Es importante que el operador y el técnico de mantenimiento comprendan el sentido de estos símbolos de advertencia según se describen. El texto numerado corresponde a los cuadros numerados de la etiqueta. Read and follow these instructions, employer safety practices, and material safety data sheets. Refer to ANS Z49.
SEGURIDAD ETIQUETA DE ADVERTENCIA 1. Esta etiqueta de advertencia se encuentra adherida a la fuente de energía. Es importante que el operador y el técnico de mantenimiento comprendan el sentido de estos símbolos de advertencia según se describen. El texto numerado corresponde a los cuadros numerados de la etiqueta. 1.1 1.2 1.3 2. 2.1 2.2 2.3 3. 3.1 3.2 3.3 4. 4.1 4.2 4.3 5. 5.1 www.hypertherm.com/weee 110647 Rev. A 6. 7.
SEGURIDAD INFORMACIÓN SOBRE LA COLECCIÓN DE POLVO SECO En algunos sitios, el polvo seco puede representar un peligro potencial de explosión. La edición del 2007 de “U.S.
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PMX30_OM_02.qxp:PMX30_OM_02.qxd 10/7/09 12:44 PM Page 2-1 Section 2 SPECIFICATIONS In this section: System description .............................................................................................................................................2-2 Power supply dimensions and weight............................................................................................................2-2 Power supply ratings ............................................................................
PMX30_OM_02.qxp:PMX30_OM_02.qxd 10/7/09 12:44 PM Page 2-2 SPECIFICATIONS System description The Powermax30 is a highly portable, 30-amp, hand-held plasma cutting system appropriate for a wide range of applications. The standard Powermax30 includes one complete set of the consumables needed for cutting (retaining cap, swirl ring, nozzle, electrode), a spare electrode, a spare nozzle, an air fitting reducer (1/4 FPT x 1/8 NPT), a consumables holder, an Operator Manual, and a Quick Setup Card.
PMX30_OM_02.qxp:PMX30_OM_02.qxd 10/7/09 12:44 PM Page 2-3 SPECIFICATIONS Power supply ratings Rated open-circuit voltage (U0) 240 VDC Rated output current (I2) 15 A to 30 A Rated output voltage (U2) 83 VDC Duty cycle at 40° C, U1=120 VAC (See data plate on power supply for more information on duty cycle.
PMX30_OM_02.qxp:PMX30_OM_02.qxd 10/7/09 12:44 PM Page 2-4 SPECIFICATIONS Torch dimensions 8.72" ( 221 mm) 8.5" (216 mm) 1.58" (40 mm) 3.10" (79 mm) 2.00" (50 mm) 1.00" (25 mm) T30v torch ratings Recommended capacity 1/4 inch (6 mm) at 30 A (35% duty cycle) Maximum capacity 3/8 inch (10 mm) at 30 A (35% duty cycle) Severance capacity 1/2 inch (12 mm) at 30 A (35% duty cycle) Weight 2-4 2.1 lbs (1.
PMX30_OM_02.qxp:PMX30_OM_02.qxd 10/7/09 12:44 PM Page 2-5 SPECIFICATIONS Symbols and markings S mark The mark indicates that the power supply and torch are suitable for use in environments with increased hazard of electrical shock. CE mark The CE mark ( ) constitutes a manufacturer’s declaration of conformity to applicable European directives and standards.
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PMX30_OM_03.qxp:PMX30_OM_03 10/7/09 12:44 PM Page 3-1 Section 3 SETUP In this section: Unpack the Powermax30 ..................................................................................................................................3-2 Claims .........................................................................................................................................................3-2 Contents ...........................................................................................
PMX30_OM_03.qxp:PMX30_OM_03 10/7/09 12:44 PM Page 3-2 SETUP Unpack the Powermax30 1. Verify that all items on your order have been received in good condition. Contact your distributor if any parts are damaged or missing. 2. Inspect the power supply for damage that may have occurred during shipping. If there is evidence of damage, refer to Claims, below. All communications regarding this equipment must include the model number and serial number located on the bottom of the power supply. 3.
PMX30_OM_03.qxp:PMX30_OM_03 10/7/09 12:44 PM Page 3-3 SETUP Position the power supply Locate the Powermax30 power supply near a 120 volt or 230 volt power receptacle. Allow at least 10 inches (0.25 m) of space at the front and back of the power supply for proper ventilation. Voltage configurations The Powermax30 power supply automatically selects either 120 volts or 230 volts, as appropriate. The maximum output voltage will vary based on your input voltage and the circuit’s amperage.
PMX30_OM_03.qxp:PMX30_OM_03 10/7/09 12:44 PM Page 3-4 SETUP Power cord considerations Powermax30 power supplies are shipped with CSA and CE power cord configurations. Power cord and plugs for CSA power supplies The power cords on the CSA power supplies are shipped with a 120V/15A (NEMA 5-15P) plug adapter and a 240V/20A (NEMA 6-50P) plug adapter in addition to the twist-lock 240V/20A (NEMA L6-20P) plug wired to the system. A 120V/20A plug adapter is available as an accessory.
PMX30_OM_03.qxp:PMX30_OM_03 10/7/09 12:44 PM Page 3-5 SETUP Power cord for CE power supplies The CE power supplies are shipped without a plug on the power cord. To operate at 230 V, obtain the correct plug and have it installed by a licensed electrician as shown below. 1 230 V plug 1 2 To line 1 terminal (brass) 2 3 To line 2 terminal (brass) 5 4 To ground terminal (green) 6 5 Outer shell 3 4 6 Cord grip 1. Strip back the cord insulation to separate wires 3, 4, and 5. 2.
PMX30_OM_03.qxp:PMX30_OM_03 10/7/09 12:44 PM Page 3-6 SETUP Extension cord recommendations A Use an extension cord of an appropriate wire size for the cord length and system voltage. Use a cord that meets national and local codes. A Inputvoltage 120 VAC 200 – 240 VAC Phase Recommended cord gauge size Length 1 1 12 AWG 14 AWG Up to 53 ft (16 m) Up to 133 ft (40.5 m) Generator recommendations When using a generator with the Powermax30, it should produce 240 VAC.
PMX30_OM_03.qxp:PMX30_OM_03 10/7/09 12:44 PM Page 3-7 SETUP Gas supply The gas supply for the Powermax30 can be shop-compressed or cylinder-compressed. A highpressure regulator must be used on either type of supply and must be capable of delivering gas to the filter on the power supply at 3.5 scfm @ 65 psi (99.1 l/min @ 4.5 bar). To ensure adequate pressure to the power supply, set the regulator to 80 to 100 psi (5.5 to 6.9 bar).
PMX30_OM_03.qxp:PMX30_OM_03 10/7/09 12:44 PM Page 3-8 SETUP Additional gas filtration When site conditions introduce moisture, oil or other contaminants into the gas line, use a threestage coalescing filtration system, such as the Eliminizer filter kit (part number 128647) available from Hypertherm distributors. A three-stage filtering system works as shown below to clean contaminants from the gas supply.
PMX30_OM_04.qxp:PMX30_OM_04 10/7/09 12:45 PM Page 4-1 Section 4 OPERATION In this section: Controls and indicators .....................................................................................................................................4-2 Front controls and LEDs.........................................................................................................................4-2 Rear controls .............................................................................................
PMX30_OM_04.qxp:PMX30_OM_04 10/7/09 12:45 PM Page 4-2 OPERATION Controls and indicators The Powermax30 has an ON/OFF rocker switch, an amperage adjustment knob and 4 indicator lights, which are described below. Front Rear I O 120V 15A 120V 20A 240V 20A Front controls and LEDs AC Power ON LED (green) When illuminated, this LED indicates that the power switch has been set at I (ON) and that the safety interlocks are satisfied.
PMX30_OM_04.qxp:PMX30_OM_04 10/7/09 12:45 PM Page 4-3 OPERATION Install the consumables WARNING INSTANT-ON TORCHES PLASMA ARC CAN CAUSE INJURY AND BURNS I O The plasma arc comes on immediately when the torch trigger is activated. Make sure the power is OFF before changing consumables. To operate the T30v torch, it must have a complete set of consumable parts installed: a retaining cap, nozzle, swirl ring and electrode. You may also use an optional deflector.
PMX30_OM_04.qxp:PMX30_OM_04 10/7/09 12:45 PM Page 4-4 OPERATION Attach the work clamp The work clamp must be attached to the workpiece while you are cutting. Ensure that the work clamp and the workpiece make good metal-to-metal contact. Attach the work clamp as close as possible to the area being cut to reduce exposure to electric and magnetic fields (EMF). Do not attach the work clamp to the portion of the workpiece to be cut away. Work clamp Power ON the system 1.
PMX30_OM_04.qxp:PMX30_OM_04 10/7/09 12:45 PM Page 4-5 OPERATION 2. Adjust the amps knob to the desired cutting current based on the input voltage and circuit size. To operate your Powermax30 system on a 120-volt, 15-amp circuit, do not set the amps higher than 20 (the dark gray part of the dial). See Section 3, Voltage configurations, for more information. 120V 15A 120V 20A 240V 20A 3.
PMX30_OM_04.qxp:PMX30_OM_04 10/7/09 12:45 PM Page 4-6 OPERATION Hand torch operation WARNING INSTANT-ON TORCHES PLASMA ARC CAN CAUSE INJURY AND BURNS Plasma arc comes on immediately when the torch trigger is activated. The plasma arc will cut quickly through gloves and skin. • Keep away from the torch tip. • Do not hold the workpiece and keep your hands clear of the cutting path. • Never point the torch toward yourself or others.
PMX30_OM_04.qxp:PMX30_OM_04 10/7/09 12:45 PM Page 4-7 OPERATION Hand torch cutting hints • Drag the nozzle lightly along the workpiece. • While cutting, make sure that sparks are exiting from the bottom of the workpiece. • If sparks are spraying up from the workpiece, move the torch more slowly, or set the output current higher. • Hold the torch nozzle perpendicular to the workpiece so that the nozzle is at a 90° angle to the cutting surface and watch the arc as it cuts along the line.
PMX30_OM_04.qxp:PMX30_OM_04 10/7/09 12:45 PM Page 4-8 OPERATION To start a cut from the edge of the workpiece 1. With the work clamp attached to the workpiece, hold the torch nozzle perpendicular to the edge of the workpiece. 2. Press the torch trigger to start the arc. Pause at the edge until the arc has cut completely through the workpiece. 3. Drag the nozzle lightly across the workpiece to proceed with the cut.
PMX30_OM_04.qxp:PMX30_OM_04 10/7/09 12:45 PM Page 4-9 OPERATION To pierce a workpiece WARNING KSPARKS AND HOT METAL CAN INJURE EYES AND BURN SKIN. When firing the torch at an angle, sparks and hot metal will spray out from the nozzle. Point the torch away from yourself and others. 1. With the work clamp attached to the workpiece, hold the torch at an angle to the workpiece with the nozzle within 1/16 inch (1.5 mm) of it before firing the torch. 2.
PMX30_OM_04.qxp:PMX30_OM_04 10/7/09 12:45 PM Page 4-10 OPERATION Cut chart The cut chart below is based on the use of 30-amp standard consumables and drag cutting. Optional deflector Retaining cap Nozzle Swirl ring Material thickness T30v torch Electrode Maximum cutting speed Material Arc current (A) inches per minute millimeters per minute 1,3 3,4 4,8 6,0 9,0 Mild steel Mild steel Mild steel Mild steel Mild steel 30 30 30 30 30 394 87 52 33 15 10007 2210 1321 838 381 18 ga. 10 ga.
PMX30_OM_04.qxp:PMX30_OM_04 10/7/09 12:45 PM Page 4-11 OPERATION Duty cycle and overheating The duty cycle is the amount of time, in minutes, that a plasma arc can remain on within a 10-minute period when operating at an ambient temperature of 104° F (40° C). With a 120 V input: • At 30 A, the arc can remain on for 3.5 minutes out of 10 minutes without causing the unit to overheat (35% duty cycle). • At 23 A, the arc can remain on for 6 minutes out of 10 (60%).
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PMX30_OM_05.qxp:PMX30_OM_05 10/7/09 12:46 PM Page 5-1 Section 5 MAINTENANCE AND PARTS In this section: Routine maintenance..........................................................................................................................................5-2 Inspect the consumables ..................................................................................................................................5-3 Basic troubleshooting ...............................................................
PMX30_OM_05.qxp:PMX30_OM_05 10/7/09 12:46 PM Page 5-2 MAINTENANCE AND PARTS Routine maintenance DANGER ELECTRIC SHOCK CAN KILL Disconnect the electrical power before you perform any maintenance. All work that requires removal of the power supply cover must be performed by a qualified technician. Every use: Inspect the consumables for proper installation and wear. AC Check the indicator lights and correct any fault conditions. Every 3 months: Inspect the trigger for damage.
PMX30_OM_05.qxp:PMX30_OM_05 10/7/09 12:46 PM Page 5-3 MAINTENANCE AND PARTS Inspect the consumables Part Inspect Action The center hole for roundness. Deflector Replace the deflector if the hole is no longer round. The gap between the deflector and the nozzle for accumulated debris. Remove the deflector and clean any material away. The center hole for roundness. Nozzle Electrode o o Good Worn The center surface for wear and verify the pit depth. Replace if the center hole is not round.
PMX30_OM_05.qxp:PMX30_OM_05 10/7/09 12:46 PM Page 5-4 MAINTENANCE AND PARTS Basic troubleshooting The following table provides an overview of the most common problems that may arise when using the Powermax30 and explains how to solve them. If you are unable to fix the problem by following this basic troubleshooting guide or if you need further assistance: 1. Call your Hypertherm distributor or authorized Hypertherm repair facility. 2. Call nearest Hypertherm office listed in the front of this manual.
PMX30_OM_05.qxp:PMX30_OM_05 10/7/09 12:46 PM Page 5-5 MAINTENANCE AND PARTS Problem Solution The power ON LED is illuminated and the torch cap LED is illuminated or blinks. • Turn OFF the power supply and tighten or install the consumables. See Section 4, Install the consumables. If the consumables become loose or were removed while the power supply is ON, turn OFF the power supply, correct the problem and then turn ON the power supply to clear this fault.
PMX30_OM_05.qxp:PMX30_OM_05 10/7/09 12:46 PM Page 5-6 MAINTENANCE AND PARTS Problem The arc blows out, but re-ignites when the torch trigger is pressed again. Solution • Inspect and replace the consumable parts if they are worn or damaged. See Inspect the consumables, in this section. • Replace the gas filter element inside the power supply if it is contaminated. See Replace the air filter element, in this section. The arc sputters and hisses.
PMX30_OM_05.qxp:PMX30_OM_05 10/7/09 12:46 PM Page 5-7 MAINTENANCE AND PARTS Repairs DANGER ELECTRIC SHOCK CAN KILL Disconnect electrical power before performing any maintenance. All work requiring removal of the power supply cover must be performed by a qualified technician. Remove and replace the cover and Nomex® barrier The first step in most maintenance and repair procedures for the Powermax30 is removing the cover and the Nomex barrier.
PMX30_OM_05.qxp:PMX30_OM_05 10/7/09 12:46 PM Page 5-8 MAINTENANCE AND PARTS Replacement 1. Hold the Nomex barrier so that the edge with the long cutout and 2 small notches is on the left and the edge with 3 notches is on the right. Long cutout 2. There is a perforation across the top, about 1inch down from the top edge. If you are replacing the Nomex barrier with a new one, you will need to fold it along this perforation so that the top edge bends away from you. 3.
PMX30_OM_05.qxp:PMX30_OM_05 10/7/09 12:46 PM Page 5-9 MAINTENANCE AND PARTS Remove an endcap Endcaps can be removed to replace them. Also some repairs are easier to make with an endcap removed. 1. Turn OFF the power, disconnect the power cord, and disconnect the gas supply. 2. Remove the cover and the Nomex barrier. 3. Lay the power supply on its side on a workbench or hold it upside down. The raised feet on the bottom of the unit have holes to provide access to the snaps that hold the endcaps in place.
PMX30_OM_05.qxp:PMX30_OM_05 10/7/09 12:46 PM Page 5-10 MAINTENANCE AND PARTS 5. There are snaps on either side of each endcap that hold the endcaps in place. Insert needlenose pliers into the opening for one of the snaps and use the pliers to squeeze it together. 6. Place a flat-head screwdriver against the raised rib next to the snap and gently turn the screwdriver to push the endcap away from the base. 7.
PMX30_OM_05.qxp:PMX30_OM_05 10/7/09 12:46 PM Page 5-11 MAINTENANCE AND PARTS 9. To replace the endcap, push it into the base to re-engage the snaps and then replace the retaining screw. 10. Replace the Nomex barrier and slide the cover back onto the power supply. 11. Position the handle over the holes in the top of the cover, then use the 2 screws to secure the cover. 12. Reconnect the electrical power and the gas supply. Disconnect the torch lead 1.
PMX30_OM_05.qxp:PMX30_OM_05 10/7/09 12:46 PM Page 5-12 MAINTENANCE AND PARTS 4. Carefully tilt the front endcap away from the power supply. The orange, blue, and purple wires from the torch lead are connected to the power board with a 3-pin connector at J12. Remove the connector from the power supply by pulling it toward the front of the power supply. J12 5. The white wire group and the red wire from the torch lead are secured to studs in the power supply’s center panel.
PMX30_OM_05.qxp:PMX30_OM_05 10/7/09 12:46 PM Page 5-13 MAINTENANCE AND PARTS 12. Replace the Nomex barrier and slide the cover back onto the power supply. Position the handle over the holes in the top of the cover, then use the 2 screws to secure the cover. 13. Reconnect the electrical power and the gas supply. Replace the work lead 1. Turn OFF the power, disconnect the power cord, and disconnect the gas supply. 2.
PMX30_OM_05.qxp:PMX30_OM_05 10/7/09 12:46 PM Page 5-14 MAINTENANCE AND PARTS 5. The work lead may be knotted to adjust the length of the wire inside the power supply. If so, untie the knot and then thread the work lead through the opening in the end cap. 6. Thread the connector end of the new work lead through the end cap and fit the strain relief into the hole in the front endcap. Unscrew the strain relief to loosen it if you need to adjust the amount of work lead on either side of it. 7.
PMX30_OM_05.qxp:PMX30_OM_05 10/7/09 12:46 PM Page 5-15 MAINTENANCE AND PARTS Replace the power cord (CSA) 1. Turn OFF the power, disconnect the power cord, and disconnect the gas supply. 2. Remove the cover from the power supply and remove the Nomex barrier from in front of the power board. 3. Remove the rear endcap. 4. The power cord has a black wire and a white wire that connect to the power switch and a green ground wire that connects to the heatsink.
PMX30_OM_05.qxp:PMX30_OM_05 10/7/09 12:46 PM Page 5-16 MAINTENANCE AND PARTS 6. Remove the screw that holds the green wire to the heatsink. There is a notch in the powerboard to provide easier access to the screw. Ground wire screw 7. On the outside of the power supply loosen the strain relief retention nut so that the wires move freely. If you are replacing the strain relief, unscrew the nut on the inside of the power supply as well. 8.
PMX30_OM_05.qxp:PMX30_OM_05 10/7/09 12:46 PM Page 5-17 MAINTENANCE AND PARTS 15. Replace the endcap. 16. Replace the Nomex barrier and slide the cover back onto the power supply. Position the handle over the holes in the top of the cover, then use the 2 screws to secure the cover. 17. Reconnect the electrical power and the gas supply. Replace the power cord (CE) 1. Turn OFF the power, disconnect the power cord, and disconnect the gas supply. 2.
PMX30_OM_05.qxp:PMX30_OM_05 10/7/09 12:46 PM Page 5-18 MAINTENANCE AND PARTS 5. Remove the brown wire the same way. 6. Remove the screw that holds the green and yellow ground wire to the heatsink. There is a notch in the powerboard to provide easier access to the screw. Ground wire screw 7. On the outside of the power supply, loosen the strain relief retention nut so that the wires move freely. If you are replacing the strain relief, unscrew the nut on the inside of the power supply as well. 8.
PMX30_OM_05.qxp:PMX30_OM_05 10/7/09 12:46 PM Page 5-19 MAINTENANCE AND PARTS 14. Screw the green and yellow ground wire to the heatsink with a torque setting of 15 inch-pounds (17.28 kg cm). 15. Position the wires in the wire chase up the side of the endcap and out of the way of the power board. 16. Line up the end of the power cord’s rubber casing with the inside edge of the strain relief. Tighten the strain relief retention nut on the outside of the endcap. 17. Replace the endcap. 18.
PMX30_OM_05.qxp:PMX30_OM_05 10/7/09 12:46 PM Page 5-20 MAINTENANCE AND PARTS 6. Unscrew the element from the filter body while being careful not to allow the element to rotate. 7. Screw the new element to the filter body. 8. Reattach the filter bowl. 9. Reposition the air filter assembly in the bracket and replace its retainer nut. 10. Reconnect the gas supply to check for leaks. 11. Slide the cover back onto the power supply.
PMX30_OM_05.qxp:PMX30_OM_05 10/7/09 12:46 PM Page 5-21 MAINTENANCE AND PARTS T30v hand torch assembly Item Part number 088001* 228111 075714 002244 228110 058503 228109 228113 1 2 3 4 5 6 7 Description T30v Hand Torch Assembly with 15 ft / 4.5 m Lead Kit: Handle Screws, #4 x 1/2 SLTD Torx PAN, S/B Safety trigger and spring replacement Kit: torch head repair O-ring: Viton .626 x .070 Kit: cap sensor replacement Kit: torch lead replacement, 15 ft / 4.
PMX30_OM_05.qxp:PMX30_OM_05 10/7/09 12:46 PM Page 5-22 MAINTENANCE AND PARTS Filter regulator Item Part number Description 1 011106 Air filter element Qty. 1 1 Work clamp Item 1 Part number Description Qty. 123868 Work cable with clamp, 15 ft / 4.
PMX30_OM_05.qxp:PMX30_OM_05 10/7/09 12:46 PM Page 5-23 MAINTENANCE AND PARTS Powermax30 labels Part number 228097 228098 Description Kit: Powermax30 labels, CE Kit: Powermax30 labels, CSA T30v CONSUMABLE PARTS Pièces Consommables T30v 220569* 220483 220480 220479 *Optional *En option 220478 Data plate Plaque signalètique PN 110583 Rev. A 110583 Read and follow these instructions, employer safety practices, and material safety data sheets. Refer to ANS Z49.
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