Hypertherm Powermax30 Service Manual - Manual (Page 65)

MAINTENANCE
3-26
powermax30
Service Manual
Replace the work lead
1. Turn OFF the power, disconnect the power cord, and disconnect the gas supply.
2. Remove the 2 screws from the handle on the top of the power supply. Remove the handle and then lift the
cover off the power supply. Remove the Nomex barrier that protects the power board.
3. Remove and set aside the screw and washer from J22 on the power board (also labeled “WORK LEAD”) that
attaches the lead to the board.
4. Either remove the front endcap, or gently tilt it away from the power supply. Remove the strain relief’s retaining
nut. Pull the work lead through the hole in the endcap.
Work lead
Work lead connection
to power board (J22)
Front end cap
Strain relief
6. On the inside of the front endcap, unscrew the torch lead’s strain relief retaining nut so that the torch lead
moves freely. Remove the torch lead by pulling the wires and gas supply line through the hole in the endcap.
7. Route the wires and the gas supply line for the new torch lead through the hole in the endcap and then through
the nut for the strain relief.
8. Tighten the torch lead’s strain relief retaining nut onto the strain relief.
9. Push the torch’s gas supply hose approximately .65 inch (16 mm) into the fitting on the bottom of the solenoid
valve.
10. Slide the ring terminal for the white wire group over the left stud (labeled “WHT” on the center panel). Slide the
ring terminal for the red wire onto the stud on the right (labeled “RED” on the center panel). Tighten the nut
onto each stud.
11. Route the orange, blue, and purple wire group over the center panel with the wires resting in the notch in the
panel. Press the connector into the slot on the power board.
12. Being careful not to pinch any of the wires, replace the Nomex barrier and slide the cover back onto the power
supply. Make sure that the bottom edges are in the tracks.
13. Reposition the endcap. Make sure that the screw hole in the ground clip aligns with the screw holes in the
endcap and the power supply. Position the handle over the holes in the top of the cover, then use the 2 screws
to secure the cover.
14. Reconnect the electrical power and the gas supply.