Document Outline

• Contents
• Electromagnetic Compatibility (EMC)
  • Introduction
  • Installation and use
  • Assessment of area
  • Methods of reducing emissions
    • Mains supply
  • Maintenance of cutting equipment
  • Cutting cables
    • Equipotential bonding
    • Earthing of the workpiece
  • Screening and shielding
• Warranty
  • Attention
  • General
  • Patent indemnity
  • Limitation of liability
  • National and local codes
  • Liability cap
  • Insurance
  • Transfer of rights
• Specifications
  • Safety information
  • System description
  • Power supply dimensions
  • System weights
  • Hypertherm system ratings
  • Torch dimensions
  • Torch weight
  • Cutting specifications
  • Symbols and marks
    • Noise levels
    • IEC symbols
• Power Supply Setup
  • Unpack the Powermax system
    • Claims
  • System contents
  • Position the plasma cutting system
  • Prepare the electrical power
    • Voltage configurations
    • Requirements for grounding
  • Power cord considerations
    • CSA power cords and plugs
    • CE and CCC power cords
    • Extension cord recommendations
    • Generator recommendations
  • Prepare the gas supply
    • Connect the gas supply
    • Additional gas filtration
• Torch Setup
  • Introduction
    • Hand torch components
  • Consumable life
  • Choose the consumables
    • Using the cut charts
    • General-purpose (standard) consumables
      • 240 V / 30 A cutting
    • FineCut consumables
      • 120 V / 25 A cutting
      • 120 V / 30 A cutting
• Operation
  • Controls and indicators
    • Rear controls
    • Front controls and LEDs
  • Operate the Powermax30 XP
    • Connect the electrical power and gas supply
  • Install the consumables
    • Attach the ground clamp
    • Power ON the system
    • Adjust the gas pressure and output current
      • Operating the system on a 120 V, 15 A circuit
      • Operating the system on a 120 V, 20 A circuit
      • Operating the system on a 240 V, 20 A circuit
    • Check the indicator LEDs
    • Verify the system is ready
  • Understand duty-cycle limitations
  • System operation guidelines
  • Hand torch operation
    • Safety catch operation
    • Hand torch cutting guidelines
      • Recommendations for cutting at 120 V
    • Edge start on a workpiece
    • Pierce a workpiece
    • Gouge a workpiece
      • Varying the gouge profile
    • Common hand-cutting faults
      • Minimizing dross
• Troubleshooting and System Tests
  • Theory of operation
    • Functional description
    • Sequence of operation
  • Troubleshooting preparation
    • Test equipment
    • Troubleshooting procedures and sequence
    • External inspection
    • Internal inspection
  • Initial resistance check
    • Check the power switch
  • Power supply overview
  • Troubleshooting guide
  • Control board LEDs
    • Use the control board Error and Reset LEDs to troubleshoot
      • Reset LED
      • Error LED
  • System tests
    • Test 1 – voltage input
    • Test 2 – power board voltage checks
    • Test 3 – VBUS and voltage balance
    • Test 4 – solenoid valve
    • Test 5 – torch stuck open or torch stuck closed
    • Test 6 – plasma start
    • Test 7 – torch cap-sensor
    • Test 8 – fan
    • Test 9 – pressure switch
• Power Supply Component Replacement
  • Disconnect the power and gas supply
  • Replacing the power supply cover
    • Remove the power supply cover
    • Install the power supply cover
  • Replacing the component barrier
    • Remove the component barrier
    • Install the component barrier
  • Detaching and reattaching the front panel
    • Detach the front panel
    • Reattach the front panel
  • Detaching and reattaching the rear panel
    • Detach the rear panel
    • Reattach the rear panel
  • Replacing the power cord and strain relief
    • Remove the power cord and strain relief
    • Install the power cord and strain relief
  • Replacing the power switch
  • Replacing the control board
  • Replacing the power board
    • Remove the power board
    • Install the power board
  • Replacing the fan
  • Replacing the drain hose, gas supply hoses, and 90° fitting
    • Remove the drain hose, gas supply hoses, and 90° fitting
    • Install the drain hose, gas supply hoses, and 90° fitting
  • Replacing the wire group
    • Remove and install the pressure switch to J4 wires
    • Remove and install the ground clip wire from the heatsink to the rear panel
    • Remove and install the ground wire from the heatsink to the magnetics assembly
    • Remove and install the ground wire from the heatsink to the air filter/regulator ground clip
  • Replacing the solenoid valve
  • Replacing the torch lead and strain relief
    • Remove the torch lead and strain relief
    • Install the torch lead and strain relief
  • Replacing the pressure switch
  • Replacing the air filter/regulator and pressure switch assembly
    • Remove the air filter/regulator and pressure switch assembly
    • Install the air filter/regulator and pressure switch assembly
  • Replacing the air inlet fittings
  • Replacing the air filter bowl and air filter element
    • Remove the air filter bowl and air filter element
    • Install the air filter element and air filter bowl
  • Replacing the front panel
    • Remove the front panel
    • Install the front panel
  • Replacing the rear panel
    • Remove the rear panel
    • Install the new rear panel
  • Replacing the base
  • Replacing the magnetics assembly
  • Replacing the work lead and ground clamp
    • Remove and install the work lead
    • Remove and install the ground clamp
• Torch Component Replacement
  • Disconnect the power, gas supply, and torch
  • Replacing the handle
    • Remove the handle
    • Install the handle
  • Replacing the trigger assembly
  • Replacing the torch body
  • Replacing the start switch
  • Replacing the cap-sensor switch
  • Replacing the torch lead
• Parts
  • Power supply parts
    • Exterior, front
    • Exterior, rear
    • Interior, power board side
    • Control board and power switch
    • Interior, fan side
      • Air filter/regulator with pressure switch assembly
    • Power supply base and magnetics
  • Duramax LT hand torch parts
  • Duramax LT hand torch consumables
    • General-purpose (standard) consumables
    • FineCut consumables
  • Accessory parts
  • Safety-critical parts
  • Recommended spare parts
  • Powermax30 XP labels
• Wiring Diagrams
  • Powermax generic timing chart
  • Powermax30 XP schematic