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
  • IEC symbols
  • Noise levels
  • Symbols and marks
• Power Supply Setup
  • Unpack the plasma 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 power cords
      • Install a plug on the power cord
    • Extension cord recommendations
    • Generator recommendations
• Torch Setup
  • Introduction
    • Hand torch components
  • Consumable life
  • Consumable use
    • Using the cut charts
    • Consumable set
      • 240 V / 30 A cutting
      • 120 V / 20 A cutting
• Operation
  • Controls and indicators
    • Rear controls
    • Front panel controls and indicator LED symbols
  • Operate the plasma system
    • Step 1 – Install the consumables
    • Step 2 – Connect the electrical power
    • Step 3 – Adjust the output current
      • Operating the system on a 120 V / 20 A circuit
      • Operating the system on a 240 V / 20 A circuit
      • Decrease output current for lower-rated power plugs
      • Cutting expanded metal
    • Step 4 – Attach the ground clamp
    • Step 5 – Power ON the system
    • Step 6 – Check the indicator LEDs
    • Step 7 – Make sure the system is ready, and start cutting
  • What to expect during and after cutting
    • Postflow
    • Internal compressor and fan activity
    • Water under the power supply
  • 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
    • 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
    • Power LED faults
    • Temperature LED faults
    • Internal compressor LED faults
    • Torch cap LED faults
    • Common cutting issues
  • Control board LEDs
    • Use the control board Rest and Error 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 on power board
    • 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 – internal compressor, compressor-driver board, and power board
      • Test 9a – Check the diagnostic LED (D5) on the compressor-driver board
      • Test 9b – Check the internal compressor
      • Test 9c – Check the compressor-driver board
      • Test 9d – Check the power board
• Power Supply Component Replacement
  • Replace the power supply cover
  • Replace the component barrier
  • Detach and reattach the front panel
  • Detach and reattach the rear panel
  • Replace the power cord and strain relief
  • Replace the power switch
  • Replace the control board
  • Replace the compressor-driver board
  • Replace the power board
  • Replace the drain hose, gas supply hoses, and 90° fitting
  • Replace the wire group
  • Replace the solenoid valve
  • Replace the torch lead and strain relief
  • Replace the air filter assembly
  • Replace the air filter bowl and air filter element
  • Replace the fan
  • Replace the heat exchange coil
  • Replace the internal compressor
  • Replace the air inlet filter in the internal compressor
  • Replace the front panel
  • Replace the rear panel
  • Replace the base
  • Replace the magnetics assembly
  • Replace the work lead and ground clamp
• Torch Component Replacement
  • Torch components
  • Replace the handle
  • Replace the trigger assembly
  • Replace the torch body
  • Replace the start switch
  • Replace the cap-sensor switch
  • Replace the torch lead
• Parts
  • Power supply parts
    • Exterior, front
    • Exterior, rear
    • Interior, power board side
    • Interior, control board and power switch
    • Interior, fan assembly
    • Interior, pneumatics (fan side)
    • Interior, wires
    • Power supply base and magnetics
  • Hand torch parts
  • Hand torch consumables
  • Accessory parts
  • Safety-critical parts
  • Recommended spare parts
  • Power supply labels
    • Consumables label
    • CSA warning label
    • CE warning label
• Wiring Diagrams
  • Process flow for troubleshooting internal compressor and temperature fault LEDs
  • Timing chart for torch start
  • Powermax30 AIR schematic