Document Outline

• Table of Contents
• Electromagnetic Compatibility (EMC)
• Warranty
• Section 1
  • Specifications
    • System description
    • Where to find information
    • Power supply dimensions and weights
      • Dimensions
      • Weights
    • Power supply ratings
    • T45v torch dimensions
    • T45m torch dimensions
    • T45v and T45m torch specifications
    • Symbols and marks
    • IEC symbols
• Section 2
  • Power Supply Setup
    • Unpack the Powermax45
      • Claims
      • Contents
    • Position the power supply
    • Prepare the electrical power
      • Voltage configurations
      • Install a line-disconnect switch
      • Requirements for grounding
    • Power cord considerations
      • Extension cord recommendations
      • Generator recommendations
    • Prepare the gas supply
      • Connect the gas supply
      • Additional gas filtration
• Section 3
  • Torch Setup
    • Introduction
    • Consumable life
    • Hand torch setup
      • Choose the consumables
      • Install the consumables
    • Machine torch setup
      • Mount the torch
      • Choose the consumables (cut charts)
      • Using the cut charts
      • T45m shielded consumables
      • Align the torch
      • Connect the remote-start pendant
      • Connect a machine interface cable
      • Accessing raw arc voltage
    • Connect the torch lead
• Section 4
  • Operation
    • Controls and indicators
      • Front controls and LEDs
      • Rear controls
    • Operate the Powermax45
      • Connect the electrical power and gas supply
      • Power ON the system
      • Set the mode switch
      • Adjust the gas pressure
      • Check the indicator LEDs
      • Attach the work clamp
    • Understand duty-cycle limitations
    • How to use the hand torch
      • Operate the safety trigger
      • Hand torch cutting hints
      • Start a cut from the edge of the workpiece
      • Pierce a workpiece
      • Gouge a workpiece
      • Common hand-cutting faults
    • How to use the machine torch
      • Ensure the torch and table are set up correctly
      • Understand and optimize cut quality
      • To pierce a workpiece using the machine torch
      • Common machine-cutting faults
• Section 5
  • Troubleshooting and System Tests
    • Theory of operation
      • General
      • 200–240 V CSA and 230 V CE 1-phase power supply functional description
      • 400 V CE 3-phase power supply functional description
      • 480 V CSA 3-phase power supply functional description
      • Sequence of operation
    • Troubleshooting preparation
      • Test equipment
      • Troubleshooting procedures and sequence
      • External inspection
      • Internal inspection
    • Initial resistance check
    • 200–240 V CSA and 230 V CE power supply overview
    • 400 V CE power supply overview
    • 480 V CSA power supply overview
    • Troubleshooting guide
    • Control Board LEDs
      • Use the control board Error and Reset LEDs to troubleshoot
    • 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 (TSO) or torch stuck closed (TSC)
      • Test 6 – plasma start
      • Test 7 – torch cap sensor
      • Test 8 – fan
      • Test 9 – pressure transducer
      • Test 10 – power switch trip coil
• Section 6
  • Component Replacement
    • Remove and replace the cover and Mylar® barrier
      • Removal
      • Replacement
    • Replace the work lead (CSA and CE)
    • Replace the power cord (200–240 V CSA)
    • Replace the power cord (230 V CE)
    • Replace the power cord (400 V CE)
    • Replace the power cord (480 V CSA)
    • Replace the fan
    • Replace the gas filter element
    • Replace the air filter and regulator
    • Replace the control board
    • Replace the power board (200–240 V CSA and 230 V CE)
    • Replace the power board (400 V CE and 480 V CSA)
• Section 7
  • Parts
    • Power supply parts
      • Exterior
      • Interior, power board side
      • Interior, fan side
      • Interior, heat sink side
    • T45v hand torch parts
      • T45v hand torch consumables
      • T30v (Powermax30) 30 A consumables
    • T45m machine torch parts
      • T45m machine torch consumables
    • Accessory parts
    • Safety-critical parts
    • Recommended spare parts
    • Powermax45 labels
• Section 8
  • Wiring Diagrams
    • Control board diagram: 200–240 V CSA and 230 V CE
    • Control board diagram: 400 V CE and 480 V CSA
    • Power board wiring diagram: 200–240 V CSA and 230 V CE
    • Power board wiring diagram: 400 V CE
    • Power board wiring diagram: 480 V CSA