Hypertherm POWERMAX 45 User manual

45
Plasma arc cutting system
Operator Manual – 805780
Revision 2

Register your new Hypertherm system
Register your product online 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.
For your records
Serial number:________________________________________________________________
Purchase date: _______________________________________________________________
Distributor: __________________________________________________________________
____________________________________________________________________________
____________________________________________________________________________
Maintenance notes:
____________________________________________________________________________
____________________________________________________________________________
____________________________________________________________________________
____________________________________________________________________________
____________________________________________________________________________
____________________________________________________________________________

Operator Manual
(P/N 805780)
Revision 2 – April, 2013
Hypertherm, Inc.
Hanover, NH USA
www.hypertherm.com
© Copyright 2013 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.
45

Hypertherm, Inc.
Etna Road, P.O. Box 5010
Hanover, NH 03755 USA
603-643-3441 Tel (Main Office)
603-643-5352 Fax (All Departments)
[email protected] (Main Office Email)
800-643-9878 Tel (Technical Service)
[email protected] (Technical Service Email)
800-737-2978 Tel (Customer Service)
customer.ser[email protected] (Customer Service Email)
866-643-7711 Tel (Return Materials Authorization)
877-371-2876 Fax (Return Materials Authorization)
[email protected] (RMA email)
Hypertherm Plasmatechnik GmbH
Technologiepark Hanau
Rodenbacher Chaussee 6
D-63457 Hanau-Wolfgang, Deutschland
49 6181 58 2100 Tel
49 6181 58 2134 Fax
49 6181 58 2123 (Technical Service)
Hypertherm (S) Pte Ltd.
82 Genting Lane
Media Centre
Annexe Block #A01-01
Singapore 349567, Republic of Singapore
65 6841 2489 Tel
65 6841 2490 Fax
65 6841 2489 (Technical Service)
Hypertherm (Shanghai) Trading Co., Ltd.
Unit 301, South Building
495 ShangZhong Road
Shanghai, 200231
PR China
86-21-60740003 Tel
86-21-60740393 Fax
Hypertherm Europe B.V.
Vaartveld 9
4704 SE
Roosendaal, Nederland
31 165 596907 Tel
31 165 596901 Fax
31 165 596908 Tel (Marketing)
31 165 596900 Tel (Technical Service)
00 800 4973 7843 Tel (Technical Service)
Hypertherm Japan Ltd.
Level 9, Edobori Center Building
2-1-1 Edobori, Nishi-ku
Osaka 550-0002 Japan
81 6 6225 1183 Tel
81 6 6225 1184 Fax
Hypertherm Brasil Ltda.
Rua Bras Cubas, 231 – Jardim Maia
Guarulhos, SP - Brasil
CEP 07115-030
55 11 2409 2636 Tel
55 11 2408 0462 Fax
Hypertherm México, S.A. de C.V.
Avenida Toluca No. 444, Anexo 1,
Colonia Olivar de los Padres
Delegación Álvaro Obregón
México, D.F. C.P. 01780
52 55 5681 8109 Tel
52 55 5683 2127 Fax
Hypertherm Korea Branch
#3904 Centum Leaders Mark B/D,
1514 Woo-dong, Haeundae-gu, Busan
Korea, 612-889
82 51 747 0358 Tel
82 51 701 0358 Fax
07/18/12

Safety information
Before operating any Hypertherm equipment, read the separate
Safety and Compliance Manual (80669C) included
with your product for important safety information.

TABLE OF CONTENTS
powermax 45 Operator Manual i
TABLE OF CONTENTS
ELECTROMAGNETIC COMPATIBILITY EMC .......................................................................................................EMC1
WARRANTY............................................................................................................................................................................W1
SECTION 1
SPECIFICATIONS
System description....................................................................................................................................................................................1-2
Where to find information ........................................................................................................................................................................1-2
Power supply dimensions and weights ................................................................................................................................................1-3
Dimensions .......................................................................................................................................................................................1-3
Weights .............................................................................................................................................................................................1-3
Power supply ratings.................................................................................................................................................................................1-4
T45v torch dimensions .............................................................................................................................................................................1-5
T45m torch dimensions............................................................................................................................................................................1-5
T45v and T45m torch specifications.....................................................................................................................................................1-6
Symbols and marks ...................................................................................................................................................................................1-7
IEC symbols ................................................................................................................................................................................................1-8
SECTION 2
POWER SUPPLY SETUP
Unpack the Powermax45.........................................................................................................................................................................2-2
Claims ................................................................................................................................................................................................2-2
Contents............................................................................................................................................................................................2-2
Position the power supply........................................................................................................................................................................2-3
Prepare the electrical power ...................................................................................................................................................................2-3
Voltage configurations....................................................................................................................................................................2-3
Install a line-disconnect switch ....................................................................................................................................................2-4
Requirements for grounding .........................................................................................................................................................2-4
Power cord considerations......................................................................................................................................................................2-4
Extension cord recommendations ...............................................................................................................................................2-5
Generator recommendations........................................................................................................................................................2-6

Table of ConTenTs
ii powermax 45 Operator Manual
Prepare the gas supply.............................................................................................................................................................................2-6
Connect the gas supply.................................................................................................................................................................2-7
Additional gas filtration...................................................................................................................................................................2-7
SECTION 3
TORCH SETUP
Introduction .................................................................................................................................................................................................3-2
Consumable life..........................................................................................................................................................................................3-2
Hand torch setup.......................................................................................................................................................................................3-2
Choose the consumables..............................................................................................................................................................3-3
Install the consumables..................................................................................................................................................................3-5
Machine torch setup..................................................................................................................................................................................3-6
Mount the torch................................................................................................................................................................................3-6
Choose the consumables (cut charts) .......................................................................................................................................3-8
Using the cut charts........................................................................................................................................................................3-8
T45m shielded consumables........................................................................................................................................................3-8
Align the torch...............................................................................................................................................................................3-24
Connect the remote-start pendant...........................................................................................................................................3-25
Connect a machine interface cable .........................................................................................................................................3-25
Accessing raw arc voltage.........................................................................................................................................................3-27
Connect the torch lead..........................................................................................................................................................................3-28
SECTION 4
OPERATION
Controls and indicators ............................................................................................................................................................................4-2
Front controls and LEDs................................................................................................................................................................4-2
Rear controls ....................................................................................................................................................................................4-3
Operate the Powermax45........................................................................................................................................................................4-3
Connect the electrical power and gas supply..........................................................................................................................4-3
Power ON the system....................................................................................................................................................................4-4
Set the mode switch.......................................................................................................................................................................4-4
Adjust the gas pressure.................................................................................................................................................................4-4
Check the indicator LEDs .............................................................................................................................................................4-6
Attach the work clamp ...................................................................................................................................................................4-6
Understand duty-cycle limitations..........................................................................................................................................................4-6
How to use the hand torch......................................................................................................................................................................4-7
Operate the safety trigger .............................................................................................................................................................4-7
Hand torch cutting hints ................................................................................................................................................................4-7
Start a cut from the edge of the workpiece...............................................................................................................................4-8
Pierce a workpiece..........................................................................................................................................................................4-9
Gouge a workpiece .....................................................................................................................................................................4-10
Common hand-cutting faults .....................................................................................................................................................4-12

Table of ConTenTs
powermax 45 Operator Manual iii
How to use the machine torch.............................................................................................................................................................4-12
Ensure the torch and table are set up correctly....................................................................................................................4-12
Understand and optimize cut quality........................................................................................................................................4-13
To pierce a workpiece using the machine torch ...................................................................................................................4-14
Common machine-cutting faults...............................................................................................................................................4-15
SECTION 5
MAINTENANCE AND REPAIR
Perform routine maintenance ..................................................................................................................................................................5-2
Inspect the consumables.........................................................................................................................................................................5-3
Basic troubleshooting...............................................................................................................................................................................5-4
Repairs .........................................................................................................................................................................................................5-6
Remove and replace the cover and Mylar®barrier ..................................................................................................................5-6
Replace the work lead (CSA and CE) .......................................................................................................................................5-7
Replace the gas filter element......................................................................................................................................................5-8
SECTION 6
PARTS
Power supply parts....................................................................................................................................................................................6-2
T45v hand torch parts...............................................................................................................................................................................6-5
T45v hand torch consumables.....................................................................................................................................................6-6
T30v (Powermax30) 30 A consumables ...................................................................................................................................6-6
T45m machine torch parts.......................................................................................................................................................................6-7
T45m machine torch consumables.............................................................................................................................................6-8
Accessory parts..........................................................................................................................................................................................6-8
Powermax45 labels ...................................................................................................................................................................................6-9

Table of ConTenTs
iv powermax 45 Operator Manual