Hypertherm Powermax30 AIR Reference manual

Field Service Bulletin
Bulletin de service sur le terrain
805330 Revision 2 December 2013
Révision 2 Décembre 2013
Powermax30® and Powermax30®XP
Air Filter/Regulator and
Pressure Switch Replacement
Remplacement du filtre à air
et du détendeur du Powermax30
et Powermax30 XP

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
© 2013 Hypertherm Inc. All rights reserved. Tous droits réservés.
Powermax and Hypertherm are trademarks of Hypertherm Inc. and may be registered in the United States and/or other countries. All other trademarks
are the property of their respective holders.
Powermax et Hypertherm sont des marques d’Hypertherm Inc. qui peuvent être déposées aux États-Unis et/ou dans d’autres pays. Toutes les autres
marques commerciales sont la propriété de leurs détenteurs respectifs.

Powermax30/30 XP Field Service Bulletin 805330 Revision 2 3
Air Filter/Regulator and Pressure Switch Replacement
Introduction
Purpose
This Field Service Bulletin describes the necessary steps to replace the air filter/regulator and pressure switch assembly
on Powermax30 power supplies.
This kit contains separate air inlet fittings for the Powermax30 and the Powermax30 XP. The fittings for the
Powermax30 XP will not work on the Powermax30 because they are too large to fit through the rear panel.
Powermax30 XP systems: Complete instructions for installing this repair kit are included in the Powermax30 XP
Service Manual (808150). To download the Service Manual, go to www.hypertherm.com and click the “Downloads
library” link.
Tools and materials needed
Assorted Phillips®and TORX®screwdrivers
1/2 inch wrench or adjustable wrench (CSA models only)
19 mm wrench or adjustable wrench (CE models only)
Thread sealant
WARNING!
ELECTRIC SHOCK CAN KILL
Disconnect electrical power before performing any maintenance.
See the Safety and Compliance Manual (80669C) for more safety
precautions.
CAUTION!
Never use PTFE tape on any joint preparation. Use only a liquid or paste thread sealant on male
threads.

4Powermax30/30 XP Field Service Bulletin 805330 Revision 2
Air Filter/Regulator and Pressure Switch Replacement
228106 Kit contents
The brass hex adapter fitting in this kit (015846) is not used in the Powermax30.
Before you begin
The gas supply hoses mentioned in the following procedures use push-to-connect fittings:
Part number Description Quantity
011116 Air filter/regulator 1
005112 Pressure switch 1
015530 Brass elbow fitting 1
015603 Brass “T” fitting 1
015691 1/8 NPT x 6 mm push-to-connect fitting 1
104704 Tubing: 6.35 mm OD x 4.23 mm ID poly, 4.75 in. 1
015618 Brass pipe fitting (Powermax30 only) 1
015550 Brass coupler (Powermax30 only) 1
015846 Brass hex adapter fitting (Powermax30 XP only) 1
Push-to-Connect
To connect, push the hose into the fitting until it stops. Pull on the hose to verify that it is secure.
To release, push the fitting collet toward the fitting, and pull the hose away from the fitting.
123
1Hose 2Collet 3O-ring

Powermax30/30 XP Field Service Bulletin 805330 Revision 2 5
Air Filter/Regulator and Pressure Switch Replacement
Replace the air filter/regulator and pressure switch
1. Set the power switch to OFF (O), disconnect the power cord from the power source, and disconnect the gas supply.
2. Remove the 2 screws from the handle on the top of the power supply.
3. Slightly tip the front and rear panels away from the power supply so that you can get the edges of the handle out from
underneath them. Remove the handle, and set it and the 2 screws aside.
4. Lift the cover off the power supply.
5. Grip the air filter/regulator with your right hand to hold it steady. With your left hand:
CSA models: Use a 1/2 inch wrench to remove the air fitting from the rear of the power supply.
CE models: Use a 19 mm wrench to remove the air fitting adapter from the rear of the power supply.
6. Disconnect the drain hose from the hole in the bottom of the power supply’s base.
7. Disconnect the red and black wires from the pins on the pressure switch.
8. Push-to-disconnect the gas supply hose from the air filter/regulator’s brass “T” fitting.

6Powermax30/30 XP Field Service Bulletin 805330 Revision 2
Air Filter/Regulator and Pressure Switch Replacement
9. Disconnect the ground wire that is attached to the clip on the air filter/regulator’s brass “T” fitting. Set the clip aside.
1
2
3
4
5
6
7
8
9
10
1Retainer nut
2Bracket
3Air fitting
4Air filter/regulator
5Drain hose
6Gas supply hose
7Red and black pressure switch wires
8Pressure switch
9Ground wire
10 Brass “T” fitting with ground clip

Powermax30/30 XP Field Service Bulletin 805330 Revision 2 7
Air Filter/Regulator and Pressure Switch Replacement
10. Unscrew the retainer nut that holds the air filter/regulator in the bracket.
11 . Tip the bottom of the air filter/regulator and pressure switch assembly away from the power supply, and slide the
assembly out of the bracket. Gently tilt the top of the rear panel away from the power supply as you remove the
assembly, if needed.
2
3
1
1Retainer nut
2Center panel bracket
3Air filter/regulator

8Powermax30/30 XP Field Service Bulletin 805330 Revision 2
Air Filter/Regulator and Pressure Switch Replacement
12. Locate the new brass coupler (015550) and pipe fitting (015618) in the kit.
13. Lightly apply thread sealant to the threads on one end of the pipe fitting, and screw the coupler onto that end of the
pipe fitting.
14. Apply a small drop of thread sealant to the threads on the other end of the pipe fitting, and screw that end of the
fitting into the side of the air filter/regulator.
If applied too heavily, excess amounts of thread sealant can contaminate the gas line.
CAUTION!
The regulator is pre-set at the factory. Do not adjust this setting.
Coupler Pipe fitting

Powermax30/30 XP Field Service Bulletin 805330 Revision 2 9
Air Filter/Regulator and Pressure Switch Replacement
15. Position the new air filter/regulator and pressure switch assembly in the center panel bracket. Hand-tighten the
retainer nut plus a quarter turn.
Do not to overtighten the retainer nut.
16. Route the drain hose through the hole in the base of the power supply.
17. Press the black wire’s connector onto the pressure switch pin that is nearest the center panel; press the red wire’s
connector onto the pressure switch pin that is furthest from the center panel.
18. Push-to-connect the gas supply hose to the fitting on the new air filter/regulator.
19. Reconnect the ground wire to the air filter’s “T” fitting using the clip you removed in step 9 on page 6.
1
5
6
8
7
4
3
2
9
1Air filter/regulator assembly
2Drain hose
3Brass “T” fitting
4Ground wire clip
5Push-to-connect fitting for gas supply hose
6Red wire
7Black wire
8Pressure switch
9Retainer nut

10 Powermax30/30 XP Field Service Bulletin 805330 Revision 2
Air Filter/Regulator and Pressure Switch Replacement
20. Reconnect the air fitting, then reconnect the gas supply and check for leaks at each fitting and hose connection point
on the air filter/regulator assembly.
21. Being careful not to pinch any wires, slide the cover onto the power supply.
22. Position the handle over the holes in the top of the cover. Reinstall the 2 screws that attach the cover and handle.
23. Reconnect the gas supply and power cord, and set the power switch to ON (I).
CAUTION!
Gas supply pressures not within the specifications in the Specifications section of your system’s
manual can cause poor cut quality, poor consumable life, and operational problems.
If the purity level of the gas is too low, or if there are leaks in the supply hoses or connections:
Cut speeds can decrease
Cut quality can deteriorate
Cutting thickness capability can decrease
Consumables life can be shortened