Hypertherm Powermax30 AIR Reference manual

Field Service Bulletin
Bulletin de service sur le terrain
805430 Revision 4 February 2015
Révision 4 Février 2015
Powermax30® , Powermax30 XP, and
Powermax30 AIR Power Cord
Replacement
Remplacement du cordon
d’alimentation des Powermax30,
Powermax30 XP et Powermax30 AIR

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)
[e-mail] (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
© 2015 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/30 AIR Field Service Bulletin 805430 3
Power Cord Replacement
Introduction
Purpose
Describes the necessary steps to replace the power cord and strain relief on CSA and CE Powermax30 power supplies.
Powermax30 XP and Powermax30 Air systems: Complete instructions for installing these repair kits, as well as the
CCC power cord repair kit (428231) for the Powermax30 XP and the CE power cord repair kit (428390) for the
Powermax30 Air, are included in the Service Manual. To download the Service Manual, go to www.hypertherm.com and
click the “Downloads library” link.
Powermax30 XP Service Manual (808150)
Powermax30 Air Service Manual (808850)
Tools and materials needed
Assorted Phillips®and TORX®screwdrivers
Needle nose pliers
Adjustable wrench
WARNING!
ELECTRIC SHOCK CAN KILL
Disconnect electrical power before performing any maintenance.
See the Safety and Compliance Manual (80669C) for more safety
precautions.

4Powermax30/30 XP/30 AIR Field Service Bulletin 805430
Power Cord Replacement
Kit 228210 contents (CSA)
The 120 V/15 A CSA plug adapter (229132) and the 240 V/20 A CSA plug adapter
(229133) must be ordered separately from the power cord kit.
Kit 228140 contents (CE)
Kit 228143 contents
Replace the power cord
Remove the rear panel
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.
Figure 1
Part number Description Quantity
229135 Power cord assembly: Powermax30, Powermax30 XP, and
Powermax30 Air L6-20P
1
Part number Description Quantity
229120 Power cord assembly: Powermax30 and Powermax30 XP CE 1
Part number Description Quantity
008389 Strain relief: 0.428 – 0.546 black vinyl 1

Powermax30/30 XP/30 AIR Field Service Bulletin 805430 5
Power Cord Replacement
4. Continue to tilt the panels outward to release the fan side of the cover from its track. Then lift the cover off the power
supply.
5. Remove the component barrier from the power board side of the power supply. The barrier is flexible and can be bent
slightly for removal.
Figure 2
6. Loosen the power cord’s strain relief nut.
7. Lay the power supply on its side.
8. Remove the retaining screw from the bottom of the rear panel.
Figure 3
Component barrier
1
2 3 4
1Rear panel
2Snap
3Retaining screw
4Raised rib

6Powermax30/30 XP/30 AIR Field Service Bulletin 805430
Power Cord Replacement
9. Insert needle nose pliers into the opening for one of the snaps and use the pliers to squeeze it together.
10. Place a blade screwdriver against the raised rib next to the snap and gently turn the screwdriver to push the panel
away from the base.
Figure 4
11 . Place another screwdriver or similar object into the opening between the panel and the base to keep the first corner
of the panel from re-engaging the snaps when you release the other corner.
Figure 5
12. Repeat step 9 and step 10 on the other corner of the panel.

Powermax30/30 XP/30 AIR Field Service Bulletin 805430 7
Power Cord Replacement
13. Disconnect the ground wire from the ground wire clip near the top of the rear panel. (See Figure 6.)
Figure 6
14. Gently pull the panel away from the power supply.
1
2
1Ground wire clip 2Rear panel

8Powermax30/30 XP/30 AIR Field Service Bulletin 805430
Power Cord Replacement
Remove the power cord (CSA)
The power cord has a black wire and a white wire that connect to the power switch and a green ground wire that
connects to the heatsink.
1. Remove the black and white wires from the top of the power switch. You can use needle nose pliers or a straight
screwdriver to ease them off, if necessary.
Figure 7
2. Remove the screw that holds the ground wire to the heatsink. A notch in the power board provides access to the
screw. (See Figure 8.)
Figure 8
N
L
PE

Powermax30/30 XP/30 AIR Field Service Bulletin 805430 9
Power Cord Replacement
3. On the outside of the power supply, loosen the power
cord’s strain relief nut (see Figure 9) so that the wires
move freely.
4. From outside of the power supply, pull the wires
through the strain relief and through the hole in the rear
panel to remove the power cord.
5. Are you replacing the strain relief?
If yes, use an adjustable wrench to unscrew the
retention nut on the inside of the power supply.
Remove the strain relief from the rear panel.
If no, continue with Install the new power cord
(CSA).
Figure 9
1
2
34
Outside
Inside
1Strain relief nut (outside the power supply)
2Strain relief
3Rear panel
4Retention nut (inside the power supply)

10 Powermax30/30 XP/30 AIR Field Service Bulletin 805430
Power Cord Replacement
Install the new power cord (CSA)
1. Are you installing a new strain relief?
If yes, insert the strain relief into the rear panel and tighten the retention nut onto the strain relief. Loosely tighten
the strain relief nut on the outside of the power supply onto the strain relief.
If no, continue with the next step.
2. Route the power cord wires through the strain relief nut and strain relief.
3. Press the connector for the black wire onto the pin on the upper left side of the power switch. Press the connector
for the white wire onto the pin on the upper right side of the power switch.
4. Tighten the green ground wire to the heatsink with a torque setting of 17.28 kg-cm (15 inch-pounds).
5. Press the wires into the track going up the side of the rear panel.