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.
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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
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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.

Powermax30/30 XP/30 AIR Field Service Bulletin 805430 11
Power Cord Replacement
Remove the power cord (CE)
1. Remove the blue and brown wires from the power switch. You can use needle nose pliers or a straight screwdriver to
ease it off, if necessary.
2. Remove the screw that holds the green/yellow ground wire to the heatsink. A notch in the power board provides
access to the screw.
Figure 10
3. On the outside of the power supply, loosen the
power cord’s strain relief nut so that the wires move
freely.
4. Remove the power plug from the old power cord.
5. From the inside of the power supply, pull the wires
through the strain relief and the hole in the rear
panel. (You cannot remove the wires from outside
the power supply because of the ferrite bead
installed on the wires.)
6. 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
(CE).
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12 Powermax30/30 XP/30 AIR Field Service Bulletin 805430
Power Cord Replacement
Figure 11
Install the new power cord (CE)
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 wires for the power cord through the strain relief from the inside of the rear panel.
Because the power cord includes the ferrite bead, you cannot route the power cord
through the strain relief from the outside of the power supply. Do not remove the ferrite
bead from the power cord wires.
3. Press the connector for the brown wire onto the pin on the upper left side of the power switch.
4. Press the connector for the blue wire onto the pin on the upper right side of the power switch.
5. Tighten the green/yellow ground wire to the heatsink with a torque setting of 17.28 kg-cm (15 inch-pounds).
6. Press the wires into the track going up the side of the rear panel.
1
2
34
Outside
Inside
1Strain relief nut (outside the power supply)
2Strain relief
3Rear panel
4Retention nut (inside the power supply)

Powermax30/30 XP/30 AIR Field Service Bulletin 805430 13
Power Cord Replacement
Reinstall the rear panel
1. Push the rear panel into the base to re-engage the snaps.
2. Verify the hole in the ground wire clip is aligned with the screw holes in the rear panel and the power supply.
3. Tighten the retaining screw with a torque setting of 8.1 kg-cm (7 inch-pounds).
4. Reconnect the ground wire to the ground wire clip.
5. Tighten the strain relief nut on the power cord.
6. Hold the component barrier so that the edge with the long cutout and the two notches is closest to the rear panel,
and the edge with the three notches is closest to the front panel.
7. A perforated line runs across the top of the barrier, about 25 mm (1 inch) below the top edge. Fold the barrier along
this perforation so that the top edge bends away from you.
8. Position the barrier so that the folded section will cover the top of the power board. The edge with the long cutout
and the two notches should align with the front panel; the edge with the three notches should align with the rear
panel.
9. Put the front-panel edge of the barrier in place first, then the rear-panel edge. The notches on each side of the barrier
should align with the ribs on the inside of the front and rear panels. As you slide the barrier into place, make sure the
bottom edge is in the same track the cover rests in.
10. Being careful not to pinch any wires, slide the cover onto the power supply. Align the bottom edges with the tracks,
and align the slot in the top of the cover with the tab on the front panel so that the louvers in the cover are in front of
the fan.
Figure 12
12
3
1Cover slot
2Front panel
3Tab

14 Powermax30/30 XP/30 AIR Field Service Bulletin 805430
Power Cord Replacement
11 . Realign the front panel with the power supply.
12. Realign the rear panel with the power supply, making sure that the hole in the ground clip is aligned with the screw
holes in both the panel and the power supply.
13. Position the handle over the holes in the top of the cover, and position the ends of the handle underneath the edges
of the panels.
14. Reinstall the 2 screws that attach the cover and handle with a torque setting of 23.0 kg-cm (20 inch-pounds).
15. Reconnect the gas supply and power cord, and set the power switch to ON (I).

Powermax30/30 XP/30 AIR Bulletin de service sur le terrain 805430 15
Remplacement du cordon d’alimentation
Introduction
Objet
Décrit les étapes nécessaires au remplacement du cordon d’alimentation et du serre-câble des sources de courant des
Powermax30 CSA et CE.
Systèmes Powermax30 XP et Powermax30 AIR : Les instructions complètes pour l’installation de ces kits de
réparation ainsi que du kit de réparation du cordon d’alimentation CCC (428231) pour le Powermax30 XP et du kit de
réparation du cordon d’alimentation CE (428390) pour le Powermax30 AIR, sont incluses dans le Manuel de service.
Pour télécharger le Manuel de service, se rendre sur www.hypertherm.com et cliquer sur le lien « Bibliothèque de
téléchargement ».
Manuel de service Powermax30 XP (808150)
Manuel de service Powermax30 AIR (808850)
Outils et matériel requis
Tournevis Phillips®et TORX®assortis.
Pinces à bec fin
Clé ajustable
AVERTISSEMENT !
UN CHOC ÉLECTRIQUE PEUT ÊTRE MORTEL
Avant tout entretien, débrancher l’alimentation électrique.
Se reporter au Manuel de sécurité et de conformité (80669C) pour
des mesures de sécurité supplémentaires.

16 Powermax30/30 XP/30 AIR Bulletin de service sur le terrain 805430
Remplacement du cordon d’alimentation
Contenu du kit 228210 (CSA)
Les adaptateurs de fiche 120 V/15 A CSA (229132) et 240 V/20 A CSA (229133)
doivent être commandés séparément du kit de cordon d’alimentation.
Contenu du kit 228140 (CE)
Contenu du kit 228143
Remplacement du cordon d’alimentation
Retirer le panneau d’extrémité arrière.
1. Couper l’alimentation (OFF) (O), débrancher le cordon d’alimentation de la source de courant et débrancher
l’alimentation en gaz.
2. Déposer les deux vis de la poignée en haut de la source de courant.
3. Basculer légèrement les panneaux d’extrémité avant et arrière de la source de courant de façon à en extraire les
bords de la poignée d’en dessous. Enlever la poignée et la mettre de côté avec les deux vis.
Figure 13
Numéro de référence Description Quantité
229135 Ensemble du cordon d’alimentation : Powermax30,
Powermax30 XP et Powermax30 AIR L6-20P
1
Numéro de référence Description Quantité
229120 Ensemble du cordon d’alimentation : Powermax30 et
Powermax30 XP CE
1
Numéro de référence Description Quantité
008389 Serre-câble : 0,428 – 0,546 vinyle noir 1

Powermax30/30 XP/30 AIR Bulletin de service sur le terrain 805430 17
Remplacement du cordon d’alimentation
4. Continuer à incliner les panneaux vers l’extérieur pour dégager le couvercle côté ventilateur de ses rails. Retirer
ensuite le couvercle de la source de courant.
5. Retirer la barrière de composant du côté du panneau d’alimentation de la source de courant. Cette barrière est
flexible et peut être pliée légèrement pour être enlevée.
Figure 14
6. Desserrer l’écrou du serre-câble du cordon d’alimentation.
7. Coucher la source de courant sur le côté.
8. Retirer les vis de retenue de la partie inférieure des panneaux avant et arrière.
Figure 15
Barrière de composant
1
2 3 4
1Panneau arrière
2Fermoir
3Vis de fixation
4Nervure en saillie

18 Powermax30/30 XP/30 AIR Bulletin de service sur le terrain 805430
Remplacement du cordon d’alimentation
9. Insérer les pinces à bec fin dans l’orifice d’un des fermoirs et serrer ses deux côtés ensemble à l’aide des pinces.
10. Appuyer un tournevis plat contre la nervure en saillie située à côté du fermoir et tourner doucement le tournevis de
sorte à éloigner le panneau du socle.
Figure 16
11 . Placer un autre tournevis ou autre objet semblable à l’intérieur de l’orifice entre le panneau et le socle, afin
d’empêcher le premier coin du panneau de s’enclencher à nouveau dans le fermoir lorsque l’autre coin est dégagé.
Figure 17
12. Répéter étape 9 et étape 10 à l’autre angle du panneau.

Powermax30/30 XP/30 AIR Bulletin de service sur le terrain 805430 19
Remplacement du cordon d’alimentation
13. Déconnecter le fil de mise à la terre du collier de mise à la terre situé près du dessus du panneau arrière.
(Consulter Figure 18.)
Figure 18
14. Tirer délicatement le panneau loin de la source de courant.
1
2
1Collier de mise à la terre 2Panneau arrière

20 Powermax30/30 XP/30 AIR Bulletin de service sur le terrain 805430
Remplacement du cordon d’alimentation
Retrait du cordon d’alimentation (CSA)
Le cordon d’alimentation possède un fil noir et un fil blanc qui se branchent sur l’interrupteur, ainsi qu’un fil de terre vert
qui se raccorde au dissipateur thermique.
1. Retirer les fils noir et blanc au-dessus de l’interrupteur d’alimentation. Si nécessaire, il est possible d’utiliser une
pince à bec fin ou un tournevis droit pour faciliter leur retrait.
Figure 19
2. Déposer la vis utilisée pour fixer le fil de terre sur le dissipateur thermique. Une encoche dans le circuit imprimé
permet l’accès à la vis. (Consulter Figure 20.)
Figure 20
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