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Hypertherm powermax45 Service Manual

Hypertherm powermax45
149 pages
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45
Plasma arc cutting system
Service Manual – 806110
Revision 2

Table of Contents

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Questions and Answers:

Hypertherm powermax45 Specifications

General IconGeneral
BrandHypertherm
Modelpowermax45
CategoryWelding System
LanguageEnglish

Summary

Specifications

System Description

A detailed overview of the Powermax45 plasma cutting system.

Power Supply Dimensions and Weights

Physical dimensions and weight specifications for the power supply unit.

Power Supply Ratings

Electrical ratings including input voltage, output current, and duty cycle.

T45v and T45m Torch Specifications

Performance data and capabilities for handheld and machine torches.

Symbols and Marks

Explanation of safety and compliance markings on the equipment.

IEC Symbols

Definitions of standard symbols used on the power supply and controls.

Power Supply Setup

Unpack the Powermax45

Steps for safely unpacking the equipment and verifying contents.

Prepare the Electrical Power

Guidance on connecting the system to appropriate electrical sources.

Install a Line-Disconnect Switch

Instructions for installing a safety disconnect switch.

Requirements for Grounding

Essential safety guidelines for proper equipment grounding.

Torch Setup

Introduction

Overview of available torches and the FastConnect system.

Consumable Life

Factors affecting the lifespan of torch consumables.

Hand Torch Setup

Procedure for installing consumables on the handheld torch.

Machine Torch Setup

Steps for mounting and connecting the machine torch.

Operation

Controls and Indicators

Description of front panel controls, LEDs, and indicators.

Operate the Powermax45

Step-by-step guide to powering on and basic operation.

How to Use the Hand Torch

Techniques for safe and effective handheld torch operation.

How to Use the Machine Torch

Guidance for optimizing cut quality with the machine torch.

Troubleshooting and System Tests

Theory of Operation

Functional descriptions of the power supply circuits.

Troubleshooting Preparation

Essential steps and safety precautions before troubleshooting.

Troubleshooting Guide

Common problems, their causes, and solutions.

System Tests

Detailed diagnostic procedures for system components.

Component Replacement

Remove and Replace the Cover and Mylar® Barrier

Procedure for accessing internal components.

Replace the Power Cord

Instructions for replacing the power supply cord.

Replace the Fan

Steps for replacing the cooling fan assembly.

Replace the Control Board

Procedure for replacing the main control board.

Parts

Power Supply Parts

List and diagrams of power supply external and internal components.

Torch Parts

Diagrams and part numbers for handheld and machine torches.

Consumables

Part numbers for torch consumables for different applications.

Recommended Spare Parts

List of commonly needed parts for service.

Wiring Diagrams

Control Board Diagram

Schematic for the control board connections and signals.

Power Board Wiring Diagram

Schematics illustrating power board internal connections.

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