Hypertherm powermax45

Hypertherm powermax45

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Service Manual

(P/N 806110)

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

Table of Contents

Default Chapter5
- Safety Information5
- Table of Contents7
Electromagnetic Compatibility (Emc)11
- Mains Supply11
- Assessment of Area11
- Maintenance of Cutting Equipment12
Warranty13
- Patent Indemnity14
Section 115
Specifications15
- System Description16
- Where to Find Information16
- Power Supply Dimensions and Weights17
  - Dimensions17
  - Weights17
- Power Supply Ratings18
- T45V Torch Dimensions19
- T45M Torch Dimensions19
- T45V and T45M Torch Specifications20
- Symbols and Marks21
- IEC Symbols22
Section 223
Power Supply Setup23
- Unpack the Powermax4524
  - Claims24
  - Contents24
- Position the Power Supply25
- Prepare the Electrical Power25
Table of Contents26
- Power Cord Considerations26
  - Extension Cord Recommendations27
  - Generator Recommendations28
- Prepare the Gas Supply28
  - Connect the Gas Supply29
  - Additional Gas Filtration29
Section 332
Torch Setup Introduction32
- Consumable Life32
- Hand Torch Setup32
- Machine Torch Setup36
- Connect the Torch Lead60
Operation62
Section 462
- Controls and Indicators62
  - Front Controls and Leds62
  - Rear Controls63
- Operate the Powermax4563
- Understand Duty-Cycle Limitations66
- How to Use the Hand Torch67
- How to Use the Machine Torch72
Section 577
Troubleshooting and System Tests77
- Theory of Operation78
- Troubleshooting Preparation81
- Initial Resistance Check83
- 200-240 V CSA and 230 V Ce Power Supply Overview84
- 400 V Ce Power Supply Overview85
- 480 V CSA Power Supply Overview86
- Troubleshooting Guide87
- Control Board Leds92
  - Use the Control Board Error and Reset Leds to Troubleshoot93
- System Tests94
Section 6105
Component Replacement105
- Remove and Replace the Cover and Mylar ® Barrier106
- Replace the Work Lead (CSA and CE)107
- Replace the Power Cord (200-240 V CSA)109
- Replace the Power Cord (230 V CE)110
- Replace the Power Cord (400 V CE)112
- Replace the Power Cord (480 V CSA)114
- Replace the Fan116
- Replace the Gas Filter Element117
- Replace the Air Filter and Regulator119
- Replace the Control Board120
- Replace the Power Board (200-240 V CSA and 230 V CE)121
- Replace the Power Board (400 V CE and 480 V CSA)125
Section 7129
Parts129
- Power Supply Parts130
- T45V Hand Torch Parts135
  - T45V Hand Torch Consumables136
  - T30V (Powermax30) 30 a Consumables136
- T45M Machine Torch Parts137
  - T45M Machine Torch Consumables138
- Accessory Parts138
- Safety-Critical Parts139
- Recommended Spare Parts140
- Powermax45 Labels141
Section 8143
Wiring Diagrams143
- Control Board Diagram: 200-240 V CSA and 230 V CE144
- Control Board Diagram: 400 V CE and 480 V CSA145
- Power Board Wiring Diagram: 400 V CE148
- Power Board Wiring Diagram: 480 V CSA149

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