Hypertherm Powermax30 AIR Service Manual User Manual

Powermax30 AIR®Plasma Arc Cutting System with Integrated Air CompressorService Manual808850|Revision0|English

10 Powermax30 AIR Service Manual 808850Contents5 Troubleshooting and System Tests ...

100 Powermax30 AIR Service Manual 8088506 – Power Supply Component ReplacementReplace the component barrierRemove the component barrier1. Set the powe

Powermax30 AIR Service Manual 808850 1016 – Power Supply Component ReplacementInstall the component barrier1. Position the component barrier so that

102 Powermax30 AIR Service Manual 8088506 – Power Supply Component ReplacementDetach and reattach the front panelSeveral repairs are easier to make if

Powermax30 AIR Service Manual 808850 1036 – Power Supply Component ReplacementFigure 27Reattach the front panel1. Push the front panel into the base o

104 Powermax30 AIR Service Manual 8088506 – Power Supply Component ReplacementDetach and reattach the rear panelSeveral repairs are easier to make if

Powermax30 AIR Service Manual 808850 1056 – Power Supply Component Replacement6. Insert a blade screwdriver into the opening for one of the snaps . Wh

106 Powermax30 AIR Service Manual 8088506 – Power Supply Component ReplacementReattach the rear panel1. Push the rear panel into the base until it sna

Powermax30 AIR Service Manual 808850 1076 – Power Supply Component ReplacementReplace the power cord and strain reliefRemove the power cord and strain

108 Powermax30 AIR Service Manual 8088506 – Power Supply Component Replacement2. Remove the black and white wires from the top of the power switch.Fig

Powermax30 AIR Service Manual 808850 1096 – Power Supply Component Replacement3. Remove the screw that holds the ground wire to the heatsink. A notch

Powermax30 AIR Service Manual 808850 11Contents6 Power Supply Component Replacement ...

110 Powermax30 AIR Service Manual 8088506 – Power Supply Component Replacement4. On the outside of the power supply, loosen the power cord’s strain re

Powermax30 AIR Service Manual 808850 1116 – Power Supply Component ReplacementCE power cords1. Complete the following procedures:a. Set the power swit

112 Powermax30 AIR Service Manual 8088506 – Power Supply Component Replacement3. Remove the screw that holds the green/yellow ground wire to the heats

Powermax30 AIR Service Manual 808850 1136 – Power Supply Component Replacement4. On the outside of the power supply, loosen the power cord’s strain re

114 Powermax30 AIR Service Manual 8088506 – Power Supply Component ReplacementInstall the power cord and strain reliefCSA power cords1. Are you instal

Powermax30 AIR Service Manual 808850 1156 – Power Supply Component ReplacementCE power cords1. Are you installing a new strain relief? If yes, insert

116 Powermax30 AIR Service Manual 8088506 – Power Supply Component ReplacementReplace the power switchRemove the power switch1. Complete the following

Powermax30 AIR Service Manual 808850 1176 – Power Supply Component ReplacementInstall the power switch1. Press the new power switch into the rear pane

118 Powermax30 AIR Service Manual 8088506 – Power Supply Component ReplacementReplace the control board1. Complete the following procedures:a. Set the

Powermax30 AIR Service Manual 808850 1196 – Power Supply Component ReplacementFigure 404. Turn the system OFF (O). Disconnect the power cord from the

12 Powermax30 AIR Service Manual 808850Contents8 Parts ...

120 Powermax30 AIR Service Manual 8088506 – Power Supply Component Replacement7. Slide the new control board into place, and attach it to the front pa

Powermax30 AIR Service Manual 808850 1216 – Power Supply Component ReplacementReplace the compressor-driver boardRemove the compressor-driver board1.

122 Powermax30 AIR Service Manual 8088506 – Power Supply Component Replacement5. Remove the 2 retaining screws from the left side and right side of t

Powermax30 AIR Service Manual 808850 1236 – Power Supply Component Replacement9. Peel both thermal protection strips off the heatsink. If the ends of

124 Powermax30 AIR Service Manual 8088506 – Power Supply Component ReplacementInstall the compressor-driver board1. Being careful not to scratch the h

Powermax30 AIR Service Manual 808850 1256 – Power Supply Component Replacement5. Place the new compressor-driver board in the power supply. Position t

126 Powermax30 AIR Service Manual 8088506 – Power Supply Component ReplacementReplace the power boardAlthough there are some technical differences bet

Powermax30 AIR Service Manual 808850 1276 – Power Supply Component Replacement4. Remove the connectors at J5, J6, and J9 on the component side of the

128 Powermax30 AIR Service Manual 8088506 – Power Supply Component Replacement6. On the back of the power board, remove the wire connectors for the tr

Powermax30 AIR Service Manual 808850 1296 – Power Supply Component Replacement11 . Being careful not to scratch the heatsink, remove the 2 screws from

Safety and Compliance SC-13Electromagnetic Compatibility (EMC)IntroductionHypertherm’s CE-marked equipment is built in compliance with standard EN6097

130 Powermax30 AIR Service Manual 8088506 – Power Supply Component ReplacementInstall the power boardBefore beginning this procedure, make sure you ha

Powermax30 AIR Service Manual 808850 1316 – Power Supply Component Replacement4. Push the red and white wires on the new power board through the gromm

132 Powermax30 AIR Service Manual 8088506 – Power Supply Component Replacement12. Being careful not to scratch the heatsink, replace the 2 screws and

Powermax30 AIR Service Manual 808850 1336 – Power Supply Component ReplacementReplace the drain hose, gas supply hoses, and 90° fittingThe power suppl

134 Powermax30 AIR Service Manual 8088506 – Power Supply Component ReplacementRemove the drain hose, gas supply hoses, and 90° fitting1. Complete the

Powermax30 AIR Service Manual 808850 1356 – Power Supply Component ReplacementFigure 54The fan and the front panel are hidden in Figure 54 to better

136 Powermax30 AIR Service Manual 8088506 – Power Supply Component ReplacementInstall the drain hose, gas supply hoses, and 90° fitting1. Push one end

Powermax30 AIR Service Manual 808850 1376 – Power Supply Component ReplacementReplace the wire groupThe wire group kit for the power supply includes 3

138 Powermax30 AIR Service Manual 8088506 – Power Supply Component Replacement8. Complete the following procedures:a. See Install the component barrie

Powermax30 AIR Service Manual 808850 1396 – Power Supply Component ReplacementRemove and install the ground clip wire from the center panel to the rea

SC-14 Safety and ComplianceElectromagnetic Compatibility (EMC)Note: The cutting circuit may or may not be earthed for safety reasons. Changing the ear

140 Powermax30 AIR Service Manual 8088506 – Power Supply Component ReplacementRemove and install the ground wire from the heatsink to the magnetics as

Powermax30 AIR Service Manual 808850 1416 – Power Supply Component ReplacementFigure 581321 Ground wire attached to heatsink2 Ground wire attached to

142 Powermax30 AIR Service Manual 8088506 – Power Supply Component ReplacementReplace the solenoid valveRemove the solenoid valve1. Complete the follo

Powermax30 AIR Service Manual 808850 1436 – Power Supply Component ReplacementInstall the solenoid valve1. Orient the new solenoid valve so that the

144 Powermax30 AIR Service Manual 8088506 – Power Supply Component ReplacementReplace the torch lead and strain reliefRemove the torch lead and strain

Powermax30 AIR Service Manual 808850 1456 – Power Supply Component Replacement3. Remove the connector at J12 by pushing the tab on the connector towar

146 Powermax30 AIR Service Manual 8088506 – Power Supply Component Replacement8. On the inside of the front panel, unscrew the retention nut on the t

Powermax30 AIR Service Manual 808850 1476 – Power Supply Component Replacement4. Facing the fan side of the power supply, slide the ring terminal for

148 Powermax30 AIR Service Manual 8088506 – Power Supply Component ReplacementReplace the air filter assemblyRemove the air filter assembly1. Complete

Powermax30 AIR Service Manual 808850 1496 – Power Supply Component ReplacementInstall the air filter assembly1. Orient the new air filter so the arrow

Safety and Compliance SC-15WarrantyAttentionGenuine Hypertherm parts are the factory-recommended replacement parts for your Hypertherm system. Any dam

150 Powermax30 AIR Service Manual 8088506 – Power Supply Component Replacement8. Check for leaks at each fitting and hose connection point on the air

Powermax30 AIR Service Manual 808850 1516 – Power Supply Component ReplacementReplace the air filter bowl and air filter elementRemove the air filter

152 Powermax30 AIR Service Manual 8088506 – Power Supply Component Replacement4. Does the air filter element need to be replaced? If yes, continue w

Powermax30 AIR Service Manual 808850 1536 – Power Supply Component Replacement4. Place the air filter element inside the air filter bowl. Press down

154 Powermax30 AIR Service Manual 8088506 – Power Supply Component Replacement9. Check for leaks and loose connections at each fitting and hose connec

Powermax30 AIR Service Manual 808850 1556 – Power Supply Component ReplacementReplace the fanRemove the fan1. Complete the following procedures:a. Set

156 Powermax30 AIR Service Manual 8088506 – Power Supply Component ReplacementInstall the fan1. Orient the fan so that the red-and-black wires extend

Powermax30 AIR Service Manual 808850 1576 – Power Supply Component ReplacementReplace the heat exchange coilRemove the heat exchange coil1. Complete t

158 Powermax30 AIR Service Manual 8088506 – Power Supply Component ReplacementInstall the heat exchange coil1. Install a new elbow fitting into the l

Powermax30 AIR Service Manual 808850 1596 – Power Supply Component Replacement5. Rotate the coil into the power supply until the top of the coil point

SC-16 Safety and ComplianceWarrantyInsuranceAt all times you will have and maintain insurance in such quantities and types, and with coverage sufficie

160 Powermax30 AIR Service Manual 8088506 – Power Supply Component ReplacementReplace the internal compressorRemove the internal compressor1. Complete

Powermax30 AIR Service Manual 808850 1616 – Power Supply Component Replacement4. Use an 8 mm (5/16 inch) wrench to remove the hex nuts from the 3 reta

162 Powermax30 AIR Service Manual 8088506 – Power Supply Component Replacement6. Hold down the base of the power supply with one hand. With your other

Powermax30 AIR Service Manual 808850 1636 – Power Supply Component ReplacementInstall the internal compressor1. Check the 3 mounting brackets on the n

164 Powermax30 AIR Service Manual 8088506 – Power Supply Component Replacement3. Rotate the internal compressor until it is inside the power supply. S

Powermax30 AIR Service Manual 808850 1656 – Power Supply Component ReplacementReplace the air inlet filter in the internal compressorRemove the air in

166 Powermax30 AIR Service Manual 8088506 – Power Supply Component ReplacementReplace the front panelRemove the front panelUse the following procedure

Powermax30 AIR Service Manual 808850 1676 – Power Supply Component Replacement4. Insert a blade screwdriver into the opening for one of the snaps . Wh

168 Powermax30 AIR Service Manual 8088506 – Power Supply Component Replacement8. Remove the 3 retaining screws from the control board , and lift it o

Powermax30 AIR Service Manual 808850 1696 – Power Supply Component ReplacementReplace the rear panelRemove the rear panelUse the following procedure t

Powermax30 AIR Service Manual 808850 17Section 1SpecificationsSafety informationBefore operating any Hypertherm equipment, read the separate Safety an

170 Powermax30 AIR Service Manual 8088506 – Power Supply Component Replacement5. Insert a blade screwdriver into the opening for one of the snaps . Wh

Powermax30 AIR Service Manual 808850 1716 – Power Supply Component ReplacementInstall the new rear panel1. Install the power cord through the new rear

172 Powermax30 AIR Service Manual 8088506 – Power Supply Component Replacement7. Push the connectors for the 2 white wires that are attached to the po

Powermax30 AIR Service Manual 808850 1736 – Power Supply Component ReplacementReplace the baseRemove the base1. Complete the following procedures:a. S

174 Powermax30 AIR Service Manual 8088506 – Power Supply Component ReplacementFigure 85Install the base1. Position the new base over the metal plate o

Powermax30 AIR Service Manual 808850 1756 – Power Supply Component ReplacementReplace the magnetics assemblyReplacement transformers and inductors (th

176 Powermax30 AIR Service Manual 8088506 – Power Supply Component Replacement3. On the fan side of the power supply, remove the ground wire screw fr

Powermax30 AIR Service Manual 808850 1776 – Power Supply Component Replacement6. Lay the power supply on its side, with the fan side facing up.7. Plac

178 Powermax30 AIR Service Manual 8088506 – Power Supply Component ReplacementInstall the magnetics assembly1. Align the screw holes in the plastic ba

Powermax30 AIR Service Manual 808850 1796 – Power Supply Component Replacement7. On the power board side of the power supply, connect the wires for th

18 Powermax30 AIR Service Manual 8088501 – SpecificationsCSA units ship with a 120 V / 15 A (NEMA 5-15P) adapter and a 240 V / 20 A (NEMA 6-50P) adapt

180 Powermax30 AIR Service Manual 8088506 – Power Supply Component ReplacementReplace the work lead and ground clampRemove and install the work lead1.

Powermax30 AIR Service Manual 808850 1816 – Power Supply Component Replacement4. On the inside of the front panel , remove the strain relief’s retaini

182 Powermax30 AIR Service Manual 8088506 – Power Supply Component ReplacementRemove and install the ground clamp1. Set the power switch to OFF (O), a

Powermax30 AIR Service Manual 808850 1836 – Power Supply Component ReplacementFigure 922341

184 Powermax30 AIR Service Manual 8088506 – Power Supply Component Replacement

Powermax30 AIR Service Manual 808850 185Section 7Torch Component ReplacementWARNING!ELECTRIC SHOCK CAN KILLDisconnect electrical power before performi

186 Powermax30 AIR Service Manual 8088507 – Torch Component ReplacementTorch componentsFigure 931537410111213142698151Right side of the handle2Cap-sen

Powermax30 AIR Service Manual 808850 1877 – Torch Component ReplacementReplace the handleRemove the handleMany repairs require the removal of the hand

188 Powermax30 AIR Service Manual 8088507 – Torch Component ReplacementFigure 946. While holding the spring in place, slide the trigger and spring up

Powermax30 AIR Service Manual 808850 1897 – Torch Component Replacement8. Slide the cap-sensor switch off its mounting post. See Figure 96 and Figure

Powermax30 AIR Service Manual 808850 191 – SpecificationsHypertherm system ratingsRated open circuit voltage (U0)256VDCOutput characteristic* Drooping

190 Powermax30 AIR Service Manual 8088507 – Torch Component ReplacementInstall the handle1. Lay the right side of the handle on a flat surface with th

Powermax30 AIR Service Manual 808850 1917 – Torch Component Replacement9. Install the handle screws.10. Pull the trigger to make sure it is positioned

192 Powermax30 AIR Service Manual 8088507 – Torch Component ReplacementFigure 996. While holding the spring in place, slide the trigger and spring up

Powermax30 AIR Service Manual 808850 1937 – Torch Component ReplacementReplace the torch body1. Complete the following procedures:a. Set the power swi

194 Powermax30 AIR Service Manual 8088507 – Torch Component ReplacementFigure 1015. Thread the new torch body into the torch lead to finger tight plus

Powermax30 AIR Service Manual 808850 1957 – Torch Component ReplacementReplace the start switch1. Complete the following procedures:a. Set the power s

196 Powermax30 AIR Service Manual 8088507 – Torch Component ReplacementReplace the cap-sensor switch1. Complete the following procedures:a. Set the po

Powermax30 AIR Service Manual 808850 1977 – Torch Component ReplacementReplace the torch leadFor details on how to remove an old torch lead from the p

198 Powermax30 AIR Service Manual 8088507 – Torch Component Replacement5. Use 2 wrenches to loosen the gas fitting that attaches the torch body to the

Powermax30 AIR Service Manual 808850 1997 – Torch Component Replacement9. Connect the cap-sensor switch and start switch.Figure 10710. Complete the fo

Powermax and Hypertherm are trademarks of Hypertherm Inc. and may be registered in the United States and other countries. All other trademarks are the

20 Powermax30 AIR Service Manual 8088501 – SpecificationsTorch dimensionsTorch weight Air T30 torch with consumables only: 0.3 kg (0.65 pounds) Air

200 Powermax30 AIR Service Manual 8088507 – Torch Component Replacement

Powermax30 AIR Service Manual 808850 201Section 8PartsUse the part numbers and kit numbers in this section to order consumables, accessories, and repl

202 Powermax30 AIR Service Manual 8088508 – PartsPower supply partsExterior, frontItem Kit number Description228096 Kit: Screws kit (not shown): Scre

Powermax30 AIR Service Manual 808850 2038 – PartsExterior, rearItem Kit number Description1 229133 CSA power cord extension: 240 V / 20 A plug adapter

204 Powermax30 AIR Service Manual 8088508 – PartsInterior, power board sideItem Kit number Description Designator1 428395 Kit: Component barrier2 4284

Powermax30 AIR Service Manual 808850 2058 – PartsInterior, control board and power switchItem Kit number Description Designator1 428404 Kit: Control b

206 Powermax30 AIR Service Manual 8088508 – PartsInterior, fan assemblyItem Kit number Description Designator1 428236 Kit: Fan assembly with plenum M1

Powermax30 AIR Service Manual 808850 2078 – PartsInterior, pneumatics (fan side)Item Kit number Description Designator1 428377 Kit: Internal compresso

208 Powermax30 AIR Service Manual 8088508 – PartsInterior, wiresItem Kit number Description428405 Kit: Wire group:1 Power board (J9) to compressor-dr

Powermax30 AIR Service Manual 808850 2098 – PartsPower supply base and magneticsItem Kit number Description1 428399 Kit: Plastic base (includes rubber

Powermax30 AIR Service Manual 808850 211 – SpecificationsCutting specifications240 VRecommended cut capacity* 8 mm (5/16 inch) at a minimum of 500 mm/

210 Powermax30 AIR Service Manual 8088508 – PartsHand torch partsYou can replace the entire hand torch and lead assembly, or you can replace individua

Powermax30 AIR Service Manual 808850 2118 – PartsHand torch consumablesTo order consumables for your Air T30 torch, use the following part numbers.You

212 Powermax30 AIR Service Manual 8088508 – PartsAccessory partsPart number Description127102 Basic plasma (circle) cutting guide027668 Deluxe plasma

Powermax30 AIR Service Manual 808850 2138 – PartsSafety-critical partsGenuine Hypertherm parts are factory-recommended parts for your Hypertherm syste

214 Powermax30 AIR Service Manual 8088508 – Parts4 428377 Kit: Internal air compressor5 428236 Kit: Fan assembly with plenum6 428375 Kit: Air filter a

Powermax30 AIR Service Manual 808850 2158 – PartsRecommended spare partsHypertherm recommends that service centers keep the following spare parts on h

216 Powermax30 AIR Service Manual 8088508 – PartsPower supply labelsThe label kits include: Consumables label Appropriate warning labels Front and

Powermax30 AIR Service Manual 808850 2178 – PartsCSA warning labelThis warning label is affixed to some power supplies. It is important that the opera

218 Powermax30 AIR Service Manual 8088508 – PartsCE warning labelThis warning label is affixed to some power supplies. It is important that the operat

Powermax30 AIR Service Manual 808850 219Section 9Wiring DiagramsThis section contains the following diagrams: Process flow for troubleshooting intern

22 Powermax30 AIR Service Manual 8088501 – SpecificationsIEC symbolsThe following symbols may appear on the power supply data plate, control labels, s

220 Powermax30 AIR Service Manual 8088509 – Wiring DiagramsProcess flow for troubleshooting internal compressor and temperature fault LEDs9(1$ FRP

Powermax30 AIR Service Manual 808850 2219 – Wiring DiagramsTiming chart for torch startIdleCompressor pressurizes(350 ms)Gas solenoid opens(15 ms)Inve

Powermax30 AIR Service Manual 808850 2229 – Wiring DiagramsPowermax30 AIR schematic013393 Rev ASHEET 1 of 2

Powermax30 AIR Service Manual 808850 2239 – Wiring Diagrams013393 Rev ASHEET 2 of 2

Powermax30 AIR Service Manual 808850 231 – SpecificationsSymbols and marksYour product may have one or more of the following markings on or near the d

24 Powermax30 AIR Service Manual 8088501 – Specifications

Powermax30 AIR Service Manual 808850 25Section 2Power Supply SetupUnpack the plasma system1. Make sure that you received all items on your order in go

26 Powermax30 AIR Service Manual 8088502 – Power Supply SetupSystem contentsThe following illustration shows the components typically included with al

Powermax30 AIR Service Manual 808850 272 – Power Supply SetupPosition the plasma cutting system Position the plasma system near an appropriate power

28 Powermax30 AIR Service Manual 8088502 – Power Supply SetupDetermine the plasma system’s cutting power in watts by multiplying its maximum output am

Powermax30 AIR Service Manual 808850 292 – Power Supply SetupRequirements for groundingProperly ground the system as follows to ensure personal safety

Powermax30 AIRService Manual808850Revision 0EnglishMarch 2015Hypertherm Inc.Hanover, NH 03755 USAwww.hypertherm.com

30 Powermax30 AIR Service Manual 8088502 – Power Supply SetupCE power cordsCE configurations ship without a plug on the power cord. To operate at 230

Powermax30 AIR Service Manual 808850 312 – Power Supply SetupExtension cord recommendationsUse an extension cord of an appropriate wire gauge for the

32 Powermax30 AIR Service Manual 8088502 – Power Supply Setup

Powermax30 AIR Service Manual 808850 33Section 3Torch SetupIntroductionThe Powermax30 AIR includes the Air T30 hand torch. This section explains how t

34 Powermax30 AIR Service Manual 8088503 – Torch SetupConsumable lifeConsumable life varies based on the following factors: Thickness of the metal.

Powermax30 AIR Service Manual 808850 353 – Torch SetupConsumable useThe hand torch ships with a complete set of consumables installed. The consumables

36 Powermax30 AIR Service Manual 8088503 – Torch SetupConsumable setA complete set of consumables includes: Electrode Swirl ring Nozzle Retaining

Powermax30 AIR Service Manual 808850 373 – Torch Setup240V/30A cuttingMetricMaterial thickness (mm) Material Arc current (A)Maximum cut speed (mm/minu

38 Powermax30 AIR Service Manual 8088503 – Torch SetupEnglishMaterial thickness (gauge/inches)Material Arc current (A)Maximum cut speed (inches/minute

Powermax30 AIR Service Manual 808850 393 – Torch Setup120 V / 20 A cuttingMetricMaterial thickness (mm) Material Arc current (A)Maximum cut speed (mm/

Hypertherm Inc.Etna Road, P.O. Box 5010Hanover, NH 03755 USA603-643-3441 Tel (Main Office)603-643-5352 Fax (All Departments)[email protected] (Main

40 Powermax30 AIR Service Manual 8088503 – Torch SetupEnglishMaterial thickness (gauge/inches)Material Arc current (A)Maximum cut speed (inches/minute

Powermax30 AIR Service Manual 808850 41Section 4OperationControls and indicatorsFamiliarize yourself with the controls and LED indicators on the syste

42 Powermax30 AIR Service Manual 8088504 – OperationFront panel controls and indicator LED symbolsPower ON LED (green) – When illuminated, this LED in

Powermax30 AIR Service Manual 808850 434–OperationOperate the plasma systemThe following topics explain how to begin cutting with the plasma system.St

44 Powermax30 AIR Service Manual 8088504 – OperationStep 2 – Connect the electrical powerPlug in the power cord.See also For information on connectin

Powermax30 AIR Service Manual 808850 454–OperationStep 3 – Adjust the output currentThe power ON LED illuminates when the system is powered ON and rea

46 Powermax30 AIR Service Manual 8088504 – OperationStep 4 – Attach the ground clampAttach the ground clamp to the workpiece. Make sure the ground cl

Powermax30 AIR Service Manual 808850 474–OperationStep 6 – Check the indicator LEDsMake sure the green power ON LED on the front of the power supply i

48 Powermax30 AIR Service Manual 8088504 – OperationUnderstand duty-cycle limitationsThe duty cycle is the percentage of time out of 10 minutes that a

Powermax30 AIR Service Manual 808850 494–OperationSystem operation guidelines To achieve the highest level of performance: Operate the system at an

WARNING!READ THE SAFETY INFORMATIONBefore operating or maintaining any Hypertherm equipment, read the Safety and Compliance Manual (80669C) for import

50 Powermax30 AIR Service Manual 8088504 – OperationHand torch operationSafety catch operationThe torch is equipped with a safety catch to prevent acc

Powermax30 AIR Service Manual 808850 514–OperationHand torch cutting guidelines Drag the torch tip lightly on the workpiece to maintain a steady cut

52 Powermax30 AIR Service Manual 8088504 – OperationEdge start on a workpieceWhen cutting material up to 10 mm (3/8 inch) thick, start the torch at th

Powermax30 AIR Service Manual 808850 534–OperationPierce a workpieceWhen cutting material up to 6 mm (1/4 inch) thick, use piercing to cut an interior

54 Powermax30 AIR Service Manual 8088504 – OperationCommon hand-cutting faultsFor more information on faults, see Troubleshooting guide on page 63. T

Powermax30 AIR Service Manual 808850 55Section 5Troubleshooting and System TestsTheory of operationFunctional descriptionAC power enters the system th

56 Powermax30 AIR Service Manual 8088505 – Troubleshooting and System TestsSequence of operationPower OFF (O)• Connect the work lead to the workpiece.

Powermax30 AIR Service Manual 808850 575 – Troubleshooting and System TestsTroubleshooting preparationThe complexity of the circuits requires that ser

58 Powermax30 AIR Service Manual 8088505 – Troubleshooting and System TestsTest equipment Multimeter with a variety of test leads, including test hoo

Powermax30 AIR Service Manual 808850 595 – Troubleshooting and System TestsExternal inspection1. Inspect the exterior of the power supply for damage t

60 Powermax30 AIR Service Manual 8088505 – Troubleshooting and System TestsCheck the power switch1. Set the power switch to OFF (O), disconnect the po

Powermax30 AIR Service Manual 808850 615 – Troubleshooting and System TestsFigure 16. If you do not find any problems during the visual inspection or

62 Powermax30 AIR Service Manual 8088505 – Troubleshooting and System TestsPower supply overviewFigure 2 – Power board side of power supplyWORK LEAD

Powermax30 AIR Service Manual 808850 635 – Troubleshooting and System TestsTroubleshooting guideThis guide provides the most common causes and solutio

64 Powermax30 AIR Service Manual 8088505 – Troubleshooting and System TestsThe power ON LED blinks.Possible cause Possible solution The incoming volt

Powermax30 AIR Service Manual 808850 655 – Troubleshooting and System TestsTemperature LED faultsThe temperature LED illuminates while the machine is

66 Powermax30 AIR Service Manual 8088505 – Troubleshooting and System TestsInternal compressor LED faultsThe internal compressor LED never illuminate

Powermax30 AIR Service Manual 808850 675 – Troubleshooting and System Tests The air inlet filter on the internal compressor is completely clogged.For

68 Powermax30 AIR Service Manual 8088505 – Troubleshooting and System TestsTorch cap LED faultsThe torch cap LED illuminates while the machine is powe

Powermax30 AIR Service Manual 808850 695 – Troubleshooting and System TestsCommon cutting issuesProblem Possible causes Possible solutionsWhen you pul

Powermax30 AIR Service Manual 808850 7Contents Electromagnetic Compatibility (EMC) ...

70 Powermax30 AIR Service Manual 8088505 – Troubleshooting and System TestsThe cut quality is poor, or the cut does not sever the metal.• The consumab

Powermax30 AIR Service Manual 808850 715 – Troubleshooting and System TestsControl board LEDsThe control board (PCB1) is located inside of the front p

72 Powermax30 AIR Service Manual 8088505 – Troubleshooting and System TestsFigure 4During normal operation, the power-ON LED on the front of the power

Powermax30 AIR Service Manual 808850 735 – Troubleshooting and System TestsError LEDThe number of times the Error LED blinks indicates the problem det

74 Powermax30 AIR Service Manual 8088505 – Troubleshooting and System TestsFigure 6 – Back of the power boardWARNING!Voltages of up to 50 VDC continue

Powermax30 AIR Service Manual 808850 755 – Troubleshooting and System TestsFigure 7 – Component side of the power board126915 5 52783410111314121Input

76 Powermax30 AIR Service Manual 8088505 – Troubleshooting and System TestsFigure 8 – Back of the compressor-driver board3211Compressor-driver board2M

Powermax30 AIR Service Manual 808850 775 – Troubleshooting and System TestsFigure 9 – Component side of the compressor-driver board12345111Retaining s

78 Powermax30 AIR Service Manual 8088505 – Troubleshooting and System TestsTest 1 – voltage inputCheck the incoming voltage and the line voltage to th

Powermax30 AIR Service Manual 808850 795 – Troubleshooting and System TestsFigure 106. If the AC voltage is incorrect, make sure you have power to the

8 Powermax30 AIR Service Manual 808850ContentsTorch dimensions ...

80 Powermax30 AIR Service Manual 8088505 – Troubleshooting and System TestsTest 2 – power board voltage checks1. Set the power switch to OFF (O), and

Powermax30 AIR Service Manual 808850 815 – Troubleshooting and System TestsTable 6All values can be ±10%.CAUTION!Do not use -VBUS (W) as ground. Doin

82 Powermax30 AIR Service Manual 8088505 – Troubleshooting and System TestsTest 3 – VBUS and voltage balance on power boardTest the power board (PCB2)

Powermax30 AIR Service Manual 808850 835 – Troubleshooting and System Tests6. Measure the voltage from W to R. See Figure 13.a. Position the test hook

84 Powermax30 AIR Service Manual 8088505 – Troubleshooting and System TestsTest 4 – solenoid valveThis test verifies the proper operation of the solen

Powermax30 AIR Service Manual 808850 855 – Troubleshooting and System TestsTest 5 – torch stuck open or torch stuck closedIf the nozzle and electrode

86 Powermax30 AIR Service Manual 8088505 – Troubleshooting and System Tests5. Turn ON (I) the power. With the system idle, quickly tap the torch trigg

Powermax30 AIR Service Manual 808850 875 – Troubleshooting and System TestsTest 6 – plasma startUse this test to make sure the control board LED is re

88 Powermax30 AIR Service Manual 8088505 – Troubleshooting and System Tests7. Check the resistance at the 2 torch-start test points on the power board

Powermax30 AIR Service Manual 808850 895 – Troubleshooting and System TestsTest 7 – torch cap-sensorTest the torch cap-sensor switch and torch leads.1

Powermax30 AIR Service Manual 808850 9Contents4 Operation ...

90 Powermax30 AIR Service Manual 8088505 – Troubleshooting and System TestsTest 8 – fanTest the fan (M1) for proper operation.1. Set the power switch

Powermax30 AIR Service Manual 808850 915 – Troubleshooting and System TestsTest 9 – internal compressor, compressor-driver board, and power boardIf th

92 Powermax30 AIR Service Manual 8088505 – Troubleshooting and System Tests7. Remove the J2 connector from the compressor-driver board.8. Set the pow

Powermax30 AIR Service Manual 808850 935 – Troubleshooting and System TestsFigure 1914. Push the solenoid valve back into place between both clips fro

94 Powermax30 AIR Service Manual 8088505 – Troubleshooting and System Tests18. Check VBUS on the red and black wires on the J3 connector (pin 1 and pi

Powermax30 AIR Service Manual 808850 955 – Troubleshooting and System TestsTest 9d – Check the power board23. Set the power switch to OFF (O).24. Remo

96 Powermax30 AIR Service Manual 8088505 – Troubleshooting and System Tests

Powermax30 AIR Service Manual 808850 97Section 6Power Supply Component ReplacementWARNING!ELECTRIC SHOCK CAN KILLDisconnect electrical power before pe

98 Powermax30 AIR Service Manual 8088506 – Power Supply Component ReplacementReplace the power supply coverRemove the power supply cover1. Set the pow

Powermax30 AIR Service Manual 808850 996 – Power Supply Component ReplacementInstall the power supply cover1. Being careful not to pinch any wires, sl