Hypertherm POWERMAX 45 Operator's Manual

Welding System

Specifications:

1021/1021644-powermax_45.pdf file (21 Nov 2023)
  • Manufacturer: Hypertherm
  • Category of Device: Welding System
  • Document: POWERMAX 45 Operator's Manual, File Type: PDF
  • Updated: 21-11-2023
  • Count of Pages: 93
Download POWERMAX 45 Manual (93 pages)

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Accompanying Data:

Hypertherm POWERMAX 45 Welding System PDF Operator's Manual (Updated: Tuesday 21st of November 2023 03:13:21 AM)

Rating: 4.9 (rated by 12 users)

Compatible devices: Powermax 30, Powermax125, HyPerformance Plasma HPR800XD, HPR130, SYNC Powermax 65, powermax1250, HyPerformance HPR130XD, Powermax1100.

Recommended Documentation:

Operator's Manual (Text Version):

(Ocr-Read Summary of Contents of some pages of the Hypertherm POWERMAX 45 Document (Main Content), UPD: 21 November 2023)
  • 66, operation 4-8 powermax 45 Operator Manual Start a cut from the edge of the workpiece •   If you fire the torch unnecessarily, you shorten the life  of the nozzle and electrode. •   Pulling, or dragging, the torch along the cut is easier  than pushing it. •   For straight-line cuts, use a straight edge as a guide.  To cut circles, use a template or a radius cutter attachment (a circle cutting g…

  • 2, Register your new Hypertherm system Register your product online at www.hypertherm.com/registration for easier technical and warranty support. You can also receive updates on new Hypertherm products and a free gift as a token of our appreciation. For your records Serial number:________________________________________________________________ Purchase date: _______________________________________________________________ Distributor: _______________________________…

  • 64, Hypertherm POWERMAX 45 operation 4-6 powermax 45 Operator Manual Check the indicator LEDs Verify that the green power ON LED on the front of the power supply is illuminated, that the gas pressure LED shows a green bar in the center of the gauge, and that none of the other LEDs are illuminated or blinking. If the temperature, torch cap sensor, or fault LEDs are illuminated or blinking, or if the power ON LED blinks, correct the fault condition before continuing. See Basic troubleshooting in the Maintenance and Repair section for more i…

  • 73, operation powermax 45 Operator Manual 4-15 Common machine-cutting faults The torch pilot arc will initiate, but will not transfer. Causes can be: •   The work cables connection on the cutting table is not making good contact or the table is not properly grounded. •   The torch-to-work distance is too great. The workpiece is not totally penetrated, and there is excessive sparking on the to…

  • 28, Power suPPly setuP 2-6 powermax 45 Operator Manual Generator recommendations Generators used with the Powermax45 should satisfy the following requirements: CSA •  1-phase, 50/60Hz, 230/240VAC •  3-phase, 50/60Hz, 480VAC CE •  1-phase, 50/60Hz, 230VAC •  3-phase, 50/60Hz, 380/400VAC (400VAC recommended for best performance) Engine driverating Engine drive outputcurrent Perfo…

  • 8, Hypertherm POWERMAX 45 Table of ConTenTs ii powermax 45 Operator Manual Prepare the gas supply .............................................................................................................................................................................2-6 Connect the gas supply .................................................................................................................................................................2-7 Additional gas filtration ..…

  • 89, Parts powermax 45 Operator Manual 6-5 T45v hand torch parts The entire hand torch and lead assembly can be replaced, or individual component parts can be replaced. Part numbers starting with 088 indicate complete torch and lead assemblies. Item Part number Description 088008* T45v hand torch assembly with 6.1m (20ft) lead 088009* T45v hand torch assembly with 15.24m (50ft) lead 1 228313 Kit: T45v torch handle replacement 2 075714 T45v torch handle screws, #4 x 1/2 SLTD Torx PAN, S/B 3 002244…

  • 79, Hypertherm POWERMAX 45 Maintenance and RepaiR powermax 45 Operator Manual 5-5 Problem Solutions The power ON LED is illuminated and the torch cap LED blinks. This indicates either a “torch stuck open” or a “torch stuck closed” situation. •   If the consumables became loose or were removed while the  power supply is ON, turn OFF the power supply, correct the problem and then turn ON the power supply to clear this fault. See Install the consumables in the Torch Setup section. •   If the consumables appear to…

  • 14, W-2 Compliance Information 9/10 WARRANTY Patent indemnity Except only in cases of products not manufactured by Hypertherm or manufactured by a person other than Hypertherm not in strict conformity with Hypertherm’s specifications and in cases of designs, processes, formulae, or combinations not developed or purported to be developed by Hypertherm, Hypertherm will have the right to defend or settle, at its own expense, any suit or proceeding brought against you alleging that the use of the Hypertherm product, alo…

  • 57, Hypertherm POWERMAX 45 torch setup powermax 45 Operator Manual 3-27 Refer to the following table when connecting the Powermax45 to a torch height controller or CNC with a machine interface cable. Signal Type Notes Connector sockets External cable wires Start (start plasma) Input Normally open. 18VDC open circuit voltage at START terminals. Requires dry contact closure to activate. 3, 4 Green, black Transfer (start machine motion) Output Normally open. Dry contact closure when the arc tran…

  • 40, torch setup 3-10 powermax 45 Operator Manual T45m shielded consumables Air flowrate (scfh) Mild steel Hot 320 English Cold 360 Recommended Maximum Arc current (amps) Material thickness Torch- to-work distance (in) Initial pierce height Pierce time delay (sec) Cut Speed (ipm) Voltage (V) Cut Speed (ipm) Voltage (V) 30 0.018 in (26 Ga) 0.06 0.15 in 250% 0.0 360 117 400* 118 0.030 in (22 Ga) 340 116 400* 117 0.036 in (20 Ga) 320 115 400* 117 0.060 i…

  • 69, Hypertherm POWERMAX 45 operation powermax 45 Operator Manual 4-11 3. Maintain an approximate 45° angle to the workpiece as you feed into the gouge. In other words, push the plasma arc in the direction of the gouge you want to create. Keep a small distance between the torch tip and the molten metal to avoid reducing consumable life or damaging the torch. Changing the torch angle changes the dimensions of the gouge. Note: A heat shield is available for added hand and torch protection (220049). You can vary the depth of th…

  • 77, Hypertherm POWERMAX 45 Maintenance and RepaiR powermax 45 Operator Manual 5-3 Inspect the consumables Part Inspect Action Shield or deflector The center hole for roundness. The gap between the shield and the nozzle for accumulated debris. Replace the shield if the hole is no longer round. Remove the shield and clean any material away. Nozzle The center hole for roundness. Replace if the center hole is not round. Replace the nozzle and the electrode together. Electrode The center surface for wear and verify the pit depth. Replace if the surface …

  • 43, torch setup powermax 45 Operator Manual 3-13 T45m shielded consumables Air flowrate (lpm) Aluminum Hot 151 Metric Cold 165.2 Recommended Maximum Arc current (amps) Material thickness (mm) Torch- to-work distance (mm) Initial pierce height Pierce time delay (sec) Cut Speed (mm/min) Voltage (V) Cut Speed (mm/min) Voltage (V) 30 1.2 1.5 3.8 mm 250% 0.0 9150 117 10160* 120 1.5 0.2 8650 118 10160* 121 1.9 5450 118 6860 121 45 1.5 1…

  • 13, Compliance Information W-1 9/10 Attention Genuine Hypertherm parts are the factory- recommended replacement parts for your Hypertherm system. Any damage or injury caused by the use of other than genuine Hypertherm parts may not be covered by the Hypertherm warranty, and will constitute misuse of the Hypertherm Product. You are solely responsible for the safe use of the Product. Hypertherm does not and cannot make any guarantee or warranty regarding the safe use of the product…

  • 22, SpecificationS 1-8 powermax 45 Operator Manual IEC symbols The following symbols may appear on the power supply data plate, control labels, switches, and LEDs. Direct current (DC) Alternating current (AC) Plasma torch cutting Plate metal cutting Expanded metal cutting Gouging AC input power connection The terminal for the external protective (earth) conductor Gas test mode l Power is ON O Power is OFF f 1 f 2 1~ An…

  • 11, Compliance Information EMC-1 7/10 ELECTROMAGNETIC COMPATIBILITY EMC Introduction Hypertherm’s CE-marked equipment is built in compliance with standard EN60974-10. The equipment should be installed and used in accordance with the information below to achieve electromagnetic compatibility. The limits required by EN60974-10 may not be adequate to completely eliminate interference when the affected equipment is in close proximity or has a high degree of sensitivity. In such cases it may be necessary…

  • 38, torch setup 3-8 powermax 45 Operator Manual Choose the consumables (cut charts) WARNING INSTANTON TORCHES PLASMA ARC CAN CAUSE INJURY AND BURNS I O The plasma arc comes on im me di ate ly when the torch trigger is activated. Make sure the power is OFF before changing consumables. A complete set of shielded consumables is shipped with the T45m machine torch. In addition, an ohmic sensing retaining cap is available for use with the T45m shielded consumables. Un…

  • 51, torch setup powermax 45 Operator Manual 3-21 T30v (Powermax30) 30A consumables 220483 Retaining cap 220480 Nozzle 220478 Electrode 220479 Swirl ring 220569 Optional deflector Mild steel Air flowrate (lpm) Metric Hot 131.2 Cold 146.3 Recommended Maximum Arc current (amps) Material thickness (mm) Torch- to-work distance (mm) Initial pierce height Pierce time delay (sec) Cut Speed (mm/min) Voltage (V) Cut Speed (mm…

  • 90, PARTS 6-6 powermax 45 Operator Manual T45v hand torch consumables Part number Description Shielded 220669 Electrode 220670 Swirl ring 220713 Retaining cap 220671 Nozzle 220674 Shield Gouging* 220675 Shield 220672 Nozzle Unshielded* 220717 Deflector 220718 Nozzle * The swirl ring, retaining cap, and electrode for these applications are the same as those for the shielded application. Unshielded consumables for the hand torch are not available in CE-regulated countries. T30v (Powermax30) 30 A consumables Part number Description 220569 Defle…

  • 7, TABLE OF CONTENTS powermax 45 Operator Manual i TABLE OF CONTENTS ELECTROMAGNETIC COMPATIBILITY EMC .......................................................................................................EMC1 WARRANTY ............................................................................................................................................................................W1 SECTION 1 SPEC…

  • 45, Hypertherm POWERMAX 45 torch setup powermax 45 Operator Manual 3-15 T45m unshielded consumables 220713 Retaining cap 220670 Swirl ring 220669 Electrode 220717 Deflector 220718 Nozzle Mild steel Air flowrate (lpm) Metric Hot 151 Cold 165.2 Recommended Maximum Arc current (amps) Material thickness (mm) Torch- to-work distance (mm) Initial pierce height Pierce time delay (sec) Cut Speed (mm/min) Voltage (V) Cut Speed (mm/min) Voltage (V) 30 0.5 2.0 5.0 mm 250% 0.0 9150 118 10160* 114 0.8 8650 118 10160* 116 0.9 8100 117 10160* 120 1.5 0.2 5800 113 …

  • 76, Maintenance and RepaiR 5-2 powermax 45 Operator Manual Perform routine maintenance DANGER ELECTRIC SHOCK CAN KILL Disconnect electrical power before performing any maintenance. Allwork requiring removal of the power supply cover must be performed by a qualified technician. Every use: Check the indicator lights and correct any fault conditions. Inspect the consumables for proper installation and wear. Every 3 months: Replace any damaged labels. Inspect the…

  • 86, PARTS 6-2 powermax 45 Operator Manual Power supply parts 1 2 3 4 5 6 Item Part number Description 1 228269 Kit: Front panel 2 228268 Kit: Rear panel 228270 Kit: Cover screws (not shown) 3 228267 Kit: Powermax45 handle and screws 4 228281 Kit: Power supply cover with labels, 200–240V CSA 228283 Kit: Power supply cover with labels, CE 428076 Kit: Power supply cover with labels (Built in America), 480V CSA 5 228300 Kit: Work lead assembly, 6.1m (20ft) 228307 Kit: Work lead assembly, 15.24m (5…

  • 80, Hypertherm POWERMAX 45 Maintenance and RepaiR 5-6 powermax 45 Operator Manual Repairs DANGER ELECTRIC SHOCK CAN KILL Disconnect electrical power before performing any maintenance. Allwork requiring removal of the power supply cover must be performed by a qualified technician. Remove and replace the cover and Mylar ® barrier The first step in most maintenance and repair procedures for the Powermax45 is removing the cover and the Mylar barrier. To protect your power supply, it is important to …

  • 36, torch setup 3-6 powermax 45 Operator Manual Machine torch setup Before using the T45m, you must: •   Mount the torch on your cutting table or other equipment. •   Choose and install the consumables. •   Align the torch. •   Attach the torch lead to the power supply. •   Set up the power supply for remote starting with either the remote-start pendant or a machine in…

  • 93, Parts powermax 45 Operator Manual 6-9 Powermax45 labels Part number Description 228272 Kit: Powermax45 labels, CE 228264 Kit: Powermax45 labels, 200–240V CSA 428075 Kit: Powermax45 labels (Built in America), 480V CSA The label kits include the consumable label, appropriate safety labels, as well as front and side decals. The consumable and safety labels are pictured below. Data plate Plaque signalètique T45v CONSUMABLE PARTS …

  • 42, torch setup 3-12 powermax 45 Operator Manual T45m shielded consumables Air flowrate (scfh) Stainless steel Hot 320 English Cold 360 Recommended Maximum Arc current (amps) Material thickness Torch- to-work distance (in) Initial pierce height Pierce time delay (sec) Cut Speed (ipm) Voltage (V) Cut Speed (ipm) Voltage (V) 30 0.018 in (26 Ga) 0.06 0.15 in 250% 0.0 360 117 400* 123 0.030 in (22 Ga) 340 116 400* 121 0.036 in (20 Ga) 320 115 400* 119 0.060 in (16 Ga) 0.2 145 111 185 118 45 0.036 in (20 Ga) 0.06 0.15 in…

  • Hypertherm POWERMAX 45 User Manual
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Operating Impressions, Questions and Answers: