Contents
Electromagnetic Compatibility (EMC)
Introduction
Installation and use
Assessment of area
Methods of reducing emissions
Mains supply
Maintenance of cutting equipment
Cutting cables
Equipotential bonding
Earthing of the workpiece
Screening and shielding
Warranty
Attention
General
Patent indemnity
Limitation of liability
National and local codes
Liability cap
Insurance
Transfer of rights
Waterjet product warranty coverage
Product
Parts coverage
Installation and Setup
System contents
What to do if components are missing or damaged
Hypertherm plasma power supply ratings
Cutting specifications
Recommended cut capacity – handheld
Pierce capacity
Maximum cut speeds (mild steel)
Gouge capacity
Noise levels
Position the plasma power supply
Power supply dimensions and weight
Work lead weights
Connect to electrical power
Install a line-disconnect switch
Requirements for grounding
The system’s rated output (cutting power)
Voltage configurations
CSA/CE/CCC 200 V – 240 V (1-phase)
CSA 208 V (1-phase)
CCC 220 V (1-phase)
CE 230 V (1-phase)
CCC 380 V (3-phase)
CE 400 V (3-phase)
CSA 480 V (3-phase)
Decrease output current and arc stretch for lower rated electrical service
Example: 230 V input on 20 A electrical service
Prepare the power cord
CSA systems
1-phase (200 V – 240 V)
3-phase (480 V)
CE/CCC systems
1-phase (200 V – 240 V)
3-phase (380 V / 400 V)
Extension cord recommendations
Generator recommendations
Adapter for 4-wire 1-phase connections (CSA 1-phase models only)
Connect the gas supply
Gas supply source
High-pressure gas cylinders
Gas flow rates
Minimum inlet pressure (while gas is flowing)
Cutting
Maximum control gouging (26 – 45 A)
Precision gouging / Marking (10 – 25 A)
Additional gas filtration
Operation
Controls and indicators
ON (I) / OFF (O) power switch
Cutting controls
Indicator LEDs
Disable the torch
Warning puffs of air
For hand torches
For machine torches
Operate the plasma system
Step 1 – Install consumables and activate torch
Step 2 – Connect torch lead
Step 3 – Connect gas supply
Step 4 – Connect work lead and work clamp
Work lead
Work clamp
Step 5 – Connect electric power and turn ON the system
Step 6 – Set mode and adjust output current (amperage)
Cutting expanded metal
Step 7 – Check cut settings and indicator LEDs
What to expect during and after cutting
Adjust the gas pressure manually
Reset the gas pressure
Change the gas pressure values between psi and bar
Understand duty cycle to prevent overheating
Cut with the Hand Torch
Hand torch components, dimensions, weights
Components
Dimensions
75° hand torch
15° hand torch
Weights
Choose the consumables
Shielded drag-cutting consumables
FineCut consumables
Specialty consumables
HyAccess cutting consumables
FlushCut™ consumables
CopperPlus™ electrode
Consumable life
Prepare to fire the torch
Hand torch cutting guidelines
Start a cut from the edge of the workpiece
Pierce a workpiece
Gouge with the Hand Torch and Machine Torch
Gouging processes
Maximum Control gouging
Maximum Control gouging consumables (26 – 45 A)
Precision gouging
Precision gouging consumables (10 – 25 A)
Specialty consumables
HyAccess gouging consumables
How to control the gouge profile
Gouge with the hand torch
Remove spot welds
Tips
Procedure
Gouge with the machine torch
Typical gouge profiles
Maximum Control gouging consumables (45 A)
Precision gouging consumables (10 A)
Troubleshooting tips for gouging
Set Up the Machine Torch
Machine torch components, dimensions, weights
Components
Dimensions
Weights
Mount the torch
Remove the gear rack
Disassemble the machine torch
Assemble the machine torch
Align the torch
Configure Controls for Mechanized Cutting
Machine torch setup overview
Set up the plasma system and machine torch for mechanized cutting
Connect the remote-start pendant
Connect the machine interface cable
External cables that do not use voltage divider board
External cables that use voltage divider board
External cables for PlasmaCAM® tables
Installation of the machine interface cable
Machine interface pinout
Machine interface cable signals
Set the 5-position voltage divider
Access raw arc voltage
Connect an optional RS-485 serial interface cable
External serial port cables
Remote mode
Cut with the Machine Torch
Choose the consumables
Mechanized shielded consumables
Mechanized shielded consumables with ohmic retaining cap
FineCut shielded consumables with ohmic retaining cap
FineCut unshielded consumables
Consumable life
Understand and optimize cut quality
Cut or bevel angle
Dross
Pierce a workpiece using the machine torch
Pierce delay
Pierce height
Pierce maximum thickness
Cut stainless steel with F5
Guidelines for Marking
Marking consumables (10 – 25 A)
Process gas: air versus argon
How the system handles postflow for marking
Types of marking
Marking samples
Marking, scoring, and dimpling profiles
Marking process guidelines
Cornering guidelines
Marking troubleshooting tips
Common marking problems and solutions
Cut Charts and Marking Charts
Using the cut charts
Troubleshooting Guide
Common cutting issues
Hand cutting issues
Mechanized cutting issues
Check the gas pressure
Check the gas quality
Cold restarts and quick restarts
Perform a cold restart
Perform a quick restart
Fault LEDs and fault codes
Gas Pressure fault LED
Torch Cap fault LED
Generator considerations
Run a gas test
Enter gas test mode
While gas test mode is active
Exit gas test mode
Routine Maintenance
Inspect the system and torch
Every use
Every consumable change or weekly (whichever is more frequent)
Every 3 months
Inspect the consumables
Replace the air filter bowl and filter element
Replacement Parts and Accessories
Plasma supply exterior, front
Plasma supply exterior, rear
Machine interface (CPC) and serial interface upgrade kits
External cables for machine interface port and serial port
75° hand torch replacement parts
15° hand torch replacement parts
Machine torch replacement parts
Accessory parts
Powermax45 XP Labels
Consumable labels and fault codes label
CSA warning label
CE/CCC warning label
Data plate
Symbols and marks
IEC symbols
of 182
Current View
Powermax45 XP®Plasma Arc Cutting SystemOperator Manual809240 | Revision 3 | English
Powermax, Duramax, FastConnect, Smart Sense, HyAccess, FlushCut, CopperPlus, and Hypertherm are trademarks ofHypertherm Inc. and may be registered in the United States and other cou ntries. All other trademarks are the property of their respective holders.Environmental stewardship is one of Hypertherm’s core values, and it is critical to our success and our customers’ success. We are striving to reduce the environmental impact of everything we do. For more information: www.hypertherm.com/environment.© 2018 Hypertherm Inc.Register your new Hypertherm systemBenefits of registration5Safety: Registration allows us to contact you in the unlikely event a safety or quality notification is required.5Education: Registration gives you free access to online product training content via the Hypertherm Cutting Institute.5Confirmation of ownership: Registration can serve as proof of purchase in case of an insurance loss.Go to www.hypertherm.com/registration for easy and fast registration.If you experience any problems with the product registration process, please contact registration@hypertherm.com.For your recordsSerial number: __________________________________________________________________________Purchase date: __________________________________________________________________________Distributor: ___________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________Maintenance notes: __________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________