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TORCH SeTUP

2-6

Duramax Retrofit Torch

Operator Manual

Machine torch setup

Before using either style of machine torch, 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 interface cable.

Consumables

Consumables

Mounting

sleeve

Mounting

sleeve

Coupler

Coupler

Gear rack

Strain relief body

Strain relief body

Strain relief nut

Main strain

relief nut

Strain relief nut

Torch lead

Torch lead

Positioning sleeve

Duramax MRT

Duramax MRT without positioning sleeve (mini torch)

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Summary of Contents for HRT

Page 1: ...Duramax Retrofit Torch HRT HRTs MRT Operator Manual 807190 Revision 1 ...

Page 2: ......

Page 3: ...anover NH USA www hypertherm com email info hypertherm com 2011 Hypertherm Inc All Rights Reserved Hypertherm Powermax and Duramax are trademarks of Hypertherm Inc and may be registered in the United States and or other countries Duramax Retrofit Torch HRT HRTs MRT ...

Page 4: ... Technical Service Hypertherm Shanghai Trading Co Ltd Unit A 5th Floor Careri Building 432 West Huai Hai Road Shanghai 200052 PR China 86 21 5258 3330 1 Tel 86 21 5258 3332 Fax Hypertherm Europe B V Vaartveld 9 4704 SE Roosendaal Nederland 31 165 596907 Tel 31 165 596901 Fax 31 165 596908 Tel Marketing 31 165 596900 Tel Technical Service 00 800 4973 7843 Tel Technical Service Hypertherm Japan Ltd ...

Page 5: ...cases electromagnetic disturbances must be reduced to the point where they are no longer troublesome Assessment of area Before installing the equipment the user shall make an assessment of potential electromagnetic problems in the surrounding area The following shall be taken into account a Other supply cables control cables signalling and telephone cables above below and adjacent to the cutting e...

Page 6: ...ase the risk that the operator could receive a shock by touching these metallic components and the electrode nozzle for laser heads at the same time The operator should be insulated from all such bonded metallic components earthing of workpiece Where the workpiece is not bonded to earth for electrical safety nor connected to earth because of its size and position for ex ample ship s hull or buildi...

Page 7: ...the date of delivery to you This warranty shall not apply to any Powermax brand power supplies that have been used with phase converters In addition Hypertherm does not warranty systems that have been damaged as a result of poor power quality whether from phase converters or incoming line power This warranty shall not apply to any Product which has been incorrectly installed modified or otherwise ...

Page 8: ...to defend shall be conditioned upon Hypertherm s sole control of and the indemnified party s cooperation and assistance in the defense of the claim limitation of liability In no event shall Hypertherm be liable to any person or entity for any incidental consequential direct indirect punitive or exemplary damages including but not limited to lost profits regardless of whether such liability is base...

Page 9: ...est who agrees to be bound by all of the terms and conditions of this Warranty Within thirty 30 days before any such transfer occurs you agree to notify in writing Hypertherm which reserves the right of approval Should you fail timely to notify Hypertherm and seek its approval as set forth herein the Warranty set forth herein shall be null and void and you will have no further recourse against Hyp...

Page 10: ...WARRANTY 9 10 W 4 Compliance Information ...

Page 11: ...l the hand torch consumables 2 5 Machine torch setup 2 6 Converting a Duramax retrofit machine torch into a mini torch 2 7 Mount the torch 2 9 Choose the machine torch consumables 2 12 Machine torch consumables 2 12 Install the machine torch consumables 2 15 Aligning the torch 2 15 Torch installation 2 16 Section 3 Operation Using the cut charts 3 3 Estimated kerf width compensation 3 3 100 amp me...

Page 12: ...1250 1650 3 38 Using the hand torch 3 41 Operate the safety trigger 3 41 Hand torch cutting hints 3 42 Start a cut from the edge of the workpiece 3 43 Pierce a workpiece 3 44 Gouge a workpiece 3 45 Common hand cutting faults 3 48 Using the machine torch 3 49 Ensure the torch and table are set up correctly 3 49 Understand and optimize cut quality 3 49 To pierce a workpiece using the machine torch 3...

Page 13: ...ection 1 Specifications In this section Component weights 1 2 Duramax HRT hand torch dimensions 1 2 Duramax HRTs hand torch dimensions 1 2 Duramax MRT full length machine torch dimensions 1 3 Duramax MRT without positioning sleeve mini torch 1 3 ...

Page 14: ... dimensions 9 9 in 25 2 cm 3 8 in 9 8 cm 75 angle 2 6 in 6 6 cm 1 0 in 2 5 cm Component weights Torch type Weight lbs kg Hand torch 25 ft 7 6 m 7 1 3 2 Hand torch 50 ft 15 m 12 5 5 7 Machine torch 25 ft 7 6 m 7 6 3 4 Machine torch 50 ft 15 m 13 2 6 0 10 2 in 25 9 cm 1 9 in 4 7 cm 15 angle 2 6 in 6 6 cm 1 0 in 2 5 cm ...

Page 15: ...mensions 15 6 in 39 6 cm 1 0 in 2 5 cm 1 4 in 3 6 cm outer dimension 1 3 in 3 3 cm flat sides 12 3 in 31 3 cm 8 1 in 20 6 cm 1 4 in 3 5 cm 1 0 in 2 5 cm 1 4 in 3 6 cm outer dimension 1 3 in 3 3 cm flat sides 1 4 in 3 5 cm Duramax MRT without positioning sleeve mini torch 6 6 in 16 8 cm 3 3 in 8 4 cm ...

Page 16: ...Specifications 1 4 Duramax Retrofit Torch Operator Manual ...

Page 17: ...rch consumables 2 3 Hand torch consumables 2 4 Install the hand torch consumables 2 5 Machine torch setup 2 6 Converting a Duramax retrofit machine torch into a mini torch 2 7 Mount the torch 2 9 Choose the machine torch consumables 2 12 Machine torch consumables 2 12 Install the machine torch consumables 2 15 Aligning the torch 2 15 Torch installation 2 16 ...

Page 18: ...ing cut the more often consumables need to be changed Average length of cut the longer the average cut the more often consumables need to be changed Type of cutting handheld cutting will require more consumable changes than machine cutting Air quality the presence of oil moisture or other contaminants will reduce consumable life Piercing edge starting piercing the metal causes more consumable wear...

Page 19: ...box for handheld torches Consumables for handheld cutting are shown on the next page Notice that the retaining cap and electrode are the same for cutting gouging and FineCut applications Only the shield nozzle and swirl ring are different For the best cut quality on thin materials you may prefer to use FineCut consumables or use a 45 A nozzle and reduce the current setting to 45 amps Consumables C...

Page 20: ...7 Swirl ring 220842 Electrode 220931 Shield 220930 Nozzle Powermax1000 Use 45 65 A consumables Powermax1250 Use 45 85 A consumables Powermax1650 Use 45 100 A consumables 220857 Swirl ring 220994 Swirl ring 220842 Electrode 220941 Nozzle 220819 Nozzle 220816 Nozzle 220990 Nozzle 220854 Retaining cap 220818 Shield 220992 Shield 1 0 0 A 6 5 A 8 5 A 220857 Swirl ring 220994 Swirl ring 220842 Electrode...

Page 21: ...etaining cap nozzle electrode and swirl ring With the power switch in the OFF O position install the torch consumables as shown below Retaining cap Nozzle Electrode Swirl ring Shield warning Instant On Torches PLASMA ARC CAN CAUSE INJURY AND BURNS 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 ...

Page 22: ...h 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 interface cable Consumables Consumables Mounting sleeve Mounting sleeve Coupler Coupler Gear rack Strain relief body Strain relief body Strain relief nut Main strain relief nut Strain relief nut Torch lead Torch lead Positioning sleeve Duramax MRT Duramax MRT wi...

Page 23: ...connecting and reconnecting the torch parts maintain the same orientation between the torch head and torch lead Twisting the torch head in relation to the torch lead can cause damage 1 Disconnect the torch lead from the power supply and remove the consumables from the torch 2 Unscrew the strain relief body from the strain relief nut and slide the strain relief body back along the torch lead 3 Unsc...

Page 24: ...ad 12 Reconnect the gas line to the torch lead 13 Reattach the torch s pilot wire to the torch body using the screw 14 Reconnect the cap sensor switch s wire connector 15 Slide the mounting sleeve over the front of the torch body Align the slot on the front of the mounting sleeve next to one of the three screw holes with the cap sensor plunger on the torch body 16 Attach the mounting sleeve to the...

Page 25: ...e and reassemble the torch refer to the figures in the section Machine torch setup on page 2 6 and follow these instructions Note While disconnecting and reconnecting the torch parts maintain the same orientation between the torch head and torch lead Twisting the torch head in relation to the torch lead can cause damage 1 Disconnect the torch lead from the power supply and remove the consumables f...

Page 26: ...e gas line on the torch lead with tape to keep dirt and other contaminants from getting in the gas line when you route the lead through the track 10 Slide the coupler positioning sleeve full length machine torch strain relief nut and strain relief body off the front of the torch lead 11 If you do not need the gear rack on a full length machine torch slide the gear rack from the positioning sleeve ...

Page 27: ... Reconnect the cap sensor switch s wire connector 19 Slide the mounting sleeve over the front of the torch body Align the slot on the front of the mounting sleeve next to one of the three screw holes with the cap sensor plunger on the torch body 20 Attach the mounting sleeve to the torch body using the three screws 21 Screw the coupler into the mounting sleeve 22 If you are mounting a full length ...

Page 28: ...ch the metal when cutting With unshielded consumables you must keep the torch a small distance about 08 inch 2 mm away from the metal Unshielded consumables generally have a shorter life than shielded consumables Machine torch consumables Mechanized shielded consumables Powermax1000 1250 1650 65 A 45 A 85 A 1 0 0 A 220817 Shield 220993 Shield 220854 Retaining cap 220941 Nozzle 220819 Nozzle 220816...

Page 29: ...0 220941 Nozzle 220819 Nozzle 220816 Nozzle Mechanized unshielded consumables Powermax1000 1250 1650 220857 Swirl ring 220990 Nozzle 220817 Shield 65 A 45 A 85 A 1 0 0 A 220994 Swirl ring 220857 Swirl ring 220842 Electrode 220941 Nozzle 220819 Nozzle 220816 Nozzle 220990 Nozzle 220854 Retaining cap 220955 Deflector Powermax1000 Use 45 65 A consumables Powermax1250 Use 45 85 A consumables Powermax1...

Page 30: ...000 1250 1650 FineCut shielded consumables Powermax1000 1250 1650 220854 Retaining cap 220953 Retaining cap 220857 Swirl ring 220857 Swirl ring 220842 Electrode 220842 Electrode 220955 Deflector 220948 Shield 220930 Nozzle 220930 Nozzle Powermax1000 Use 45 65 A consumables Powermax1250 Use 45 85 A consumables Powermax1650 Use 45 100 A consumables 220857 Swirl ring 220994 Swirl ring 220797 Nozzle 2...

Page 31: ...e machine torch consumables in a manner similar to the hand torch consumables Refer to Install the hand torch consumables on page 2 5 WARNING INSTANT ON TORCHES PLASMA ARC CAN CAUSE INJURY AND BURNS The plasma arc comes on im me di ate ly when the torch is activated Make sure the power is OFF before changing the consumables Aligning the torch Mount the machine torch perpendicular to the workpiece ...

Page 32: ...al Torch installation 1 Turn OFF the power 2 Remove the power cord from the power receptacle 3 Open the Easy Torch Removal ETR door and route the lead through the end cap _ 4 0 5 0 50 60 AC 70 80 V BAR 6 0 PSI AMPS 30 40 100 80 60 OFF ON ETR door End cap ...

Page 33: ... the quick release collar and insert the lead s gas fitting 6 Slide the quick release collar forward to lock the gas fitting in place Make sure that the gas fitting is secure 7 Make sure that the red dot on the connector is on top then plug in the electrical connector Close the ETR door Quick release collar ...

Page 34: ...Torch setup 2 18 Duramax Retrofit Torch Operator Manual ...

Page 35: ...or Powermax1000 1250 1650 3 18 45 amp mechanized shielded cutting for Powermax1000 1250 1650 3 20 100 amp mechanized unshielded cutting for Powermax1650 3 24 85 amp mechanized unshielded cutting for Powermax1650 3 26 65 amp mechanized unshielded cutting for Powermax1250 1650 3 30 45 amp mechanized unshielded cutting for Powermax1000 1250 1650 3 34 FineCut consumables for Powermax1000 1250 1650 3 3...

Page 36: ... Torch Operator Manual Using the machine torch 3 49 Ensure the torch and table are set up correctly 3 49 Understand and optimize cut quality 3 49 To pierce a workpiece using the machine torch 3 52 Common machine cutting faults 3 52 ...

Page 37: ...ear and the voltage setting should be increased to maintain the correct Torch to Work Distance Note Hypertherm collected the data under laboratory test conditions using new consumables Estimated kerf width compensation The widths in the tables on the following two pages are for reference The data is obtained with the Best Quality settings Differences between installations and material composition ...

Page 38: ... 85 A Shielded 1 6 1 8 1 9 2 1 2 3 2 4 2 5 80 A Shielded 1 7 1 7 1 8 1 8 1 9 2 1 2 2 65 A Shielded 1 4 1 5 1 8 1 9 2 0 2 2 2 4 60 A Shielded 1 5 1 5 1 6 1 7 1 8 1 8 2 0 45 A Shielded 0 9 1 1 1 5 1 6 1 8 FineCut 0 6 0 6 1 4 1 5 85 A Unshielded 1 7 1 7 1 8 1 9 2 1 2 2 2 4 65 A Unshielded 1 6 1 6 1 8 1 8 1 9 2 0 45 A Unshielded 0 5 1 0 1 3 1 5 1 5 Aluminum 100 A Shielded 2 1 2 1 2 1 2 1 2 1 2 3 85 A ...

Page 39: ...3 0 078 0 090 0 095 0 100 80 A Shielded 0 066 0 072 0 077 0 082 0 088 65 A Shielded 0 062 0 065 0 068 0 070 0 076 0 088 0 090 0 091 60 A Shielded 0 065 0 069 0 073 0 080 0 088 45 A Shielded 0 035 0 054 0 055 0 061 0 065 0 066 FineCut 0 024 0 043 0 049 0 051 85 A Unshielded 0 070 0 073 0 075 0 080 0 085 0 090 65 A Unshielded 0 062 0 064 0 066 0 068 0 075 0 081 45 A Unshielded 0 020 0 050 0 051 0 05...

Page 40: ...220842 Electrode 220842 Electrode 220953 Ohmic sensing retaining cap 220990 Nozzle 220990 Nozzle Recommended cut speeds are a good starting point for finding the best quality cut best angle least dross and best cut surface finish Adjust the speed for your application and table to obtain the desired cut quality Maximum cut speeds are the fastest speeds possible to cut material without regard to cut...

Page 41: ...ed in mm ipm mm min ipm mm min 100 154 0 5 1 4 6 4 164 4165 253 6426 157 0 5 3 8 9 5 92 2336 142 3606 160 1 0 1 2 12 7 70 1778 108 2743 161 1 0 5 8 15 9 50 1270 77 1955 162 1 5 3 4 19 0 33 838 57 1447 165 NA 1 25 4 21 533 33 838 Mild steel Stainless steel Aluminum Arc current Arc voltage Pierce delay Material thickness Recommended cut speed Maximum cut speed in mm ipm mm min ipm mm min 100 154 0 5...

Page 42: ... 220816 Nozzle 220816 Nozzle 85 A 85 A Best Quality Settings cut speed and voltage Settings that provide the starting point for finding the best cut quality best angle least dross best cut surface finish Adjust the speed for your application and table to obtain the desired result Production Settings cut speed and voltage 80 of the maximum speed ratings These speeds result in the greatest number of...

Page 43: ...8 12 4 5 300 0 7 1280 130 1600 130 16 1 0 870 134 930 133 20 6 0 400 1 5 570 137 680 136 25 Edge Start 350 142 450 141 30 200 146 300 144 English Material Thickness Torch to Work Distance Initial Pierce Height Pierce Delay Time Best Quality Settings Production Settings Cut Speed Voltage Cut Speed Voltage in in in seconds ipm Volts ipm Volts 10 GA 0 06 0 15 250 0 0 250 122 336 121 3 16 0 2 185 123 ...

Page 44: ...00 122 8 2450 124 3050 124 10 4 5 300 1550 127 1900 126 12 0 7 1100 131 1400 130 16 1 0 700 135 760 134 20 Edge Start 480 138 570 137 25 300 143 370 141 English Material Thickness Torch to Work Distance Initial Pierce Height Pierce Delay Time Best Quality Settings Production Settings Cut Speed Voltage Cut Speed Voltage in in in seconds ipm Volts ipm Volts 10 GA 0 06 0 15 250 0 2 275 122 336 120 3 ...

Page 45: ... 126 4900 126 8 2650 130 3470 129 10 4 5 300 1920 132 2500 131 12 0 7 1450 134 1930 133 16 1 0 950 139 1200 137 20 Edge Start 600 143 880 141 25 380 146 540 144 English Material Thickness Torch to Work Distance Initial Pierce Height Pierce Delay Time Best Quality Settings Production Settings Cut Speed Voltage Cut Speed Voltage in in in seconds ipm Volts ipm Volts 1 8 0 06 0 15 250 0 2 300 122 360 ...

Page 46: ...ctrode 220842 Electrode 220953 Ohmic sensing retaining cap 220816 Nozzle 220816 Nozzle 85 A 85 A Recommended cut speeds are a good starting point for finding the best quality cut best angle least dross and best cut surface finish Adjust the speed for your application and table to obtain the desired cut quality Maximum cut speeds are the fastest speeds possible to cut material without regard to cut...

Page 47: ...s Recommended cut speed Maximum cut speed in mm ipm mm min ipm mm min 80 134 0 25 3 16 4 8 140 3556 216 5486 136 0 50 1 4 6 4 103 2616 158 4013 139 0 75 3 8 9 5 54 1372 83 2108 142 1 2 12 7 33 838 50 1270 145 1 0 5 8 15 9 22 559 34 864 150 N A 3 4 19 0 16 406 24 610 153 1 25 4 9 229 14 356 Arc current Arc voltage Pierce delay Material thickness Recommended cut speed Maximum cut speed in mm ipm mm ...

Page 48: ...953 Ohmic sensing retaining cap 65 A 65 A Best Quality Settings cut speed and voltage Settings that provide the starting point for finding the best cut quality best angle least dross best cut surface finish Adjust the speed for your application and table to obtain the desired result Production Settings cut speed and voltage 80 of the maximum speed ratings These speeds result in the greatest number...

Page 49: ...2230 128 10 4 5 300 0 7 1100 131 1500 129 12 1 2 850 134 1140 131 16 6 0 400 2 0 560 138 650 136 20 Edge Start 350 142 450 142 25 210 145 270 145 English Material Thickness Torch to Work Distance Initial Pierce Height Pierce Delay Time Best Quality Settings Production Settings Cut Speed Voltage Cut Speed Voltage in in in seconds ipm Volts ipm Volts 16 GA 0 06 0 15 250 0 1 260 123 294 121 10 GA 190...

Page 50: ...25 6150 124 6 2450 126 2850 126 8 0 7 1500 129 1860 129 10 4 5 300 960 132 1250 132 12 1 2 750 135 920 134 16 Edge Start 500 139 500 139 20 300 143 370 143 English Material Thickness Torch to Work Distance Initial Pierce Height Pierce Delay Time Best Quality Settings Production Settings Cut Speed Voltage Cut Speed Voltage in in in seconds ipm Volts ipm Volts 16 GA 0 06 0 15 250 0 1 345 124 426 121...

Page 51: ...5 6000 126 7350 125 6 3200 130 4400 128 8 0 7 1950 133 2750 130 10 4 5 300 1200 136 1650 132 12 1 2 1000 138 1330 136 16 Edge Start 650 143 800 141 20 380 147 560 145 English Material Thickness Torch to Work Distance Initial Pierce Height Pierce Delay Time Best Quality Settings Production Settings Cut Speed Voltage Cut Speed Voltage in in in seconds ipm Volts ipm Volts 1 16 0 06 0 15 250 0 1 365 1...

Page 52: ...g 220857 Swirl ring 220842 Electrode 220842 Electrode 220953 Ohmic sensing retaining cap 65 A 65 A Recommended cut speeds are a good starting point for finding the best quality cut best angle least dross and best cut surface finish Adjust the speed for your application and table to obtain the desired cut quality Maximum cut speeds are the fastest speeds possible to cut material without regard to c...

Page 53: ... in mm ipm mm min ipm mm min 60 135 0 1 16 1 6 433 10995 666 16916 138 0 25 1 8 3 2 260 6604 400 10160 141 1 4 6 4 94 2388 145 3683 146 0 75 3 8 9 5 48 1219 74 1880 149 1 50 1 2 12 7 30 762 51 1295 153 5 8 15 9 21 545 33 838 Mild steel Stainless steel Aluminum Arc current Arc voltage Pierce delay Material thickness Recommended cut speed Maximum cut speed in mm ipm mm min ipm mm min 60 134 0 16 Ga ...

Page 54: ...ode 220953 Ohmic sensing retaining cap 45 A Best Quality Settings cut speed and voltage Settings that provide the starting point for finding the best cut quality best angle least dross best cut surface finish Adjust the speed for your application and table to obtain the desired result Production Settings cut speed and voltage 80 of the maximum speed ratings These speeds result in the greatest numb...

Page 55: ...9000 130 10200 129 2 0 3 6600 130 7800 129 3 0 4 3850 133 4900 131 4 2200 134 3560 131 6 0 5 1350 137 2050 132 English Material Thickness Torch to Work Distance Initial Pierce Height Pierce Delay Time Best Quality Settings Production Settings Cut Speed Voltage Cut Speed Voltage in in in seconds ipm Volts ipm Volts 26 GA 0 02 0 08 400 0 0 350 128 500 128 22 GA 350 128 450 128 18 GA 0 1 350 129 400 ...

Page 56: ... 1 9000 130 10200 130 2 0 3 6000 132 8660 131 3 0 4 3100 132 4400 132 4 2000 134 2600 134 6 0 5 900 140 1020 139 English Material Thickness Torch to Work Distance Initial Pierce Height Pierce Delay Time Best Quality Settings Production Settings Cut Speed Voltage Cut Speed Voltage in in in seconds ipm Volts ipm Volts 26 GA 0 02 0 08 400 0 0 350 130 500 129 22 GA 350 130 450 129 18 GA 0 1 350 130 40...

Page 57: ...n Volts 1 1 5 3 8 250 0 0 8250 136 11000 136 2 0 1 6600 136 9200 135 3 0 2 3100 139 6250 134 4 0 4 2200 141 4850 135 6 0 5 1500 142 2800 137 English Material Thickness Torch to Work Distance Initial Pierce Height Pierce Delay Time Best Quality Settings Production Settings Cut Speed Voltage Cut Speed Voltage in in in seconds ipm Volts ipm Volts 1 32 0 06 0 15 250 0 0 325 136 450 136 1 16 0 1 325 13...

Page 58: ... for finding the best quality cut best angle least dross and best cut surface finish Adjust the speed for your application and table to obtain the desired cut quality Maximum cut speeds are the fastest speeds possible to cut material without regard to cut quality 1 0 0 A 220854 Retaining cap 220994 Swirl ring 220842 Electrode 220990 Nozzle 220955 Deflector ...

Page 59: ...rrent Arc voltage Pierce delay Material thickness Recommended cut speed Maximum cut speed in mm ipm mm min ipm mm min 100 137 0 5 1 4 6 4 166 4216 255 6477 139 0 5 3 8 9 5 99 2514 153 3886 142 1 0 1 2 12 7 70 1778 107 2717 147 1 0 5 8 15 9 50 1270 77 1955 150 1 5 3 4 19 0 33 838 51 1295 154 NA 1 25 4 20 508 31 787 Mild steel Stainless steel Aluminum Arc current Arc voltage Pierce delay Material th...

Page 60: ...ttings cut speed and voltage Settings that provide the starting point for finding the best cut quality best angle least dross best cut surface finish Adjust the speed for your application and table to obtain the desired result Production Settings cut speed and voltage 80 of the maximum speed ratings These speeds result in the greatest number of cut parts but not necessarily the best possible cut q...

Page 61: ...00 119 8 2400 121 3100 121 10 1560 123 2070 122 12 6 0 300 0 7 1200 126 1600 124 16 Edge Start 820 132 930 128 20 540 137 640 132 25 320 143 400 137 English Material Thickness Torch to Work Distance Initial Pierce Height Pierce Delay Time Best Quality Settings Production Settings Cut Speed Voltage Cut Speed Voltage in in in seconds ipm Volts ipm Volts 14 GA 0 08 0 20 250 0 1 280 117 416 116 10 GA ...

Page 62: ...800 118 6 0 5 3400 120 4570 121 8 2250 121 2970 122 10 6 0 300 0 5 1430 123 1840 124 12 0 7 1000 129 1340 128 16 Edge Start 650 134 730 133 20 360 138 570 137 English Material Thickness Torch to Work Distance Initial Pierce Height Pierce Delay Time Best Quality Settings Production Settings Cut Speed Voltage Cut Speed Voltage in in in seconds ipm Volts ipm Volts 14 GA 0 08 0 20 250 0 1 340 117 452 ...

Page 63: ...6000 122 8100 120 6 0 5 3300 125 4930 122 8 2350 127 3250 124 10 6 0 300 0 5 1800 128 2140 127 12 0 7 1300 133 1720 130 16 Edge Start 840 139 1130 134 20 470 144 700 138 English Material Thickness Torch to Work Distance Initial Pierce Height Pierce Delay Time Best Quality Settings Production Settings Cut Speed Voltage Cut Speed Voltage in in in seconds ipm Volts ipm Volts 1 8 0 08 0 20 250 0 2 280...

Page 64: ... Settings cut speed and voltage Settings that provide the starting point for finding the best cut quality best angle least dross best cut surface finish Adjust the speed for your application and table to obtain the desired result Production Settings cut speed and voltage 80 of the maximum speed ratings These speeds result in the greatest number of cut parts but not necessarily the best possible cu...

Page 65: ...118 5250 118 6 2550 120 3560 120 8 1620 123 2230 121 10 6 0 300 0 7 970 127 1500 122 12 Edge Start 760 129 1140 124 16 500 134 650 129 20 280 138 400 133 English Material Thickness Torch to Work Distance Initial Pierce Height Pierce Delay Time Best Quality Settings Production Settings Cut Speed Voltage Cut Speed Voltage in in in seconds ipm Volts ipm Volts 16 GA 0 08 0 20 250 0 1 255 116 308 117 1...

Page 66: ...8500 117 4 0 5 5050 119 6500 119 6 2300 121 3070 121 8 0 7 1400 123 1900 122 10 6 0 300 0 7 920 126 1250 123 12 Edge Start 710 130 925 127 16 430 135 500 133 English Material Thickness Torch to Work Distance Initial Pierce Height Pierce Delay Time Best Quality Settings Production Settings Cut Speed Voltage Cut Speed Voltage in in in seconds ipm Volts ipm Volts 16 GA 0 08 0 20 250 0 1 340 116 437 1...

Page 67: ...00 123 4 0 5 5400 125 7640 124 6 3000 127 3900 126 8 0 7 1800 130 2460 127 10 6 0 300 0 7 1100 133 1640 129 12 Edge Start 900 135 1250 133 16 600 139 700 136 English Material Thickness Torch to Work Distance Initial Pierce Height Pierce Delay Time Best Quality Settings Production Settings Cut Speed Voltage Cut Speed Voltage in in in seconds ipm Volts ipm Volts 1 16 0 08 0 20 250 0 1 325 122 476 12...

Page 68: ...ty Settings cut speed and voltage Settings that provide the starting point for finding the best cut quality best angle least dross best cut surface finish Adjust the speed for your application and table to obtain the desired result Production Settings cut speed and voltage 80 of the maximum speed ratings These speeds result in the greatest number of cut parts but not necessarily the best possible ...

Page 69: ...1 5 0 1 7700 120 10200 121 2 0 3 6150 119 7800 122 3 0 4 3950 121 4900 123 4 2350 123 3560 124 6 0 5 1400 126 2050 124 English Material Thickness Torch to Work Distance Initial Pierce Height Pierce Delay Time Best Quality Settings Production Settings Cut Speed Voltage Cut Speed Voltage in in in seconds ipm Volts ipm Volts 26 GA 0 06 0 15 250 0 0 350 120 500 120 22 GA 350 120 450 120 18 GA 0 1 350 ...

Page 70: ...0 1 9000 121 10200 120 2 0 3 6000 122 9600 120 3 0 4 3250 123 4750 120 4 1900 128 3000 122 6 0 5 700 130 1450 124 English Material Thickness Torch to Work Distance Initial Pierce Height Pierce Delay Time Best Quality Settings Production Settings Cut Speed Voltage Cut Speed Voltage in in in seconds ipm Volts ipm Volts 26 GA 0 02 0 08 400 0 0 350 120 500 119 22 GA 350 120 450 119 18 GA 0 1 350 118 4...

Page 71: ...in Volts 1 1 5 3 8 250 0 0 7400 126 11000 121 2 0 1 4400 127 9200 123 3 0 2 2800 129 6250 125 4 0 4 2100 132 4700 126 6 0 5 1050 135 2250 127 English Material Thickness Torch to Work Distance Initial Pierce Height Pierce Delay Time Best Quality Settings Production Settings Cut Speed Voltage Cut Speed Voltage in in in seconds ipm Volts ipm Volts 1 32 0 06 0 15 250 0 0 325 126 450 121 1 16 0 1 200 1...

Page 72: ...harts in this section apply to both shielded and unshielded consumables 220854 Retaining cap 220857 Swirl ring 220842 Electrode 220955 Deflector 220930 Nozzle Best Quality Settings cut speed and voltage Settings that provide the starting point for finding the best cut quality best angle least dross best cut surface finish Adjust the speed for your application and table to obtain the desired result...

Page 73: ... 40 1 5 3 8 250 0 0 8250 78 0 6 8250 78 0 8 0 1 8250 78 1 45 0 2 8250 78 1 5 0 4 6400 78 2 5250 82 3 0 5 2750 83 4 0 6 1900 84 English Material Thickness Amps Torch to Work Distance Initial Pierce Height Pierce Delay Time Best Quality Settings Cut Speed Voltage A in in seconds ipm Volts 26 GA 40 0 06 0 15 250 0 0 325 78 24 GA 325 78 22 GA 0 1 325 78 20 GA 325 78 18 GA 45 0 2 325 78 16 GA 0 4 250 7...

Page 74: ...5 40 0 5 2 0 400 0 0 8250 68 0 6 8250 68 0 8 0 1 8250 68 1 45 0 2 8250 68 1 5 0 4 6150 70 2 4800 71 3 0 5 2550 81 4 0 6 1050 84 English Material Thickness Amps Torch to Work Distance Initial Pierce Height Pierce Delay Time Best Quality Settings Cut Speed Voltage A in in seconds ipm Volts 26 GA 40 0 02 0 08 400 0 0 325 68 24 GA 325 68 22 GA 0 1 325 68 20 GA 325 68 18 GA 45 0 2 325 68 16 GA 0 4 240 ...

Page 75: ...head and press the red torch trigger as show below Using the hand torch WARNING Instant On Torches PLASMA ARC CAN CAUSE INJURY AND BURNS Plasma arc comes on im me di ate ly when the torch trigger is activated The plasma arc will cut quickly through gloves and skin Wear correct and appropriate protective equipment Keep away from the torch tip Do not hold the workpiece and keep your hands clear of t...

Page 76: ... you fire the torch unnecessarily you will shorten the life of the nozzle and electrode Pulling or dragging the torch along the cut is easier than pushing the torch 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 guide See Section 4 Maintenance and Parts for part numbers for the Hypertherm plasma cutting guides for ...

Page 77: ...amp attached to the workpiece hold the torch nozzle perpendicular 90 to the edge of the workpiece 2 Press the torch s trigger to start the arc Pause at the edge until the arc has cut completely through the workpiece 3 Drag the torch tip lightly across the workpiece to proceed with the cut Maintain a steady even pace ...

Page 78: ...angle to the workpiece Slowly rotate the torch to a perpendicular 90 position 3 Hold the torch in place while continuing to press the trigger When sparks exit below the workpiece the arc has pierced the material 4 When the pierce is complete drag the nozzle lightly along the workpiece to proceed with the cut WARNING SPARKS AND HOT METAL CAN INJURE EYES AND BURN SKIN When firing the torch at an ang...

Page 79: ...k piece 3 Maintain an approximate 45 angle to the workpiece as you feed into the gouge 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 s angle changes the dimensions of the gouge Di rec tion of travel 45 WARNING SPARKS AND HOT METAL CAN IN...

Page 80: ...ece and varying the current output of the power supply Angle Speed Standoff Typical Gouge Profile for 60A 65A Operation Typical Gouge Profile for 80A 85A Operation Width 0 26 in 6 6 mm Width 0 28 in 7 1 mm Depth 0 14 in 3 6 mm Depth 0 24 in 6 1 mm Operating parameters Speed 20 25 ipm 50 8 63 5 cm min Standoff 1 4 3 8 in 6 4 9 5 mm Angle 35 40 Operating parameters Speed 20 25 ipm 50 8 63 5 cm min S...

Page 81: ...he standoff of the torch will decrease width and increase depth Increasing the angle of the torch more vertical will decrease width and increase depth Decreasing the angle of the torch less vertical will increase width and decrease depth Increasing the current of the power supply will increase width and increase depth Decreasing the current of the power supply will decrease width and decrease dept...

Page 82: ...mables The work clamp is not attached properly to the workpiece The gas pressure or gas flow rate is too low Cut quality is poor The causes can be The metal being cut is too thick for the amperage The wrong consumables are being used gouging consumables are installed instead of drag cutting consumables for example You are moving the torch too quickly or too slowly The arc sputters and consumables ...

Page 83: ...ting table s rails and drive system Unsteady machine motion can cause a regular wavy pattern on the cut surface Ensure that the torch does not touch the workpiece during cutting Contact with the workpiece can damage the shield and nozzle and affect the cut surface Understand and optimize cut quality There are several factors to consider in cut quality Cut angle The degree of angularity of the cut ...

Page 84: ...o work distance especially if the cut angles are all positive or all negative Also consider the material being cut if the metal is magnetized or hardened you are more likely to experience cut angle problems Dross Some amount of dross will always be present when cutting with air plasma However you can minimize the amount and type of dross by adjusting your system correctly for your application Exce...

Page 85: ...duces the least dross As the workpiece heats up more dross can accumulate on subsequent cuts Worn or damaged consumables may produce excess dross Straightness of the cut surface A typical plasma cut surface is slightly concave The cut surface may become more concave or convex Correct torch height is required to keep the cut surface acceptably close to straight Worn consumables also affect the stra...

Page 86: ...cut Common machine cutting faults The torch s pilot arc will initiate but will not transfer Causes can be The work cable is not making good contact with the cutting table or the cutting table is not making good contact with the workpiece The torch to work distance is too large The workpiece is not totally penetrated and there is excessive sparking on the top of the workpiece Causes can be The cons...

Page 87: ...chanized application replace the nozzle and the electrode together The direction of the torch travel is incorrect The high quality cut is always on the right with respect to the forward motion of the torch The distance between the torch and the workpiece is not correct The cutting speed is not correct See Using the cut charts on page 3 3 for more information The consumables life is shortened Cause...

Page 88: ...OPERATION 3 54 Duramax Retrofit Torch Operator Manual ...

Page 89: ...rch Operator Manual 4 1 Section 4 Maintenance and parts In this section Perform routine maintenance 4 2 Inspect the consumables 4 3 Hand torch replacement parts 4 4 Machine torch replacement parts 4 6 Accessory parts 4 7 ...

Page 90: ... of the power supply with compressed air or a vacuum Replace any damaged labels Inspect the consumables for proper installation and wear Inspect the trigger for damage Inspect the torch body for cracks and exposed wires Replace any damaged parts Every 6 months Every 3 months Or AC V DANGER ELECTRIC SHOCK CAN KILL Disconnect the electrical power before you perform any maintenance All work that requ...

Page 91: ... hole is not round Electrode Replace electrode if the surface is worn or the pit depth is greater than 1 16 inch 1 6 mm deep Swirl ring The surface inside the swirl ring for damage or wear and the gas holes for blockages Replace swirl ring if the surface is damaged or worn or any of the gas holes are blocked Torch o ring The surface for damage wear or a lack of lubrication If the o ring is dry lub...

Page 92: ...itch replacement 228721 Kit H65 H85 H65s H85s HRT HRTs Safety trigger with spring replacement 228784 Kit HRT HRTs Torch lead replacement 25 ft 7 6 m 228785 Kit HRT HRTs Torch lead replacement 50 ft 15 2 m 228788 Kit HRT Hand torch assembly with 25 ft 7 6 m lead 228789 Kit HRT Hand torch assembly with 50 ft 15 2 m lead 228792 Kit HRT Torch main body replacement The entire hand torch and lead assemb...

Page 93: ...ment 228721 Kit H65 H85 H65s H85s HRT HRTs Safety trigger with spring replacement 228784 Kit HRT HRTs Torch lead replacement 25 ft 7 6 m 228785 Kit HRT HRTs Torch lead replacement 50 ft 15 2 m 228807 Kit HRTs Hand torch assembly with 25 ft 7 6 m lead 228808 Kit HRTs Hand torch assembly with 50 ft 15 2 m lead 228809 Kit HRTs Torch main body replacement The entire hand torch and lead assembly can be...

Page 94: ...orch replacement parts Duramax MRT Front mounting ring Pilot wire terminal screw Cap sensor switch Torch head O ring Consumables Mounting sleeve Coupler Gear rack 32 pitch Strain relief body Strain relief nut Torch lead Positioning sleeve Wire connector for cap sensor switch ...

Page 95: ...it M65 M85 MRT positioning sleeve 228738 Kit M65 M85 MRT removable gear rack 228786 Kit MRT torch lead replacement 25 ft 7 6 m 228787 Kit MRT torch lead replacement 50 ft 15 2 m 228790 Kit MRT Machine torch assembly with 25 ft 7 6 m lead 228791 Kit MRT Machine torch assembly with 50 ft 15 2 m lead 228793 Kit MRT torch main body replacement The torch assembly also includes a variety of Duramax cons...

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