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Hypertherm Powermax 65, Operator'S Manual

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Hypertherm Powermax 65 Operator'S Manual Download Page 102

OPeRATION

4-2 

powermax

65/85

 

Operator Manual

Using the machine torch ................................................................................................................................4-24

Ensure the torch and table are set up correctly .............................................................................4-24
Understand and optimize cut quality .................................................................................................4-24
To pierce a workpiece using the machine torch ............................................................................4-27
Common machine-cutting faults ........................................................................................................4-27

Summary of Contents for Powermax 65

Page 1: ...Plasma arc cutting systems Operator Manual 806650 Revision 0 85 ...

Page 2: ..._____________________________________ ____________________________________________________________________ ____________________________________________________________________ Maintenance notes ________________________________________________________________________ ________________________________________________________________________ ____________________________________________________________...

Page 3: ...erm Inc Hanover NH USA www hypertherm com email info hypertherm com Copyright 2010 Hypertherm Inc All Rights Reserved Hypertherm and Powermax are trademarks of Hypertherm Inc and may be registered in the United States and or other countries powermax65 powermax85 ...

Page 4: ...e 349567 Republic of Singapore 65 6841 2489 Tel 65 6841 2490 Fax 65 6841 2489 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 T...

Page 5: ...nt of potential electro magnetic 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 equipment b Radio and television transmitters and receivers c Computer and other control equipment d Safety critical equipment for example guarding of industrial equipment e Health of...

Page 6: ...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 example ship s hull or building steelwork a connection bonding the workpiece to earth may reduce emissions in some but not all instances Care should be taken to prevent the earthing of the workpiece increasing the risk of injury to u...

Page 7: ...tion which shall not be unreasonably withheld properly packed to Hypertherm s place of business in Hanover New Hampshire or to an authorized Hypertherm repair facility all costs insurance and freight prepaid Hypertherm shall not be liable for any repairs replacement or adjustments of Products covered by this warranty except those made pursuant to this paragraph or with Hypertherm s prior written c...

Page 8: ...rk be suitable for the end use installation site When Hypertherm products are shipped to one country for export to another country the product must be configured and certified properly for the end use site Higher level systems When a system integrator adds additional equipment such as cutting tables motor drives motion controllers or robots to a Hypertherm plasma cutting system the combined system...

Page 9: ...vent shall Hypertherm s liability whether such liability is based on breach of contract tort strict liability breach of warranties failure of essential purpose or otherwise for any claim action suit or proceeding arising out of or relating to the use of the Products exceed in the aggregate the amount paid for the Products that gave rise to such claim Insurance At all times you will have and mainta...

Page 10: ...Table of Contents vi powermax65 85 Operator Manual WARRANTY vi Hypertherm ...

Page 11: ...chine torch dimensions 1 11 M65m M85m mini machine torch dimensions 1 11 Powermax65 cutting specifications 1 12 Powermax85 cutting specifications 1 13 Symbols and markings 1 14 IEC symbols 1 15 Section 2 Power Supply Setup Unpack the Powermax65 or Powermax85 system 2 2 Claims 2 2 Contents 2 3 Position the power supply 2 4 Prepare the electrical power 2 4 Install a line disconnect switch 2 5 Requir...

Page 12: ...tion 2 14 Connect the gas supply 2 15 Section 3 Torch Setup Introduction 3 3 Consumable life 3 3 Hand torch setup 3 4 Choose the hand torch consumables 3 5 Hand torch consumables 3 6 Install the hand torch consumables 3 7 Machine torch setup 3 8 Converting an M65 M85 torch to an M65m M85m torch 3 9 Mount the torch 3 11 Choose the machine torch consumables 3 14 Machine torch consumables 3 14 Instal...

Page 13: ...Status screen 4 6 Operating the Powermax65 or Powermax85 4 9 Connect the electrical power gas supply and torch lead 4 9 Attach the work lead to the power supply 4 10 Attach the work clamp to the workpiece 4 11 Turn ON the system 4 12 Set the operating mode switch 4 12 Check the indicators 4 13 Manually adjusting the gas pressure 4 13 Adjusting the current amperage 4 14 Understanding duty cycle lim...

Page 14: ...ts 4 27 Section 5 Maintenance and Repair Perform routine maintenance 5 2 Inspect the consumables 5 3 Basic troubleshooting 5 4 Fault codes and solutions 5 6 Replace the gas filter element 5 10 Section 6 Parts Power supply parts 6 2 Hand torch replacement parts 6 5 H65 H85 6 5 H65s H85s 6 5 Hand torch consumables 6 8 Machine torch replacement parts 6 9 M65 M85 M65m M85m 6 9 Machine torch consumable...

Page 15: ...ts 1 5 Powermax65 power supply ratings 1 6 Powermax85 power supply ratings 1 8 H65 H85 75 hand torch dimensions 1 10 H65s H85s 15 hand torch dimensions 1 10 M65 M85 full length machine torch dimensions 1 11 M65m M85m mini machine torch dimensions 1 11 Powermax65 cutting specifications 1 12 Powermax85 cutting specifications 1 13 Symbols and markings 1 14 IEC symbols 1 15 ...

Page 16: ...H85 hand torch with a complete set of the consumables needed for cutting shield retaining cap nozzle electrode swirl ring a consumables box containing 2 spare electrodes 2 spare nozzles 1 gouging nozzle and 1 gouging shield and a work cable Reference materials include operator manual quick setup card registration card setup DVD and safety manual The typical mechanized Powermax system includes a Du...

Page 17: ...s extension cord requirements and generator recommendations see Section 2 Power Supply Setup Handheld and machine torch consumables cut charts and torch setup information see Section 3 Torch Setup Information about the controls and LEDs steps for system operation and hints for improving cut quality see Section 4 Operation Routine maintenance and repair see Section 5 Maintenance and Repair Part num...

Page 18: ...Specifications 1 4 powermax65 85 Operator Manual Power supply dimensions 9 2 in 234 mm 19 0 in 483 mm 17 0 in 432 mm ...

Page 19: ...9 9 27 2 50 4 22 8 65 85 A lbs kg Hand torch 25 ft 7 6 m 6 8 3 1 Hand torch 50 ft 15 m 12 2 5 5 Hand torch 75 ft 23 m 17 6 8 0 Machine torch 25 ft 7 6 m 7 6 3 4 Machine torch 50 ft 15 m 13 2 6 0 Machine torch 75 ft 23 m 18 8 8 5 65 A 85 A lbs kg lbs kg Work lead 25 ft 7 6 m 2 8 1 3 6 8 3 1 Work lead 50 ft 15 m 5 0 2 3 7 5 3 4 Work lead 75 ft 23 m 6 9 3 1 10 6 4 8 ...

Page 20: ...3 to 131 F 25 to 55 C Power factor 200 480 V CSA 1 phase 200 600 V CSA 3 phase 380 400 V CE 3 phase 0 99 0 97 0 94 0 73 0 94 Rsce Short Circuit Ratio CE models only U1 Volts AC rms 3PH Rsce 400 VAC 225 7 EMC classification CISPR 11 CE models only 4 Class A Input voltage U1 Input current I1 at rated output U2 MAX I2 MAX See Section 2 Power Supply Setup for more information CSA CE2 3 200 208 240 480...

Page 21: ...KVA 1 Defined as a plot of output voltage versus output current 3 Equipment complies with IEC 61000 3 11 provided that the supply impedance Zmax is 0 201 or less It is the responsibility of the installer or user of the equipment to ensure by consultation with the distribution network operator if necessary that the equipment is connected only to a supply with a impedance of 0 201 or less 4 WARNING ...

Page 22: ... to 40 C Storage temperature 13 to 131 F 25 to 55 C Power factor 200 480 V CSA 1 phase 200 600 V CSA 3 phase 380 400 V CE 3 phase 0 99 0 96 0 94 0 76 0 94 Rsce Short Circuit Ratio CE models only U1 Volts AC rms 3PH Rsce 400 VAC 225 7 EMC classification CISPR 11 CE models only 4 Class A Input voltage U1 Input current I1 at rated output U2 MAX I2 MAX See Section 2 Power Supply Setup for more informa...

Page 23: ...KVA 3 Equipment complies with IEC 61000 3 11 provided that the supply impedance Zmax is 0 201 or less It is the responsibility of the installer or user of the equipment to ensure by consultation with the distribution network operator if necessary that the equipment is connected only to a supply with a impedance of 0 201 or less 4 WARNING This Class A equipment is not intended for use in residentia...

Page 24: ...rmax65 85 Operator Manual H65 H85 75 hand torch dimensions 9 9 in 25 2 cm 3 8 in 9 8 cm 75 angle 10 2 in 25 9 cm 1 9 in 4 7 cm 15 angle H65s H85s 15 hand torch dimensions 2 6 in 6 6 cm 2 6 in 6 6 cm 1 0 in 2 5 cm 1 0 in 2 5 cm ...

Page 25: ...ensions 15 6 in 39 6 cm 1 0 in 2 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 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 4 in 3 5 cm M65m M85m mini machine torch dimensions 6 6 in 16 8 cm 3 3 in 8 4 cm ...

Page 26: ...acities are the same as the handheld capacities 1 2 in 12 mm Maximum cut speed mild steel 1 4 in 6 mm 145 ipm 4000 mm min 1 2 in 12 mm 50 ipm 1400 mm min 3 4 in 19 mm 24 ipm 600 mm min 1 in 25 mm 12 ipm 320 mm min Gouging capacity Metal removal rate on mild steel 10 7 lbs hr 4 8 kg hr Duramax series torch weights refer to Component weights on page 1 5 Duty cycle and voltage information refer to Po...

Page 27: ...same as the handheld capacities 3 4 in 19 mm Maximum cut speed mild steel 1 4 in 6 mm 200 ipm 5500 mm min 1 2 in 12 mm 70 ipm 2000 mm min 3 4 in 19 mm 36 ipm 900 mm min 1 in 25 mm 21 ipm 550 mm min 1 1 4 in 32 mm 13 ipm 330 mm min Gouging capacity Metal removal rate on mild steel 19 5 lbs hr 8 8 kg hr Duramax series torch weights refer to Component weights on page 1 5 Duty cycle and voltage inform...

Page 28: ...s Underwriters Laboratories Incorporated UL or TÜV CE marking The CE marking signifies the manufacturer s declaration of conformity to applicable European directives and standards Only those versions of Hypertherm products with a CE marking located on or near the data plate have been tested for compliance with the European Low Voltage Directive and the European Electromagnetic Compatibility EMC Di...

Page 29: ...er source either 1 phase or 3 phase Power is OFF Power is ON f1 f2 1 AC Power is ON LED Inlet gas pressure fault LCD Missing or loose consumables LCD Power supply is out of temperature range LCD Volt amp curve drooping characteristic IEC symbols The following symbols may appear on the power supply data plate control labels switches LEDs and LCD screen System fault LED Plate metal cutting Expanded ...

Page 30: ...Specifications 1 16 powermax65 85 Operator Manual ...

Page 31: ...ction for the Powermax65 2 6 Single phase power cord not for CE model 2 7 Three phase power cord plug installation 2 7 Power connection for the Powermax85 2 8 Single phase power cord not for CE model 2 9 Single phase power cord installation 2 10 Three phase power cord plug installation 2 11 Extension cord recommendations 2 11 Extension cord specifications 2 12 Engine driven generator recommendatio...

Page 32: ...supply 3 Before you set up and operate this Hypertherm system read the separate Safety and Compliance Manual included with your system for important safety information Claims Claims for damage during shipment If your unit was damaged during shipment you must file a claim with the carrier Hypertherm will furnish you with a copy of the bill of lading upon request If you need additional assistance ca...

Page 33: ...ator Manual 2 3 Operator Manual Safety Manual Quick Setup Card Registration Card Contents Verify the items in the box against the illustration Box with extra consumables located next to air filter Setup DVD Or Remote start pendant optional ...

Page 34: ...supply is not suitable for use in rain or snow To avoid toppling do not set the power supply on an incline greater than 10 degrees Prepare the electrical power Hypertherm designated HYP on the data plate input current ratings are used to determine conductor sizes for power connection and installation instructions The HYP rating is determined under maximum normal operating conditions and the higher...

Page 35: ...ontain a power operated mechanism that serves as an emergency stop Have appropriate slow blow fuses installed See Power connection for the Powermax65 on page 2 6 or Power connection for the Powermax85 on page 2 8 for recommended fuse sizes Requirements for grounding To ensure personal safety proper operation and to reduce electromagnetic interference EMI the power supply must be properly grounded ...

Page 36: ...380 400 V 3 phase only The rated output is 25 65 A 139 VDC CSA model Single phase Three phase Input voltage 200 208 230 240 480 200 208 230 240 400 480 600 Input current at 9 0 kw output 52 44 22 32 27 15 13 13 Input current during arc stretch 74 74 38 45 45 27 23 23 Fuse slow blow 80 80 40 50 50 30 25 25 CE model Three phase Input voltage 380 400 Input current at 9 0 kw output 15 5 15 Input curre...

Page 37: ...cord Refer to Single phase power cord installation on page 2 10 for instructions Three phase power cord plug installation The Powermax65 power supplies are shipped with an 8 AWG 4 wire power cord on CSA models A 2 5 mm2 4 wire HAR power cord is provided on CE models To operate the Powermax65 use a plug that meets national and local electrical codes The plug must be connected to the power cord by a...

Page 38: ...0 400 V 3 phase only The rated output is 25 85 A 143 VDC CSA model Single phase Three phase Input voltage 200 208 230 240 480 200 208 230 240 400 480 600 Input current at 12 2 kw output 70 60 29 42 36 21 18 17 Input current during arc stretch 98 98 50 60 60 38 31 30 Fuse slow blow 100 100 50 60 60 40 30 30 CE model Three phase Input voltage 380 400 Input current at 12 2 kw output 20 5 20 Input cur...

Page 39: ...to install an appropriate power cord Refer to Single phase power cord installation on page 2 10 for instructions Caution C When using the Powermax85 CSA model power supply CE model is 3 phase only with a 1 phase power source replace the supplied power cord with a 6 AWG 16 mm2 3 wire power cord The power cord must be connected by a licensed electrician ...

Page 40: ...x65 85 Operator Manual Single phase power cord installation Strip and prepare the power cord wires as shown below L1 L2 Ground 10 14 5 in 368 mm 6 in 152 mm L1 L2 Power switch Ground screw Route lead through strain relief and tighten ...

Page 41: ... they do not include the power supply s power cord Three phase power cord plug installation The Powermax85 power supplies are shipped with an 8 AWG 4 wire power cord on CSA models A 4 mm2 4 wire HAR power cord is provided on CE models To operate the Powermax85 use a plug that meets national and local electrical codes The plug must be connected to the power cord by a licensed electrician The proced...

Page 42: ...10 6 8 10 6 16 400 480 3 12 4 12 4 12 4 12 4 12 4 600 3 12 4 12 4 12 4 12 4 12 4 65 A CE Input voltage VAC Phase mm2 mm2 mm2 mm2 mm2 380 3 4 4 4 4 4 400 3 4 4 4 4 4 85 A CSA Input voltage VAC Phase AWG mm2 AWG mm2 AWG mm2 AWG mm2 AWG mm2 200 240 1 6 16 6 16 6 16 4 25 2 35 480 1 10 6 10 6 10 6 8 10 8 10 200 240 3 8 10 8 10 8 10 6 16 4 25 400 480 3 10 6 10 6 10 6 10 6 10 6 600 3 10 6 10 6 10 6 10 6 ...

Page 43: ...d for best performance Engine drive rating System output current Performance arc stretch 20 kw 85 A Full 15 kw 70 A Limited 15 kw 65 A Full 12 kw 65 A Limited 12 kw 40 A Full 8 kw 40 A Limited 8 kw 30 A Full Note N Based on the generator rating age and condition adjust the cutting current as needed If a fault occurs while using a generator turning the power switch quickly to OFF and then to ON aga...

Page 44: ... 0 5 microns 400 for particle sizes in the range of 0 5 1 microns and 10 for particle sizes in the range of 1 5 microns The maximum water vapor dew point should be 40 C 40 F The maximum oil aerosol liquid and vapor content should be less than 0 1 mg m3 Additional gas filtration When site conditions introduce moisture oil or other contaminants into the gas line use a 3 stage coalescing filtration s...

Page 45: ...with a 3 8 inch 9 5 mm internal diameter and a 1 4 NPT quick disconnect coupler or a 1 4 NPT x G 1 4 BSPP CE units quick disconnect coupler warning Do not allow the gas supply pressure to exceed 135 psi 9 3 bar The filter bowl may explode if this pressure is exceeded The recommended inlet pressure while gas is flowing is 85 135 psi 5 9 9 3 bar ...

Page 46: ...n the recommended inlet pressure is not available Torch lead length 25 ft 7 62 m 50 ft 15 24 m 75 ft 22 86 m Cutting 75 psi 5 2 bar 80 psi 5 5 bar 85 psi 5 9 bar Gouging 60 psi 4 1 bar 65 psi 4 5 bar 70 psi 4 8 bar Gas flow rates Cutting 400 scfh 6 7 scfm 190 slpm at a minimum 85 psi 5 9 bar Gouging 450 scfh 7 5 scfm 210 slpm at a minimum 70 psi 4 8 bar ...

Page 47: ...l the hand torch consumables 3 7 Machine torch setup 3 8 Converting an M65 M85 torch to an M65m M85m torch 3 9 Mount the torch 3 11 Choose the machine torch consumables 3 14 Machine torch consumables 3 14 Install the machine torch consumables 3 17 Aligning the torch 3 17 Connecting an optional remote start pendant 3 18 Connecting an optional machine interface cable 3 19 Connecting the torch lead 3...

Page 48: ...rts 3 25 Estimated kerf width compensation 3 26 85 A shielded consumables 3 28 65 A shielded consumables 3 32 45 A shielded consumables 3 36 FineCut consumables 3 40 85 A unshielded consumables 3 43 65 A unshielded consumables 3 47 45 A unshielded consumables 3 51 ...

Page 49: ...etal being cut The average length of the cut Whether you are doing machine or hand cutting The air quality presence of oil moisture or other contaminants Whether you are piercing the metal or starting cuts from the edge Proper torch to work distance when gouging or cutting with unshielded consumables Proper pierce height Whether you are cutting in continuous pilot arc mode or normal mode Cutting w...

Page 50: ...TORCH SETUP 3 4 powermax65 85 Operator Manual Consumables Consumables Safety trigger Safety trigger Hand torch setup H65 H85 H65s H85s ...

Page 51: ...s box Both styles of hand torches shown above use the same consumables Hand torches use shielded consumables Therefore you can drag the torch tip along the metal Consumables for hand 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 ...

Page 52: ... 220819 Nozzle 220819 Nozzle 220816 Nozzle 220857 Swirl ring 220857 Swirl ring 220842 Electrode 220842 Electrode Drag cutting consumables Powermax65 Drag cutting consumables Powermax85 Gouging consumables 220854 Retaining cap 220857 Swirl ring 220842 Electrode 220798 Shield 220797 Nozzle FineCut consumables 220854 Retaining cap 220947 Swirl ring 220842 Electrode 220931 Shield 220930 Nozzle ...

Page 53: ...ning 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 warning Instant On Torches PLASMA ARC CAN CAUSE INJURY AND BURNS Shield 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 54: ...es 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 M65 M85 M...

Page 55: ...ng 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 Unscrew the ...

Page 56: ...2 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 tor...

Page 57: ...d reassemble the torch refer to the figures in the section Machine torch setup on page 3 8 and follow these instructions Note N 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 fro...

Page 58: ...s 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 towa...

Page 59: ...onnect 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 mach...

Page 60: ...h 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 Both styles of machine torches use the same consumables Machine torch consumables 220817 Shield 220817 Shield 220854 Retaining cap 220941 Nozzle 220941 Nozzle 220819 Nozzle 220819 Nozzle 2...

Page 61: ...sumables Powermax65 65 A 45 A 85 A 65 A 45 A 85 A 220817 Shield 220817 Shield 220854 Retaining cap 220857 Swirl ring 220857 Swirl ring 220842 Electrode 220842 Electrode 220953 Ohmic sensing retaining cap Mechanized shielded consumables Powermax85 Mechanized shielded with ohmic consumables Powermax85 220941 Nozzle 220941 Nozzle 220819 Nozzle 220819 Nozzle 220816 Nozzle 220816 Nozzle ...

Page 62: ...bles FineCut shielded consumables 220854 Retaining cap 220953 Retaining cap 220857 Swirl ring 220857 Swirl ring 220842 Electrode 220842 Electrode 220955 Deflector 220948 Shield 220930 Nozzle 220930 Nozzle 65 A 45 A 85 A 220955 Deflector 220854 Retaining cap 220857 Swirl ring 220842 Electrode Mechanized unshielded consumables Powermax85 220941 Nozzle 220819 Nozzle 220816 Nozzle ...

Page 63: ... operate the machine torch a complete set of consumable parts must be installed shield retaining cap nozzle electrode and swirl ring With the power switch in the OFF O position install the machine torch consumables in a manner similar to the hand torch consumables Refer to Install the hand torch consumables on page 3 7 Aligning the torch Mount the machine torch perpendicular to the workpiece in or...

Page 64: ...nal 25 foot 7 6 m 50 foot 15 m or 75 foot 23 m remote start pendant Remove the receptacle cover and plug the Hypertherm remote start pendant into the receptacle on the rear of the power supply Note N The remote start pendant is for use only with a machine torch It will not operate if a handheld torch is installed Receptacle for the remote start pendant or a machine interface cable ...

Page 65: ... an impedance protected functional extra low voltage ELV output to prevent shock energy and fire under normal conditions at the machine interface receptacle and under single fault conditions with the machine interface wiring The voltage divider is not fault tolerant and ELV outputs do not comply with safety extra low voltage SELV requirements for direct connection to computer products Hypertherm o...

Page 66: ... pin connector on the torch height controller or CNC Secure it with the screws on the D sub connector If you are using a cable with wires and spade connectors on the other end terminate the machine interface cable inside the electrical enclosure of listed and certified torch height controllers or CNC controllers to prevent unauthorized access to the connections after installation Verify that the c...

Page 67: ...tart 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 transfers 120 VAC 1 A maximum at the machine interface relay or switching device supplied by the customer 12 14 Red black Ground Ground 13 Voltage divider Output Divided arc signal...

Page 68: ...0 1 to a different setting 1 Turn OFF the power supply and disconnect the power cord 2 Remove the power supply cover 3 Locate the voltage divider DIP switches on the left side of the power supply Note N The figure below shows the default setting 50 1 with the number 4 switch up 4 Set the DIP switches to one of the following settings and replace the power supply cover ...

Page 69: ...ly in order to access raw arc voltage Refer to Field Service Bulletin 806180 WARNING HIGH VOLTAGE AND CURRENT Connecting directly to the plasma circuit for access to raw arc voltage increases the risk of shock hazard energy hazard and fire hazard in the event of a single fault The output voltage and the output current of the circuit are specified on the data plate ...

Page 70: ...ed button Connecting the torch lead The Powermax65 and Powermax85 are equipped with FastConnectTM a quick disconnect system for connecting and disconnecting handheld and machine torch leads When connecting or disconnecting a torch first turn OFF the system To connect either torch push the connector into the receptacle on the front of the power supply ...

Page 71: ...ion Maximum cut speeds are the fastest speeds possible to cut material without regard to cut quality 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 Note N Hypertherm collected the data under laboratory test conditions using new cons...

Page 72: ... 1 1 4 1 5 1 7 FineCut 0 7 0 7 1 3 1 3 85A Unshielded 1 7 1 8 1 9 2 0 2 1 2 1 2 3 65A Unshielded 1 6 1 6 1 7 1 8 1 9 2 0 45A Unshielded 0 5 0 9 1 3 1 3 Stainless Steel 85A Shielded 1 6 1 8 1 9 2 1 2 3 2 4 2 5 65A Shielded 1 4 1 5 1 8 1 9 2 0 2 2 2 4 45A Shielded 0 9 1 1 1 5 1 6 1 8 FineCut 0 6 0 6 1 4 1 5 85A Unshielded 1 7 1 7 1 8 1 9 2 1 2 2 2 4 65A Unshielded 1 6 1 6 1 8 1 8 1 9 2 0 45A Unshiel...

Page 73: ...0 071 0 073 0 078 0 090 0 095 0 100 65A Shielded 0 062 0 065 0 068 0 070 0 076 0 088 0 090 0 091 45A Shielded 0 035 0 054 0 055 0 061 0 065 0 066 FineCut 0 024 0 043 0 049 0 051 85A Unshielded 0 070 0 073 0 075 0 080 0 085 0 090 65A Unshielded 0 062 0 064 0 066 0 068 0 075 0 081 45A Unshielded 0 020 0 050 0 051 0 054 0 057 0 059 Aluminum 1 32 1 16 1 8 3 16 1 4 3 8 1 2 5 8 3 4 85A Shielded 0 080 0 ...

Page 74: ...Operator Manual 220817 Shield 220817 Shield 220854 Retaining cap 220857 Swirl ring 220857 Swirl ring 220842 Electrode 220842 Electrode 220953 Ohmic sensing retaining cap 85 A shielded consumables 220816 Nozzle 220816 Nozzle 85 A 85 A ...

Page 75: ...1680 127 2600 129 12 4 5 300 0 7 1280 130 2000 130 16 1 0 870 134 1150 132 20 1 5 570 137 850 135 25 Edge Start 350 142 550 139 30 200 146 370 143 English Material Thickness Torch to Work Distance Initial Pierce Height Pierce Delay Time Recommended Maximum Cut Speed Voltage Cut Speed Voltage in in seconds ipm Volts ipm Volts 10GA 0 06 0 15 250 0 0 250 122 420 117 3 16 in 0 2 185 123 275 121 1 4 in...

Page 76: ...3700 122 5700 121 8 2450 124 3800 123 10 1550 127 2400 124 12 4 5 300 0 7 1100 131 1750 125 16 1 0 700 135 950 131 20 Edge Start 480 138 700 132 25 300 143 480 135 English Material Thickness Torch to Work Distance Initial Pierce Height Pierce Delay Time Recommended Maximum Cut Speed Voltage Cut Speed Voltage in in seconds ipm Volts ipm Volts 10GA 0 06 0 15 250 0 2 275 122 420 116 3 16 in 200 122 3...

Page 77: ... 6 0 5 3800 126 6100 121 8 2650 130 4300 123 10 1920 132 3100 125 12 4 5 300 0 7 1450 134 2400 127 16 1 0 950 139 1500 130 20 Edge Start 600 143 1100 133 25 380 146 670 140 English Material Thickness Torch to Work Distance Initial Pierce Height Pierce Delay Time Recommended Maximum Cut Speed Voltage Cut Speed Voltage in in seconds ipm Volts ipm Volts 1 8 in 0 06 0 15 250 0 2 300 122 450 117 1 4 in...

Page 78: ...Operator Manual 65 A shielded consumables 220817 Shield 220817 Shield 220854 Retaining cap 220819 Nozzle 220819 Nozzle 220857 Swirl ring 220857 Swirl ring 220842 Electrode 220842 Electrode 220953 Ohmic sensing retaining cap 65 A 65 A ...

Page 79: ...000 129 8 1700 129 2800 130 10 4 5 300 0 7 1100 131 1900 130 12 1 2 850 134 1400 132 16 2 0 560 138 800 136 20 Edge Start 350 142 560 140 25 210 145 320 143 English Material Thickness Torch to Work Distance Initial Pierce Height Pierce Delay Time Recommended Maximum Cut Speed Voltage Cut Speed Voltage in in seconds ipm Volts ipm Volts 16GA 0 06 0 15 250 0 1 260 123 370 118 10GA 190 125 280 123 3 1...

Page 80: ... 4 0 5 5200 125 7700 124 6 2450 126 3600 126 8 0 7 1500 129 2300 127 10 4 5 300 960 132 1550 127 12 1 2 750 135 1150 129 16 Edge Start 500 139 650 134 20 300 143 450 136 English Material Thickness Torch to Work Distance Initial Pierce Height Pierce Delay Time Recommended Maximum Cut Speed Voltage Cut Speed Voltage in in seconds ipm Volts ipm Volts 16GA 0 06 0 15 250 0 1 345 124 530 121 10GA 240 12...

Page 81: ...00 123 4 0 5 6000 126 9150 124 6 3200 130 5500 127 8 0 7 1950 133 3450 129 10 4 5 300 1200 136 2050 130 12 1 2 1000 138 1650 132 16 Edge Start 650 143 1000 134 20 380 147 700 137 English Material Thickness Torch to Work Distance Initial Pierce Height Pierce Delay Time Recommended Maximum Cut Speed Voltage Cut Speed Voltage in in seconds ipm Volts ipm Volts 1 16 in 0 06 0 15 250 0 1 365 121 535 121...

Page 82: ...Operator Manual 45 A shielded consumables 220817 Shield 220854 Retaining cap 220941 Nozzle 220857 Swirl ring 220842 Electrode 45 A 220817 Shield 220941 Nozzle 220857 Swirl ring 220842 Electrode 220953 Ohmic sensing retaining cap 45 A ...

Page 83: ...1 9000 128 12700 128 1 5 0 1 9000 130 12700 128 2 0 3 6600 130 9750 128 3 0 4 3850 133 6150 130 4 2200 134 4450 131 6 0 5 1350 137 2550 132 English Material Thickness Torch to Work Distance Initial Pierce Height Pierce Delay Time Recommended Maximum Cut Speed Voltage Cut Speed Voltage in in seconds ipm Volts ipm Volts 26GA 0 06 0 15 250 0 0 350 128 500 128 22GA 350 128 500 128 18GA 0 1 350 129 500...

Page 84: ...30 1 9000 130 12700 130 1 5 0 1 9000 130 12700 130 2 0 3 6000 132 10800 130 3 0 4 3100 132 5550 131 4 2000 134 3250 132 6 0 5 900 140 1250 138 English Material Thickness Torch to Work Distance Initial Pierce Height Pierce Delay Time Recommended Maximum Cut Speed Voltage Cut Speed Voltage in in seconds ipm Volts ipm Volts 26GA 0 06 0 15 250 0 0 350 130 500 130 22GA 350 130 500 130 18GA 0 1 350 130 ...

Page 85: ...in Volts mm min Volts 1 1 5 3 8 250 0 0 8250 136 12700 136 2 0 1 6600 136 11500 133 3 0 2 3100 139 7800 133 4 0 4 2200 141 6050 134 6 0 5 1500 142 3500 136 English Material Thickness Torch to Work Distance Initial Pierce Height Pierce Delay Time Recommended Maximum Cut Speed Voltage Cut Speed Voltage in in seconds ipm Volts ipm Volts 1 32 in 0 06 0 15 250 0 0 325 136 500 137 1 16 in 0 1 325 136 50...

Page 86: ...g cap 220857 Swirl ring 220842 Electrode 220948 Shield 220930 Nozzle FineCut consumables Note N The cut charts in this section apply to both shielded and unshielded consumables 220854 Retaining cap 220857 Swirl ring 220842 Electrode 220955 Deflector 220930 Nozzle ...

Page 87: ...6 8250 78 12700 81 0 8 0 1 8250 78 12700 80 1 45 0 2 8250 78 12700 82 1 5 0 4 6400 78 8500 81 2 5250 82 6250 81 3 0 5 2750 83 3650 81 4 0 6 1900 84 2450 81 English Material Thickness Amps Torch to Work Distance Initial Pierce Height Pierce Delay Time Recommended Maximum Cut Speed Voltage Cut Speed Voltage A in in seconds ipm Volts ipm Volts 26GA 40 0 06 0 15 250 0 0 325 78 500 80 24GA 325 78 500 8...

Page 88: ...6 8250 68 12700 65 0 8 0 1 8250 68 12700 64 1 45 0 15 8250 68 12700 65 1 5 0 4 6150 70 10650 64 2 4800 71 8150 64 3 0 5 2550 81 3250 68 4 0 6 1050 84 1250 72 English Material Thickness Amps Torch to Work Distance Initial Pierce Height Pierce Delay Time Recommended Maximum Cut Speed Voltage Cut Speed Voltage A in in seconds ipm Volts ipm Volts 26GA 40 0 02 0 08 400 0 0 325 68 500 68 24GA 325 68 500...

Page 89: ...TORCH SETUP powermax65 85 Operator Manual 3 43 85 A unshielded consumables 220955 Deflector 220854 Retaining cap 220857 Swirl ring 220842 Electrode 220816 Nozzle 85 A ...

Page 90: ...450 120 5500 120 8 2400 121 3900 121 10 1560 123 2600 122 12 6 0 300 0 7 1200 126 2000 124 16 Edge Start 820 132 1150 126 20 540 137 800 131 25 320 143 500 137 English Material Thickness Torch to Work Distance Initial Pierce Height Pierce Delay Time Recommended Maximum Cut Speed Voltage Cut Speed Voltage in in seconds ipm Volts ipm Volts 14GA 0 08 0 20 250 0 1 300 116 540 112 10GA 0 2 280 117 520 ...

Page 91: ...0 2 5600 118 9800 118 6 0 5 3400 120 5700 122 8 2250 121 3700 124 10 6 0 300 0 5 1430 123 2300 125 12 0 7 1000 129 1700 127 16 Edge Start 650 134 910 131 20 360 138 720 136 English Material Thickness Torch to Work Distance Initial Pierce Height Pierce Delay Time Recommended Maximum Cut Speed Voltage Cut Speed Voltage in in seconds ipm Volts ipm Volts 14GA 0 08 0 20 250 0 1 365 117 580 114 10GA 0 2...

Page 92: ... 116 4 0 2 6000 122 10000 117 6 0 5 3300 125 6150 119 8 2350 127 4100 121 10 6 0 300 0 5 1800 128 2650 124 12 0 7 1300 133 2160 127 16 Edge Start 840 139 1400 132 20 470 144 900 137 English Material Thickness Torch to Work Distance Initial Pierce Height Pierce Delay Time Recommended Maximum Cut Speed Voltage Cut Speed Voltage in in seconds ipm Volts ipm Volts 1 8 in 0 08 0 20 250 0 2 280 120 460 1...

Page 93: ...TORCH SETUP powermax65 85 Operator Manual 3 47 65 A unshielded consumables 220955 Deflector 220854 Retaining cap 220857 Swirl ring 220842 Electrode 220819 Nozzle 65 A ...

Page 94: ...17 4 0 5 4250 118 6550 117 6 2550 120 4100 119 8 1620 123 2800 120 10 6 0 300 0 7 970 127 1880 122 12 Edge Start 760 129 1400 124 16 500 134 800 128 20 280 138 560 132 English Material Thickness Torch to Work Distance Initial Pierce Height Pierce Delay Time Recommended Maximum Cut Speed Voltage Cut Speed Voltage in in seconds ipm Volts ipm Volts 16GA 0 08 0 20 250 0 1 255 116 385 115 10GA 190 118 ...

Page 95: ... 0 2 6600 118 10600 119 4 0 5 5050 119 8200 119 6 2300 121 3800 120 8 0 7 1400 123 2400 121 10 6 0 300 0 7 920 126 1550 123 12 Edge Start 710 130 1150 127 16 480 135 630 132 English Material Thickness Torch to Work Distance Initial Pierce Height Pierce Delay Time Recommended Maximum Cut Speed Voltage Cut Speed Voltage in in seconds ipm Volts ipm Volts 16GA 0 08 0 20 250 0 1 340 116 540 118 10GA 23...

Page 96: ...0 123 3 0 2 6550 124 12000 123 4 0 5 5400 125 9500 123 6 3000 127 4850 124 8 0 7 1800 130 3000 126 10 6 0 300 0 7 1100 133 2050 127 12 Edge Start 900 135 1560 129 16 600 139 880 132 English Material Thickness Torch to Work Distance Initial Pierce Height Pierce Delay Time Recommended Maximum Cut Speed Voltage Cut Speed Voltage in in seconds ipm Volts ipm Volts 1 16 in 0 08 0 20 250 0 1 325 122 590 ...

Page 97: ...TORCH SETUP powermax65 85 Operator Manual 3 51 45 A unshielded consumables 220955 Deflector 220854 Retaining cap 220857 Swirl ring 220842 Electrode 220941 Nozzle 45 A ...

Page 98: ... 1 9000 120 12700 122 1 5 0 1 7700 120 12700 122 2 0 3 6150 119 9750 120 3 0 4 3950 121 6150 122 4 2350 123 4450 124 6 0 5 1400 126 2550 123 English Material Thickness Torch to Work Distance Initial Pierce Height Pierce Delay Time Recommended Maximum Cut Speed Voltage Cut Speed Voltage in in seconds ipm Volts ipm Volts 26GA 0 06 0 15 250 0 0 350 120 500 122 22GA 350 120 500 122 18GA 0 1 350 119 50...

Page 99: ...119 1 9000 121 12700 119 1 5 0 1 9000 121 12700 119 2 0 3 6000 122 12700 119 3 0 4 3250 123 5950 119 4 1900 128 3700 119 6 0 5 700 130 1800 127 English Material Thickness Torch to Work Distance Initial Pierce Height Pierce Delay Time Recommended Maximum Cut Speed Voltage Cut Speed Voltage in in seconds ipm Volts ipm Volts 26GA 0 06 0 15 250 0 0 350 120 500 119 22GA 350 120 500 119 18GA 0 1 350 118...

Page 100: ...min Volts mm min Volts 1 1 5 3 8 250 0 0 7400 126 12700 119 2 0 1 4400 127 11500 119 3 0 2 2800 129 7800 122 4 0 4 2100 132 5850 123 6 0 5 1050 135 2800 126 English Material Thickness Torch to Work Distance Initial Pierce Height Pierce Delay Time Recommended Maximum Cut Speed Voltage Cut Speed Voltage in in seconds ipm Volts ipm Volts 1 32 in 0 06 0 15 250 0 0 325 126 500 120 1 16 in 0 1 200 126 5...

Page 101: ...to the power supply 4 10 Attach the work clamp to the workpiece 4 11 Turn ON the system 4 12 Set the operating mode switch 4 12 Check the indicators 4 13 Manually adjusting the gas pressure 4 13 Adjusting the current amperage 4 14 Understanding duty cycle limitations 4 15 Using the hand torch 4 16 Operate the safety trigger 4 16 Hand torch cutting hints 4 17 Start a cut from the edge of the workpi...

Page 102: ...85 Operator Manual Using the machine torch 4 24 Ensure the torch and table are set up correctly 4 24 Understand and optimize cut quality 4 24 To pierce a workpiece using the machine torch 4 27 Common machine cutting faults 4 27 ...

Page 103: ...selector Operating mode switch Adjustment knob Controls and indicators The Powermax65 and Powermax85 power supplies have the following ON OFF switch adjustment knob automatic manual pressure setting mode selector current gas selector operating mode switch indicator LEDs and a status screen Rear controls ON I OFF O power switch Activates the power supply and its control circuits ...

Page 104: ...supply For information about these fault conditions and how to correct them see Basic troubleshooting on page 5 4 Operating mode switch The operating mode switch can be set in one of four positions Continuous pilot arc Cuts expanded metal or grate Non continuous pilot arc Cuts or pierces metal plate This is the standard setting for normal drag cutting Gouge Gouges metal plate Torch lock Same as th...

Page 105: ...a specific cutting application When you switch from manual mode to automatic mode the power supply automatically sets the gas pressure and the amperage setting is unchanged When you switch from automatic mode to manual mode the power supply remembers the previous manual gas pressure setting and the amperage setting is unchanged When you reset the power the power supply remembers the previous mode ...

Page 106: ...si The gas pressure bar is also a visual indicator of the gas pressure Status screen The status screen shows system status and fault information Torch started Fault icon Fault code Torch is cutting Remote connected Current setting amps Current selection cursor Pressure selection cursor Pressure setting Visual pressure setting ...

Page 107: ...ting on page 5 4 Note N Only one fault code is displayed If more than one fault occurs at the same time only the fault code with the highest priority is displayed System status icons The screen displays icons to indicate the system s status Gas pressure bar When the arrow is centered in the vertical bar the reference pressure of the automatic pressure setting the gas pressure is set to the preset ...

Page 108: ...Gas Indicates that the gas is disconnected from the rear of the power supply or there is a problem with the gas supply Internal Serial Communications Interface Indicates a problem with the SCI communications between the control board and the DSP board Torch cap sensor Indicates that the consumables are loose improperly installed or missing Turn OFF the power properly install the consumables and tu...

Page 109: ...er connection for the Powermax65 on page 2 6 or Power connection for the Powermax85 on page 2 8 Plug in the power cord and connect the gas supply line For more information about the electrical requirements and the gas supply requirements of the Powermax65 and Powermax85 see Section 2 Power Supply Setup To connect the torch push the FastConnectTM connector into the receptacle on the front of the po...

Page 110: ...e a work lead that is appropriate for your power supply Use a 65 A work lead with the Powermax65 Use an 85 A work lead with the Powermax85 The amperage is marked near the rubber boot of the work lead connector 2 Push the work lead connector all the way into the receptacle on the power supply and turn clockwise approximately 1 4 turn until the connector is fully seated against the stop in order to ...

Page 111: ...ead of attaching the work clamp to the workpiece See your table manufacturer s instructions Note the following Ensure that the work clamp and the workpiece make good metal to metal contact Remove rust dirt paint coatings and other debris to ensure the power supply makes proper contact with the workpiece For the best cut quality attach the work clamp as close as possible to the area being cut Do no...

Page 112: ... job that requires a continuous pilot arc Using this mode to cut standard metal plate reduces consumable life For cutting or piercing metal This is the standard setting for normal drag cutting For gouging metal Note Using this mode while cutting results in poor cut quality Locks the torch in the ON fire position With this option selected press the trigger to fire the torch You can then release the...

Page 113: ...e power the power supply remembers the previous mode gas pressure and amperage settings To adjust the pressure 1 Press the automatic manual pressure setting mode selector so that the LED next to the selector illuminates Refer to the diagram in Front controls and LEDs on page 4 3 2 Press the current gas selector until the selection cursor is opposite the gas pressure setting in the status screen 3 ...

Page 114: ...setting in the status screen 2 Turn the adjustment knob to change the amperage 3 If you wish to exit manual mode press the automatic manual pressure setting mode selector The LED goes off Note N When you exit manual mode the gas pressure resets to the factory optimized value When you switch between manual mode and automatic mode the power supply retains the amperage setting When you reset the powe...

Page 115: ... on for 6 minutes out of 10 60 At 46 A the arc can remain on for 10 minutes out of 10 100 With a Powermax85 At 85 A the arc can remain on for 6 minutes out of 10 minutes without causing the unit to overheat 60 duty cycle At 74 A the arc can remain on for 8 minutes out of 10 80 At 66 A the arc can remain on for 10 minutes out of 10 100 If the duty cycle is exceeded the power supply overheats the te...

Page 116: ... 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 the c...

Page 117: ... 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 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 guide See Section 6 Parts for part numbers for the Hypertherm plasma cutting guides for cutting circles and making bevel...

Page 118: ...ttached 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 119: ...e 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 angle s...

Page 120: ...ing the torch 2 Hold the torch at a 45 angle to the workpiece with a small gap between the torch tip and the workpiece Press the trigger to obtain a pilot arc Transfer the arc to the work 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...

Page 121: ...to the workpiece and varying the current output of the power supply Angle Speed Standoff Typical Gouge Profile for 65 A Typical Gouge Profile for 85 A Width 26 in 6 6 mm Width 28 in 7 1 mm Depth 14 in 3 6 mm Depth 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 Standoff 1 4 3 8 in 6 ...

Page 122: ...creasing the standoff of the torch will increase width and decrease depth Decreasing the 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 ...

Page 123: ...s 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 life ...

Page 124: ... 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 edge...

Page 125: ...ork 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 Excess ...

Page 126: ...s 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 straight...

Page 127: ...Remove the dross if the torch will contact it during the 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 sp...

Page 128: ...lace 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 25 for more information The consumables life is shortened Causes can be The arc curren...

Page 129: ...erator Manual 5 1 Section 5 Maintenance and Repair In this section Perform routine maintenance 5 2 Inspect the consumables 5 3 Basic troubleshooting 5 4 Fault codes and solutions 5 6 Replace the gas filter element 5 10 ...

Page 130: ... 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 DANGER ELECTRIC SHOCK CAN KILL Disconnect the electrical power before you perform any maintenance All work that requires rem...

Page 131: ...e 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 lubrica...

Page 132: ...etal to metal connection Inspect the work clamp for damage and repair as necessary The pierce height distance may be too large Move the torch closer to the workpiece and fire the torch again Basic troubleshooting The following table provides an overview of the most common problems that can arise when using the Powermax65 or Powermax85 and explains how to solve them Note N Fault icons and correspon...

Page 133: ...rs and hisses The gas filter s element is contaminated Replace the element See Replace the gas filter element on page 5 10 Inspect the gas line for moisture If necessary install or repair the gas filtration to the power supply See Preparethegassupply onpage2 14 The cut quality is poor Verify that the torch is being used correctly See Section 4 Operation Inspect the consumables for wear and replace...

Page 134: ...the system continues to operate On Off Adjust the gas inlet pressure as needed 0 13 AC input unstable Warning the system continues to operate Blink fast Off Correct the power source 0 20 Low gas pressure On On Check the input gas supply Adjust the gas pressure to the acceptable range using Manual mode See Manually adjusting the gaspressure onpage4 13 0 21 Gas flow lost while cutting On On Restore ...

Page 135: ...ile the power supply is ON turn OFF the power supply correct the problem and then turn ON the power supply to clear this fault If the consumables appear to be installed correctly the torch may be damaged Contact your Hypertherm distributor or authorized repair facility 0 40 Over under temperature On On Leave the power supply on to allow the fan to cool the power supply If the internal temperature ...

Page 136: ...If the consumables appear to be installed correctly the torch may be damaged Contact your Hypertherm distributor or authorized repair facility 0 51 Start trigger signal on at power up This situation indicates that the power supply is receiving a start signal It is sometimes referred to as a stuck start On On If the power supply is turned on while the torch trigger is pressed the system is disabled...

Page 137: ...nder voltage Check the line increase the voltage 0 61 AC input unstable Shutdown On On The incoming line current is unstable Power down and correct the line problem before continuing 0 98 Internal communication failure On On Power down wait 20 seconds power up A qualified service technician must open the power supply case and check the ribbon cable between the control board and the DSP board 0 99 ...

Page 138: ...ment 7 Replace the dirty element with a new element Reinstall clockwise the plastic retaining nut to finger tight only 8 Insert the filter bowl with the thumb latch positioned approximately 45 degrees to the right of center This is the same orientation in which the filter bowl was pulled down and removed 9 Vertically align the filter bowl with metal guard and firmly push the filter bowl up to the ...

Page 139: ...pair powermax65 85 Operator Manual 5 11 Filter bowl Helpful to lift here when replacing filter bowl Thumb latch The white filter element and plastic retaining nut are visible after removing the filter bowl Remove Install ...

Page 140: ...Maintenance and Repair 5 12 powermax65 85 Operator Manual ...

Page 141: ...his section Power supply parts 6 2 Hand torch replacement parts 6 5 H65 H85 6 5 H65s H85s 6 5 Hand torch consumables 6 8 Machine torch replacement parts 6 9 M65 M85 M65m M85m 6 9 Machine torch consumables 6 12 Accessory parts 6 14 Powermax65 85 labels 6 15 ...

Page 142: ...ar panel 228646 Kit Powermax65 CE rear panel 228647 Kit Powermax85 CSA rear panel 228653 Kit Powermax85 CE rear panel 228642 Kit Powermax65 85 cover screws 228666 Kit Powermax65 CSA power supply cover 228674 Kit Powermax65 CE power supply cover 228676 Kit Powermax85 CSA power supply cover 228675 Kit Powermax85 CE power supply cover 108797 Adjustment knob 108732 Operating mode switch Operating mode...

Page 143: ... 24 m 128652 Remote start pendant for machine torch 75 ft 22 86 m 023206 Machine interface cable start plasma arc transfer ground 25 ft 7 63 m 023279 Machine interface cable start plasma arc transfer ground 50 ft 15 24 m 228350 Machine interface cable start plasma arc transfer adjustable voltage divider ground 25 ft 7 6 m spade connectors 228351 Machine interface cable start plasma arc transfer ad...

Page 144: ... element inside filter bowl Fan subassembly Part number Description 228686 Kit Powermax65 85 fan subassembly 228685 Kit Powermax65 85 air filter 228695 Kit Powermax65 85 air filter element 228688 Kit Powermax65 85 pressure switch 228687 Kit Powermax65 85 solenoid valve 228689 Kit Powermax65 85 pressure transducer ...

Page 145: ...parts H65 H85 Torch handle Torch handle Torch lead Torch lead Handle screws Handle screws Safety trigger and spring Safety trigger and spring O ring O ring Torch head Torch head Cap sensor switch Pilot terminal screw Pilot terminal screw Cap sensor switch H65s H85s ...

Page 146: ... torch assembly with 25 ft 7 6 m lead 087086 H85 Hand torch assembly with 50 ft 15 2 m lead 087087 H85 Hand torch assembly with 75 ft 22 9 m lead 087088 H85s Hand torch assembly with 10 ft 3 0 m lead 087089 H85s Hand torch assembly with 25 ft 7 6 m lead 087090 H85s Hand torch assembly with 50 ft 15 2 m lead 087091 H85s Hand torch assembly with 75 ft 22 9 m lead 228717 Kit H65 H85 Torch handle repl...

Page 147: ...placement 10 ft 3 0 m 228723 Kit H65 H85 Torch lead replacement 25 ft 7 6 m 228724 Kit H65 H85 Torch lead replacement 50 ft 15 2 m 228725 Kit H65 H85 Torch lead replacement 75 ft 22 9 m 228726 Kit H65s H85s Torch lead replacement 10 ft 3 0 m 228727 Kit H65s H85s Torch lead replacement 25 ft 7 6 m 228728 Kit H65s H85s Torch lead replacement 50 ft 15 2 m 228729 Kit H65s H85s Torch lead replacement 7...

Page 148: ... 45 A Nozzle 220819 65 A Nozzle 220816 85 A Nozzle 220842 Electrode 220857 Swirl ring Gouging 220798 65 A 85 A shield 220854 Retaining cap 220797 65 A 85 A nozzle 220842 Electrode 220857 Swirl ring FineCut 45 A 220931 Deflector 220854 Retaining cap 220930 Nozzle 220842 Electrode 220947 Swirl ring Hand torch consumables ...

Page 149: ...hine torch The M65m and M85m mini machine torches do not have a positioning sleeve and gear rack 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 150: ...M65m Mini machine torch assembly with 50 ft 15 2 m lead 083263 M65m Mini machine torch assembly with 75 ft 22 9 m lead 087092 M85 Machine torch assembly with 15 ft 4 6 m lead 087093 M85 Machine torch assembly with 25 ft 7 6 m lead 087094 M85 Machine torch assembly with 35 ft 10 7 m lead 087095 M85 Machine torch assembly with 50 ft 15 2 m lead 087096 M85 Machine torch assembly with 75 ft 22 9 m lea...

Page 151: ...ensor switch replacement 058503 O ring 075504 Pilot terminal screw 228730 Kit M65 M65m M85 M85m torch lead replacement 15 ft 4 6 m 228731 Kit M65 M65m M85 M85m torch lead replacement 25 ft 7 6 m 228732 Kit M65 M65m M85 M85m torch lead replacement 35 ft 10 7 m 228733 Kit M65 M65m M85 M85m torch lead replacement 50 ft 15 2 m 228734 Kit M65 M65m M85 M85m torch lead replacement 75 ft 22 9 m ...

Page 152: ...ining cap 220941 45 A Nozzle 220819 65 A Nozzle 220816 85 A Nozzle 220842 Electrode 220857 Swirl ring Unshielded 220955 Deflector 220854 Retaining cap 220941 45 A Nozzle 220819 65 A Nozzle 220816 85 A Nozzle 220842 Electrode 220857 Swirl ring Gouging 220798 65 A 85 A shield 220854 Retaining cap 220797 65 A 85 A nozzle 220842 Electrode 220857 Swirl ring ...

Page 153: ...45 A1 220955 Deflector 220948 Shield 220854 Retaining cap 220953 Ohmic retaining cap 220930 Nozzle 220842 Electrode 220857 Swirl ring 1 The deflector 220955 is used only with the standard retaining cap 220854 The shield 220948 is used only with the ohmic retaining cap 220953 ...

Page 154: ...223195 Kit 65 A Work lead with C style clamp 50 ft 15 2 m 223196 Kit 65 A Work lead with C style clamp 75 ft 22 9 m 223197 Kit 65 A Work lead with magnet clamp 25 ft 7 5 m 223198 Kit 65 A Work lead with magnet clamp 50 ft 15 2 m 223199 Kit 65 A Work lead with magnet clamp 75 ft 22 9 m 223200 Kit 65 A Work lead with ring terminal 25 ft 7 5 m 223201 Kit 65 A Work lead with ring terminal 50 ft 15 2 m...

Page 155: ... 25 ft 7 5 m 223207 Kit 85 A Work lead with magnet clamp 50 ft 15 2 m 223208 Kit 85 A Work lead with magnet clamp 75 ft 22 9 m 223209 Kit 85 A Work lead with ring terminal 25 ft 7 5 m 223210 Kit 85 A Work lead with ring terminal 50 ft 15 2 m 223211 Kit 85 A Work lead with ring terminal 75 ft 22 9 m 229370 Kit Powermax65 85 Wheel kit assembly Part number Description 228649 Kit Powermax65 labels CSA...

Page 156: ...ut être préjudiciable pour l opérateur et les personnes qui se trouvent sur les lieux de travail Consulter le manuel avant de faire fonctionner Le non respect des ces instructions de sécurité peut entraîner la mort 1 Les étincelles de coupage peuvent provoquer une explosion ou un incendie 1 1 Ne pas couper près des matières inflammables 1 2 Un extincteur doit être à proximité et prêt à être utilis...

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