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Hypertherm Powermax 65, Service Manual

The Hypertherm Powermax 65 is a high-performance cutting system, designed for professional operators. To get the most out of this powerful tool, make sure to download the free Operator's Manual from our trusted website. This comprehensive manual provides step-by-step instructions and valuable insights to help you maximize the potential of your Powermax 65.

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Torch SeTup

3-4

 

powermax

65/85

 Service Manual

Choose the hand torch consumables

Hypertherm includes a box of consumables with your system. Both styles of hand torches shown on the previous page 

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 thin materials, you may prefer to use FineCut consumables, or use a 45 A nozzle and reduce 

the amperage to that setting.

Summary of Contents for Powermax 65

Page 1: ...Service Manual 807120 Revision 1 Plasma arc cutting systems ...

Page 2: ...______________ Distributor _____________________________________________ ________________________________________________________ ________________________________________________________ Maintenance notes ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________...

Page 3: ...ypertherm Inc Hanover NH USA www hypertherm com email info hypertherm com 2012 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: ...89 Tel 65 6841 2490 Fax 65 6841 2489 Technical Service Hypertherm Shanghai Trading Co Ltd Unit 301 South Building 495 ShangZhong Road Shanghai 200231 PR China 86 21 60740003 Tel 86 21 60740393 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 H...

Page 5: ...s 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 signaling and telephone cables above below and adjacent to the cutting equipm...

Page 6: ... 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 the 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 steel work a connection bonding the work...

Page 7: ...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 damaged Hypertherm provides repair replacement or adjustment of the Product as the sole and exclusive rem...

Page 8: ...h damages National and local codes National and local codes governing plumbing and electrical installation shall take precedence over any instructions contained in this manual In no event shall Hypertherm be liable for injury to persons or property damage by reason of any code violation or poor work practices Liability cap In no event shall Hypertherm s liability if any whether such liability is b...

Page 9: ...wermax65 85 Service Manual v Safety information Before operating any Hypertherm equipment read the separate Safety and Compliance Manual 80669C included with your product for important safety information ...

Page 10: ...vi powermax65 85 Service Manual ...

Page 11: ...4 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 Requirements for grounding 2 5 Power connection 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...

Page 12: ...able 3 17 Connecting the torch lead 3 22 Using the cut charts 3 23 Estimated kerf width compensation 3 24 85 A shielded consumables 3 26 65 A shielded consumables 3 30 45 A shielded consumables 3 34 FineCut consumables 3 38 85 A unshielded consumables 3 43 65 A unshielded consumables 3 47 45 A unshielded consumables 3 51 Section 4 Operation Controls and indicators 4 2 Rear controls 4 2 Front contr...

Page 13: ...power supply functional description 5 4 380 400 V CE 3 phase power supply functional description 5 5 Sequence of operation 5 6 Troubleshooting preparation 5 7 Test equipment 5 7 Troubleshooting procedures and sequence 5 7 External inspection 5 9 Internal inspection 5 9 Initial resistance check 5 9 Check the power switch 5 9 Hypertherm IGBT tester 5 12 Indicator LEDs and device tests 5 12 IGBT test...

Page 14: ... Component Replacement Remove and replace the power supply cover and Mylar barrier 6 2 Remove the power supply cover and Mylar barrier 6 2 Replace the Mylar barrier 6 3 Replace the power supply cover 6 4 Replace the power cord 6 5 Replace the power cord 200 600 V 3 phase CSA 400 V 3 phase CE 6 5 Replace the power cord 200 480 V 1 phase CSA 6 10 Replace the work lead 6 11 Replace the fan 6 12 Repla...

Page 15: ...lacement parts 7 12 Duramax 15 hand torch replacement parts 7 13 Hand torch consumables 7 14 Duramax 180 full length machine torch replacement parts 7 15 Duramax 180 mini machine torch replacement parts 7 17 Machine torch consumables 7 19 Accessory parts 7 20 Powermax65 and Powermax85 labels 7 21 Safety critical parts 7 22 Recommended spare parts 7 24 Section 8 Wiring Diagrams Cutting timing diagr...

Page 16: ...Table of Contents xii powermax65 85 Service Manual ...

Page 17: ...ent weights 1 5 Powermax65 power supply ratings 1 6 Powermax85 power supply ratings 1 8 Duramax 75 hand torch dimensions 1 10 Duramax 15 hand torch dimensions 1 10 Duramax 180 full length machine torch dimensions 1 11 Duramax 180 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 18: ...knesses up to 1 1 4 inches 32 mm and pierce thicknesses up to 3 4 inch 19 mm FastConnect provides a simple push button torch connection to the power supply for quick torch changes The typical handheld Powermax system includes a Duramax series 75 hand torch with a consumables box and work lead cable Reference materials include operator manual quick setup card registration card setup DVD and safety ...

Page 19: ... 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 Maintenance and repair see the troubleshooting section Replacing components see the Component replacement section Service Manual Part numbers and o...

Page 20: ...Specifications 1 4 powermax65 85 Service Manual Power supply dimensions 9 2 in 234 mm 19 0 in 483 mm 17 0 in 432 mm ...

Page 21: ... 9 27 2 50 4 22 8 65 85 A lbs kg Hand torch 7 6 m 25 ft 6 8 3 1 Hand torch 15 m 50 ft 12 2 5 5 Hand torch 23 m 75 ft 17 6 8 0 Machine torch 7 6 m 25 ft 7 6 3 4 Machine torch 15 m 50 ft 13 2 6 0 Machine torch 23 m 75 ft 18 8 8 5 65 A 85 A lbs kg lbs kg Work lead 7 6 m 25 ft 2 8 1 3 6 8 3 1 Work lead 15 m 50 ft 5 0 2 3 7 5 3 4 Work lead 23 m 75 ft 6 9 3 1 10 6 4 8 ...

Page 22: ...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 23: ...th a short circuit power Ssc greater than or equal to 2035 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 T...

Page 24: ... 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 25: ...th a short circuit power Ssc greater than or equal to 2035 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 T...

Page 26: ...ermax65 85 Service Manual Duramax 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 Duramax 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 27: ...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 Duramax 180 mini machine torch dimensions 6 6 in 16 8 cm 3 3 in 8 4 cm ...

Page 28: ...hout torch height control 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 1 5 Component weights Duty cycle and voltage information refer to 1 6 Powermax65 power supply rati...

Page 29: ...t control 5 8 in 16 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 1 5 Component weights Duty cycle and voltage information refer to 1 8 Powermax85 ...

Page 30: ... 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 Dir...

Page 31: ...t AC O Power is OFF Plasma torch cutting f1 f2 1 An inverter based power source either 1 phase or 3 phase Plate metal cutting Volt amp curve drooping characteristic Expanded metal cutting AC Power is ON LED Gouging System fault LED AC input power connection Inlet gas pressure fault LCD The terminal for the external protective earth conductor Missing or loose consumables LCD Power supply is out of ...

Page 32: ...Specifications 1 16 powermax65 85 Service Manual ...

Page 33: ...tion 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 recommendation...

Page 34: ...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 35: ...ice 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 36: ... 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 HYP input current value should be used for installation purposes The maximum output voltage will vary based on your input voltage and the cir...

Page 37: ...sition Contain a power operated mechanism that serves as an emergency stop Have appropriate slow blow fuses installed See 2 6 Power connection for the Powermax65 or 2 8 Power connection for the Powermax85 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 The powe...

Page 38: ...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 39: ...2 3 wire power cord The power cord must be connected by a licensed electrician 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 l...

Page 40: ... 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 curr...

Page 41: ...need to install an appropriate power cord Refer to 2 10 Single phase power cord installation for instructions Caution 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 6AWG 16 mm2 3 wire power cord The power cord must be connected by a licensed electrician ...

Page 42: ...x65 85 Service 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 43: ...n The procedure is similar to installing a single phase power cord as shown in the section 2 10 Single phase power cord installation The figure below shows the additional wire connected to L3 Extension cord recommendations Any extension cord must have an appropriate wire size for the cord length and system voltage Use a cord that meets national and local codes The table on the next page provides t...

Page 44: ...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 45: ...d for best performance Note 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 again sometimes called a quick reset may not clear the fault Instead turn OFF the power supply and wait 30 to 45 seconds before turning ON again Engine drive rating System output current Per...

Page 46: ...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 sy...

Page 47: ...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 48: ...when the recommended inlet pressure is not available Torch lead length 7 6 m 25 ft 15 m 50 ft 23 m 75 ft 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 49: ...unt the torch 3 10 Choose the machine torch consumables 3 12 Machine torch consumables 3 12 Install the machine torch consumables 3 15 Aligning the torch 3 15 Connecting an optional remote start pendant 3 16 Connecting an optional machine interface cable 3 17 Connecting the torch lead 3 22 Using the cut charts 3 23 Estimated kerf width compensation 3 24 85 A shielded consumables 3 26 65 A shielded...

Page 50: ...etal 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 with a continuous pilot arc causes more consumable wear Under normal conditions the electrode will wear out first during machine cutting and the nozzle will wear out first when hand cut...

Page 51: ...Torch Setup powermax65 85 Service Manual 3 3 Consumables Safety trigger Safety trigger Hand torch setup Duramax 75 hand torch Duramax 15 hand torch Consumables ...

Page 52: ...se 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 thin materials you may prefer to use FineCut consumables or use a 45 A nozzle and red...

Page 53: ...ut consumables 220818 Shield 220818 Shield 220854 Retaining cap 220854 Retaining cap 220941 Nozzle 220941 Nozzle 220819 Nozzle 220819 Nozzle 220816 Nozzle 220857 Swirl ring 220857 Swirl ring 220842 Electrode 220842 Electrode 220854 Retaining cap 220857 Swirl ring 220842 Electrode 220798 Shield 220797 Nozzle 220854 Retaining cap 220947 Swirl ring 220842 Electrode 220931 Shield 220930 Nozzle ...

Page 54: ...ing cap nozzle electrode and swirl ring With the power switch in the OFF O position install the torch consumables as shown below 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 Retaining cap Electrode Swirl ring Shield Nozzle ...

Page 55: ...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 Duramax 180 full length machine torch Duramax 180 mini machine torch 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 l...

Page 56: ...nd 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 stra...

Page 57: ... 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 torc...

Page 58: ...the section 3 7 Machine torch setup 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 from the torch 2 Unscrew the strain relief body from the str...

Page 59: ...sumables end of the sleeve 12 Route the torch lead through the cutting table s track 13 Slide the strain relief body and strain relief nut over the torch lead 14 If you are mounting a full length machine torch slide the positioning sleeve over the torch head 15 Slide the coupler over the torch lead 16 Reconnect the gas line to the torch lead 17 Reattach the torch s pilot wire to the torch body usi...

Page 60: ...small distance about 2 3 mm 08 12 inch away from the metal Unshielded consumables generally have a shorter life than shielded consumables Depending upon which system you order you may receive a starter consumable kit with a standard retaining cap or ohmic retaining cap Both styles of machine torches use the same consumables Machine torch consumables Mechanized shielded consumables Powermax65 22094...

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: ...les 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: ...s To 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 3 6 Install the hand torch consumables Aligning the torch Mount the machine torch perpendicular to the workpiece in order ...

Page 64: ...rt number 128650 25 foot 7 6 m Part number 128651 50 foot 15 m Part number 128652 75 foot 23 m Remove the receptacle cover and plug the Hypertherm remote start pendant into the receptacle on the rear of the power supply Note 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 interfa...

Page 65: ...edance 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 offers s...

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: ...rt start plasma Input Normally open 18 VDC open circuit voltage at START terminals Requires dry contact closure to activate 3 4 Green black Transfer start machine motion Output Normally open Dry contact closure when the arc 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 si...

Page 68: ...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 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 20 1 21 1 1 30 1 40 1 50 1 ...

Page 69: ...ield Service Bulletin 807060 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: ...ct 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 To remove the torch press the red button on the connector and pull the connector out of the receptacle Red button ...

Page 71: ...tationary at the pierce height before the torch starts the cutting motion 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 spee...

Page 72: ...2 2 2 3 45A Shielded 1 1 1 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...

Page 73: ... 0 057 0 059 Stainless Steel 85A Shielded 0 068 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 ...

Page 74: ...Service 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: ... 2070 128 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 seconds ipm Volts ipm Volts 10GA 0 06 0 15 250 0 0 250 122 336 121 3 16 in 0 2 1...

Page 76: ...700 122 4600 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 seconds ipm Volts ipm Volts 10GA 0 06 0 15 250 0 2 275 122 336 ...

Page 77: ...6 0 5 3800 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 seconds ipm Volts ipm Volts 1 8 in 0 06 0 15 250 0 2 30...

Page 78: ...Service Manual 65 A shielded consumables 65 A 65 A 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 ...

Page 79: ... 1700 129 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 seconds ipm Volts ipm Volts 16GA 0 06 0 15 250 0 1 260 123 294 121 10G...

Page 80: ... 4 0 5 5200 125 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 seconds ipm Volts ipm Volts 16GA 0 06 0 15 250 0 1 345 12...

Page 81: ...00 124 4 0 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 seconds ipm Volts ipm Volts 1 16 in 0 06 0 15 25...

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

Page 83: ...1 9000 128 10800 128 1 5 0 1 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 seconds ipm Volts ipm Volts 26GA 0 06 0 15 250 0 0 350 128 500 128 22GA 350 128 450 12...

Page 84: ...29 1 9000 130 10800 130 1 5 0 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 seconds ipm Volts ipm Volts 26GA 0 06 0 15 250 0 0 350 130 500 129 22GA 350 130 450 ...

Page 85: ...in Volts mm min 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 seconds ipm Volts ipm Volts 1 32 in 0 06 0 15 250 0 0 325 136 450 136 1...

Page 86: ...ables Note The cut charts in this section apply to both shielded and unshielded consumables 220953 Retaining cap 220857 Swirl ring 220842 Electrode 220948 Shield 220930 Nozzle 220854 Retaining cap 220857 Swirl ring 220842 Electrode 220955 Deflector 220930 Nozzle ...

Page 87: ... seconds mm min Volts 0 5 40 1 5 2 25 150 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 4800 78 3 0 5 2750 78 4 0 6 1900 78 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 26GA 40 0 06 0 09 150 0 0 325 78 24GA 325 78 22GA 0 1 325 78 20GA 325 78 18GA 45 0 2 3...

Page 88: ... seconds mm min Volts 0 5 40 0 5 2 0 400 0 0 8250 68 0 6 8250 68 0 8 0 1 8250 68 1 45 0 15 8250 68 1 5 0 4 6150 70 2 4800 71 3 0 5 2550 80 4 0 6 1050 80 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 26GA 40 0 02 0 08 400 0 0 325 68 24GA 325 68 22GA 0 1 325 68 20GA 325 68 18GA 45 0 2 3...

Page 89: ... min Volts 0 5 30 1 5 2 25 150 0 0 3800 69 0 6 3800 68 0 8 0 1 3800 70 1 40 0 2 3800 72 1 5 0 4 3800 75 2 45 3700 76 3 0 5 2750 78 4 1900 78 English Material Thickness Current Torch to Work Distance Initial Pierce Height Pierce Delay Time Recommended Cut Speed Voltage A inches inches seconds ipm Volts 26GA 30 0 06 0 09 150 0 0 150 70 24GA 150 68 22GA 0 1 150 70 20GA 150 71 18GA 40 0 2 150 73 16GA ...

Page 90: ...mm seconds mm min Volts 0 5 30 0 5 2 0 400 0 0 3800 69 0 6 3800 69 0 8 0 1 3800 69 1 40 0 15 3800 69 1 5 0 4 2900 69 2 2750 69 3 45 0 5 2550 80 4 0 6 1050 80 English Material Thickness Current Torch to Work Distance Initial Pierce Height Pierce Delay Time Recommended Cut Speed Voltage A in in seconds ipm Volts 26GA 30 0 02 0 08 400 0 0 150 69 24GA 150 69 22GA 0 1 150 69 20GA 150 69 18GA 40 0 2 145...

Page 91: ...Torch Setup powermax65 85 Service Manual 3 43 85 A unshielded consumables 85 A 220955 Deflector 220854 Retaining cap 220857 Swirl ring 220842 Electrode 220816 Nozzle ...

Page 92: ...3450 120 4400 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 seconds ipm Volts ipm Volts 14GA 0 08 0 20 250 0 1 280 117 416 116...

Page 93: ...0 2 5600 118 7800 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 seconds ipm Volts ipm Volts 14GA 0 08 0 20 250 0 1 34...

Page 94: ... 119 4 0 2 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 seconds ipm Volts ipm Volts 1 8 in 0 08 0 20 ...

Page 95: ...Torch Setup powermax65 85 Service Manual 3 47 65 A unshielded consumables 65 A 220955 Deflector 220854 Retaining cap 220857 Swirl ring 220842 Electrode 220819 Nozzle ...

Page 96: ...8 4 0 5 4250 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 seconds ipm Volts ipm Volts 16GA 0 08 0 20 250 0 1 255 116 ...

Page 97: ...3 0 2 6600 118 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 seconds ipm Volts ipm Volts 16GA 0 08 0 20 250 0 1 34...

Page 98: ...6550 124 9500 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 seconds ipm Volts ipm Volts 1 16 in 0 08 0 20 250 0 1 325...

Page 99: ...Torch Setup powermax65 85 Service Manual 3 51 45 A unshielded consumables 45 A 220955 Deflector 220854 Retaining cap 220857 Swirl ring 220842 Electrode 220941 Nozzle ...

Page 100: ... 1 9000 120 10800 121 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 seconds ipm Volts ipm Volts 26GA 0 06 0 15 250 0 0 350 120 500 120 22GA 350 120 450 1...

Page 101: ...119 1 9000 121 10800 119 1 5 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 seconds ipm Volts ipm Volts 26GA 0 06 0 15 250 0 0 350 120 500 119 22GA 350 120 450...

Page 102: ...min Volts mm min 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 seconds ipm Volts ipm Volts 1 32 in 0 06 0 15 250 0 0 325 126 450 121 ...

Page 103: ...ting mode switch 4 9 Check the indicators 4 10 Manually adjusting the gas pressure 4 10 Adjusting the current amperage 4 11 Understanding duty cycle limitations 4 12 Using the hand torch 4 13 Operate the safety trigger 4 13 Hand torch cutting hints 4 14 Start a cut from the edge of the workpiece 4 15 Pierce a workpiece 4 16 Gouge a workpiece 4 17 Common hand cutting faults 4 20 Using the machine t...

Page 104: ...wer supply and its control circuits Power ON LED green When illuminated this LED indicates that the power switch has been set to I ON and that the safety interlocks are satisfied When blinking the power supply has a fault Fault LED yellow When illuminated this LED indicates that there is a fault with the power supply For information about these fault conditions and how to correct them refer to sec...

Page 105: ...the gas pressure or the amperage This LED is illuminated in manual mode Note Manual mode should be used by experienced users who need to optimize the gas setting override the automatic gas setting for 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 autom...

Page 106: ...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 factory defined value If the pressure is higher than the preset value the arrow appears above the mid point of the bar If the pressure is lower than the preset value the arrow appears below the mid point...

Page 107: ... troubleshooting information Warning The system continues to run Fault The system stops cutting If you can not correct the problem and restart the system contact your distributor or Hypertherm Technical Service Error The system requires service Contact your distributor or Hypertherm Technical Service Temperature Indicates that the temperature of the power supply power module is outside the accepta...

Page 108: ...the power supply refer to Section 2 Power Supply Setup 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 power supply You will attach the work lead ...

Page 109: ...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 ac...

Page 110: ...ad 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 not...

Page 111: ...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 112: ...he gas setting override the automatic gas setting for 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 t...

Page 113: ... 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 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 power...

Page 114: ...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 tem...

Page 115: ... Wear correct and appropriate protective equipment Keep away from the torch tip Do not hold the workpiece and keep your hands clear of the cutting path Never point the torch toward yourself or others Operate the safety trigger The hand torches are equipped with a safety trigger to prevent accidental firings When you are ready to use the torch flip the trigger s safety cover forward toward the torc...

Page 116: ...he 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 the Parts section for part numbers for the Hypertherm plasma cutting guides for cutting circles and making bevel...

Page 117: ...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 118: ... 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 sp...

Page 119: ...ce 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 INJURE ...

Page 120: ...tandoff distance varying the angle of the torch 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 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 Width 26 in 6 6 mm Width 28 in 7 1 mm Depth 14 in 3 6 mm Depth 24 in 6 1 mm ...

Page 121: ...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 122: ...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 123: ...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 124: ...ence 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 dross appears on the top edge of both pieces of the plate when the torch is too low or voltage is too low when using a torch height control Adjust the torch or adjust the voltage i...

Page 125: ...the consumables When piercing materials close to the maximum thickness for a specific process consider the following important factors Allow a lead in distance approximately equal to the thickness of the material being pierced For example 20 mm 3 4 in material requires a 20 mm lead in To avoid damage to the shield from the buildup of molten material created by the pierce do not allow the torch to ...

Page 126: ... need to be replaced For optimized performance in a mechanized application replace the nozzle and the electrode together The cutting speed is not correct Refer to the cut charts in Section 3 Torch Setup for more information The current amperage is set too low Refer to the cut charts in Section 3 Torch Setup for more information The cut angle is not square Causes can be The consumables are worn and...

Page 127: ...uence 5 7 External inspection 5 9 Internal inspection 5 9 Initial resistance check 5 9 Check the power switch 5 9 Hypertherm IGBT tester 5 12 Indicator LEDs and device tests 5 12 IGBT test preparation 5 13 IGBT device test using the Hypertherm tester 5 14 Troubleshoot the Hypertherm IGBT tester 5 14 Schematic for building an IGBT tester 5 15 IGBT device test using a non Hypertherm tester 5 16 200 ...

Page 128: ... Troubleshooting guide 5 32 System tests 5 38 Test 1 Voltage input 5 39 Test 2 DC Power Buss 5 40 Test 3 Output diodes 5 42 Test 4 Inverter and PFC temperature sensor 5 43 Test 5 Flyback circuit DC minor voltages 5 46 Test 6 Torch stuck open TSO 5 48 Test 7 Start signal 5 50 Test 8 Torch cap switch 5 51 Test 9 Electronic regulator 5 52 Test 10 Pressure sensor 5 53 Test 11 Fan 5 54 Test 12 AUX swit...

Page 129: ...nob Controls and indicators The Powermax65 and Powermax85 controls and indicators are described in Section 4 Operation These figures are included for reference ON I OFF O power switch Activates the power supply and its control circuits Torch started Fault icon Fault code Arc is transferred Remote connected Current setting amps Current selection cursor Pressure selection cursor Pressure setting Vis...

Page 130: ...e and control circuit It provides a 760 VDC bus voltage when the input AC voltage is between 200 and 540 VAC At 600 VAC the nominal bus voltage is 840 VDC The inverter consists of a dual IGBT package Q12 the power transformer an output current sensor and the control circuit The inverter operates as a pulse width modulated half bridge circuit driving an isolation transformer The output of the isola...

Page 131: ...e Q9 the power transformer a current sensor and the control circuit The inverter operates as a pulse width modulated half bridge circuit driving an isolation transformer The output of the isolation transformer is rectified by the output bridge D44 and D46 The output circuitry consists of 2 current sensors located on the power board the pilot arc IGBT Q10 and the output choke The digital signal pro...

Page 132: ...ce drops after the cut Release the plasma start trigger on the hand torch or the remote start switch for the machine torch The electronic regulator activates The gas flow starts The cutting arc starts Position the torch over the workpiece Pull the plasma start trigger on the hand torch or press the remote start switch for the machine torch The green power ON LED illuminates indicating the system i...

Page 133: ...ultimeter IGBT insulated gate bipolar transistor tester part number 128883 Troubleshooting procedures and sequence When performing the troubleshooting procedures Read the Safety and Compliance Manual 80669C for detailed safety information Refer to Section 6 Component Replacement Refer to Section 7 Parts Refer to Section 8 Wiring Diagrams After the problem has been located and repaired refer to the...

Page 134: ...ctrical parts If power is required for servicing use extreme caution when working near live electrical circuits Dangerous voltages exist inside the power supply that can cause serious injury or death Do not attempt to repair the power board or control board Do not cut away or remove any protective conformal coating from either board To do so will risk a short circuit between the AC input circuit a...

Page 135: ...esistance values must be taken with the power cord disconnected and all internal power supply wires attached Perform the steps in Internal inspection before continuing in this section If resistance values are not close 25 to the values given in this section isolate the problem by removing wires attached to the resistance check points or component until the problem is found After the problem has be...

Page 136: ...oubleshooting and System Tests 5 10 powermax65 85 Service Manual 500 kΩ 200 600 V CSA 500 kΩ 500 kΩ 20 MΩ Ground is at bottom of heat sink Ground is at top of heat sink 350 kΩ 400 V CE 350 kΩ 350 kΩ 20 MΩ ...

Page 137: ...kΩ Output to ground 20 MΩ If no problems were found during the visual inspection or the initial resistance check and the power supply still does not operate correctly see the Troubleshooting guide Note The Troubleshooting guide provides most probable causes and solutions Study the system wiring diagram and understand the theory of operation before troubleshooting Before purchasing any major replac...

Page 138: ...r for a short circuited IGBT when switch is pressed to the left Red fail LED When illuminated this LED indicates that the IGBT failed the test for an open IGBT when switch is pressed to the right or for a short circuited IGBT when switch is pressed to the left Red low battery LED When illuminated this LED indicates that the remaining voltage in the battery is insufficient to power the test circuit...

Page 139: ... three common configurations of an IGBT Each connection on the IGBT will be labeled with an abbreviation They may be labeled as C E G or 1 2 3 with a schematic that shows numbers and pin functions Yellow lead Gate 2 G2 Black lead Emitter 2 E2 Red lead Collector 2 C2 IGBT Inverter Test 1 Yellow lead Gate G Black lead Emitter E Red lead Collector C IGBT PFC Yellow lead Gate G Red lead Collector C Bl...

Page 140: ... the short circuit test None Left X Battery below 8 V Replace battery Left Dead battery Replace battery Right X IGBT is open Replace IGBT Right X IGBT passed the open test None Right X Battery below 8 V Replace battery Right Dead battery Replace battery Troubleshoot the Hypertherm IGBT tester 1 Inspect the leads and the IGBT tester for damage 2 Verify that the battery voltage is greater than 8 V 3...

Page 141: ... E1 4 Gate 1 G1 5 Emitter 1 E1 6 Emitter 2 E2 7 Gate 2 G2 9 VDC battery R4 2 0K 009036 Normally open N O pushbutton switch Yellow Minigrabber test clip R1 3 01M 009464 Black Minigrabber test clip Q1 150 A 1400 V 109125 R3 2 0K 009036 Red LED lamp 109092 Red Minigrabber test clip D1 1 2 3 5 6 7 Schematic for building an IGBT tester 4 ...

Page 142: ...that the 9 V battery reads greater than 8 0 V 3 Connect the test leads as shown below 4 With the test leads connected and without pressing the pushbutton switch the LED should not illuminate If the LED is illuminated then the IGBT is shorted Replace the IGBT 5 With the test leads connected press the pushbutton switch This time the LED should illuminate If the LED does not illuminate then the IGBT ...

Page 143: ...ower switch S1 200 600 V CSA power supply overview Power board Flyback circuit Control board Digital signal processor DSP board Ground Test points Gate drive connectors Gate drive connector PFC temperature sensor Nozzle wire Electrode wire Transformer wires Output inductor wire Damper resistor wires 3uF Capacitors PFC inductor wires ...

Page 144: ... J24 TP13 J29 TP11 TP12 380 400 V CE power supply overview Power switch S1 Power board Flyback circuit Control board Digital signal processor DSP board Test points Ground Gate drive connectors 3uF Capacitor MOV sub assembly PFC inductor wires Transformer wires Nozzle wire Electrode wire Output inductor wire ...

Page 145: ...CSA power supply overview power board removed Power switch S1 Output snubber resistor Optional serial board PFC snubber resistor Inverter snubber resistor Pilot arc IGBT Output diode bridge Input diode bridge Snubber resistor Inverter IGBT module Bulk capacitors PFC IGBT Ground ...

Page 146: ...ervice Manual 380 400 V CE power supply overview power board removed Input diode bridge Inverter IGBT module Power switch S1 Ground Bulk capacitors Output snubber resistor Optional serial board Inverter snubber resistor Pilot arc IGBT Output diode bridge ...

Page 147: ...roubleshooting faults display the service screen by simultaneously pressing the automatic manual and current gas mode selectors for approximately two 2 seconds The service screen displays Designator Description I Current set read C LCD contrast B LCD brightness percent P Pressure set read G Gas test enable 1 disable 0 IP Boost circuit current not present in CE machines VL Incoming AC line voltage ...

Page 148: ...ervice screen simultaneously press the automatic manual and current gas mode selectors The operator screen displays Important fault icons One of the following fault icons may appear on the LCD display in operator mode Warning The system continues to operate Fault The system stops cutting and is able to recover when the fault is cleared Error The system needs service Performing a cold restart Somet...

Page 149: ...Refer to 5 21 Displaying the service screen On Off Adjust the gas inlet pressure as needed Check for kinked or blocked air lines Perform Test 10 0 12 2 Output gas pressure high DSP firmware revision J or later Refer to 5 21 Displaying the service screen The gas subsystem is not working properly Check the valve Perform Test 10 0 12 3 Output gas pressure unstable DSP firmware revision J or later Ref...

Page 150: ...he fault log in the service screen to identify the major fault 0 20 0 Low gas pressure Test 10 The gas pressure has fallen below the minimum pressure for that process mode and lead length On On Ensure the gas line is properly installed Replace the air filter element if dirty Replace the gas supply line if restricted Ensure the inlet pressure is 85 to 135 PSI 5 9 to 9 3 bar 0 21 0 Gas flow lost whi...

Page 151: ...ight is on during the gas test Toggle back to 0 and exit manual mode Replace the regulator if necessary If the problem persists contact your Hypertherm distributor or authorized repair facility 0 30 1 Torch stuck closed Test 6 The nozzle and electrode will not separate after a start is received The regulator may not be functioning properly 0 40 0 PFC Boost IGBT module under temperature Test 4 On O...

Page 152: ...k start On On If the power supply is turned on while the torch trigger is pressed the system is disabled Release the trigger and cycle the power to the machine Check for continuity between Pin 6 and Pin 7 of the torch connector There should be very low resistance when the torch trigger is pulled Test with a known working torch 0 52 0 Torch not connected On On Plug a torch lead into the FastConnect...

Page 153: ...or fault with the system On On Display the service screen A qualified service technician must service the system Contact your distributor or authorized repair facility 1 nn n These fault codes usually relate to the DSP board and can only be seen on the service screen Fault code Description System test number Power LED Fault LED Fault icon Solutions 1 00 0 Digital signal processor fault On On These...

Page 154: ...eck the auxiliary switch cable Perform Test 12 2 10 0 Inverter module temp sensor open Test 4 Check the associated wiring Check the resistance across the thermistor It should be about 10 kΩ at room temperature If no problems are found it is possible that the inverter heat sink temperature sensor assembly 228805 has failed 2 10 1 Inverter module temp sensor shorted Test 4 2 11 0 Pressure sensor ope...

Page 155: ...e 3 11 1 PFC module temp sensor shorted Test 4 Check the associated wiring If necessary replace the PFC Boost IGBT module 3 11 2 PFC module temp sensor circuit error Check the temperature circuit on the power board If Test 4 is good replace the power board 3 20 0 Fill valve Test 9 Indicates that the Fill Valve is not connected Check the associated wiring If necessary replace the electronic regulat...

Page 156: ...C supply from the flyback circuit is out of range Replace the power board 3 43 0 Inverter capacitors unbalanced Test 2 Voltage across one or both inverter caps is more than 25 different than nominal CSA units have a 760 VDC bus voltage Nominal is 380 VDC for each cap Fault condition 275 or 485 VDC across either capacitor CE units at 400 VAC have a 560 VDC bus voltage Nominal is 280 VDC for each ca...

Page 157: ...ut of phase Test the two inverter IGBTs in the module Replace the module if either is faulty If necessary replace the power board 3 52 0 Shoot through 3 60 0 Power board The DSP does not recognize the power board The code is for future machines where the current DSP board will not work with future power boards 3 70 0 Internal serial communications fault There is a fault with the communication betw...

Page 158: ... more than 15 below the rated voltage Perform Test 1 to check the incoming voltage and the power switch Perform Test 12 on CSA units Faulty power board PCB3 fan or solenoid valve Perform Test 5 to check the flyback circuit Faulty power board PCB3 or IGBT Perform Tests 1 2 and 3 and replace any faulty components Faulty control board PCB1 Replace the control board PCB1 Faulty DSP board Replace the D...

Page 159: ... Poor continuity exists between the work lead and the workpiece The workpiece is dirty The work clamp is damaged The pierce height distance is too large The transfer current sensor is bad Clean the area where the work clamp contacts the workpiece to ensure a good metal to metal connection Inspect the work clamp for damage and repair as necessary If the pierce height distance is too large move the ...

Page 160: ...3 bar Repair air leaks or restrictions Manually adjust the gas pressure on the power supply Poor air quality Air filter element is dirty Moisture or contaminants in the gas supply line Replace the air filter element Add appropriate filtration and purge the lines with nitrogen to flush out oil and moisture Insufficient input power Undersized electrical supply installation Breaker or fuse Supply wir...

Page 161: ...oor work lead connection the output from the power supply is too low the power board is producing low current or the selected cutting mode is incorrect The consumables need to be replaced Inspect the consumables and replace if necessary The work lead may be damaged or not properly connected to the work piece Inspect the work lead for damage Reposition it and clean the work surface to ensure good c...

Page 162: ...ger is pressed again The consumables are worn or damaged the gas filter element is contaminated or the input gas pressure is not at the proper level The consumables need to be replaced Replace the consumables as needed The gas filter element needs to be replaced Replace the gas filter s element if it is contaminated The gas pressure is too high or too low Manually adjust the gas pressure as needed...

Page 163: ...ther coatings Damaged work lead Check the resistance across the work lead If the resistance is greater than 3 Ω repair or replace the work lead Faulty pilot arc IGBT Turn the power OFF remove the consumables and check the resistance between the cathode and the work piece If the resistance is less than 5 kΩ check the resistance across the pilot arc IGBT two screws on 08 If the resistance is less th...

Page 164: ...ce check in Test 2 below These tests should only be performed by a qualified service technician Wear the proper personal protective equipment and use approved tools and measurement equipment Before purchasing a major replacement component verify the problem with Hypertherm Technical Service 1 800 643 9878 or the nearest Hypertherm repair facility Several connectors require you to remove a white ca...

Page 165: ...of the input diode bridge Output VDC Line Voltage x 1 414 VDC Note All values are 15 Three phase L1 Black CSA Brown CE L2 White CSA Black CE L3 Red CSA Gray CE PE Green CSA Green Yellow CE LV LV 1 732 LV LV LV X 1 414 If there is a fault and the diode bridge output value is correct Display the service screen and confirm that the value VL is 15 of AC line voltage LV incoming line voltage If there i...

Page 166: ...unting screws from the bulk capacitors and pull the caps away from the power board Measure resistances described in the following tables CSA Test points Value TP 10 and 12 25 kΩ TP 11 and 12 25 kΩ CE Test points Value TP 11 and 13 18 kΩ TP 12 and 13 18 kΩ WORK LEAD BLK BLK J13 J16 J17 J18 J19 J26 TP12 J28 TP10 TP11 WORK LEAD J13 J2 J1 J18 J19 J27 J30 J23 J24 TP13 J29 TP11 TP12 Replace the bulk cap...

Page 167: ...e Wear proper personal protective equipment PPE before testing powered equipment All values are 15 Check the inverter IGBT voltages as described below The voltage measured across the bulk capacitors half the buss voltage or the smaller values above should be the same before and during torch operation 375 VDC Bulk capacitors Bulk capacitors Inverter IGBT module 425 VDC 280 VDC 750 VDC 850 VDC 560 V...

Page 168: ...h diode the value should be open very high resistance with the meter leads in one direction and 0 1 V to 1 0 V with the meter leads reversed A diode is shorted if the value is less than 0 1 V Replace the bridge A diode is open if the value is greater than 1 0 V in both directions Replace the bridge Note In each case common black should be on 3 3 2 1 3 2 1 3 2 1 3 2 1 ...

Page 169: ...check the F field for the live most recent fault code Fault code 0 40 appears on the operator screen but you need to identify the specific 0 40 fault code variation 0 40 0 PFC module under temperature 0 40 1 PFC module over temperature 0 40 2 Inverter module under temperature 0 40 3 Inverter module over temperature If fault code 0 99 appears on the operator screen display the service screen and ch...

Page 170: ...2 on the plug Resistance should be about 5 5 kΩ 3 If the resistance is incorrect replace the PFC IGBT gate drive wires and PFC temperature sensor wire 4 If the value is correct measure resistance between pins 1 and 2 on the power board with the temperature sensor disconnected The resistance should be about 4 7 kΩ 5 If the value is correct replace DSP board 6 If the value is incorrect replace power...

Page 171: ... 2 Measure the resistance between pins 1 and 3 on the plug 3 If the resistance is not within 15 of 10 kΩ replace the temperature sensor 4 If the value is correct remove the DSP board and measure the resistance between pins 1 and 3 on the power board with the temperature sensor disconnected The resistance should be approximately 57 6 kΩ 5 If the value is correct replace the DSP board 6 If the value...

Page 172: ... It provides 3 3 VDC 5 VDC 24 VDC and 48 VDC Check the voltages as described in the table If a value is not within 15 perform the appropriate test later in this section Volts DC Test points use chassis for negative CSA units CE units 48 J3 Pin 1 J5 Pin 1 24 J1 Pin 1 J3 Pin 3 5 0 J5 Pin 3 J7 Pin 3 3 3 J11 Pin 4 J14 Pin 4 DSP board J11 CSA J14 CE Pin 4 J5 CSA J7 CE Pin 3 Fan J3 CSA J5 CE Pin 4 Fan J...

Page 173: ... power board If the 5 VDC value is incorrect Remove the pressure sensor connector J5 CSA or J7 for CE units and repeat the test If the value is now correct replace the pressure sensor If the value is still incorrect remove the DSP board and repeat the test If the value is now correct replace the DSP board If the value is still incorrect replace the power board If the 24 VDC value is incorrect Remo...

Page 174: ...inuity between the dual black wires connected to the center post of the pilot arc IGBT and the red wire connecting to J28 With gas flowing through the torch gas test mode 1 there should be very high resistance between those two points Note To set the system to gas test mode display the service screen refer to page 5 21 Displaying the service screen move the cursor to G gas and use the adjustment k...

Page 175: ...sumables are bad If the resistance is still greater than 100 Ω measure the resistance in the torch between the pilot arc wires Pin 1 or 2 and negative arc power the center connection If the resistance is still too high replace the torch and lead Note The retaining cap should be snug but not over tightened All values are 15 Check the function of the pilot arc IGBT Turn the machine off and disconnec...

Page 176: ...he torch from the system Close the trigger switch and check the resistance between Pin 6 and Pin 7 If there is very high resistance inspect the lead and trigger switch for opens and replace or repair as necessary If there is no problem found with the torch wiring or trigger switch and there is still no arc or start icon Turn the machine off and disconnect power Remove the nozzle and electrode from...

Page 177: ...n Pin 5 and Pin 7 in the torch lead plug a If the resistance is very high check for opens in the torch leads and cap sensor switch b If there is no problem with the leads or switch test the circuit boards Turn off the machine and disconnect power Put a jumper wire between J20 pins 1 and 2 Reconnect power and turn on the machine If the cap sensor switch icon is not displayed verify the DSP board by...

Page 178: ...the electronic regulator control cable J4 for CSA J6 for CE from the power board If air continues to flow replace the electronic regulator If the air stops flowing verify the DSP board by replacing it with a known good one If the DSP board is not the problem replace the power board Pressure sensor J5 CSA J7 CE Fan J3 CSA J5 CE Electronic regulator J4 CSA J6 CE Inverter temperature sensor J2 CSA J4...

Page 179: ...ge 5 21 Displaying the service screen Enable the gas test by moving the cursor to the G field and turning the adjustment knob to display 1 in the field To turn off the gas test turn the adjustment knob to display 0 in the field Note the flowing gas pressure in the P field to the right of the slash 5 Measure VDC between Pin 2 and Pin 1 The value should be 0 0463 times the pressure for example 68 PS...

Page 180: ...for CE units 4 Turn the machine on 5 With the fan control cable connected to J3 for CSA units and J5 for CE measure the DC voltage between Pin 1 and Pin 4 in the plug a If the voltage is 48 VDC 5 replace the fan b If the voltage is not correct Remove the fan control cable and re measure the DC voltage on the power board connector between Pin 1 and Pin 4 of J3 J5 If the voltage is 48 VDC replace th...

Page 181: ...onnect the power 2 Disconnect the auxiliary switch cable from J1 on the power board 3 Measure the resistance on the cable plug between Pin 4 and Pin 5 4 If the power switch is closed ON there should be very low resistance 5 If the power switch is open OFF there should be very high resistance 6 If the resistance measurement doesn t agree check the cable plug and switch for opens or shorts ...

Page 182: ...Troubleshooting and System Tests 5 56 powermax65 85 Service Manual ...

Page 183: ...A 400 V 3 phase CE 6 5 Replace the power cord 200 480 V 1 phase CSA 6 10 Replace the work lead 6 11 Replace the fan 6 12 Replace the air filter element 6 14 Replace the air filter subassembly 6 15 Replace the power board 6 17 Remove the DSP board 6 17 Replace the power board 380 400V CE 6 19 Replace the power board 200 600V CSA 6 22 Install the DSP board 6 25 Replace the Mylar barrier and power su...

Page 184: ...procedures Front of power supply 1 Turn OFF the power disconnect the power cord and disconnect the gas supply 2 Using a T15 TORX or blade screwdriver remove the 8 small screws 2 from the power supply cover 3 Using a T20 TORX or blade screwdriver remove the 8 large screws 1 from the power supply cover 4 Lift the cover 3 off the power supply 1 1 1 2 2 1 2 2 1 3 5 Remove the Mylar barrier from the po...

Page 185: ...y frame 3 Be careful not to damage wires or accidentally disconnect wires from the connectors 4 Gently bend the top of the barrier at the perforation so that the top bends over the top of the power supply 5 Slide the barrier down so that the bottom edge fits inside the power supply frame 4 6 Reattach the metal strap at the top of the power supply to secure the front and rear panels Be careful not ...

Page 186: ...sure that the vent in the side of the cover is over the fan Be careful not to pinch any wires 2 Using a T15 TORX or blade screwdriver install the 8 small screws 2 into the power supply cover Tighten the screws to 15 in lbs 17 3 kg cm 3 Using a T20 TORX or blade screwdriver install the 8 large screws 1 into the power supply cover Tighten the screws to 15 in lbs 17 3 kg cm Front of power supply 1 1 ...

Page 187: ...e the existing 3 phase power cord 1 Turn OFF the power disconnect the power cord and disconnect the gas supply 2 Remove the power supply cover and Mylar barrier Refer to page 6 2 Remove and replace the power supply cover and Mylar barrier 3 Loosen the set screws that secure the three power wires to the top of the power switch Note For CSA models use a 2 Phillips screwdriver For CE models use a 1 P...

Page 188: ...outside of the power supply unscrew the power cord s strain relief retention nut so that the wires move freely Slide the nut back along the old power cord 7 Pull the wires through the strain relief in the rear panel to remove the old power cord Note A CE power cord must be pulled forward through the strain relief 8 If you are replacing the old strain relief a Use an adjustable wrench to unscrew th...

Page 189: ...l 3 Route the new power cord wires through the strain relief in the rear panel 4 Route the black white and red wires to the top of the power switch 5 Insert the wire connectors into the top of the power switch and use a 2 Phillips screwdriver to tighten the set screws to 10 in lbs 11 5 kg cm Refer to the figure above for the correct color assignments L1 L2 and L3 are marked on the power switch abo...

Page 190: ...inum washer over the strain relief inside the power supply c Secure the strain relief on the inside of the power supply using the new strain relief nut Hand tighten the nut and then over tighten slightly more Install the new 3 phase power cord CE model In CE systems the standard strain relief hole in the rear panel of the power supply is too big to accommodate the smaller CE power cord Therefore C...

Page 191: ...lips screwdriver to tighten the set screws to 10 in lbs 11 5 kg cm Refer to the figure on the previous page for the correct color assignments L1 L2 and L3 are marked on the power switch above each set screw 6 Secure the green yellow ground wire to the heatsink using the Phillips screw and tighten to 20 in lbs 23 0 kg cm with the star washer between the ring terminal and the heat sink 7 Position th...

Page 192: ... 152 mm L1 L2 Power switch Ground screw Route lead through strain relief and tighten Caution 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 Install a plug on the power cord CSA Use a plug that meets national and loca...

Page 193: ...he key on the work lead connector with the opening at the top of the receptacle on the power supply Caution Make sure you use 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 Caution Ensure the work lead is fully seated in the receptacle to ...

Page 194: ...cord and disconnect the gas supply 2 Remove the power supply cover 3 Remove the fan shroud by pulling it straight off the fan housing 4 Detach the fan wire connector from J3 CSA or J5 CE on the top rear of the power board Replace the fan Fan shroud Fan wire bundle Grommet Fan connector J3 CSA J5 CE ...

Page 195: ...rner of the fan 7 Slide the old fan out from the power supply 8 Slide the new fan into place 9 Replace the 4 retaining screws 10 Route the fan wire through the grommet 11 Attach the fan wire connector to J3 CSA or J5 CE on the top rear of the power board 12 Position the fan shroud onto the fan housing with the wider end at the bottom and snap it into place 13 Replace the power supply cover 14 Reco...

Page 196: ...tall clockwise the plastic retaining nut to finger tight only 9 Clean the filter bowl 10 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 11 Vertically align the filter bowl with metal guard and firmly push the filter bowl up to the top of the receptacle to seat t...

Page 197: ...on page 6 14 Replace the air filter element 4 Disconnect the two wires from the top of the pressure switch 5 Disconnect the ground wire from the air filter body 6 Disconnect the gas supply hose from the air filter Pull back the orange ring on the push to connect tube connector and pull the tube out of the connector 7 Remove the three screws that hold the gas fitting to the rear panel 8 Remove the ...

Page 198: ... 17 7 kg cm 12 Install the new filter guide onto the air filter subassembly 13 Connect the gas supply hose to the air filter 14 Connect the ground wire to the air filter body 15 Connect the two wires to the top of the pressure switch 16 Install the filter bowl onto the filter subassembly at the rear of the power supply Refer to the instructions and figure on page 6 14 Replace the air filter elemen...

Page 199: ...ion board installed will not have a connector plugged into the top of the DSP board 2 Use a 2 Phillips screwdriver to remove the 2 screws 2 from the DSP board Two rows of connector pins 4 are located on the back of the DSP board 3 as shown in the figures below The dashed rectangle identifies the location of the pins on the back of the board 3 Carefully pull the DSP board 3 straight out from the po...

Page 200: ...Component Replacement 6 18 powermax65 85 Service Manual 1 4 6 2 3 3 3 5 DSP back view DSP front view ...

Page 201: ...driver 10 Remove the three remaining diode screws 11 Disconnect the nozzle wire black using a 2 Phillips screwdriver to remove the pilot arc IGBT screw on the left 12 Remove the remaining pilot arc IGBT screw 13 Disconnect the electrode wire red using a 2 Phillips screwdriver to remove the screw at J29 14 Remove the three heat sink mounting screws using a 2 Phillips screwdriver Note It may be nece...

Page 202: ... Heat sink mounting screw Pilot arc IGBT screws 2 PFC inductor wires Capacitor screws Board mounting screw Board mounting screw Board mounting screw Input bridge screws 5 Transformer wires Output inductor wire Electrode wire Board mounting screw Work lead 3uF Capacitor Viewing holes Snubber resistor screws 4 Diode screws 4 Nozzle wire Inverter IGBT screws 3 Heat sink mounting screw located behind ...

Page 203: ...rews to 20 in lbs 23 0 kg cm Note All screw mounting holes which secure a wire to the power board except for J29 have a yellow silkscreen outline on the board depicting the placement of the ring terminal 9 Install the four diode screws securing the output inductor wire to the board with the upper left screw Use a 2 Phillips screwdriver to tighten all four screws to 20 in lbs 23 0 kg cm 10 Install ...

Page 204: ...ng a 2 Phillips screwdriver 10 Disconnect the output inductor wire by removing the upper left diode screw with a 2 Phillips screwdriver 11 Remove the three remaining diode screws 12 Disconnect the nozzle wire black using a 2 Phillips screwdriver to remove the pilot arc IGBT screw on the left 13 Remove the remaining pilot arc IGBT screw 14 Disconnect the electrode wire red using a 2 Phillips screwd...

Page 205: ...ctor wires Capacitor screws Board mounting screw Board mounting screw Board mounting screw Input bridge screws 2 Transformer wires Output inductor wire Electrode wire Board mounting screw Work lead 3uF Capacitor 3uF Capacitor Viewing holes Snubber resistor screws 4 Diode screws 4 Nozzle wire Inverter IGBT screws 3 Heat sink mounting screw located behind edge of front end panel Snubber resistor scr...

Page 206: ...red to J28 using a 2 Phillips screwdriver to tighten the screw to 20 in lbs 23 0 kg cm 8 Install the two pilot arc IGBT screws securing the nozzle wire black to the board with the left screw Use a 2 Phillips screwdriver to tighten both screws to 20 in lbs 23 0 kg cm Note All screw mounting holes which secure a wire to the power board except for J28 have a yellow silkscreen outline on the board dep...

Page 207: ...three gate drive wires into their respective power board connectors J17 J18 and J19 Plug the PFC temperature sensor wire into the J16 power board connector Gently pull on each wire to ensure that they are fully seated Install the DSP board Refer to the figure on the next page 1 Connect the ribbon cable to the ribbon cable connector 6 on the back of the DSP board 3 2 Align the two alignment pins 7 ...

Page 208: ...view 1 4 2 3 DSP front view Replace the Mylar barrier and power supply cover 1 Replace the Mylar barrier Refer to page 6 3 Replace the Mylar barrier 2 Replace the power supply cover Refer to page 6 4 Replace the power supply cover 3 Reconnect the electrical power and the gas supply ...

Page 209: ...l attached to the bottom of the power supply and can only move a short distance Note The figure below shows the front panel separated from the base for clarity You can remove the two screws in the base and separate the front panel from the base if it is easier to access the components 6 Remove the three screws that secure the control board to the front panel using a 1 Phillips screwdriver Two scre...

Page 210: ... 7 in lbs 8 kg cm 14 Push the operating mode switch knob with the white line onto the mode switch post Align the flat edge inside the knob with the flat side of the post 15 Push the adjustment knob onto the remaining post 16 Carefully push the top of the front panel against the power supply Be sure not to pinch any wires between the front panel and the heat sink on the power supply 17 Replace the ...

Page 211: ...uctions in the section beginning on page 6 17 Replace the power board 4 Remove the old components from the heat sink 5 Use isopropyl alcohol to remove the old thermal grease 6 Install the new components to the heat sink as shown in the appropriate figure below 7 Use thermal grease on all components Apply a thin coat 3 mils or paper equivalent to the component 8 Gently tighten all screws and then t...

Page 212: ...k gently tighten all screws and then tighten all screws to the required torque Note All screws listed are Phillips head pan head machine screws 4 Torque to 15 in lbs 17 3 kg cm M4 X 10 2SEM Torque to 20 in lbs 23 kg cm M5 X 16 2SEM Torque to 35 in lbs 40 kg cm M6 X 16 12 5 2SEM TRI CHRM Torque to 10 in lbs 11 5 kg cm M3 X 10 1SEM 1 2 3 4 ...

Page 213: ...ponent to the heat sink gently tighten all screws and then tighten all screws to the required torque Note All screws listed are Phillips head pan head machine screws Torque to 15 in lbs 17 3 kg cm M4 X 10 2SEM Torque to 20 in lbs 23 kg cm M5 X 16 2SEM Torque to 35 in lbs 40 kg cm M6 X 16 12 5 2SEM TRI CHRM 1 2 3 ...

Page 214: ...EM Torque to 20 in lbs 23 kg cm M5 X 16 2SEM Torque to 35 in lbs 40 kg cm M6 X 16 12 5 2SEM TRI CHRM Torque to 10 in lbs 11 5 kg cm M3 X 10 1SEM 1 2 3 4 4 When securing a component to the heat sink gently tighten all screws and then tighten all screws to the required torque Note All screws listed are Phillips head pan head machine screws ...

Page 215: ...sink gently tighten all screws and then tighten all screws to the required torque Note All screws listed are Phillips head pan head machine screws Torque to 15 in lbs 17 3 kg cm M4 X 10 2SEM Torque to 20 in lbs 23 kg cm M5 X 16 2SEM Torque to 35 in lbs 40 kg cm M6 X 16 12 5 2SEM TRI CHRM 1 2 3 Note 3 on the left ...

Page 216: ...Component Replacement 6 34 powermax65 85 Service Manual ...

Page 217: ...k assembly 7 8 65A CSA 7 8 65A CE 7 9 85A CSA 7 10 85A CE 7 11 Duramax 75 hand torch replacement parts 7 12 Duramax 15 hand torch replacement parts 7 13 Hand torch consumables 7 14 Duramax 180 full length machine torch replacement parts 7 15 Duramax 180 mini machine torch replacement parts 7 17 Machine torch consumables 7 19 Accessory parts 7 20 Powermax65 and Powermax85 labels 7 21 Safety critica...

Page 218: ...max85 CE rear panel 6 228642 Kit Powermax65 and Powermax85 cover screws 7 228666 Kit Powermax65 CSA power supply cover with labels 8 228674 Kit Powermax65 CE power supply cover with labels 9 228676 Kit Powermax85 CSA power supply cover with labels 10 228675 Kit Powermax85 CE power supply cover with labels 11 108797 Adjustment knob 12 108732 Operating mode knob 13 228710 Kit Powermax65 and Powermax...

Page 219: ...79 Machine interface cable start stop arc transfer signals 15 m 50 ft spade connectors 228350 Machine interface cable start stop arc transfer signals for divided arc voltage 7 6 m 25 ft spade connectors 228351 Machine interface cable start stop arc transfer signals for divided arc voltage 50 ft 15 m spade connectors 223048 Machine interface cable start stop arc transfer signals for divided arc vol...

Page 220: ... Powermax65 control board 2 228658 Kit Powermax85 control board 3 228656 Kit Powermax65 and Powermax85 DSP board 4 228659 Kit Powermax65 Power board CSA 5 228662 Kit Powermax85 Power board CSA 6 228644 Kit Powermax65 CSA Power Switch 7 228655 Kit Powermax85 CSA Power Switch 228690 Kit Powermax65 CSA wire group 228700 Kit Powermax85 CSA wire group 228705 Kit Powermax65 and Powermax85 Mylar barrier ...

Page 221: ... 1 228657 Kit Powermax65 control board 2 228658 Kit Powermax85 control board 3 228656 Kit Powermax65 and Powermax85 DSP board 4 228708 Kit Powermax65 Power board CE 5 228672 Kit Powermax85 Power board CE 6 228671 Kit Powermax65 and Powermax85 CE Power Switch 228698 Kit Powermax65 CE wire group 228677 Kit Powermax85 CE wire group 228705 Kit Powermax65 and Powermax85 Mylar barrier ...

Page 222: ...Parts 7 6 powermax65 85 Service Manual 1 2 3 4 25 5 6 7 8 9 10 Interior fan side 16 17 18 19 20 11 12 13 14 21 22 23 24 15 ...

Page 223: ...8654 Kit Powermax85 transformer CE 12 228683 Kit Powermax65 CSA bulk capacitor 2 in kit 13 228684 Kit Powermax65 CE bulk capacitor 2 in kit 14 228681 Kit Powermax85 CSA bulk capacitor 2 in kit 15 228682 Kit Powermax85 CE bulk capacitor 2 in kit 16 228697 Kit Powermax65 and Powermax85 machine interface cable with voltage divider board 17 228641 Kit Powermax65 and Powermax85 tubing part number 10448...

Page 224: ...ermax85 CE input diode bridge with thermal grease 5 228692 Kit Powermax65 pilot arc IGBT with thermal grease 6 228706 Kit Powermax65 and Powermax85 15 Ω snubber resistor with thermal grease 7 228693 Kit Powermax65 and Powermax85 5 Ω snubber resistor with thermal grease 8 228707 Kit Powermax65 PFC IGBT with thermal grease 9 228740 Kit Powermax65 and Powermax85 damper resistor with thermal grease 12...

Page 225: ...93 Kit Powermax65 and Powermax85 5 Ω snubber resistor 3 228703 Kit Powermax85 CSA Powermax65 CE inverter IGBT 4 228742 Kit Powermax65 CSA CE Powermax85 CE input diode bridge 5 228692 Kit Powermax65 pilot arc IGBT 6 228706 Kit Powermax65 and Powermax85 15 Ω snubber resistor 127128 Thermal grease T grease 2500 10cc 1 2 3 4 5 6 ...

Page 226: ...stor 3 228703 Kit Powermax85 CSA Powermax65 CE inverter IGBT 4 228741 Kit Powermax85 CSA input diode bridge 5 228701 Kit Powermax85 pilot arc IGBT 6 228706 Kit Powermax65 and Powermax85 15 Ω snubber resistor 7 228693 Kit Powermax65 and Powermax85 5 Ω snubber resistor 8 228699 Kit Powermax85 PFC IGBT 9 228740 Kit Powermax65 and Powermax85 damper resistor 127128 Thermal grease T grease 2500 10cc ...

Page 227: ...e 2 228693 Kit Powermax65 and Powermax85 5 Ω snubber resistor 3 228702 Kit Powermax85 CE inverter IGBT 4 228742 Kit Powermax85 CSA CE Powermax85 CE input diode bridge 5 228701 Kit Powermax85 pilot arc IGBT 6 228706 Kit Powermax65 and Powermax85 15 Ω snubber resistor 127128 Thermal grease T grease 2500 10cc 1 2 3 4 5 6 ...

Page 228: ... terminal screw MSCR 4 40 X 5 16 SW CN SEM PH PAN S Z 6 228719 Kit Duramax 75 hand torch cap sensor switch replacement 7 228959 Kit Duramax hand torch lead replacement 7 6 m 25 ft 8 228960 Kit Duramax hand torch lead replacement 15 m 50 ft 9 228961 Kit Duramax hand torch lead replacement 23 m 75 ft 10 128642 Kit Trigger start switch replacement 11 228714 Kit Duramax 75 hand torch main body replace...

Page 229: ...s 4 x 1 2 slotted TORX pan head S B 3 228721 Kit Duramax 75 15 hand torch safety trigger with spring replacement 4 058519 O ring VITON 673 X 063 5 075504 Pilot terminal screw MSCR 4 40 X 5 16 SW CN SEM PH PAN S Z 6 228109 Kit Powermax30 45 65 85 105 15 hand torch T30v T45v HRTs cap sensor switch replacement 7 228959 Kit Duramax hand torch lead replacement 7 6 m 25 ft 8 228960 Kit Duramax hand torc...

Page 230: ...41 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 220931 Deflector 220854 Retaining cap 220930 Nozzle 220842 Electrode 220947 Swirl ring Hand torch consumables ...

Page 231: ...Parts powermax65 85 Service Manual 7 15 Duramax 180 full length machine torch replacement parts 1 2 3 4 5 6 7 8 9 11 12 13 10 ...

Page 232: ...ble gear rack replacement 3 228735 Kit Powermax65 85 105 180 full length mini machine torch MRT front mounting sleeve 4 228736 Kit Powermax65 85 105 180 full length mini machine torch MRT adapter ring coupler 5 228716 Kit Powermax65 85 105 180 full length mini machine torch main body replacement 6 228720 Kit Duramax MRT 180 machine and robotic torch cap sensor switch replacement 7 058519 O ring VI...

Page 233: ... Manual 7 17 Duramax 180 mini machine torch replacement parts Note This illustration shows the Duramax 180 machine torch The Duramax 180 mini machine torches do not have a positioning sleeve and gear rack 1 2 3 4 5 6 7 8 9 11 10 ...

Page 234: ...05 180 full length mini machine torch MRT adapter ring coupler 3 228716 Kit Powermax65 85 105 180 full length mini machine torch main body replacement 4 228720 Kit Duramax MRT 180 machine and robotic torch cap sensor switch replacement 5 058519 O ring VITON 673 X 063 6 075504 Pilot terminal screw MSCR 4 40 X 5 16 SW CN SEM PH PAN S Z 7 228730 Kit Powermax65 85 105 180 full length mini machine torc...

Page 235: ...aining 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 FineCut1 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 sta...

Page 236: ... Work lead with C style clamp 7 6 m 25 ft 223195 Kit 65 A Work lead with C style clamp 15 m 50 ft 223196 Kit 65 A Work lead with C style clamp 23 m 75 ft 223200 Kit 65 A Work lead with ring terminal 7 6 m 25 ft 223201 Kit 65 A Work lead with ring terminal 15 m 50 ft 223202 Kit 65 A Work lead with ring terminal 23 m 75 ft 223035 Kit 85 A Work lead with hand clamp 7 6 m 25 ft 223034 Kit 85 A Work le...

Page 237: ...it Powermax65 labels CSA 228650 Kit Powermax65 labels CE 228651 Kit Powermax85 labels CE 228652 Kit Powermax85 labels CSA Powermax65 and Powermax85 labels The label kits include the consumable label appropriate safety labels display panel label power switch label and side decals ...

Page 238: ...ntain the warranty and all system certifications including CE CSA GOST and CCC certification 1 2 3 4 5 Item Part number Description 1 228659 Kit Powermax65 Power board CSA and subcomponents 2 228662 Kit Powermax85 Power board CSA and subcomponents 3 228708 Kit Powermax65 Power board CE and subcomponents 4 228672 Kit Powermax85 Power board CE and subcomponents 5 228644 Kit Powermax65 CSA Power Swit...

Page 239: ...ermax85 transformer CSA 6 228654 Kit Powermax85 transformer CE 7 228683 Kit Powermax65 CSA bulk capacitor 2 in kit 8 228684 Kit Powermax65 CE bulk capacitor 2 in kit 9 228681 Kit Powermax85 CSA bulk capacitor 2 in kit 10 228682 Kit Powermax85 CE bulk capacitor 2 in kit 11 228661 Kit Powermax65 PFC inductor CSA 12 228670 Kit Powermax65 PFC inductor CE 13 228668 Kit Powermax85 PFC inductor CSA 14 22...

Page 240: ...wermax65 power board CSA 228662 Kit Powermax85 power board CSA 228708 Kit Powermax65 power board CE 228672 Kit Powermax85 power board CE 228644 Kit Powermax65 CSA Power Switch 228655 Kit Powermax85 CSA Power Switch 228671 Kit Powermax65 and Powermax85 CE Power Switch 228663 Kit Powermax65 transformer CSA 228669 Kit Powermax65 transformer CE 228667 Kit Powermax85 transformer CSA 228654 Kit Powermax...

Page 241: ...30v T45v HRTs cap sensor switch replacement 059473 Powermax65 85 105 75 hand torch assembly with 7 6 m 25 ft lead 059474 Powermax65 85 105 75 hand torch assembly with 15 m 50 ft lead 059470 Powermax65 85 105 15 hand torch assembly with 7 6 m 25 ft lead 059471 Powermax65 85 105 15 hand torch assembly with 15 m 50 ft lead 228959 Kit Duramax hand torch lead replacement 7 6 m 25 ft 228960 Kit Duramax ...

Page 242: ... machine torch MRT front mounting sleeve 228736 Kit Powermax65 85 105 180 full length mini machine torch MRT adapter ring coupler 228720 Kit Duramax MRT 180 machine and robotic torch cap sensor switch replacement 228731 Kit Powermax65 85 105 180 full length mini machine torch lead replacement 7 6 m 25 ft 228732 Kit Powermax65 85 105 180 full length mini machine torch lead replacement 10 7 m 35 ft ...

Page 243: ...5 Service Manual 8 1 Section 8 Wiring Diagrams In this section Cutting timing diagram page 1 of 2 8 3 Cutting timing diagram page 2 of 2 8 4 Electrical schematic diagram CSA 8 5 Electrical schematic diagram CE 8 6 ...

Page 244: ...Wiring Diagrams 8 2 powermax65 85 Service Manual ...

Page 245: ...TSO T_TSO Check TSO T_TSC Check TSC INV ON 0x11 Torch gas ramping up delay Description Timeouts and Delays Minimum pilot time delay Delay from Gas Up to TSO test Delay from Gas Up to TSC test Torch consumable Reseat Time Regular pilot current setting Current Setpoints Pilot current boost value Assumptions This diagram represents most but not all possible State transitions No Faults Occur System is...

Page 246: ... R l a i t i n I A REVISIONS CUTTING FSM TIMGING DIAGRAM NORMAL SEQ_State Pilot Arc Switch CUT 0x40 I Command I Pilot I Work Lead Arc Voltage SEQ_Timer 5ms 5ms PILOT CPA 0x22 0 4A 30A CUT 0x40 KNOB pilot_current_set 1 6A 25A 2A ms PILOT 0x21 KNOB TRANSFER 0x30 Digitized EA Digitized XFR KNOB 16383 30A 20A 2A ms pilot_current_set pilot_current_set I_PILOT_HIGH_DELTA pilot_current_set I_PILOT_HIGH_D...

Page 247: ...8 5 Electrical schematic diagram CSA ...

Page 248: ...8 6 Electrical schematic diagram CE ...

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