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Hypertherm powermax65, Operator'S Manual

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Hypertherm powermax65 Operator'S Manual Download Page 3

Operator Manual

(P/N 806650)

Revision 2 – December 2012

Hypertherm, Inc. 

Hanover, NH  USA 

www.hypertherm.com 

email: [email protected]

© 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.

powermax

65

powermax

85

Summary of Contents for powermax65

Page 1: ...Plasma arc cutting systems Operator Manual 806650 Revision 2 ...

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

Page 3: ...ertherm 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 Operator 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 Operator 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: ...orkpiece using the machine torch 4 23 Common machine cutting faults 4 24 Section 5 Maintenance and Repair Perform routine maintenance 5 2 Inspect the consumables 5 3 Basic troubleshooting 5 4 Fault codes and solutions 5 6 Replace the gas filter element 5 10 Section 6 Parts Power supply parts 6 2 Duramax 75 hand torch replacement parts 6 6 Duramax 15 hand torch replacement parts 6 7 Hand torch cons...

Page 14: ...Table of Contents x powermax65 85 Operator Manual ...

Page 15: ...nent 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 16: ...cknesses 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 17: ...n 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 ...

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

Page 19: ...9 9 27 2 50 4 22 8 65 85 A lbs kg Hand torch 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 20: ...3 to 131 F 25 to 55 C Power factor 200 480 V CSA 1 phase 200 600 V CSA 3 phase 380 400 V CE 3 phase 0 99 0 97 0 94 0 73 0 94 Rsce Short Circuit Ratio CE models only U1 Volts AC rms 3PH Rsce 400 VAC 225 7 EMC classification CISPR 11 CE models only 4 Class A Input voltage U1 Input current I1 at rated output U2 MAX I2 MAX See Section 2 Power Supply Setup for more information CSA CE2 3 200 208 240 480...

Page 21: ...ith 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 ...

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

Page 23: ...ith 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 ...

Page 24: ...ermax65 85 Operator 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 25: ...mensions 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 26: ...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 27: ...ht 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 28: ... 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 29: ...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 30: ...Specifications 1 16 powermax65 85 Operator Manual ...

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

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

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

Page 34: ...e 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 ci...

Page 35: ...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 36: ...380 400 V 3 phase only The rated output is 25 65 A 139 VDC CSA model Single phase Three phase Input voltage 200 208 230 240 480 200 208 230 240 400 480 600 Input current at 9 0 kw output 52 44 22 32 27 15 13 13 Input current during arc stretch 74 74 38 45 45 27 23 23 Fuse slow blow 80 80 40 50 50 30 25 25 CE model Three phase Input voltage 380 400 Input current at 9 0 kw output 15 5 15 Input curre...

Page 37: ...m2 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 ...

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

Page 39: ... 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 40: ...x65 85 Operator Manual Single phase power cord installation Strip and prepare the power cord wires as shown below L1 L2 Ground 10 14 5 in 368 mm 6 in 152 mm L1 L2 Power switch Ground screw Route lead through strain relief and tighten ...

Page 41: ...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 42: ...10 6 8 10 6 16 400 480 3 12 4 12 4 12 4 12 4 12 4 600 3 12 4 12 4 12 4 12 4 12 4 65 A CE Input voltage VAC Phase mm2 mm2 mm2 mm2 mm2 380 3 4 4 4 4 4 400 3 4 4 4 4 4 85 A CSA Input voltage VAC Phase AWG mm2 AWG mm2 AWG mm2 AWG mm2 AWG mm2 200 240 1 6 16 6 16 6 16 4 25 2 35 480 1 10 6 10 6 10 6 8 10 8 10 200 240 3 8 10 8 10 8 10 6 16 4 25 400 480 3 10 6 10 6 10 6 10 6 10 6 600 3 10 6 10 6 10 6 10 6 ...

Page 43: ...ed 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 Pe...

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

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

Page 46: ... 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 47: ...ount 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 shielde...

Page 48: ...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 49: ...Torch Setup powermax65 85 Operator Manual 3 3 Consumables Safety trigger Safety trigger Hand torch setup Duramax 75 hand torch Duramax 15 hand torch Consumables ...

Page 50: ...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 re...

Page 51: ...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 52: ...ning 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 53: ... 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 ...

Page 54: ...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 55: ... 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 56: ... 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 st...

Page 57: ...nsumables 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 us...

Page 58: ...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 59: ...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 60: ...bles FineCut shielded consumables 220854 Retaining cap 220953 Retaining cap 220857 Swirl ring 220857 Swirl ring 220842 Electrode 220842 Electrode 220955 Deflector 220948 Shield 220930 Nozzle 220930 Nozzle 65 A 45 A 85 A 220955 Deflector 220854 Retaining cap 220857 Swirl ring 220842 Electrode Mechanized unshielded consumables Powermax85 220941 Nozzle 220819 Nozzle 220816 Nozzle ...

Page 61: ...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 62: ...art 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 interf...

Page 63: ...pedance 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 ...

Page 64: ...e 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 ...

Page 65: ...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 66: ... 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 67: ...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 68: ...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 69: ...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 70: ... 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 ...

Page 71: ...4 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 72: ...Operator Manual 220817 Shield 220817 Shield 220854 Retaining cap 220857 Swirl ring 220857 Swirl ring 220842 Electrode 220842 Electrode 220953 Ohmic sensing retaining cap 85 A shielded consumables 220816 Nozzle 220816 Nozzle 85 A 85 A ...

Page 73: ... 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 74: ...3700 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 75: ...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 76: ...Operator 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 77: ...8 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 10...

Page 78: ...3 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 1...

Page 79: ...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 80: ...Operator 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 81: ...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 82: ...129 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 83: ...min 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 ...

Page 84: ...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 85: ...m seconds mm min Volts 0 5 40 1 5 3 8 250 0 0 8250 78 0 6 8250 78 0 8 0 1 8250 78 1 45 0 2 8250 78 1 5 0 4 6400 78 2 5250 82 3 0 5 2750 83 4 0 6 1900 84 English Material Thickness Amps Torch to Work Distance Initial Pierce Height Pierce Delay Time Best Quality Settings Cut Speed Voltage A in in seconds ipm Volts 26GA 40 0 06 0 15 250 0 0 325 78 24GA 325 78 22GA 0 1 325 78 20GA 325 78 18GA 45 0 2 3...

Page 86: ...m 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 2 8250 68 1 5 0 4 6150 70 2 4800 71 3 0 5 2550 81 4 0 6 1050 84 English Material Thickness Amps Torch to Work Distance Initial Pierce Height Pierce Delay Time Best Quality Settings Cut Speed Voltage A in in seconds ipm Volts 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 87: ...m 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 88: ... 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 14...

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

Page 90: ...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 91: ...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 92: ...0 119 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 93: ...Torch Setup powermax65 85 Operator Manual 3 47 65 A unshielded consumables 65 A 220955 Deflector 220854 Retaining cap 220857 Swirl ring 220842 Electrode 220819 Nozzle ...

Page 94: ...18 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 95: ...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 96: ... 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 32...

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

Page 98: ... 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 99: ... 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 45...

Page 100: ... 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 101: ...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 102: ...ower 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 se...

Page 103: ... 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 auto...

Page 104: ...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 105: ...r 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 accept...

Page 106: ...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 107: ...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 108: ...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 109: ... 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 110: ...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 automatic mode to manual mode the power supply remembers the previous manual gas pressure setting and the amperage setting is unchanged When you reset ...

Page 111: ... 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 112: ... on for 6 minutes out of 10 60 At 46 A the arc can remain on for 10 minutes out of 10 100 With a Powermax85 At 85 A the arc can remain on for 6 minutes out of 10 minutes without causing the unit to overheat 60 duty cycle At 74 A the arc can remain on for 8 minutes out of 10 80 At 66 A the arc can remain on for 10 minutes out of 10 100 If the duty cycle is exceeded the power supply overheats the te...

Page 113: ...n 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 tor...

Page 114: ...the torch unnecessarily you will shorten the life of the nozzle and electrode Pulling or dragging the torch along the cut is easier than pushing it For straight line cuts use a straight edge as a guide To cut circles use a template or a radius cutter attachment a circle cutting guide See the Parts section for part numbers for the Hypertherm plasma cutting guides for cutting circles and making beve...

Page 115: ...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 116: ...e to the workpiece Slowly rotate the torch to a perpendicular 90 position 3 Hold the torch in place while continuing to press the trigger When sparks exit below the workpiece the arc has pierced the material 4 When the pierce is complete drag the nozzle lightly along the workpiece to proceed with the cut WARNING SPARKS AND HOT METAL CAN INJURE EYES AND BURN SKIN When firing the torch at an angle s...

Page 117: ...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 118: ...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 119: ...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 120: ...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 121: ... 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 122: ...ience 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 ...

Page 123: ... 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 124: ...d 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 an...

Page 125: ...erator Manual 5 1 Section 5 Maintenance and Repair In this section Perform routine maintenance 5 2 Inspect the consumables 5 3 Basic troubleshooting 5 4 Fault codes and solutions 5 6 Replace the gas filter element 5 10 ...

Page 126: ... the power supply with compressed air or a vacuum Replace any damaged labels Inspect the consumables for proper installation and wear Inspect the trigger for damage Inspect the torch body for cracks and exposed wires Replace any damaged parts Every 6 months Every 3 months Or DANGER ELECTRIC SHOCK CAN KILL Disconnect the electrical power before you perform any maintenance All work that requires rem...

Page 127: ...e is not round Electrode Replace electrode if the surface is worn or the pit depth is greater than 1 16 inch 1 6 mm deep Swirl ring The surface inside the swirl ring for damage or wear and the gas holes for blockages Replace swirl ring if the surface is damaged or worn or any of the gas holes are blocked Torch o ring The surface for damage wear or a lack of lubrication If the o ring is dry lubrica...

Page 128: ...ood metal to metal connection Inspect the work clamp for damage and repair as necessary The pierce height distance may be too large Move the torch closer to the workpiece and fire the torch again Basic troubleshooting The following table provides an overview of the most common problems that can arise when using the Powermax65 or Powermax85 and explains how to solve them Note Fault icons and corres...

Page 129: ...sses The gas filter s element is contaminated Replace the element See 5 10 Replace the gas filter element Inspect the gas line for moisture If necessary install or repair the gas filtration to the power supply See Section 2 Power Supply Setup for more information The cut quality is poor Verify that the torch is being used correctly See Section 4 Operation Inspect the consumables for wear and repla...

Page 130: ... the system continues to operate Blinks 3 Hz Off Correct the power source 0 19 Power board hardware protection One or more power board hardware faults or noise detected On On The inverter shuts down and does not fire again for several seconds If the fault is caused by electrical noise the fault clears in a few seconds and the machine operates normally If a true fault continues to occur the 0 99 fa...

Page 131: ... torch stuck open or a torch stuck closed situation On On If the consumables became loose or were removed while the power supply is ON turn OFF the power supply correct the problem and then turn ON the power supply to clear this fault If the consumables appear to be installed correctly the torch may be damaged Contact your Hypertherm distributor or authorized repair facility 0 40 Over under temper...

Page 132: ...If the consumables appear to be installed correctly the torch may be damaged Contact your Hypertherm distributor or authorized repair facility 0 51 Start trigger signal on at power up This situation indicates that the power supply is receiving a start signal It is sometimes referred to as a stuck start On On If the power supply is turned on while the torch trigger is pressed the system is disabled...

Page 133: ...nder voltage Check the line increase the voltage 0 61 AC input unstable Shutdown On On The incoming line current is unstable Power down and correct the line problem before continuing 0 98 Internal communication failure On On Power down wait 20 seconds power up A qualified service technician must open the power supply case and check the ribbon cable between the control board and the DSP board 0 99 ...

Page 134: ...ing nut to finger tight only 8 Insert the filter bowl with the thumb latch positioned approximately 45 degrees to the right of center This is the same orientation in which the filter bowl was pulled down and removed 9 Vertically align the filter bowl with metal guard and firmly push the filter bowl up to the top of the receptacle to seat the bowl It is helpful to lift the bowl with your left index...

Page 135: ...75 hand torch replacement parts 6 6 Duramax 15 hand torch replacement parts 6 7 Hand torch consumables 6 8 Duramax 180 full length machine torch replacement parts 6 9 Duramax 180 mini machine torch replacement parts 6 11 Machine torch consumables 6 13 Accessory parts 6 14 Powermax65 85 labels 6 15 ...

Page 136: ...ar panel 228646 Kit Powermax65 CE rear panel 228647 Kit Powermax85 CSA rear panel 228653 Kit Powermax85 CE rear panel 228642 Kit Powermax65 85 cover screws 228666 Kit Powermax65 CSA power supply cover 228674 Kit Powermax65 CE power supply cover 228676 Kit Powermax85 CSA power supply cover 228675 Kit Powermax85 CE power supply cover 108797 Adjustment knob 108732 Operating mode switch Operating mode...

Page 137: ...Description 228691 Kit Powermax65 85 CSA power cord 228679 Kit Powermax65 CE power cord 228678 Kit Powermax85 CE power cord 228680 Kit Powermax65 85 power cord strain relief 128650 Remote start pendant for machine torch 7 6 m 25 ft 128651 Remote start pendant for machine torch 15 m 50 ft 128652 Remote start pendant for machine torch 23 m 75 ft ...

Page 138: ... connectors 228351 Machine interface cable start stop arc transfer signals for divided arc voltage 15 m 50 ft spade connectors 223048 Machine interface cable start stop arc transfer signals for divided arc voltage 7 6 m 25 ft D sub connector with screws 123896 Machine interface cable start stop arc transfer signals for divided arc voltage 15 m 50 ft D sub connector with screws 127204 Powermax45 65...

Page 139: ...r bowl Fan subassembly Part number Description 228686 Kit Powermax65 85 fan subassembly 228685 Kit Powermax65 85 air filter 228695 Kit Powermax65 85 air filter element inside filter bowl 428015 Kit AF30 air filter bowl guard 228688 Kit Powermax65 85 pressure switch 228687 Kit Powermax65 85 solenoid valve 228689 Kit Powermax65 85 pressure transducer ...

Page 140: ... torch safety trigger with spring replacement 228714 Kit Duramax 75 hand torch main body replacement torches built before May 2012 228958 Kit Duramax 75 hand torch main body replacement torches built after May 2012 058519 O ring VITON 673 X 063 075504 Pilot terminal screw MSCR 4 40 X 5 16 SW CN SEM PH PAN S Z 228719 Kit Duramax 75 hand torch cap sensor switch replacement 228959 Kit Duramax hand to...

Page 141: ...rigger with spring replacement 228715 Kit Duramax 15 hand torch main body replacement torches built before May 2012 228957 Kit Duramax 15 hand torch main body replacement torches built after May 2012 058519 O ring VITON 673 X 063 075504 Pilot terminal screw MSCR 4 40 X 5 16 SW CN SEM PH PAN S Z 228109 Kit Powermax30 45 65 85 105 15 hand torch T30v T45v HRTs cap sensor switch replacement 228959 Kit...

Page 142: ... 220842 Electrode 45 65 85 105 A 220857 Swirl ring 65 85 A Gouging 220798 Gouging shield 65 85 105 A 220854 Retaining cap 45 65 85 105 A 220797 Gouging nozzle 65 85 A 220842 Electrode 45 65 85 105 A 220857 Swirl ring 65 85 A FineCut 220931 FineCut Deflector 220854 Retaining cap 45 65 85 105 A 220930 FineCut Nozzle 220842 Electrode 45 65 85 105 A 220947 FineCut Swirl ring Hand torch consumables ...

Page 143: ...hine torch replacement parts Front mounting ring Pilot wire terminal screw Cap sensor switch Torch head O ring Consumables Mounting sleeve Coupler Gear rack 32 pitch Strain relief body Strain relief nut Torch lead Positioning sleeve Wire connector for cap sensor switch ...

Page 144: ...RT removable gear rack replacement 228735 Kit Powermax65 85 105 180 full length mini machine torch MRT front mounting sleeve 228736 Kit Powermax65 85 105 180 full length mini machine torch MRT adapter ring coupler 228716 Kit Powermax65 85 105 180 full length mini machine torch main body replacement 228720 Kit Duramax MRT 180 machine and robotic torch cap sensor switch replacement 058519 O ring VIT...

Page 145: ...achine torch The Duramax 180 mini machine torches do not have a positioning sleeve and gear rack Front mounting ring Pilot wire terminal screw Cap sensor switch Torch head O ring Consumables Mounting sleeve Coupler Gear rack 32 pitch Strain relief body Strain relief nut Torch lead Positioning sleeve Wire connector for cap sensor switch ...

Page 146: ...5 85 105 180 full length mini machine torch MRT adapter ring coupler 228716 Kit Powermax65 85 105 180 full length mini machine torch main body replacement 228720 Kit Duramax MRT 180 machine and robotic torch cap sensor switch replacement 058519 O ring VITON 673 X 063 075504 Pilot terminal screw MSCR 4 40 X 5 16 SW CN SEM PH PAN S Z 228730 Kit Powermax65 85 105 180 full length mini machine torch le...

Page 147: ...819 65 A Nozzle 220816 85 A Nozzle 220842 Electrode 45 65 85 105 A 220857 Swirl ring 65 85 A Gouging 220798 Gouging shield 65 85 105 A 220854 Retaining cap 45 65 85 105 A 220797 Gouging nozzle 65 85 A 220842 Electrode 45 65 85 105 A 220857 Swirl ring 65 85 A FineCut1 220955 Deflector 65 85 105 A 220948 FineCut shield 220854 Retaining cap 45 65 85 105 A 220953 Ohmic retaining cap 45 65 85 105 A 220...

Page 148: ...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 lead with hand cla...

Page 149: ...ion ou un incendie 1 1 Ne pas couper près des matières inflammables 1 2 Un extincteur doit être à proximité et prêt à être utilisé 1 3 Ne pas utiliser un fût ou un autre contenant fermé comme table de coupage 2 L arc plasma peut blesser et brûler éloigner la buse de soi Il s allume instantanément quand on l amorce 2 1 Couper l alimentation avant de démonter la torche 2 2 Ne pas saisir la pièce à co...

Page 150: ...Parts 6 16 powermax65 85 Operator Manual ...

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