Hypertherm HRT User Manual

Duramax™ Retrofit Torch

HRT, HRTs, and MRT for

powermax1000

powermax1650

, powermax1250®, and

Operator Manual – 807190

Revision 3

Duramax™ Retrofit Torch

HRT, HRTs, and MRT for

powermax1000

and powermax1650

Operator Manual

(P/N 807190)

Revision 3 – May 2012

, powermax1250®,

Hypertherm, Inc.

Hanover, NH USA

www.hypertherm.com

email: info@hypertherm.com

Hypertherm, Powermax, and Duramax are trademarks of Hypertherm, Inc.

andmayberegisteredintheUnited States and/or other countries.

Hypertherm, Inc.

Etna Road, P.O. Box 5010 Hanover, NH 03755 USA 603-643-3441 Tel (Main Office) 603-643-5352 Fax (All Departments) info@hypertherm.com (Main Office Email)

800-643-9878 Tel (Technical Service)

technical.service@hypertherm.com (Technical Service Email)

800-737-2978 Tel (Customer Service)

customer.service@hypertherm.com (Customer Service Email)

866-643-7711 Tel (Return Materials Authorization) 877-371-2876 Fax (Return Materials Authorization)

return.materials@hypertherm.com (RMA email)

Hypertherm Automation

5 Technology Drive, Suite 300 West Lebanon, NH 03784 USA 603-298-7970 Tel 603-298-7977 Fax

Hypertherm Plasmatechnik GmbH

Technologiepark Hanau Rodenbacher Chaussee 6 D-63457 Hanau-Wolfgang, Deutschland 49 6181 58 2100 Tel 49 6181 58 2134 Fax

49 6181 58 2123 (Technical Service)

Hypertherm (S) Pte Ltd.

82 Genting Lane Media Centre Annexe Block #A01-01 Singapore 349567, Republic of Singapore 65 6841 2489 Tel 65 6841 2490 Fax

65 6841 2489 (Technical Service)

Hypertherm (Shanghai) Trading Co., Ltd.

Unit A, 5th Floor, Careri Building 432 West Huai Hai Road Shanghai, 200052 PR China 86-21 5258 3330/1 Tel 86-21 5258 3332 Fax

Hypertherm Europe B.V.

Vaartveld 9 4704 SE Roosendaal, Nederland 31 165 596907 Tel 31 165 596901 Fax 31 165 596908 Tel (Marketing)

31 165 596900 Tel (Technical Service) 00 800 4973 7843 Tel (Technical Service)

Hypertherm Japan Ltd.

Level 9, Edobori Center Building 2-1-1 Edobori, Nishi-ku Osaka 550-0002 Japan 81 6 6225 1183 Tel 81 6 6225 1184 Fax

Hypertherm Brasil Ltda.

Rua Bras Cubas, 231 – Jardim Maia Guarulhos, SP - Brasil CEP 07115-030 55 11 2409 2636 Tel 55 11 2408 0462 Fax

Hypertherm México, S.A. de C.V.

Avenida Toluca No. 444, Anexo 1, Colonia Olivar de los Padres Delegación Álvaro Obregón México, D.F. C.P. 01780 52 55 5681 8109 Tel 52 55 5683 2127 Fax

Hypertherm Korea Branch

#3904 Centum Leaders Mark B/D, 1514 Woo-dong, Haeundae-gu, Busan Korea, 612-889 82 51 747 0358 Tel 82 51 701 0358 Fax

03/15/12

ELECTROMAGNETIC COMPATIBILITY (EMC)

Introduction

Hypertherm’s CE‑marked equipment is built in compliance with standard EN60974‑10. The equipment should be installed and used in accordance with the information be low to achieve electromagnetic compatibility.

The limits required by EN60974‑10 may not be adequate to completely eliminate interference when the affected equipment is in close proximity or has a high degree of sen sitivity. Insuch cases it may be nec essary to use other mea sures to further reduce interference.

This cutting equipment is designed for use only in an in dus tri al environment.

Installation and use

The user is responsible for installing and using the plasma equipment according to the manufacturer’s instructions. If electromagnetic disturbances are detected then it shall be the responsibility of the user to resolve the situation with the technical assistance of the manufacturer. In some cases this remedial action may be as simple as earthing the cutting circuit, see Earthing of Workpiece. Inother cases it could involve constructing an electromagnetic screen enclosing the power source and the work complete with associated input filters. In all cases electromagnetic disturbances must be reduced to the point where they are no longer troublesome.

Assessment of area

Before installing the equipment the user shall make an assessment of potential electromagnetic problems in the surrounding

area. The following shall be taken into account:

a. Other supply cables, control cables,

signalling and telephone cables; above, below and adjacent to the cutting equipment.

b. Radio and television transmitters and

receivers.

c. Computer and other control equip ment.

d. Safety critical equipment, for example

guarding of industrial equipment.

e. Health of the people around, for example the

use of pacemakers and hearing aids.

f. Equipment used for calibration or

measurement.

g. Immunity of other equipment in the

environment. User shall ensure that other equipment being used in the environment is compatible. This may require additional protection measures.

h. Time of day that cutting or other activities are

to be carried out.

The size of the surround ing area to be considered will depend on the structure of the building and other activities that are taking place. The surrounding area may extend beyond the bound aries of the premises.

Methods of reducing emissions

Mains supply

Cutting equipment must be connected to the mains supply according to the manufacturer’s recommendations. If interference occurs, it may be necessary to take additional precautions

Compliance Information EMC-1

9/10

ElEctromagnEtic compatibility (Emc)

such as filtering of the mains supply. Consideration should be given to shielding the supply cable of permanently installed cutting equipment, in metallic conduit or equivalent. Shielding should be electrically continuous throughout its length. The shielding should be connected to the cutting mains supply so that good electrical contact is maintained between the conduit and the cutting pow er source enclosure.

Maintenance of cutting equipment

The cutting equipment must be routinely maintained according to the manufacturer’s recommendations. All access and service doors and covers should be closed and properly fastened when the cutting equipment is in operation. The cutting equipment should not be modified in any way except as set forth in and in accordance with the manufacturer’s written instructions. For example, the spark gaps of arc striking and stabilizing devices should be adjusted and maintained according to the manufacturer’s recommendations.

Cutting cables

The cutting cables should be kept as short aspossible and should be positioned close together, running at or close to the floor level.

Equipotential bonding

Bonding of all metallic components in the cutting installation and adjacent to it should be considered. However, metallic com po nents bonded to the workpiece will increase the risk that the operator could receive a shock by touching these metallic components and the electrode (nozzle for laser heads) at the same time. The operator should be insulated from all such bonded metallic components.

Earthing of workpiece

Where the workpiece is not bonded to earth for electrical safety, nor connected to earth because of its size and position, for example, ship’s hull or building steelwork, a connection bonding the work piece to earth may reduce emis sions in some, but not all instances. Careshould be taken to prevent the earthing ofthe workpiece increasing the risk of injury to users, or damage to other electrical equipment. Where necessary, the connection of the workpiece to earth should be made by a direct connection to the workpiece, but in some countries where direct connection is not permitted, the bonding should be achieved by suitable capacitances selected according to national regulations.

Note: the cutting circuit may or may not be earthed for safety reasons. Changing the earthing arrangements should only be authorized by a person who is competent to assess whether the changes will increase the risk of injury, for example, by allowing parallel cutting current return paths which may damage the earth cir cuits of other equipment. Further guidance is provided in IEC 60974‑9, Arc Welding Equip ment, Part 9: Installation and Use.

Screening and shielding

Selective screening and shielding of other cables and equipment in the surrounding area may alleviate problems of interference. Screening of the entire plasma cutting installation may be con sid ered for special applications.

EMC-2 Compliance Information

9/10

WARRANTY

Attention

Genuine Hypertherm parts are the factory‑ recommended replacement parts for your Hypertherm system. Any damage or injury caused by the use of other than genuine Hypertherm parts may not be covered by the Hypertherm warranty, and will constitute misuse of the Hypertherm Product.

You are solely responsible for the safe use of the Product. Hypertherm does not and cannot make any guarantee or warranty regarding the safe use of the product in your environment.

General

Hypertherm, Inc. warrants that its Products shall be free from defects in materials and workmanship for the specific periods of time set forth herein and as follows: if Hypertherm is notified of a defect (i) with respect to the power supply within a period of two (2) years from the date of its delivery to you, with the exception of Powermax brand power supplies, which shall be within a period of three (3) years from the date of delivery to you, and (ii) with respect to the torch and leads within a period of one (1) year from its date of delivery to you, and with respect to torch lifter assemblies within a period of one (1) year from its date of delivery to you, and with respect to laser heads within a period of one (1) year from its date of delivery to you, and with respect to Automation products one (1) year from its date of delivery to you, with the exception of the EDGE Pro CNC and ArcGlide THC, which shall be within a period of two (2) years from the date of delivery to you.

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

Hypertherm provides repair, replacement or adjustment of the Product as the sole and exclusive remedy, if and only if the warranty set forth herein properly is invoked and applies. Hypertherm, at its sole option, shall repair, replace, or adjust, free of charge, any defective Products covered by this warranty which shall be returned with Hypertherm’s prior authorization (which shall not be unreasonably withheld), properly packed, to Hypertherm’s place of business in Hanover, New Hampshire, or to an authorized Hypertherm repair facility, all costs, insurance and freight pre paid by the customer. Hypertherm shall not be liable for any repairs, replacement, or adjustments of Products covered by this warranty, except those made pursuant to this paragraph and with Hypertherm’s prior written consent.

The warranty set forth above is exclusive and is in lieu of all other warranties, express, implied, statutory, or otherwise with respect to the Products or as to the results which may be obtained therefrom, and all implied warranties or conditions of quality or of merchantability or fitness for a particular purpose or against infringement. The foregoing shall constitute the sole and exclusive remedy for any breach by Hypertherm of its warranty.

Compliance Information W-1

9/10

Warranty

WARRANTY

Distributors/OEMs may offer different or additional warranties, but Distributors/OEMs are not authorized to give any additional warranty protection to you or make any representation to you purporting to be binding upon Hypertherm.

Patent indemnity

Except only in cases of products not manufactured by Hypertherm or manufactured by a person other than Hypertherm not in strict conformity with Hypertherm’s specifications and in cases of designs, processes, formulae, or combinations not developed or purported to be developed by Hypertherm, Hypertherm will have the right to defend or settle, at its own expense, any suit or proceeding brought against you alleging that the use of the Hypertherm product, alone and not in combination with any other product not supplied by Hypertherm, infringes any patent of any third party. You shall notify Hypertherm promptly upon learning of any action or threatened action in connection with any such alleged infringement (and in any event no longer than fourteen (14) days after learning of any action or threat of action), and Hypertherm’s obligation to defend shall be conditioned upon Hypertherm’s sole control of, and the indemnified party’s cooperation and assistance in, the defense of the claim.

Limitation of liability

In no event shall Hypertherm be liable to any person or entity for any incidental, consequential direct, indirect, punitive or exemplary damages (including but not limited to lost profits) regardless of whether such liability is based on breach of contract, tort, strict liability, breach of warranty, failure of essential purpose, or otherwise, and even if advised of the possibility of such 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 based on breach of contract, tort, strict liability, breach of warranties, failure of essential purpose or otherwise, for any claim, action, suit or proceeding (whether in court, arbitration, regulatory proceeding or otherwise) arising out of or relating to the use of the Products exceed in the aggregate the amount paid for the Products that gave rise to such claim.

Insurance

At all times you will have and maintain insurance in such quantities and types, and with coverage sufficient and appropriate to defend and to hold Hypertherm harmless in the event of any cause of action arising from the use of the products.

W-2 Compliance Information

9/10

Transfer of rights

You may transfer any remaining rights you may have hereunder only in connection with the sale of all or substantially all of your assets or capital stock to a successor in interest who agrees to be bound by all of the terms and conditions of this Warranty. Within thirty (30) days before any such transfer occurs, you agree to notify in writing Hypertherm, which reserves the right of approval. Should you fail timely to notify Hypertherm and seek its approval as set forth herein, the Warranty set forth herein shall be null and void and you will have no further recourse against Hypertherm under the Warranty or otherwise.

Warranty

Compliance Information W-3

9/10

Warranty

W-4 Compliance Information

9/10

Safety information

Before operating any Hypertherm equipment, read the separate Safety and Compliance Manual (80669C) included with your product for important safety information.

Table of ConTenTs

ELECTROMAGNETIC COMPATIBILITY (EMC) ....................................................................EMC-1

WARRANTY ........................................................................................................................................W-1

Safety information ................................................................................................................................. 1

Section 1

Specifications ......................................................................................................................................1-1

Component weights .......................................................................................................................................... 1‑2

Duramax HRT hand torch dimensions .......................................................................................................... 1‑2

Duramax HRTs hand torch dimensions ........................................................................................................ 1‑2

Duramax MRT full‑length machine torch dimensions ................................................................................ 1‑3

Duramax MRT without positioning sleeve (mini torch) .............................................................................. 1‑3

Section 2

Torch Setup ..........................................................................................................................................2-1

Introduction ......................................................................................................................................................... 2‑2

Consumable life .................................................................................................................................................. 2‑2

Hand torch setup ............................................................................................................................................... 2‑3

Choose the hand torch consumables ................................................................................................ 2‑3

Hand torch consumables ...................................................................................................................... 2‑4

Install the hand torch consumables ..................................................................................................... 2‑5

Machine torch setup.......................................................................................................................................... 2‑6

Converting a Duramax retrofit machine torch into a mini torch .................................................... 2‑7

Mount the torch ........................................................................................................................................ 2‑9

Choose the machine torch consumables ........................................................................................2‑12

Machine torch consumables ...............................................................................................................2‑12

Install the machine torch consumables ............................................................................................2‑15

Aligning the torch ..................................................................................................................................2‑15

Torch installation ..............................................................................................................................................2‑16

Section 3

Operation ..............................................................................................................................................3-1

Using the cut charts .......................................................................................................................................... 3‑2

Estimated kerf‑width compensation .................................................................................................... 3‑2

100 amp mechanized shielded cutting for Powermax1650.......................................................... 3‑5

85 amp mechanized shielded cutting for Powermax1650 ............................................................ 3‑7

80 amp mechanized shielded cutting for Powermax1250/1650 ..............................................3‑11

Duramax Retrofit Torch Operator Manual i

Table of ConTenTs

65 amp mechanized shielded cutting for Powermax1250/1650 ..............................................3‑13

60 amp mechanized shielded cutting for Powermax1000/1250/1650 ...................................3‑17

45 amp mechanized shielded cutting for Powermax1000/1250/1650 ...................................3‑19

100 amp mechanized unshielded cutting for Powermax1650 ...................................................3‑23

85 amp mechanized unshielded cutting for Powermax1650......................................................3‑25

65 amp mechanized unshielded cutting for Powermax1250/1650 ..........................................3‑29

45 amp mechanized unshielded cutting for Powermax1000/1250/1650 ..............................3‑33

FineCut® consumables for Powermax1000/1250/1650.............................................................3‑37

Using the hand torch .......................................................................................................................................3‑42

Operate the safety trigger ...................................................................................................................3‑42

Hand torch cutting hints ......................................................................................................................3‑43

Start a cut from the edge of the workpiece.....................................................................................3‑44

Pierce a workpiece ................................................................................................................................3‑45

Gouge a workpiece ..............................................................................................................................3‑46

Common hand‑cutting faults ..............................................................................................................3‑49

Using the machine torch ................................................................................................................................3‑50

Ensure the torch and table are set up correctly .............................................................................3‑50

Understand and optimize cut quality .................................................................................................3‑50

To pierce a workpiece using the machine torch ............................................................................3‑53

Common machine‑cutting faults ........................................................................................................3‑53

Section 4

Maintenance and parts .....................................................................................................................4-1

Perform routine maintenance .......................................................................................................................... 4‑2

Inspect the consumables ................................................................................................................................. 4‑3

Hand torch replacement parts ........................................................................................................................ 4‑4

Machine torch replacement parts .................................................................................................................. 4‑6

Accessory parts.................................................................................................................................................. 4‑7

ii Duramax Retrofit Torch Operator Manual

Section 1

Specifications

In this section:

Component weights .......................................................................................................................................... 1‑2

Duramax HRT hand torch dimensions .......................................................................................................... 1‑2

Duramax HRTs hand torch dimensions ........................................................................................................ 1‑2

Duramax MRT full‑length machine torch dimensions ................................................................................ 1‑3

Duramax MRT without positioning sleeve (mini torch) .............................................................................. 1‑3

Duramax Retrofit Torch Operator Manual 1-1

SpecificationS

Component weights

Torch type Weight – lbs (kg)

Hand torch 25 ft (7.6 m) 7.1 (3.2) Hand torch 50 ft (15 m) 12.5 (5.7) Machine torch 25 ft (7.6 m) 7.6 (3.4) Machine torch 50 ft (15 m) 13.2 (6.0)

Duramax HRT hand torch dimensions

9.9 in (25.2 cm)

75°

3.8 in

(9.8 cm)

angle

1.0 in

(2.5 cm)

Duramax HRTs hand torch dimensions

10.2 in (25.9 cm)

15°

1.9 in

(4.7 cm)

angle

1.0 in

(2.5 cm)

2.6 in

(6.6 cm)

2.6 in

(6.6 cm)

1-2 Duramax Retrofit Torch Operator Manual

SpecificationS

Duramax MRT full-length machine torch dimensions

15.6 in

(39.6 cm)

1.0 in

(2.5 cm)

8.1 in

(20.6 cm)

12.3 in

(31.3 cm)

1.4 in

(3.5 cm)

1.4 in (3.6 cm) outer dimension, 1.3 in

(3.3cm) flat sides

Duramax MRT without positioning sleeve (mini torch)

6.6 in

(16.8 cm)

1.0 in

(2.5 cm)

Duramax Retrofit Torch Operator Manual 1-3

1.4 in

(3.5 cm)

3.3 in

(8.4 cm)

1.4 in (3.6 cm) outer dimension, 1.3 in

(3.3cm) flat sides

SpecificationS

1-4 Duramax Retrofit Torch Operator Manual

Section 2

Torch Setup