Hypertherm HRT2 User Manual

Duramax™ Retrofit Torch

HRT2 and MRT2 for

powermax600®, powermax800

®

,

powermax900

®

, MAX42®, and MAX43

®

Operator Manual – 807530

Revision 1

Duramax™ Retrofit Torch

HRT2 and MRT2 for

powermax600

powermax900

Operator Manual

(P/N 807530)

Revision 1 – May 2012

®

,powermax800

®

,MAX42®,and MAX43

®

,

®

Hypertherm, Inc.

Hanover, NH USA

www.hypertherm.com

email: [e-mail]

© 2012 Hypertherm, Inc.

All Rights Reserved

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

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

Hypertherm, Inc.

Etna Road, P.O. Box 5010
Hanover, NH 03755 USA
603-643-3441 Tel (Main Office)
603-643-5352 Fax (All Departments)
[e-mail] (Main Office Email)

800-643-9878 Tel (Technical Service)

[e-mail] (Technical Service Email)

800-737-2978 Tel (Customer Service)

[e-mail] (Customer Service Email)

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

[e-mail] (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
below 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
sensitivity. In such cases it may be necessary to use other
measures to further reduce interference.

This cutting equipment is designed for use only in an
industrial 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 the workpiece. 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, signaling and

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

b. Radio and television transmitters and receivers.

c. Computer and other control equipment.

d. Safety critical equipment, for example guarding

ofindustrial equipment.

e. Health of 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 surrounding 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 boundaries 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 such as filtering of the mains
supply.

Compliance Information EMC-1

7/ 10

ELECTROMAGNETIC COMPATIBILITY

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 power 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 components 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.

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 workpiece to earth
may reduce emissions in some, but not all instances.
Care should be taken to prevent the earthing of the
workpiece increasing the risk of injury to 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 in crease the risk of
injury, for example, by allowing parallel cutting current
return paths which may damage the earth circuits
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 considered for special
applications.

The operator should be insulated from all such bonded
metallic components.

EMC-2 Compliance Information

7/ 10

WARRANTY

Attention

Genuine Hypertherm parts are the factory­recommended 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
and MicroEDGE Pro CNCs and ArcGlide THC, which
shall be within a period of two (2) years from the date of
delivery to you.

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.

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.

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.

Compliance Information W-1

9/10

WARRANTY

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.

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.

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.

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.

W-2 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 ..................................................................................................................................................................... 2

Section 1

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

Component weights .................................................................................................................................................................................1-2

Duramax HRT2 hand torch dimensions ...............................................................................................................................................1-2

Duramax MRT2 full-length machine torch dimensions .....................................................................................................................1-2

Duramax MRT2 without positioning sleeve (mini torch) ...................................................................................................................1-2

Section 2

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

Introduction ................................................................................................................................................................................................2-2

Consumable life .........................................................................................................................................................................................2-2

Hand torch setup ......................................................................................................................................................................................2-2

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

Install the hand torch consumables ............................................................................................................................................2-4

Machine torch setup.................................................................................................................................................................................2-5

Converting a Duramax retrofit machine torch into a mini torch ...........................................................................................2-6

Mount the torch ...............................................................................................................................................................................2-8

Choose the machine torch consumables .............................................................................................................................. 2-10

Install the machine torch consumables .................................................................................................................................. 2-12

Aligning the torch ........................................................................................................................................................................ 2-12

Torch installation .................................................................................................................................................................................... 2-13

Torches with a quick disconnect connector ......................................................................................................................... 2-13

Torches without a quick disconnect connector - Powermax600 CE ............................................................................. 2-14

ON/OFF Pendant connection .................................................................................................................................................. 2-15

Section 3

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

Using the cut charts .................................................................................................................................................................................3-2

55 amp mechanized shielded consumables ............................................................................................................................3-3

50 amp mechanized shielded consumables ............................................................................................................................3-4

45 amp mechanized shielded consumables ............................................................................................................................3-5

40 amp mechanized shielded consumables ............................................................................................................................3-8

45 amp mechanized unshielded consumables .......................................................................................................................3-9

40 amp mechanized unshielded consumables .................................................................................................................... 3-12

FineCut® consumables .............................................................................................................................................................. 3-13

Using the hand torch ............................................................................................................................................................................. 3-17

Operate the safety trigger ......................................................................................................................................................... 3-17

Hand torch cutting hints ............................................................................................................................................................ 3-18

Start a cut from the edge of the workpiece...........................................................................................................................3-19

Pierce a workpiece ...................................................................................................................................................................... 3-20

Gouge a workpiece .................................................................................................................................................................... 3-21

General guidelines for gouging ................................................................................................................................................ 3-22

Duramax Retrofit Torch Operator Manual i

Table of ConTenTs

Common hand-cutting faults .................................................................................................................................................... 3-22

Using the machine torch ...................................................................................................................................................................... 3-23

Ensure the torch and table are set up correctly ................................................................................................................... 3-23

Understand and optimize cut quality ....................................................................................................................................... 3-23

To pierce a workpiece using the machine torch .................................................................................................................. 3-26

Common machine-cutting faults .............................................................................................................................................. 3-26

Section 4

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

Perform routine maintenance .................................................................................................................................................................4-2

Inspect the consumables ........................................................................................................................................................................4-3

Hand torch replacement parts – Duramax HRT
Machine torch replacement parts – Duramax MRT

Accessory parts.........................................................................................................................................................................................4-6

2 ...........................................................................................................................................................................4-4

2 ...................................................................................................................................................................4-5

ii Duramax Retrofit Torch Operator Manual

Section 1

Specifications

In this section:

Component weights ......................................................................................................................................................................................... 1-2

Duramax HRT2 hand torch dimensions .......................................................................................................................................................1-2

Duramax MRT2 full-length machine torch dimensions ............................................................................................................................. 1-2

Duramax MRT2 without positioning sleeve (mini torch) ........................................................................................................................... 1-2

Duramax Retrofit Torch Operator Manual 1-1

SpecificationS

Component weights

Torch type Weight – kg (lbs)

Hand torch 7.6 m (25 ft) 3.2 (7.1)

Hand torch 15 m (50 ft) 5.7 (12.6)

Machine torch 7.6 m (25 ft) 3.4 (7.5)
Machine torch 15 m (50 ft) 5.9 (13.0)

Duramax HRT2 hand torch dimensions

25.2 cm (9.9 in.)

75°

9.8 cm

(3.8 in.)

angle

2.5 cm

(1.0 in.)

Duramax MRT2 full-length machine torch dimensions

39.6 cm

(15.6 in.)

2.5 cm

(1.0 in.)

20.6 cm
(8.1 in.)

31.3 cm

(12.3 in.)

3.5 cm

(1.4 in.)

Duramax MRT2 without positioning sleeve (mini torch)

6.6 cm

(2.6 in.)

3.6 cm (1.4 in.) outer
dimension, 3.3 cm

(1.3 in.) flat sides

16.8 cm
(6.6 in.)

2.5 cm

(1.0 in.)

3.5 cm

(1.4 in.)

8.4 cm

(3.3 in.)

3.6 cm (1.4 in.) outer
dimension, 3.3 cm

(1.3 in.) flat sides

1-2 Duramax Retrofit Torch Operator Manual

Section 2

Torch Setup

In this section:

Introduction ........................................................................................................................................................................................................ 2-2

Consumable life ................................................................................................................................................................................................. 2-2

Hand torch setup .............................................................................................................................................................................................. 2-2

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

Install the hand torch consumables .................................................................................................................................................... 2-4

Machine torch setup......................................................................................................................................................................................... 2-5

Converting a Duramax retrofit machine torch into a mini torch ................................................................................................... 2-6

Mount the torch ....................................................................................................................................................................................... 2-8

Choose the machine torch consumables ....................................................................................................................................... 2-10

Install the machine torch consumables ...........................................................................................................................................2-12

Aligning the torch .................................................................................................................................................................................2-12

Torch installation .............................................................................................................................................................................................2-13

Torches with a quick disconnect connector ..................................................................................................................................2-13

Torches without a quick disconnect connector - Powermax600 CE ......................................................................................2-14

ON/OFF Pendant connection ...........................................................................................................................................................2-15

Duramax Retrofit Torch Operator Manual 2-1

Torch seTup

Introduction

Duramax™ series handheld and machine retrofit torches are available for the Powermax600, Powermax800, Powermax900,
MAX42, and MAX43 systems. The torches are cooled by ambient air and do not require special cooling procedures.

This section explains how to setup your torch and choose the appropriate consumables for the job.

Consumable life

How often you need to change the consumables on your retrofit torch will depend on a number of factors:

• Thickness of the material – the thicker the material being cut, the more often consumables need to be changed.

• Average length of cut – the longer the average cut, the more often consumables need to be changed.

• Type of cutting – handheld cutting will require more consumable changes than machine cutting.

• Air quality – the presence of oil, moisture, or other contaminants will reduce consumable life.

• Piercing / edge starting – piercing the metal causes more consumable wear then starting cuts from the edge of the

metal.

• Proper torch-to-work distance – when gouging or cutting with unshielded consumables, maintaining proper torch­to-work distance will result in better consumable life.

• Proper pierce height – maintaining proper pierce height will result in better consumable life.

• Cutting in “continuous pilot arc” mode or normal cutting mode – cutting with a continuous pilot arc causes more

consumable wear than cutting in normal cutting mode.

You will find more information about proper cutting techniques in Section 3, Operation.

Hand torch setup

Duramax HRT

2

Consumables

Safety trigger

2-2 Duramax Retrofit Torch Operator Manual

TORCH SETUP

Choose the hand torch consumables

Duramax retrofit torches are shipped with a full set of cutting consumables pre-installed. Hypertherm also includes spare
cutting electrodes, nozzles, and gouging consumables in the consumables box, for handheld torches.

Consumables for handheld cutting are shown on the next page. Notice that the retaining cap and electrode are the same for
cutting, gouging, and FineCut® applications. Only the shield, nozzle, and swirl ring are different.

For the best cut quality on thin materials, you may prefer to use FineCut consumables, or use a 45A nozzle and reduce the
current setting to 45 or 40 amps.

Hand torch consumables

Drag-cutting consumables

4
5
A

220818

Shield

Gouging consumables

220798

Shield

FineCut® consumables

220931

Shield

Retaining cap

220854

Retaining cap

220854

Retaining cap

220854

220941

Nozzle

220797

Nozzle

220930

Nozzle

220842

Electrode

220842

Electrode

220842

Electrode

220857

Swirl ring

220857

Swirl ring

220947

Swirl ring

Duramax Retrofit Torch Operator Manual 2-3

Torch seTup

Install the hand torch consumables

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.

To operate the hand 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 torch consumables asshown below.

Swirl ring

Electrode

Nozzle

Retaining cap

Shield

2-4 Duramax Retrofit Torch Operator Manual

Machine torch setup

TORCH SETUP

Duramax MRT

2

Consumables

Mounting

sleeve

Coupler

Positioning sleeve

Gear rack

Duramax MRT2 without positioning sleeve (mini torch)

Consumables

Mounting

sleeve

Coupler

Strain relief

nut

Strain relief nut

Main strain

Torch lead

Strain relief

body

relief nut

Torch lead

Strain relief

body

Before using either style of machine torch, you must:

• Mount the torch on your cutting table or other equipment.

• Choose and install the consumables.

• Align the torch.

• Attach the torch lead to the power supply.

• Set up the power supply for remote starting with either the remote-start pendant or a machine interface cable.

Duramax Retrofit Torch Operator Manual 2-5

Torch seTup

Converting a Duramax retrofit machine torch into a mini torch

You can convert a full-length machine torch to a mini-machine torch by removing the positioning sleeve. Refer to the figures
on the previous page while completing the following instructions.

Note: If you are converting a full-length machine torch to a mini-machine torch and mounting the torch at the same

time, skip this section and follow the instructions in the next section, “Mount the torch”.

1. Disconnect the torch lead from the power supply and remove the consumables from the torch.

Note: While disconnecting and reconnecting the torch parts, maintain the same orientation between the torch body

and torch lead. Twisting the torch body in relation to the torch lead can cause damage.

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 strain relief nut from the positioning sleeve and slide the nut back along the torch lead.

4. Unscrew the positioning sleeve from the coupler.

5. Unscrew the coupler from the mounting sleeve.

6. Remove the three screws from the consumables end of the mounting sleeve and slide the mounting sleeve off the front
of the torch body.

7. Disconnect the wire connector for the cap-sensor switch.

8. Use a #2 Phillips screwdriver to remove the screw that secures the pilot arc wire to the torch body.

9. Use 1/4-inch and 3/8-inch wrenches, or two adjustable wrenches, to loosen the nut that secures the gas supply line to
the torch body. Set the torch body aside.

10. Slide the coupler and positioning sleeve off the front of the torch lead.

Pilot arc wire

terminal screw

Gas supply line nut

Torch body

Wire connector for

cap-sensor switch

2-6 Duramax Retrofit Torch Operator Manual