Hypertherm HRT2 User Manual

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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: 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 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:

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

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

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

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

TORCH SETUP

11. Slide the coupler over the torch lead.

12. Use two wrenches to tighten the gas supply line nut onto the threaded torch body fitting.

13. Secure the pilot arc wire to the torch body by tightening the pilot arc wire terminal 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. Secure the mounting sleeve to the torch body by tightening the three screws.

17. Screw the coupler into the mounting sleeve.

18. Screw the strain relief nut into the coupler.

19. Screw the strain relief body into the strain relief nut.

Duramax Retrofit Torch Operator Manual 2-7

Torch seTup

Mount the torch

Depending on the type of cutting table you have, you may or may not need to disassemble the torch to route it through the track and mount it. If your cutting table’s track is large enough for you to thread the torch through it without removing the torch body from the lead, do so and then attach the torch to the lifter per the manufacturer’s instructions.

Note: The Duramax machine torches can be mounted on a wide variety of X-Y tables, track burners, pipe bevelers,

and other equipment. Install the torch per the manufacturer’s instructions and follow the instructions below for disassembly if necessary.

If you need to disassemble and reassemble the torch, refer to the figures in the “Machine torch setup” section while completing the following instructions.

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 (full-length machine torch) 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.

Pilot arc wire

terminal screw

Gas supply line nut

Torch body

Wire connector for

cap-sensor switch

2-8 Duramax Retrofit Torch Operator Manual

TORCH SETUP

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.

Note: Cover the end of the gas line on the torch lead with tape to keep dirt and other contaminants from getting in

the gas line when you route the lead through the track.

10. Slide the coupler, positioning sleeve (full-length machine torch), strain relief nut, and strain relief body off the front of the torch lead.

11. If you do not need the gear rack on a full-length machine torch, slide the gear rack from the positioning sleeve toward the consumables 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. Use two wrenches to tighten the gas supply line nut onto the threaded torch body fitting.

17. Secure the pilot arc wire to the torch body by tightening the pilot arc wire terminal screw.

18. Reconnect the cap-sensor switch’s wire connector.

19. Slide the mounting sleeve over the front of the torch body. Align the slot on the front of the mounting sleeve (next to one of the three screw holes) with the cap-sensor plunger on the torch body.

20. Secure the mounting sleeve to the torch body by tightening the three screws.

21. Screw the coupler into the mounting sleeve.

22. If you are mounting a full-length machine torch, screw the positioning sleeve into the coupler.

23. Reconnect the strain relief nut and strain relief body.

24. Attach the torch to the lifter per the manufacturer’s instructions.

Duramax Retrofit Torch Operator Manual 2-9

Torch seTup

Choose the machine torch consumables

Powermax systems with the Duramax MRT2 retrofit torch are shipped with a complete set of consumables. Hypertherm also includes spare electrodes and nozzles. In addition, an ohmic-sensing retaining cap is available for use with shielded consumables. With shielded consumables, the torch tip may touch the metal when cutting. With unshielded consumables, you must keep the torch a small distance, about 2 mm (0.08 inch), away from the metal. Unshielded consumables generally have a shorter life than shielded consumables.

Machine torch consumables

Mechanized shielded consumables

4 5 A

220817

Shield

220854

Retaining cap

220941

Nozzle

Mechanized shielded with ohmic consumables

4 5 A

220817

Shield

220953

Ohmic-sensing

retaining cap

220941

Nozzle

Mechanized unshielded consumables

4 5 A

220955

Deflector

220854

Retaining cap

220941

Nozzle

220842

Electrode

220842

Electrode

220842

Electrode

220857

Swirl ring

220857

Swirl ring

220857

Swirl ring

2-10 Duramax Retrofit Torch Operator Manual

Gouging consumables

TORCH SETUP

FineCut

220798

Shield

shielded

220948

Shield

unshielded consumables

220955

Deflector

220854

Retaining cap

220953

Retaining cap

220854

Retaining cap

220797

Nozzle

220930

Nozzle

220930

Nozzle

220842

Electrode

220842

Electrode

220842

Electrode

220857

Swirl ring

220857

Swirl ring

220857

Swirl ring

Duramax Retrofit Torch Operator Manual 2-11

Torch seTup

Install the machine 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 is activated. Make sure the power is OFF before changing the consumables.

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 “Install the hand torch consumables” on page 2-4.

Aligning the torch

Mount the machine torch perpendicular to the workpiece in order to get a vertical cut. Use a square to align the torch at 0° and 90°.

Torch

0°

90°

2-12 Duramax Retrofit Torch Operator Manual

TORCH SETUP

Torch installation

Torches with a quick disconnect connector

1. Turn OFF the power switch and remove the power cord from the power receptacle.

2. Disconnect the gas supply hose from the power supply.

3. Align the connector key-way on the torch lead with the receptacle on the power supply and push in until the pins seat.

4. Before tightening, turn the connector securing ring 1/4 turn to the left to ensure that the securing ring threads and the connector receptacle threads are aligned.

5. Turn the securing ring to the right to tighten.

6. Clean the top of the power supply and apply the new consumable label over the existing label.

Key-way

Quick disconnect

connector

Consumable label

(Part # 210126)

Securing ring

Note: If the receptacle is missing or damaged it should be replaced with a new receptacle.

Part Number Description

028522 MAX42 receptacle 028523 MAX43 receptacle 029962 Powermax800 receptacle 128493 Powermax600 receptacle 129325 Powermax900 receptacle

Receptacle

Duramax Retrofit Torch Operator Manual 2-13

Torch seTup

Torches without a quick disconnect connector - Powermax600 CE

1. Turn OFF the power switch and remove the power cord from the power receptacle.

2. Disconnect the gas supply hose from the power supply.

Caution: Do not tighten the strain relief collar (4) onto the torch lead until the gas fitting (3) is tight, or the gas

connection may leak.

3. Install the strain relief (1) and secure with nut (2).

4. Connect and tighten the gas fitting (3).

5. Tighten the strain relief collar (4) onto the lead.

6. Connect the electrical connections (5), (6) and (7). Tighten the terminal block screws to 12 kg cm (10 in.-lb).

Caution: These are high current connections. Proper

torque is critical.

2-14 Duramax Retrofit Torch Operator Manual

ON/OFF Pendant connection

TORCH SETUP

On/Off pendant

The Duramax MRT2 torch lead is supplied with a pigtail so that the on/off pendant may be used. If you want to use a different on/off switch configuration, note that the wiring configuration to the 3-socket female receptacle on the pigtail is as follows:

Socket A White Wire Socket B Not Used Socket C Black Wire

Pigtail from machine

torch lead

Duramax Retrofit Torch Operator Manual 2-15

Torch seTup

2-16 Duramax Retrofit Torch Operator Manual

Section 3

Operation

In this section:

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

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

Duramax Retrofit Torch Operator Manual 3-1

OPERATION

Using the cut charts

The following sections provide cut charts for each set of mechanized consumables. A consumable diagram with part numbers precedes each cut chart.

The cut charts are intended to provide a good starting point for each different cut assignment. Every cutting system requires “fine tuning” for each cutting application in order to obtain the desired cut quality.

The arc voltage increases as the consumables wear and the voltage setting should be increased to maintain the correct Torch-to-Work Distance.

The 45 amp nozzle (part number 220941) provides the best results across the 40 - 55 amp cutting range for both the mechanized shielded and unshiedled consumables.

Note: Hypertherm collected the data under laboratory test conditions using new consumables.

• Maximum travel speeds are the fastest travel speeds possible to cut the material without regard to cut quality.

• Optimum travel speeds provide the best cut angle, least dross and best cut surface finish.

• 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 speeds result in the greatest number of cut parts, but not necessarily the best possible cut quality.

3-2 Duramax Retrofit Torch Operator Manual

55 amp mechanized shielded consumables

•Torch-to-workdistanceforthefollowingcutchartis1.5mm(1/16inch)forallcuts.

4 5 A

OPERATION

220817

Shield

220817

Shield

Ohmic-sensing

Mild Steel

Arc Current Arc Voltage

134 127 134 0.25

138 0.75 144 146 149

Stainless

Arc Current Arc Voltage

134 0 136 0.25 139 0.50

145 0.75 146 149 154

Aluminum

Arc Current Arc Voltage

135 0 138

141 146 0.75 149 153

220854

Retaining cap

220953

retaining cap

Motion

Delay

Motion

Delay

Motion

Delay

0.25

220941

Nozzle

4 5 A

220941

Nozzle

Material Thickness Maximum Travel Speeds Optimum Travel Speeds

Inches mm

16 Ga 1.5 10 Ga 3.4

1/4” 6.4 3/8” 9.5 1/2” 12.7 5/8” 15.9 3/4” 19.0

Material Thickness Maximum Travel Speeds Optimum Travel Speeds

Inches mm

16 Ga 4.8 10 Ga 3.4

1/4” 6.4 3/8” 9.5 1/2” 12.7 5/8” 15.9 3/4” 19.0

Material Thickness Maximum Travel Speeds Optimum Travel Speeds

Inches mm

1/16” 1.6

1/8” 3.2 1/4” 6.4 3/8” 9.5 1/2” 12.7 5/8” 15.9

220842

Electrode

220842

Electrode

IPM mm/min IPM mm/min 627 15926 502 12751 264 6706 211 5359 118 2997 78 1981

IPM mm/min IPM mm/min 625 15875 406 10312 244 6198 159 4039

IPM mm/min IPM mm/min 666 16916 433 10998 400 10160 260 6604 129 3277 83 2108

220857

Swirl ring

220857

Swirl ring

61 1549 39 991 41 1041 26 660 28 711 18 457 19 483 12 305

98 2489 64 1626 51 1295 32 813 34 864 22 559 23 584 15 381 15 381 10 254

71 1803 46 1168 50 1270 29 737 29 737 18 457

* Piercing material in this range is not recommended, it will shorten consumable life. Starting cuts at the edge of the

metal is recommended.

Duramax Retrofit Torch Operator Manual 3-3

OPERATION

50 amp mechanized shielded consumables

•Torch-to-workdistanceforthefollowingcutchartis1.5mm(1/16inch)forallcuts.

4 5 A

Mild Steel

Arc

Current

Stainless

Arc

Current

Aluminum

Arc

Current

220817

Shield

220817

Shield

Arc

Voltage

134 128 132 0.25 136 0.75 145 151 157

Arc

Voltage

134 0 136 0.25 139 0.50 145 0.75 146 149 154

Arc

Voltage

135 0 138 141 146 0.75 149 153

220854

Retaining cap

220953

Ohmic-sensing

retaining cap

Motion

Delay

Motion

Delay

Motion

Delay

0.25

220941

Nozzle

4 5 A

220941

Nozzle

Material Thickness Maximum Travel Speeds Optimum Travel Speeds

Inches mm

16 Ga 1.5 10 Ga 3.4

1/4” 6.4 3/8” 9.5 1/2” 12.7 5/8” 15.9 3/4” 19.0

Material Thickness Maximum Travel Speeds Optimum Travel Speeds

Inches mm

16 Ga 4.8 10 Ga 3.4

1/4” 6.4 3/8” 9.5 1/2” 12.7 5/8” 15.9 3/4” 19.0

Material Thickness Maximum Travel Speeds Optimum Travel Speeds

Inches mm

1/16” 1.6

1/8” 3.2 1/4” 6.4 3/8” 9.5 1/2” 12.7 5/8” 15.9

220842

Electrode

220842

Electrode

IPM mm/min IPM mm/min 627 15926 502 12751 230 5842 184 4674 100 2540 65 1651

50 1270 33 838 32 813 20 508 23 584 15 381 15 381 9 229

IPM mm/min IPM mm/min 625 15875 406 10312 213 5410 139 3531

83 2108 54 1372 42 1067 27 686 26 660 17 432 19 483 12 305 12 305 8 203

IPM mm/min IPM mm/min 666 16916 433 10998 400 10160 260 6604 110 2794 71 1803

58 1473 37 940 39 991 23 584 24 610 15 381

220857

Swirl ring

220857

Swirl ring

* Piercing material in this range is not recommended, it will shorten consumable life. Starting cuts at the edge of the

metal is recommended.

3-4 Duramax Retrofit Torch Operator Manual

45 amp mechanized shielded consumables

4 5

OPERATION

220817

Shield

220817

Shield

45A Shielded Air flow rate - slpm/scfh

Mild Steel

220854

Retaining cap

220953

Ohmic-sensing

retaining cap

220941

Nozzle

4 5

220941

Nozzle

220842

Electrode

220842

Electrode

220857

Swirl ring

220857

Swirl ring

Hot 177 / 376

Cold 201 / 427

Metric

Material

Thickness

Torch-

to-Work

Distance

Initial Pierce

Height

Pierce Delay

Time

Best Quality Settings Production Settings

Cut Speed Voltage Cut Speed Voltage

mm mm mm % seconds (mm/min) Volts (mm/min) Volts

0.5 1 9000 128 10800 128

0.0

9000 128 12500 126

1.5 0.1 9000 130 10200 129 2 0.3 6600 130 7800 129 3 4 2200 134 3560 131

1.5 3.8 250

0.4

3850 133 4900 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

inches inches inches % seconds ipm Volts ipm Volts

26GA 22GA 350 128 450 128 18GA

0.02 0.08 400

16GA 350 130 400 129 14GA 12GA 10GA 100 134 164 131

0.06 0.15 250

0.0

0.1

0.2 270 130 320 129

0.4

350 128 500 128

350 129 400 128

190 133 216 131

3/16 0.5 70 135 108 132

1/4 0.6 48 137 73 132

Duramax Retrofit Torch Operator Manual 3-5

OPERATION

4 5 A

220817

Shield

220817

Shield

45A Shielded Air flow rate - slpm/scfh

Stainless Steel

220854

Retaining cap

220953

Ohmic-sensing

retaining cap

220941

Nozzle

4 5 A

220941

Nozzle

220842

Electrode

220842

Electrode

220857

Swirl ring

220857

Swirl ring

Hot 177 / 376

Cold 201 / 427

Metric

Material

Thickness

Torch-

to-Work

Distance

Initial Pierce

Height

Pierce

Delay Time

Best Quality Settings Production Settings

Cut Speed Voltage Cut Speed Voltage

mm mm mm % seconds (mm/min) Volts (mm/min) Volts

0.5 1 9000 130 10800 130

0.0

9000 130 12500 129

1.5 0.1 9000 130 10200 130 2 0.3 6000 132 8660 131 3 4 2000 134 2600 134

1.5 3.8 250

0.4

3100 132 4400 132

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

inches inches % seconds ipm Volts ipm Volts 26GA 22GA 350 130 450 129 18GA

0.02 0.08 400

16GA 350 130 400 130 14GA 12GA 10GA 100 133 134 134

0.06 0.15 250

0.0

0.1

0.2 250 132 360 131

0.4

350 130 500 129

350 130 400 130

140 132 206 131

3/16 in. 0.5 52 135 58 135

1/4 in. 0.6 30 141 35 140

3-6 Duramax Retrofit Torch Operator Manual

OPERATION

4 5 A

220817

Shield

220817

Shield

45A Shielded Air flow rate - slpm/scfh

Aluminum

220854

Retaining cap

220953

Ohmic-sensing

retaining cap

220941

Nozzle

4 5 A

220941

Nozzle

220842

Electrode

220842

Electrode

220857

Swirl ring

220857

Swirl ring

Hot 177 / 376

Cold 201 / 427

Metric

Material

Thickness

Torch-

to-Work

Distance

Initial Pierce

Height

Pierce

Delay Time

Best Quality Settings Production Settings

Cut Speed Voltage Cut Speed Voltage

mm mm mm % seconds (mm/min) Volts (mm/min) Volts

0.0 8250 136 11000 136 2 0.1 6600 136 9200 135 3 0.2 3100 139 6250 134

1.5 3.8 250 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

inches inches inches % seconds ipm Volts ipm Volts

1/32

0.0 325 136 450 136 1/16 0.1 325 136 400 136 3/32 0.2 200 136 328 134

0.06 0.15 250 1/8 0.4 100 140 224 134 1/4 0.5 54 142 96 137

Duramax Retrofit Torch Operator Manual 3-7

OPERATION

40 amp mechanized shielded consumables

•Torch-to-workdistanceforthefollowingcutchartis1.5mm(1/16inch)forallcuts.

4 5

Mild Steel

Arc

Current

Stainless

Arc

Current

Aluminum

Arc

Current

220817

Shield

220817

Shield

Arc

Voltage

147 148 149 152 144 0.25 146 0.50 147 0.75 149 1.00

Arc

Voltage

139 139 142 144 144 147 0.50 149 0.75 149 1.00

Arc

Voltage

150 152 146 0.25 149 0.50 151 1.00

220854

Retaining cap

220953

Ohmic-sensing

retaining cap

Motion

Delay

Motion

Delay

0.25

Motion

Delay

220941

Nozzle

4 5

220941

Nozzle

Material Thickness Maximum Travel Speeds Optimum Travel Speeds

Inches mm

26 GA 0.5 22 GA 0.8 18 GA 1.3 16 GA 1.5 14 GA 1.9 10 GA 3.4

3/16 4.7

1/4 6.4

Material Thickness Maximum Travel Speeds Optimum Travel Speeds

Inches mm

26 GA 0.5 22 GA 0.8 18 GA 1.3 16 GA 1.5 14 GA 1.9 10 GA 3.4

3/16 4.7

1/4 6.4

Material Thickness Maximum Travel Speeds Optimum Travel Speeds

Inches mm

1/32 0.8 1/16 1.5 3/32 2.4

1/8 3.2 1/4 6.4

220842

Electrode

220842

Electrode

IPM mm/min IPM mm/min 638 16205 415 10541 500 12700 325 8255 312 7925 203 5156 176 4470 114 2896 640 16256 221 5613 151 3835 98 2489

97 2464 63 1600 74 1880 48 1219

IPM mm/min IPM mm/min 631 16027 410 10414 496 12598 322 8179 592 15037 335 8509 374 9500 243 6172 221 5613 144 3658 107 2718 70 1778

67 1702 44 1118 47 1194 31 787

IPM mm/min IPM mm/min 610 15494 397 10084 268 6807 174 4420 293 7442 190 4826 204 5182 133 3378

76 1930 49 1245

220857

Swirl ring

220857

Swirl ring

3-8 Duramax Retrofit Torch Operator Manual

45 amp mechanized unshielded consumables

4 5 A

OPERATION

220955

Deflector

45A Unshielded Air flow rate - slpm/scfh

Mild Steel

220854

Retaining cap

220941

Nozzle

220842

Electrode

220857

Swirl ring

Hot 177 / 376

Cold 201 / 427

Metric

Material

Thickness

Torch-

to-Work

Distance

Initial Pierce

Height

Pierce

Delay Time

Best Quality Settings Production Settings

Cut Speed Voltage Cut Speed Voltage

mm mm mm % seconds (mm/min) Volts (mm/min) Volts

0.5 1 9000 120 10800 121

0.0

9000 120 12500 120

1.5 0.1 7700 120 10200 121 2 0.3 6150 119 7800 122 3 4 2350 123 3560 124

1.5 3.8 250

0.4

3950 121 4900 123

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

inches inches % seconds ipm Volts ipm Volts 26GA 22GA 350 120 450 120 18GA 16GA 300 121 400 121 14GA 0.2 250 119 320 122

0.06 0.15 250 12GA 10GA 100 123 164 124

0.0

0.1

0.4

350 120 500 120

350 119 400 121

200 120 216 123

3/16 in. 0.5 85 122 108 124

1/4 in. 0.6 48 127 73 124

Duramax Retrofit Torch Operator Manual 3-9

OPERATION

4 5

220955

Deflector

45A Unshielded Air flow rate - slpm/scfh

Stainless Steel

220854

Retaining cap

220941

Nozzle

220842

Electrode

220857

Swirl ring

Hot 177 / 376

Cold 201 / 427

Metric

Material

Thickness

Torch-

to-Work

Distance

Initial Pierce

Height

Pierce Delay

Time

Best Quality Settings Production Settings

Cut Speed Voltage Cut Speed Voltage

mm mm mm % seconds (mm/min) Volts (mm/min) Volts

0.5 1 9000 121 10800 119

0.0

9000 121 12500 119

1.5 0.1 9000 121 10200 120 2 0.3 6000 122 9600 120 3 4 1900 128 3000 122

1.5 3.8 250

0.4

3250 123 4750 120

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

inches inches % seconds ipm Volts ipm Volts 26GA 22GA 350 120 450 119 18GA

0.02 0.08 400

16GA 350 121 400 120 14GA 12GA 10GA 100 125 140 121

0.06 0.15 250

0.0

0.1

0.2 300 122 400 120

0.4

350 120 500 119

350 118 400 119

150 121 224 120

3/16 in. 0.5 42 131 88 123

1/4 in. 0.6 25 130 48 124

3-10 Duramax Retrofit Torch Operator Manual

OPERATION

4 5

220955

Deflector

45A Unshielded Air flow rate - slpm/scfh

Aluminum

220854

Retaining cap

220941

Nozzle

220842

Electrode

220857

Swirl ring

Hot 177 / 376

Cold 201 / 427

Metric

Material

Thickness

Torch-

to-Work

Distance

Initial Pierce

Height

Pierce

Delay Time

Best Quality Settings Production Settings

Cut Speed Voltage Cut Speed Voltage

mm mm mm % seconds (mm/min) Volts (mm/min) Volts

0.0 7400 126 11000 121 2 0.1 4400 127 9200 123 3 0.2 2800 129 6250 125

1.5 3.8 250 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

inches inches inches % seconds ipm Volts ipm Volts

1/32

0.0 325 126 450 121 1/16 0.1 200 126 400 122 3/32 0.2 150 127 328 124

0.06 0.15 250 1/8 0.4 100 130 224 125 1/4 0.5 36 136 72 127

Duramax Retrofit Torch Operator Manual 3-11

OPERATION

40 amp mechanized unshielded consumables

•Torch-to-workdistanceforthefollowingcutchartis1.5mm(1/16inch)forallcuts.

5 A

220955

Deflector

Retaining cap

Mild Steel

Arc

Current

Arc

Voltage

125

128 130 131

40 129 0.25

Stainless

Arc

Current

Arc

Voltage

127 127 123

127 128

Aluminum

Arc

Current

Arc

Voltage

125 127

40 127 0.25

220854

Motion

Delay

Motion

Delay

0.25

Motion

Delay

220941

Nozzle

Material Thickness Maximum Travel Speeds Optimum Travel Speeds

Inches mm

26 GA 0.5 22 GA 0.8 18 GA 1.3 16 GA 1.5 14 GA 1.9

Material Thickness Maximum Travel Speeds Optimum Travel Speeds

Inches mm

26 GA 0.5 22 GA 0.8 18 GA 1.3 16 GA 1.5 14 GA 1.9

Material Thickness Maximum Travel Speeds Optimum Travel Speeds

Inches mm

1/32 0.8 1/16 1.5 3/32 2.4

220842

Electrode

220857

Swirl ring

IPM mm/min IPM mm/min 550 13970 353 8966 484 12294 315 8001 238 6045 155 3937 167 4242 109 2769 326 8280 212 5385

IPM mm/min IPM mm/min 561 14249 365 9271 453 11506 295 7493 500 12700 325 8255 367 9322 239 6071 220 5588 143 3632

IPM mm/min IPM mm/min 564 14326 366 9296 236 5994 153 3886 261 6629 170 4318

3-12 Duramax Retrofit Torch Operator Manual

FineCut

consumables

Note: The cut charts in this section apply to both shielded and unshielded consumables

OPERATION

FineCut

Mild Steel

Metric

Material

Thickness

220948

Shield

220955

Deflector

Current

220953

Retaining cap

220854

Retaining cap

Torch-

to-Work

Distance

220930

Nozzle

220930

Nozzle

Initial Pierce Height

220842

Electrode

220842

Electrode

220857

Swirl ring

220857

Swirl ring

Pierce Delay

Time

Recommended

Cut Speed Voltage

mm A mm mm % seconds (mm/min) Volts

0.5

0.6 8250 78

8250 78

0.8 0.1 8250 78

1.5

2 4800 78

1.5 2.25 150

0.2 8250 78

0.4

6400 78

3 0.5 2750 78 4 0.6 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 24GA 325 78 22GA

20GA 325 78 18GA

0.06 0.09 150 16GA 14GA 200 78

45 12GA 10GA 95 78

0.0

0.1

0.2 325 78

0.4

0.5

325 78

250 78

120 78

Duramax Retrofit Torch Operator Manual 3-13

OPERATION

220948

220955

Deflector

FineCut

Stainless Steel

Metric

Material

Thickness

Shield

Current

220953

Retaining cap

220854

Retaining cap

Torch-

to-Work

Distance

220930

Nozzle

220930

Nozzle

Initial Pierce Height

220842

Electrode

220842

Electrode

220857

Swirl ring

220857

Swirl ring

Pierce Delay

Time

Recommended

Cut Speed Voltage

mm A mm mm % seconds (mm/min) Volts

0.5

0.6 8250 68

8250 68

0.8 0.1 8250 68 1

1.5 2 4800 71

0.5 2.0 400

0.15 8250 68

0.4

6150 70

3 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 inches inches % seconds ipm Volts 26GA 24GA 325 68 22GA

20GA 325 68 18GA

0.02 0.08 400 16GA 14GA 200 70

0.0

0.1

0.2 325 68

0.4

325 68

240 70

12GA 0.5 120 80 10GA 0.6 75 80

3-14 Duramax Retrofit Torch Operator Manual

OPERATION

220948

Shield

220955

Deflector

Low Speed FineCut

Mild Steel

Metric

Material

Thickness

Current

220953

Retaining cap

220854

Retaining cap

Torch-

to-Work

Distance

220930

Nozzle

220930

Nozzle

Initial Pierce Height

220842

Electrode

220842

Electrode

220857

Swirl ring

220857

Swirl ring

Pierce Delay

Time

Recommended

Cut Speed Voltage

mm A mm mm % seconds (mm/min) Volts

0.5

0.6 3800 68

3800 69

0.8 0.1 3800 70 1 *

1.5 *

1.5 2.25 150

2 3 0.5 2750 78

0.2 3800 72

0.4

3800 75 3700 76

4 0.6 1900 78

English

Material

Thickness

Torch-

to-Work

Distance

Initial Pierce Height

Pierce Delay

Time

Recommended

Cut Speed Voltage

A inches inches % seconds ipm Volts 26GA 24GA 150 68 22GA

20GA 150 71

18GA * 16GA *

0.06 0.09 150

14GA 12GA

10GA 95 78

0.0

0.1

0.2 150 73

0.4

0.5

150 70

150 75 150 76 120 78

Note: *Not a dross-free cut.

Duramax Retrofit Torch Operator Manual 3-15

OPERATION

220948

Shield

220955

Deflector

Low Speed FineCut

Stainless Steel

Metric

Material

Thickness

Current

220953

Retaining cap

220854

Retaining cap

Torch-

to-Work

Distance

220930

Nozzle

220930

Nozzle

Initial Pierce Height

220842

Electrode

220842

Electrode

220857

Swirl ring

220857

Swirl ring

Pierce Delay

Time

Recommended

Cut Speed Voltage

mm A mm mm % seconds (mm/min) Volts

0.5

0.6 3800 69

3800 69

0.8 0.1 3800 69 1

1.5

0.5 2.0 400

2 2750 69 3 4 0.6 1050 80

English

Material

Thickness

Torch-

to-Work

Distance

Initial Pierce Height

0.15 3800 69

0.4

2900 69

0.5 2550 80

Pierce Delay

Time

Recommended

Cut Speed Voltage

A inches inches % seconds ipm Volts 26GA 24GA 150 69 22GA

20GA 150 69 18GA 16GA

0.02 0.08 400

14GA 110 69 12GA 10GA 0.6 75 80

0.0

0.1

0.2 145 69

0.4

0.5 120 80

150 69

115 69

3-16 Duramax Retrofit Torch Operator Manual

OPERATION

Using the hand torch

WARNING

INSTANTON TORCHES

PLASMA ARC CAN CAUSE INJURY AND BURNS

Plasma arc comes on im me di ate ly when the torch trigger is activated. The plasma arc will cut quickly through gloves and skin.

• Wear correct and appropriate protective equipment.

• Keep away from the torch tip.

• Do not hold the workpiece and keep your hands clear of the 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 torch head) and press the red torch trigger as show below.

Duramax Retrofit Torch Operator Manual 3-17

OPERATION

Hand torch cutting hints

• Drag the torch tip lightly along the workpiece to maintain a steady cut.

• While cutting, make sure that sparks exit from the bottom of the workpiece. The sparks should lag slightly

behind the torch as you cut (15° — 30° angle from vertical).

• If sparks spray up from the workpiece, move the torch more slowly, or set the output current higher.

• With hand torches, hold the torch nozzle perpendicular to

the workpiece so that the nozzle is at a 90° angle to the cutting surface. Observe the cutting arc as the torch cuts.

90°

• If you fire 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 the torch.

• For straight-line cuts, use a straight edge as a guide. To cut circles, use a template or a radius cutter

attachment (a circle cutting guide). See Section 4, Maintenance and Parts, for part numbers for the Hypertherm plasma cutting guides for cutting circles and making bevel cuts.

3-18 Duramax Retrofit Torch Operator Manual

Start a cut from the edge of the workpiece

1. With the work clamp attached 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.

OPERATION

3. Drag the torch tip lightly across the workpiece to proceed with the cut. Maintain a steady, even pace.

Duramax Retrofit Torch Operator Manual 3-19

OPERATION

Pierce a workpiece

SPARKS AND HOT METAL CAN INJURE EYES AND BURN SKIN. When firing the torch at an angle, sparks and hot metal will spray out from the nozzle. Point the torch away from yourself and others.

1. With the work clamp attached to the workpiece, hold the torch at an approximate 30° angle to the workpiece with the torch tip within 1.5 mm (1/16 inch) of the workpiece before firing the torch.

WARNING

2. Fire the torch while still at an angle 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.

3-20 Duramax Retrofit Torch Operator Manual

OPERATION

Gouge a workpiece

WARNING

SPARKS AND HOT METAL CAN INJURE EYES AND BURN SKIN. When firing

the torch at an angle, sparks and hot metal will spray out from the nozzle. Point the torch away from yourself and others.

1. Hold the torch so that the torch tip is within 1.5 mm (1/16 inch) from the workpiece before firing the torch.

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

45°

Di rec tion of travel

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.

Duramax Retrofit Torch Operator Manual 3-21

OPERATION

General guidelines for gouging

The following actions have the stated effects on the gouge profile:

• Increasing the speed of the torch will decrease width and decrease depth.

• Decreasing the speed of the torch will increase width and increase depth.

• Increasing 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 depth.

• Decreasing the current of the power supply will decrease width and decrease depth.

Common hand-cutting faults

The torch does not cut completely through the workpiece. The causes can be:

• The cut speed is too fast.

• The consumables are worn.

• The metal being cut is too thick for the selected amperage.

• Gouging consumables are installed instead of drag-cutting consumables.

• 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 is shorter than expected. The cause can be:

• Moisture in the gas supply.

• Incorrect gas pressure.

• Consumables incorrectly installed.

3-22 Duramax Retrofit Torch Operator Manual

OPERATION

Using the machine torch

Since the Powermax with a machine torch can be used with a wide variety of cutting tables, track burners, pipe bevelers, and so on, you will need to refer to the manufacturer’s instructions for specifics on operating the machine torch in your configuration. However, the information in the following sections will help you optimize cut quality and maximize consumable life.

Ensure the torch and table are set up correctly

• Use a square to align the torch at right angles to the workpiece in two dimensions.

• The torch may travel more smoothly if you clean, check and “tune” the cutting 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.

• Dross — The molten material that solidifies on the top or bottom of the workpiece.

• Straightness of the cut surface — The cut surface can be concave or convex.

The following sections explain how these factors can affect cut quality.

Cut or bevel angle

• A positive cut angle, or bevel, results when more material is removed from the top of the cut than from the bottom.

• A negative cut angle results when more material is removed from the bottom of the cut.

Duramax Retrofit Torch Operator Manual 3-23

OPERATION

Problem

Negative cut angle

Square cut

Positive cut angle

Note: The squarest cut angle will be on the right side with respect to the forward motion of the torch. The left side

will always have some degree of bevel.

To determine whether a cut-angle problem is being caused by the plasma system or the drive system, make a test cut and measure the angle of each side. Next, rotate the torch 90° in its holder and repeat the process. If the angles are the same in both tests, the problem is in the drive system.

If a cut-angle problem persists after “mechanical causes” have been eliminated (see “Ensure the torch and table are set up correctly” on the previous page), check the torch-to-work distance, especially if the cut angles are all positive or all negative. Also consider the material being cut: if the metal is magnetized or hardened, you are more likely to experience cut angle problems.

Cause

The torch is too low.

The torch is too high.

Solution

Raise the torch; or if you are using a torch height control, increase the arc voltage.

Lower the torch; or if you are using a torch height control, decrease the arc voltage.

3-24 Duramax Retrofit Torch Operator Manual

OPERATION

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 in small increments (5 volts or less) until the dross is reduced.

Low-speed dross forms when the torch’s cutting speed is too slow and the arc angles ahead. It forms as a heavy, bubbly deposit at the bottom of the cut and can be removed easily. Increase the speed to reduce this type of dross.

High-speed dross forms when the cutting speed is too fast and the arc angles behind. It forms as a thin, linear bead of solid metal attached very close to the cut. It is more firmly attached to the bottom of the cut than at low speed and is difficult to remove. To reduce high-speed dross:

• Decrease the cutting speed.

• Decrease the torch-to-work distance.

Note: Dross is more likely to form on warm or hot metal than on cool metal. For example, the first cut in a series

of cuts usually produces the least dross. As the workpiece heats up, more dross can accumulate on subsequent cuts.

Worn or damaged consumables may produce excess dross.

Straightness of the cut surface

A typical plasma cut surface is slightly concave.

The cut surface may become more concave, or convex. Correct torch height is required to keep the cut surface acceptably close to straight. Worn consumables also affect the straightness of the cut.

A strongly concave cut surface occurs when the torch-to-work distance is too low. Increase the torch-towork distance to straighten the cut surface.

A convex cut surface occurs when the torch-to-work distance is too great or the cutting current is too high. First, try lowering the torch, then reduce the cutting current.

Duramax Retrofit Torch Operator Manual 3-25

OPERATION

To pierce a workpiece using the machine torch

As with the hand torch, you can start a cut with the machine torch at the edge of the workpiece or by piercing the workpiece. Piercing will result in a shorter consumable life than with edge starts.

The pierce delay must be sufficiently long that the arc can pierce the material before the torch moves, but not so long that the arc “wanders” while trying to find the edge of a large hole.

When piercing maximum thicknesses, the ring of dross that forms during the pierce may become high enough to contact the torch when the torch begins to move after the pierce is complete. Remove the dross if the torch will contact it during the cut.

Common machine-cutting faults

The torch’s pilot arc will initiate, but will not transfer. Causes can be:

• The work cable is not making good contact with the cutting table or the cutting table is not making good contact with the workpiece.

• The torch-to-work distance is too large.

The workpiece is not totally penetrated, and there is excessive sparking on the top of the workpiece. Causes can be:

• The consumables are worn and need to be replaced. For optimized performance in a mechanized application, replace the nozzle and the electrode together.

• The work cable is not making good contact with the cutting table or the cutting table is not making good contact with the workpiece.

• The current (amperage) is set too low. See “Using the cut charts” on page 3-2 for more information.

• The cut speed is too high. See “Using the cut charts” on page 3-2 for more information.

• The metal being cut exceeds the maximum capacity for the selected amperage.

Dross forms on the bottom of the cut. Causes can be:

• The consumables are worn and need to be replaced. For optimized performance in a mechanized application, replace the nozzle and the electrode together.

• The cutting speed is not correct. See “Using the cut charts” on page 3-2 for more information.

• The current (amperage) is set too low. See “Using the cut charts” on page 3-2 for more information.

3-26 Duramax Retrofit Torch Operator Manual

OPERATION

The cut angle is not square. Causes can be:

• The torch is not square to the workpiece.

• The consumables are worn and need to be replaced. For optimized performance in a mechanized application,

replace the nozzle and the electrode together.

• The direction of the torch travel is incorrect. The high-quality cut is always on the right with respect to the

forward motion of the torch.

• The distance between the torch and the workpiece is not correct.

• The cutting speed is not correct. See “Using the cut charts” on page 3-2 for more information.

The consumables’ life is shortened. Causes can be:

• The arc current, arc voltage, travel speed, and other variables are not set as recommended in the cut charts.

• Firing the arc in the air (beginning or ending the cut off of the plate surface). Starting at the edge is acceptable

as long as the arc makes contact with the workpiece when started.

• Starting a pierce with an incorrect torch height. Refer to the cut charts for the specific initial pierce height.

Duramax Retrofit Torch Operator Manual 3-27

OPERATION

3-28 Duramax Retrofit Torch Operator Manual

Section 4

Maintenance and parts

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

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

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

2 ....................................................................................................................................................................................

2 ............................................................................................................................................................................

4-4 4-5

Duramax Retrofit Torch Operator Manual 4-1

MAINTENANCE AND pArTs

Perform routine maintenance

Disconnect the electrical power before you perform any maintenance. Allwork that requires removal of the power supply cover must be performed by a qualified technician.

DANGER

ELECTRIC SHOCK CAN KILL

Every use:

Check indicator lights and fault icons. Correct any fault conditions.

Every 3 months:

Replace any damaged labels.

Inspect the power cord and plug. Replace if damaged.

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.

Inspect the torch lead. Replace if damaged.

Every 6 months:

Clean the inside of the power supply

with compressed air or a vacuum.

4-2 Duramax Retrofit Torch Operator Manual

Inspect the consumables

Part Inspect Action

Shield or

deflector

The center hole for roundness.

The gap between the shield and the nozzle for accumulated debris.

MAINTENANCE AND pArTs

Replace the shield if the hole is no longer round.

Remove the shield and clean away any material.

Nozzle

Electrode

Swirl ring

Torch o-ring

The center hole for roundness.

Good Worn

Max. 1.5 mm (1/16 in)

The surface inside the swirl ring for damage or wear and the gas holes for blockages.

The surface for damage, wear, or a lack of lubrication.

Replace nozzle if the center hole is not round.

Replace electrode if the surface is worn or the pit depth is greater than 1/16 inch (1.6mm) deep.

Replace swirl ring if the surface is damaged or worn or any of the gas holes are blocked.

If the o-ring is dry, lubricate it and the threads with a thin layer of silicone lubricant. If the o-ring is worn or damaged, replace it.

Duramax Retrofit Torch Operator Manual 4-3

MAINTENANCE AND pArTs

Hand torch replacement parts – Duramax HRT

Coupler

Cap-sensor

switch

Pilot arc wire

terminal screw

Torch body

O-ring

Safety trigger

and spring

Trigger start

switch

Torch handle

Torch lead

Handle screws

The HRT2 torch assembly can be replaced, or individual component parts can be replaced. The HRT2 torch assembly includes a variety of Duramax consumables.

Part number Description

005252 Trigger start switch 058519 O-ring 075504 Pilot arc wire terminal screw 075714 Handle screws, #4 x 1/2 slotted TORX pan head, S/B 128926* Kit: Quick disconnect repair 228954 Kit: Duramax 75°/HRT2 torch handle replacement 228719 Kit: Duramax 75°/HRT2 cap-sensor switch replacement 228721 Kit: Safety trigger with spring replacement 228924* Kit: HRT2 lead replacement, 7.6 m (25 ft) 228925* Kit: HRT2 lead replacement, 15.2 m (50 ft) 228926** Kit: HRT2 lead replacement, 7.6 m (25 ft) – without quick disconnect 228927** Kit: HRT2 lead replacement, 15.2 m (50 ft) – without quick disconnect 228916* Kit: HRT2 torch assembly with 7.6 m (25 ft) lead 228917* Kit: HRT2 torch assembly with 15.2 m (50 ft) lead 228918** Kit: HRT2 torch assembly with 7.6 m (25 ft) lead – without quick disconnect 228919** Kit: HRT2 torch assembly with 15.2 m (50 ft) lead – without quick disconnect 228950 Kit: HRT2 torch main body replacement, coupler with 12.7 mm (1/2 in.) threads

* For use with Powermax600, Powermax800, Powermax900, MAX42, and MAX43 CSA systems. ** For use with Powermax600 CE systems.

4-4 Duramax Retrofit Torch Operator Manual

MAINTENANCE AND pArTs

Machine torch replacement parts – Duramax MRT

Consumables

Pilot arc wire

terminal screw

Mounting

sleeve

Coupler

Torch bodyO-ring

Positioning sleeve

Gear rack (32 pitch)

Cap-sensor

switch

Strain relief nut

Strain relief body

Wire connector for

cap-sensor switch

Torch lead

The MRT2 torch assembly can be replaced, or individual component parts can be replaced. The MRT2 torch assembly includes a variety of Duramax consumables.

Part number Description

058519 O-ring 075504 Pilot arc wire terminal screw 128926* Kit: Quick disconnect repair 228720 Kit: Cap-sensor switch replacement 228735 Kit: M65/M65m/M85/M85m/MRT2 front mounting sleeve 228736 Kit: M65/M65m/M85/M85m/MRT2 adapter ring (coupler) 228737 Kit: M65/M85/MRT2 positioning sleeve 228738 Kit: M65/M85/MRT2 removable gear rack 228928* Kit: MRT2 lead replacement, 7.6 m (25 ft) 228929* Kit: MRT2 lead replacement, 15.2 m (50 ft) 228930** Kit: MRT2 lead replacement, 7.6 m (25 ft) – without quick disconnect 228931** Kit: MRT2 lead replacement, 15.2 m (50 ft) – without quick disconnect 228920* Kit: MRT2 torch assembly with 7.6 m (25 ft) lead 228921* Kit: MRT2 torch assembly with 15.2 m (50 ft) lead 228922** Kit: MRT2 torch assembly with 7.6 m (25 ft) lead – without quick disconnect 228923** Kit: MRT2 torch assembly with 15.2 m (50 ft) lead – without quick disconnect 228793 Kit: MRT2 torch main body replacement

* For use with Powermax600, Powermax800, Powermax900, MAX42, and MAX43 CSA systems. ** For use with Powermax600 CE systems.

Duramax Retrofit Torch Operator Manual 4-5

MAINTENANCE AND pArTs

Accessory parts

Part number Description

024548 Leather torch sheathing, 7.5 m (25 ft) 127102 Basic plasma (circles and lines) cutting guide 027668 Deluxe plasma (circles and lines) cutting guide

4-6 Duramax Retrofit Torch Operator Manual

Hypertherm HRT2 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

WARRANTY

Safety information

Component weights

Duramax HRT2 hand torch dimensions

Duramax MRT2 full-length machine torch dimensions

Duramax MRT2 without positioning sleeve (mini torch)

Introduction

Consumable life

Hand torch setup

Choose the hand torch consumables

Install the hand torch consumables

Machine torch setup

Converting a Duramax retrofit machine torch into a mini torch

Mount the torch

Choose the machine torch consumables

Install the machine torch consumables

Aligning the torch

Torch installation

Torches with a quick disconnect connector

Torches without a quick disconnect connector - Powermax600 CE

ON/OFF Pendant connection

Using the cut charts

55 amp mechanized shielded consumables

50 amp mechanized shielded consumables

45 amp mechanized shielded consumables

40 amp mechanized shielded consumables

45 amp mechanized unshielded consumables

40 amp mechanized unshielded consumables

Using the hand torch

Operate the safety trigger

Hand torch cutting hints

Start a cut from the edge of the workpiece

Pierce a workpiece

Gouge a workpiece

General guidelines for gouging

Common hand-cutting faults

Using the machine torch

Ensure the torch and table are set up correctly

Understand and optimize cut quality

To pierce a workpiece using the machine torch

Common machine-cutting faults

Perform routine maintenance

Inspect the consumables

Accessory parts