Hypertherm Manual Family Operator Manual (OM)

Powermax65/85/105 SYNC

Parts Guide

810490 – REVISION 4

ENGLISH

Powermax, SYNC, SmartSYNC, EDGE Pro, and Hypertherm are trademarks of Hypertherm, Inc. and may be registered in the United States and other countries. All other trademarks are the property of their respective holders.

Environmental stewardship is one of Hypertherm’s core values, and it is critical to our success and our customers’ success. We are striving to reduce the environmental impact of everything we do. For more information:www.hypertherm.com/environment.

Powermax65/85/105 SYNC

Parts Guide

810490

REVISION 4

ENGLISH

Original instructions

January 2023

Hypertherm, Inc.

Hanover, NH 03755 USA

www.hypertherm.com

Hypertherm, Inc.

21 Great Hollow 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)

800-643-9878 Tel (Technical Service)

technical.service@hypertherm.com (Technical Service)

800-737-2978 Tel (Customer Service)

customer.service@hypertherm.com (Customer Service)

Hypertherm México, S.A. de C.V.

52 55 5681 8109 Tel 52 55 5681 7978 Tel soporte.tecnico@hypertherm.com (Technical Service)

Hypertherm Plasmatechnik GmbH

Sophie-Scholl-Platz 5 63452 Hanau Germany 00 800 33 24 97 37 Tel 00 800 49 73 73 29 Fax

31 (0) 165 596900 Tel (Technical Service) 00 800 4973 7843 Tel (Technical Service)

technicalservice.emeia@hypertherm.com (Technical Service)

Hypertherm (Singapore) Pte Ltd.

Solaris @ Kallang 164 164 Kallang Way #03-13 Singapore 349248, Republic of Singapore 65 6841 2489 Tel 65 6841 2490 Fax marketing.asia@hypertherm.com (Marketing) techsupportapac@hypertherm.com (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 htjapan.info@hypertherm.com (Main Office) techsupportapac@hypertherm.com (Technical Service)

Hypertherm Europe B.V.

Laan van Kopenhagen 100 3317 DM Dordrecht Nederland 31 165 596907 Tel 31 165 596901 Fax 31 165 596908 Tel (Marketing)

31 (0) 165 596900 Tel (Technical Service) 00 800 4973 7843 Tel (Technical Service)

technicalservice.emeia@hypertherm.com (Technical Service)

Hypertherm (Shanghai) Trading Co., Ltd.

B301, 495 ShangZhong Road Shanghai, 200231 PR China 86-21-80231122 Tel 86-21-80231120 Fax

86-21-80231128 Tel (Technical Service)

techsupport.china@hypertherm.com (Technical Service)

South America & Central America: Hypertherm Brasil Ltda.

Rua Bras Cubas, 231 – Jardim Maia Guarulhos, SP – Brasil CEP 07115-030 55 11 2409 2636 Tel tecnico.sa@hypertherm.com (Technical Service)

Hypertherm Korea Branch

#3904. APEC-ro 17. Heaundae-gu. Busan. Korea 48060 82 (0)51 747 0358 Tel 82 (0)51 701 0358 Fax marketing.korea@hypertherm.com (Marketing) techsupportapac@hypertherm.com (Technical Service)

Hypertherm Pty Limited

GPO Box 4836 Sydney NSW 2001, Australia 61 7 3103 1695 Tel 61 7 3219 9010 Fax au.sales@hypertherm.com (Main Office) techsupportapac@hypertherm.com (Technical Service)

Hypertherm (India) Thermal Cutting Pvt. Ltd

A-18 / B-1 Extension, Mohan Co-Operative Industrial Estate, Mathura Road, New Delhi 110044, India 91-11-40521201/ 2/ 3 Tel 91-11 40521204 Fax htindia.info@hypertherm.com (Main Office) technicalservice.emeia@hypertherm.com (Technical Service)

For training and education resources, go to the Hypertherm Cutting Institute (HCI) online at

www.hypertherm.com/hci.

ENGLISH

WARNING! Before operating any Hypertherm equipment, read the safety instructions in your product’s manual, the Safety and Compliance Manual (80669C),

Waterjet Safety and Compliance Manual (80943C), and Radio Frequency Warning Manual (80945C). Failure to follow safety instructions can result in personal injury

or in damage to equipment. Copies of the manuals can come with the product in electronic and printed formats.

Electronic copies are also on our website. Many manuals are available in multiple languages at www.hypertherm.com/docs.

BG (БЪЛГAPCКИ/BULGARIAN)

ПРЕДУПРЕЖДЕНИЕ! Преди да работите с което и да е оборудване Hypertherm, прочетете инструкциите за безопасност в ръководството на вашия продукт, „Инструкция за безопасност и съответствие“ (80669C), „Инструкция за безопасност и съответствие на Waterjet“ (80943С) и „Инструкция за предупреждение за радиочестота“ (80945С).

Продуктът може да е съпроводен от копия на ръководствата в електронен и в печатен формат. Тези в електронен формат са достъпни също на уебсайта ни. Много ръководства са налице на няколко езика на адрес www.hypertherm.com/docs.

CS (ČESKY/CZECH)

VAROVÁNÍ! Před uvedením jakéhokoli zařízení Hypertherm do provozu si přečtěte bezpečnostní pokyny v příručce k produktu a v Manuálu pro bezpečnost

a dodržování předpisů (80669C), Manuálu pro bezpečnost a dodržování předpisů při řezání vodním paprskem (80943C) a Manuálu varování ohledně rádiových frekvencí (80945C).

Kopie příruček mohou být součástí dodávky produktu, a to v elektronické i tištěné formě. Elektronické kopie jsou k dispozici i na našich webových stránkách. Mnoho příruček je k dispozici v různých jazycích na stránce www.hypertherm.com/docs.

DA (DANSK/DANISH)

ADVARSEL! Inden Hypertherm udstyr tages i brug skal sikkerhedsinstruktionerne i produktets manual og i Manual om sikkerhed og overholdelse af krav (80669C), Manual om sikkerhed og overholdelse af krav for vandstråleskæring (80943C), og Manual om radiofrekvensadvarsel (80945C), gennemlæses.

Kopier af manualerne kan leveres med produktet i elektronisk og trykt format. Elektroniske kopier findes også på vores hjemmeside. Mange manualer er tilgængelige på flere sprog på www.hypertherm.com/docs.

DE (DEUTSCH/GERMAN)

WARNUNG! Bevor Sie ein Hypertherm-Gerät in Betrieb nehmen, lesen Sie bitte die Sicherheitsanweisungen in Ihrer Bedienungsanleitung, das Handbuch für Sicherheit

und Übereinstimmung (80669C), das Handbuch für Sicherheit und Compliance bei Wasserstrahl-Schneidanlagen (80943C) und das Handbuch für HochfrequenzWarnung (80945C).

Bedienungsanleitungen und Handbücher können dem Gerät in elektronischer Form oder als Druckversion beiliegen. In elektronischer Form liegen sie auch auf unserer Website vor. Viele Handbücher stehen in verschiedenen Sprachen auf

www.hypertherm.com/docs zur Verfügung.

ES (ESPAÑOL/SPANISH)

¡ADVERTENCIA! Antes de operar cualquier equipo Hypertherm, lea las instrucciones de seguridad del manual de su producto, del Manual de seguridad

y cumplimiento (80669C), del Manual de seguridad y cumplimiento en corte con chorro de agua (80943C) y del Manual de advertencias de radiofrecuencia

(80945C). El producto puede incluir copias de los manuales en formato digital e impreso.

Las copias digitales también están en nuestra página web. Hay diversos manuales disponibles en varios idiomas en www.hypertherm.com/docs.

ET (EESTI/ESTONIAN)

HOIATUS! Enne Hyperthermi mis tahes seadme kasutamist lugege läbi toote kasutusjuhendis olevad ohutusjuhised ning Ohutus- ja vastavusjuhend (80669C), Veejoa ohutuse ja vastavuse juhend (80943C) ja Raadiosageduse hoiatusjuhend (80945C). Ohutusjuhiste eiramine võib põhjustada vigastusi ja kahjustada seadmeid.

Juhiste koopiad võivad tootega kaasas olla elektrooniliselt või trükituna. Elektroonilised koopiad on saadaval ka meie veebilehel. Paljud kasutusjuhendid on erinevates keeltes saadaval veebilehel www.hypertherm.com/docs.

FI (SUOMI/FINNISH)

VAROITUS! Ennen minkään Hypertherm-laitteen käyttöä lue tuotteen käyttöoppaassa olevat turvallisuusohjeet, turvallisuuden ja vaatimustenmukaisuuden

käsikirja (80669C), vesileikkauksen turvallisuuden ja vaatimustenmukaisuuden käsikirja (80943C) ja radiotaajuusvaroitusten käsikirja (80945C).

Käyttöoppaiden kopiot voivat olla tuotteen mukana sähköisessä ja tulostetussa muodossa. Sähköiset kopiot ovat myös verkkosivustollamme. Monet käyttöoppaat ovat myös saatavissa useilla kielillä www.hypertherm.com/docs.

FR (FRANÇAIS/FRENCH)

AVERTISSEMENT! Avant d’utiliser tout équipement Hypertherm, lire les consignes de sécurité dumanuel de votre produit, duManuel de sécurité et de conformité (80669C), du Manuel de sécurité et de conformité du jet d’eau (80943C) et du Manuel d'avertissement relatif aux radiofréqunces (80945C).

Les exemplaires des manuels qui accompagnent le produit peuvent être sous forme électronique ou papier. Les manuels sous forme électronique se trouvent également sur notre site Internet. Plusieurs manuels sont offerts en plusieurs langues à www.hypertherm.com/docs.

GR (ΕΛΛΗΝΙΚΆ/GREEK)

ΠΡΟΕΙΔΟΠΟΙΗΣΗ! Πριν θέσετε σε λειτουργία οποιονδήποτε εξοπλισμό της Hypertherm, διαβάστε τις οδηγίες ασφαλείας στο εγχειρίδιο του προϊόντος και στο

εγχειρίδιο ασφάλειας και συμμόρφωσης (80669C), στο εγχειρίδιο ασφάλειας και συμμόρφωσης του waterjet (80943C) και στο εγχειρίδιο προειδοποιήσεων για τις ραδιοσυχνότητες (80945C).

Το προϊόν μπορεί να συνοδεύεται από αντίγραφα των εγχειριδίων σε ηλεκτρονική και έντυπη μορφή. Τα ηλεκτρονικά αντίγραφα υπάρχουν επίσης στον ιστότοπό μας. Πολλά εγχειρίδια είναι διαθέσιμα σε διάφορες γλώσσες στο

www.hypertherm.com/docs.

HU (MAGYAR/HUNGARIAN)

VIGYÁZAT! Mielőtt bármilyen Hypertherm berendezést üzemeltetne, olvassa el a biztonsági információkat a termék kézikönyvében, a Biztonsági

és szabálykövetési kézikönyvben (80669C), a Vízsugaras biztonsági és szabálykövetési kézikönyvben (80943C) és a Rádiófrekvenciás figyelmeztetéseket tartalmazó kézikönyvben (80945C).

A termékhez a kézikönyv példányai elektronikus és nyomtatott formában is mellékelve lehetnek. Az elektronikus példányok webhelyünkön is megtalálhatók. Számos kézikönyv áll rendelkezésre több nyelven a www.hypertherm.com/docs weboldalon.

ID (BAHASA INDONESIA/INDONESIAN)

PERINGATAN! Sebelum mengoperasikan peralatan Hypertherm, bacalah petunjuk keselamatan dalam manual produk Anda, Manual Keselamatan dan Kepatuhan (80669C), Manual Keselamatan dan Kepatuhan Jet Air (80943C), dan Manual Peringatan Frekuensi Radio (80945C). Kegagalan mengikuti petunjuk keselamatan dapat menyebabkan cedera pribadi atau kerusakan pada peralatan.

Produk mungkin disertai salinan manual atau petunjuk dalam format elektronik maupun cetak. Salinan elektronik juga tersedia di situs web kami. Berbagai manual tersedia dalam beberapa bahasa di www.hypertherm.com/docs.

IT (ITALIANO/ITALIAN)

AVVERTENZA! Prima di usare un’attrezzatura Hypertherm, leggere le istruzioni sulla sicurezza nel manuale del prodotto, nel Manuale sulla sicurezza e la conformità (80669C), nel Manuale sulla sicurezza e la conformità Waterjet (80943C) e nel Manuale di avvertenze sulla radiofrequenza(80945C).

Copie del manuale possono accompagnare il prodotto in formato cartaceo o elettronico. Le copie elettroniche sono disponibili anche sul nostro sito web. Molti manuali sono disponibili in diverse lingue all’indirizzo www.hypertherm.com/docs.

JA (日本語/JAPANESE)

警告 ! Hypertherm 機器を操作する前に、この製品説明書にある安全情報、「安全とコンプライアンスマニュアル」 (80669C) 、「ウォータージェットの安全とコンプライアンス」 (80943C)、「高周波警告」 (80945C) をお読みください。

説明書のコピーは、電子フォーマット、または印刷物として製品に同梱されています。電子コピーは当社ウェブサイトにも掲載されています。説明書の多くは www.hypertherm.com/docs にて複数の言語でご用意しています。

KO (뼑뼑霢꽩 KOREAN)

陲隕+\SHUWKHUP녚ꟹꌱꩡ끞뼍韥놹꾅뇑븽꫙ꐺ꫑꿵껽놹ꗄ鞑뇊늵ꯍ ꫙ꐺ꫑&낁뫥뇤껽놹ꗄ鞑뇊늵ꯍ꫙ꐺ꫑&鞭ꍡ隕ꓩ꫕늱볁ꯍ 陲隕꫙ꐺ꫑&꾅驍꿵넽鱉껽놹덵렝냹넲냱겢겑꿙

놹녅뿊겒隱넭ꭹ鷑뿊겒냱ꈑ꫙ꐺ꫑ꩡꚭ넩뇑븽隱뼝颍뇑險鷕ꯍ넽걪鱽鲙 놹녅ꩡꚭ鵹+\SHUWKHUP낮ꩡ넩뱭꾅꫑ꚩ겙ꯍ넽냱ꐥ꫙ꐺ꫑ꩡꚭ냵

www.hypertherm.com/docs 꾅꫑꾡ꆡ꽭꽩ꈑ뇑險鷞鱽鲙

NE (NEDERLANDS/DUTCH)

WAARSCHUWING! Lees voordat u Hypertherm-apparatuur gebruikt de veiligheidsinstructies in de producthandleiding, in de Veiligheids-

en nalevingshandleiding (80669C) in de Veiligheids- en nalevingshandleiding voor waterstralen (80943C) en in de Waarschuwingshandleiding radiofrequentie

(80945C). De handleidingen kunnen in elektronische en gedrukte vorm met het product worden

meegeleverd. Elektronische versies zijn ook beschikbaar op onze website. Veel handleidingen zijn in meerdere talen beschikbaar via www.hypertherm.com/docs.

NO (NORSK/NORWEGIAN)

ADVARSEL! Før du bruker noe Hypertherm-utstyr, må du lese sikkerhetsinstruksjonene i produktets håndbok, håndboken om sikkerhet og samsvar (80669C), håndboken om vannjet sikkerhet og samsvar (80943C), og håndboken om radiofrekvensadvarsler (80945C).

Eksemplarer av håndbøkene kan følge med produktet i elektronisk og trykt form. Elektroniske eksemplarer finnes også på nettstedet vårt. Mange håndbøker er tilgjengelig i flere språk på www.hypertherm.com/docs.

PL (POLSKI/POLISH)

OSTRZEŻENIE! Przed rozpoczęciem obsługi jakiegokolwiek systemu firmy Hypertherm należy się zapoznać z instrukcjami bezpieczeństwa zamieszczonymi w podręczniku produktu, w podręczniku bezpieczeństwa i zgodności (80669C), podręczniku bezpieczeństwa i zgodności systemów strumienia wody (80943C) oraz podręczniku z ostrzeżeniem o częstotliwości radiowej (80945C).

Do produktu mogą być dołączone podręczniki użytkownika wformie elektronicznej idrukowanej. Kopie elektroniczne znajdują się również wnaszej witrynie internetowej. Wiele podręczników jest dostępnych wróżnych językach pod adresem

www.hypertherm.com/docs.

PT (PORTUGUÊS/PORTUGUESE)

ADVERTÊNCIA! Antes de operar qualquer equipamento Hypertherm, leia as instruções de segurança no manual do seu produto, no Manual

de Segurança e de Conformidade (80669C), no Manual de Segurança e de Conformidade do Waterjet (80943C) e no Manual de Advertência de radiofrequência (80945C).

Cópias dos manuais podem vir com o produto nos formatos eletrônico e impresso. Cópias eletrônicas também são encontradas em nosso website. Muitos manuais estão disponíveis em vários idiomas em www.hypertherm.com/docs.

RO (ROMÂNĂ/ROMANIAN)

AVERTIZARE! Înainte de utilizarea oricărui echipament Hypertherm, citiți instrucțiunile de siguranță din manualul produsului, manualul de siguranță și conformitate (80669C), manualul de siguranță și conformitate Waterjet (80943C) și din manualul de avertizare privind radiofrecvența (80945C).

Produsul poate fi însoțit de copii ale manualelor în format tipărit și electronic. Exemplarele electronice sunt disponibile și pe site-ul nostru web. Numeroase manuale sunt disponibile în mai mult limbi la adresa:

www.hypertherm.com/docs.

RU (PУССКИЙ/RUSSIAN)

БЕРЕГИСЬ! Перед работой с любым оборудованием Hypertherm ознакомьтесь с инструкциями по безопасности, представленными в руководстве, которое поставляется вместе с продуктом, в Руководстве по безопасности и

соответствию (80669С), в Руководстве по безопасности и соответствию для водоструйной резки (80943C) и Руководстве по предупреждению о радиочастотном излучении (80945С).

Копии руководств, которые поставляются вместе с продуктом, могут быть представлены в электронном и бумажном виде. Электронные копии также доступны на нашем веб-сайте. Целый ряд руководств доступны на нескольких языках по ссылке www.hypertherm.com/docs.

SK (S LOVENČINA/ SLOVAK)

VÝSTRAHA! Pred použitím akéhokoľvek zariadenia od spoločnosti Hypertherm si prečítajte bezpečnostné pokyny v návode na obsluhu vášho zariadenia a v Manuáli

o bezpečnosti a súlade s normami (80669C), Manuáli o bezpečnosti a súlade snormami pre systém rezania vodou (80943C) avManuáli sinformáciami orádiofrekvencii (80945C).

Návod na obsluhu sa dodáva spolu sproduktom velektronickej atlačenej podobe. Jeho elektronický formát je dostupný aj na našej webovej stránke. Mnohé znávodov na obsluhu sú dostupné vo viacjazyčnej mutácii na stránke

www.hypertherm.com/docs.

SL (S LOVEN ŠČINA/SLOVENIAN)

OPOZORILO! Pred uporabo katerekoli Hyperthermove opreme preberite varnostna navodila v priročniku vašega izdelka, v Priročniku za varnost in skladnost (80669C), v Priročniku za varnost in skladnost sistemov rezanja z vodnim curkom (80943C) in v Priročniku Opozorilo o radijskih frekvencah (80945C).

Izvodi priročnikov so lahko izdelku priloženi v elektronski in tiskani obliki. Elektronski izvodi so na voljo tudi na našem spletnem mestu. Številni priročniki so na voljo v različnih jezikih na naslovu www.hypertherm.com/docs.

SR (SRPSKI/SERBIAN)

UPOZORENJE! Pre rukovanja bilo kojom Hyperthermovom opremom pročitajte uputstva o bezbednosti u svom priručniku za proizvod, Priručniku o bezbednosti

i usaglašenosti (80669C), Priručniku o bezbednosti i usaglašenosti Waterjet tehnologije (80943C) i Priručniku sa upozorenjem o radio-frekvenciji (80945C).

Уз производ се испоручују копије приручника у електронском или штампаном формату. Електронске копије су такође доступне на нашем веб-сајту. Многи приручници су доступни на више језика на адреси www.hypertherm.com/docs.

SV (SVENSKA/SWEDISH)

VARNING! Läs häftet säkerhetsinformationen i din produkts säkerhets- och efterlevnadsmanual (80669C), säkerhets- och efterlevnadsmanualen för Waterjet

(80943C) och varningsmanualen för radiofrekvenser (80945C) för viktig säkerhetsinformation innan du använder eller underhåller Hypertherm-utrustning.

Kopior av manualerna kan medfölja produkten i elektroniskt och tryckt format. Elektroniska kopior finns också på vår webbplats. Många manualer finns på flera språk på www.hypertherm.com/docs.

THࡗࡩࡠࡩࡷࡎ࡙THAI

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TR (TÜRKÇE/TURKISH)

UYARI! Bir Hypertherm ekipmanını çalıştırmadan önce, ürününüzün kullanım kılavuzunda, Güvenlik ve Uyumluluk Kılavuzu’nda (80669C), Su Jeti Güvenlik ve Uyumluluk Kılavuzu’nda (80943C) ve Radyo Frekansı Uyarısı Kılavuzu’nda (80945C) yer alan güvenlik talimatlarını okuyun.

Kılavuzların kopyaları, elektronik ve basılı formatta ürünle birlikte verilebilir. Elektronik kopyalar web sitemizde de yer alır. Kılavuzların birçoğu www.hypertherm.com/docs adresinde birçok dilde mevcuttur.

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www.hypertherm.com/docs ᇭ

How to use this guide........................................................................................................................ 10

Service inquiries ...................................................................................................................................... 10

Related documents................................................................................................................................. 10

Plasma power supply exterior, front ............................................................................................. 11

Work leads................................................................................................................................................ 12

Powermax65 SYNC.................................................................................................................... 12

Powermax85 SYNC.................................................................................................................... 13

Powermax105 SYNC ................................................................................................................. 13

Plasma supply exterior, rear............................................................................................................ 15

Machine interface and RS-485 serial interface upgrade kits ................................................ 17

External cables for machine interface receptacle and RS-485 serial interface receptacle .. 18

Machine interface cables ......................................................................................................... 18

RS-485 serial interface cables................................................................................................ 19

75° hand torch replacement parts.................................................................................................. 20

15° hand torch replacement parts .................................................................................................. 21

Powermax65/85/105 SYNC Parts Guide 810490 7

Contents

Hand torch cartridges........................................................................................................................ 22

Drag cutting.............................................................................................................................................. 22

FineCut cutting ........................................................................................................................................ 22

Gouging cartridges................................................................................................................................. 23

Maximum Control gouging........................................................................................................ 23

Maximum Removal gouging...................................................................................................... 23

Specialty cartridges................................................................................................................................ 23

FlushCut cutting .......................................................................................................................... 23

HyAccess gouging...................................................................................................................... 24

HyAccess drag cutting .............................................................................................................. 24

45° long hand torch replacement parts ........................................................................................ 25

90° long hand torch replacement parts ........................................................................................ 26

Long hand torch cartridges.............................................................................................................. 27

Drag cutting.............................................................................................................................................. 27

Full-length machine torch replacement parts ............................................................................ 28

Mini-machine torch replacement parts ........................................................................................ 29

Machine torch cartridges.................................................................................................................. 30

Standard cutting...................................................................................................................................... 30

Ohmic ring .................................................................................................................................... 30

FineCut cutting ........................................................................................................................................ 30

Gouging..................................................................................................................................................... 31

Maximum Control gouging........................................................................................................ 31

Maximum Removal gouging...................................................................................................... 31

Specialty cartridges................................................................................................................................ 31

FlushCut cutting .......................................................................................................................... 31

HyAccess gouging...................................................................................................................... 32

HyAccess cutting........................................................................................................................ 32

180° robotic torch replacement parts............................................................................................ 33

90° robotic torch replacement parts.............................................................................................. 34

45° robotic torch replacement parts.............................................................................................. 35

8 810490 Parts Guide Powermax65/85/105 SYNC

Contents

Robotic torch cartridges ................................................................................................................... 36

Standard cutting...................................................................................................................................... 36

Ohmic ring .................................................................................................................................... 36

FineCut cutting ........................................................................................................................................ 36

Gouging..................................................................................................................................................... 37

Maximum Control gouging........................................................................................................ 37

Maximum Removal gouging...................................................................................................... 37

Specialty cartridges................................................................................................................................ 37

FlushCut cutting .......................................................................................................................... 37

HyAccess gouging...................................................................................................................... 38

HyAccess cutting........................................................................................................................ 38

Accessory parts ................................................................................................................................... 39

Powermax65/85/105 SYNC labels................................................................................................. 40

Cartridge labels ....................................................................................................................................... 40

CSA warning label.................................................................................................................................. 41

Descriptions of warning label icons.................................................................................................... 42

Powermax65/85/105 SYNC Parts Guide 810490 9

How to use this guide

Use the part numbers and kit numbers in this guide to order replacement parts and accessories for your plasma power supply and torch.

Service inquiries

For aid with repairing or replacing internal components:

1. Speak to your Hypertherm distributor or authorized Hypertherm repair facility.

2. Speak to the nearest Hypertherm office shown in the front of this guide.

Plasma power supply exterior, front

Item Part number Description

1 528009 Kit: Powermax65 SYNC plasma power supply cover with labels, CSA (no screws

included)

1 528010 Kit: Powermax65 SYNC plasma power supply cover with labels, CE/CCC (no screws

included)

1 528011 Kit: Powermax85 SYNC plasma power supply cover with labels, CSA (no screws

included)

1 528012 Kit: Powermax85 SYNC plasma power supply cover with labels, CE/CCC (no screws

included)

1 528013 Kit: Powermax105 SYNC plasma power supply cover with labels, CSA (no screws

included)

1 528014 Kit: Powermax105 SYNC plasma power supply cover with labels, CE/CCC (no screws

included)

2 428143 Kit: Adjustment knob

3 428141 Kit: Replacement screws (16) for plasma power supply cover

Powermax65/85/105 SYNC Parts Guide 810490 11

Plasma power supply exterior, front

Hand clamp C-style clamp Ring terminal

2 3

4 5

Work leads

NOTICE

Work leads are approved for specific amperages, lengths, and connectors. Make sure that you use a work lead that is approved for your plasma power supply. The amperage of a work lead is identified near the rubber boot of the work lead connector.

Powermax65 SYNC

Item Part number Description

1 223125 65 A work lead with hand clamp, 7.6 m (25 foot)

1 223126 65 A work lead with hand clamp, 15 m (50 foot)

1 223127 65 A work lead with hand clamp, 23 m (75 foot)

2 223194 65 A work lead with C-style clamp, 7.6 m (25 foot)

2 223195 65 A work lead with C-style clamp, 15 m (50 foot)

2 223196 65 A work lead with C-style clamp 23 m (75 foot)

3 223200 65 A work lead with ring terminal, 7.6 m (25 foot)

3 223201 65 A work lead with ring terminal, 15 m (50 foot)

3 223202 65 A work lead with ring terminal, 23 m (75 foot)

4 008337 Ground hand clamp: 300 A

5 428921 Kit: C-style clamp with hardware

You can make a work lead for the Powermax65 SYNC and



Powermax85 SYNC by installing the 008337 hand clamp or the 428921 C-style clamp on the approved amperage ring terminal work lead from Hypertherm. Make sure that you use a work lead that is the correct amperage for your plasma power supply.

12 810490 Parts Guide Powermax65/85/105 SYNC

Powermax85 SYNC

Item Part number Description

1 223035 85 A work lead with hand clamp, 7.6 m (25 foot)

1 223034 85 A work lead with hand clamp, 15 m (50 foot)

1 223033 85 A work lead with hand clamp, 23 m (75 foot)

2 223203 85 A work lead with C-style clamp, 7.6 m (25 foot)

2 223204 85 A work lead with C-style clamp, 15 m (50 foot)

2 223205 85 A work lead with C-style clamp 23 m (75 foot)

3 223209 85 A work lead with ring terminal, 7.6 m (25 foot)

3 223210 85 A work lead with ring terminal, 15 m (50 foot)

3 223211 85 A work lead with ring terminal, 23 m (75 foot)

4 008337 Ground hand clamp: 300 A

5 428921 Kit: C-style clamp with hardware

Plasma power supply exterior, front

You can make a work lead for the Powermax65 SYNC and



Powermax105 SYNC

Item Part number Description

1 223254 105 A work lead with hand clamp, 7.6 m (25 foot)

1 223255 105 A work lead with hand clamp, 15 m (50 foot)

1 223256 105 A work lead with hand clamp, 23 m (75 foot)

2 223287 105 A work lead with C-style clamp, 7.6 m (25 foot)

2 223288 105 A work lead with C-style clamp, 15 m (50 foot)

2 223289 105 A work lead with C-style clamp, 23 m (75 foot)

3 223284 105 A work lead with ring terminal, 7.6 m (25 foot)

3 223285 105 A work lead with ring terminal, 15 m (50 foot)

3 223286 105 A work lead with ring terminal, 23 m (75 foot)

4 008337 Ground hand clamp: 300 A

You can make a work lead by installing the 008337 hand clamp on the



approved amperage ring terminal work lead from Hypertherm. Make sure that you use a work lead that is the correct amperage for your plasma power supply.

Powermax65/85/105 SYNC Parts Guide 810490 13

Plasma power supply exterior, front

14 810490 Parts Guide Powermax65/85/105 SYNC

Plasma supply exterior, rear

Item Part number Description

1 428352 Kit: Air filter bowl, polycarbonate (comes with plasma power supply, includes the O-ring

but not the filter element)

2 428415* Kit: Air filter bowl, nylon (optional – for work sites with oily air*) (includes the O-ring but not

the filter element)

3 228695 Kit: Air filter element and O-ring (compatible with both filter bowl types)

4 428685 Kit: Gas inlet fittings

• Industrial interchange quick-disconnect nipple with 1/4 NPT threads

• British Pipe Thread adapter G-1/4 BSPP with 1/4 NPT threads

5 228691 Kit: Powermax65/85 SYNC power cord with strain relief, CSA models, 3 m (10 foot)

5 528015 Kit: Powermax65 SYNC power cord with strain relief, CE/CCC models, 3 m (10 foot)

5 528016 Kit: Powermax85 SYNC power cord with strain relief, CE/CCC models, 3 m (10 foot)

5 228885 Kit: Powermax105 SYNC power cord with strain relief, CSA models, 3 m (10 foot)

5 228886 Kit: Powermax105 SYNC power cord with strain relief, 230 V – 400 V CE models, 3 m

(10 foot)

Powermax65/85/105 SYNC Parts Guide 810490 15

Plasma supply exterior, rear

Item Part number Description

5 428949 Kit: Powermax105 SYNC power cord with strain relief, 380 V CCC / 400 V CE models,

3 m (10 foot)

6 228680 Kit: Strain relief for Powermax65/85 SYNC power cords (all models)

6 228915 Kit: Strain relief for Powermax105 SYNC power cords, CSA models

6 228913 Kit: Strain relief for Powermax105 SYNC power cords, 230 V – 400 V CE models

6 228914 Kit: Strain relief for Powermax105 SYNC power cords, 380 V CCC / 400 V CE models

* The polycarbonate filter bowl that comes with the plasma power supply is compatible with most gas supply systems,

but it is important to keep the gas line clean. Organic solvents, chemicals, cutting oil, synthetic oil, alkali, and thread lock solutions can cause damage to the polycarbonate filter bowl over time. You can use the optional nylon bowl (428415) if conditions at your work site make it difficult to prevent harsh chemicals from getting into the gas line.

16 810490 Parts Guide Powermax65/85/105 SYNC

Machine interface and RS-485 serial interface upgrade kits

Item Part number Description

1 228539 Kit: Serial interface receptacle with internal cables and RS-485 serial interface PCB

2 228697 Kit: Machine interface receptacle with internal cables and voltage divider PCB for

Powermax65/85 SYNC (does not include cover for receptacle)

2 528045 Kit: Machine interface receptacle with internal cables and voltage divider PCB for

Powermax105 SYNC (does not include cover for receptacle)

3 128650 Remote start pendant for machine torch, 7.6 m (25 foot)

3 128651 Remote start pendant for machine torch, 15 m (50 foot)

3 128652 Remote start pendant for machine torch, 23 m (75 foot)

3 428755 Remote start pendant for machine torch, 46 m (150 foot)

428975 Kit: Replacement switch for remote start pendant (not shown)

4 127204 Cover for machine interface receptacle

The remote start pendant connects to the machine interface receptacle.



EDGE®Connect CNC: To connect Hypertherm’s EDGE Connect CNC



with a Powermax65/85/105 SYNC, refer to the EDGE Connect Installation and Setup Manual (809340).

EDGE®Pro CNC: To connect Hypertherm’s EDGE Pro CNC with a



Powermax65/85/105 SYNC, refer to the Phoenix Software V9 Series Installation and Setup Manual (806410).

Technical documentation is available at www.hypertherm.com/docs.



Powermax65/85/105 SYNC Parts Guide 810490 17

Machine interface and RS-485 serial interface upgrade kits

External cables for machine interface receptacle and RS-485 serial interface receptacle

Hypertherm offers a variety of external cables that connect to the machine interface receptacle and the RS-485 serial interface receptacle. For setup information refer to the Powermax65/85/105 SYNC Mechanized Cutting Guide (810480).

Machine interface cables

Item Part number Description

1 023206 External machine interface cable*, 4 spade connectors, 7.6 m (25 foot)

1 023279 External machine interface cable*, 4 spade connectors, 15 m (50 foot)

2 228350 Kit: External machine interface cable

2 228351 Kit: External machine interface cable

3 223354 External machine interface cable

3 223355 External machine interface cable

3 223048 External machine interface cable

3 223356 External machine interface cable

3 123896 External machine interface cable

4 223733 External machine interface cable

ratio (for example, PlasmaCAM

4 223734 External machine interface cable

ratio (for example, PlasmaCAM

* Communicates start, stop, and arc transfer signals. Uses an external voltage divider PCB.

** Communicates start, stop, arc transfer, and divided arc voltage signals. Uses the internal voltage divider PCB.

†

Communicates start, stop, and divided arc voltage signals. Uses the internal voltage divider PCB.

**, 6 spade connectors, 7.6 m (25 foot)

**, 6 spade connectors, 15 m (50 foot)

**, D-sub connector with screws, 3.0 m (10 foot)

**, D-sub connector with screws, 6.0 m (20 foot)

**, D-sub connector with screws, 7.6 m (25 foot)

**, D-sub connector with screws, 10.7 m (35 foot)

**, D-sub connector with screws, 15 m (50 foot)

†

for mechanized cutting systems with a 21.1:1 voltage

systems), 6-pin DIN connector, 4.6 m (15 foot)

†

for mechanized cutting systems with a 21.1:1 voltage

systems), 6-pin DIN connector, 6.0 m (20 foot)

18 810490 Parts Guide Powermax65/85/105 SYNC

Machine interface and RS-485 serial interface upgrade kits

RS-485 serial interface cables

The RS-485 serial interface cables communicate information for controlling operating mode, amperage, and gas pressure and control mode.

Item Part number Description

1 223236 External RS-485 cable, unterminated, 7.6 m (25 foot)

1 223237 External RS-485 cable, unterminated, 15 m (50 foot)

2 223239 External RS-485 cable, 9-pin D-sub connector for Hypertherm controls, 7.6 m (25 foot)

2 223240 External RS-485 cable, 9-pin D-sub connector for Hypertherm controls, 15 m (50 foot)

Powermax65/85/105 SYNC Parts Guide 810490 19

75° hand torch replacement parts

Item Part number Description

1 059726 Torch assembly with 7.6 m (25 foot) lead

1 059727 Torch assembly with 15 m (50 foot) lead

1 059728 Torch assembly with 23 m (75 foot) lead

1 059770 Torch assembly with 30 m (100 foot) lead

2 428950 Kit: O-rings, 5 per kit (for torch head)

3 528066 Kit: Torch contact ring, 2 per kit (for torch head)

4 428863 Kit: Quick-disconnect shell (shell with button – does not include torch lead or connector)

20 810490 Parts Guide Powermax65/85/105 SYNC

15° hand torch replacement parts

Item Part number Description

1 059723 Torch assembly with 7.6 m (25 foot) lead

1 059724 Torch assembly with 15 m (50 foot) lead

1 059725 Torch assembly with 23 m (75 foot) lead

2 428950 Kit: O-rings, 5 per kit (for torch head)

3 528066 Kit: Torch contact ring, 2 per kit (for torch head)

4 428863 Kit: Quick-disconnect shell (shell with button – does not include torch lead or connector)

Powermax65/85/105 SYNC Parts Guide 810490 21

Hand torch cartridges

Hand cutting cartridges are yellow.

Drag cutting

Part number Description

428937 105 A cartridge

428935 85 A cartridge

428931 65 A cartridge

428927 45 A cartridge

FineCut cutting

Part number Description

428928 30 A – 45 A cartridge

22 810490 Parts Guide Powermax65/85/105 SYNC

Gouging cartridges

Gouging cartridges are green. They can be used on hand torches and machine torches.

Maximum Control gouging

Part number Description

428939 105 A cartridge

428933 45 A – 85 A cartridge

Maximum Removal gouging

Part number Description

Hand torch cartridges

428938 105 A cartridge

428932 45 A – 85 A cartridge

Specialty cartridges

Specialty cartridges are black.

FlushCut cutting

FlushCut cutting cartridges can be used on hand torches and machine torches.

Part number Description

428954 105 A cartridge

428953 85 A cartridge

428952 65 A cartridge

Powermax65/85/105 SYNC Parts Guide 810490 23

Hand torch cartridges

HyAccess gouging

HyAccess gouging cartridges can be used on hand torches and machine torches.

Part number Description

428987 65 A cartridge

HyAccess drag cutting

Part number Description

428984 65 A cartridge

24 810490 Parts Guide Powermax65/85/105 SYNC

45° long hand torch replacement parts

Item Part number Description

1 528116 0.6 m (2 foot) long handheld torch assembly with 15 m (50 foot) lead

1 528114 1.2 m (4 foot) long handheld torch assembly with 7.6 m (25 foot) lead

1 528118 1.2 m (4 foot) long handheld torch assembly with 15 m (50 foot) lead

2 428950 Kit: O-rings, 5 per kit (for torch head)

3 528066 Kit: Torch contact ring, 2 per kit (for torch head)

4 428863 Kit: Quick-disconnect shell (shell with button – does not include torch lead or connector)

5 528100 Kit: Long handheld torch auxiliary handle with screws

Powermax65/85/105 SYNC Parts Guide 810490 25

90° long hand torch replacement parts

Item Part number Description

1 528117 0.6 m (2 foot) long handheld torch assembly with 15 m (50 foot) lead

1 528119 1.2 m (4 foot) long handheld torch assembly with 15 m (50 foot) lead

2 428950 Kit: O-rings, 5 per kit (for torch head)

3 528066 Kit: Torch contact ring, 2 per kit (for torch head)

4 428863 Kit: Quick-disconnect shell (shell with button – does not include torch lead or connector)

5 528100 Kit: Long handheld torch auxiliary handle with screws

26 810490 Parts Guide Powermax65/85/105 SYNC