Hypertherm Manual Family Service Manual (SM)

Powermax45 XP

Plasma Arc Cutting System

Service Manual

809230 | Revision 2 | English

Powermax, Duramax, FastConnect, Smart Sense, HyAccess, FlushCut, CopperPlus, 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.

Powermax45 XP

Service Manual

809230

Revision 2

English

Original instructions

April 2018

Hypertherm Inc.

Hanover, NH 03755 USA

www.hypertherm.com

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 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 Soporte.Tecnico@hypertherm.com (Technical Service Email)

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.emea@hypertherm.com (Technical Service Email)

Hypertherm (Singapore) Pte Ltd.

82 Genting Lane Media Centre Annexe Block #A01-01 Singapore 349567, Republic of Singapore 65 6841 2489 Tel 65 6841 2490 Fax Marketing.asia@hypertherm.com (Marketing Email) TechSupportAPAC@hypertherm.com (Technical Service Email)

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 Email) TechSupportAPAC@hypertherm.com (Technical Service Email)

Hypertherm Europe B.V.

Vaartveld 9, 4704 SE Roosendaal, 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.emea@hypertherm.com (Technical Service Email)

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 Email)

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 Email)

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 Email) TechSupportAPAC@hypertherm.com (Technical Service Email)

Hypertherm Pty Limited

GPO Box 4836 Sydney NSW 2001, Australia 61 (0) 437 606 995 Tel 61 7 3219 9010 Fax au.sales@Hypertherm.com (Main Office Email) TechSupportAPAC@hypertherm.com (Technical Service Email)

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 Email) TechSupportAPAC@hypertherm.com (Technical Service Email)

1/28/16

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 and in the Safety and Compliance Manual (80669C). Failure to follow safety instructions can result in personal injury or in damage to equipment.

Copies of the manuals may accompany the product in electronic and printed formats. You can also obtain copies of the manuals, in all languages available for each manual, from the “Documents library” at www.hypertherm.com.

DANSK / DANIS H

ADVARSEL! Inden Hypertherm udstyr tages i brug skal sikkerhedsinstruktionerne i produktets manual og i Manual om sikkerhed og overholdelse af krav (80669C), gennemlæses. Følges sikkerhedsvejledningen ikke kan det resultere i personskade eller beskadigelse af udstyret.

Kopier af manualerne kan ledsage produktet i elektroniske og trykte formater. Du kan også få kopier af manualer, på alle sprog der er til rådighed for hver manuel, fra “Dokumentbiblioteket” på www.hypertherm.com.

DEUTSCH / GERMAN

WARNUNG! Bevor Sie ein Hypertherm-Gerät in Betrieb nehmen, lesen Sie bitte die Sicherheitsanweisungen in Ihrer Bedienungsanleitung sowie im Handbuch für Sicherheit und Übereinstimmung (80669C). Das Nichtbefolgen der Sicherheitsanweisungen kann zu Verletzungen von Personen oder Schäden am Gerät führen.

Bedienungsanleitungen und Handbücher können dem Gerät in elektronischer Form oder als Druckversion beiliegen. Alle Handbücher und Anleitungen können in den jeweils verfügbaren Sprachen auch in der „Dokumente-Bibliothek“ unter www.hypertherm.com heruntergeladen werden.

FRANÇAIS / FRENCH

AVERTISSEMENT! Avant d’utiliser tout équipement Hypertherm, lire les consignes de sécurité importantes dans le manuel de votre produit et dans le Manuel de sécurité et de conformité (80669C). Le non-respect des consignes de sécurité peut engendrer des blessures physiques ou des dommages à l’équipement.

Des copies de ces manuels peuvent accompagner le produit en format électronique et papier. Vous pouvez également obtenir des copies de chaque manuel dans toutes les langues disponibles à partir de la «Bibliothèque de documents» sur www.hypertherm.com.

ESPAÑOL / SPANISH

¡ADVERTENCIA! Antes de operar cualquier equipo Hypertherm, leer las instrucciones de seguridad del manual de su producto y del Manual de Seguridad y Cumplimiento (80669C). No cumplir las instrucciones de seguridad podría dar lugar a lesiones personales o daño a los equipos.

Pueden venir copias de los manuales en formato electrónico e impreso junto con el producto. También se pueden obtener copias de los manuales, en todos los idiomas disponibles para cada manual, de la “Biblioteca de documentos” en www.hypertherm.com.

ITALIANO / ITALIAN

AVVERTENZA! Prima di usare un’attrezzatura Hypertherm, leggere le istruzioni sulla sicurezza nel manuale del prodotto e nel Manuale sulla sicurezza e la conformità (80669C). Il mancato rispetto delle istruzioni sulla sicurezza può causare lesioni personali o danni all’attrezzatura.

Il prodotto può essere accompagnato da copie elettroniche e cartacee del manuale. È anche possibile ottenere copie del manuale, in tutte le lingue disponibili per ogni manuale, dall’“Archivio documenti” all’indirizzo

www.hypertherm.com.

NEDERLANDS / DUTCH

WAARSCHUWING! Lees voordat u Hypertherm-apparatuur gebruikt de veiligheidsinstructies in de producthandleiding en in de Veiligheids- en nalevingshandleiding (80669C). Het niet volgen van de veiligheidsinstructies kan resulteren in persoonlijk letsel of schade aan apparatuur.

De handleidingen kunnen in elektronische en gedrukte vorm met het product worden meegeleverd. De handleidingen, elke handleiding beschikbaar in alle talen, zijn ook verkrijgbaar via de “Documentenbibliotheek” op www.hypertherm.com.

PORTUGUÊS / PORTUGUESE

ADVERTÊNCIA! Antes de operar qualquer equipamento Hypertherm, leia as instruções de segurança no manual do seu produto e no Manual de Segurança e de Conformidade (80669C). Não seguir as instruções de segurança pode resultar em lesões corporais ou danos ao equipamento.

Cópias dos manuais podem acompanhar os produtos nos formatos eletrônico e impresso. Também é possível obter cópias dos manuais em todos os idiomas disponíveis para cada manual na “Biblioteca de documentos” em

www.hypertherm.com

日本語 / JAPANESE

警告 ! Hypertherm 機器を操作する前に、安全に関する重要な情報について、この製品説明書にある安全情報、および製品に同梱されている別冊の

「安全とコンプライアンスマニュアル」 (80669C) をお読みください。安全

情報に従わないと怪我や装置の損傷を招くことがあります。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。各説明書は、 www.hypertherm.com の「ドキュメントライブラリ」から各言語で入手できます。

简体中文 / CHINESE (SIMPLIFIED)

警告！在操作任何海宝设备之前，请阅读产品手册和《安全和法规遵守手册》 (80669C) 中的安全操作说明。若未能遵循安全操作说明，可能会造成人员受伤或设备损坏。

随产品提供的手册可能提供电子版和印刷版两种格式。您也可从 “Documents library” （文档资料库）中获取每本手册所有可用语言的副本，

网址为 www.hypertherm.com.

NORSK / NORWEGIAN

ADVARSEL! Før du bruker noe Hypertherm-utstyr, må du lese sikkerhetsinstruksjonene i produktets håndbok og i Håndboken om sikkerhet og samsvar (80669C). Unnlatelse av å følge sikkerhetsinstruksjoner kan føre til personskade eller skade på utstyr.

Eksemplarer av håndbøkene kan medfølge produktet i elektroniske og trykte utgaver. Du kan også få eksemplarer av håndbøkene i alle tilgjengelige språk for hver håndbok fra dokumentbiblioteket på www.hypertherm.com.

SVENSKA / SWEDISH

VARNING! Läs häftet säkerhetsinformationen i din produkts säkerhets- och efterlevnadsmanual (80669C) för viktig säkerhetsinformation innan du

använder eller underhåller Hypertherm-utrustning. Underlåtenhet att följa dessa säkerhetsinstruktionerkan resultera i personskador eller skador på utrustningen.

Kopior av manualen kan medfölja produkten i elektronisk och tryckform. Du hittar även kopior av manualerna i alla tillgängliga språk i dokumentbiblioteket (Documents library) på www.hypertherm.com.

한국어 / KOREAN

경고! Hypertherm 장비를 사용하기 전에 제품 설명서와 안전 및 규정 준수 설명서 (80669C)에 나와 있는 안전 지침을 읽으십시오. 안전 지침을 준수하지 않으면 신체 부상이나 장비 손상을 초래할 수 있습니다.

전자 형식과 인쇄된 형식으로 설명서 사본이 제품과 함께 제공될 수 있습니다. www.hypertherm.com 의 'Documents library (문서라이브러리)'

에서도모든언어로이용할수있는설명서사본을얻을수있습니다.

ČESKY / CZECH

VAROVÁNÍ! Před uvedením jakéhokoliv zařízení Hypertherm do provozu si přečtěte bezpečnostní pokyny v příručce k produktu a v Manuálu pro bezpečnost a dodržování předpisů (80669C). Nedodržování bezpečnostních pokynů může mít za následek zranění osob nebo poškození majetku.

Kopie příruček a manuálů mohou být součástí dodávky produktu, a to v elektronické i tištěné formě. Kopie příruček a manuálů ve všech jazykových verzích, v nichž byly dané příručky a manuály vytvořeny, naleznete v „Knihovně dokumentů“ na webových stránkách www.hypertherm.com.

TÜRKÇE / TURKISH

UYARI! Bir Hypertherm ekipmanını çalıştırmadan önce, ürün kullanım kılavuzunda ve Güvenlik ve Uyumluluk Kılavuzu’nda (80669C) yer alan güvenlik talimatlarını okuyun. Güvenlik talimatlarına uyulmaması durumunda kişisel yaralanmalar veya ekipman hasarı meydana gelebilir.

Kılavuzların kopyaları, elektronik ve basılı formatta ürünle birlikte verilebilir. Her biri tüm dillerde yayınlanan kılavuzların kopyalarını www.hypertherm.com adresindeki “Documents library” (Dosyalar kitaplığı) başlığından da elde edebilirsiniz.

POLSKI / POLISH

OSTRZEŻENIE! Przed rozpoczęciem obsługi jakiegokolwiek systemu firmy Hypertherm należy się zapoznać z instrukcjami bezpieczeństwa zamieszczonymi w podręczniku produktu oraz w Podręczniku bezpieczeństwa i zgodności (80669C). Nieprzestrzeganie instrukcji bezpieczeństwa może skutkować obrażeniami ciała i uszkodzeniem sprzętu.

Do produktu mogą być dołączone kopie podręczników w formacie elektronicznym i drukowanym. Kopie podręczników, wkażdym udostępnionym języku, można również znaleźć w„Bibliotece dokumentów” pod adresem

www.hypertherm.com.

PУССКИЙ / RUSSIAN

БЕРЕГИСЬ! Перед работой с любым оборудованием Hypertherm ознакомьтесь с инструкциями по безопасности, представленными в руководстве, которое поставляется вместе с продуктом, а также в Руководстве по безопасности и соответствию (80669J). Невыполнение инструкций по безопасности может привести к телесным повреждениям или повреждению оборудования.

Копии руководств, которые поставляются вместе с продуктом, могут быть представлены в электронном и бумажном виде. Копии руководств на всех языках, на которые переведено то или иное руководство, можно также загрузить в разделе «Библиотека документов» на веб-сайте

www.hypertherm.com.

SUOMI / FINNISH

VAROITUS! Ennen minkään Hypertherm-laitteen käyttöä lue tuotteen käyttöoppaassa olevat turvallisuusohjeet ja turvallisuus- ja vaatimustenmukaisuusohje (80669C). Turvallisuusohjeiden laiminlyönti voi aiheuttaa henkilökohtaisen loukkaantumisen tai laitevahingon.

Käyttöoppaiden kopiot voivat olla tuotteen mukana elektronisessa ja tulostetussa muodossa. Voit saada käyttöoppaiden kopiot kaikilla kielillä ”latauskirjastosta”, joka on osoitteessa www.hypertherm.com.

БЪЛГAPCКИ / BULGARIAN

ПРЕДУПРЕЖДЕНИЕ! Преди да работите с което и да е оборудване Hypertherm, прочетете инструкциите за безопасност в ръководството на вашия продукт и „Инструкция за безопасност и съответствие“ (80669C). Неспазването на инструкциите за безопасност би могло да доведе до телесно нараняване или до повреда на оборудването.

Копия на ръководствата може да придружават продукта в електронен и в печатен формат. Можете да получите копия на ръководствата, предлагани на всички езици, от „Documents library“ (Библиотека за документи) на адрес www.hypertherm.com.

ROMÂNĂ / ROMANIAN

AVERTIZARE! Înainte de utilizarea oricărui echipament Hypertherm, citii instruciunile de sigurană din cadrul manualului produsului și din cadrul Manualului de siguranță și conformitate (80669C). Nerespectarea instruciunilor de sigurană pot rezulta în vătămare personală sau în avarierea echipamentului.

Produsul poate fi însoit de copii ale manualului în format tipărit și electronic. De asemenea, dumneavoastră puteţi obţine copii ale manualelor, în toate limbile disponibile pentru fiecare manual, din cadrul secţiunii „Bibliotecă documente” aflată pe site-ul www.hypertherm.com.

MAGYAR / HUNGARIAN

VIGYÁZAT! Mielőtt bármilyen Hypertherm berendezést üzemeltetne, olvassa el a biztonsági információkat a termék kézikönyvében és a Biztonsági és szabálykövetési kézikönyvben (80669C). A biztonági utasítások betartásának elmulasztása személyi sérüléshez vagy a berendezés károsodásához vezethet.

A termékhez a kézikönyv példányai elektronikus és nyomtatott formában is mellékelve lehetnek. A kézikönyvek példányai (minden nyelven) a

www.hypertherm.com

könyvtár) részben is beszerezhetők.

ΕΛΛΗΝΙΚΆ / GREEK

ΠΡΟΕΙΟΠΟΙΗΣΗ! Πριν θέσετε σε λειτουργία οποιονδήποτε εξοπλισό της Hypertherm, διαβάστε τις οδηγίες ασφαλείας στο εγχειρίδιο του προϊόντος και στο Εγχειρίδιο ασφάλειας και συμμόρφωσης (80669C). Η η τήρηση των οδηγιών ασφαλείας πορεί να επιφέρει σωατική βλάβη ή ζηιά στον εξοπλισό.

Αντίγραφα των εγχειριδίων πορεί να συνοδεύουν το προϊόν σε ηλεκτρονική και έντυπη ορφή. Μπορείτε, επίσης, να λάβετε αντίγραφα των εγχειριδίων σε όλες τις γλώσσες που διατίθενται για κάθε εγχειρίδιο από την ψηφιακή βιβλιοθήκη εγγράφων (Documents library) στη διαδικτυακή τοποθεσία

www.hypertherm.com

繁體中文 / CHINESE (TRADITIONAL)

警告！在操作任何 Hypertherm 設備前，請閱讀您產品手冊和《安全和法務遵從手冊》(80669C) 內的安全指示。不遵守安全指示可能會導致人身傷害或設備損壞。

手冊複本可能以電子和印刷格式隨附產品提供。您也可以在

www.hypertherm.com 的「文檔資料庫」內獲取所有手冊的多語種複本。

SLOVENŠČINA / SLOVENIAN

OPOZORILO! Pred uporabo katerekoli Hyperthermove opreme preberite varnostna navodila v priročniku vašega izdelka ter v Priročniku za varnost in skladnost (80669C). Neupoštevanje navodil za uporabo lahko povzroči telesne poškodbe ali materialno škodo.

Izdelku so lahko priloženi izvodi priročnikov v elektronski ali tiskani obliki. Izvode priročnikov v vseh razpoložljivih jezikih si lahko prenesete tudi iz knjižnice dokumentov “Documents library” na naslovu www.hypertherm.com.

SRPSKI / SERBIAN

UPOZORENJE! Pre rukovanja bilo kojom Hyperthermovom opremom pročitajte uputstva o bezbednosti u svom priručniku za proizvod i u Priručniku o bezbednosti i usaglašenosti (80669C). Oglušavanje o praćenje uputstava o bezbednosti može da ima za posledicu ličnu povredu ili oštećenje opreme.

Može se dogoditi da kopije priručnika prate proizvod u elektronskom i štampanom formatu. Takođe možete da pronađete kopije priručnika, na svim jezicima koji su dostupni za svaki od priručnika, u “Biblioteci dokumenata” (“Documents library”) na www.hypertherm.com.

SLOVENČINA / SLOVAK

VÝSTRAHA! Pred použitím akéhokoľvek zariadenia od spoločnosti Hypertherm si prečítajte bezpečnostné pokyny v návode na obsluhu vášho zariadenia avManuáli o bezpečnosti a súlade s normami (80669C). V prípade nedodržania bezpečnostných pokynov môže dôjsť k ujme na zdraví alebo poškodeniu zariadenia.

Kópia návodu, ktorá je dodávaná s produktom, môže mať elektronickú alebo tlačenú podobu. Kópie návodov, vo všetkých dostupných jazykoch, sú k dispozícii aj v sekcii z „knižnice Dokumenty“ na www.hypertherm.com.

weboldalon a „Documents library” (Dokumentum

Electromagnetic Compatibility (EMC) ............................................................................ SC-17

Introduction....................................................................................................................................................SC-17

Installation and use ......................................................................................................................................SC-17

Assessment of area .....................................................................................................................................SC-17

Methods of reducing emissions................................................................................................................SC-17

Mains supply......................................................................................................................................SC-17

Maintenance of cutting equipment...........................................................................................................SC-17

Cutting cables...............................................................................................................................................SC-17

Equipotential bonding .....................................................................................................................SC-17

Earthing of the workpiece ..............................................................................................................SC-18

Screening and shielding.............................................................................................................................SC-18

Warranty............................................................................................................................... SC-19

Attention.........................................................................................................................................................SC-19

General...........................................................................................................................................................SC-19

Patent indemnity...........................................................................................................................................SC-19

Limitation of liability......................................................................................................................................SC-19

National and local codes............................................................................................................................SC-19

Liability cap....................................................................................................................................................SC-20

Insurance........................................................................................................................................................SC-20

Transfer of rights ..........................................................................................................................................SC-20

Powermax45 XP Service Manual 809230 7

Contents

Waterjet product warranty coverage.......................................................................................................SC-20

Product...............................................................................................................................................SC-20

Parts coverage..................................................................................................................................SC-20

1 Installation and Setup.............................................................................................................. 21

System contents.................................................................................................................................................. 22

What to do if components are missing or damaged....................................................................... 23

Hypertherm plasma power supply ratings..................................................................................................... 23

Cutting specifications ........................................................................................................................................ 24

Recommended cut capacity – handheld........................................................................................... 24

Pierce capacity ........................................................................................................................................ 24

Maximum cut speeds (mild steel)........................................................................................................ 25

Gouge capacity ....................................................................................................................................... 25

Noise levels............................................................................................................................................... 25

Position the plasma power supply .................................................................................................................. 26

Power supply dimensions and weight................................................................................................ 28

Work lead weights...................................................................................................................... 28

Connect to electrical power ............................................................................................................................. 29

Install a line-disconnect switch............................................................................................................ 29

Requirements for grounding................................................................................................................. 30

The system’s rated output (cutting power) ....................................................................................... 30

Voltage configurations ........................................................................................................................... 30

CSA/CE/CCC 200 V – 240 V (1-phase) ............................................................................ 31

CSA 208 V (1-phase)................................................................................................................ 31

CCC 220 V (1-phase)............................................................................................................... 31

CE 230 V (1-phase)................................................................................................................... 31

CCC 380 V (3-phase)............................................................................................................... 32

CE 400 V (3-phase)................................................................................................................... 32

CSA 480 V (3-phase)................................................................................................................ 32

Decrease output current and arc stretch for lower rated electrical service .............................. 33

Example: 230 V input on 20 A electrical service................................................................. 33

Prepare the power cord..................................................................................................................................... 34

CSA systems ........................................................................................................................................... 34

1-phase (200 V – 240 V).......................................................................................................... 34

3-phase (480 V).......................................................................................................................... 34

CE/CCC systems................................................................................................................................... 34

1-phase (200 V – 240 V).......................................................................................................... 34

3-phase (380 V / 400 V)........................................................................................................... 34

Extension cord recommendations....................................................................................................... 35

8 809230 Service Manual Powermax45 XP

Contents

Generator recommendations................................................................................................................ 35

Adapter for 4-wire 1-phase connections (CSA 1-phase models only) ......................... 36

Connect the gas supply .................................................................................................................................... 36

Gas supply source.................................................................................................................................. 37

High-pressure gas cylinders..................................................................................................... 38

Gas flow rates.......................................................................................................................................... 39

Minimum inlet pressure (while gas is flowing).................................................................................. 39

Cutting........................................................................................................................................... 39

Maximum control gouging (26 – 45 A).................................................................................. 40

Precision gouging / Marking (10 – 25 A).............................................................................. 40

Additional gas filtration........................................................................................................................... 41

2 Operation.................................................................................................................................... 43

Controls and indicators ..................................................................................................................................... 43

ON (I)/OFF(O) power switch ........................................................................................................... 43

Cutting controls....................................................................................................................................... 44

Indicator LEDs ......................................................................................................................................... 45

Disable the torch................................................................................................................................................. 46

Warning puffs of air................................................................................................................................ 47

For hand torches ......................................................................................................................... 48

For machine torches................................................................................................................... 48

Operate the plasma system.............................................................................................................................. 48

Step 1 – Install consumables and activate torch ............................................................................ 48

Step 2 – Connect torch lead ............................................................................................................... 50

Step 3 – Connect gas supply.............................................................................................................. 51

Step 4 – Connect work lead and work clamp ................................................................................. 51

Work lead...................................................................................................................................... 51

Work clamp .................................................................................................................................. 52

Step 5 – Connect electric power and turn ON the system.......................................................... 53

Step 6 – Set mode and adjust output current (amperage)........................................................... 53

Cutting expanded metal............................................................................................................. 54

Step 7 – Check cut settings and indicator LEDs............................................................................ 54

What to expect during and after cutting........................................................................................................ 55

Adjust the gas pressure manually ................................................................................................................... 56

Reset the gas pressure.......................................................................................................................... 58

Change the gas pressure values between psi and bar.............................................................................. 59

Understand duty cycle to prevent overheating............................................................................................. 60

Powermax45 XP Service Manual 809230 9

Contents

3 Cut with the Hand Torch.......................................................................................................... 61

Hand torch components, dimensions, weights............................................................................................ 62

Components............................................................................................................................................. 62

Dimensions ............................................................................................................................................... 62

75° hand torch ............................................................................................................................. 62

15° hand torch ............................................................................................................................. 62

Weights..................................................................................................................................................... 63

Minimum bend radius for torch leads ................................................................................................. 63

Choose the consumables ................................................................................................................................. 64

Shielded drag-cutting consumables................................................................................................... 65

FineCut consumables ............................................................................................................................ 65

Specialty consumables.......................................................................................................................... 65

HyAccess cutting consumables .............................................................................................. 65

FlushCut™ consumables ........................................................................................................... 66

CopperPlus™ electrode............................................................................................................. 68

Consumable life................................................................................................................................................... 68

Prepare to fire the torch..................................................................................................................................... 70

Hand torch cutting guidelines.......................................................................................................................... 72

Start a cut from the edge of the workpiece .................................................................................................. 73

Pierce a workpiece ............................................................................................................................................. 74

4 Gouge with the Hand Torch and Machine Torch ................................................................ 77

Gouging processes............................................................................................................................................ 77

Maximum Control gouging.................................................................................................................... 78

Maximum Control gouging consumables (26 – 45 A)....................................................... 78

Precision gouging ................................................................................................................................... 78

Precision gouging consumables (10 – 25 A) ...................................................................... 78

Specialty consumables.......................................................................................................................... 79

HyAccess gouging consumables............................................................................................ 79

How to control the gouge profile .................................................................................................................... 80

Gouge with the hand torch............................................................................................................................... 81

Remove spot welds ................................................................................................................................ 82

Tips................................................................................................................................................. 82

Procedure ..................................................................................................................................... 83

Gouge with the machine torch ........................................................................................................................ 86

Typical gouge profiles............................................................................................................................ 87

Maximum Control gouging consumables (45 A) ................................................................. 87

Precision gouging consumables (10 A)................................................................................. 89

Troubleshooting tips for gouging .................................................................................................................... 91

10 809230 Service Manual Powermax45 XP

Contents

5 Set Up the Machine Torch ...................................................................................................... 93

Machine torch components, dimensions, weights ...................................................................................... 94

Components............................................................................................................................................. 94

Dimensions ............................................................................................................................................... 94

Weights..................................................................................................................................................... 95

Minimum bend radius for torch leads ................................................................................................. 95

Mount the torch ................................................................................................................................................... 95

Remove the gear rack ............................................................................................................................ 95

Disassemble the machine torch........................................................................................................... 96

Assemble the machine torch................................................................................................................ 98

Align the torch................................................................................................................................................... 100

6 Configure Controls for Mechanized Cutting...................................................................... 101

Machine torch setup overview ...................................................................................................................... 101

Set up the plasma system and machine torch for mechanized cutting................................... 102

Connect the remote-start pendant .............................................................................................................. 103

Connect the machine interface cable ......................................................................................................... 104

External cables that do not use voltage divider board................................................................. 104

External cables that use voltage divider board.............................................................................. 105

Cable signals (for troubleshooting)...................................................................................... 106

External cables for PlasmaCAM

Cable signals (for troubleshooting)...................................................................................... 107

Installation of the machine interface cable ..................................................................................... 108

Machine interface pinout ........................................................................................................ 108

Machine interface cable signals............................................................................................ 109

Set the 5-position voltage divider ........................................................................................ 110

Access raw arc voltage .................................................................................................................................. 111

Connect an optional RS-485 serial interface cable ................................................................................ 111

External serial port cables .................................................................................................................. 112

Remote mode........................................................................................................................................ 112

tables ............................................................................. 107

7 Cut with the Machine Torch................................................................................................. 113

Choose the consumables .............................................................................................................................. 113

Mechanized shielded consumables................................................................................................. 114

Mechanized shielded consumables with ohmic retaining cap................................................... 114

FineCut shielded consumables with ohmic retaining cap.......................................................... 115

FineCut unshielded consumables.................................................................................................... 115

Consumable life................................................................................................................................................ 115

Powermax45 XP Service Manual 809230 11

Contents

Understand and optimize cut quality ........................................................................................................... 116

Cut or bevel angle................................................................................................................................ 116

Dross....................................................................................................................................................... 117

Pierce a workpiece using the machine torch............................................................................................. 118

Pierce delay........................................................................................................................................... 118

Pierce height ......................................................................................................................................... 118

Pierce maximum thickness................................................................................................................. 118

Cut stainless steel with F5............................................................................................................................. 119

8 Guidelines for Marking.......................................................................................................... 121

Marking consumables (10 – 25 A) .............................................................................................................. 121

Process gas: air versus argon....................................................................................................................... 122

How the system handles postflow for marking ............................................................................. 122

Types of marking .............................................................................................................................................. 123

Marking samples................................................................................................................................... 123

Marking, scoring, and dimpling profiles .......................................................................................... 125

Marking process guidelines........................................................................................................................... 126

Cornering guidelines ........................................................................................................................... 127

Marking troubleshooting tips......................................................................................................................... 127

Common marking problems and solutions..................................................................................... 128

9 Cut Charts and Marking Charts........................................................................................... 131

Using the cut charts ........................................................................................................................................ 132

Mild Steel – 45 A – Air – Shielded ............................................................................................................. 134

Stainless Steel – 45 A – Air – Shielded .................................................................................................... 135

Aluminum – 45 A – Air – Shielded.............................................................................................................. 136

Mild Steel – FineCut – Air – Shielded and Unshielded.......................................................................... 137

Stainless Steel – FineCut – Air – Shielded and Unshielded................................................................. 138

Mild Steel – FineCut Low Speed – Air – Shielded and Unshielded ................................................... 139

Stainless Steel – FineCut Low Speed – Air – Shielded and Unshielded.......................................... 140

Stainless Steel – 45 A – F5 – Shielded..................................................................................................... 141

Marking and Dimpling – Air – Shielded...................................................................................................... 142

Marking and Dimpling – Argon – Shielded................................................................................................ 143

12 809230 Service Manual Powermax45 XP

Contents

10 Troubleshooting and System Tests ..................................................................................... 145

Theory of operation.......................................................................................................................................... 145

Overview ................................................................................................................................................ 145

200 – 240 V 1-phase power supply functional description...................................................... 145

400 V CE/CCC 3-phase power supply functional description................................................ 146

480 V CSA 3-phase power supply functional description ........................................................ 147

Sequence of operation ....................................................................................................................... 148

Troubleshooting preparation ......................................................................................................................... 149

Troubleshooting procedures and sequence.................................................................................. 150

Test equipment..................................................................................................................................... 151

External inspection............................................................................................................................... 151

Internal inspection................................................................................................................................ 151

Initial resistance check.................................................................................................................................... 152

Check the power switch and snubber resistors ........................................................................... 152

Check the gas pressure ................................................................................................................................. 156

Check the gas quality...................................................................................................................................... 157

Run a gas test................................................................................................................................................... 158

Enter gas test mode ............................................................................................................................ 158

While gas test mode is active ............................................................................................... 159

Exit gas test mode................................................................................................................................ 159

Cold restarts and quick restarts ................................................................................................................... 160

Perform a cold restart.......................................................................................................................... 160

Perform a quick restart........................................................................................................................ 160

Power supply overview ................................................................................................................................... 161

200 – 240 V 1-phase power supply............................................................................................... 161

400 V CE/CCC and 480 V CSA 3-phase power supply.......................................................... 162

Fault LEDs and fault codes............................................................................................................................ 163

Internal component faults (fault code formats 1-nn-n, 2-nn-n, 3-nn-n) ................................. 168

Gas Pressure fault LED ...................................................................................................................... 170

Torch Cap fault LED............................................................................................................................ 171

Generator considerations................................................................................................................... 172

Troubleshooting guide ........................................................................................................................ 172

Issues with cut quality......................................................................................................................... 176

Torch-related faults.............................................................................................................................. 178

Continuity check....................................................................................................................... 178

Torch-disable switch and warning puffs of air .................................................................. 178

Power board LEDs........................................................................................................................................... 179

When the Reset LED indicates a DSP fault .................................................................................. 180

Powermax45 XP Service Manual 809230 13

Contents

System tests...................................................................................................................................................... 181

Grounding options............................................................................................................................... 182

Test 1 – voltage input ......................................................................................................................... 183

Check the incoming voltage .................................................................................................. 183

Check the voltage at the power switch .............................................................................. 185

Test 2 – power board voltage checks ............................................................................................ 187

Test 3 – VBUS and voltage balance on power board ................................................................ 189

Test 4 – solenoid valve – no gas input ........................................................................................... 192

Test valve after cold restart.................................................................................................... 193

Test valve after disconnecting from power board ............................................................ 194

Test 5 – solenoid valve – low gas pressure .................................................................................. 195

External checks......................................................................................................................... 195

Internal checks.......................................................................................................................... 196

Cold restart................................................................................................................................ 196

Test 6 – solenoid valve pressure sensor........................................................................................ 197

Check for electrical interference and pinched wires ....................................................... 197

Check the power input and solenoid valve coils .............................................................. 198

Check the solenoid valve sensor and power board sensor input................................. 200

Test 7 – torch stuck open (TSO) or torch stuck closed (TSC) ................................................ 201

Test 8 – plasma start........................................................................................................................... 204

Test 9 – torch cap sensor.................................................................................................................. 206

Check the torch and the torch lead..................................................................................... 206

Check the power supply (torch receptacle and power board) ..................................... 207

Test 10 – fan......................................................................................................................................... 209

Test 11 – power switch trip coil (1-phase models)..................................................................... 210

11 Power Supply Component Replacement............................................................................. 211

Install a machine interface cable for raw arc voltage............................................................................... 212

Replace the air filter bowl and filter element.............................................................................................. 212

Replace the power supply cover and handle ............................................................................................ 215

Replace the component barrier .................................................................................................................... 218

Detach and reattach the front panel............................................................................................................ 220

Detach and reattach the rear panel ............................................................................................................. 223

Replace the machine interface (CPC) port and voltage divider board ............................................... 227

Set the voltage divider board ............................................................................................................ 230

Install the RS-485 serial interface port....................................................................................................... 231

Replace the display board and ribbon cable............................................................................................. 234

Replace the power switch – 1-phase models .......................................................................................... 236

Replace the power switch – 3-phase models .......................................................................................... 237

Replace the power cord and strain relief – 1-phase models ................................................................ 239

14 809230 Service Manual Powermax45 XP

Contents

Replace the power cord and strain relief – 3-phase models ................................................................ 241

Replace the EMI board (CE/CCC 1-phase models only)...................................................................... 243

Replace internal wires – 1-phase models.................................................................................................. 245

Replace internal wires – 3-phase models.................................................................................................. 249

Replace the power board............................................................................................................................... 253

Replace the snubber resistors...................................................................................................................... 259

Replace the capacitors................................................................................................................................... 261

Replace the fan................................................................................................................................................. 264

Replace the air filter assembly ...................................................................................................................... 267

Replace the gas inlet fittings ......................................................................................................................... 269

Replace the solenoid valve assembly.......................................................................................................... 271

Replace the gas supply hoses and 90° fitting........................................................................................... 274

Replace the front panel................................................................................................................................... 276

Replace the torch quick-disconnect receptacle....................................................................................... 277

Replace the work lead receptacle................................................................................................................ 280

Replace the rear panel.................................................................................................................................... 282

12 Hand Torch Component Replacement................................................................................. 285

Torch components........................................................................................................................................... 286

75° hand torch...................................................................................................................................... 286

15° hand torch...................................................................................................................................... 287

Replace the handle.......................................................................................................................................... 288

Replace the torch-disable slider................................................................................................................... 293

Replace the trigger assembly........................................................................................................................ 294

Replace the torch body or the torch lead................................................................................................... 295

Torch body replacement kits ............................................................................................................. 295

Torch lead replacement kits............................................................................................................... 295

Replace the start switch................................................................................................................................. 298

Replace the cap-sensor switch/torch-disable switch assembly........................................................... 299

Replace the quick-disconnect shell............................................................................................................. 300

13 Machine Torch Component Replacement .......................................................................... 303

Torch components........................................................................................................................................... 304

Replace the torch shell................................................................................................................................... 305

Replace the torch-disable slider................................................................................................................... 310

Replace the torch body or the torch lead................................................................................................... 311

Torch main body replacement kit ..................................................................................................... 311

Torch lead replacement kits............................................................................................................... 311

Powermax45 XP Service Manual 809230 15

Contents

Replace the cap-sensor switch/torch-disable switch assembly........................................................... 314

Replace the quick-disconnect shell............................................................................................................. 315

14 Replacement Parts and Accessories .................................................................................. 317

Plasma supply exterior, front.......................................................................................................................... 318

Plasma supply exterior, rear........................................................................................................................... 319

Machine interface (CPC) and serial interface upgrade kits................................................................... 320

External cables for machine interface port and serial port ......................................................... 321

Front panel and receptacles, display board, power switch.................................................................... 322

Plasma supply interior, power board ........................................................................................................... 323

Plasma supply interior, pneumatics and fan............................................................................................... 324

Plasma supply interior, wires, CSA 1-phase ............................................................................................. 325

Plasma supply interior, wires and EMI board, CE/CCC 1-phase ........................................................ 326

Plasma supply interior, wires, 3-phase ....................................................................................................... 327

75° hand torch replacement parts ............................................................................................................... 328

15° hand torch replacement parts ............................................................................................................... 329

Machine torch replacement parts................................................................................................................. 330

Accessory parts................................................................................................................................................ 332

Safety critical parts .......................................................................................................................................... 333

Recommended spare parts ........................................................................................................................... 334

Powermax45 XP Labels ................................................................................................................................. 336

Consumable labels and fault codes label....................................................................................... 336

CSA warning label............................................................................................................................... 337

CE/CCC warning label....................................................................................................................... 338

Data plate........................................................................................................................................................... 339

Symbols and marks ......................................................................................................................................... 340

IEC symbols .......................................................................................................................................... 341

15 System Diagrams.................................................................................................................... 343

Powermax45 XP schematic – 200 – 240 V 1-phase models .............................................................. 345

Powermax45 XP schematic – 400 V CE/CCC and 480 V CSA 3-phase models ......................... 346

Timing chart for torch start............................................................................................................................. 347

16 809230 Service Manual Powermax45 XP

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 workpiece. In other cases, it could involve constructing an electromagnetic screen enclosing the power source and the work complete with associated input filters. In all cases, electromagnetic disturbances must be reduced to the point where they are no longer troublesome.

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.

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

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.

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.

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

Safety and compliance SC-17

Electromagnetic Compatibility (EMC)

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 increase 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 Equipment, 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.

SC-18 Safety and compliance

Warranty

Attention

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

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

General

Hypertherm Inc. warrants that its Products shall be free from defects in materials and workmanship for the specific periods of time set forth herein and as follows: if Hypertherm is notified of a defect (i) with respect to the plasma 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, with the exception of the HPRXD short torch with integrated lead, which shall be within a period of six (6) months from the 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 Automation products one (1) year from its date of delivery to you, with the exception of the EDGE Connect CNC, EDGE Connect T CNC, EDGE Connect TC CNC, EDGE Pro CNC, EDGE Pro Ti CNC, MicroEDGE Pro CNC, and ArcGlide THC, which shall be within a period of two (2) years from the date of delivery to you, and (iii) with respect to HyIntensity fiber laser components within a period of two (2) years from the date of its delivery to you, with the exception of laser heads and beam delivery cables, which shall be within a period of one (1) year from its date of delivery to you.

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

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

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

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

Patent indemnity

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

Limitation of liability

In no event shall Hypertherm be liable to any person or entity for any incidental, consequential direct, indirect, punitive or exemplary damages (including but not limited to lost profits) regardless of whether such liability is based on breach of contract, tort, strict liability, breach of warranty, failure of essential purpose, or otherwise, and even if advised of the possibility of such damages. Hypertherm shall not be liable for any losses to Distributor based on down time, lost production or lost profits. It is the intention of the Distributor and Hypertherm that this provision be construed by a court as being the broadest limitation of liability consistent with applicable law.

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.

Safety and compliance SC-19

Warranty

Liability cap

In no event shall Hypertherm’s liability, if any, whether such liability is based on breach of contract, tort, strict liability, breach of warranties, failure of essential purpose or otherwise, for any claim, action, suit or proceeding (whether in court, arbitration, regulatory proceeding or otherwise) arising out of or relating to the use of the Products exceed in the aggregate the amount paid for the Products that gave rise to such claim.

Insurance

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

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.

Waterjet product warranty coverage

Product Parts coverage

HyPrecision pumps 27 months from the ship date, or 24 months

from the date of proven installation, or 4,000 hours, whichever occurs first

PowerDredge abrasive removal system

EcoSift abrasive recycling system

Abrasive metering devices

On/off valve air actuators

Diamond orifices 600 hours of use with the use of a thimble

Consumable parts are not covered by this warranty. Consumable parts include, but are not limited to, high-pressure water seals, check valves, cylinders, bleed-down valves, low-pressure seals, high-pressure tubing, low- and high-pressure water filters and abrasive collection bags. All third-party pumps, pump accessories, hoppers, hopper accessories, dryer boxes, dryer box accessories and plumbing accessories are covered by the respective manufacturers’ warranties and not covered by this warranty.

15 months from the ship date or 12 months from the date of proven installation, whichever occurs first

filter and compliance with Hypertherm’s water quality requirements

SC-20 Safety and compliance

Installation and Setup

The Powermax45 XP is a portable 45 A plasma cutting system that you can use for many handheld and mechanized cutting and gouging applications. The system’s automatic gas and automatic voltage features make it easy to set up and use even if you have limited plasma cutting experience.

With the Powermax45 XP you can:

 Use air or nitrogen to cut electrically

conductive metals such as mild steel, stainless steel, and aluminum

 Cut thicknesses up to 16 mm (5/8 inch)  Pierce thicknesses up to 12 mm (1/2 inch)  Sever thicknesses up to 29 mm (1-1/8 inch)  Use 2 different gouging processes for a wide

range of gouging applications: Maximum Control gouging (26 A – 45 A) and Precision gouging (10 A – 25 A)

 Mark metal surfaces using air or argon  Use F5 to cut stainless steel  Disable the Duramax Lock hand and machine

torches without turning OFF the power supply using the torch-disable switch

 Quickly switch between torches using the

FastConnect™ system (quick-disconnect)

Powermax45 XP Service Manual 809230 21

Installation and Setup

1 Documentation:

•Operator Manual

•Quick Setup Card

• Registration card

• Safety and Compliance Manual

2 Starter consumable kit

3 15° or 75° hand torch with lead or

machine torch with lead

4 Work clamp with work lead

5 Remote-start pendant (optional – mechanized

configurations only)

6 CE/CCC and 480 V CSA models: power

cord with no power plug (some models ship without a power cord)

7 CSA 200 V – 240 V models: power cord with

50 A, 250 V plug (NEMA 6-50P)

8 Region-specific gas inlet fitting (may not be

preinstalled)

9 Plasma power supply

System contents

22 809230 Service Manual Powermax45 XP



You can order additional consumables and accessories from any Hypertherm distributor. See Replacement Parts and Accessories on page 317.

What to do if components are missing or damaged

 Claims for damage during shipment

 File a claim with the carrier if your system was damaged during shipment.  Obtain the system’s model number and serial number, located on the bottom of the

plasma power supply.

 Obtain a copy of the bill of lading from Hypertherm.

 Claims for missing or damaged merchandise

 Contact your Hypertherm distributor if any component is missing or damaged.

If you need additional assistance, call the nearest Hypertherm office listed in the front of this manual.

Hypertherm plasma power supply ratings

Installation and Setup

Rated open-circuit voltage (U0) 200 – 240 V, CSA/CE/CCC

400 V, CE/CCC

480 V, CSA

275 VDC 265 VDC 275 VDC

Output characteristic* Drooping

Rated output current (I

Rated output voltage (U

Duty cycle at 40°C (104°F)

) 10A–45A

) 145 VDC

†

50% at 45 A (I2) / 145 VDC (U2) 60% at 41 A (I

100% at 32 A (I

) / 145 VDC (U2)

Operating temperature -10°C – 40°C (14°F – 104°F)

Storage temperature -25°C – 55° C (-13°F – 131°F)

Power factor 200 – 240 V, 1-phase, CSA/CE/CCC

400 V, 3-phase, CE/CCC

480 V, 3-phase, CSA

– Short Circuit Ratio

sce

(CE systems only)

EMC emissions classification CISPR 11 (CE models only)

‡

U1– Volts AC rms, 3-phase

400 V CE

Class A

0.99

0.94

0.93

R 250

sce

Input voltage (U at rated output (U

(See Voltage configurations on page 30.)

Gas type Air Nitrogen (N

Powermax45 XP Service Manual 809230 23

) / Input current (I1)

2MAXI2MAX

)

200 – 240 V CSA 230 V CE/CCC**, 400 V CE/CCC**,

480 V CSA

200 – 240 V, 1-phase, 50/60 Hz, 39 – 32 A

††

230 V, 1-phase, 50/60 Hz, 33 A

‡‡

400 V, 3-phase, 50/60 Hz, 11 A 480 V, 3-phase, 50/60 Hz, 9.4 A

) F5*** Argon

†††

Installation and Setup

Gas quality Clean, dry,

oil-free per

ISO 8573-1

Class 1.2.2

Recommended gas inlet flow rate/pressure

Maximum control gouging 165.2 L/min at 4.1 bar (350 scfh at 60 psi)

99.95% pure Clean, dry,

oil-free

Cutting 188.8 L/min at 5.9 bar (400 scfh at 85 psi)

99.98% pure (F5 = 95%

nitrogen [N

hydrogen [H])

], 5%

Precision gouging, marking 165.2 L/min at 3.8 bar (350 scfh at 55 psi)

* Defined as a plot of output voltage versus output current.

†

See the data plate on the bottom of the power supply for more information on duty cycle and for IEC ratings.

‡

WARNING: This Class A equipment is not intended for use in residential locations where the electrical power is provided by the public low voltage supply system. There may be potential difficulties in delivering electromagnetic compatibility in those locations, due to conducted as well as radiated disturbances.

** This product meets the technical requirements of IEC 61000-3-3 and is not subject to conditional connection.

††

Equipment complies with IEC 61000-3-12.

‡‡

Equipment complies with IEC 61000-3-12 provided that the short-circuit power Ssc is greater than or equal to 1911 KVA at the interface point between the user’s supply and the public system. It is the responsibility of the installer or user of the equipment to ensure, by consultation with the distribution network operator if necessary, that the equipment is connected only to a supply with a short-circuit power S

*** F5 recommended only for cutting stainless steel. See page 119.

†††

Argon recommended only for marking applications at 10 – 25 A. See page 121.

greater than or equal to 1911 KVA.

99.99% pure Clean, dry,

oil-free

Cutting specifications

Recommended cut capacity – handheld

Cut speed Material thickness

500 mm/min (20 inches per minute [in/min])* 16 mm (5/8 inch)

250 mm/min (10 in/min)* 22 mm (7/8 inch)

125 mm/min (5 in/min)* – severance capacity 29 mm (1-1/8 inch)

* Cut capacity speeds are not necessarily maximum speeds. They are the speeds that must be achieved to

be rated at that thickness.

Pierce capacity

Torch type Material thickness

Handheld 12 mm (1/2 inch)

Mechanized with a programmable torch height control 12 mm (1/2 inch)

24 809230 Service Manual Powermax45 XP

Maximum cut speeds (mild steel)

Maximum cut speeds are the results of Hypertherm’s laboratory testing. Actual cutting speeds may vary based on different cutting applications.

Material thickness Cut speed

6 mm (1/4 inch) 2286 mm/min (90 in/min)

9mm (3/8inch) 1219 mm/min (48 in/min)

12 mm (1/2 inch) 762 mm/min (30 in/min)

16 mm (5/8 inch) 508 mm/min (20 in/min)

19 mm (3/4 inch) 330 mm/min (13 in/min)

25 mm (1 inch) 178 mm/min (7 in/min)

Gouge capacity

Installation and Setup

Process Metal type

Maximum Control gouging (26 – 45 A) Mild steel 45 A 3.4 kg/hour (7.5 pounds/hour)

Precision gouging (10 – 25 A) Mild steel 10 A 0.2 kg/hour (0.5 pounds/hour)

Noise levels

This plasma system may exceed acceptable noise levels as defined by national and local codes. Always wear proper ear protection when cutting or gouging. Any noise measurements taken depend on the specific environment in which the system is used. Refer to Noise can damage hearing in the Safety and Compliance Manual (80669C) included with your system.

In addition, you can find an Acoustical Noise Data Sheet for your system at www.hypertherm.com

1. Click “Documents library” near the bottom of the page.

2. Select a product from the “Product type” menu in the “Search” section of the page.

3. Select “Regulatory” from the “All Categories” menu.

4. Select “Acoustical Noise Data Sheets” from the “All subcategories” menu.

Output current

Metal removal rate

Powermax45 XP Service Manual 809230 25

Installation and Setup

Clearance:

>0.25m (10inches)

3m (10feet)

Position the plasma power supply

CHANCE OF ELECTRIC SHOCK Never cut under water or submerge the torch in water. Electric shock can cause

serious injury.

TOXIC FUME S CAN CAUSE INJURY OR DEATH Some metals, including stainless steel, may release toxic fumes when cut. Make sure

your work site has adequate ventilation to ensure that the air quality level meets all local and national standards and regulations. Refer to the Safety and Compliance Manual (80669C) for more information.

WARNING

 Do not use the system in rain or

snow.

 Position the plasma power supply

near an appropriate power receptacle. Its power cord is approximately 3.0 m (10 feet).

 Allow at least 0.25 m (10 inches)

of space around the power supply for proper ventilation.

26 809230 Service Manual Powermax45 XP

 Place the power supply on a

>10°

stable, level surface before using. It can tip over if set at an angle greater than 10°.

 Do not place the power supply

on its side. Doing so can block the louvers on the side of the cover and prevent proper air circulation needed to cool internal components.

Installation and Setup

Powermax45 XP Service Manual 809230 27

Installation and Setup

443 mm

(17.4 inches)

173 mm

(6.8 inches)

312 mm

(12.3 inches)

357 mm

14.1 inches)

Power supply dimensions and weight

Power supply with

power cord

200 – 240 V CSA 12 kg (26 pounds) 15 kg (33 pounds)

230V CE/CCC 12kg (27pounds) 15kg (33pounds)

400V CE/CCC 11kg (25pounds) 14kg (31pounds)

480V CSA 11kg (25pounds) 14kg (31pounds)

Power supply (and power cord) with

6.1 m (20 foot) hand torch and

7.6 m (25 foot) work lead

Work lead weights

Work lead Weight

Work clamp with 7.6m (25foot) work lead 1.2kg (2.6pounds)

Work clamp with 15 m (50 foot) work lead 2.1 kg (4.7 pounds)

For hand torch weights, see page 63. For machine torch weights,



seepage95.

28 809230 Service Manual Powermax45 XP

Installation and Setup

Connect to electrical power

Use the Hypertherm input current ratings to determine conductor sizes for power connection and installation instructions. The Hypertherm ratings are designated HYP on the data plate on the bottom of the power supply. Use the higher HYP input current value for installation purposes. See page 339 for a sample data plate.

NOTICE

Protect the circuit with appropriately sized time-delay fuses and a line-disconnect switch.

The maximum output voltage varies based on input voltage and the circuit’s amperage. Because the current draw varies during startup, time-delay fuses are recommended. See Voltage configurations on page 30. Time-delay fuses can withstand currents up to 10 times the rated value for short periods of time.

Install a line-disconnect switch

 Use a line-disconnect switch for

each plasma power supply to allow the operator to turn off the incoming power quickly in an emergency.

 Place the switch so that it is

easily accessible to the operator. Installation must be performed by a licensed electrician according to national and local codes.

 The interrupt level of the switch

must equal or exceed the continuous rating of the fuses/breakers.

 The switch should also:

 Isolate the electrical

equipment and disconnect all live conductors from the incoming supply voltage when in the OFF position.

 Have one OFF and one ON position that are clearly marked with O (OFF) and I (ON).  Have an external operating handle that can be locked in the OFF position.  Contain a power-operated mechanism that serves as an emergency stop.  Have appropriate slow-blow fuses installed. See Voltage configurations on page 30 for

recommended fuse/breaker sizes.

Powermax45 XP Service Manual 809230 29

Installation and Setup

Requirements for grounding

To aid personal safety, proper operation, and to reduce electromagnetic interference (EMI), the power supply must be properly grounded.

 The power supply must be grounded through the power cord according to

national and local electrical codes.

 Three-phase service must be of the 4-wire type with a green or green/yellow wire for

protective earth ground and must comply with national and local requirements.

 Refer to the Safety and Compliance Manual (80669C) included with your system for more

information on grounding.

The system’s rated output (cutting power)

A plasma system’s cutting power is determined more by its wattage output than by its amperage output. The rated output for this system is:

 10 A – 45 A maximum output current  145 VDC maximum rated output voltage  6.5 kW cutting power

To determine the cutting power in watts (W), multiply the maximum output amperage (A) by the maximum rated output voltage (VDC):

Voltage configurations

The system automatically adjusts for proper operation at the current input voltage without requiring any switching or rewiring. However, you must:

 Install a set of consumables in the torch. See Step 1 – Install consumables and activate

torch on page 48.

 Set the output current using the adjustment knob on the front panel. See Step 6 – Set

mode and adjust output current (amperage) on page 53.

To operate the power supply at full output and 50% duty cycle as rated, you must size your electrical service accordingly. The following tables show the maximum rated output for typical input voltages. The output setting to use depends on the thickness of the metal and is limited by the input power to the system.

The recommended fuse/breaker sizes account for spikes in input current



that occur when you stretch the plasma arc. Stretching the plasma arc is common in some applications, such as gouging.

45 A × 145 VDC = 6,525 W (6.5 kW)

30 809230 Service Manual Powermax45 XP

Installation and Setup

CSA/CE/CCC 200 V – 240 V (1-phase)

Input voltage 200 V – 240 V

Input current at rated output (45 A x 145 V = 6.5 kW) 39 A – 32 A

Input current at arc stretch 44 A – 36 A

Recommended fuse/breaker size 50 A

Voltage tolerance 20% / -15%

CSA 208 V (1-phase)

Input voltage 208 V

Input current at rated output (45 A x 145 V = 6.5 kW) 37 A

Input current at arc stretch 43 A

Recommended fuse/breaker size 50 A

Voltage tolerance 20% / -15%

CCC 220 V (1-phase)

Input voltage 220 V

Input current at rated output (45 A x 145 V = 6.5 kW) 33 A

Input current at arc stretch 39 A

Recommended fuse/breaker size 50 A

Voltage tolerance 20% / -15%

CE 230 V (1-phase)

Input voltage 230 V

Input current at rated output (45 A x 145 V = 6.5 kW) 33 A

Input current at arc stretch 37 A

Recommended fuse/breaker size 48 A

Voltage tolerance 20% / -15%

Powermax45 XP Service Manual 809230 31

Installation and Setup

CCC 380 V (3-phase)

Input voltage 380 V

Input current at rated output (45 A x 145 V = 6.5 kW) 12 A

Input current at arc stretch 20 – 15 A

Recommended fuse/breaker size 20 A

Voltage tolerance 20% / -10%

CE 400 V (3-phase)

Input voltage 400 V

Input current at rated output (45 A x 145 V = 6.5 kW) 11 A

Input current at arc stretch 20 – 15 A

Recommended fuse/breaker size 20 A

Voltage tolerance +20% / -15%

CSA 480 V (3-phase)

Input voltage 480 V

Input current at rated output (45 A x 145 V = 6.5 kW) 9.4 A

Input current at arc stretch 17 – 12 A

Recommended fuse/breaker size 20 A

Voltage tolerance +20% / -10%

32 809230 Service Manual Powermax45 XP

Installation and Setup

Decrease output current and arc stretch for lower rated electrical service

If you operate the power supply on an electrical service rated lower than what is recommended in Voltage configurations on page 30, you may need to:

 Turn down the cutting current (amperage setting). See Step 6 – Set mode and adjust

output current (amperage) on page 53.

 Avoid stretching the plasma arc for prolonged periods. The more you stretch the plasma arc,

the more current the system draws and the more likely you are to overheat the system or trip the circuit breaker.

NOTICE

Do not operate this system on a 15 A or 16 A circuit breaker.

Example: 230 V input on 20 A electrical service

If you use a 1-phase system with an input voltage of 230 V on a 20 A breaker, the recommended output current is 19 A.

Input voltage 230 V

Input current at rated output (19 A x 145 V = 2.8 kW) 18 A

Input current at arc stretch 19 A

Voltage tolerance 20% / -15%

Powermax45 XP Service Manual 809230 33

Installation and Setup

NEMA 6-50P (1-phase)

Prepare the power cord

CSA systems

1-phase (200 V – 240 V)

 10 AWG 3-wire power cord  50 A, 250 V power plug

(NEMA 6-50P) included

To connect to a generator



that requires a 4-wire connection, refer to Adapter

for 4-wire 1-phase connections (CSA 1-phase models only) on page 36.

3-phase (480 V)

 14 AWG 4-wire power cord (some models ship without a power cord)  Power plug not included*

* An appropriate plug must be installed on the power cord by a licensed electrician according to national and

local codes.

CE/CCC systems

1-phase (200 V – 240 V)

 6mm  Power plug not included*

3-phase (380 V / 400 V)

 2.5 mm  Power plug not included*

* An appropriate plug must be installed on the power cord by a licensed electrician according to national and

local codes.

3-wire H07RN-F power cord

4-wire H07RN-F power cord

34 809230 Service Manual Powermax45 XP

Extension cord recommendations

Use an extension cord that:

 Is an appropriate wire gauge for the cord length and system voltage  Meets national and local codes

Extension cords can cause the machine to receive less input voltage than



the output of the circuit. This can limit the operation of your system.

Installation and Setup

Input voltage Phase

200– 240VAC 1

380 – 480 VAC 3

Generator recommendations

Generators used with this system must meet the voltage requirements in the following table and in Hypertherm plasma power supply ratings on page 23.

Engine drive rating Plasma system output current Performance (arc stretch)

10 kW 4 5 A F ul l

8kW 45A Limited

6kW 30A Full

Cord Length Cord Gauge

up to 15 m (50 feet) 10 mm

15–30m (50–100feet) 16mm

30 – 45 m (100 – 150 feet) 25 mm

up to 15 m (50 feet) 4 mm

15 – 45 m (50 – 150 feet) 6 mm

(8 AWG)

(6 AWG)

(4 AWG)

(12 AWG)

(10 AWG)

 Adjust the cutting current (amperage) as needed based on the rating, age, and condition of

the generator.

Powermax45 XP Service Manual 809230 35

Installation and Setup

 A 10 kW generator is recommended for cutting applications that require full arc stretch,

such as many gouging applications. It allows for the spikes in input current that occur when you stretch the plasma arc.

 If a fault occurs while using a generator, turn OFF (O) the system. Wait approximately

1 minute before you turn the system back ON (I).

Adapter for 4-wire 1-phase connections (CSA 1-phase models only)

Some generators require a 4-wire single phase connection (for example, NEMA 14-50R). In this case, use an adapter to connect the power supply’s 3-wire power cord plug (NEMA 6-50P) to the 4-wire connector on the generator.

Connect the gas supply

WARNING

The filter bowl in the power supply may explode if the gas pressure exceeds 9.3 bar (135 psi).

 All models: Use an inert gas hose with internal diameter of 9.5 mm (3/8 inch) or greater. Do

not use hoses with an internal diameter less than 9.5 mm (3/8 inch). Hoses that are too small can cause issues with cut quality and cut performance.

 CSA models: An industrial

interchange quick-disconnect nipple with 1/4 NPT threads comes with the system.

 CE/CCC models: A British Pipe

Thread adapter G-1/4 BSPP with 1/4 NPT threads comes with the system.

 The gas inlet fitting that comes

with the system may or may not be preinstalled. To install the fitting, screw it into place on the back of the power supply.

 CSA models: Tighten the 1/4 NPT fitting to 115 kg·cm (100 inch·pounds). The fitting

comes with thread sealant preapplied.

 CE/CCC models: Tighten the G-1/4 BSPP adapter to 104 kg·cm (90 inch·pounds).

36 809230 Service Manual Powermax45 XP

Gas supply source

Recommended gas supply pressure: 5.5 – 6.9 bar (80 – 100 psi)

Maximum gas supply pressure: 9.3 bar (135 psi)

Recommended flow rate and pressure: 189 slpm at 5.9 bar (400 scfh at 85 psi)

Minimum flow rate: 165.2 slpm (350 scfh)

Maximum particle size: 0.1 micron at maximum concentration of 0.1 mg/m

Maximum water vapor dewpoint: -40°C (-40°F)

Maximum oil concentration: 0.1 mg/m

(for aerosol, liquid, and vapor)

* Per ISO8573-1:2010, Class 1.2.2. That is, it should have a maximum number of solid particulate per meter cubed

of 20,000 for particle sizes in the range of 0.1 – 0.5 microns, a maximum of 400 for particle sizes in the range of

0.5 – 1 microns, and a maximum of 10 for particle sizes in the range of 1 – 5 microns.

Installation and Setup

NOTICE

Synthetic lubricants containing esters that are used in some air compressors will damage polycarbonates used in the air filter bowl.

 Use shop-compressed gas or cylinder-compressed gas.

 Use a high-pressure regulator on either type of gas supply. The regulator must be

capable of delivering gas to the air inlet on the power supply at the flow rate and pressure specified above.

 Use only clean, moisture-free gas.

 Oil, water, vapor, and other contaminants in the gas supply can damage internal

Powermax45 XP Service Manual 809230 37

components over time.

 Poor gas supply quality results in:

 Reduced cut quality and cut speeds  Reduced cut thickness capability  Reduced consumable life

Installation and Setup

High-pressure gas cylinders

GAS CYLINDERS CAN EXPLODE IF DAMAGED Gas cylinders contain gas under high pressure. If damaged, a cylinder can explode. For high pressure regulators, adhere to the manufacturer’s guidelines for safe

installation, operation, and maintenance. Before plasma cutting with compressed gas, read the safety instructions in the

Safety and Compliance Manual (80669C). Failure to follow safety instructions can result in personal injury or in damage to equipment.

EXPLOSION HAZARD – CUTTING WITH FUEL GASES Do not use combustible fuel gases or oxidizing gases with Powermax systems.

These gases can result in explosive conditions during plasma cutting operations.

WARNING

You can use the following gases to cut with this system. See Hypertherm plasma power supply ratings on page 23 for requirements on gas quality.

 Air  Nitrogen  F5 (stainless steel only – see page 119)  Argon (recommended for marking applications only – see page 122)

If you use high-pressure gas cylinders as the gas supply:

 Refer to the manufacturer’s specifications for installation and maintenance procedures of

high-pressure regulators.

 Make sure the cylinder valves are clean and free of oil, grease, and other contaminants.

Open each cylinder valve just long enough to blow out any dust that may be present.

 Make sure the cylinder is equipped with an adjustable high-pressure regulator that is

capable of:

 Gas outlet pressures up to 6.9 bar (100 psi). Never exceed the maximum gas

pressure of 9.3 bar (135 psi).

 Gas flow rates of 235.9 L/min (500 scfh).

 Connect the supply hose securely to the cylinder.

38 809230 Service Manual Powermax45 XP

Gas flow rates

Refer to the cut charts starting on page 131 for flow rates specific to each cutting process specified (based on the type of metal, the type of gas, and the output current).

Process Gas flow rate

Cutting 188.8 slpm (400 scfh) at a minimum 5.9 bar (85 psi)

Installation and Setup

Maximum control gouging (26 – 45 A)

Precision gouging / marking (10 – 25 A)

165.2 slpm (350 scfh) at a minimum 4.1 bar (60 psi)

165.2 slpm (350 scfh) at a minimum 3.8 bar (55 psi)

Minimum inlet pressure (while gas is flowing)

WARNING

The filter bowl in the power supply may explode if the gas pressure exceeds 9.3 bar (135 psi).

The following pressure specifications apply for air, nitrogen, F5, and argon. Never exceed an inlet gas supply pressure of 9.3 bar (135 psi).

You may need to adjust these pressures based on the equipment and conditions specific to your environment. For example, additional gas filtration installed between the gas supply and the plasma power supply may increase the required minimum inlet pressure. Consult the filter manufacturer.

Cutting

Torch lead length – hand torches Minimum inlet pressure

6.1m (20feet) 5.5bar (80psi)

15 m (50 feet) 5.9bar (80psi)

Torch lead length – machine torches Minimum inlet pressure

7.6m(25feet) 5.5bar (80psi)

11 m (35 feet) 5.5bar (80psi)

15 m (50 feet) 5.9 bar (85 psi)

Powermax45 XP Service Manual 809230 39

Installation and Setup

Maximum control gouging (26 – 45 A)

Torch lead length – hand torches Minimum inlet pressure

6.1m (20feet) 3.8bar (55psi)

15 m (50 feet) 4.1bar (60psi)

Torch lead length – machine torches Minimum inlet pressure

7.6m(25feet) 3.8bar (55psi)

11 m (35 feet) 3.8bar (55psi)

15 m (50 feet) 4.1 bar (60 psi)

Precision gouging / Marking (10 – 25 A)

Torch lead length – hand torches Minimum inlet pressure

6.1m (20feet) 3.5bar (50psi)

15 m (50 feet) 3.8bar (55psi)

Torch lead length – machine torches Minimum inlet pressure

7.6m(25feet) 3.5bar (50psi)

11 m (35 feet) 3.5bar (50psi)

15 m (50 feet) 3.8 bar (55 psi)

40 809230 Service Manual Powermax45 XP

Additional gas filtration

Air filter bowl

Water and particle

filter

Oil filter Oil vapor filter

Gas supply

It is extremely important to maintain a clean, dry gas line in order to:

 Prevent oil, water, dirt, and other contaminants from damaging internal components.  Achieve optimal cut quality and consumable life.

Dirty, oily air is the root cause of many common problems that occur in Powermax systems, and in some instances it can void the warranty on the power supply and on the torch. See the gas quality recommendations in the ratings table on page 23.

The power supply contains a built-in air filter. Regularly check the filter element inside the air filter bowl and replace as needed. See Replace the air filter bowl and filter element on page 212.

The built-in air filter should not take the place of adequate external filtration. If you work in an environment that is extremely warm and humid, or if work site conditions introduce oil, vapors, or other contaminants into the gas line, install an external filtration system that cleans the gas supply before it enters the plasma power supply.

Installation and Setup

A 3-stage coalescing filtration system is recommended. A 3-stage filtering system works as follows to clean contaminants from the gas supply.

Install the filtering system between the gas supply and the power supply. Additional gas filtration may require higher pressure from the source.

Powermax45 XP Service Manual 809230 41

Installation and Setup

42 809230 Service Manual Powermax45 XP

Controls and indicators

200 – 240 V 400 V, 480 V

ON (I)/OFF(O) power switch

The power switch is located on the front panel.

Operation

Powermax45 XP Service Manual 809230 43

Operation

Cutting controls

Mode button – Press this button to toggle between cut mode and gouge/marking

mode. The system automatically adjusts the gas pressure based on:

 The mode selected  The torch connected to the power supply  The length of the torch lead

Cut Mode LED (green) – When illuminated, this LED indicates that the system is

ready to perform plasma cutting operations.

Gouge/Marking Mode LED (green) – When illuminated, this LED indicates that the

system is ready to perform plasma gouging or marking operations.

2-digit display – This display shows the output current (10 – 45 A) by default.

When certain system faults occur, this display shows a fault code. See Fault LEDs and fault codes on page 163.

If you manually adjust the gas pressure, this display shows the gas pressure. See Adjust the gas pressure manually on page 56.

AMPS LED (green) – When illuminated, this LED indicates that the 2-digit display

shows the cutting current (amperage). When the 2-digit display shows other values, such as gas pressure or a fault

code, the AMPS LED is not illuminated.

Adjustment knob – Use this knob to set the cutting current between 10 A and 45 A

in 1-unit increments. You can also use this knob to increase or decrease the gas pressure. See Adjust

the gas pressure manually on page 56.

44 809230 Service Manual Powermax45 XP

Indicator LEDs

Power ON LED (green) – When illuminated, this LED indicates that the power switch is set to

Operation

ON (I) and the system is ready to cut.

Gas Pressure LED (yellow) – When illuminated, this fault LED indicates that the inlet gas

pressure is too low or that there is no inlet gas connection.

System Fault LED (yellow) – When illuminated, this fault LED indicates that there is a fault

with the power supply. In many instances, when this LED illuminates, a fault code also flashes on the 2-digit display. See Fault LEDs and fault codes on page 163.

Torch Cap LED (yellow) – When illuminated, this fault LED indicates that the consumables

are loose, improperly installed, or missing.

Temperature LED (yellow) – When illuminated, this fault LED indicates that the system’s

temperature is outside the acceptable operating range.

Some fault conditions cause multiple LEDs to illuminate or blink at the



same time. For information on what these fault conditions are and how to clear them, see

Fault LEDs and fault codes on page 163.

Powermax45 XP Service Manual 809230 45

Operation

Disable the torch

The Duramax Lock torches include a switch that enables you to lock the torch. This torch-disable switch prevents the torch from firing accidentally even when the power supply is ON. Use this switch to lock the torch when it is not in use, when you need to change the consumables, or when you need to move the power supply or torch while the system is powered ON.

Tor ch LOCK position:

 The torch-disable switch is

in the backward position, closer to the torch lead.

 The yellow label with the

“X” indicates the torch is not ready to fire.

 Point the torch away from

yourself and others, and pull the trigger to make sure it does not fire.

 Change the consumables (if

needed).

Tor ch “ready to fire” position:

 The torch-disable switch is

in the forward position, closer to the torch head.

 The green label with the

“ ” indicates the torch is ready to fire.

 Do NOT change the

consumables.

 To change the

consumables without danger of the torch firing accidentally, lock the torch or turn OFF the power supply.

The first time you pull



the torch trigger after you set the torch to the “ready to fire” position, the torch emits multiple puffs of air in quick succession. This warns you that the torch is active and will fire an arc the next time the trigger is pulled. Seepage47.

46 809230 Service Manual Powermax45 XP

Warning puffs of air

1 2

The first time you try to fire the torch after moving the torch-disable switch to the yellow lock (X) position and then back to the green “ready to fire” ( ) position:

Operation

WARNING

INSTANT-ON TORCHES – PLASMA ARC CAN CAUSE INJURY, BURNS The plasma arc ignites immediately when you pull the torch trigger.

Before changing consumables, one of the following actions must be taken. Whenever possible, complete the first action.

 Turn OFF (O) the plasma power supply.

 Move the torch-disable switch to the yellow lock (X) position

(closest to the torch lead). Pull the trigger to make sure the torch does not fire a plasma arc.

 The plasma arc does not fire.  The torch emits multiple puffs of air in quick succession. The torch vibrates slightly with each

puff of air.

 The power supply makes an audible pressure-release sound with each puff of air.

This feedback serves as a warning. It does not indicate a fault condition. It alerts you that the torch is activated and will produce a plasma arc the next time the torch is fired.

The Torch Cap LED on the front panel illuminates when you



remove the consumables or set the torch-disable switch to the yellow lock (X) position while the plasma power supply is still ON. The LED extinguishes after you install the consumables and set the torch-disable switch to the green “ready to fire” ( ) position.

Powermax45 XP Service Manual 809230 47

Operation

For hand torches

After moving the torch-disable switch to the green “ready to fire” ( ) position:

a. Pull the torch trigger 1 time to get the warning puffs of air. b. Pull the torch trigger again to fire a plasma arc.

For machine torches

After moving the torch-disable switch to the green “ready to fire” ( ) position:

a. Run a START/STOP command from the CNC to get the warning puffs of air.

If this feature is integrated into your CNC, there may be other steps to



follow that are specific to the CNC.

b. Start the torch again to fire a plasma arc.

Operate the plasma system

Step 1 – Install consumables and activate torch

WARNING

INSTANT-ON TORCHES – PLASMA ARC CAN CAUSE INJURY, BURNS The plasma arc ignites immediately when you pull the torch trigger.

Before changing consumables, one of the following actions must be taken. Whenever possible, complete the first action.

 Turn OFF (O) the plasma power supply.

 Move the torch-disable switch to the yellow lock (X) position

(closest to the torch lead). Pull the trigger to make sure the torch does not fire a plasma arc.

WARNING

RISK OF BURNS AND ELECTRIC SHOCK – WEAR INSULATED GLOVES Always wear insulated gloves when changing the consumables. The

consumables get very hot during cutting and can cause severe burns. Touching the consumables can also result in electric shock if the power

supply in ON and the torch-disable switch is not in the yellow lock (X) position.

48 809230 Service Manual Powermax45 XP

1. Turn OF F (O) the power

Tighten to finger tight.

Do not over-tighten.

switch on the power supply, or move the torch-disable switch on the torch to the yellow lock (X) position.

2. Point the torch away from yourself and others, and pull the trigger to make sure it does not fire.

3. Choose the correct consumables for your cutting, gouging, or marking application.

 Cutting and piercing

with a hand torch: See Choose the consumables on page 64.

Operation

 Cutting and piercing

with a machine torch: See Choose the consumables on page 113.

 Gouging: See Gouging processes on page 77.  Marking: See Marking consumables (10 – 25 A) on page 121.

4. Install a complete set of consumables in the hand torch or machine torch as shown:

Swirl ring Electrode Nozzle Retaining cap Shield (or deflector)

Consumables are not



preinstalled on new torches. Remove the vinyl cap from the torch before installing the consumables.

Powermax45 XP Service Manual 809230 49

Operation

Red button

5. Move the torch-disable switch on the torch to the green “ready to fire” ( )

position.

Step 2 – Connect torch lead

 Turn OF F ( O) the power

supply before you connect or disconnect a torch.

 To connect a hand torch

or machine torch, push the connector into the receptacle on the front of the power supply.

 To disconnect the torch,

press the red button on the connector and pull the connector out of the receptacle.

50 809230 Service Manual Powermax45 XP

Step 3 – Connect gas supply

Keyed opening at right of work lead receptacle

 If needed, install the gas inlet fitting that came with the system onto the back of the power

supply. See page 36.

 Connect the gas supply line to the fitting on the back of the power supply.  For gas supply requirements, see Gas supply source on page 37.

Operation

Step 4 – Connect work lead and work clamp

NOTICE

Make sure you use a work lead that is appropriate for your power supply. Use a 45 A work lead with the Powermax45 XP. The amperage is marked near the rubber boot of the work lead connector.

To prevent overheating, check the work lead often to make sure it is fully seated in the receptacle.

Work lead

1. Insert the work lead connector into the receptacle on the front of the power supply. Align the key on the connector with the opening on the right of the receptacle.

2. Push the work lead connector all the way into the receptacle. Turn the connector clockwise a 1/4 turn until the connector is fully seated against the stop.

Powermax45 XP Service Manual 809230 51

Operation

Work clamp

NOTICE

Do not attach the work clamp under water. If the power supply is below the work clamp, water can enter the power supply via the work lead and cause severe damage.

 Hand cutting: The work clamp must be connected to the workpiece you are cutting.  Mechanized cutting: If you are using this system with a cutting table, you can connect the

work clamp directly to the table or to the workpiece you are cutting. See your table manufacturer’s instructions.

 Make sure the work clamp makes

good metal-to-metal contact with the workpiece or cutting table.

 Remove rust, dirt, paint, coatings,

and other debris so the work clamp makes proper contact with the workpiece or cutting table.

 To achieve the best cut quality,

attach the work clamp as close as possible to the area being cut.

NOTICE

Do not attach the work clamp to the portion of the workpiece to be cut away.

52 809230 Service Manual Powermax45 XP

Step 5 – Connect electric power and turn ON the system

200 – 240 V

400 V, 480 V

1. Plug in the power cord.

 When you first receive your system, the power cord may not have a power plug installed.

For information on connecting the proper plug to the power cord, see Prepare the power cord on page 34.

 For more information on the system’s electrical requirements, see Connect to electrical

power on page 29.

2. Set the power switch to the ON (I) position.

Operation

Step 6 – Set mode and adjust output current (amperage)

1. Press the Mode button to toggle between Cut mode and Gouge/Marking mode.

The system’s Smart Sense™ technology automatically regulates the gas



pressure for optimum cutting according to the selected mode, the torch type, and the length of the torch lead.

2. Turn the adjustment knob to set the output current to a maximum of 45 A. The 2-digit display shows the output current in amperage.

Powermax45 XP Service Manual 809230 53

Operation

Cutting expanded metal

To cut expanded metal, use the consumables for shielded cutting that come with the system. The system does not require a dedicated mode for cutting expanded metal.

Expanded metal has a slotted or mesh pattern. Cutting expanded metal



wears out consumables more quickly because it requires a continuous pilot arc. A pilot arc occurs when the torch is fired but the plasma arc is not in contact with the workpiece.

Step 7 – Check cut settings and indicator LEDs

Before you start to cut, make sure:

The green power ON LED on the front of the power supply is illuminated.

The correct mode LED is illuminated (cut or gouge/marking). Also make sure the consumables installed on the torch match the selected mode.

The output current (amperage) displayed on the front panel is correct, and the AMPS LED is illuminated.

None of the 4 fault LEDs are illuminated or blinking.

If any of the fault LEDs illuminate or blink, or if the power ON LED blinks, this indicates a fault. Correct the fault condition before continuing. See Fault LEDs and fault codes on page 163.

54 809230 Service Manual Powermax45 XP

What to expect during and after cutting

Postflow – After you complete a cut and

release the torch trigger, air continues to flow from the torch in order to cool the consumables. This is referred to as postflow.

The length of postflow depends on the mode and the output current. Under certain conditions, it also depends on the gas supply.

Mode Output current Length of postflow

Cut 10–45A 20seconds

Gouge/marking 26 – 45 A 20 seconds

Gouge/marking 10 – 25 A 10 seconds for air (or nitrogen)

Operation

3 seconds for argon

Exception for argon: The system recognizes when argon is being used and reduces postflow from 10 seconds to 3 seconds in order to minimize gas usage. To achieve 3-second postflow, the system must be set to Gouge/Marking mode with the output current set between 10 – 25 A. When the torch fires without transferring the pilot arc to the workpiece, postflow is 10 seconds even when the supply gas is argon.

Fan activity – The cooling fan inside the

plasma power supply runs intermittently during and after cutting in order to cool internal components.

Powermax45 XP Service Manual 809230 55

Operation

Warning puffs of air – When you set the

torch-disable switch to the “ready to fire” ( ) position after the

torch has been locked, the torch does not fire the first time you pull the trigger. Instead, the torch emits multiple puffs of air in quick succession. With each puff of air, the torch vibrates slightly, and the power supply emits an audible pressure-release sound. This serves as a warning to alert you that the torch is active and will fire an arc the next time you pull the trigger. See page 47.

For the machine torch, run a START/STOP command from the CNC to



cause the torch to emit the puffs of air. On the next start signal, the torch will fire an arc.

The Torch Cap LED on the front panel illuminates when you



Adjust the gas pressure manually

The power supply automatically regulates the gas pressure for you. However, you can adjust the gas pressure manually if you need to for a specific application.

Overriding the system’s gas pressure setting should be done only by



experienced users who need to optimize the gas setting for a specific cutting application.

1. Select the mode, and set the output current. In this example, we selected gouge/marking mode and set the output current to 45 A.

 Set the mode and

output current first because doing so can reset the gas pressure. See page 58.

56 809230 Service Manual Powermax45 XP

2. Press-and-hold the Mode

Press-and-hold the button while turning the knob.

button with one hand. Turn the adjustment knob to the desired gas pressure with the other hand. In this example, we turned down the gas pressure to 35 psi.

 As you manually

adjust the gas pressure, the AMPS LED turns off, and the 2-digit display changes from amperage to gas pressure, as follows:

 CSA models: The gas pressure displays in psi by default.  CE/CCC models: The gas pressure displays in bar by default.

You can change the display values for gas pressure. See page 59.



Operation

3. Release the Mode button.

 After you release the

Mode button, the AMPS LED illuminates again, and the 2-digit display changes from gas pressure back to amperage.

 The selected mode LED blinks to let you know that the gas pressure has been manually

adjusted. It continues to blink until you reset the pressure.

 To view the gas pressure setting again, repeat step 2 above, or enter gas test mode.

See Run a gas test on page 158.

Powermax45 XP Service Manual 809230 57

Operation

Press the button to reset the gas pressure.

Reset the gas pressure

When you manually adjust the gas pressure, the pressure you set remains in place until you reset it. You can reset the gas pressure by pressing the Mode button.

When you reset the gas pressure, the selected mode LED stops blinking.



The gas pressure also resets to the default setting when:

 You are in gouge/marking mode and you change the output current from:

 The Maximum Control gouging process (26 – 45 A) to the Precision gouging process

(10 – 25 A)

 The Precision gouging process (10 – 25 A) to the Maximum Control gouging process

(26 – 45 A)

 You connect a different torch to the power supply.

Turning the power supply OFF and ON does not reset the gas pressure.



58 809230 Service Manual Powermax45 XP

Change the gas pressure values between psi and bar

Press-and-hold for 15 seconds to toggle between psi and bar.

psi bar

 CSA models: The gas pressure displays in psi by default.  CE/CCC models: The gas pressure displays in bar by default.

To change the gas pressure display values from psi to bar or from bar to psi:

1. Press-and-hold the Mode button for approximately 15 seconds until the 2-digit display shows P.U.

Operation

2. Release the Mode button. The system will now display gas pressure values in bar instead of psi or in psi instead of bar.

Powermax45 XP Service Manual 809230 59

Operation

Understand duty cycle to prevent overheating

Duty cycle – Percentage of time during a 10-minute interval that a plasma arc can remain on

without causing the system to overheat.

Output current Duty cycle*

45 A 50%

41 A 60%

32 A 100%

* Assumes ambient operating temperature of 40°C (104°F).

When you exceed the duty cycle and the system overheats:

 The plasma arc shuts off.

 The Temperature LED illuminates.

 The cooling fan inside the power supply runs.

When the system overheats:

a. Leave the system on to allow the fan to cool the power supply. b. Wait for the Temperature LED to turn off before you start to cut again.

Stretching the plasma arc for prolonged periods negatively impacts duty cycle. Whenever possible, drag the torch on the workpiece. See Start a cut from the edge of the workpiece on page 73.

If you operate the system on a lower rated electrical service, stretching the plasma arc for prolonged periods can cause the system to overheat more quickly and can cause the circuit breaker to trip. See Decrease output

current and arc stretch for lower rated electrical service on

page 33.

60 809230 Service Manual Powermax45 XP

Cut with the Hand Torch

Duramax Lock hand torches come in 15° and 75° models.

 The 75° hand torch is a general purpose torch designed for the widest range of applications.  The 15° hand torch is designed to direct heat away from the operator during heavy gouging.

It also facilitates cutting overhead or in hard to reach areas.

Duramax Lock torch features include:

 A torch-disable switch that prevents the torch from firing accidentally even when the power

supply is ON. See Disable the torch on page 46.

 The FastConnect

switch from one torch to another.

quick-disconnect system to easily remove the torch for transport or to

 Automatic cooling with ambient air. Special cooling procedures are not needed.

This section provides an overview of hand torch parts, dimensions, consumables, cutting guidelines, and basic cutting methods. For gouging information, see Gouge with the Hand Torch and Machine Tor ch on page 77.

To resolve issues with cut quality, refer to Troubleshooting guide on



page 172.

The Duramax Lock hand torches ship without consumables installed. To install the consumables, see page 48.

Powermax45 XP Service Manual 809230 61

Cut with the Hand Torch

Consumables

Safety trigger

Torch-disable switch

260 mm (10.2 inch)

10 2 m m

(4.0 inch)

75°

61 mm (2.4 inch)

25 mm (1.0 inch)

69 mm (2.7 inch)

269 mm (10.6 inch)

51 mm

(2.0 inch)

69 mm (2.7 inch)

15°

325 mm (12.8 inch)

25 mm (1.0 inch)

Hand torch components, dimensions, weights

Components

Dimensions

75° hand torch

15° hand torch

62 809230 Service Manual Powermax45 XP

Weights

10 2 m m 4inch

204 mm 8inch

Diameter = 2 x Radius = 204 mm (8 inches)

Torch We igh t

Hand torch with 6.1 m (20 foot) lead 1.8 kg (3.9 pounds)

Hand torch with 15 m (50 foot) lead 3.7 kg (8.1 pounds)

Minimum bend radius for torch leads

The recommended minimum bend radius for torch leads is 102 mm (4 inches).

Cut with the Hand Torch

Powermax45 XP Service Manual 809230 63

Cut with the Hand Torch

Choose the consumables

The 15° and 75° Duramax Lock hand torches use the same consumables.

Your system ships with a starter consumable kit that includes the shielded consumables on page 65 plus 1 extra electrode and 1 extra nozzle.

Consumable Type Purpose

Shielded drag-cutting Drag cut for the widest range of cutting applications.

FineCut

HyAccess

FlushCut

Achieve narrower kerf on thin mild steel and stainless steel up to 3mm (10gauge).

Cut or gouge in hard to reach areas or confined spaces.

Cut as close to the base as possible without piercing or damaging the workpiece.

Maximum Control gouging (26 – 45 A)* Remove metal and achieve a controlled gouge profile.

Precision gouging (10 – 25 A)*

Marking (10 – 25 A)

* For details on gouging processes and consumables, see Gouging processes on page 77.

†

For details on marking consumables, see Marking consumables (10 – 25 A) on page 121.

†

Achieve very shallow gouge and lower metal removal rate than with Maximum Control gouging, such as for spot weld removal.

Mark metal surfaces using air or argon.

When you use the following shielded and FineCut consumables, select Cut mode on the front panel. See page 53.

64 809230 Service Manual Powermax45 XP

Shielded drag-cutting consumables

220818

Shield

220854

Retaining cap

220941

Nozzle

220857

Swirl ring

220842

Electrode

220931

Deflector

220854

Retaining cap

220930

Nozzle

220947

Swirl ring

220842

Electrode

420410

Cutting nozzle

420408

Electrode

220857

Swirl ring

420413

Retaining cap

FineCut consumables

Cut with the Hand Torch

Specialty consumables

HyAccess cutting consumables

HyAccess consumables extend the reach of the regular shielded consumables by approximately

7.5 cm (3 inches). Use them with your hand torch to achieve greater reach and visibility.

HyAccess gouging consumables are also available. See page 79.



You can expect to cut approximately the same thicknesses as with the regular shielded consumables. You may need to reduce your cut speed slightly to achieve the same cut quality. Typically, you can expect HyAccess consumables to last approximately half as long as the regular shielded consumables.

Powermax45 XP Service Manual 809230 65

Cut with the Hand Torch

420633

Nozzle

420635

Electrode

420634

Swirl ring

420540

Retaining ring

420536

Cap

You can order each HyAccess consumable separately or in starter kits. When the tip of the nozzle wears out, replace the entire nozzle.

The 428445 cutting starter kit contains:

 1 HyAccess electrode  1 HyAccess cutting nozzle  1 HyAccess retaining cap

The 428414 cutting/gouging starter kit contains:

 2 HyAccess electrodes  1 HyAccess cutting nozzle  1 HyAccess gouging nozzle  1 HyAccess retaining cap  1 swirl ring (standard Powermax45 XP swirl ring)

FlushCut™ consumables

FlushCut consumables are designed to remove lugs, pad eyes, and other attachments without piercing or damaging the workpiece underneath. FlushCut consumables produce an angled plasma arc that enables you to cut very close to the base material without leaving a large amount of residual material to grind off.

You can expect to cut approximately the same thicknesses as with the regular shielded consumables. However, make sure to account for any added thickness that may be present from weld beads. Consumable life will vary, but typically you can expect FlushCut consumables to last approximately 3/4 as long as the regular shielded consumables.

You can order FlushCut consumables individually or in a starter kit (428746) that contains 1 of each consumable shown above. If you order FlushCut consumables individually:

 The minimum order quantity for the electrode is 5.  All other FlushCut consumables can be ordered in single quantities.

66 809230 Service Manual Powermax45 XP

Cut with the Hand Torch

WARNING

ARC RAYS CAN BURN EYES AND SKIN When you use FlushCut consumables, wear a face shield that covers your entire

face. Use a shield with a shade 10 lens. Plasma arc rays produce intense visible and invisible (ultraviolet and infrared) rays

that can burn eyes and skin.

WARNING

INSTANT-ON TORCHES – PLASMA ARC CAN CAUSE INJURY, BURNS Before rotating the FlushCut nozzle, one of the following actions must

be taken. Whenever possible, complete the first action.

 Turn OFF (O) the plasma power supply.

 Move the torch-disable switch to the yellow lock (X) position

(closest to the torch lead). Pull the trigger to make sure the torch does not fire a plasma arc.

To inst a l l :

1. Turn OF F (O) the power supply, or set the torch-disable switch to the yellow lock (X) position.

2. Put the swirl ring, electrode, cap, and nozzle on the torch. Rotate the

nozzle based on the direction you plan to cut. Make sure the flat side of the nozzle is on the bottom so you can drag it along the workpiece.

3. Fully tighten the retaining ring onto the cap.

Repeat these steps while cutting if you need to change the orientation of the nozzle in order to complete the cut.

Tips:

 Drag the flat side of the nozzle along the base, but maintain a standoff of approximately

3 mm – 6 mm (1/8 inch to 1/4 inch) from the vertical workpiece you are cutting.

 You can use the FlushCut consumables in Gouge/Marking mode to remove residual material

from the base workpiece. Turn down the amperage as needed.

 Replace the cap when the outer sleeve no longer slides freely up

and down.

Powermax45 XP Service Manual 809230 67

Cut with the Hand Torch

220777

CopperPlus™ electrode

The CopperPlus electrode (220777) delivers at least 2 times longer consumable life over standard consumables (Hypertherm consumables designed for the system). This electrode is designed exclusively for use with Duramax and Duramax Lock torches when cutting metal up to 12 mm (1/2 inch).

Consumable life

Many factors influence how often you need to change the consumables on your hand torch:

 Poor gas supply quality

 It is extremely important to maintain a clean, dry gas line. The presence of oil, water,

vapor, and other contaminants in the gas supply can degrade cut quality and consumable life. See page 37 and page 41.

 Cutting technique

 Whenever possible, start cuts from the edge of the workpiece. This helps to extend the

life of the shield and the nozzle. See page 73.

 Use the proper piercing technique for the thickness of metal you are cutting. In many

instances, a rolling pierce technique is an efficient way to pierce the metal while minimizing the consumable wear that naturally occurs during piercing. See page 74 for an explanation of the straight pierce and rolling pierce techniques and when each is appropriate.

 Shielded versus non-shielded consumables

 Non-shielded consumables use a deflector instead of a shield. They can provide better

visibility and accessibility for some cutting applications. The trade-off is that non-shielded consumables generally have a shorter life than shielded consumables.

 Thickness of metal being cut

 In general, the thicker the metal being cut, the more quickly the consumables become

worn. For best results, do not exceed the thickness specifications for this system. See page 24.

 Expanded metal cutting

 Expanded metal has a slotted or mesh pattern. Cutting expanded metal wears out

consumables more quickly because it requires a continuous pilot arc. A pilot arc occurs when the torch is fired but the plasma arc is not in contact with the workpiece.

68 809230 Service Manual Powermax45 XP

Cut with the Hand Torch

 Incorrect consumables for output current and mode

 To optimize consumable life, make sure the consumables installed on the torch match

the selected mode and output current. For example:

 Do not use gouging consumables when the system is set to Cut mode. See

page 53.

 Do not set the output current between 26 A and 45 A with the Precision gouging

consumables installed.

 Unnecessary arc stretch when cutting

 To maximize consumable life, avoid stretching the arc when it is not necessary. Drag the

torch on the workpiece whenever possible. See page 72.

 Insufficient arc stretch when gouging

 A proper arc stretch while gouging maintains distance between the torch tip and the

molten metal that builds up during the gouge. See page 81.

 An arc stretch of 19 – 25 mm (3/4 – 1 inch) is recommended for gouging with the

Maximum Control gouging consumables at 26 – 45 A.

 An arc stretch of 10 – 11 mm (3/8 – 1/2 inch) is recommended for gouging with the

Precision gouging consumables at 10 A– 25 A.

As a general rule, the consumables last approximately 1 to 2 hours of actual “arc on” time for hand cutting. However, consumable life can vary a lot based on the factors listed above.

Powermax45 XP Service Manual 809230 69

Cut with the Hand Torch

Prepare to fire the torch

INSTANT-ON TORCHES – PLASMA ARC CAN CAUSE INJURY, BURNS The plasma arc ignites immediately when you pull the torch trigger.

Before changing consumables, one of the following actions must be taken. Whenever possible, complete the first action.

The plasma arc will cut quickly through gloves and skin.

WARNING

 Turn OFF (O) the plasma power supply.

 Move the torch-disable switch to the yellow lock (X) position

(closest to the torch lead). Pull the trigger to make sure the torch does not fire a plasma arc.

 Wear correct and appropriate protective equipment.

 Keep hands, clothing, and objects away from the torch tip.

 Do not hold the workpiece. Keep your hands clear of the

cutting path.

 Never point the torch toward yourself or others.

WARNING

RISK OF BURNS AND ELECTRIC SHOCK – WEAR INSULATED GLOVES Always wear insulated gloves when changing the consumables. The

consumables get very hot during cutting and can cause severe burns.

Touching the consumables can also result in electric shock if the power supply in ON and the torch-disable switch is not in the yellow lock (X) position.

To prevent accidental firing, the hand torch is equipped with a torch-disable switch and a safety trigger. To fire the torch:

1. Install the correct consumables. See page 48.

70 809230 Service Manual Powermax45 XP

2. Make sure the torch-disable switch is

in the green “ready to fire” ( ) position.

The first time you pull the



torch trigger after you set the torch to the “ready to fire” position, the torch may emit multiple puffs of air in quick succession. This warns you that the torch is active and will fire an arc the next time the trigger is pulled. Seepage47.

3. Flip the trigger’s safety cover forward (toward the torch head) and press the red torch trigger.

Cut with the Hand Torch

Powermax45 XP Service Manual 809230 71

Cut with the Hand Torch

90°

Hand torch cutting guidelines

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

Sometimes the torch sticks slightly to the workpiece when you cut with



FineCut consumables.

 Pulling, or dragging, the torch along the cut is easier than pushing it.  If sparks spray up from the workpiece, move the torch more slowly, or set the output current

higher.

 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).

 Hold the torch tip perpendicular to the

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

 If you fire the torch unnecessarily, you

will shorten the life of the nozzle and electrode.

 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). For beveled cuts, use a bevel cutting guide. See Accessory parts on page 332.

To troubleshoot issues with cut quality, see Troubleshooting guide on



page 172.

72 809230 Service Manual Powermax45 XP

Start a cut from the edge of the workpiece

Edge starting, when possible, is a good way to reduce damage to the shield and nozzle that can be caused by the slag produced during piercing. This helps to optimize consumable life.

1. With the work clamp attached to the workpiece, hold the torch tip perpendicular (90°) to the edge of the workpiece.

Cut with the Hand Torch

2. Press the torch’s trigger to start the arc. Pause at the edge until the arc has cut completely through the workpiece.

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

Powermax45 XP Service Manual 809230 73

Cut with the Hand Torch

30° for rolling pierce

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. Always wear proper protective equipment including gloves and eye protection.

The hand torch can pierce interior features on metal with a thickness of up to 12 mm (1/2 inch).

The type of pierce to perform depends on the thickness of the metal.

 Straight pierce – To cut metal that is thinner than 8 mm (5/16 inch).  Rolling pierce – To cut metal that is 8 mm (5/16 inch) or thicker.

1. Attach the work clamp to the workpiece.

WARNING

2. Straight pierce: Hold the torch perpendicular (90°) to the workpiece. Rolling pierce: 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.

74 809230 Service Manual Powermax45 XP

Cut with the Hand Torch

3. Straight pierce: Press the torch trigger to start the arc. Rolling pierce: Press the torch trigger to start the arc while still at an angle to the workpiece,

then rotate the torch to the perpendicular (90°) position.

4. Hold the torch in place while continuing to press the trigger. When sparks exit below the workpiece, the arc has pierced the material.

5. When the pierce is complete, drag the torch tip lightly along the workpiece to proceed with the cut.

Powermax45 XP Service Manual 809230 75

Cut with the Hand Torch

76 809230 Service Manual Powermax45 XP

Gouge with the Hand Torch and Machine Torch

Make sure the Gouge/Marking Mode LED is illuminated.

Gouging processes

This system offers 2 gouging processes. Each process uses its own set of consumables:

 Maximum Control gouging

 Use this process to remove metal and to achieve a controlled gouge profile.

 Precision gouging

 Use this process to achieve a very shallow gouge and a lower metal removal rate than

with Maximum Control gouging. For example, this process is useful for removing spot welds and for washing material at very low depths.

Before you use either process, press the Mode button on the front panel to set the plasma power supply to Gouge/Marking mode. See page 53.

Powermax45 XP Service Manual 809230 77

Gouge with the Hand Torch and Machine Torch

420419

Nozzle

420480

Shield

220854

Retaining cap

220857

Swirl ring

220842

Electrode

220854

Retaining cap

420415

Nozzle

220857

Swirl ring

220842

Electrode

420414

Deflector

Maximum Control gouging

 Use the Maximum Control gouging consumables.

Hypertherm also offers Maximum Removal gouging consumables. At



higher amperages on other Powermax systems, you can use the Maximum Removal consumables for greater metal removal rate and deeper gouge profiles. However, at 45 A with this system and torch, the Maximum Removal consumables do not offer an advantage over the Maximum Control consumables in terms of metal removal rate. You can expect each set of consumables to produce similar results on this system.

 Set the output current between 26 A and 45 A.

 Gouging at lower amperages (10 – 25 A) can limit the torch’s arc stretch capability. In

some instances it may also cause the arc to extinguish or trigger a “torch stuck open” (TSO) fault. See page 171.

Maximum Control gouging consumables (26 – 45 A)

Precision gouging

 Use the Precision gouging consumables.  Set the output current between 10 A and 25 A.

 Gouging at higher amperages (26 – 45 A) can shorten the life of the nozzle.

Precision gouging consumables (10 – 25 A)

78 809230 Service Manual Powermax45 XP

Specialty consumables

420412

Gouging nozzle

420408

Electrode

220857

Swirl ring

420413

Retaining cap

HyAccess gouging consumables

HyAccess consumables extend the reach of the regular shielded consumables by approximately

7.5 cm (3 inches). Use them with your hand torch to achieve greater reach and visibility.

HyAccess cutting consumables are also available. For more information



on HyAccess consumables, see page 65.

Gouge with the Hand Torch and Machine Torch

You can order each HyAccess consumable separately or in starter kits. When the tip of the nozzle wears out, replace the entire nozzle.

The 428446 gouging starter kit contains:

 1 HyAccess electrode  1 HyAccess gouging nozzle  1 HyAccess retaining cap

The 428414 cutting/gouging starter kit contains:

 2 HyAccess electrodes  1 HyAccess cutting nozzle  1 HyAccess gouging nozzle  1 HyAccess retaining cap  1 swirl ring (standard Powermax45 XP swirl ring)

Powermax45 XP Service Manual 809230 79

Gouge with the Hand Torch and Machine Torch

Standoff

Angle

Rotation of torch (relative to torch center line)

Torch center line

Speed

How to control the gouge profile

The following factors affect the width and the depth of the gouge profile. Adjust these elements to achieve the gouge you need.

 Output current of the plasma power supply – Turn down the amperage on the front panel

to make the gouge narrower and more shallow.

 If you are using the Maximum Control gouging consumables, keep the amperage

between 26 – 45 A.

 If you are using the Precision gouging consumables, keep the amperage between

10 – 2 5 A .

 Angle of the torch to the workpiece – Position the torch in a more upright position to

make the gouge narrower and deeper. Tilt down the torch so that it is closer to the workpiece to make the gouge wider and more shallow.

 Rotation of the torch – Rotate the torch relative to the torch center line to make the gouge

flatter and steeper on one side.

 Torch-to-work standoff – Move the torch further away from the workpiece to make the

gouge wider and more shallow. Move the torch closer to the workpiece to make the gouge narrower and deeper.

 Speed of the torch over the workpiece – Slow down to make the gouge wider and

deeper. Speed up to make the gouge narrower and more shallow.

80 809230 Service Manual Powermax45 XP

Gouge with the hand torch

40°

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. Always wear proper protective equipment including gloves and eye protection.

1. Install the Maximum Control gouging consumables or the Precision gouging consumables.

2. Set the system to Gouge/Marking mode. See page 53.

3. Set the output current to match the consumables installed:

 Maximum Control gouging consumables: 26 – 45 A  Precision gouging consumables: 10 – 25 A

Gouge with the Hand Torch and Machine Torch

WARNING

4. Hold the torch at approximately a 40° angle to the workpiece before firing the torch.

 Maximum Control gouging consumables: Hold the torch approximately 6 mm (1/4 inch)

above the workpiece.

 Precision gouging consumables: Hold the torch approximately 2 – 3 mm above the

workpiece.

Press the trigger to obtain a pilot arc. Transfer the arc to the workpiece.

5. Stretch the arc as follows:

 Maximum Control gouging consumables: 19 – 25 mm (3/4 – 1 inch)  Precision gouging consumables: 10 – 11 mm (3/8 – 1/2 inch)

Powermax45 XP Service Manual 809230 81

Gouge with the Hand Torch and Machine Torch

Direction of

travel

6. Change the torch’s angle as needed to achieve the desired dimensions for the gouge. Maintain the same 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 at least a small distance between the torch tip and the molten metal



to avoid reducing consumable life or damaging the torch.

Remove spot welds

To remove a spot weld, gouge around the weld in order to cut completely through the top layer of metal without damaging the layer underneath.

The Precision gouging consumables were designed specifically for applications like removing spot welds. When used at a lower amperage, these consumables provide:

 Very good visibility due to a plasma arc that is less bright and that allows you to see the

metal being gouged more clearly

 A very high width-to-depth ratio, which provides much better control of the metal removal

rate

Tips

Many different techniques can be used to remove spot welds. The method described in the following procedure is recommended as a good starting point. It is intended to minimize possible damage to the underneath layer.

Regardless of technique, these tips can help you to successfully remove spot welds:

 Keep the torch pointed in the same direction all the way around the spot weld.

 By keeping the torch pointed in the same direction, you avoid blowing slag over areas

you already gouged. This reduces the clean-up needed on the underneath layer. It also makes the process more ergonomic and efficient, since you do not need to rotate the torch or the workpiece while gouging.

 Maintain a proper arc stretch.

 Maintain an arc stretch of approximately 10 – 11 mm (3/8 – 1/2 inch) as you gouge

around the weld. This provides good visibility and prevents the torch tip from hitting slag, which can shorten consumable life and interrupt the gouge.

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Gouge with the Hand Torch and Machine Torch

40° – 45°

Spot weld

40° – 45°

Left-handed approach Right-handed approach

 Start at a lower output current, and gradually increase it.

 Start with the current set to 10 A if you have never removed a spot weld before. Once

you develop a technique you are comfortable with, try gradually increasing the output current. This enables you to gouge with better speed and efficiency.

Procedure

This procedure describes how to separate 2 metal layers and then remove the spot weld from the underneath layer.

The pictures in this procedure show mild steel plates. The slag on



stainless steel is darker, more jagged, and harder to remove.

1. Install the Precision gouging consumables.

2. On the front panel, select Gouge/Marking mode. Set the output current to 10 – 25 A.

3. Position the torch on one side of the spot weld. Hold the torch at approximately a 40° – 45°

angle to the workpiece.

4. Press the trigger to obtain a pilot arc. Transfer the arc to the workpiece, then stretch the arc to approximately 10–11mm (3/8–1/2inch). Maintain this arc as you gouge.

5. Make 2 separate gouges in an “L”-shaped motion to gouge all the way around the spot weld. See Table 1 on page 84.

 Table 1 shows one example of this technique (for both right-handed and left-handed

gouging). You can start at different points around the spot weld. The important thing is to keep the torch pointed in the same direction all the way around the weld.

 As you gouge, use very short strokes in a back-and-forth weaving motion until you have

cut through the top layer.

 You may need to adjust the angle of the torch slightly, depending on the thickness of the

metal.

Powermax45 XP Service Manual 809230 83

Gouge with the Hand Torch and Machine Torch

Spot weld

Start

Stop

Start

Stop

Spot weld

Start

Stop

Start

Stop

Tabl e 1 – Gouging around the spot weld

Right-handed approach

Left-handed approach

84 809230 Service Manual Powermax45 XP

6. Make sure you have gouged completely through the top layer. Pull the metal plates apart.

7. Use the same gouging process to remove the spot weld that remains on the bottom plate.

 To avoid damaging the

bottom plate, you may want to turn down the output current to 10 A. Increase the current if needed based on the thickness of the metal.

 Hold the torch at a 40° – 45°

angle. Slightly adjust the angle of the torch as needed based on the thickness of the metal.

 Stretch the arc to approximately 10 – 11 mm (3/8 – 1/2 inch) as you gouge.  Use very short strokes in a back-and-forth weaving motion until you have removed the

spot weld.

Gouge with the Hand Torch and Machine Torch

Some scraping or grinding may be required to completely remove all



remnants of the spot weld from the bottom plate.

Spot weld on bottom plate Spot weld removed

Powermax45 XP Service Manual 809230 85

Gouge with the Hand Torch and Machine Torch

Standoff

Angle

Rotation of torch (relative to torch center line)

Torch center line

Speed

Gouge with the machine torch

You can vary the gouge profile by adjusting the:

 Output current (amperage) of the power supply  Angle of the torch to the workpiece  Rotation of the torch relative to the torch center line  Torch-to-work st a n d off  Speed of the torch over the workpiece

See page 80 for more details.

86 809230 Service Manual Powermax45 XP

Typical gouge profiles

Depth

3.2 mm (0.1 inch)

Width

6.8 mm (0.3 inch)

Maximum Control gouging consumables (45 A)

Operating parameters

Speed 254–1016mm/min (10–40in/min)

Standoff 6mm (1/4inch)

Angle 40° – 50°

Output current 26 – 45 A

Consumables Maximum Control gouging consumables

Gas Air

45 A

Metal removal rate on mild steel:

3.4 kg/hour (7.5 pounds/hour)

Gouge with the Hand Torch and Machine Torch

The following tables show the 45 A gouging profile at 40° and 50° on mild steel and stainless steel. These settings are intended to serve as a starting point to help you determine the best gouging profile for a given cutting job. Adjust these settings as needed for your application and table to obtain the desired result.

Tabl e 2 – Mild steel (Metric)

Torch angle Speed (mm/min) Depth (mm) Width (mm) Width/depth ratio

254 4.6 8.4 1.83

508 3.2 6.8 2.13

40°

50°

762 1.9 5.9 3.11

1016 1.4 5.2 3.71

254 5.0 6.7 1.34

508 3.4 5.2 1.53

762 2.7 4.9 1.81

1016 2.2 4.6 2.09

Powermax45 XP Service Manual 809230 87

Gouge with the Hand Torch and Machine Torch

Tabl e 3 – Mild steel (English)

Torch angle Speed (in/min) Depth (inches) Width (inches) Width/depth ratio

10 0.183 0.331 1.81

20 0.126 0.268 2.13

40°

30 0.074 0.231 3.12

40 0.055 0.206 3.74

10 0.195 0.263 1.35

50°

Tabl e 4 – Stainless steel (Metric)

Torch angle Speed (mm/min) Depth (mm) Width (mm) Width/depth ratio

40°

50°

Tabl e 5 – Stainless steel (English)

Torch angle Speed (in/min) Depth (inches) Width (inches) Width/depth ratio

20 0.132 0.205 1.55

30 0.107 0.192 1.79

40 0.088 0.181 2.06

254 2.9 6.2 2.14

508 2.0 5.7 2.85

101 6 1 4.8 4 .8

254 5.3 5.7 1.08

508 3.5 5.0 1.43

1016 2.0 3.8 1.90

10 0.114 0.245 2.15

40°

50°

88 809230 Service Manual Powermax45 XP

20 0.080 0.222 2.76

40 0.048 0.190 3.96

10 0.210 0.224 1.07

20 0.139 0.199 1.43

40 0.080 0.150 1.88

Precision gouging consumables (10 A)

Depth

0.5mm (0.02inch)

Width

2.5 mm (0.1 inch)

Speed 254–762mm/min (10–30in/min)

Standoff 0.3–1.3mm (0.01–0.05inch)*

Angle 40° – 50°

Output current 10 – 2 5 A

Consumables Precision gouging consumables

Gas Air

* Increase the standoff to a maximum of 3 – 4 mm (0.12 – 0.16 inch) for a very light gouge.

10 A

Metal removal rate on mild steel:

0.2 kg/hour (0.5 pounds/hour)

Gouge with the Hand Torch and Machine Torch

Operating parameters

The following tables show the 10 A gouging profile at 40° and 50° on mild steel. These settings are intended to serve as a starting point to help you determine the best gouging profile for a given cutting job. Adjust these settings as needed for your application and table to obtain the desired result.

Tabl e 6 – Mild steel (Metric)

Torch angle Standoff (mm)

0.3 254 0.5 3.3 6.6

0.3 508 0.3 2.4 8

0.3 762 0.1 2.2 22

40°

1.3 254 0.3 3 10

1.3 508 0.1 2.2 22

1.3 762 0.05 1.9 38

Speed

(mm/min)

Depth (mm) Width (mm)

Width/depth

ratio

Powermax45 XP Service Manual 809230 89

Gouge with the Hand Torch and Machine Torch

Torch angle Standoff (mm)

0.3 254 1.1 2.6 2.36

0.3 508 0.6 2.3 3.83

0.3 762 0.4 2.0 5

50°

Tabl e 7 – Mild steel (English)

Torch angle

40°

1.3 254 1.1 2.8 2.55

1.3 508 0.5 2.4 4.8

1.3 762 0.25 2.1 8.4

Standoff

(inches)

0.01 10 0.0207 0.129 6.23

0.01 20 0.0113 0.095 8.41

0.01 30 0.0044 0.088 20

0.05 10 0.0122 0.12 9.84

Speed

(mm/min)

Speed (in/min) Depth (inches) Width (inches)

Depth (mm) Width (mm)

Width/depth

ratio

Width/depth

ratio

50°

0.05 20 0.004 0.088 22

0.05 30 0.002 0.074 37

0.01 10 0.0427 0.103 2.41

0.01 20 0.0222 0.09 4.05

0.01 30 0.0147 0.08 5.44

0.05 10 0.043 0.11 2.56

0.05 20 0.0208 0.095 4.57

0.05 30 0.01 0.084 8.4

90 809230 Service Manual Powermax45 XP

Troubleshooting tips for gouging

When gouging, always make sure:

 Gouging consumables are installed, and the output current matches those consumables.  The power supply is set to Gouge/Marking mode.

Many common metal removal issues can be resolved by installing new consumables in the torch. Do not use worn or damaged consumables.

Problem Solution

Gouge with the Hand Torch and Machine Torch

The arc goes out during gouging.

The torch tip bumps into slag.

The gouge is too deep. • Decrease the angle of the torch to the workpiece.

The gouge is too shallow. • Increase the angle of the torch to the workpiece.

The gouge is too wide. • Increase the angle of the torch to the workpiece.

• Decrease the arc stretch (standoff).

• Increase the angle of the torch to the workpiece.

• Increase the arc stretch (standoff).

• Keep the torch tip pointed in the direction of the gouge you want to create.

• Increase the arc stretch (standoff).

• Increase the gouging speed.

• Decrease the output current. Do not set the output current below 26 A if you are using the Maximum Control gouging consumables.

• Decrease the arc stretch (standoff).

• Decrease the gouging speed.

• Increase the output current. Do not set the output current above 25 A if you are using the Precision gouging consumables.

• Decrease the arc stretch (standoff).

• Increase the gouging speed.

• Decrease the output current. Do not set the output current below 26 A if you are using the Maximum Control gouging consumables.

The gouge is too narrow. • Decrease the angle of the torch to the workpiece.

• Increase the arc stretch (standoff).

• Decrease the gouging speed.

• Increase output current. Do not set the output current above 25 A if you are using the Precision gouging consumables.

Powermax45 XP Service Manual 809230 91

Gouge with the Hand Torch and Machine Torch

Problem Solution

When removing a spot weld, the arc pierces the bottom metal plate.

The spot weld is not visible while gouging.

• Decrease the output current (amperage).

• Make sure the Precision gouging consumables are installed.

• Maintain a steady gouging speed and gouge only until the bottom metal plate is visible.

• Increase the arc stretch to approximately 10 – 11 mm (3/8 – 1/2 inch).

• Stretch the arc to approximately 10 – 11 mm (3/8 – 1/2 inch) for better visibility of the spot weld.

• Make sure the Precision gouging consumables are installed.

• Make sure the output current is not set above 25 A.

92 809230 Service Manual Powermax45 XP

Set Up the Machine Torch

Duramax Lock machine torch features include:

 A torch-disable switch that prevents the torch from firing accidentally even when the power

supply is ON. See Disable the torch on page 46.

 The FastConnect

switch from one torch to another.

 Automatic cooling with ambient air. Special cooling procedures are not needed.

This section provides information on:

 Machine torch components and dimensions  Setup details for installing the torch on X-Y tables, track burners, pipe bevelers, or other

mechanized equipment

quick-disconnect system to easily remove the torch for transport or to

Powermax45 XP Service Manual 809230 93

Set Up the Machine Torch

1 Consumables

2 32-pitch removable gear rack

3 Torch-disable switch

4 To r ch lead

5 Shell

6 Switch position lines

7 Strain relief for torch lead

33 mm

(1.3 inch)

310 mm (12.2 inch)

370 mm (14.6 inch)

35 mm*

(1.4 inch)

212 mm (8.4 inch)

25 mm (1.0 inch)

Machine torch components, dimensions, weights

Components

Dimensions

* This measurement is for the outer dimension of the torch. The height of the outer torch shell is 41 mm

(1.6 inch) when the torch-disable switch is included.

94 809230 Service Manual Powermax45 XP

Weights

10 2 m m 4inch

204 mm 8inch

Diameter = 2 x Radius = 204 mm (8 inches)

Torch We igh t

Machine torch with 7.6 m (25 foot) lead 3.2 kg (7.1 pounds)

Machine torch with 10.7 m (35 foot) lead 4.2 kg (9.3 pounds)

Machine torch with 15 m (50 foot) lead 5.8 kg (12.7 pounds)

Minimum bend radius for torch leads

The recommended minimum bend radius for torch leads is 102 mm (4 inches).

Set Up the Machine Torch

Mount the torch

The machine torch can be mounted on a wide variety of X-Y tables, track burners, pipe bevelers, and other equipment. Install the torch per the table or equipment manufacturer’s instructions.

If your cutting table’s track is large enough for you to route the torch through it without removing the torch shell, do so and then attach the torch to the lifter per the manufacturer’s instructions.

Remove the gear rack

The gear rack can be mounted on either side of the torch. If you need to remove the gear rack, remove the 2 screws that secure the rack to the torch shell.

Powermax45 XP Service Manual 809230 95

Set Up the Machine Torch

Gear rack

When you install the gear rack, tighten the screws by hand. To avoid



stripping the screws, do not overtighten.

Disassemble the machine torch

Use the following procedure if you need to disassemble the torch to route the torch through the cutting table’s track or other mounting system.

NOTICE

While disconnecting and reconnecting the torch parts, do not twist the torch or the lead. Maintain the same orientation between the torch head and torch lead. Twisting the torch head in relation to the torch lead can damage the torch wires.

1. Disconnect the torch from the plasma power supply.

2. Remove the consumables from the torch.

3. Place the torch on a flat surface with the left side of the shell facing up.

The left side of the shell is the side with the screws.



4. Remove the 7 screws from the torch shell. Set the screws aside.

96 809230 Service Manual Powermax45 XP

Set Up the Machine Torch

5. Carefully pry the left side of the shell away from the torch.

6. Remove the plastic slider for the torch-disable switch and set it aside.

7. The torch body fits snugly into the right side of the shell. Gently pry the head of the torch body

out and away from the right side of the shell to remove it.

8. Disconnect the wires that sit in the right shell. Press down the tab on the wire connector to pull the 2 sides apart.

9. You can now route the torch body and the torch lead through the mounting system for the cutting table.

Slide the strain relief along the torch lead as needed to move it out of the



way as you route the torch lead through the track.

Powermax45 XP Service Manual 809230 97

Set Up the Machine Torch

Assemble the machine torch

If you disassembled the torch to route it through the cutting table’s track or other mounting system, use the following procedure to reassemble the torch.

While disconnecting and reconnecting the torch parts, do not twist the



torch or the lead. Maintain the same orientation between the torch head and torch lead. Twisting the torch head in relation to the torch lead can cause damage to the torch wires.

1. Place the right torch shell on a flat surface.

2. Make sure the cap-sensor switch and the torch-disable switch sit in the right torch shell as

shown. Mounting posts in the torch shell hold each switch in place.

3. Connect the wires from the torch body to the wires from the cap-sensor switch/torch-disable switch assembly .

4. Place the wire connector on the mounting shelf in the right torch shell as shown. Route the blue and black wires from the cap-sensor switch and the torch-disable switch outside

of and below the mounting shelf. This helps to prevent the wires from getting pinched and damaged when the torch is fully assembled.

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Set Up the Machine Torch

5. Push the head of the torch body into the right torch shell as shown. Make sure:

 The torch shell fits over the flat edges of the torch head. The rounded edge of the torch

head should be facing up.

 The wire connector from the previous step remains in place on the mounting shelf. Hold

the wire connector in place as you fit the torch body into the torch shell.

6. Fit the rest of the torch body into the right torch shell as shown. As you do, tuck all of the wires under the torch body. Do not pinch or crimp the wires. Make sure none of the wires are covering the screw holes in the torch shell.

7. Fit the strain relief into the base of the right torch shell.

8. Put the plastic slider for the

torch-disable switch into place in the yellow lock (X) position.

If you try to put the torch back



together with the slider in the green “ready to fire” ( ) position, you can damage the torch-disable switch that is inside the shell behind the torch body.

Powermax45 XP Service Manual 809230 99

Set Up the Machine Torch

90°

9. Attach the left torch shell to the right torch shell using the 7 screws. Firmly grasp the torch shells at the base near the strain relief and hold them together as you install the screws.

NOTICE

Be careful to avoid pinching the wires between the torch shells. This can damage the wires and prevent the torch from operating properly.

10. Examine the torch to make sure no wires are pinched where the torch shells meet.

11 . Install the gear rack on the torch shell.

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

13. Reinstall the consumables on the torch. See page 48.

Align the torch

 Mount the machine torch

perpendicular to the workpiece to get a vertical cut. Use a square to align the torch at a 90° angle to the workpiece.

 Position the mounting bracket

lower on the torch to minimize vibration at the tip of the torch.

 Do not overtighten the

mounting bracket. Excessive pressure from the clamp can warp or damage the torch shell over time.

100 809230 Service Manual Powermax45 XP

Hypertherm Manual Family Service Manual (SM)

Specifications and Main Features

Frequently Asked Questions

User Manual

Contents

Electromagnetic Compatibility (EMC)

Warranty

Installation and Setup

System contents

What to do if components are missing or damaged

Hypertherm plasma power supply ratings

Cutting specifications

Recommended cut capacity – handheld

Pierce capacity

Maximum cut speeds (mild steel)

Gouge capacity

Noise levels

Position the plasma power supply

Power supply dimensions and weight

Work lead weights

Connect to electrical power

Install a line-disconnect switch

Requirements for grounding

The system’s rated output (cutting power)

Voltage configurations

CSA/CE/CCC 200 V – 240 V (1-phase)

CSA 208 V (1-phase)

CCC 220 V (1-phase)

CE 230 V (1-phase)

CCC 380 V (3-phase)

CE 400 V (3-phase)

CSA 480 V (3-phase)

Decrease output current and arc stretch for lower rated electrical service

Example: 230 V input on 20 A electrical service

Prepare the power cord

CSA systems

1-phase (200 V – 240 V)

3-phase (480 V)

CE/CCC systems

1-phase (200 V – 240 V)

3-phase (380 V / 400 V)

Extension cord recommendations

Generator recommendations

Adapter for 4-wire 1-phase connections (CSA 1-phase models only)

Connect the gas supply

Gas supply source

High-pressure gas cylinders

Gas flow rates

Minimum inlet pressure (while gas is flowing)

Cutting

Maximum control gouging (26 – 45 A)

Precision gouging / Marking (10 – 25 A)

Additional gas filtration

Controls and indicators

ON (I)/OFF(O) power switch

Operation

Cutting controls

Indicator LEDs

Disable the torch

Warning puffs of air

For hand torches

For machine torches

Operate the plasma system

Step 1 – Install consumables and activate torch

Step 2 – Connect torch lead

Step 3 – Connect gas supply

Step 4 – Connect work lead and work clamp

Work lead

Work clamp

Step 5 – Connect electric power and turn ON the system

Step 6 – Set mode and adjust output current (amperage)

Cutting expanded metal

Step 7 – Check cut settings and indicator LEDs

What to expect during and after cutting

Adjust the gas pressure manually

Reset the gas pressure

Change the gas pressure values between psi and bar

Understand duty cycle to prevent overheating

Cut with the Hand Torch

Hand torch components, dimensions, weights