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.
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.
Assessment of area
Before installing the equipment, the user shall make an assessment
of potential electromagnetic problems in the surrounding area. The
following shall be taken into account:
a. Other supply cables, control cables, signaling and telephone
cables; above, below and adjacent to the cutting equipment.
b. Radio and television transmitters and receivers.
c. Computer and other control equipment.
d. Safety critical equipment, for example guarding of industrial
equipment.
e. Health of the people around, for example the use of
pacemakers and hearing aids.
f. Equipment used for calibration or measurement.
g. Immunity of other equipment in the environment. User shall
ensure that other equipment being used in the environment is
compatible. This may require additional protection measures.
h. Time of day that cutting or other activities are to be carried out.
The size of the surrounding area to be considered will depend on the
structure of the building and other activities that are taking place. The
surrounding area may extend beyond the boundaries of the premises.
Methods of reducing emissions
Mains supply
Cutting equipment must be connected to the mains supply according to
the manufacturer’s recommendations. If interference occurs, it may be
necessary to take additional precautions such as filtering of the mains
supply.
Consideration should be given to shielding the supply cable of
permanently installed cutting equipment, in metallic conduit or
equivalent. Shielding should be electrically continuous throughout its
length. The shielding should be connected to the cutting mains supply
so that good electrical contact is maintained between the conduit and
the cutting power source enclosure.
Maintenance of cutting equipment
The cutting equipment must be routinely maintained according to
the manufacturer’s recommendations. All access and service doors
and covers should be closed and properly fastened when the cutting
equipment is in operation. The cutting equipment should not be
modified in any way, except as set forth in and in accordance with the
manufacturer’s written instructions. For example, the spark gaps of
arc striking and stabilizing devices should be adjusted and maintained
according to the manufacturer’s recommendations.
Cutting cables
The cutting cables should be kept as short as possible and should be
positioned close together, running at or close to the floor level.
Equipotential bonding
Bonding of all metallic components in the cutting installation and
adjacent to it should be considered.
However, metallic components bonded to the workpiece will increase
the risk that the operator could receive a shock by touching these
metallic components and the electrode (nozzle for laser heads) at the
same time.
The operator should be insulated from all such bonded metallic
components.
Compliance Information SC-1
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 in crease
the risk of injury, for example, by allowing parallel cutting current return
paths which may damage the earth circuits of other equipment. Further
guidance is provided in IEC 60974-9, Arc Welding 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-2 Compliance Information
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 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.
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 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.
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.
Compliance Information SC-3
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 inthe aggregate
the amount paid for the Products that gave rise to suchclaim.
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.
SC-4 Compliance Information
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.
Powermax65/85 Service Manual
v
vi Powermax65/85 Service Manual
TABLE OF CONTENTS
Section 1
Specifications
Safety information ................................................................................................................................................................................... 1-2
System description ................................................................................................................................................................................. 1-2
Where to find information .....................................................................................................................................................................1-3
Power supply dimensions ..................................................................................................................................................................... 1-4
Powermax65 power supply ratings ....................................................................................................................................................1-6
Powermax85 power supply ratings ....................................................................................................................................................1-8
Duramax 75° hand torch dimensions .............................................................................................................................................. 1-10
Duramax 15° hand torch dimensions .............................................................................................................................................. 1-10
Symbols and marks ............................................................................................................................................................................. 1-14
Unpack the Powermax65 or Powermax85 system .........................................................................................................................2-2
Position the power supply.....................................................................................................................................................................2-4
Prepare the electrical power ................................................................................................................................................................2-4
Install a line-disconnect switch .................................................................................................................................................2-5
Requirements for grounding ...................................................................................................................................................... 2-5
Power connection for the Powermax65 ............................................................................................................................................2-6
Single-phase power cord (not for CE/CCC model) ............................................................................................................ 2-7
Three-phase power cord – plug installation ..........................................................................................................................2-7
Power connection for the Powermax85 ............................................................................................................................................2-8
Single-phase power cord (not for CE/CCC model) ............................................................................................................ 2-9
Single-phase power cord installation ................................................................................................................................... 2-10
Three-phase power cord – plug installation ....................................................................................................................... 2-11
Prepare the gas supply ....................................................................................................................................................................... 2-14
Additional gas filtration ............................................................................................................................................................. 2-14
Connect the gas supply ........................................................................................................................................................... 2-15
Consumable life .......................................................................................................................................................................................3-2
CopperPlus™ electrode for Duramax torches........................................................................................................................3-2
Hand torch setup .................................................................................................................................................................................... 3-3
Choose the hand torch consumables .....................................................................................................................................3-4
Hand torch consumables ...........................................................................................................................................................3-4
Install the hand torch consumables ..........................................................................................................................................3-6
Converting a full-length machine torch to a mini machine torch ....................................................................................... 3-8
Mount the torch .......................................................................................................................................................................... 3-10
Choose the machine torch consumables ............................................................................................................................ 3-12
Install the machine torch consumables ................................................................................................................................ 3-15
Aligning the torch ...................................................................................................................................................................... 3-15
Connecting an optional remote-start pendant ................................................................................................................... 3-16
Connecting an optional machine interface cable ............................................................................................................... 3-17
Connecting an optional RS-485 serial interface cable .................................................................................................... 3-21
Connecting the torch lead ................................................................................................................................................................. 3-22
Using the cut charts ............................................................................................................................................................................ 3-23
85 A unshielded consumables ............................................................................................................................................... 3-43
65 A unshielded consumables ............................................................................................................................................... 3-47
45 A unshielded consumables ............................................................................................................................................... 3-51
Section 4
Operation
Controls and indicators ......................................................................................................................................................................... 4-2
Front controls and LEDs ............................................................................................................................................................. 4-2
Status screen ................................................................................................................................................................................4-4
Operating the Powermax65 or Powermax85 ................................................................................................................................... 4-6
Connect the electrical power, gas supply, and torch lead .................................................................................................4-6
Attach the work lead to the power supply .............................................................................................................................. 4-7
Attach the work clamp to the workpiece ................................................................................................................................4-8
Turn ON the system ..................................................................................................................................................................... 4-9
Set the operating mode switch ................................................................................................................................................. 4-9
Check the indicators ................................................................................................................................................................. 4-10
Manually adjusting the gas pressure ..................................................................................................................................... 4-10
Adjusting the current (amperage) .......................................................................................................................................... 4-11
Using the hand torch ........................................................................................................................................................................... 4-13
Operate the safety trigger ....................................................................................................................................................... 4-13
Hand torch cutting hints .......................................................................................................................................................... 4-14
Start a cut from the edge of the workpiece......................................................................................................................... 4-15
Pierce a workpiece .................................................................................................................................................................... 4-16
Gouge a workpiece .................................................................................................................................................................. 4-17
Common hand-cutting faults .................................................................................................................................................. 4-20
Using the machine torch .................................................................................................................................................................... 4-21
Ensure the torch and table are set up correctly ................................................................................................................. 4-21
Understand and optimize cut quality ..................................................................................................................................... 4-21
To pierce a workpiece using the machine torch ................................................................................................................ 4-23
Common machine-cutting faults ............................................................................................................................................ 4-24
Section 5
Troubleshooting and System Tests
Controls and indicators ......................................................................................................................................................................... 5-3
Theory of operation .................................................................................................................................................................................5-4
General ...........................................................................................................................................................................................5-4
200 – 600 V CSA 1- or 3-phase power supply functional description .......................................................................... 5-4
380/400 V CCC/CE 3-phase power supply functional description ............................................................................... 5-5
Sequence of operation ................................................................................................................................................................ 5-6
Test equipment .............................................................................................................................................................................5-7
Troubleshooting procedures and sequence .......................................................................................................................... 5-7
Check the power switch ............................................................................................................................................................. 5-9
Indicator LEDs and device tests ............................................................................................................................................ 5-12
IGBT test preparation ............................................................................................................................................................... 5-13
IGBT device test using the Hypertherm tester ................................................................................................................... 5-14
Troubleshoot the Hypertherm IGBT tester .......................................................................................................................... 5-14
Schematic for building an IGBT tester ................................................................................................................................. 5-15
IGBT device test using a non-Hypertherm tester .............................................................................................................. 5-16
200 – 600 V CSA power supply overview .................................................................................................................................... 5-17
380/400 V CCC/CE power supply overview ............................................................................................................................... 5-18
200 – 600 V CSA power supply overview (power board removed) ....................................................................................... 5-19
380/400 V CCC/CE power supply overview (power board removed) .................................................................................. 5-20
Displaying the service screen ................................................................................................................................................. 5-21
Important fault icons ................................................................................................................................................................. 5-22
Performing a cold restart ......................................................................................................................................................... 5-22
Fault codes and solutions ........................................................................................................................................................ 5-23
System tests.......................................................................................................................................................................................... 5-38
Test 1 – Voltage input .............................................................................................................................................................. 5-39
Test 2 – DC Power Bus .......................................................................................................................................................... 5-40
Test 3 – Output diodes............................................................................................................................................................ 5-43
Test 4 – Inverter and PFC temperature sensor .................................................................................................................. 5-44
Test 5 – Flyback circuit (DC minor voltages) ..................................................................................................................... 5-46
Test 6 – Torch stuck open (TSO) ......................................................................................................................................... 5-49
Test 7 – Start signal ................................................................................................................................................................. 5-51
Test 8 – Torch cap switch ...................................................................................................................................................... 5-52
Test 9 – Electronic regulator .................................................................................................................................................. 5-53
Test 10 – Pressure sensor ...................................................................................................................................................... 5-54
Test 11 – Fan ............................................................................................................................................................................. 5-55
Test 12 – AUX switch .............................................................................................................................................................. 5-56
Section 6
Component Replacement
Remove and replace the power supply cover and component barrier .......................................................................................6-3
Remove the power supply cover and component barrier ................................................................................................... 6-3
Replace the component barrier .................................................................................................................................................6-4
Replace the power supply cover ..............................................................................................................................................6-5
Replace the power cord ........................................................................................................................................................................ 6-6
Replace the power cord (200–600V 3-phase CSA, 380/400V 3-phase CCC/CE) ............................................6-6
Replace the power cord (200 – 480 V 1-phase CSA) ................................................................................................... 6-11
Replace the power switch ................................................................................................................................................................. 6-12
Loosen the old power switch ................................................................................................................................................. 6-12
Remove the old power switch (CE model).......................................................................................................................... 6-13
Remove the old power switch (CSA model) ...................................................................................................................... 6-14
Install the new power switch (CE model) ............................................................................................................................ 6-15
Install the new power switch (CSA model) ......................................................................................................................... 6-16
Attach the power switch and label (all models) ................................................................................................................. 6-17
Replace the work lead ........................................................................................................................................................................ 6-18
Replace the fan .................................................................................................................................................................................... 6-19
Replace the air filter element and air filter bowl ............................................................................................................................ 6-21
Remove the air filter bowl ........................................................................................................................................................ 6-21
Identify the air filter assembly model ..................................................................................................................................... 6-22
Install the air filter element for plastic or nylon bowl.......................................................................................................... 6-23
Install the air filter element for metal guarded bowl ........................................................................................................... 6-24
Install the air filter bowl (metalguarded, plastic, or nylon) ............................................................................................... 6-25
Replace the air filter assembly .......................................................................................................................................................... 6-26
Remove the air filter assembly ................................................................................................................................................ 6-26
Install the air filter assembly .................................................................................................................................................... 6-28
xPowermax65/85 Service Manual
TABLE OF CONTENTS
Replace the solenoid valve ................................................................................................................................................................ 6-29
Remove the outer components .............................................................................................................................................. 6-29
Remove the old solenoid valve ............................................................................................................................................... 6-30
Install the new solenoid valve ................................................................................................................................................. 6-31
Reinstall the outer components ............................................................................................................................................. 6-31
Replace the power board .................................................................................................................................................................. 6-32
Remove the DSP board ........................................................................................................................................................... 6-32
Replace the power board (380/400V CE) ......................................................................................................................... 6-34
Replace the power board (200 – 600V CSA) ................................................................................................................... 6-37
Install the DSP board ............................................................................................................................................................... 6-40
Replace the component barrier and power supply cover. ............................................................................................... 6-41
Replace the bulk capacitors .............................................................................................................................................................. 6-42
Remove the old bulk capacitors ............................................................................................................................................. 6-42
Install the new bulk capacitors ............................................................................................................................................... 6-44
Replace the control board or ribbon cable .................................................................................................................................... 6-45
Replace the heat sink components ................................................................................................................................................. 6-47
65A CE ........................................................................................................................................................................................ 6-49
85A CE ........................................................................................................................................................................................ 6-51
Replace the transformer ..................................................................................................................................................................... 6-52
Remove the old transformer .................................................................................................................................................... 6-52
Install the new transformer ...................................................................................................................................................... 6-54
Replace the PFC inductor ................................................................................................................................................................. 6-57
Remove the old PFC inductor (CE model) .......................................................................................................................... 6-57
Install the new PFC inductor (CE model) ............................................................................................................................ 6-59
Remove the old PFC inductor (CSA model) ...................................................................................................................... 6-61
Install the new PFC inductor (CSA model) ......................................................................................................................... 6-63
Section 7
Parts
Power supply parts ................................................................................................................................................................................. 7-2
Exterior, front .................................................................................................................................................................................7-2
Interior, power board side (200 – 600V CSA) .....................................................................................................................7-5
Interior, power board side (380/400V CE) ............................................................................................................................ 7-6
Interior, fan side ............................................................................................................................................................................7-7
65A CE ........................................................................................................................................................................................ 7-10
85A CE ........................................................................................................................................................................................ 7-12
Powermax65/85 Service Manual
xi
TABLE OF CONTENTS
Duramax 75° hand torch replacement parts .................................................................................................................................. 7-13
Duramax 15° hand torch replacement parts .................................................................................................................................. 7-14
Hand torch consumables ................................................................................................................................................................... 7-15
Duramax 180° full-length machine torch replacement parts ..................................................................................................... 7-16
Duramax 180° mini machine torch replacement parts ................................................................................................................ 7-18
Recommended spare parts ............................................................................................................................................................... 7-25
Safety information ................................................................................................................................................................................... 1-2
System description ................................................................................................................................................................................. 1-2
Where to find information .....................................................................................................................................................................1-3
Power supply dimensions ..................................................................................................................................................................... 1-4
Powermax65 power supply ratings ....................................................................................................................................................1-6
Powermax85 power supply ratings ....................................................................................................................................................1-8
Duramax 75° hand torch dimensions .............................................................................................................................................. 1-10
Duramax 15° hand torch dimensions .............................................................................................................................................. 1-10
Symbols and marks ............................................................................................................................................................................. 1-14
Before you set up and operate your Hypertherm system, read the separate Safety and Compliance Manual included
with your system for important safety information.
System description
The Powermax65 and Powermax85 are highly portable, 65-amp and 85-amp, handheld and mechanized plasma cutting
systems appropriate for a wide range of applications. The Powermax systems use air or nitrogen to cut electrically
conductive metals, such as mild steel, stainless steel, or aluminum. Smart Sense™ technology automatically adjusts the
gas pressure according to cutting mode and torch lead length for optimum cutting.
The Powermax65 can cut thicknesses up to 1 inch (25mm) with a handheld torch and pierce thicknesses up to
5/8inch (16mm). The Powermax85 can cut thicknesses up to 1-1/4inches (32mm) and pierce thicknesses up to
3/4inch (19mm). FastConnect™ provides a simple push-button torch connection to the power supply for quick torch
changes.
The typical handheld Powermax system includes a Duramax™ series 75° hand torch with a consumables box and work
lead cable. Reference materials include: operator manual, quick setup card, registration card, setup DVD, and safety
manual.
The typical mechanized Powermax system includes a Duramax series 180° full-length machine torch with a consumables
box, work lead cable, and remote-start pendant. Reference materials include: operator manual, quick setup card,
registration card, setup DVD, and safety manual.
You can order additional styles of torches, consumables, and accessories – such as the plasma cutting guide – from
any Hypertherm distributor. See the Parts section for a list of spare and optional parts.
Powermax65 and Powermax85 power supplies are shipped without a plug on the power cord. See Section 2 Power Supply Setup for more information.
1-2Powermax65/85 Service Manual
SPECIFICATIONS
Where to find information
System specifications such as size, weight, detailed electrical specifications, and cut speeds can be found in this
section. For information on:
• Setup requirements, including power requirements, grounding, power cord configurations, extension cord
requirements, and generator recommendations – see Section 2, Power Supply Setup.
• Handheld and machine torch consumables, cut charts, and torch setup information – see Section 3, Torch Setup.
• Information about the controls and LEDs, steps for system operation, and hints for improving cut quality – see
Section 4, Operation.
• Maintenance and repair – see the troubleshooting section.
• Replacing components – see the Component replacement section (Service Manual).
• Part numbers and ordering information for accessories, consumables, and replacement parts – see the Parts
section.
• Timing and schematic diagrams – see the Wiring diagrams section (Service Manual).
Powermax65/85Service Manual 1-3
SPECIFICATIONS
Power supply dimensions
17.0 in
(432 mm)
19.0 in
(483 mm)
9.2 in
(234 mm)
1-4 Powermax65/85 Service Manual
Component weights
65 A CSA65 A CE/CCC85 A CSA85 A CE/CCC
lbs (kg)lbs (kg)lbs (kg)lbs (kg)
Power supply54.1 (24.5)47.0 (21.3)59.9 (27.2)50.4 (22.8)
65/85 A
lbs (kg)
Hand torch 7.6 m (25 ft)6.8 (3.1)
Hand torch 15 m (50 ft)12.2 (5.5)
Hand torch 23 m (75 ft)17.6 (8.0)
Machine torch 7.6 m (25 ft)7.6 (3.4)
Machine torch 15 m (50 ft)13.2 (6.0)
Machine torch 23 m (75 ft)18.8 (8.5)
65 A85 A
lbs (kg)lbs (kg)
Work lead 7.6 m (25 ft)2.8 (1.3)6.8 (3.1)
Work lead 15 m (50 ft)5.0 (2.3)7.5 (3.4)
Work lead 23 m (75 ft)6.9 (3.1)10.6 (4.8)
SPECIFICATIONS
The recommended minimum bend radius for Powermax65/85 torch leads is 76mm (3.0inches).
76mm
(3.0inch)
76mm
(3.0inch)
Diameter=2 x Radius=152mm (6.0inches)
152mm
(6.0inch)
Powermax65/85Service Manual 1-5
SPECIFICATIONS
Powermax65 power supply ratings
Rated open-circuit voltage (U0)
CSA, 1-phase, 3-phase
CE/CCC, 3-phase
Output characteristic
*
Rated output current (I2)20 – 65 A
Rated output voltage (U2)139 VDC
CSA 296 VDC
CE/CCC 270 VDC
Drooping
Duty cycle at 40° C (104° F)
(See data plate on power supply
for more information on duty
cycle.)
CSA
CCC/CE
50% @ 65 A, 230 – 600 V, 1/3 PH
40% @ 65 A, 200 – 208 V, 1/3 PH
100% @ 46 A, 230 – 600 V, 1/3 PH
50% @ 65 A, 380/400 V, 3 PH
100% @ 46 A, 380/400 V, 3 PH
Operating temperature14° to 104° F (-10° to 40° C)
Storage temperature-13° to 131° F (-25° to 55° C)
Power factor
200 – 480 V CSA, 1-phase
200 – 600 V CSA, 3-phase
380/400 V CCC/CE,
0.99 – 0.97
0.94 – 0.73
0.94
3-phase
R
– Short Circuit Ratio (CE/CCC models only)U1 – Volts AC rms, 3PHR
sce
400 VAC225.7
EMC classification CISPR 11 (CE/CCC models
‡
only)
Input voltage (U1)/ Input
current (I1) at rated output (U
, I
MAX
) (See Section 2
2 MAX
2
CSA
Power Supply Setup for more
information.)
CCC/CE
Class A
200/208/240/480 V, 1 PH, 50/60 Hz
52/50/44/22 A
200/208/240/480/600 V, 3 PH, 50/60 Hz
32/31/27/13/13 A
* Defined as a plot of output voltage versus output current.
**
Equipment complies with IEC 61000-3-12 provided that the short-circuit power Ssc is greater than or equal to
2035KVA 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
†
Equipment complies with IEC 61000-3-11 provided that the supply impedance, Zmax, is 0.201 or less. 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 impedance of 0.201 or less.
‡
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 ensuring electromagnetic
compatibility in those locations, due to conducted as well as radiated disturbances.
greater than or equal to 2035 KVA.
sc
Powermax65/85Service Manual 1-7
SPECIFICATIONS
Powermax85 power supply ratings
Rated open-circuit voltage (U0)
CSA, single-phase, 3-phase
CCC/CE, 3-phase
Output characteristic
*
Drooping
Rated output current (I2)25 – 85 A
Rated output voltage (U2)143 VDC
Duty cycle at 40° C (104° F)
(See data plate on power supply
for more information on duty
cycle.)
Operating temperature14° to 104° F (-10° to 40° C)
Storage temperature-13° to 131° F (-25° to 55° C)
Power factor
200 – 480 V CSA, 1-phase
200 – 600 V CSA, 3-phase
380/400 V CCC/CE,
0.99 – 0.96
0.94 – 0.76
0.94
3-phase
R
– Short Circuit Ratio (CCC/CE models only)U1 – Volts AC rms, 3PHR
sce
EMC classification CISPR 11 (CCC/CE models
‡
only)
Input voltage (U1)/ Input
current (I1) at rated output
(U
2MAX
, I
) (See Section 2
2 MAX
Power Supply Setup for more
information.)
Gas typeAirNitrogen
Gas qualityClean, dry, oil-free per
60% @ 85 A, 230 – 600 V, 3 PH
60% @ 85 A, 480 V, 1 PH
50% @ 85 A, 240 V, 1 PH
50% @ 85 A 200 – 208 V, 3 PH
40% @ 85 A 200 – 208 V, 1 PH
100% @ 66 A, 230 – 600 V, 1/3 PH
60% @ 85 A, 380/400 V, 3 PH
100% @ 66 A, 380/400 V, 3 PH
400 VAC225.7
Class A
200/208/240/480 V, 1 PH, 50/60 Hz
70/68/58/29 A
200/208/240/480/600 V, 3 PH, 50/60 Hz
42/40/35/18/17 A
**,†
380/400 V, 3 PH, 50/60 Hz
20.5/19.5 A
99.95% pure
sce
1-8Powermax65/85 Service Manual
SPECIFICATIONS
* Defined as a plot of output voltage versus output current.
**
Equipment complies with IEC 61000-3-12 provided that the short-circuit power Ssc is greater than or equal to
2035KVA 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
†
Equipment complies with IEC 61000-3-11 provided that the supply impedance, Zmax, is 0.201 or less. 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 impedance of 0.201 or less.
‡
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 ensuring electromagnetic
compatibility in those locations, due to conducted as well as radiated disturbances.
greater than or equal to 2035 KVA.
sc
Powermax65/85Service Manual 1-9
SPECIFICATIONS
Duramax 75° hand torch dimensions
9.9 in
(25.2 cm)
75°
3.8 in
(9.8 cm)
angle
1.0 in
(2.5 cm)
Duramax 15° hand torch dimensions
15°
1.9 in
(4.7 cm)
angle
1.0 in
(2.5 cm)
2.6 in
(6.6 cm)
10.2 in
(25.9 cm)
2.6 in
(6.6 cm)
1-10 Powermax65/85 Service Manual
Duramax 180° full-length machine torch dimensions
15.6 in
(39.6 cm)
1.0 in
(2.5 cm)
8.1 in
(20.6 cm)
12.3 in
(31.3 cm)
1.4 in
(3.5 cm)
Duramax 180° mini machine torch dimensions
6.6 in
(16.8 cm)
SPECIFICATIONS
1.4 in (3.6 cm) outer
dimension, 1.3 in
(3.3cm) flat sides
1.0 in
(2.5 cm)
1.4 in
(3.5 cm)
3.3 in
(8.4 cm)
1.4 in (3.6 cm) outer
dimension, 1.3 in
(3.3cm) flat sides
Powermax65/85Service Manual 1-11
SPECIFICATIONS
Powermax65 cutting specifications
Handheld cut capacity (material thickness)
Recommended cut capacity at 20 ipm (500 mm/min)*3/4 in (19 mm)
Recommended cut capacity at 10 ipm (250 mm/min)*1 in (25 mm)
Severance capacity at 5 ipm (125 mm/min)*1-1/4 in (32 mm)
Pierce capacity (material thickness)
Pierce capacity for handheld cutting, or mechanized
cutting with torch height control
Pierce capacity for mechanized cutting without torch
height control
Maximum cut speed** (mild steel)
1/4 in (6 mm)145 ipm (4000 mm/min)
1/2 in (12 mm)50 ipm (1400 mm/min)
3/4 in (19 mm)24 ipm (600 mm/min)
1 in (25 mm)12 ipm (320 mm/min)
Gouging capacity
Maximum Removal metal removal rate on mild steel10.7 lbs/hr (4.8 kg/hr)
Maximum Control metal removal rate on mild steel7.5 lbs/hr (3.4 kg/hr)
Duramax series torch weights (refer to 1-5 Component weights)
Duty cycle and voltage information (refer to 1-6 Powermax65 power supply ratings)
5/8 in (16 mm)
1/2 in (12 mm)
* Cut capacity speeds are not necessarily maximum speeds. They are the speeds that must be achieved to be rated
atthat thickness.
** Maximum cut speeds are the results of Hypertherm’s laboratory testing. Actual cutting speeds may vary based
ondifferent cutting applications.
1-12 Powermax65/85 Service Manual
Powermax85 cutting specifications
Handheld cut capacity (material thickness)
Recommended cut capacity at 20 ipm (500 mm/min)*1 in (25 mm)
Recommended cut capacity at 10 ipm (250 mm/min)*1-1/4 in (32 mm)
Severance capacity at 5 ipm (125 mm/min)*1-1/2 in (38 mm)
Pierce capacity (material thickness)
Pierce capacity for handheld cutting, or mechanized
cutting with torch height control
Pierce capacity for mechanized cutting without torch
height control
Maximum cut speed** (mild steel)
1/4 in (6 mm)200 ipm (5500 mm/min)
1/2 in (12 mm)70 ipm (2000 mm/min)
3/4 in (19 mm)36 ipm (900 mm/min)
1 in (25 mm)21 ipm (550 mm/min)
1-1/4 in (32 mm)13 ipm (330 mm/min)
Gouging capacity
Maximum Removal metal removal rate on mild steel19.5 lbs/hr (8.8 kg/hr)
Maximum Control metal removal rate on mild steel13.7 lbs/hr (6.2 kg/hr)
Duramax series torch weights (refer to 1-5 Component weights)
Duty cycle and voltage information (refer to 1-8 Powermax85 power supply ratings)
3/4 in (19 mm)
5/8 in (16 mm)
SPECIFICATIONS
* Cut capacity speeds are not necessarily maximum speeds. They are the speeds that must be achieved to be rated
atthat thickness.
** Maximum cut speeds are the results of Hypertherm’s laboratory testing. Actual cutting speeds may vary based
ondifferent cutting applications.
Powermax65/85Service Manual 1-13
SPECIFICATIONS
Symbols and marks
Your product may have one or more of the following markings on or near the data plate. Due to differences and conflicts
in national regulations, not all marks are applied to every version of a product.
S mark
The S mark indicates that the power supply and torch are suitable for operations carried out in environments with increased
hazard of electrical shock according to IEC 60974-1.
CSA mark
Products with a CSA mark meet the United States and Canadian regulations for product safety. The products were
evaluated, tested, and certified by CSA-International. Alternatively, the product may have a mark by one of the other
Nationally Recognized Testing Laboratories (NRTL) accredited in both the United States and Canada, such as UL or TÜV.
CE mark
The CE marking signifies the manufacturer’s declaration of conformity to applicable European directives and standards. Only
those versions of products with a CE marking located on or near the data plate have been tested for compliance with the
European Low Voltage Directive and the European Electromagnetic Compatibility (EMC) Directive. EMC filters needed to
comply with the European EMC Directive are incorporated within versions of the product with a CE marking.
Eurasian Customs Union (CU) mark
CE versions of products that include an EAC mark of conformity meet the product safety and EMC requirements for export
to Russia, Belarus, and Kazakhstan.
GOST-TR mark
CE versions of products that include a GOST-TR mark of conformity meet the product safety and EMC requirements for
export to the Russian Federation.
C-Tick mark
CE versions of products with a C-Tick mark comply with the EMC regulations required for sale in Australia and New
Zealand.
CCC mark
s
The China Compulsory Certification (CCC) mark indicates that the product has been tested and found compliant with
product safety regulations required for sale in China.
UkrSEPRO mark
The CE versions of products that include a UkrSEPRO mark of conformity meet the product safety and EMC requirements
for export to the Ukraine.
Serbian AAA mark
CE versions of products that include a AAA Serbian mark meet the product safety and EMC requirements for export to
Serbia.
1-14Powermax65/85 Service Manual
SPECIFICATIONS
IEC symbols
The following symbols may appear on the power supply data plate, control labels, switches, LEDs, and LCD screen.
Direct current (DC)lPower is ON
Alternating current
(AC)
Plasma torch cutting
O
1~
f
1
f
2
Power is OFF
An inverter-based power
source, either 1-phase or
3-phase
Plate metal cutting
Expanded metal
cutting
AC
Volt/amp curve,
“drooping” characteristic
Power is ON (LED)
GougingSystem fault (LED)
AC input power
connection
The terminal for the
external protective
(earth) conductor
Inlet gas pressure fault
(LCD)
Missing or loose
consumables (LCD)
Power supply is out of
temperature range (LCD)
Powermax65/85Service Manual 1-15
SPECIFICATIONS
1-16 Powermax65/85 Service Manual
Section 2
POWER SUPPLY SETUP
In this section:
Unpack the Powermax65 or Powermax85 system .........................................................................................................................2-2
Position the power supply.....................................................................................................................................................................2-4
Prepare the electrical power ................................................................................................................................................................2-4
Install a line-disconnect switch .................................................................................................................................................2-5
Requirements for grounding ...................................................................................................................................................... 2-5
Power connection for the Powermax65 ............................................................................................................................................2-6
Single-phase power cord (not for CE/CCC model) ............................................................................................................ 2-7
Three-phase power cord – plug installation ..........................................................................................................................2-7
Power connection for the Powermax85 ............................................................................................................................................2-8
Single-phase power cord (not for CE/CCC model) ............................................................................................................ 2-9
Single-phase power cord installation ................................................................................................................................... 2-10
Three-phase power cord – plug installation ....................................................................................................................... 2-11
Prepare the gas supply ....................................................................................................................................................................... 2-14
Additional gas filtration ............................................................................................................................................................. 2-14
Connect the gas supply ........................................................................................................................................................... 2-15
Powermax65/85 Service Manual 2-1
POWER SUPPLY SETUP
Unpack the Powermax65 or Powermax85 system
1. Verify that all items on your order have been received in good condition. Contact your distributor if any parts are
damaged or missing.
2. Inspect the power supply for damage that may have occurred during shipping. If there is evidence of damage, refer
to “Claims” below. All communications regarding this equipment must include the model number and the serial
number located on the back of the power supply.
3. Before you set up and operate this Hypertherm system, read the separate Safety and Compliance Manual included
with your system for important safety information.
Claims
• Claims for damage during shipment – If your unit was damaged during shipment, youmust file a claim
with the carrier. Hypertherm will furnish you with a copy of the bill oflading upon request. If you need additional
assistance, call the nearest Hypertherm office listed in the front of this manual.
• Claims for defective or missing merchandise – If any component is missing or defective, contact your
Hypertherm distributor. If you need additional assistance, call thenearest Hypertherm office listed in the front of
this manual.
2-2 Powermax65/85 Service Manual
Contents
Verify the items in the box against the illustration.
Operator Manual
Quick Setup Card
Registration Card
Setup DVD
Safety Manual
Remote-start pendant (optional)
POWER SUPPLY SETUP
Or
Box with extra
consumables
(located next
to air filter)
Powermax65/85 Service Manual 2-3
POWER SUPPLY SETUP
Position the power supply
Locate the power supply near an appropriate power receptacle for your installation: 200–480 volts (CSA 1-phase),
200–600 volts (CSA 3-phase), or 380/400 volts (3-phase CCC/CE). The power supply has a 10-foot (3m) power
cord. Allow at least 10inches (0.25m) of space around the power supply for proper ventilation.
The power supply is not suitable for use in rain or snow.
To avoid toppling, do not set the power supply on an incline greater than 10 degrees.
Prepare the electrical power
Hypertherm (designated HYP on the data plate) input current ratings are used to determine conductor sizes for power
connection and installation instructions. The HYP rating is determined under maximum normal operating conditions and
the higher HYP input current value should be used for installation purposes.
The maximum output voltage will vary based on your input voltage and the circuit’s amperage. Because the current draw
varies during startup, slow-blow fuses are recommended as shown in the charts below. Slow-blow fuses can withstand
currents up to 10 times the rated value for short periods of time.
Caution: Protect the circuit with appropriately sized time-delay (slow-blow) fuses and a
line-disconnect switch.
2-4 Powermax65/85 Service Manual
POWER SUPPLY SETUP
Install a line-disconnect switch
Use a line-disconnect switch for each power supply so that the operator can turn off the incoming power quickly in an
emergency. Locate 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. In addition, the switch should:
• 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 2-6 Power connection for the Powermax65 or 2-8 Power connection for the Powermax85 for recommended fuse sizes.
Requirements for grounding
To ensure 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.
• Single-phase service must be of the 3-wire type with a green or green/yellow wire for the protective earth
ground and must comply with national and local requirements. Do not use a 2-wire service.
• 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 separate Safety and Compliance Manual included with your system for more information on
grounding.
Powermax65/85 Service Manual 2-5
POWER SUPPLY SETUP
Power connection for the Powermax65
The Powermax65 CSA model is a universal power supply that can configure itself to operate with AC voltages from
200to 600, 1- or 3-phase. The CCC/CE model is 380/400 V, 3-phase only. The rated output is 25 – 65A, 139 VDC.
CSA modelSingle-phaseThree-phase
Input voltage200 – 208230 – 240480200 – 208230 – 240400480600
Input current at
9.0kw output
Input current
during arc stretch
Fuse (slow-blow)8080405050302525
CE/CCC modelThree-phase
Input voltage380/400
Input current at
9.0kw output
Input current
during arc stretch
Fuse (slow-blow)30
5244223227151313
7474384545272323
15.5/15
27
2-6Powermax65/85 Service Manual
POWER SUPPLY SETUP
Single-phase power cord (not for CE/CCC model)
To operate your Powermax65 on 1-phase power, you will need to install an appropriate power cord. Refer to 2-10
Single‑phase power cord installation for instructions.
Caution: When using the Powermax65 CSA model power supply with a 1-phase power
source, replace the supplied power cord with an 8 AWG (10 mm2) 3-wire power
cord. The power cord must be connected by a licensed electrician. (CE/CCC
model is 3-phase only.)
Three-phase power cord – plug installation
The Powermax65 power supplies are shipped with an 8 AWG 4-wire power cord on CSA models. A 2.5 mm2, 4-wire
style H07RN-F* power cord is provided on CE/CCC models. To operate the Powermax65, use a plug that meets
national and local electrical codes. The plug must be connected to the power cord by a licensed electrician.
The procedure is similar to installing a single-phase power cord as shown in the section 2-10 Single‑phase power cord installation. The figure below shows the additional wire connected to L3.
* Style H07RN-F cord is a harmonized, heavy duty, flexible, rubber insulated, black neoprene jacketed multi-conductor
IEC60245-4/ EN50525 European power cord with “CE” printed on the cord. The H07RN-F cord used by
Hypertherm also has CCC certification to GB/T5013.4 with “CCC” printed on the cord.
L1
L2
L3
Powermax65/85 Service Manual 2-7
POWER SUPPLY SETUP
Power connection for the Powermax85
The Powermax85 CSA model is a universal power supply that can configure itself to operate with AC voltages from
200to 600, 1- or 3-phase (600V 3-phase only). The CCC/CE model is 380/400 V, 3-phase only. The rated output is
25 – 85A, 143 VDC.
CSA modelSingle-phaseThree-phase
Input voltage200 – 208230 – 240480200 – 208230 – 240 400480600
Input current at
12.2 kw output
Input current
during arc stretch
Fuse (slow-blow)100100506060403030
CE/CCC modelThree-phase
Input voltage380/400
Input current at
12.2 kw output
Input current
during arc stretch
Fuse (slow-blow)40
7060294236211817
9898506060383130
20.5/20
38
2-8Powermax65/85 Service Manual
POWER SUPPLY SETUP
Single-phase power cord (not for CE/CCC model)
To operate your Powermax85 on 1-phase power, you will need to install an appropriate power cord. Refer to 2-10
Single‑phase power cord installation for instructions.
Caution: When using the Powermax85 CSA model power supply with a 1-phase power
source, replace the supplied power cord with a 6AWG (16 mm2) 3-wire power
cord. The power cord must be connected by a licensed electrician. (CE/CCC
model is 3-phase only.)
Powermax65/85 Service Manual 2-9
POWER SUPPLY SETUP
Single-phase power cord installation
Strip and prepare the power cord wires as shown below.
14.5 in
(368 mm)
L1
Ground
4 in
(102 mm)
L2
#10
Route lead through
strainrelief and tighten
L1
L2
Power switch
Ground screw
2-10Powermax65/85 Service Manual
POWER SUPPLY SETUP
Three-phase power cord – plug installation
The Powermax85 power supplies are shipped with an 8 AWG 4-wire power cord on CSA models. A 4 mm2, 4-wire
style H07RN-F* power cord is provided on CE/CCC models. To operate the Powermax85, use a plug that meets
national and local electrical codes. The plug must be connected to the power cord by a licensed electrician.
The procedure is similar to installing a single-phase power cord as shown in the section 2-10 Single‑phase power cord installation. The figure below shows the additional wire connected to L3.
L1
L2
* Style H07RN-F cord is a harmonized, heavy duty, flexible, rubber insulated, black neoprene jacketed multi-conductor
IEC60245-4/ EN50525 European power cord with “CE” printed on the cord. The H07RN-F cord used by
Hypertherm also has CCC certification to GB/T5013.4 with “CCC” printed on the cord.
L3
Extension cord recommendations
Any extension cord must have an appropriate wire size for the cord length and system voltage. Usea cord that meets
national and local codes.
The table on the next page provides the recommended gauge sizes for various lengths and input voltages. The lengths
in the tables are the length of the extension cord only; they do not include the power supply’s power cord.
Generators used with the Powermax65 or Powermax85 should satisfy the following requirements:
CSA
• 1-phase, 50/60 Hz, 230/240 VAC
• 3-phase, 50/60 Hz, 200-600 VAC (480 VAC recommended for best performance)
CE/CCC
• 3-phase, 50/60 Hz, 380/400 VAC (400 VAC recommended for best performance)
Engine drive
rating
20 kw85 AFull
15 kw70 ALimited
15 kw65 AFull
12 kw65 ALimited
12 kw40 AFull
8 kw40 ALimited
8 kw30 AFull
Note: Based on the generator rating, age, and condition, adjust the cutting current as needed.
If a fault occurs while using a generator, turning the power switch quickly to OFF and then to ON again
(sometimes called a “quick reset”) may not clear the fault. Instead, turn OFF the power supply and wait 30 to
45 seconds before turning ON again.
System output
current
Performance
(arc stretch)
Powermax65/85 Service Manual 2-13
POWER SUPPLY SETUP
1
2
Prepare the gas supply
The gas supply can be shop-compressed or cylinder-compressed. A high-pressure regulator must be used on either
type of supply and must be capable of delivering gas to the air inlet on the power supply.
If the supply quality is poor, cut speeds decrease, cut quality deteriorates, cutting thickness capability decreases, and
the life of the consumables shortens. To address these issues, use an optional air filtration system. See Additional gas filtration, below.
For optimal performance, the gas should be compliant with ISO8573-1:2010, Class 1.2.2 (that is, it should have a
maximum number of solid particulate per m3 of <20,000 for particle sizes in the range of 0.1-0.5 microns, <400 for
particle sizes in the range of 0.5-1 microns, and <10 for particle sizes in the range of 1-5 microns). The maximum water
vapor dew point should be <-40° C (-40° F). The maximum oil (aerosol, liquid, and vapor) content should be less than
0.1 mg/m3.
Additional gas filtration
When site conditions introduce moisture, oil, or other contaminants into the gas line, use a 3-stage coalescing filtration
system. A 3-stage filtering system works as shown below toclean contaminants from the gas supply.
Water and particle filterOil filterOil vapor filter
Gas supply
The filtering system should be installed between the gas supply and the power supply. Additional gas filtration may
increase the required minimum inlet pressure.
Hypertherm offers these optional external filter kits:
The Eliminizer moisture removal air filter kit (128647) removes water and dirt from the gas supply. For more
information, refer to Field Service Bulletin 804180.
The oil removal air filter kit (428719) removes oil, oil vapor, and dirt from the gas supply. For more information,
refer to Field Service Bulletin 809610.
Note: For additional parts related to these filter kits, see page 7‑21 Accessory parts.
If you use both external filters, install them in the order shown to prevent damage to the gas line and equipment.
Powermax65
Powermax85
2-14Powermax65/85 Service Manual
POWER SUPPLY SETUP
Connect the gas supply
Connect the gas supply to the power supply using an inert-gas hose with a 3/8inch (9.5mm) internal diameter and a
1/4NPT quick-disconnect coupler, or a 1/4NPT x G-1/4BSPP (CE/CCC units) quick-disconnect coupler.
The recommended inlet pressure while gas is
flowing is 85 – 135 psi (5.9 – 9.3 bar).
Powermax65/85 Service Manual 2-15
POWER SUPPLY SETUP
WARNING
Do not allow the gas supply pressure to exceed 135 psi (9.3 bar). The filter bowl may explode if this
pressure is exceeded.
Minimum inlet pressure (while gas is flowing)
This table shows the minimum required inlet pressure when the recommended inlet pressure is not available.
Cutting400 scfh, 6.7 scfm (190 slpm) at a minimum 85 psi (5.9 bar)
Maximum Removal gouging450 scfh, 7.5 scfm (210 slpm) at a minimum 70 psi (4.8 bar)
Maximum Control gouging450 scfh, 7.5 scfm (210 slpm) at a minimum 70 psi (4.8 bar)
Consumable life .......................................................................................................................................................................................3-2
CopperPlus™ electrode for Duramax torches........................................................................................................................3-2
Hand torch setup .................................................................................................................................................................................... 3-3
Choose the hand torch consumables .....................................................................................................................................3-4
Hand torch consumables ...........................................................................................................................................................3-4
Install the hand torch consumables ..........................................................................................................................................3-6
Converting a full-length machine torch to a mini machine torch ....................................................................................... 3-8
Mount the torch .......................................................................................................................................................................... 3-10
Choose the machine torch consumables ............................................................................................................................ 3-12
Install the machine torch consumables ................................................................................................................................ 3-15
Aligning the torch ...................................................................................................................................................................... 3-15
Connecting an optional remote-start pendant ................................................................................................................... 3-16
Connecting an optional machine interface cable ............................................................................................................... 3-17
Connecting an optional RS-485 serial interface cable .................................................................................................... 3-21
Connecting the torch lead ................................................................................................................................................................. 3-22
Using the cut charts ............................................................................................................................................................................ 3-23
85 A unshielded consumables ............................................................................................................................................... 3-43
65 A unshielded consumables ............................................................................................................................................... 3-47
45 A unshielded consumables ............................................................................................................................................... 3-51
Powermax65/85 Service Manual 3-1
TORCH SETUP
Introduction
Duramax™ series handheld and machine torches are available for the Powermax65 and Powermax85 systems. The
FastConnectTM quick-disconnect system makes it easy to remove the torch for transport or to switch from one torch
to the other if your applications require the use of different torches. The torches are cooled by ambient air and do not
require special cooling procedures.
This section explains how to set up your torch and choose the appropriate consumables for the job.
Consumable life
How often you need to change the consumables on your Powermax65 or Powermax85 will depend on a number of
factors:
• The thickness of the metal being cut.
• The average length of the cut.
• Whether you are doing machine or hand cutting.
• The air quality (presence of oil, moisture, or other contaminants).
• Whether you are piercing the metal or starting cuts from the edge.
• Proper torch-to-work distance when gouging or cutting with unshielded consumables.
• Proper pierce height.
• Whether you are cutting in “continuous pilot arc” mode or normal mode. Cutting with a continuous pilot arc
causes more consumable wear.
Under normal conditions, the electrode will wear out first during machine cutting and the nozzle will wear out first when
hand cutting.
A general rule is that a set of consumables lasts approximately 2 to 3 hours of actual “arc on” time for hand cutting,
depending on these factors. For mechanized cutting, consumables should last about 3 to 5 hours.
You will find more information about proper cutting techniques in Section 4, Operation.
CopperPlus™ electrode for Duramax torches
The CopperPlus electrode (part number220777) delivers at least two times longer consumable life over standard
consumables (Hypertherm consumables designed for the system). This electrode is designed exclusively for use with
Duramax torches when cutting metal 12mm (1/2inch) and under, and is compatible with 40A to 105A settings.
3-2 Powermax65/85 Service Manual
Hand torch setup
Duramax 75° hand torch
TORCH SETUP
Duramax 15° hand torch
Consumables
Consumables
Safety trigger
Safety trigger
Powermax65/85 Service Manual 3-3
TORCH SETUP
Choose the hand torch consumables
Hypertherm includes a box of consumables with your system. Both styles of hand torches shown on the previous page
use the same consumables.
Hand torches use shielded consumables. Therefore, you can drag the torch tip along the metal.
Consumables for hand cutting are shown on the next page. Notice that the retaining cap and electrode are the same for
cutting, gouging, and FineCut® applications. Only the shield, nozzle, and swirl ring are different.
These 2sets of gouging consumables can be used for both hand cutting and machine cutting:
• Maximum Removal gouging–For aggressive metal removal, deep gouge profiles, and extreme metal washing.
• Maximum Control gouging–For more precise metal removal, shallower gouge profiles, and light metal washing.
For the best cut quality on thin materials, you may prefer to use FineCut consumables, or use a 45A nozzle and reduce
the amperage to that setting.
To cut or gouge in hard to access or confined spaces, use HyAccessTM consumables. These 65A consumables extend
the reach of the general-purpose (standard) consumables by approximately 7.5cm (3inches). You can expect to
achieve approximately the same cut thicknesses and cut quality as with the general-purpose consumables at 65A.
Two HyAccess nozzles are available:
• One standard nozzle designed for a broad range of cutting applications
• One gouging nozzle designed specifically for gouging
When the tip of either nozzle wears out, replace the entire nozzle.
Hand torch consumables
Drag-cutting consumables: Powermax65
4
5
A
220941
Nozzle
6
5
220818
Shield
220854
Retaining cap
A
220819
Nozzle
220842
Electrode
220857
Swirl ring
3-4 Powermax65/85 Service Manual
Drag-cutting consumables: Powermax85
220818
Shield
220854
Retaining cap
Maximum Removal gouging consumables
4
5
A
220941
Nozzle
6
5
A
220819
Nozzle
8
5
A
220816
Nozzle
220842
Electrode
TORCH SETUP
220857
Swirl ring
220798
Shield
220854
Retaining cap
Maximum Control gouging consumables
220854
Retaining cap
220854
Retaining cap
FineCut
420480
Shield
®
consumables
220931
Shield
HyAccess 65A consumables
220797
Nozzle
220797
Nozzle
220930
Nozzle
420410
Standard nozzle
220842
Electrode
220842
Electrode
220842
Electrode
220857
Swirl ring
220857
Swirl ring
220947
Swirl ring
420412
Gouging nozzle
420413
Retaining cap
420408
Electrode
220857
Swirl ring
Powermax65/85 Service Manual 3-5
TORCH SETUP
Install the hand torch consumables
WARNING
INSTANTON TORCHES
PLASMA ARC CAN CAUSE INJURY AND BURNS
The plasma arc comes on im me di ate ly when the torch trigger is activated. Make sure the
power is OFF before changing consumables.
To operate the hand torch, a complete set of consumable parts must be installed: shield, retaining cap, nozzle,
electrode, and swirl ring.
With the power switch in the OFF (O) position, install the torch consumables asshown below.
Swirl ring
Electrode
Nozzle
Retaining cap
Shield
3-6 Powermax65/85 Service Manual
Machine torch setup
Duramax 180° full-length machine torch
Mounting
Consumables
sleeve
Coupler
Positioning sleeve
Strain relief nut
TORCH SETUP
Torch lead
Gear rack
Main strain
relief nut
Strain relief body
Duramax 180° mini machine torch
Mounting
Consumables
sleeve
Coupler
Strain relief nut
Torch lead
Strain relief body
Before using either style of machine torch, you must:
• Mount the torch on your cutting table or other equipment.
• Choose and install the consumables.
• Align the torch.
• Attach the torch lead to the power supply.
• Set up the power supply for remote starting with either the remote-start pendant or a machine interface cable.
Powermax65/85 Service Manual 3-7
TORCH SETUP
Converting a full-length machine torch to a mini machine torch
You can convert a full-length machine torch to a mini machine torch by removing the positioning sleeve.
Note: If you are converting a full-length machine torch to a mini machine torch and mounting the torch at the same
time, skip this section and follow the instructions in 3-10 Mount the torch.
Refer to the figures in the section 3-7 Machine torch setup and follow these instructions.
Note: While disconnecting and reconnecting the torch parts, maintain the same orientation between the torch head
and torch lead. Twisting the torch head in relation to the torch lead can cause damage.
1. Disconnect the torch lead from the power supply and remove the consumables from the torch.
2. Unscrew the strain relief body from the strain relief nut and slide the strain relief body back along the torch lead.
3. Unscrew the strain relief nut from the positioning sleeve and slide the nut back along the torch lead.
4. Unscrew the positioning sleeve from the coupler.
5. Unscrew the coupler from the mounting sleeve.
6. Remove the three screws from the consumables end of the mounting sleeve and slide the mounting sleeve off the
front of the torch body.
3-8Powermax65/85 Service Manual
Pilot wire
terminalscrew
TORCH SETUP
Torch head
7. Disconnect the wire connector for the cap-sensor switch.
8. Remove the screw that secures the torch’s pilot wire to the torch body.
9. Use 1/4-inch and 3/8-inch wrenches, or adjustable wrenches, to loosen the nut that secures the gas supply line to
the torch lead. Set the torch body aside.
10. Slide the coupler and positioning sleeve off the front of the torch lead.
11. Slide the coupler over the torch lead.
12. Reconnect the gas line to the torch lead.
13. Reattach the torch’s pilot wire to the torch body using the screw.
14. Reconnect the cap-sensor switch’s wire connector.
15. Slide the mounting sleeve over the front of the torch body. Align the slot on the front of the mounting sleeve (next to
one of the three screw holes) with the cap-sensor plunger on the torch body.
16. Attach the mounting sleeve to the torch body using the three screws.
17. Screw the coupler into the mounting sleeve.
18. Screw the strain relief nut into the coupler.
Gas supply line
connection
Wire connector for
cap-sensor switch
19. Screw the strain relief body into the strain relief nut.
Powermax65/85 Service Manual 3-9
TORCH SETUP
Mount the torch
Depending on the type of cutting table you have, you may or may not need to disassemble the torch to route it through
the track and mount it. If your cutting table’s track is large enough for you to thread the torch through it without removing
the torch body from the lead, do so and then attach the torch to the lifter per the manufacturer’s instructions.
Note: The Duramax machine torches can be mounted on a wide variety of X-Y tables, track burners, pipe bevelers,
and other equipment. Install the torch per the manufacturer’s instructions and follow the instructions below
for disassembly if necessary.
If you need to disassemble and reassemble the torch, refer to the figures in the section 3-7 Machine torch setup and
follow these instructions.
Note: While disconnecting and reconnecting the torch parts, maintain the same orientation between the torch head
and torch lead. Twisting the torch head in relation to the torch lead can cause damage.
1. Disconnect the torch lead from the power supply and remove the consumables from the torch.
2. Unscrew the strain relief body from the strain relief nut and slide the strain relief body back along the torch lead.
3. Unscrew the strain relief nut from the positioning sleeve (full-length machine torch) and slide the nut back along the
torch lead.
4. Unscrew the positioning sleeve from the coupler.
5. Unscrew the coupler from the mounting sleeve.
6. Remove the three screws from the consumables end of the mounting sleeve and slide the mounting sleeve off the
front of the torch body.
Pilot wire
terminalscrew
Torch head
Gas supply line
connection
Wire connector for
cap-sensor switch
3-10Powermax65/85 Service Manual
TORCH SETUP
7. Disconnect the wire connector for the cap-sensor switch.
8. Remove the screw that secures the torch’s pilot wire to the torch body.
9. Use 1/4-inch and 3/8-inch wrenches, or adjustable wrenches, to loosen the nut that secures the gas supply line to
the torch lead. Set the torch body aside.
Note: Cover the end of the gas line on the torch lead with tape to keep dirt and other contaminants from
getting in the gas line when you route the lead through the track.
10. Slide the coupler, positioning sleeve (full-length machine torch), strain relief nut, and strain relief body off the front of
the torch lead.
11. If you do not need the gear rack on a full-length machine torch, slide the gear rack from the positioning sleeve
toward the consumables end of the sleeve.
12. Route the torch lead through the cutting table’s track.
13. Slide the strain relief body and strain relief nut over the torch lead.
14. If you are mounting a full-length machine torch, slide the positioning sleeve over the torch head.
15. Slide the coupler over the torch lead.
16. Reconnect the gas line to the torch lead.
17. Reattach the torch’s pilot wire to the torch body using the screw.
18. Reconnect the cap-sensor switch’s wire connector.
19. Slide the mounting sleeve over the front of the torch body. Align the slot on the front of the mounting sleeve (next to
one of the three screw holes) with the cap-sensor plunger on the torch body.
20. Attach the mounting sleeve to the torch body using the three screws.
21. Screw the coupler into the mounting sleeve.
22. If you are mounting a full-length machine torch, screw the positioning sleeve into the coupler.
23. Reconnect the strain relief nut and strain relief body.
24. Attach the torch to the lifter per the manufacturer’s instructions.
Powermax65/85 Service Manual 3-11
TORCH SETUP
Choose the machine torch consumables
Powermax systems with the Duramax 180° full-length machine torch or Duramax 180° mini machine torch are shipped
with a box of consumables. In addition, an ohmic-sensing retaining cap is available for use with shielded consumables.
With shielded consumables, the torch tip may touch the metal when cutting. With unshielded consumables, you must
keep the torch a small distance, about 2-3 mm (.08-.12 inch), away from the metal. Unshielded consumables generally
have a shorter life than shielded consumables. Depending upon which system you order, you may receive a starter
consumable kit with a standard retaining cap or ohmic retaining cap.
Both styles of machine torches use the same consumables.
Machine torch consumables
Mechanized shielded consumables: Powermax65
4
5
A
220941
Nozzle
6
5
220817
Shield
220854
Retaining cap
A
220819
Nozzle
220842
Electrode
220857
Swirl ring
Mechanized shielded with ohmic consumables: Powermax65
4
5
A
220941
Nozzle
6
5
220817
Shield
220953
Ohmic-sensing
retaining cap
A
220819
Nozzle
220842
Electrode
220857
Swirl ring
3-12 Powermax65/85 Service Manual
Mechanized unshielded consumables: Powermax65
4
5
A
220941
Nozzle
6
5
220955
Deflector
220854
Retaining cap
A
220819
Nozzle
Mechanized shielded consumables: Powermax85
4
5
A
220941
Nozzle
6
5
A
220842
Electrode
TORCH SETUP
220857
Swirl ring
220817
Shield
220854
Retaining cap
220819
Nozzle
8
5
A
220842
Electrode
220816
Nozzle
Mechanized shielded with ohmic consumables: Powermax85
4
5
A
220941
Nozzle
6
5
A
220817
Shield
220953
Ohmic-sensing
retainingcap
220819
Nozzle
8
5
A
220816
Nozzle
220842
Electrode
220857
Swirl ring
220857
Swirl ring
Powermax65/85 Service Manual 3-13
TORCH SETUP
Mechanized unshielded consumables: Powermax85
4
5
A
220941
Nozzle
6
5
A
220955
Deflector
220854
Retaining cap
Maximum Removal gouging consumables
220798
Shield
220854
Retaining cap
Maximum Control gouging consumables
420480
Shield
220854
Retaining cap
220819
Nozzle
8
5
A
220816
Nozzle
220797
Nozzle
220797
Nozzle
220842
Electrode
220842
Electrode
220842
Electrode
220857
Swirl ring
220857
Swirl ring
220857
Swirl ring
FineCut® shielded consumables
220948
Shield
220953
Ohmic-sensing
retaining cap
220930
Nozzle
220842
Electrode
220947
Swirl ring
FineCut® unshielded consumables
220955
Deflector
220854
Retaining cap
220930
Nozzle
220842
Electrode
220947
Swirl ring
3-14Powermax65/85 Service Manual
TORCH SETUP
Install the machine torch consumables
WARNING
INSTANT-ON TORCHES
PLASMA ARC CAN CAUSE INJURY AND BURNS
The plasma arc comes on im me di ate ly when the torch is activated. Make sure the
power is OFF before changing the consumables.
To operate the machine torch, a complete set of consumable parts must be installed: shield, retaining cap, nozzle,
electrode, and swirl ring.
With the power switch in the OFF (O) position, install the machine torch consumables in a manner similar to the hand
torch consumables. Refer to 3-6 Install the hand torch consumables.
Aligning the torch
Mount the machine torch perpendicular to the workpiece in order to get a vertical cut. Use a square to align the torch at
0° and 90°.
Torch
0°
90°
Powermax65/85 Service Manual 3-15
TORCH SETUP
Connecting an optional remote-start pendant
Powermax65 and Powermax85 configurations with a Duramax machine torch can include an optional remote-start
pendant.
• Part number 128650: 25 foot (7.6 m)
• Part number 128651: 50 foot (15 m)
• Part number 128652: 75 foot (23 m)
• Part number 428755: 150 foot (45 m)
Remove the receptacle cover and plug the Hypertherm remote-start pendant into the receptacle on the rear of the
power supply.
Note: The remote-start pendant is for use only with a machine torch. It will not operate if a handheld torch is
installed.
Receptacle for the
remote-start pendant or a
machine interface cable.
3-16Powermax65/85 Service Manual
TORCH SETUP
Connecting an optional machine interface cable
The Powermax65 and Powermax85 power supplies are equipped with an optional, factory-installed, five-position
voltage divider that is designed to be safely connected without tools. The built-in voltage divider provides a scaled down
arc voltage of 20:1, 21.1:1, 30:1, 40:1, and 50:1 (maximum output of 18V). An optional receptacle on the rear of the
power supply provides access to the scaled down arc voltage and signals for arc transfer and plasma start.
Note: The factory presets the voltage divider to 50:1. To change the voltage divider to a different setting, refer to
3-20 Setting the five‑position voltage divider.
Notice:The voltage divider PCB is a simple resistive divider of raw arc voltage. To prevent ground
loops and electrical interference, you must isolate the divided arc signal.
Caution: The factory-installed voltage divider PCB supplies a voltage that is in proportion to the arc
voltage. The DIP switch settings on the voltage divider PCB control the output in open circuit
conditions, to a maximum output of one of the following voltages: 18V for Powermax65/85,
15V for Powermax65/85/105 SYNC. This output is an impedance-protected, functional
extra-low voltage (ELV) output. This type of output prevents shock, energy, and fire under
normal conditions at the machine interface receptacle and in single-fault conditions with
the machine interface wiring. The voltage divider PCB is not fault tolerant and ELV outputs
do not comply with safety extra-low voltage (SELV) requirements for direct connection to
electrical devices.
Hypertherm offers several choices of machine interface cables for the Powermax65 and Powermax85:
• To use the built-in voltage divider that provides a scaled down arc voltage in addition to signals for arc transfer
and plasma start:
-Use part number 228350 (7.6 m, 25 ft) or 228351 (15 m, 50 ft) for wires terminated with spade
connectors. This cable is required if you want to connect a torch height controller to the power supply.
-Use part number 123896 (15 m, 50 ft) for a cable terminated with a D-sub connector. (Compatible with
Hypertherm’s Edge Ti and Sensor PHC products.)
• To use signals for arc transfer and plasma start only, use either part number 023206 (7.6 m, 25 ft) or part
number 023279 (15 m, 50 ft). These cables have spade connectors as shown below.
Powermax65/85 Service Manual 3-17
TORCH SETUP
Note: The cover on the machine interface receptacle prevents dust and moisture from damaging the receptacle
when not in use. This cover should be replaced if damaged or lost (part number 127204).
See the Parts section for more information.
Installation of the machine interface cable must be performed by a qualified service technician. To install a machine
interface cable:
1. Turn OFF the power and disconnect the power cord.
2. Remove the machine interface receptacle’s cover from the rear of the power supply.
3. Connect the Hypertherm machine interface cable to the power supply.
4. If you are using a cable with a D-sub connector on the other end, plug it into the appropriate pin connector on the
torch height controller or CNC. Secure it with the screws on the D-sub connector.
If you are using a cable with wires and spade connectors on the other end, terminate the machine interface
cable inside the electrical enclosure of listed and certified torch height controllers or CNC controllers to prevent
unauthorized access to the connections after installation. Verify that the connections are correct and that all live
parts are enclosed and protected before operating the equipment.
Note: The integration of Hypertherm equipment and customer-supplied equipment including interconnecting cords
and cables, if not listed and certified as a system, is subject to inspection by local authorities at the final
installation site.
The connector sockets for each type of signal available through the machine interface cable are shown in the figure
below. The table provides details about each signal type.
2
1
3
4
5
6
14
13
12
3-18Powermax65/85 Service Manual
TORCH SETUP
Refer to the following table when connecting the Powermax65 or Powermax85 to a torch height controller or CNC
controller with a machine interface cable.
SignalTypeNotes
Normally open.
Start
(start plasma)
Transfer
(start machine
motion)
Voltage dividerOutput
GroundGround13Green/yellow
Input
Output
18 VDC open circuit voltage at START
terminals. Requires dry contact closure to
activate.
Normally open. Dry contact closure when
the arc transfers.
120 VAC/1 A maximum at the machine
interface relay or switching device
(supplied by the customer).
Divided arc signal of 20:1, 21.1:1, 30:1,
40:1, 50:1 (provides a maximum of 18 V).
Arc voltage sockets 5 and 6 are used for
pin-to-pin connection to legacy cables.
Sockets 1 and 2 are duplicate arc voltage
sockets for future use. Sockets 1 and 2
are not used for most installations.
Connector
sockets
3GreenBlack
4BlackRed
12RedWhite
14BlackGreen
5, 1 (-)
(Electrode)
6, 2 (+)
(Work)
External
cable wires
Black (-)Black (-)
White (+)Red (+)
Internal
cable wires
External cable wiresInternal cable wires
Cable 228350/228351
Powermax65/85 Service Manual 3-19
TORCH SETUP
Setting the five-position voltage divider
To change the factory preset voltage divider from 50:1 to a different setting:
1. Turn OFF the power supply and disconnect the power cord.
2. Remove the power supply cover.
3. Locate the voltage divider DIP switches on the left side of the power supply.
Note: The figure below shows the default setting (50:1) with the number 4 switch up.
C1C4
C2
R5
J5
GRN
C3
D1
R6
R7
J1
J2
21.1304050
S1
BLK
BLK
L1
X12
RED
R1
RED
R2
R4
R3
J4
J3
ALLDOWN=20
L1
4. Set the DIP switches to one of the following settings.
20:121.1:130:140:150:1
5. Replace the power supply cover.
J1
J3
BLK
RED
C1C4
R5
R6
C2
J5
C3
21.1 30 40
GRN
D1
R7
J2
50
S1
BLK
L1
X12
R1
R2
R3
L1
ALL
DOWN = 20
RED
R4
J4
Accessing raw arc voltage
To access divided raw arc voltage, refer to Field Service Bulletin 807060.
WARNING
HIGH VOLTAGE AND CURRENT
Connecting directly to the plasma circuit for access to raw arc voltage increases the risk of shock
hazard, energy hazard, and fire hazard in the event of a single fault. The output voltage and the
output current of the circuit are specified on the data plate.
3-20 Powermax65/85 Service Manual
TORCH SETUP
Connecting an optional RS-485 serial interface cable
The RS-485 serial interface connector on the back of the power supply allows you to connect an external device to your
Powermax. For example, you can remotely operate the Powermax with a CNC controller.
The Powermax power supply must be equipped with a factory-installed (or user-installed) RS-485 serial interface
connector on the rear panel. The receptacle on the rear of the power supply provides access to the RS-485 board
inside the power supply.
RS-485 Connector
If your power supply is not equipped with the RS-485 connector, order kit228539, “Powermax65/85/105 RS-485
board with cables”. Follow the installation instructions in Application Note807220. To search for and download the
Application Note, log into Xnet at www.hypertherm.com and click the “Documents library” link.
With the RS-485 connector installed:
1. Shut off the power supply.
2. Connect the RS-485 cable from your external device to the receptacle on the back of the Powermax power supply.
Serial port cables
The following serial cables are available with the specified lengths and connectors:
The Powermax65 and Powermax85 are equipped with FastConnectTM, a quick-disconnect system for connecting and
disconnecting handheld and machine torch leads. When connecting or disconnecting a torch, first turn OFF the system.
To connect either torch, push the connector into the receptacle on the front of the power supply.
To remove the torch, press the red button on the connector and pull the connector out of the receptacle.
Red button
3-22Powermax65/85 Service Manual
TORCH SETUP
Using the cut charts
The following sections provide cut charts for each set of mechanized consumables. A consumable diagram with part
numbers precedes each set of charts. For each consumable type, there are Metric and English charts for mild steel,
stainless steel, and aluminum.
Note: For cut charts on using F5gas to cut stainless steel, refer to the Use F5 to Cut Stainless Steel
application note (809060). You can download this document from the Documents library at
www.hypertherm.com.
Each chart contains the following information:
• Material Thickness – Thickness of the workpiece (metal plate being cut).
• Torch-to-Work Distance – For shielded consumables, the distance between the shield and the workpiece
during cutting. For unshielded consumables, the distance between the nozzle and the workpiece during cutting.
• Initial Pierce Height – Distance between the shield (shielded) or the nozzle (unshielded) and the workpiece
when the torch is triggered, prior to descending to the cut height.
• Pierce Delay Time – Length of time the triggered torch remains stationary at the pierce height before the torch
starts the cutting motion.
• Best Quality Settings (cut speed and voltage) – Settings that provide the starting point for finding the best
cut quality (best angle, least dross, best cut-surface finish). Adjust the speed for your application and table to
obtain the desired result.
• Production Settings (cut speed and voltage) – 80% of the maximum speed ratings. These speeds result in the
greatest number of cut parts, but not necessarily the best possible cut quality.
Note: The arc voltage increases as the consumables wear and the voltage setting should be increased to
maintain the correct Torch-to-Work Distance.
Each cut chart lists hot and cold air flow rates.
• Hot air flow rate – Plasma is on, the system is operating at running current, and the system is in a steady state
at the default system pressure (automatic mode).
• Cold air flow rate – Plasma is off and the system is in a steady state with air flowing through the torch at the
default system pressure.
Note: Hypertherm collected the data under laboratory test conditions using new consumables.
Powermax65/85 Service Manual 3-23
TORCH SETUP
Estimated kerf-width compensation
The widths in the tables below are for reference. The data are obtained with the “Best Quality” settings. Differences
between installations and material composition may cause actual results to vary from those shown in the tables.