Hypertherm Manual Family Service Manual (SM)

®

Powermax65

®

Powermax85

Plasma Arc Cutting Systems

Service Manual

807120 | Revision 4 | English

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.

Powermax

65

Powermax

Service Manual

807120

85

Revision 4 – March 2022

Hypertherm Inc.

Hanover, NH USA

www.hypertherm.com

© 2022 Hypertherm Inc.

All Rights Reserved

Hypertherm and Powermax are trademarks of Hypertherm Inc.

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

Hypertherm, Inc.

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

800-643-9878 Tel (Technical Service)

[e-mail] (Technical Service)

800-737-2978 Tel (Customer Service)

[e-mail] (Customer Service)

Hypertherm México, S.A. de C.V.

52 55 5681 8109 Tel
52 55 5681 7978 Tel
[e-mail] (Technical Service)

Hypertherm Plasmatechnik GmbH

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

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

[e-mail] (Technical Service)

Hypertherm (Singapore) Pte Ltd.

Solaris @ Kallang 164
164 Kallang Way #03-13
Singapore 349248, Republic of Singapore
65 6841 2489 Tel
65 6841 2490 Fax
[e-mail] (Marketing)
[e-mail] (Technical Service)

Hypertherm Japan Ltd.

Level 9, Edobori Center Building
2-1-1 Edobori, Nishi-ku
Osaka 550-0002 Japan
81 6 6225 1183 Tel
81 6 6225 1184 Fax
[e-mail] (Main Office)
[e-mail] (Technical Service)

Hypertherm (Shanghai) Trading Co., Ltd.

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

86-21-80231128 Tel (Technical Service)

[e-mail] (Technical Service)

South America & Central America: Hypertherm Brasil Ltda.

Rua Bras Cubas, 231 – Jardim Maia
Guarulhos, SP – Brasil
CEP 07115-030
55 11 2409 2636 Tel
[e-mail] (Technical Service)

Hypertherm Korea Branch

#3904. APEC-ro 17. Heaundae-gu. Busan.
Korea 48060
82 (0)51 747 0358 Tel
82 (0)51 701 0358 Fax
[e-mail] (Marketing)
[e-mail] (Technical Service)

Hypertherm Pty Limited

GPO Box 4836
Sydney NSW 2001, Australia
61 7 3103 1695 Tel
61 7 3219 9010 Fax
[e-mail] (Main Office)
[e-mail] (Technical Service)

Hypertherm (India) Thermal Cutting Pvt. Ltd

A-18 / B-1 Extension,
Mohan Co-Operative Industrial Estate,
Mathura Road, New Delhi 110044, India
91-11-40521201/ 2/ 3 Tel
91-11 40521204 Fax
[e-mail] (Main Office)
[e-mail] (Technical Service)

Hypertherm Europe B.V.

Vaartveld 9, 4704 SE
Roosendaal, Nederland
31 165 596907 Tel
31 165 596901 Fax
31 165 596908 Tel (Marketing)

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

[e-mail] (Technical Service)

ELECTROMAGNETIC COMPATIBILITY EMC

Introduction

Hypertherm’s CE-marked equipment is built in compliance with
standard EN60974-10. The equipment should be installed and used
in accordance with the information below to achieve electromagnetic
compatibility.

The limits required by EN60974-10 may not be adequate to completely
eliminate interference when the affected equipment is in close proximity
or has a high degree of sensitivity. In such cases it may be necessary to
use other measures to further reduce interference.

This cutting equipment is designed for use only in an industrial
environment.

Installation and use

The user is responsible for installing and using the plasma equipment
according to the manufacturer’s instructions.

If electromagnetic disturbances are detected then it shall be the
responsibility of the user to resolve the situation with the technical
assistance of the manufacturer. In some cases this remedial action
may be as simple as earthing the cutting circuit, see Earthing of
the workpiece. In other cases, it could involve constructing an
electromagnetic screen enclosing the power source and the work
complete with associated input filters. In all cases, electromagnetic
disturbances must be reduced to the point where they are no longer
troublesome.

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 inthe aggregate
the amount paid for the Products that gave rise to suchclaim.

Insurance

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

Transfer of rights

You may transfer any remaining rights you may have hereunder only in
connection with the sale of all or substantially all of your assets or capital
stock to a successor in interest who agrees to be bound by all of the
terms and conditions of this Warranty. Within thirty (30) days before any
such transfer occurs, you agree to notify in writing Hypertherm, which
reserves the right of approval. Should you fail timely to notify Hypertherm
and seek its approval as set forth herein, the Warranty set forth herein
shall be null and void and you will have no further recourse against
Hypertherm under the Warranty or otherwise.

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

Component weights ............................................................................................................................................................................... 1-5

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

Duramax 180° full-length machine torch dimensions .................................................................................................................. 1-11

Duramax 180° mini machine torch dimensions ............................................................................................................................. 1-11

Powermax65 cutting specifications ................................................................................................................................................. 1-12

Powermax85 cutting specifications ................................................................................................................................................. 1-13

Symbols and marks ............................................................................................................................................................................. 1-14

IEC symbols .......................................................................................................................................................................................... 1-15

Section 2
Power Supply Setup

Unpack the Powermax65 or Powermax85 system .........................................................................................................................2-2

Claims .............................................................................................................................................................................................2-2

Contents ......................................................................................................................................................................................... 2-3

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

Extension cord recommendations .................................................................................................................................................... 2-11

Extension cord specifications ................................................................................................................................................. 2-12

Engine-driven generator recommendations ........................................................................................................................ 2-13

Prepare the gas supply ....................................................................................................................................................................... 2-14

Additional gas filtration ............................................................................................................................................................. 2-14

Connect the gas supply ........................................................................................................................................................... 2-15

Powermax65/85 Service Manual

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TABLE OF CONTENTS

Section 3
Torch Setup

Introduction ..............................................................................................................................................................................................3-2

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

Machine torch setup...............................................................................................................................................................................3-7

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

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

Estimated kerf-width compensation ...................................................................................................................................... 3-24

85 A shielded consumables ................................................................................................................................................... 3-26

65 A shielded consumables ................................................................................................................................................... 3-30

45 A shielded consumables ................................................................................................................................................... 3-34

FineCut® consumables ............................................................................................................................................................ 3-38

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

Rear controls .................................................................................................................................................................................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

Understanding duty-cycle limitations .................................................................................................................................... 4-12

viii Powermax65/85 Service Manual

TABLE OF CONTENTS

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

Troubleshooting preparation ................................................................................................................................................................5-7

Test equipment .............................................................................................................................................................................5-7

Troubleshooting procedures and sequence .......................................................................................................................... 5-7

External inspection ....................................................................................................................................................................... 5-9

Internal inspection ........................................................................................................................................................................5-9

Initial resistance check ...........................................................................................................................................................................5-9

Check the power switch ............................................................................................................................................................. 5-9

Hypertherm IGBT tester .......................................................................................................................................................... 5-12

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

Fault codes ............................................................................................................................................................................................ 5-21

Displaying the service screen ................................................................................................................................................. 5-21

Important fault icons ................................................................................................................................................................. 5-22

Performing a cold restart ......................................................................................................................................................... 5-22

Fault codes and solutions ........................................................................................................................................................ 5-23

Powermax65/85 Service Manual

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TABLE OF CONTENTS

Troubleshooting guide ........................................................................................................................................................................ 5-32

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–600V 3-phase CSA, 380/400V 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 (metalguarded, 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

x Powermax65/85 Service Manual

TABLE OF CONTENTS

Replace the solenoid valve ................................................................................................................................................................ 6-29

Remove the outer components .............................................................................................................................................. 6-29

Review solenoid valve models ................................................................................................................................................ 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 CSA ..................................................................................................................................................................................... 6-48

65A CE ........................................................................................................................................................................................ 6-49

85A CSA ..................................................................................................................................................................................... 6-50

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

Exterior, rear ................................................................................................................................................................................... 7-3

Interior, power board side (200 – 600V CSA) .....................................................................................................................7-5

Interior, power board side (380/400V CE) ............................................................................................................................ 7-6

Interior, fan side ............................................................................................................................................................................7-7

Heat sink assembly ................................................................................................................................................................................. 7-9

65A CSA ........................................................................................................................................................................................ 7-9

65A CE ........................................................................................................................................................................................ 7-10

85A CSA ..................................................................................................................................................................................... 7-11

85A CE ........................................................................................................................................................................................ 7-12

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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

Machine torch consumables ............................................................................................................................................................. 7-20

Accessory parts.................................................................................................................................................................................... 7-21

Powermax65 and Powermax85 labels ............................................................................................................................................ 7-22

Safety-critical parts.............................................................................................................................................................................. 7-23

Recommended spare parts ............................................................................................................................................................... 7-25

Section 8
Wiring Diagrams

Powermax generic timing chart ...........................................................................................................................................................8-3

Electrical schematic diagram (CSA) ..................................................................................................................................................8-4

Electrical schematic diagram (CE) .....................................................................................................................................................8-5

xii Powermax65/85 Service Manual

Section 1

SPECIFICATIONS

In this section:

Safety information ................................................................................................................................................................................... 1-2

System description ................................................................................................................................................................................. 1-2

Where to find information .....................................................................................................................................................................1-3

Power supply dimensions ..................................................................................................................................................................... 1-4

Component weights ............................................................................................................................................................................... 1-5

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

Duramax 180° full-length machine torch dimensions .................................................................................................................. 1-11

Duramax 180° mini machine torch dimensions ............................................................................................................................. 1-11

Powermax65 cutting specifications ................................................................................................................................................. 1-12

Powermax85 cutting specifications ................................................................................................................................................. 1-13

Symbols and marks ............................................................................................................................................................................. 1-14

IEC symbols .......................................................................................................................................................................................... 1-15

Powermax65/85 Service Manual 1-1

SPECIFICATIONS

Safety information

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 (25mm) with a handheld torch and pierce thicknesses up to
5/8inch (16mm). The Powermax85 can cut thicknesses up to 1-1/4inches (32mm) and pierce thicknesses up to
3/4inch (19mm). 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.

1-2 Powermax65/85 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).

Powermax65/85 Service 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 CSA 65 A CE/CCC 85 A CSA 85 A CE/CCC

lbs (kg) lbs (kg) lbs (kg) lbs (kg)

Power supply 54.1 (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 A 85 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 76mm (3.0inches).

76mm

(3.0inch)

76mm

(3.0inch)

Diameter=2 x Radius=152mm (6.0inches)

152mm

(6.0inch)

Powermax65/85 Service 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 temperature 14° 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, 3PH R

sce

400 VAC 225.7

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

**,†

380/400 V, 3 PH, 50/60 Hz

15.5/15 A

sce

Gas type Air Nitrogen

Gas quality Clean, dry, oil-free per

99.95% pure

ISO8573-1 Class 1.2.2

Recommended gas inlet flow
rate/pressure

Cutting: 400 scfh, 6.7 scfm (190 slpm) @ 85 psi (5.9 bar)
Maximum Removal gouging: 450 scfh, 7.5 scfm (210 slpm) @
70 psi (4.8 bar)
Maximum Control gouging: 450 scfh, 7.5 scfm (210 slpm) @
70 psi (4.8 bar)

1-6 Powermax65/85 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

2035KVA at the interface point between the user’s supply and the public system. It is the responsibility of the installer
or user of the equipment to ensure, by consultation with the distribution network operator if necessary, that the
equipment is connected only to a supply with a short-circuit power S

†

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

Powermax65/85 Service 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 temperature 14° 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, 3PH R

sce

EMC classification CISPR 11 (CCC/CE models

‡

only)
Input voltage (U1)/ Input

current (I1) at rated output
(U

2MAX

, I

) (See Section 2

2 MAX

Power Supply Setup for more
information.)

Gas type Air Nitrogen
Gas quality Clean, dry, oil-free per

ISO 8573-1 Class 1.2.2

Recommended gas inlet flow
rate/pressure

Cutting: 400 scfh, 6.7 scfm (190 slpm) @ 85 psi (5.9 bar)
Maximum Removal gouging: 450 scfh, 7.5 scfm (210 slpm)
@ 70 psi (4.8 bar)
Maximum Control gouging: 450 scfh, 7.5 scfm (210 slpm) @
70 psi (4.8 bar)

CSA

CCC/CE

CSA

CCC/CE

CSA

CCC/CE

305 VDC
270 VDC

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 VAC 225.7

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

1-8 Powermax65/85 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

2035KVA at the interface point between the user’s supply and the public system. It is the responsibility of the installer
or user of the equipment to ensure, by consultation with the distribution network operator if necessary, that the
equipment is connected only to a supply with a short-circuit power S

†

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

Powermax65/85 Service 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

(3.3cm) 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

(3.3cm) flat sides

Powermax65/85 Service 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 steel 10.7 lbs/hr (4.8 kg/hr)
Maximum Control metal removal rate on mild steel 7.5 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

atthat thickness.

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

ondifferent 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 steel 19.5 lbs/hr (8.8 kg/hr)
Maximum Control metal removal rate on mild steel 13.7 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

atthat thickness.

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

ondifferent cutting applications.

Powermax65/85 Service 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.

1-14 Powermax65/85 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) l Power 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)

Gouging System 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)

Powermax65/85 Service 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

Claims .............................................................................................................................................................................................2-2

Contents ......................................................................................................................................................................................... 2-3

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

Extension cord recommendations .................................................................................................................................................... 2-11

Extension cord specifications ................................................................................................................................................. 2-12

Engine-driven generator recommendations ........................................................................................................................ 2-13

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, youmust file a claim

with the carrier. Hypertherm will furnish you with a copy of the bill oflading 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 thenearest 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 (3m) power
cord. Allow at least 10inches (0.25m) 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
200to 600, 1- or 3-phase. The CCC/CE model is 380/400 V, 3-phase only. The rated output is 25 – 65A, 139 VDC.

CSA model Single-phase Three-phase

Input voltage 200 – 208 230 – 240 480 200 – 208 230 – 240 400 480 600
Input current at

9.0kw output
Input current

during arc stretch
Fuse (slow-blow) 80 80 40 50 50 30 25 25

CE/CCC model Three-phase

Input voltage 380/400
Input current at

9.0kw output
Input current

during arc stretch
Fuse (slow-blow) 30

52 44 22 32 27 15 13 13

74 74 38 45 45 27 23 23

15.5/15

27

2-6 Powermax65/85 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/T5013.4 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
200to 600, 1- or 3-phase (600V 3-phase only). The CCC/CE model is 380/400 V, 3-phase only. The rated output is
25 – 85A, 143 VDC.

CSA model Single-phase Three-phase

Input voltage 200 – 208 230 – 240 480 200 – 208 230 – 240 400 480 600
Input current at

12.2 kw output
Input current

during arc stretch
Fuse (slow-blow) 100 100 50 60 60 40 30 30

CE/CCC model Three-phase

Input voltage 380/400
Input current at

12.2 kw output
Input current

during arc stretch
Fuse (slow-blow) 40

70 60 29 42 36 21 18 17

98 98 50 60 60 38 31 30

20.5/20

38

2-8 Powermax65/85 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

strainrelief and tighten

L1

L2

Power switch

Ground screw

2-10 Powermax65/85 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/T5013.4 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. Usea 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.

Powermax65/85 Service Manual 2-11

POWER SUPPLY SETUP

Extension cord specifications

Extension cord length

< 10 ft

(< 3 m)

10 – 25 ft

(3 – 7.6 m)

25 – 50 ft

(7.5 – 15 m)

50 – 100 ft

(15 – 30 m)

100 – 150 ft

(30 – 45 m)

65 A CSA

Input voltage

2

(VAC) Phase AWG (mm

) AWG (mm2) AWG (mm2) AWG (mm2) AWG (mm2)

200 – 240 1 8 (10) 8 (10) 8 (10) 6 (16) 4 (25)

480 1 12 (4) 12 (4) 12 (4) 10 (6) 10 (6)

200 – 240 3 10 (6) 10 (6) 10 (6) 8 (10) 6 (16)

400/480 3 12 (4) 12 (4) 12 (4) 12 (4) 12 (4)

600 3 12 (4) 12 (4) 12 (4) 12 (4) 12 (4)

65 A CE/CCC

Input voltage
(VAC) Phase mm

2

mm

2

mm

2

mm

2

mm

380 3 4 4 4 4 4
400 3 4 4 4 4 4

85 A CSA

Input voltage
(VAC) Phase AWG (mm

2

) AWG (mm2) AWG (mm2) AWG (mm2) AWG (mm2)

200 – 240 1 6 (16) 6 (16) 6 (16) 4 (25) 2 (35)

2

480 1 10 (6) 10 (6) 10 (6) 8 (10) 8 (10)

200 – 240 3 8 (10) 8 (10) 8 (10) 6 (16) 4 (25)
400/480 3 10 (6) 10 (6) 10 (6) 10 (6) 10 (6)
600 3 10 (6) 10 (6) 10 (6) 10 (6) 10 (6)

85 A CE/CCC

Input voltage
(VAC) Phase mm

2

mm

2

mm

2

mm

2

mm

380 3 6 6 6 6 6

400 3 6 6 6 6 6

2

2-12 Powermax65/85 Service Manual

POWER SUPPLY SETUP

Engine-driven generator recommendations

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 kw 85 A Full

15 kw 70 A Limited

15 kw 65 A Full

12 kw 65 A Limited

12 kw 40 A Full

8 kw 40 A Limited

8 kw 30 A Full

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 toclean contaminants from the gas supply.

Water and particle filter Oil filter Oil 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

2-14 Powermax65/85 Service Manual

POWER SUPPLY SETUP

Connect the gas supply

Connect the gas supply to the power supply using an inert-gas hose with a 3/8inch (9.5mm) internal diameter and a
1/4NPT quick-disconnect coupler, or a 1/4NPT x G-1/4BSPP (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.

Torch lead length

7.6 m (25 ft) 15 m (50 ft) 23 m (75 ft)

Cutting 75 psi (5.2 bar) 80 psi (5.5 bar) 85 psi (5.9 bar)
Maximum Removal gouging 60 psi (4.1 bar) 65 psi (4.5 bar) 70 psi (4.8 bar)
Maximum Control gouging 60 psi (4.1 bar) 65 psi (4.5 bar) 70 psi (4.8 bar)

Gas flow rates

Cutting 400 scfh, 6.7 scfm (190 slpm) at a minimum 85 psi (5.9 bar)
Maximum Removal gouging 450 scfh, 7.5 scfm (210 slpm) at a minimum 70 psi (4.8 bar)
Maximum Control gouging 450 scfh, 7.5 scfm (210 slpm) at a minimum 70 psi (4.8 bar)

2-16 Powermax65/85 Service Manual

Section 3

TORCH SETUP

In this section:

Introduction ..............................................................................................................................................................................................3-2

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

Machine torch setup...............................................................................................................................................................................3-7

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

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

Estimated kerf-width compensation ...................................................................................................................................... 3-24

85 A shielded consumables ................................................................................................................................................... 3-26

65 A shielded consumables ................................................................................................................................................... 3-30

45 A shielded consumables ................................................................................................................................................... 3-34

FineCut® consumables ............................................................................................................................................................ 3-38

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 number220777) 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 12mm (1/2inch) and under, and is compatible with 40A to 105A 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 2sets 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 45A nozzle and reduce
the amperage to that setting.

To cut or gouge in hard to access or confined spaces, use HyAccessTM consumables. These 65A consumables extend
the reach of the general-purpose (standard) consumables by approximately 7.5cm (3inches). You can expect to
achieve approximately the same cut thicknesses and cut quality as with the general-purpose consumables at 65A.

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 65A 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

INSTANTON TORCHES

PLASMA ARC CAN CAUSE INJURY AND BURNS

The plasma arc comes on im me di ate ly when the torch trigger is activated. Make sure the
power is OFF before changing consumables.

To operate the hand torch, a complete set of consumable parts must be installed: shield, retaining cap, nozzle,
electrode, and swirl ring.

With the power switch in the OFF (O) position, install the torch consumables asshown below.

Swirl ring

Electrode

Nozzle

Retaining cap

Shield

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.

3-8 Powermax65/85 Service Manual

Pilot wire

terminalscrew

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

terminalscrew

Torch head

Gas supply line

connection

Wire connector for

cap-sensor switch

3-10 Powermax65/85 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

retainingcap

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

3-14 Powermax65/85 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.

3-16 Powermax65/85 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 18V). 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: 18V for Powermax65/85,
15V 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

3-18 Powermax65/85 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.

Signal Type Notes

Normally open.

Start

(start plasma)

Transfer

(start machine

motion)

Voltage divider Output

Ground Ground 13 Green/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

3 Green Black

4 Black Red

12 Red White

14 Black Green

5, 1 (-)

(Electrode)

6, 2 (+)

(Work)

External

cable wires

Black (-) Black (-)

White (+) Red (+)

Internal

cable wires

External cable wires Internal 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.

C1 C4

C2

R5

J5

GRN

C3

D1

R6

R7

J1

J2

21.13040 50

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.

20:1 21.1:1 30:1 40:1 50:1

5. Replace the power supply cover.

J1

J3

BLK

RED

C1 C4

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 kit228539, “Powermax65/85/105 RS-485
board with cables”. Follow the installation instructions in Application Note807220. 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:

• 223236 – RS-485 cable, unterminated, 7.6m (25feet)

• 223237 – RS-485 cable, unterminated, 15m (50feet)

• 223239 – RS-485 cable, 9-pin D-sub connector for Hypertherm controls, 7.6m (25feet)

• 223240 – RS-485 cable, 9-pin D-sub connector for Hypertherm controls, 15m (50feet)

Powermax65/85 Service Manual 3-21

TORCH SETUP

Connecting the torch lead

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

3-22 Powermax65/85 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 F5gas 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.

Estimated kerf-width compensation – Metric (mm)

Thickness (mm)

Process

85A Shielded 1.7 1.8 1.9 2.0 2.2 2.4 2.6
65A Shielded 1.6 1.6 1.8 1.9 2.0 2.2 2.3
45A Shielded 1.1 1.1 1.4 1.5 1.7
FineCut 0.7 0.7 1.3 1.3
85A Unshielded 1.7 1.8 1.9 2.0 2.1 2.1 2.3
65A Unshielded 1.6 1.6 1.7 1.8 1.9 2.0
45A Unshielded 0.5 0.9 1.3 1.3

85A Shielded 1.6 1.8 1.9 2.1 2.3 2.4 2.5
65A Shielded 1.4 1.5 1.8 1.9 2.0 2.2 2.4
45A Shielded 0.9 1.1 1.5 1.6 1.8
FineCut 0.6 0.6 1.0 1.4
85A Unshielded 1.7 1.7 1.8 1.9 2.1 2.2 2.4
65A Unshielded 1.6 1.6 1.8 1.8 1.9 2.0
45A Unshielded 0.5 1.0 1.3 1.5 1.5

85A Shielded 2.0 1.9 2.0 2.1 2.2 2.4 2.6
65A Shielded 1.9 1.9 1.9 2.0 2.1 2.3 2.5
45A Shielded 1.5 1.5 1.6 1.5
85A Unshielded 1.9 1.9 1.9 2.0 2.0 2.1 2.2
65A Unshielded 1.8 1.8 1.8 1.8 1.9 2.0
45A Unshielded 1.6 1.5 1.4 1.5

0.5 1 2 3 6 8 10 12 16 20
Mild Steel

Stainless Steel

Aluminum

3-24 Powermax65/85 Service Manual

TORCH SETUP

Estimated kerf-width compensation – English (inches)

Thickness (inches)

Process

85A Shielded 0.068 0.071 0.073 0.078 0.090 0.095 0.100
65A Shielded 0.062 0.065 0.068 0.070 0.076 0.088 0.090 0.091
45A Shielded 0.035 0.054 0.055 0.061 0.065 0.066
FineCut 0.024 0.043 0.049 0.051
85A Unshielded 0.070 0.073 0.075 0.080 0.085 0.090
65A Unshielded 0.062 0.064 0.066 0.068 0.075 0.081
45A Unshielded 0.020 0.050 0.051 0.054 0.057 0.059

85A Shielded 0.065 0.068 0.070 0.080 0.094 0.095 0.096
65A Shielded 0.056 0.062 0.068 0.073 0.076 0.090 0.093 0.096
45A Shielded 0.032 0.055 0.058 0.067 0.069 0.069
FineCut 0.018 0.036 0.040 0.055
85A Unshielded 0.068 0.070 0.072 0.080 0.090 0.095
65A Unshielded 0.061 0.064 0.067 0.070 0.072 0.080
45A Unshielded 0.020 0.054 0.052 0.060 0.058 0.058

85A Shielded 0.080 0.078 0.075 0.080 0.090 0.095 0.100
65A Shielded 0.073 0.074 0.075 0.076 0.083 0.091 0.100
45A Shielded 0.059 0.061 0.065 0.060
85A Unshielded 0.075 0.075 0.075 0.080 0.082 0.088
65A Unshielded 0.070 0.070 0.070 0.070 0.072 0.079
45A Unshielded 0.062 0.058 0.057 0.061

22GA 18GA 14GA 10GA 3/16 1/4 3/8 1/2 5/8 3/4

Mild Steel

Stainless Steel

Aluminum

1/32 1/16 1/8 3/16 1/4 3/8 1/2 5/8 3/4

Powermax65/85 Service Manual 3-25

TORCH SETUP

85 A shielded consumables

8
5
A

220817

Shield

220817

Shield

220854

Retaining cap

220953

Ohmic-sensing

retaining cap

220816

Nozzle

8
5
A

220816

Nozzle

220842

Electrode

220842

Electrode

220857

Swirl ring

220857

Swirl ring

3-26 Powermax65/85 Service Manual

TORCH SETUP

85A Shielded Air flow rate - slpm/scfh

Mild Steel

Metric

Material

Thickness

Torch-

to-Work

Distance

Initial Pierce

Height

Pierce

Delay

Time

Best Quality Settings Production Settings

Cut Speed Voltage Cut Speed Voltage

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

3

0.1 6800 122 9200 120
4 0.2 5650 122 7300 122
6
8 2500 125 3100 127

10 1680 127 2070 128
12

1.5

16 1.0 870 134 930 133

3.8 250

4.5 300

3600 123 4400 125

0.5

0.7 1280 130 1600 130

20 6.0 400 1.5 570 137 680 136
25
30 200 146 300 144

Edge Start

350 142 450 141

Hot 190 / 400

Cold 235 / 500

English

Material

Thickness

Torch-

to-Work

Distance

Initial Pierce

Height

Pierce

Delay

Time

Best Quality Settings Production Settings

Cut Speed Voltage Cut Speed Voltage

in in % seconds ipm Volts ipm Volts

10GA

3/16 in 0.2 185 123 220 123

1/4 in

0.15 250

3/8 in 70 126 86 127
1/2 in
5/8 in 1.0 35 134 37 133

0.06

0.18 300

0.2 250 122 336 121

130 123 160 126

0.5

45 131 56 131

3/4 in 0.24 400 1.5 24 136 29 135
7/8 in

1 in 13 142 17 141

1-1/8 in 9 145 13 143

Edge Start

19 139 22 138

1-1/4 in 7 148 10 146

Powermax65/85 Service Manual 3-27

TORCH SETUP

85A Shielded Air flow rate - slpm/scfh

Stainless Steel

Metric

Material

Thickness

Torch-

to-Work

Distance

Initial Pierce Height

Pierce

Delay Time

Best Quality Settings Production Settings

Cut Speed Voltage Cut Speed Voltage

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

3
4 0.2 6100 122 7500 120
6

3.8 250

8 2450 124 3050 124
10
12 0.7 1100 131 1400 130

1.5

4.5 300

0.1 7500 122 9200 120

3700 122 4600 122

0.5
1550 127 1900 126

16 1.0 700 135 760 134
20
25 300 143 370 141

Edge Start

480 138 570 137

Hot 190 / 400

Cold 235 / 500

English

Material

Thickness

Torch-

to-Work

Distance

Initial Pierce Height

Pierce

Delay Time

Best Quality Settings Production Settings

Cut Speed Voltage Cut Speed Voltage

in in % seconds ipm Volts ipm Volts

10GA

3/16 in 200 122 240 121

1/4 in

0.15 250

3/8 in 65 126 80 125
1/2 in
5/8 in 1.0 28 135 30 134

0.06

0.18 300

0.2

0.5

3/4 in
7/8 in 16 140 19 139

Edge Start

275 122 336 120

130 122 164 122

36 132 48 131

20 137 24 136

1 in 11 143 14 141

3-28 Powermax65/85 Service Manual

TORCH SETUP

85A Shielded Air flow rate - slpm/scfh

Aluminum

Metric

Material

Thickness

Torch-

to-Work

Distance

Initial Pierce

Height

Pierce

Delay Time

Best Quality Settings Production Settings

Cut Speed Voltage Cut Speed Voltage

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

3
4 0.2 6500 123 8000 123
6

3.8 250

8 2650 130 3470 129
10
12 0.7 1450 134 1930 133

1.5

4.5 300

0.1 8000 122 9400 121

3800 126 4900 126

0.5
1920 132 2500 131

16 1.0 950 139 1200 137
20
25 380 146 540 144

Edge Start

600 143 880 141

Hot 190 / 400

Cold 235 / 500

English

Material

Thickness

Torch-

to-Work

Distance

Initial Pierce

Height

Pierce

Delay Time

Best Quality Settings Production Settings

Cut Speed Voltage Cut Speed Voltage

in in % seconds ipm Volts ipm Volts
1/8 in
1/4 in

0.15 250
3/8 in 80 132 104 131
1/2 in
5/8 in 1.0 38 139 48 137

0.06

0.18 300

3/4 in
7/8 in 20 144 29 142

Edge Start

0.2 300 122 360 121
130 127 172 127

0.5

50 135 68 133

25 142 37 140

1 in 14 146 20 144

Powermax65/85 Service Manual 3-29

TORCH SETUP

65 A shielded consumables

6
5

A

220817

Shield

220817

Shield

220854

Retaining cap

220953

Ohmic-sensing

retaining cap

220819

Nozzle

6
5

A

220819

Nozzle

220842

Electrode

220842

Electrode

220857

Swirl ring

220857

Swirl ring

3-30 Powermax65/85 Service Manual

TORCH SETUP

65A Shielded Air flow rate - slpm/scfh

Mild Steel

Metric

Material

Thickness

Torch-

to-Work

Distance

Initial Pierce

Height

Pierce

Delay

Time

Best Quality Settings Production Settings

Cut Speed Voltage Cut Speed Voltage

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

3
4
6 2550 127 3240 127

3.8 250

0.2 5200 125 6100 123
4250 125 5100 124

0.5

8 1700 129 2230 128
10
12 1.2 850 134 1140 131

1.5

4.5 300

0.7 1100 131 1500 129

16 6.0 400 2.0 560 138 650 136
20
25 210 145 270 145

Edge Start

350 142 450 142

Hot 160 / 340

Cold 220 / 470

English

Material

Thickness

Torch-

to-Work

Distance

Initial Pierce

Height

Pierce

Delay

Time

Best Quality Settings Production Settings

Cut Speed Voltage Cut Speed Voltage

in in % seconds ipm Volts ipm Volts

10GA

3/16 in 0.2 140 126 168 125

1/4 in 0.5 90 127 116 127

0.15 250

0.1 190 125 224 123

3/8 in 0.7 45 130 62 129
1/2 in 0.18 300 1.2 30 135 40 132

0.06
5/8 in 0.24 400 2.0 23 138 26 136
3/4 in
7/8 in 12 143 14 143

Edge Start

15 141 19 141

1 in 8 145 10 145

Powermax65/85 Service Manual 3-31

TORCH SETUP

65A Shielded Air flow rate - slpm/scfh

Stainless Steel

Metric

Material

Thickness

Torch-

to-Work

Distance

Initial Pierce

Height

Pierce

Delay Time

Best Quality Settings Production Settings

Cut Speed Voltage Cut Speed Voltage

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

2

0.1 8100 125 10000 121
3 0.2 6700 125 8260 123
4
6 2450 126 2850 126
8

1.5
10
12 1.2 750 135 920 134
16
20 300 143 370 143

3.8 250

4.5 300

Edge Start

0.5

0.7

5200 125 6150 124

1500 129 1860 129

960 132 1250 132

500 139 500 139

Hot 160 / 340

Cold 220 / 470

English

Material

Thickness

Torch-

to-Work

Distance

Initial Pierce

Height

Pierce

Delay Time

Best Quality Settings Production Settings

Cut Speed Voltage Cut Speed Voltage

in in % seconds ipm Volts ipm Volts

10GA

3/16 in 0.2 155 126 168 125

1/4 in 0.5 80 126 96 126
3/8 in 0.7 40 131 52 131

0.06

0.15 250

0.1 240 125 296 123

1/2 in 0.18 300 1.2 26 136 32 135
5/8 in
3/4 in 14 142 15 142

Edge Start

20 139 20 139

3-32 Powermax65/85 Service Manual

TORCH SETUP

65A Shielded Air flow rate - slpm/scfh

Aluminum

Metric

Material

Thickness

Torch-

to-Work

Distance

Initial Pierce

Height

Pierce Delay

Time

Best Quality Settings Production Settings

Cut Speed Voltage Cut Speed Voltage

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

2

0.1 8800 121 10300 122
3 0.2 7400 124 8800 124
4
6 3200 130 4400 128
8

1.5
10
12 1.2 1000 138 1330 136
16
20 380 147 560 145

3.8 250

4.5 300

Edge Start

0.5

0.7

6000 126 7350 125

1950 133 2750 130
1200 136 1650 132

650 143 800 141

Hot 160 / 340

Cold 220 / 470

English

Material

Thickness

Torch-

to-Work

Distance

Initial Pierce

Height

Pierce Delay

Time

Best Quality Settings Production Settings

Cut Speed Voltage Cut Speed Voltage

in in % seconds ipm Volts ipm Volts

1/16 in

1/8 in 280 124 336 124
1/4 in 0.5 105 131 152 128
3/8 in 0.7 50 135 68 131

0.06

0.15 250

0.1

365 121 428 121

1/2 in 0.18 300 1.2 35 139 48 138
5/8 in
3/4 in 16 146 24 144

Edge Start

26 143 32 141

Powermax65/85 Service Manual 3-33

TORCH SETUP

45 A shielded consumables

4
5

A

220817

Shield

220817

Shield

220854

Retaining cap

220953

Ohmic-sensing

retaining cap

220941

Nozzle

4
5

A

220941

Nozzle

220842

Electrode

220842

Electrode

220857

Swirl ring

220857

Swirl ring

3-34 Powermax65/85 Service Manual

TORCH SETUP

45A Shielded Air flow rate - slpm/scfh

Mild Steel

Metric

Material

Thickness

Torch-

to-Work

Distance

Initial Pierce

Height

Pierce Delay

Time

Best Quality Settings Production Settings

Cut Speed Voltage Cut Speed Voltage

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

0.5
1 9000 128 10800 128

0.0

9000 128 12500 126

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

1.5 3.8 250

0.4

3850 133 4900 131

6 0.5 1350 137 2050 132

English

Material

Thickness

Torch-

to-Work

Distance

Initial Pierce

Height

Pierce Delay

Time

Best Quality Settings Production Settings

Cut Speed Voltage Cut Speed Voltage

in in % seconds ipm Volts ipm Volts
26GA
22GA 350 128 450 128
18GA
16GA 350 130 400 129
14GA 0.2 270 130 320 129

0.06 0.15 250
12GA
10GA 100 134 164 131

0.0

0.1

0.4

350 128 500 128

350 129 400 128

190 133 216 131

3/16 in 0.5 70 135 108 132

1/4 in 0.6 48 137 73 132

Hot 150 / 310

Cold 210/ 450

Powermax65/85 Service Manual 3-35

TORCH SETUP

45A Shielded Air flow rate - slpm/scfh

Stainless Steel

Metric

Material

Thickness

Torch-

to-Work

Distance

Initial Pierce

Height

Pierce

Delay Time

Best Quality Settings Production Settings

Cut Speed Voltage Cut Speed Voltage

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

0.5
1 9000 130 10800 130

0.0

9000 130 12500 129

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

1.5 3.8 250

0.4

3100 132 4400 132

6 0.5 900 140 1020 139

English

Material

Thickness

Torch-

to-Work

Distance

Initial Pierce

Height

Pierce

Delay Time

Best Quality Settings Production Settings

Cut Speed Voltage Cut Speed Voltage

in in % seconds ipm Volts ipm Volts
26GA
22GA 350 130 450 129
18GA
16GA 350 130 400 130
14GA 0.2 250 132 360 131

0.06 0.15 250
12GA
10GA 100 133 134 134

0.0

0.1

0.4

350 130 500 129

350 130 400 130

140 132 206 131

3/16 in 0.5 52 135 58 135

1/4 in 0.6 30 141 35 140

Hot 150 / 310

Cold 210/ 450

3-36 Powermax65/85 Service Manual

TORCH SETUP

45A Shielded Air flow rate - slpm/scfh

Aluminum

Metric

Material

Thickness

Torch-

to-Work

Distance

Initial Pierce

Height

Pierce

Delay Time

Best Quality Settings Production Settings

Cut Speed Voltage Cut Speed Voltage

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

1

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

1.5 3.8 250
4 0.4 2200 141 4850 135
6 0.5 1500 142 2800 137

English

Material

Thickness

Torch-

to-Work

Distance

Initial Pierce

Height

Pierce

Delay Time

Best Quality Settings Production Settings

Cut Speed Voltage Cut Speed Voltage

in in % seconds ipm Volts ipm Volts

1/32 in

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

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

Hot 150 / 310

Cold 210/ 450

Powermax65/85 Service Manual 3-37

TORCH SETUP

FineCut® consumables

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

220948

Shield

220955

Deflector

220953

Ohmic-sensing

retaining cap

220854

Retaining cap

220930

Nozzle

220930

Nozzle

220842

Electrode

220842

Electrode

220947

Swirl ring

220947

Swirl ring

3-38 Powermax65/85 Service Manual

TORCH SETUP

FineCut Air flow rate - slpm/scfh

Mild Steel

Metric

Material

Thickness

Amps

Torch-

to-Work

Distance

Initial Pierce Height

Pierce Delay

Time

Cut Speed Voltage

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

0.5

0.6 8250 78

40

0.0

8250 78

0.8 0.1 8250 78
1

1.5
2 4800 78

45

1.5 3.8 250

0.2 8250 78

0.4

6400 78

3 0.5 2500 78
4 0.6 1900 78

Hot 155 / 330

Cold 215 / 460

Best Quality Settings

English

Material

Thickness

Amps

Torch-

to-Work

Distance

Initial Pierce Height

Pierce Delay

Time

Best Quality Settings

Cut Speed Voltage

A in in % seconds ipm Volts
26GA
24GA 325 78
22GA

40

20GA 325 78
18GA

0.06 0.15 250
16GA
14GA 200 78

45
12GA
10GA 95 78

0.0

0.1

0.2 325 78

0.4

0.5

325 78

325 78

250 78

120 78

Powermax65/85 Service Manual 3-39

TORCH SETUP

FineCut Air flow rate - slpm/scfh

Stainless Steel

Metric

Material

Thickness

Amps

Torch-

to-Work

Distance

Initial Pierce Height

Pierce

Delay Time

Cut Speed Voltage

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

0.5

0.6 8250 68

40

0.0

0.8 0.1 8250 68
1

1.5
2 4800 71

45

0.5 2.0 400

0.2 8250 68

0.4

3 0.5 2550 80
4 0.6 1050 84

Hot 155 / 330

Cold 215 / 460

Best Quality Settings

8250 68

6150 70

English

Material

Thickness

Amps

Torch-

to-Work

Distance

Initial Pierce Height

Pierce

Delay Time

Best Quality Settings

Cut Speed Voltage

A in in % seconds ipm Volts
26GA
24GA 325 68
22GA

40

20GA 325 68
18GA

0.02 0.08 400
16GA
14GA 200 70

45

0.0

0.1

0.2 325 68

0.4

325 68

325 68

240 70

12GA 0.5 120 80
10GA 0.6 75 80

3-40 Powermax65/85 Service Manual

TORCH SETUP

Low Speed FineCut Air flow rate – slpm/scfh
Mild Steel

Metric

Material

Thickness

Current

Torch-

to-Work

Distance

Initial Pierce Height

Pierce Delay

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

0.5

0.6 3800 68

30

0.8 0.1 3800 70
1 *

1.5 *

40

1.5 3.8 250

2
3 0.5 2750 78

45

4 0.6 1900 78

Hot 155 / 330

Cold 215 / 460

Recommended

Time

0.0

Cut Speed Voltage

3800 69

0.2 3800 72

0.4

3800 75
3700 76

English

Material

Thickness

Current

Torch-

to-Work

Distance

Initial Pierce Height

Pierce Delay

Time

Recommended

Cut Speed Voltage

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

30

20GA 150 71
18GA

16GA *

40

0.06 0.15 250

14GA *

12GA

45

10GA 95 78

0.0

0.1

0.2 150 73

0.4

0.5

150 70

150 70

150 75
150 76
120 78

*Not a dross-free cut.

Powermax65/85 Service Manual 3-41

TORCH SETUP

Low Speed FineCut Air flow rate – slpm/scfh
Stainless Steel

Metric

Material

Thickness

Current

Torch-

to-Work

Distance

Initial Pierce Height

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

0.5

0.6 3800 69

30

0.8 0.1 3800 69
1

1.5

40

0.5 2.0 400

2 2750 69
3
4 0.6 1050 80

45

Hot 155 / 330
Cold 215 / 460

Pierce Delay

Time

0.0

Recommended

Cut Speed Voltage

3800 69

0.15 3800 69

0.4

2900 69

0.5 2550 80

English

Material

Thickness

Current

Torch-

to-Work

Distance

Initial Pierce Height

Pierce Delay

Time

Recommended

Cut Speed Voltage

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

30

20GA 150 69
18GA
16GA

40

0.02 0.08 400

14GA 110 69
12GA
10GA 0.6 75 80

45

0.0

0.1

0.2 145 69

0.4

0.5 120 80

150 69

150 69

115 69

3-42 Powermax65/85 Service Manual

85 A unshielded consumables

TORCH SETUP

8

5
A

220955

Deflector

220854

Retaining cap

220816

Nozzle

220842

Electrode

220857

Swirl ring

Powermax65/85 Service Manual 3-43

TORCH SETUP

85A Unshielded Air flow rate - slpm/scfh

Mild Steel

Metric

Material

Thickness

Torch-

to-Work

Distance

Initial Pierce

Height

Pierce

Delay Time

Best Quality Settings Production Settings

Cut Speed Voltage Cut Speed Voltage

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

3

0.1 6240 118 9000 117
4 0.2 5250 118 7200 117
6
8 2400 121 3100 121

10 1560 123 2070 122

2.0

5.0 250

3450 120 4400 119

0.5

12 6.0 300 0.7 1200 126 1600 124
16
20 540 137 640 132

Edge Start

820 132 930 128

25 320 143 400 137

Hot 190 / 400

Cold 235 / 500

English

Material

Thickness

Torch-

to-Work

Distance

Initial Pierce

Height

Pierce

Delay Time

Best Quality Settings Production Settings

Cut Speed Voltage Cut Speed Voltage

in in % seconds ipm Volts ipm Volts

10GA

3/16 in 175 119 220 118

1/4 in

0.20 250

3/8 in 65 122 86 122
1/2 in 0.24 300 0.6 42 127 56 125

0.08

0.2

0.5

5/8 in
3/4 in 23 136 27 131
7/8 in 18 140 21 134

Edge Start

230 118 328 117

125 120 160 119

33 131 37 128

1 in 12 144 15 138

3-44 Powermax65/85 Service Manual

TORCH SETUP

85A Unshielded Air flow rate - slpm/scfh

Stainless Steel

Metric

Material

Thickness

Torch-

to-Work

Distance

Initial Pierce

Height

Pierce Delay

Time

Best Quality Settings Production Settings

Cut Speed Voltage Cut Speed Voltage

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

2
3 7000 118 9660 117
4 0.2 5600 118 7800 118

5.0 250
6
8 2250 121 2970 122

10
12 0.7 1000 129 1340 128
16
20 360 138 570 137

2.0

6.0 300

Edge Start

0.1

0.5

0.5 1430 123 1840 124

8550 117 11300 116

3400 120 4570 121

650 134 730 133

Hot 190 / 400

Cold 235 / 500

English

Material

Thickness

Torch-

to-Work

Distance

Initial Pierce

Height

Pierce Delay

Time

Best Quality Settings Production Settings

Cut Speed Voltage Cut Speed Voltage

in in % seconds ipm Volts ipm Volts

10GA

3/16 in 180 119 249 119

0.20 250

1/4 in
3/8 in 60 122 77 123

0.08

0.2

0.5

250 118 352 118

120 120 160 121

1/2 in 0.24 300 0.6 35 131 46 129
5/8 in
3/4 in 17 137 24 136

Edge Start

26 134 29 133

Powermax65/85 Service Manual 3-45

TORCH SETUP

85A Unshielded Air flow rate - slpm/scfh

Aluminum

Metric

Material

Thickness

Torch-

to-Work

Distance

Initial Pierce

Height

Pierce

Delay Time

Best Quality Settings Production Settings

Cut Speed Voltage Cut Speed Voltage

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

2
3 7350 120 9600 119
4 0.2 6000 122 8100 120

5.0 250
6
8 2350 127 3250 124

10
12 0.7 1300 133 1720 130
16
20 470 144 700 138

2.0

6.0 300

Edge Start

0.1

0.5

0.5 1800 128 2140 127

8700 118 11200 118

3300 125 4930 122

840 139 1130 134

Hot 190 / 400

Cold 235 / 500

English

Material

Thickness

Torch-

to-Work

Distance

Initial Pierce

Height

Pierce

Delay Time

Best Quality Settings Production Settings

Cut Speed Voltage Cut Speed Voltage

in in % seconds ipm Volts ipm Volts

1/8 in

3/16 in 200 123 271 120

1/4 in
3/8 in 75 127 88 126

0.08

0.20 250

0.2

0.5

280 120 368 119

110 126 172 122

1/2 in 0.24 300 0.6 45 135 62 131
5/8 in
3/4 in 22 143 32 137

Edge Start

34 139 45 134

3-46 Powermax65/85 Service Manual

65 A unshielded consumables

TORCH SETUP

6

5
A

220955

Deflector

220854

Retaining cap

220819

Nozzle

220842

Electrode

220857

Swirl ring

Powermax65/85 Service Manual 3-47

TORCH SETUP

65A Unshielded Air flow rate - slpm/scfh

Mild Steel

Metric

Material

Thickness

Torch-

to-Work

Distance

Initial Pierce

Height

Pierce Delay

Time

Best Quality Settings Production Settings

Cut Speed Voltage Cut Speed Voltage

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

3
4
6 2550 120 3560 120
8 1620 123 2230 121

10 6.0 300 0.7 970 127 1500 122

2.0

5.0 250

12
16 500 134 650 129

Edge Start

0.2 5200 118 6330 118
4250 118 5250 118

0.5

760 129 1140 124

20 280 138 400 133

Hot 160 / 340

Cold 220 / 470

English

Material

Thickness

Torch-

to-Work

Distance

Initial Pierce

Height

Pierce Delay

Time

Best Quality Settings Production Settings

Cut Speed Voltage Cut Speed Voltage

in in % seconds ipm Volts ipm Volts

10GA

3/16 in 0.2 135 119 172 119

0.20 250

0.1 190 118 232 118

1/4 in 0.5 90 120 116 120
3/8 in 0.24 300 0.7 40 126 62 122
1/2 in
5/8 in 20 134 26 129

0.08
27 130 40 125

Edge Start

3/4 in 13 137 18 132

3-48 Powermax65/85 Service Manual

TORCH SETUP

65A Unshielded Air flow rate - slpm/scfh

Stainless Steel

Metric

Material

Thickness

Torch-

to-Work

Distance

Initial Pierce

Height

Pierce

Delay Time

Best Quality Settings Production Settings

Cut Speed Voltage Cut Speed Voltage

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

2

0.1 7950 117 10300 116
3 0.2 6600 118 8500 117
4
6 2300 121 3070 121
8 0.7 1400 123 1900 122

2.0

5.0 250

0.5

5050 119 6500 119

10 6.0 300 0.7 920 126 1250 123
12
16 430 135 500 133

Edge Start

710 130 925 127

Hot 160 / 340

Cold 220 / 470

English

Material

Thickness

Torch-

to-Work

Distance

Initial Pierce

Height

Pierce

Delay Time

Best Quality Settings Production Settings

Cut Speed Voltage Cut Speed Voltage

in in % seconds ipm Volts ipm Volts

10GA

3/16 in 0.2 150 120 194 120

1/4 in 0.5 75 121 100 121
3/8 in 0.24 300 0.7 38 125 52 122

0.08

1/2 in
5/8 in 17 135 20 133

0.20 250

Edge Start

0.1 235 118 304 118

25 132 32 129

Powermax65/85 Service Manual 3-49

TORCH SETUP

65A Unshielded Air flow rate - slpm/scfh

Aluminum

Metric

Material

Thickness

Torch-

to-Work

Distance

Initial Pierce

Height

Pierce

Delay Time

Best Quality Settings Production Settings

Cut Speed Voltage Cut Speed Voltage

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

2

0.1 7750 123 11300 122
3 0.2 6550 124 9500 123
4
6 3000 127 3900 126
8 0.7 1800 130 2460 127

2.0

5.0 250

0.5

5400 125 7640 124

10 6.0 300 0.7 1100 133 1640 129
12
16 600 139 700 136

Edge Start

900 135 1250 133

Hot 160 / 340

Cold 220 / 470

English

Material

Thickness

Torch-

to-Work

Distance

Initial Pierce

Height

Pierce

Delay Time

Best Quality Settings Production Settings

Cut Speed Voltage Cut Speed Voltage

in in % seconds ipm Volts ipm Volts

1/16 in

1/8 in 250 124 360 123

0.20 250

0.1

325 122 476 122

3/16 in 175 125 245 124

1/4 in 0.5 100 127 128 126

0.08

3/8 in 0.24 300 0.7 45 132 68 128
1/2 in
5/8 in 24 138 28 136

Edge Start

32 136 44 134

3-50 Powermax65/85 Service Manual

45 A unshielded consumables

TORCH SETUP

4
5
A

220955

Deflector

220854

Retaining cap

220941

Nozzle

220842

Electrode

220857

Swirl ring

Powermax65/85 Service Manual 3-51

TORCH SETUP

45A Unshielded Air flow rate - slpm/scfh

Mild Steel

Metric

Material

Thickness

Torch-

to-Work

Distance

Initial Pierce

Height

Pierce

Delay Time

Best Quality Settings Production Settings

Cut Speed Voltage Cut Speed Voltage

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

0.5
1 9000 120 10800 121

0.0

9000 120 12500 120

1.5 0.1 7700 120 10200 121

2 0.3 6150 119 7800 122
3
4 2350 123 3560 124

1.5 3.8 250

0.4

3950 121 4900 123

6 0.5 1400 126 2050 124

English

Material

Thickness

Torch-

to-Work

Distance

Initial Pierce

Height

Pierce

Delay Time

Best Quality Settings Production Settings

Cut Speed Voltage Cut Speed Voltage

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

0.06 0.15 250
12GA
10GA 100 123 164 124

0.0

0.1

0.4

350 120 500 120

350 119 400 121

200 120 216 123

3/16 in 0.5 85 122 108 124

1/4 in 0.6 48 127 73 124

Hot 150 / 310

Cold 210 / 450

3-52 Powermax65/85 Service Manual