Hypertherm Powermax105 Service Manual

Plasma arc cutting systems

Service Manual – 807580 Revision 1

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powermax

Service Manual

(P/N 807580)

105

Revision 1 – November 2013

Hypertherm, Inc.

Hanover, NH USA

www.hypertherm.com

email: info@hypertherm.com

Hypertherm and Powermax are trademarks of Hypertherm, Inc.

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

Hypertherm Inc.

Etna Road, P.O. Box 5010 Hanover, NH 03755 USA 603-643-3441 Tel (Main Office) 603-643-5352 Fax (All Departments) info@hypertherm.com (Main Office Email)

800-643-9878 Tel (Technical Service)

technical.service@hypertherm.com (Technical Service Email)

800-737-2978 Tel (Customer Service)

customer.service@hypertherm.com (Customer Service Email)

866-643-7711 Tel (Return Materials Authorization) 877-371-2876 Fax (Return Materials Authorization)

return.materials@hypertherm.com (RMA email)

Hypertherm Plasmatechnik GmbH

Technologiepark Hanau Rodenbacher Chaussee 6 D-63457 Hanau-Wolfgang, Deutschland 49 6181 58 2100 Tel 49 6181 58 2134 Fax

49 6181 58 2123 (Technical Service)

Hypertherm (S) Pte Ltd.

82 Genting Lane Media Centre Annexe Block #A01-01 Singapore 349567, Republic of Singapore 65 6841 2489 Tel 65 6841 2490 Fax

65 6841 2489 (Technical Service)

Hypertherm (Shanghai) Trading Co., Ltd.

Unit 301, South Building 495 ShangZhong Road Shanghai, 200231 PR China 86-21-60740003 Tel 86-21-60740393 Fax

Hypertherm Europe B.V.

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

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

Hypertherm Japan Ltd.

Level 9, Edobori Center Building 2-1-1 Edobori, Nishi-ku Osaka 550-0002 Japan 81 6 6225 1183 Tel 81 6 6225 1184 Fax

Hypertherm Brasil Ltda.

Rua Bras Cubas, 231 – Jardim Maia Guarulhos, SP - Brasil CEP 07115-030 55 11 2409 2636 Tel 55 11 2408 0462 Fax

Hypertherm México, S.A. de C.V.

Avenida Toluca No. 444, Anexo 1, Colonia Olivar de los Padres Delegación Álvaro Obregón México, D.F. C.P. 01780 52 55 5681 8109 Tel 52 55 5683 2127 Fax

Hypertherm Korea Branch

#3904 Centum Leaders Mark B/D, 1514 Woo-dong, Haeundae-gu, Busan Korea, 612-889 82 51 747 0358 Tel 82 51 701 0358 Fax

12/2/13

ELECTROMAGNETIC COMPATIBILITY EMC

Introduction

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

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

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

Installation and use

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

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

Assessment of area

Before installing the equipment, the user shall make an assessment of potential electromagnetic problems in the surrounding area. The following shall be taken into account:

a. Other supply cables, control cables, signaling and

telephone cables; above, below and adjacent to the cutting equipment.

b. Radio and television transmitters and receivers.

c. Computer and other control equipment.

d. Safety critical equipment, for example guarding

ofindustrial equipment.

e. Health of the people around, for example the use

ofpacemakers and hearing aids.

f. Equipment used for calibration or measurement.

g. Immunity of other equipment in the environment. User

shall ensure that other equipment being used in the environment is compatible. This may require additional protection measures.

h. Time of day that cutting or other activities are to be

carried out.

The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place. The surrounding area may extend beyond the boundaries of the premises.

Methods of reducing emissions

Mains supply

Cutting equipment must be connected to the mains supply according to the manufacturer’s recommendations. If interference occurs, it may be necessary to take additional precautions such as filtering of the mains supply.

Compliance Information EMC-1

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ELECTROMAGNETIC COMPATIBILITY

Consideration should be given to shielding the supply cable of permanently installed cutting equipment, in metallic conduit or equivalent. Shielding should be electrically continuous throughout its length. The shielding should be connected to the cutting mains supply so that good electrical contact is maintained between the conduit and the cutting power source enclosure.

Maintenance of cutting equipment

The cutting equipment must be routinely maintained according to the manufacturer’s recommendations. All access and service doors and covers should be closed and properly fastened when the cutting equipment is in operation. The cutting equipment should not be modified in any way, except as set forth in and in accordance with the manufacturer’s written instructions. For example, the spark gaps of arc striking and stabilizing devices should be adjusted and maintained according to the manufacturer’s recommendations.

Cutting cables

The cutting cables should be kept as short as possible and should be positioned close together, running at or close to the floor level.

Equipotential bonding

Earthing of the workpiece

Where the workpiece is not bonded to earth for electrical safety, nor connected to earth because of its size and position, for example, ship’s hull or building steel work, a connection bonding the workpiece to earth may reduce emissions in some, but not all instances. Care should be taken to prevent the earthing of the workpiece increasing the risk of injury to users, or damage to other electrical equipment. Where necessary, the connection of the workpiece to earth should be made by a direct connection to the workpiece, but in some countries where direct connection is not permitted, the bonding should be achieved by suitable capacitances selected according to national regulations.

Note: The cutting circuit may or may not be earthed for safety reasons. Changing the earthing arrangements should only be authorized by a person who is competent to assess whether the changes will in crease the risk of injury, for example, by allowing parallel cutting current return paths which may damage the earth circuits of other equipment. Further guidance is provided in IEC60974-9, Arc Welding Equip ment, Part 9: Installation and Use.

Screening and shielding

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.

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.

EMC-2 Compliance Information

7/ 10

WARRANTY

Attention

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

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

General

Hypertherm, Inc. warrants that its Products shall be free from defects in materials and workmanship for the specific periods of time set forth herein and as follows: if Hypertherm is notified of a defect (i)with respect to the 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, 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.

product which has been incorrectly installed, modified, or otherwise damaged.

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

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

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

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

Compliance Information W-1

9/10

WARRANTY

Patent indemnity

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

Limitation of liability

In no event shall Hypertherm be liable to any person or entity for any incidental, consequential direct, indirect, punitive or exemplary damages (including but not limited to lost profits) regardless of whether such liability is based on breach of contract, tort, strict liability, breach of warranty, failure of essential purpose, or otherwise, and even if advised of the possibility of such damages.

National and local codes

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.

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.

W-2 Compliance Information

9/10

Safety information

Before operating any Hypertherm equipment, read the separate Safety and Compliance Manual (80669C) included with your product for important safety information.

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Section 1 Specifications

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

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

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

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

Component weights (105 A systems) ............................................................................................................................................... 1-5

Powermax105 power supply ratings .................................................................................................................................................. 1-6

Duramax 75° hand torch dimensions ................................................................................................................................................. 1-8

Duramax 15° hand torch dimensions ................................................................................................................................................. 1-8

Duramax 180° full-length machine torch dimensions ..................................................................................................................... 1-9

Duramax 180° mini machine torch dimensions ................................................................................................................................ 1-9

Powermax105 cutting specifications .............................................................................................................................................. 1-10

Symbols and markings ........................................................................................................................................................................ 1-11

Noise levels ........................................................................................................................................................................................... 1-11

IEC symbols .......................................................................................................................................................................................... 1-12

Section 2 Power Supply Setup

Unpack the Powermax 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 Powermax105 .......................................................................................................................................... 2-6

Three-phase power cord and plug installation ...................................................................................................................... 2-8

Extension cord recommendations ....................................................................................................................................................... 2-9

Extension cord specifications .................................................................................................................................................... 2-9

Engine-driven generator recommendations ........................................................................................................................ 2-10

Prepare the gas supply ....................................................................................................................................................................... 2-11

Additional gas filtration ............................................................................................................................................................. 2-11

Connect the gas supply ........................................................................................................................................................... 2-12

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Section 3 Basic System Operations

Controls and indicators ......................................................................................................................................................................... 3-2

Rear controls .................................................................................................................................................................................3-2

Front controls and LEDs ............................................................................................................................................................. 3-2

Status screen ................................................................................................................................................................................3-4

Operating the Powermax105 ............................................................................................................................................................... 3-6

Connect the electrical power, gas supply, and torch lead .................................................................................................3-6

Attach the work lead to the power supply .............................................................................................................................. 3-7

Attach the work clamp to the workpiece ................................................................................................................................3-8

Turn ON the system ..................................................................................................................................................................... 3-9

Set the operating mode switch ................................................................................................................................................. 3-9

Check the indicators ................................................................................................................................................................. 3-10

Manually adjusting the gas pressure ..................................................................................................................................... 3-10

Adjusting the current (amperage) .......................................................................................................................................... 3-11

Electrode end-of-life detection feature ........................................................................................................................................... 3-11

Understanding duty-cycle limitations .............................................................................................................................................. 3-12

Section 4 Hand Torch Setup

Introduction ..............................................................................................................................................................................................4-2

Consumable life .......................................................................................................................................................................................4-2

Hand torch components .......................................................................................................................................................................4-3

Choose the hand torch consumables ................................................................................................................................................ 4-4

Drag-cutting 105 A consumables ............................................................................................................................................ 4-4

Drag-cutting 45 A, 65 A, 85 A consumables ........................................................................................................................ 4-4

Hand torch consumables ...................................................................................................................................................................... 4-5

Gouging consumables ................................................................................................................................................................ 4-5

FineCut® consumables ............................................................................................................................................................... 4-5

Install the hand torch consumables .................................................................................................................................................... 4-6

Connecting the torch lead .................................................................................................................................................................... 4-7

Section 5 Hand Cutting

Using the hand torch .............................................................................................................................................................................. 5-2

Operate the safety trigger ..................................................................................................................................................................... 5-2

Hand torch cutting hints ........................................................................................................................................................................ 5-3

Start a cut from the edge of the workpiece ...................................................................................................................................... 5-4

Pierce a workpiece ................................................................................................................................................................................. 5-5

Gouge a workpiece ................................................................................................................................................................................ 5-6

Gouge profile ................................................................................................................................................................................5-7

Varying the gouge profile ............................................................................................................................................................ 5-8

Common hand-cutting faults ................................................................................................................................................................ 5-8

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Section 6 Machine Torch Setup

Machine torch components .................................................................................................................................................................. 6-4

Converting a full-length machine torch to a mini machine torch .................................................................................................6-5

Mount the torch ....................................................................................................................................................................................... 6-7

Choose the machine torch consumables ..........................................................................................................................................6-9

Machine torch consumables ................................................................................................................................................................6-9

Mechanized shielded 105 A consumables ............................................................................................................................6-9

Mechanized shielded 45 A, 65 A, 85 A consumables ........................................................................................................6-9

Mechanized shielded with ohmic 105 A consumables .................................................................................................... 6-10

Mechanized shielded with ohmic 45 A, 65 A, 85 A consumables ................................................................................ 6-10

Mechanized unshielded 105 A consumables ..................................................................................................................... 6-10

Mechanized unshielded 45 A, 65 A, 85 A consumables ................................................................................................. 6-10

Gouging consumables ............................................................................................................................................................. 6-11

FineCut® shielded consumables ........................................................................................................................................... 6-11

FineCut® unshielded consumables ...................................................................................................................................... 6-11

Install the machine torch consumables ........................................................................................................................................... 6-12

Aligning the torch ................................................................................................................................................................................. 6-12

Connecting the torch lead ................................................................................................................................................................. 6-13

Using the cut charts ............................................................................................................................................................................ 6-14

Estimated kerf-width compensation ...................................................................................................................................... 6-15

105 A Shielded consumables ................................................................................................................................................ 6-17

105 A Shielded cutting (Mild Steel) ..................................................................................................................................... 6-18

105 A Shielded cutting (Stainless Steel) ............................................................................................................................ 6-19

105 A Shielded cutting (Aluminum) ...................................................................................................................................... 6-20

85 A Shielded consumables ................................................................................................................................................... 6-21

85 A Shielded cutting (Mild Steel) ........................................................................................................................................ 6-22

85 A Shielded cutting (Stainless Steel) ............................................................................................................................... 6-23

85 A Shielded cutting (Aluminum) ........................................................................................................................................ 6-24

65 A Shielded consumables ................................................................................................................................................... 6-25

65 A Shielded cutting (Mild Steel) ........................................................................................................................................ 6-26

65 A Shielded cutting (Stainless Steel) ............................................................................................................................... 6-27

65 A Shielded cutting (Aluminum) ........................................................................................................................................ 6-28

45 A Shielded consumables ................................................................................................................................................... 6-29

45 A Shielded cutting (Mild Steel) ........................................................................................................................................ 6-30

45 A Shielded cutting (Stainless Steel) ............................................................................................................................... 6-31

45 A Shielded cutting (Aluminum) ........................................................................................................................................ 6-32

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FineCut® consumables ............................................................................................................................................................ 6-33

FineCut (Mild Steel) .................................................................................................................................................................. 6-34

FineCut (Stainless Steel) ......................................................................................................................................................... 6-35

Low Speed FineCut (Mild Steel) ........................................................................................................................................... 6-36

Low Speed FineCut (Stainless Steel) .................................................................................................................................. 6-37

105 A Unshielded consumables ............................................................................................................................................ 6-38

105 A Unshielded cutting (Mild Steel) ................................................................................................................................. 6-39

105 A Unshielded cutting (Stainless Steel) ........................................................................................................................ 6-40

105 A Unshielded cutting (Aluminum) ................................................................................................................................. 6-41

85 A Unshielded consumables .............................................................................................................................................. 6-42

85 A Unshielded cutting (Mild Steel) ................................................................................................................................... 6-43

85 A Unshielded cutting (Stainless Steel) .......................................................................................................................... 6-44

85 A Unshielded cutting (Aluminum) .................................................................................................................................... 6-45

65 A Unshielded consumables .............................................................................................................................................. 6-46

65 A Unshielded cutting (Mild Steel) ................................................................................................................................... 6-47

65 A Unshielded cutting (Stainless Steel) .......................................................................................................................... 6-48

65 A Unshielded cutting (Aluminum) .................................................................................................................................... 6-49

45 A Unshielded consumables .............................................................................................................................................. 6-50

45 A Unshielded cutting (Mild Steel) ................................................................................................................................... 6-51

45 A Unshielded cutting (Stainless Steel) .......................................................................................................................... 6-52

45 A Unshielded cutting (Aluminum) .................................................................................................................................... 6-53

Section 7 Mechanized Cutting

Connecting an optional remote-start pendant ................................................................................................................................. 7-2

Connecting an optional machine interface cable ............................................................................................................................ 7-3

Machine interface pinout ............................................................................................................................................................7-5

Setting the five-position voltage divider .................................................................................................................................. 7-6

Accessing raw arc voltage ....................................................................................................................................................................7-7

Connecting an optional RS485 serial interface cable ................................................................................................................... 7-7

Using the machine torch .......................................................................................................................................................................7-8

Setting up the torch and table ............................................................................................................................................................. 7-8

Understand and optimize cut quality .................................................................................................................................................. 7-8

Cut or bevel angle ........................................................................................................................................................................ 7-8

Dross ............................................................................................................................................................................................... 7-9

Piercing a workpiece using the machine torch ............................................................................................................................. 7-10

Common machine-cutting faults ...................................................................................................................................................... 7-11

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Section 8 Troubleshooting and System Tests

Controls and indicators ......................................................................................................................................................................... 8-3

Theory of operation .................................................................................................................................................................................8-4

General ...........................................................................................................................................................................................8-4

200-600 V CSA 3-phase power supply functional description .......................................................................................8-4

230-400 V CE, 380 V CCC/230-400 V CE 3-phase power supply functional description ....................................8-5

400 V CE, 380 V CCC 3-phase power supply functional description ........................................................................... 8-5

Sequence of operation ................................................................................................................................................................ 8-6

Troubleshooting preparation ................................................................................................................................................................8-7

Test equipment .............................................................................................................................................................................8-7

Troubleshooting procedures and sequence .......................................................................................................................... 8-7

External inspection ....................................................................................................................................................................... 8-9

Internal inspection ........................................................................................................................................................................8-9

Initial resistance check ...........................................................................................................................................................................8-9

Check the power switch ............................................................................................................................................................. 8-9

Hypertherm IGBT tester .......................................................................................................................................................... 8-12

Indicator LEDs and device tests ............................................................................................................................................ 8-12

IGBT test preparation ............................................................................................................................................................... 8-13

IGBT device test using the Hypertherm tester ................................................................................................................... 8-14

Troubleshoot the Hypertherm IGBT tester .......................................................................................................................... 8-14

Schematic for building an IGBT tester ................................................................................................................................. 8-15

IGBT device test using a non-Hypertherm tester .............................................................................................................. 8-16

200-600 V CSA power supply overview ....................................................................................................................................... 8-17

230-400 V CE, 380 V CCC/230-400 V CE power supply overview .................................................................................... 8-18

380 V CCC, 400 V CE power supply overview ........................................................................................................................... 8-19

200-600 V CSA power supply overview (power board removed) .......................................................................................... 8-20

230-400 V CE, 380 V CCC/230-400 V CE power supply overview (power board removed) ....................................... 8-21

380 V CCC, 400 V CE power supply overview (power board removed) .............................................................................. 8-22

Fault codes ............................................................................................................................................................................................ 8-23

Displaying the service screen ................................................................................................................................................. 8-23

Important fault icons ................................................................................................................................................................. 8-24

Performing a cold restart ......................................................................................................................................................... 8-24

Fault codes and solutions ........................................................................................................................................................ 8-25

Troubleshooting guide ........................................................................................................................................................................ 8-36

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System tests.......................................................................................................................................................................................... 8-42

Test 1 – Voltage input .............................................................................................................................................................. 8-43

Test 2 – DC Power Buss ........................................................................................................................................................ 8-44

Test 3 – Output diodes............................................................................................................................................................ 8-46

Test 4 – Inverter and PFC temperature sensor .................................................................................................................. 8-47

Test 5 – Flyback circuit (DC minor voltages) ..................................................................................................................... 8-50

Test 6 – Torch stuck open (TSO)/torch stuck closed (TSC) ......................................................................................... 8-52

Test 7 – Start signal ................................................................................................................................................................. 8-54

Test 8 – Torch cap switch ...................................................................................................................................................... 8-55

Test 9 – Electronic regulator .................................................................................................................................................. 8-56

Test 10 – Pressure sensor ...................................................................................................................................................... 8-57

Test 11 – Fan ............................................................................................................................................................................. 8-58

Test 12 – AUX switch .............................................................................................................................................................. 8-59

Section 9 Power Supply Component Replacement

Replacing the air filter element ............................................................................................................................................................9-3

Replacing the work lead connector .................................................................................................................................................... 9-3

Installing the optional filter kit ............................................................................................................................................................... 9-3

Replacing the power supply cover .....................................................................................................................................................9-3

Replacing the component barrier ........................................................................................................................................................ 9-3

Installing the machine interface cable with voltage divider board ............................................................................................... 9-4

Installing the machine interface cable ................................................................................................................................................ 9-4

Installing the RS485 serial interface cable ....................................................................................................................................... 9-4

Replacing the power cord ....................................................................................................................................................................9-5

Replacing the strain relief connector ..................................................................................................................................................9-5

Replacing the power switch ................................................................................................................................................................. 9-6

Replacing the control board ................................................................................................................................................................. 9-6

Replacing the DSP board ..................................................................................................................................................................... 9-6

Replacing the power board .................................................................................................................................................................. 9-7

Replacing the input diode bridge ........................................................................................................................................................ 9-7

Replacing the output diode bridge ..................................................................................................................................................... 9-8

Replacing the pilot arc IGBT ................................................................................................................................................................ 9-8

Replacing the inverter IGBT module .................................................................................................................................................. 9-8

Replacing the PFC IGBT module .......................................................................................................................................................9-9

Replacing the snubber resistor ............................................................................................................................................................9-9

Replacing the damper resistor .......................................................................................................................................................... 9-10

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Replacing the thermal sensor ........................................................................................................................................................... 9-10

Replacing the fan shroud ................................................................................................................................................................... 9-10

Replacing the fan ................................................................................................................................................................................. 9-11

Replacing the pressure transducer ................................................................................................................................................. 9-11

Replacing the pressure switch ......................................................................................................................................................... 9-11

Replacing the air filter subassembly ................................................................................................................................................ 9-12

Replacing the solenoid valve ............................................................................................................................................................. 9-12

Replacing the gas tubing ................................................................................................................................................................... 9-12

Replacing the bulk capacitors........................................................................................................................................................... 9-13

Replacing the torch quick disconnect receptacle ........................................................................................................................ 9-13

Replacing the work lead receptacle ................................................................................................................................................ 9-13

Replacing the output inductor .......................................................................................................................................................... 9-14

Replacing the transformer .................................................................................................................................................................. 9-14

Replacing the PFC inductor .............................................................................................................................................................. 9-14

Replacing the front end panel ........................................................................................................................................................... 9-15

Replacing the rear end panel ............................................................................................................................................................ 9-15

Installing the machine interface cable for raw arc voltage ......................................................................................................... 9-15

Section 10 Torch Component Replacement

Hand torch: Replacing the start switch .......................................................................................................................................... 10-2

Hand torch: Replacing the cap-sensor switch ............................................................................................................................. 10-2

Hand torch: Replacing the handles ................................................................................................................................................. 10-2

Hand torch: Replacing the trigger ................................................................................................................................................... 10-3

Hand torch: Replacing the torch body ............................................................................................................................................ 10-3

Hand torch: Replacing the torch lead ............................................................................................................................................. 10-3

Hand torch: Replacing the quick disconnect housing ................................................................................................................ 10-4

Machine torch: Replacing the mounting sleeve ............................................................................................................................ 10-4

Machine torch: Replacing the cap-sensor switch ........................................................................................................................ 10-4

Machine torch: Replacing the torch body ...................................................................................................................................... 10-4

Machine torch: Replacing the coupler ............................................................................................................................................ 10-5

Machine torch: Replacing the gear rack ......................................................................................................................................... 10-5

Machine torch: Replacing the positioning sleeve ......................................................................................................................... 10-5

Machine torch: Replacing the torch lead ....................................................................................................................................... 10-6

Machine torch: Replacing the quick disconnect housing .......................................................................................................... 10-6

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Table of ConTenTs

Section 11 Parts

Power supply parts .............................................................................................................................................................................. 11-2

Exterior front ............................................................................................................................................................................... 11-2

Exterior rear ................................................................................................................................................................................. 11-3

Interior, power board side (200-600 V CSA) ..................................................................................................................... 11-5

Interior, power board side (230-400 V CE) ........................................................................................................................ 11-6

Interior, power board side (400 V CE/380 V CCC) ......................................................................................................... 11-7

Interior, fan side ......................................................................................................................................................................... 11-8

Heat sink assembly ............................................................................................................................................................................11-10

200-600 V CSA heat sink components ............................................................................................................................11-10

230-400 V CE heat sink components ...............................................................................................................................11-11

400 V CE/ 380 V CCC heat sink components ...............................................................................................................11-12

Duramax 75° hand torch replacement parts ................................................................................................................................ 11-13

Duramax 15° hand torch replacement parts ................................................................................................................................ 11-14

Hand torch consumables .................................................................................................................................................................11-15

Duramax 180° full-length machine torch replacement parts ...................................................................................................11-16

Duramax 180° mini machine torch replacement parts ..............................................................................................................11-18

Machine torch consumables ...........................................................................................................................................................11-20

Accessory parts..................................................................................................................................................................................11-21

Powermax105 labels .........................................................................................................................................................................11-21

Safety-critical parts............................................................................................................................................................................11-22

200-600 V CSA ......................................................................................................................................................................11-22

230-400 V CE .........................................................................................................................................................................11-23

400 V CE/380 V CCC ..........................................................................................................................................................11-24

Power supply fan side ............................................................................................................................................................11-25

Recommended spare parts .............................................................................................................................................................11-26

Section 12 Wiring Diagrams

Powermax Generic Timing Chart ..................................................................................................................................................... 12-3

Schematic diagram (CSA,230-400VCE,380VCCC/230-400VCE) ............................................................................ 12-4

Schematic diagram (380 V CCC, 400 V CE) .............................................................................................................................. 12-5

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Section 1 SPECIFICATIONS

In this section:

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

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

Component weights (105 A systems) ..................................................................................................................................................1-5

Powermax105 power supply ratings .....................................................................................................................................................1-6

Duramax 75° hand torch dimensions ....................................................................................................................................................1-8

Duramax 15° hand torch dimensions ....................................................................................................................................................1-8

Duramax 180° full-length machine torch dimensions ........................................................................................................................1-9

Duramax 180° mini machine torch dimensions ...................................................................................................................................1-9

Powermax105 cutting specifications ................................................................................................................................................. 1-10

Symbols and markings ...........................................................................................................................................................................1-11

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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 Powermax105 is a highly portable, 105-amp, handheld and mechanized plasma cutting system appropriate for a wide range of applications. The Powermax system uses 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 Powermax105 can cut thicknesses up to 38 mm (1-1/2 inches) and pierce thicknesses up to 22 mm (7/8 inch). 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.

See your Hypertherm distributor for other system configurations. You can order additional styles of torches, consumables, and accessories such as the plasma cutting guide. See the Parts section for a list of spare and optional parts.

Powermax105 power supplies are shipped without a plug on the power cord. See the Power Supply Setup section for more information.

Note: Some CCC certified configurations do not ship with a power cord.

Powermax105 3-phase systems include the following models:

• The 200–600 V CSA model is a universal power supply that can automatically adjust to operate with AC voltages from 200 to 600 V.

• The 230-400 V CE model can automatically adjust from 230 to 400 V.

• The 380 V CCC/230–400 V CE model can automatically adjust from 230 to 400 V.

Note: To maintain CE certification, install power cord kit 228886.

• The 400 V CE model is 400 V only.

• The 380 V CCC model is 380 V only.

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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 the Power Supply Setup section.

• Handheld and machine torch consumables, cut charts, and torch setup information — See the Hand Torch

Setup or Machine Torch Setup section.

• Information about the controls and LEDs, steps for system operation, and hints for improving cut quality — See

the Basic System Operations, Hand Cutting, and Mechanized Cutting sections.

The manual also contains sections on troubleshooting and ordering parts for your system.

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SpecificationS

Power supply dimensions

432 mm

(17.0 in.)

508 mm

(20.0 in.)

592 mm

(23.3 in.)

274 mm

(10.8 in.)

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Component weights (105 A systems)

200–600 V CSA 230–400 V CE 400 V CE 380 V CCC 380 V CCC/

Power supply 40 kg (88lbs) 39 kg (87lbs) 35 kg (78lbs) With power cord

35 kg (78 lbs)

No power cord

34 kg (74 lbs)

With 7.6 m (25ft) hand torch and 7.6 m (25ft) work lead

Hand torch 7.6 m (25 ft) 3.3 kg (7.3 lbs) Hand torch 15 m (50 ft) 5.9 kg (13.0 lbs) Hand torch 23 m (75 ft) 8.4 kg (18.5 lbs)

45 kg (100lbs) 45 kg (100lbs) 41 kg (91lbs) With power cord

41 kg (91 lbs)

No power cord

39 kg (87 lbs)

SpecificationS

230–400 V CE

No power cord

36 kg (79 lbs)

No power cord

42 kg (92 lbs)

Machine torch 4.6 m (15 ft) 2.4 kg (5.4 lbs) Machine torch 7.6 m (25 ft) 3.4 kg (7.6 lbs) Machine torch 11 m (35 ft) 4.5 kg (10.0 lbs) Machine torch 15 m (50 ft) 6.2 kg (13.7 lbs) Machine torch 23 m (75 ft) 8.7 kg (19.3 lbs)

Work lead 7.6 m (25 ft) 2.4 kg (5.3 lbs) Work lead 15 m (50 ft) 4.4 kg (9.6 lbs) Work lead 23 m (75 ft) 6.1 kg (13.4 lbs)

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SpecificationS

Powermax105 power supply ratings

Rated open-circuit voltage (U0)

380 V CCC/230–400 V CE

Output characteristic

Rated output current (I2) 30–105 A

Rated output voltage (U2) 160 VDC

Duty cycle at 40° C (104° F) 200–600 V CSA 80% @ 105 A, 480–600 V, 3-PH

Drooping

or380VCCC/230–400V CE 80% @ 105 A, 400 V, 3-PH

200–600 V CSA

230–400 V CE

400 V CE

380 V CCC

230–400 V CE

400 V CE 80% @ 105 A, 400 V, 3-PH

380 V CCC 80% @ 105 A, 380 V, 3-PH

300 VDC 288 VDC 288 VDC 292 VDC 280 VDC

70% @ 105 A 240 V, 3-PH 54% @ 105 A 208 V, 3-PH 50% @ 105 A, 200 V, 3-PH 100% @ 94 A, 480–600 V, 3-PH 100% @ 88 A, 240 V, 3-PH 100% @ 77 A, 208 V, 3-PH 100% @ 74 A, 200 V, 3-PH

70% @ 105 A, 230 V, 3-PH 100% @ 94 A, 400 V, 3-PH 100% @ 88 A, 230 V, 3-PH

100% @ 94 A, 400 V, 3-PH

100% @ 94 A, 380 V, 3-PH

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

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

Power factor 200–600 V CSA, 3-PH 230–400 V CE, 3-PH 380 V CCC/230–400 V CE, 3-PH 400 V CE, 3-PH 380 V CCC, 3-PH

– Short Circuit Ratio (CE models only) U1 – Volts AC rms, 3-PH R

sce

0.94–0.77

0.94–0.92

0.94

230-400 V CE

400 V CE

sce

275 230

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SpecificationS

EMC classification CISPR 11 (CE models only)

Input voltage (U1)/ Input current (I1) at rated output (U

2 MAX

, I

2 MAX

) (See the

Power Supply Setup section for more information.)

Class A

200–600 V CSA 200/208/240/480/600 V, 3-PH, 50/60 Hz

58/56/49/25/22 A

380 V CCC/

230–400 V CE 230–400 V CE

230-400 V, 3-PH, 50/60 Hz

2,3

50/29 A

2,3

230-400 V, 3-PH, 50/60 Hz 50/29 A

400 V CE

3,5

400 V, 3-PH, 50/60 Hz 28 A

380 V CCC 380 V, 3-PH, 50/60 Hz

30 A

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

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 5528

Cutting: 220 slpm (460 scfh , 7.7 scfm) @ 5.9 bar (85 psi) Gouging: 230 slpm (480 scfh, 8.0 scfm) @ 4.8 bar (70 psi)

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

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

greater than or equal to 5528 KVA.

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.

Equipment complies with IEC 61000-3-12 provided that the short-circuit power Ssc is greater than or equal to 4462

greater than or equal to 4462 KVA.

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SpecificationS

Duramax 75° hand torch dimensions

25.2 cm (9.9 in.)

75°

9.9 cm

(3.9 in.)

angle

2.5 cm

(1.0 in.)

Duramax 15° hand torch dimensions

15°

5.1 cm

(2.0 in.)

angle

2.5 cm

(1.0 in.)

6.6 cm

(2.6 in.)

25.9 cm (10.2 in.)

6.6 cm

(2.6 in.)

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Duramax 180° full-length machine torch dimensions

39.6 cm

(15.6 in.)

2.5 cm

(1.0 in.)

20.6 cm (8.1 in.)

31.3 cm

(12.3 in.)

3.5 cm

(1.4 in.)

Duramax 180° mini machine torch dimensions

16.8 cm (6.6 in.)

SpecificationS

3.6 cm (1.4 in.)

outer dimension,

3.3cm (1.3 in.) flat sides

2.5 cm

(1.0 in.)

3.5 cm

(1.4 in.)

8.4 cm

(3.3 in.)

3.6 cm (1.4 in.)

outerdimension,

3.3cm (1.3 in.) flatsides

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SpecificationS

Powermax105 cutting specifications

Handheld cut capacity (material thickness)

Recommended cut capacity at 500 mm/min (20 ipm)* 32 mm (1-1/4 in.) Recommended cut capacity at 250 mm/min (10 ipm)* 38 mm (1-1/2 in.) Severance capacity at 125 mm/min (5 ipm)* 50 mm (2 in.)

Pierce capacity (material thickness)

Pierce capacity for handheld cutting, or mechanized cutting with programmable torch height control

Pierce capacity for mechanized cutting without programmable torch height control

Maximum cut speed** (mild steel)

6 mm (1/4 in.) 5600 mm/min (220 ipm) 12 mm (1/2 in.) 2400 mm/min (95 ipm) 20 mm (3/4 in.) 1300 mm/min (50 ipm) 25 mm (1 in.) 760 mm/min (30 ipm) 32 mm (1-1/4 in.) 510 mm/min (20 ipm)

Gouging capacity

Metal removal rate on mild steel (65 A) 4.8 kg/hr (10.7 lbs/hr) Metal removal rate on mild steel (85 A) 8.8 kg/hr (19.5 lbs/hr) Metal removal rate on mild steel (105 A) 9.8 kg/hr (21.7 lbs/hr)

Duramax series torch weights (refer to page 1-5 Component weights (105 A systems)] )

Duty cycle and voltage information (refer to page 1-6 Powermax105 power supply ratings)

22 mm (7/8 in.)

20 mm (3/4 in.)

* 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.

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Symbols and markings

Your Hypertherm 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 symbol

The S mark symbol indicates that the power supply and torch are suit able for operations carried out in en vi ron ments with increased hazard of elec tri cal shock per IEC 60974-1.

CSA mark

Hypertherm 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 Underwriters Laboratories, Incorporated (UL) or TÜV.

CE marking

The CE marking signifies the manufacturer’s declaration of conformity to applicable European directives andstandards. Only those versions of Hypertherm 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.

GOST-R mark

CE versions of Hypertherm products that include a GOST-R mark of conformity meet the product safety andEMC requirements for export to the Russian Federation.

c-Tick mark

CE versions of Hypertherm products with a c-Tick mark comply with the EMC regulations required for sale inAustralia and New Zealand.

CCC mark

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

CE versions of Hypertherm products that include a UkrSEPRO mark of conformity meet the product safety and EMC requirements for export to the Ukraine.

Noise levels

Acceptable noise levels as defined by national and local codes may be exceeded by this plasma system. Always wear proper ear protection when cutting or gouging. Any noise measurements taken are dependant on the specific environment in which the system is used. See also Noise can damage hearing in the Safety and Compliance Manual included with your system. Specific information by product can be found in the Hypertherm downloads library at:

https://www.hypertherm.com/

Click Downloads library, select a product from the Product Type drop-down menu, select “Regulatory” from the Category drop-down menu, and select “Acoustical Noise Data Sheets” from the Sub Category drop-down menu.

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IEC symbols

The following symbols may appear on the power supply data plate, control labels, switches, LEDs, and LCD screen.

Direct current (DC)

Alternating current (AC)

Plasma torch cutting

Plate metal cutting

Expanded metal cutting

Gouging

AC input power connection

The terminal for the external protective (earth) conductor

Power is ON

Power is OFF

An inverter-based power source, either 1-phase or 3-phase

Volt/amp curve, “drooping” characteristic

Power is ON (LED)

System fault (LED)

Inlet gas pressure fault (LCD)

Missing or loose consumables (LCD)

Power supply is out of temperature range (LCD)

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Section 2 POWER SUPPLY SETUP

In this section:

Unpack the Powermax 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 Powermax105 .............................................................................................................................................2-6

Three-phase power cord and plug installation .........................................................................................................................2-8

Extension cord recommendations ..........................................................................................................................................................2-9

Extension cord specifications .......................................................................................................................................................2-9

Engine-driven generator recommendations ........................................................................................................................... 2-10

Prepare the gas supply ..........................................................................................................................................................................2-11

Additional gas filtration ................................................................................................................................................................ 2-11

Connect the gas supply .............................................................................................................................................................. 2-12

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Unpack the Powermax 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.

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The following illustration shows typical system components. A vinyl cap is installed on torches that ship with new systems. Consumables are included in the consumables box.

Operator Manual

Quick Setup Card

Registration Card

Setup DVD

Safety Manual

Remote-start pendant (optional)

Box with extra consumables (located next to air filter)

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Position the power supply

Locate the power supply near an appropriate power receptacle for your installation:

• 200–600 volts (3-phase, CSA certified)

• 230–400 volts (3-phase, CE certified)

• 380/230–400 volts (3-phase, CCC/CE certified) without power cord

Note: To maintain CE certification, install power cord kit 228886.

• 400 volts (3-phase, CE certified)

• 380 volts (3-phase, CCC certified).

The power supply has a 3 m (10 ft) power cord (depending upon the model). Allow at least 0.25 m (10 inches) 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 on page 2-6. 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.

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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 page 2-6 Power connection for the Powermax105 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.

• 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.

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Power connection for the Powermax105

Powermax105 3-phase systems include the following models:

• The 200–600 V CSA model is a universal power supply that can automatically adjust to operate with ACvoltages from 200 to 600 V.

• The 230–400 V CE model can automatically adjust from 230 to 400 V.

• The 380 V CCC/230–400 V CE model can automatically adjust from 230 to 400 V.

Note: To maintain CE certification, install power cord kit 228886.

• The 400 V CE model is 400 V only.

• The 380 V CCC model is 380 V only.

The rated output is 30–105 A, 160 VDC.

200–600 V CSA,

Input voltage (V) 200 208 240 480 600 Input current (A) at rated output (16.8 kw) 58 56 49 25 22 Input current (A) at arc stretch 82 82 78 40 35 Fuse, slow-blow (A) 80 80 80 40 40

230–400 V CE

Input voltage (V) 230 400 Input current (A) at rated output (16.8 kw) 50 29 Input current (A) at arc stretch 80 46 Fuse, slow-blow (A) 80 50

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380 V CCC/230–400 V CE

Input voltage (V) 230 400 380 Input current (A) at rated output (16.8 kw) 50 29 30 Input current (A) at arc stretch 80 46 42 Fuse, slow-blow (A) 80 50 50

400 V CE

Input voltage (V) 400 Input current (A) at rated output (16.8 kw) 28 Input current (A) at arc stretch 44 Fuse, slow-blow (A) 50

380 V CCC

Input voltage (V) 380 Input current (A) at rated output (16.8 kw) 30 Input current (A) at arc stretch 42 Fuse, slow-blow (A) 50

Power SuPPly SetuP

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Three-phase power cord and plug installation

Powermax105 power supplies are shipped with the following power cords:

• CSA models: 6 AWG 4-wire power cord

• 230–400 V CE: 10 mm2, 4-wire HAR power cord

• 380 V CCC/230–400 V CE ships without a power cord

Note: To maintain CE certification, install power cord kit 228886.

• 400 V CE: 6 mm2, 4-wire HAR power cord

• 380 V CCC: 6 mm2, 4-wire CCC power cord (some models ship without a power cord)

To operate the Powermax105, use a plug that meets national and local electrical codes. The plug must be connected to the power cord by a licensed electrician.

Strip and prepare the power cord wires as shown below.

CSA

419 mm

(16.5 in.)

203 mm

(8 in.)

Ground

L1 L2 L3

6 mm (.25 in.)

Route lead through strain relief and tighten

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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.

Extension cord specifications

Extension cord length

< 3 m

(<10ft)

3–7.5 m

(10–25ft)

7.5–15 m

(25–50ft)

15–30 m

(50–100ft)

30–45 m

(100–150ft)

200–600 V CSA

Input voltage (VAC) Phase mm2 (AWG) mm2 (AWG) mm2 (AWG) mm2 (AWG) mm2 (AWG)

200–240 3 16 (6) 16 (6) 16 (6) 25 (4) 35 (2)

480–600 3 6 (10) 6 (10) 6 (10) 6 (10) 6 (10)

230–400 V CE

Input voltage (VAC) Phase mm

230 3 16 16 16 25 25

400 3 10 10 10 10 10

380 V CCC/230–400 V CE

Input voltage (VAC) Phase mm

230 3 16 16 16 25 25

400 3 10 10 10 10 10

380 3 10 10 10 10 10

400 V CE

Input voltage (VAC) Phase mm

400 3 10 10 10 10 10

380 V CCC

Input voltage (VAC) Phase mm

380 3 10 10 10 10 10

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Engine-driven generator recommendations

Generators used with the Powermax105 should satisfy the following requirements:

200–600 V CSA

3-phase, 50/60 Hz, 200–600 VAC (480 VAC recommended for best performance)

230–400 V CE

3-phase, 50/60 Hz, 230–400 VAC (400 VAC recommended for best performance)

380 V CCC/230–400 V CE

3-phase, 50/60 Hz, 230–400 VAC (400 VAC recommended for best performance)

400 V CE

3-phase, 50/60 Hz, 400 VAC (400 VAC recommended for best performance)

380 V CCC

3-phase, 50/60 Hz, 380 VAC (380 VAC recommended for best performance)

Engine drive

rating

30 kw 105 A Full

22.5–25 105 A Limited

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 60 to 70 seconds before turning ON again.

System output

current

Performance

(arcstretch)

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Prepare the gas supply

The air can be supplied by a compressor or from high-pressure cylinders. 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. 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, such as the Eliminizer filter kit (part number 228890) available from Hypertherm distributors. 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.

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Connect the gas supply

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

The recommended inlet pressure while gas is flowing is 5.9 – 9.3 bar (85 – 135 psi).

WARNING

Do not allow the gas supply pressure to exceed 9.3 bar (135 psi). The filter bowl may explode if this pressure is exceeded.

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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) 15.2 m (50 ft) 22.9 m (75 ft)

Cutting 5.2 bar (75 psi) 5.5 bar (80 psi) 5.9 bar (85 psi) Gouging 4.1 bar (60 psi) 4.5 bar (65 psi) 4.8 bar (70 psi)

Gas flow rates

Cutting 220 slpm (460 scfh, 7.7 scfm) at a minimum 5.9 bar (85 psi) Gouging 230 slpm (480 scfh, 8.0 scfm) at a minimum 4.8 bar (70 psi)

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Section 3 BASIC SYSTEM OPERATIONS

In this section:

Controls and indicators ............................................................................................................................................................................3-2

Rear controls ....................................................................................................................................................................................3-2

Front controls and LEDs ................................................................................................................................................................3-2

Status screen ...................................................................................................................................................................................3-4

Operating the Powermax105 ..................................................................................................................................................................3-6

Connect the electrical power, gas supply, and torch lead ....................................................................................................3-6

Attach the work lead to the power supply .................................................................................................................................3-7

Attach the work clamp to the workpiece ...................................................................................................................................3-8

Turn ON the system ........................................................................................................................................................................3-9

Set the operating mode switch ....................................................................................................................................................3-9

Check the indicators ....................................................................................................................................................................3-10

Manually adjusting the gas pressure ........................................................................................................................................3-10

Adjusting the current (amperage) ............................................................................................................................................. 3-11

Electrode end-of-life detection feature .............................................................................................................................................. 3-11

Understanding duty-cycle limitations ................................................................................................................................................. 3-12

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Service Manual 3-1

Basic system OperatiOns

Controls and indicators

Powermax105 power supplies have the following: ON/OFF switch, adjustment knob, automatic/manual pressure setting mode selector, current/gas selector, operating mode switch, indicator LEDs, and a status screen. These controls and indicators are described on the following pages.

Rear controls

ON (I)/OFF (O) power switch

Activates the power supply and its control circuits.

Front controls and LEDs

Adjustment knob

Status screen

Fault LED (yellow)

Automatic/manual pressure

setting mode selector

Fault LED (yellow)

When illuminated, this LED indicates that there is a fault with the power supply.

Power ON LED (green)

When illuminated, this LED indicates that the power switch has been set to I (ON) and that the safety interlocks are satisfied. When blinking, the power supply has a fault.

Current/gas

selector

Operating

modeswitch

Modes described

onnext page

Power ON LED

(green)

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Basic system OperatiOns

Operating mode switch

The operating mode switch can be set in one of four positions:

• Continuous pilot arc. Cuts expanded metal or grate.

• Non-continuous pilot arc. Cuts or pierces metal plate. This is the standard

setting for normal drag-cutting.

• Gouge. Gouges metal plate.

• Torch lock. Same as the non-continuous pilot arc mode except the torch is

locked in the ON position when you release the trigger during a cut. The torch goes out when the transfer is lost or the torch is retriggered.

Automatic/manual pressure setting mode selector

The selector switches between automatic and manual mode. In automatic mode, the power supply automatically sets the gas pressure based upon the torch type and lead length and the adjustment knob sets only the amperage. In manual mode, the adjustment knob sets either the gas pressure or the amperage. This LED is illuminated in manual mode.

Note: Manual mode should be used by experienced users who need to optimize the gas setting

(override the automatic gas setting) for a specific cutting application.

When you switch from manual mode to automatic mode, the power supply automatically sets the gas pressure and the amperage setting is unchanged. When you switch from automatic mode to manual mode, the power supply remembers the previous manual gas pressure setting and the amperage setting is unchanged.

When you reset the power, the power supply remembers the previous mode, gas pressure, and amperage settings.

Current/gas selector

When in manual mode, this selector toggles between amperage and gas pressure for manual adjustments using the adjustment knob.

Adjustment knob

This knob adjusts the amperage. When operating in manual mode, this knob can also adjust the gas pressure, overriding the automatic setting for optimized applications.

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Basic system OperatiOns

Status screen

The status screen shows system status and fault information.

Torch is cutting

Torch started

Fault icon

Fault code

Remote

connected

Visual pressure

Electrode end of life

detection manually disabled

Pressure

setting

Current setting (amps)

Current selection cursor

Pressure selection cursor

Gas pressure indicators

In manual mode, the gas pressure is displayed in bar and psi. The gas pressure bar is also a visual indicator of the gas pressure.

Gas pressure bar

When the arrow is centered in the vertical bar (the reference pressure of the automatic pressure setting), the gas pressure is set to the preset (factory-defined) value. If the pressure is higher than the preset value, the arrow appears above the mid-point of the bar. If the pressure is lower than the preset value, the arrow appears below the mid-point of the bar.

Note: In automatic mode, the power supply adjusts the pressure to the preset value. You can use manual

mode to adjust the pressure to satisfy the needs of a particular cutting job. Refer to page 3-10 Manually adjusting the gas pressure.

System status icons

The screen displays icons to indicate the system’s status.

Torch started

Indicates that the torch has received a start signal.

Torch is cutting

Indicates that the cutting arc has transferred to the metal and the torch is cutting.

Remote control

Indicates that a remote control or CNC is controlling the power supply using serial communications. All local controls are disabled.

Electrode end-of-life detection manually disabled

Indicates that the electrode end-of-life detection feature is manually disabled.

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Fault codes

When a power supply or torch fault occurs, the system displays a fault code in the lower-left corner of the status screen and displays a corresponding fault icon above the code. The first digit is always zero. The other two digits identify the problem. Fault code information is included later in this manual.

Note: Only one fault code is displayed. If more than one fault occurs at the same time, only the fault code with the

highest priority is displayed.

Fault icons

The fault icons that appear on the left side of the status screen are described below. A fault code also appears to identify the fault. Refer to the troubleshooting information later in this manual.

Warning

The system continues to run.

Fault

The system stops cutting. If you can not correct the problem and restart the system, contact your distributor or Hypertherm Technical Service.

Error

The system requires service. Contact your distributor or Hypertherm Technical Service.

Torch cap sensor

Indicates that the consumables are loose, improperly installed, or missing. Turn OFF the power, properly install the consumables, and turn ON the system again to reset the power supply.

Temperature

Indicates that the temperature of the power supply power module is outside the acceptable operating range.

Gas

Indicates that the gas is disconnected from the rear of the power supply or there is a problem with the gas supply.

Internal Serial Communications Interface

Indicates a problem with the SCI communications between the control board and the DSP board.

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Operating the Powermax105

Follow the steps below to begin cutting or gouging with the Powermax system.

Note: This section provides basic operating instructions. Before operating your Powermax in a production

environment, refer to the Hand Torch Setup section or the Machine Torch Setup section.

Connect the electrical power, gas supply, and torch lead

For information on connecting the proper plug to the power cord, refer to the Power Supply Setup section.

Plug in the power cord and connect the gas supply line. For more information about the electrical requirements and the gas supply requirements of the Powermax, see the Power Supply Setup section. To connect the torch, push the FastConnectTM connector into the receptacle on the front of the power supply You will attach the work lead in the next section.

Power cord (does not

ship with plug)

Torch lead

Gas supply

line

Work lead

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Attach the work lead to the power supply

Caution: Make sure you use a work lead that is appropriate for your power supply. Use

a 105A work lead with the Powermax105. The amperage is marked near the rubber boot of the work lead connector.

1. Insert the work lead connector into the receptacle on the front of the power supply.

Note: The receptacle is keyed. Align the key on the work lead connector with the opening at the top of the

receptacle on the power supply.

Keyed opening at

top of

Work lead receptacle on

power supply

receptacle

2. Push the work lead connector all the way into the receptacle on the power supply and turn clockwise, approximately 1/4 turn, until the connector is fully seated against the stop in order to achieve an optimal electrical connection.

Caution: Ensure the work lead is fully seated in the receptacle to prevent overheating.

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Attach the work clamp to the workpiece

The work clamp must be connected to the workpiece while you are cutting. If you are using the Powermax105 with a cutting table, you can connect the work lead directly to the table instead of attaching the work clamp to the workpiece. See your table manufacturer’s instructions.

Note the following:

• Ensure that the work clamp and the workpiece make good metal-to-metal contact. Remove rust, dirt, paint, coatings, and other debris to ensure the work lead makes proper contact with the workpiece.

• For the best cut quality, attach the work clamp as close as possible to the area being cut.

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

Work clamp

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Turn ON the system

Set the ON/OFF switch to the ON (I) position.

Off

Set the operating mode switch

Use the operating mode switch to select the type of work you want to perform.

Basic system OperatiOns

In automatic gas mode, Smart Sense™ technology automatically adjusts the gas pressure according to the selected cutting mode and torch lead length for optimum cutting.

For cutting expanded metal, grates, metal containing holes, or any job that requires a continuous pilot arc. Using this mode to cut standard metal plate reduces consumable life.

For cutting or piercing metal. This is the standard setting for normal drag-cutting.

For gouging metal. (Note: Using this mode while cutting results in poor cut quality.)

Locks the torch in the ON (fire) position. With this option selected, press the trigger to fire the torch. You can then release the trigger while continuing to cut. Press the trigger again to stop the arc. The torch goes out when transfer is lost.

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Basic system OperatiOns

Check the indicators

Verify the following:

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

• The Fault LED is not illuminated.

• No error icons appear in the status screen.

If a fault icon appears in the status screen, or the Fault LED is illuminated, or the power ON LED is blinking, correct the fault condition before continuing. More troubleshooting information is included later in this manual.

Manually adjusting the gas pressure

For normal operations, the power supply automatically adjusts the gas pressure. If you need to adjust the gas pressure for a specific application, you can use manual mode to do so.

Note: Manual mode should be used by experienced users who need to optimize the gas setting (override the

automatic gas setting) for a specific cutting application.

When you reset the power, the power supply remembers the previous mode, gas pressure, and amperage settings.

To adjust the pressure:

1. Press the automatic/manual pressure setting mode selector so that the LED next to the selector illuminates. Refer to

the diagram on page 3-2 Front controls and LEDs.

2. Press the current/gas selector until the selection cursor is opposite the gas pressure setting in the status screen.

3. Turn the adjustment knob to adjust the gas pressure to the desired level. Watch the arrow in the pressure bar as you adjust the pressure.

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Adjusting the current (amperage)

Turn the adjustment knob to adjust the current for your particular cutting application.

If the system is in manual mode, do the following to adjust the amperage.

1. Press the current/gas selector until the selection cursor is opposite the amperage setting in the status screen.

2. Turn the adjustment knob to change the amperage.

3. If you wish to exit manual mode, press the automatic/manual pressure setting mode selector. The LED goes off.

Note: When you exit manual mode, the gas pressure resets to the factory-optimized value.

When you switch between manual mode and automatic mode, the power supply retains the amperage setting. When you reset the power, the power supply returns to the previous mode (automatic mode or manual mode) and remembers the previous amperage setting.

Electrode end-of-life detection feature

The electrode end-of-life detection feature on the Powermax105 protects the torch and workpiece from damage by automatically stopping power to the torch when the electrode reaches its end of life. Fault code 0-32 also displays on the front panel status screen. If you have the current set below 55 A, this feature is automatically disabled without displaying the icon on the status screen.

To manually disable the feature, press the current/gas selector button (see figure below) five times on the control panel. The system must be in the auto mode and the selector presses must be less than one second apart. Re-enable the feature by repeating this procedure. An icon (see figure below) displays on the status screen when the feature is manually disabled.

Electrode end of life detection manually disabled

Current/gas selector

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Basic system OperatiOns

Understanding duty-cycle limitations

The duty cycle is the amount of time, in minutes, that a plasma arc can remain on within a 10-minute period when operating at an ambient temperature of 40° C (104° F).

With a Powermax105:

• At 105 A (480-600 V CSA, 400 V CE, 380 V CCC), the arc can remain on for 8 minutes out of 10 minutes

without causing the unit to overheat (80% duty cycle).

• At 94 A (480-600 V CSA, 400 V CE, 380 V CCC), the arc can remain on for 10 minutes out of 10 (100%).

See the Specifications section for a complete list of duty cycle specifications.

If the duty cycle is exceeded, the power supply overheats, the temperature fault icon appears in the status screen, the arc shuts off, and the cooling fan continues to run. You can not resume cutting until the temperature fault icon disappears and the fault LED goes off.

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Section 4 HAND TORCH SETUP

In this section:

Hand torch components ..........................................................................................................................................................................4-3

Choose the hand torch consumables ...................................................................................................................................................4-4

Drag-cutting 105 A consumables ...............................................................................................................................................4-4

Drag-cutting 45 A, 65 A, 85 A consumables ...........................................................................................................................4-4

Hand torch consumables .........................................................................................................................................................................4-5

Gouging consumables ...................................................................................................................................................................4-5

FineCut® consumables ..................................................................................................................................................................4-5

Install the hand torch consumables .......................................................................................................................................................4-6

Connecting the torch lead .......................................................................................................................................................................4-7

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Service Manual 4-1

Hand TorcH SeTup

Introduction

Duramax™ series hand torches are available for Powermax105 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 hand torch and choose the appropriate consumables for the job.

Consumable life

How often you need to change the consumables on your torch will depend on a number of factors:

• The thickness of the metal being cut.

• The average length of the cut.

• 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 nozzle will wear out first when hand cutting. As general rule, a set of consumables lasts approximately 1 to 3 hours of actual “arc on” time for hand cutting.

You will find more information about proper cutting techniques in the Hand Cutting section.

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Hand torch components

Note: Torches ship without consumables installed.

Duramax 75° hand torch

Hand TorcH SeTup

Duramax 15° hand torch

Consumables

Safety trigger

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Service Manual 4-3

Hand 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.

For the best cut quality on thin materials (approximately 4mm/10GA or less), you may prefer to use FineCut consumables, or use a 45A nozzle and reduce the amperage to that setting.

Drag-cutting 105 A consumables

1 0

5 A

220992

Shield

220854

Retaining cap

Drag-cutting 45 A, 65 A, 85 A consumables

220941

220819

220818

Shield

220854

Retaining cap

220816

220990

Nozzle

4 5 A

Nozzle

6 5 A

Nozzle

8 5 A

Nozzle

220842

Electrode

220842

Electrode

220994

Swirl ring

220994

Swirl ring

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Hand torch consumables

Gouging consumables

Hand TorcH SeTup

0 5 A

220798

Shield

FineCut® consumables

220931

Shield

220854

Retaining cap

220854

Retaining cap

220991

Nozzle

220930

Nozzle

220842

Electrode

220842

Electrode

220994

Swirl ring

220947

Swirl ring

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Service Manual 4-5

Hand 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. Torches ship without consumables installed. Pull off the vinyl cap before installing your consumables.

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

Swirl ring

Electrode

Nozzle

Retaining cap

Shield

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Connecting the torch lead

The Powermax105 is 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 the 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

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Hand TorcH SeTup

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Section 5 HAND CUTTING

In this section:

Using the hand torch .................................................................................................................................................................................5-2

Operate the safety trigger ........................................................................................................................................................................5-2

Hand torch cutting hints ...........................................................................................................................................................................5-3

Start a cut from the edge of the workpiece .........................................................................................................................................5-4

Gouge a workpiece ...................................................................................................................................................................................5-6

Gouge profile ...................................................................................................................................................................................5-7

Varying the gouge profile ...............................................................................................................................................................5-8

Common hand-cutting faults ...................................................................................................................................................................5-8

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Service Manual 5-1

Hand Cutting

Using the hand torch

WARNING:

INSTANTON TORCHES

PLASMA ARC CAN CAUSE INJURY AND BURNS

Plasma arc comes on immediately when the torch trigger is activated. The plasma arc will cut quickly through gloves and skin.

       

Operate the safety trigger

The hand torches are equipped with a safety trigger to prevent accidental firings. When you are ready to use the torch, flip the trigger’s safety cover forward (toward the torch head) and press the red torch trigger as show below.

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Hand Cutting

Hand torch cutting hints

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

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

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

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

• With either the Duramax 75° hand torch or Duramax 15° hand

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

90°

• If you fire the torch unnecessarily, you will shorten the life of the nozzle and electrode.

• Pulling, or dragging, the torch along the cut is easier than pushing it.

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

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

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Hand Cutting

Start a cut from the edge of the workpiece

1. With the work clamp attached to the workpiece, hold the torch nozzle perpendicular (90°) to the edge of the workpiece.

2. Press the torch’s trigger to start the arc. Pause at the edge until the arc has cut completely through the workpiece.

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

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Pierce a workpiece

When firing the torch at an angle, sparks and hot metal will spray out from the nozzle. Point the torch away from yourself and others.

1. With the work clamp attached to the workpiece, hold the torch

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

Hand Cutting

WARNING:

2. Fire the torch while still at an angle to the workpiece. Slowly

rotate the torch to a perpendicular (90°) position.

3. Hold the torch in place while continuing to press the trigger.

When sparks exit below the workpiece, the arc has pierced the material.

4. When the pierce is complete, dragthe nozzle lightly along the

workpiece to proceed with the cut.

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Hand Cutting

Gouge a workpiece

WARNING:

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

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

45°

Di rec tion of travel

3. Maintain an approximate 45° angle to the workpiece as you feed into the gouge. Push the plasma arc in the direction of the gouge you want to create. Keep a small distance between the torch tip and the molten metal to avoid reducing consumable life or damaging the torch.

Changing the torch’s angle changes the dimensions of the gouge.

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Hand Cutting

Gouge profile

You can vary the gouge profile by varying the speed of the torch over the workpiece, varying the torch-to-work standoff distance, varying the angle of the torch to the workpiece, and varying the current output of the power supply.

Speed

Standoff

Typical Gouge Profile for 65A

Metal removal rate on mild steel

4.8kg/hr (10.7 lbs/hr)

Typical Gouge Profile for 85A

Metal removal rate on mild steel

8.8kg/hr (19.5 lbs/hr)

Typical Gouge Profile for 105A

Metal removal rate on mild steel

9.8kg/hr (21.7 lbs/hr)

Angle

Width

6.6 mm (.26 in.)

Width

7.1 mm (.28 in.)

Width

7.4 mm (.29 in.)

Speed

Standoff

Angle

Operating parameters

50.8-63.5 cm/min (20-25 ipm)

6.4-9.5 mm (1/4-3/8 in.) 35-40°

Depth

3.6 mm (.14 in.)

Depth

6.1 mm (.24 in.)

Depth

6.4 mm (.25 in.)

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Hand Cutting

Varying the gouge profile

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

 Increasing the speed of the torch will decrease width and decrease depth.

 Decreasing the speed of the torch will increase width and increase depth.

 Increasing the standoff of the torch will increase width and decrease depth.

 Decreasing the standoff of the torch will decrease width and increase depth.

 Increasing the angle of the torch (more vertical) will decrease width and increase depth.

 Decreasing the angle of the torch (less vertical) will increase width and decrease depth.

 Increasing the current of the power supply will increase width and increase depth.

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

Common hand-cutting faults

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

• The cut speed is too fast.

• The consumables are worn.

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

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

• The work clamp is not attached properly to the workpiece.

• The gas pressure or gas flow rate is too low.

Cut quality is poor. The causes can be:

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

• The wrong consumables are being used (gouging consumables are installed instead of drag-cutting

consumables, for example).

• You are moving the torch too quickly or too slowly.

The arc sputters and consumables life is shorter than expected. The cause can be:

• Moisture in the gas supply.

• Incorrect gas pressure.

• Consumables incorrectly installed.

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Service Manual

Section 6 MACHINE TORCH SETUP

In this section:

Machine torch components .....................................................................................................................................................................6-4

Converting a full-length machine torch to a mini machine torch ....................................................................................................6-5

Choose the machine torch consumables .............................................................................................................................................6-9

Machine torch consumables ...................................................................................................................................................................6-9

Mechanized shielded 105 A consumables ...............................................................................................................................6-9

Mechanized shielded 45 A, 65 A, 85 A consumables ...........................................................................................................6-9

Mechanized shielded with ohmic 105 A consumables ....................................................................................................... 6-10

Mechanized shielded with ohmic 45 A, 65 A, 85 A consumables ................................................................................... 6-10

Mechanized unshielded 105 A consumables ........................................................................................................................ 6-10

Mechanized unshielded 45 A, 65 A, 85 A consumables .................................................................................................... 6-10

Gouging consumables ................................................................................................................................................................ 6-11

FineCut® shielded consumables .............................................................................................................................................. 6-11

FineCut® unshielded consumables .........................................................................................................................................6-11

Install the machine torch consumables ..............................................................................................................................................6-12

Connecting the torch lead .................................................................................................................................................................... 6-13

Using the cut charts ............................................................................................................................................................................... 6-14

Estimated kerf-width compensation .........................................................................................................................................6-15

105 A Shielded consumables ................................................................................................................................................... 6-17

105 A Shielded cutting (Mild Steel) ........................................................................................................................................ 6-18

105 A Shielded cutting (Stainless Steel) ............................................................................................................................... 6-19

105 A Shielded cutting (Aluminum) .........................................................................................................................................6-20

85 A Shielded consumables ......................................................................................................................................................6-21

85 A Shielded cutting (Mild Steel) ........................................................................................................................................... 6-22

85 A Shielded cutting (Stainless Steel) ..................................................................................................................................6-23

85 A Shielded cutting (Aluminum) ........................................................................................................................................... 6-24

65 A Shielded consumables ......................................................................................................................................................6-25

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Service Manual 6-1

Machine Torch SeTup

65 A Shielded cutting (Mild Steel) ........................................................................................................................................... 6-26

65 A Shielded cutting (Stainless Steel) ..................................................................................................................................6-27

65 A Shielded cutting (Aluminum) ........................................................................................................................................... 6-28

45 A Shielded consumables ......................................................................................................................................................6-29

45 A Shielded cutting (Mild Steel) ........................................................................................................................................... 6-30

45 A Shielded cutting (Stainless Steel) ..................................................................................................................................6-31

45 A Shielded cutting (Aluminum) ........................................................................................................................................... 6-32

FineCut® consumables ............................................................................................................................................................... 6-33

FineCut (Mild Steel) ..................................................................................................................................................................... 6-34

FineCut (Stainless Steel) ............................................................................................................................................................6-35

Low Speed FineCut (Mild Steel) .............................................................................................................................................. 6-36

Low Speed FineCut (Stainless Steel) ..................................................................................................................................... 6-37

105 A Unshielded consumables ...............................................................................................................................................6-38

105 A Unshielded cutting (Mild Steel) .................................................................................................................................... 6-39

105 A Unshielded cutting (Stainless Steel) ...........................................................................................................................6-40

105 A Unshielded cutting (Aluminum) .................................................................................................................................... 6-41

85 A Unshielded consumables ................................................................................................................................................. 6-42

85 A Unshielded cutting (Mild Steel) ......................................................................................................................................6-43

85 A Unshielded cutting (Stainless Steel) ............................................................................................................................. 6-44

85 A Unshielded cutting (Aluminum) ....................................................................................................................................... 6-45

65 A Unshielded consumables ................................................................................................................................................. 6-46

65 A Unshielded cutting (Mild Steel) ......................................................................................................................................6-47

65 A Unshielded cutting (Stainless Steel) ............................................................................................................................. 6-48

65 A Unshielded cutting (Aluminum) ....................................................................................................................................... 6-49

45 A Unshielded consumables ................................................................................................................................................. 6-50

45 A Unshielded cutting (Mild Steel) ......................................................................................................................................6-51

45 A Unshielded cutting (Stainless Steel) ............................................................................................................................. 6-52

45 A Unshielded cutting (Aluminum) ....................................................................................................................................... 6-53

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Machine Torch SeTup

Introduction

Duramax™ series machine torches are available for Powermax105 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 machine torch and choose the appropriate consumables for the job.

Consumable life

How often you need to change the consumables on your torch will depend on a number of factors:

• The thickness of the metal being cut.

• The average length of the cut.

• 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. As general rule, a set of consumables should last about 1 to 5 hours for mechanized cutting, depending upon the job.

You will find more information about proper cutting techniques in the Mechanized Cutting section.

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Service Manual 6-3

Machine Torch SeTup

Machine torch components

Duramax 180° full-length machine torch

Consumables

Duramax 180° mini machine torch

Before using either style of machine torch, you must:

Mounting sleeve

Coupler

Consumables

Mounting sleeve

Strain relief nut

Positioning sleeve

Gear rack Strain relief body

Coupler

Strain relief nut

Main strain relief nut

Torch lead

Strain relief body

Torch lead

• Mount the torch on your cutting table or other equipment.

• Choose and install the consumables.

• Align the torch square to the plate.

• 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.

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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 on page 6-7 Mount the torch.

Refer to the figures on page 6-4 Machine torch components 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.

Pilot wire terminal screw

Torch head

7. Disconnect the wire connector for the cap-sensor switch.

8. Use a #2 Phillips screwdriver to remove the screw that secures the torch’s pilot wire to the torch body.

Gas supply line

connection

Wire connector for cap-sensor switch

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Service Manual 6-5

Machine Torch SeTup

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.

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

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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 on page 6-4 Machine torch components 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

Wire connector for

Torch head

7. Disconnect the wire connector for the cap-sensor switch.

Gas supply line

connection

cap-sensor switch

8. Use a #2 Phillips screwdriver to 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.

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Service Manual 6-7

Machine Torch SeTup

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. If you are mounting a mini machine torch, set aside the positioning sleeve.

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. If you are mounting a mini machine torch, the strain relief nut attaches directly to the coupler in the next step.

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

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

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Machine 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 105 A consumables

220993

Shield

220854

Retaining cap

220990

Nozzle

Mechanized shielded 45 A, 65 A, 85 A consumables

220941

Nozzle

220819

220817

Shield

220854

Retaining cap

Nozzle

220816

Nozzle

220994

Swirl ring

220994

Swirl ring

220842

Electrode

220842

Electrode

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Service Manual 6-9

Machine Torch SeTup

Mechanized shielded with ohmic 105 A consumables

220993

Shield

220953

Ohmic-sensing

retaining cap

220990

Nozzle

220994

Swirl ring

Mechanized shielded with ohmic 45 A, 65 A, 85 A consumables

220941

Nozzle

220819

220817

Shield

220953

Ohmic-sensing

retaining cap

Nozzle

220994

Swirl ring

220816

Nozzle

Mechanized unshielded 105 A consumables

220842

Electrode

220842

Electrode

220955

Deflector

220854

Retaining cap

220990

Nozzle

220994

Swirl ring

220842

Electrode

Mechanized unshielded 45 A, 65 A, 85 A consumables

220941

Nozzle

220819

220955

Deflector

220854

Retaining cap

Nozzle

220816

Nozzle

220994

Swirl ring

220842

Electrode

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Service Manual

Gouging consumables

Machine Torch SeTup

220798

Shield

220854

Retaining cap

FineCut® shielded consumables

220948

Shield

220953

Ohmic-sensing

retaining cap

FineCut® unshielded consumables

220955

Deflector

220854

Retaining cap

220991

Nozzle

220930

Nozzle

220930

Nozzle

220994

Swirl ring

220842

Electrode

220994

Swirl ring

220842

Electrode

220994

Swirl ring

220842

Electrode

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Service Manual 6-11

Machine 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 the Hand torch setup section.

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°

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Service Manual

Machine Torch SeTup

Connecting the torch lead

To remove the torch, press the red button on the connector and pull the connector out of the receptacle.

Red button

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Service Manual 6-13

Machine 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.

Each chart contains the following information:

• Amperage setting — Except for FineCut charts, the amperage setting at the top left side of the page applies to

all the settings given on that page. In FineCut charts, the amperage setting for each thickness, either 45 or 40 (45, 40, or 30 for low speed), is included in the chart.

• 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) — 70% to 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.

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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

105 A Shielded 2.1 2.2 2.2 2.2 2.5 2.7 3.3 85 A Shielded 1.7 1.8 1.9 2.0 2.2 2.4 2.6 65 A Shielded 1.6 1.6 1.8 1.9 2.0 2.2 2.3 45 A Shielded 1.1 1.1 1.4 1.5 1.7 FineCut 0.9 0.7 0.5 0.6 Low Speed FineCut 0.6 0.7 0.7 0.6 105 A Unshielded 2.1 2.3 2.5 2.4 2.7 2.9 3.2 85 A Unshielded 1.7 1.8 1.9 2.0 2.1 2.1 2.3 65 A Unshielded 1.6 1.6 1.7 1.8 1.9 2.0 45 A Unshielded 0.5 0.9 1.3 1.3

105 A Shielded 1.9 2.1 2.3 2.3 2.3 2.6 2.9 85 A Shielded 1.6 1.8 1.9 2.1 2.3 2.4 2.5 65 A Shielded 1.4 1.5 1.8 1.9 2.0 2.2 2.4 45 A Shielded 0.9 1.1 1.5 1.6 1.8 FineCut 0.2 0.5 0.4 0.5 Low Speed FineCut 0.6 0.5 0.6 0.5 105 A Unshielded 2.0 2.2 2.4 2.5 2.7 2.7 3.1 85 A Unshielded 1.7 1.7 1.8 1.9 2.1 2.2 2.4 65 A Unshielded 1.6 1.6 1.8 1.8 1.9 2.0 45 A Unshielded 0.5 1.0 1.3 1.5 1.5

105 A Shielded 2.3 2.3 2.4 2.6 2.7 3.0 3.5 85 A Shielded 2.0 1.9 2.0 2.1 2.2 2.4 2.6 65 A Shielded 1.9 1.9 1.9 2.0 2.1 2.3 2.5 45 A Shielded 1.5 1.5 1.6 1.5 105 A Unshielded 2.2 2.4 2.5 2.6 2.7 3.0 3.3 85 A Unshielded 1.9 1.9 1.9 2.0 2.0 2.1 2.2 65 A Unshielded 1.8 1.8 1.8 1.8 1.9 2.0 45 A Unshielded 1.6 1.5 1.4 1.5

0.5 1 2 3 6 8 10 12 16 20 25 Mild Steel

Stainless Steel

Aluminum

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Service Manual 6-15

Machine Torch SeTup

Estimated kerf-width compensation – English (inches)

Thickness (inches)

Process

105 A Shielded 0.083 0.088 0.089 0.100 0.101 0.133 85 A Shielded 0.068 0.071 0.073 0.078 0.090 0.095 0.100 65 A Shielded 0.062 0.065 0.068 0.070 0.076 0.088 0.090 0.091 45 A Shielded 0.035 0.054 0.055 0.061 0.065 0.066 FineCut 0.028 0.026 0.016 0.023 Low Speed FineCut 0.026 0.030 0.027 0.023 105 A Unshielded 0.083 0.097 0.098 0.107 0.111 0.125 85 A Unshielded 0.070 0.073 0.075 0.080 0.085 0.090 65 A Unshielded 0.062 0.064 0.066 0.068 0.075 0.081 45 A Unshielded 0.020 0.050 0.051 0.054 0.057 0.059

105 A Shielded 0.076 0.089 0.091 0.092 0.099 0.113 85 A Shielded 0.065 0.068 0.070 0.080 0.094 0.095 0.096 65 A Shielded 0.056 0.062 0.068 0.073 0.076 0.090 0.093 45 A Shielded 0.032 0.055 0.058 0.067 0.069 0.069 FineCut 0.025 0.019 0.014 0.027 Low Speed FineCut 0.025 0.023 0.021 0.027 105 A Unshielded 0.080 0.095 0.101 0.106 0.104 0.122 85 A Unshielded 0.066 0.068 0.070 0.072 0.080 0.090 0.095 65 A Unshielded 0.061 0.064 0.067 0.070 0.072 0.080 45 A Unshielded 0.020 0.054 0.052 0.060 0.058 0.058

105 A Shielded 0.091 0.092 0.102 0.107 0.111 0.138 85 A Shielded 0.080 0.078 0.075 0.080 0.090 0.095 0.100 65 A Shielded 0.073 0.074 0.075 0.076 0.083 0.091 0.100 45 A Shielded 0.059 0.061 0.065 0.060 105 A Unshielded 0.089 0.098 0.102 0.106 0.117 0.132 85 A Unshielded 0.075 0.075 0.075 0.080 0.082 0.088 65 A Unshielded 0.070 0.070 0.070 0.070 0.072 0.079 45 A 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 1

Mild Steel

Stainless Steel

Aluminum

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

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Service Manual

105 A Shielded consumables

Machine Torch SeTup

220993

Shield

220993

Shield

220854

Retaining cap

220953

Ohmic-sensing

retaining cap

220990

Nozzle

220990

Nozzle

220994

Swirl ring

220994

Swirl ring

220842

Electrode

220842

Electrode

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Service Manual 6-17

Machine Torch SeTup

105 A Shielded cutting (Mild Steel)

Air flow rate – slpm/scfh

Hot 217 / 460

Cold 250 / 530

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

8 10 2260 145 2790 145 12 1690 145 2060 148

6.4 200

16 20 780 152 940 152

3.2

0.5 4140 144 5090 145 3140 145 3870 145

0.75

1.0

1060 149 1310 149

550 159 580 158 30 370 162 410 161 32 350 166 370 161

Edge Start 35 290 168 320 165 40 190 173 210 170

English

Material

Thickness

Torch-

to-Work

Distance

Initial Pierce Height

Pierce

Delay Time

Best Quality Settings Production Settings

Cut Speed Voltage Cut Speed Voltage

inches inches inches % seconds ipm Volts ipm Volts

1/4 3/8 1/2 62 146 76 148 5/8 3/4 33 151 40 150 7/8 1.25 26 154 30 157

0.125

0.25 200

1 1-1/8 15 162 17 160 1-1/4 14 166 15 161

Edge Start

0.5 156 144 192 145

0.75

1.0

94 145 116 145

42 149 52 149

21 160 22 158

1-1/2 9 171 10 168

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Service Manual

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105 A Shielded cutting (Stainless Steel)

Air flow rate – slpm/scfh

Hot 217 / 460

Cold 250 / 530

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

6 8 3460 141 4210 142

10 2240 144 2670 142

6.4 200

0.5

4870 139 6000 141

12 0.6 1490 148 1860 144 16 0.75 950 149 1080 149

3.2 20 8.0 250 1.25 660 154 810 152 25 30 340 164 360 160

Edge Start

440 158 530 156

32 300 166 320 163

English

Material

Thickness

Torch-

to-Work

Distance

Initial Pierce Height

Pierce

Delay Time

Best Quality Settings Production Settings

Cut Speed Voltage Cut Speed Voltage

inches inches inches % seconds ipm Volts ipm Volts

1/4 3/8 94 143 112 142 1/2 55 148 68 145

0.25 200

0.5

185 139 224 141

5/8 0.75 38 149 43 149 3/4 0.31 250 1.25 28 153 34 151 7/8

0.125 22 156 27 153

1 17 158 20 156

1-1/8 14 162 16 159

Edge Start

1-1/4 12 166 13 163

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Service Manual 6-19

Machine Torch SeTup

105 A Shielded cutting (Aluminum)

Air flow rate – slpm/scfh

Hot 217 / 460

Cold 250 / 530

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

8 10 2640 152 3280 151 12 16 1290 157 1660 155

3.2

6.4 200

0.5 5980 145 7090 144

0.75

1.0

4170 149 5020 148

1910 156 2450 154

20 1.25 1020 163 1190 162 25 30 430 173 570 171

Edge Start

660 166 790 165

32 340 175 490 173

English

Material

Thickness

Torch-

to-Work

Distance

Initial Pierce Height

Pierce

Delay Time

Best Quality Settings Production Settings

Cut Speed Voltage Cut Speed Voltage

inches inches inches % seconds ipm Volts ipm Volts

1/4

0.5 223 146 265 145 3/8 0.75 110 151 136 150 1/2 5/8 51 157 66 155 3/4 1.25 43 162 50 161

0.125

7/8

1 25 166 30 165

1-1/8 20 171 25 169

0.25 200

Edge Start

1.0

71 156 91 154

34 164 40 163

1-1/4 15 175 20 173

6-20 powermax

105

Service Manual

85 A Shielded consumables

MACHINE TORCH SETUP

220817

Shield

220817

Shield

220854

Retaining cap

220953

Ohmic-sensing

retaining cap

220816

Nozzle

220816

Nozzle

220842

Electrode

220842

Electrode

220994

Swirl ring

220994

Swirl ring

powermax

105

Service Manual 6-21

Machine Torch SeTup

85 A Shielded cutting (Mild Steel)

Air flow rate – slpm/scfh

Hot 194 / 412

Cold 236 / 500

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

0.1 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

English

Material

Thickness

Torch-

to-Work

Distance

Initial Pierce

Edge Start

Height

Pierce

Delay

Time

350 142 450 141

Best Quality Settings Production Settings

Cut Speed Voltage Cut Speed Voltage

inches inches inches % seconds ipm Volts ipm Volts

10GA

3/16 0.2 185 123 220 123

1/4

0.15 250

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

0.06

0.18 300

0.0 250 122 336 121

130 123 160 126

0.5

45 131 56 131

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

1 13 142 17 141

1-1/8 9 145 13 143

Edge Start

19 139 22 138

1-1/4 7 148 10 146

6-22 powermax

105

Service Manual

Machine Torch SeTup

85 A Shielded cutting (Stainless Steel)

Air flow rate – slpm/scfh

Hot 194 / 412

Cold 236 / 500

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

English

Material

Thickness

Torch-

to-Work

Distance

Initial Pierce Height

Edge Start

Pierce

Delay Time

480 138 570 137

Best Quality Settings Production Settings

Cut Speed Voltage Cut Speed Voltage

inches inches inches % seconds ipm Volts ipm Volts

10GA

3/16 200 122 240 121

1/4

0.15 250

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

0.06

0.18 300

0.2

0.5

3/4 7/8 16 140 19 139

Edge Start

275 122 336 120

130 122 164 122

36 132 48 131

20 137 24 136

1 11 143 14 141

powermax

105

Service Manual 6-23

Machine Torch SeTup

85 A Shielded cutting (Aluminum)

Air flow rate – slpm/scfh

Hot 194 / 412

Cold 236 / 500

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

English

Material

Thickness

Torch-

to-Work

Distance

Initial Pierce

Edge Start

Height

Pierce

Delay Time

600 143 880 141

Best Quality Settings Production Settings

Cut Speed Voltage Cut Speed Voltage

inches inches inches % seconds ipm Volts ipm Volts

1/8 1/4

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

0.06

0.18 300

3/4 7/8 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 14 146 20 144

6-24 powermax

105

Service Manual

65 A Shielded consumables

Machine Torch SeTup

6 5

220817

Shield

220817

Shield

220854

Retaining cap

220953

Ohmic-sensing

retaining cap

220819

Nozzle

6 5

220819

Nozzle

220842

Electrode

220842

Electrode

220994

Swirl ring

220994

Swirl ring

powermax

105

Service Manual 6-25

Machine Torch SeTup

65 A Shielded cutting (Mild Steel)

Air flow rate – slpm/scfh

Hot 175 / 370

Cold 209 / 443

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

0.1 6050 124 7000 121 3 0.2 5200 125 6100 123 4 6 2550 127 3240 127 8 1700 129 2230 128

1.5

10 12 1.2 850 134 1140 131

3.8 250

4.5 300

0.5

0.7 1100 131 1500 129

4250 125 5100 124

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

English

Material

Thickness

Torch-

to-Work

Distance

Initial Pierce

Edge Start

Height

Pierce

Delay

Time

350 142 450 142

Best Quality Settings Production Settings

Cut Speed Voltage Cut Speed Voltage

inches inches inches % seconds ipm Volts ipm Volts 16GA 10GA 190 125 224 123

3/16 0.2 140 126 168 125

0.15 250

0.1

260 123 294 121

1/4 0.5 90 127 116 127 3/8 0.7 45 130 62 129 1/2 0.18 300 1.2 30 135 40 132

0.06

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

Edge Start

15 141 19 141

1 8 145 10 145

6-26 powermax

105

Service Manual

Machine Torch SeTup

65 A Shielded cutting (Stainless Steel)

Air flow rate – slpm/scfh

Hot 175 / 370

Cold 209 / 443

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

0.1 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

English

Material

Thickness

Torch-

to-Work

Distance

3.8 250

4.5 300

Edge Start

Initial Pierce

Height

0.5

0.7

Pierce

Delay Time

5200 125 6150 124

1500 129 1860 129

960 132 1250 132

500 139 500 139

Best Quality Settings Production Settings

Cut Speed Voltage Cut Speed Voltage

inches inches inches % seconds ipm Volts ipm Volts

16GA 10GA 240 125 296 123

3/16 0.2 155 126 168 125

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

0.06

0.15 250

0.1

345 124 426 121

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

Edge Start

20 139 20 139

powermax

105

Service Manual 6-27

Machine Torch SeTup

65 A Shielded cutting (Aluminum)

Air flow rate – slpm/scfh

Hot 175 / 370

Cold 209 / 443

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

0.1 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

English

Material

Thickness

Torch-

to-Work

Distance

3.8 250

4.5 300

Edge Start

Initial Pierce

Height

0.5

0.7

Pierce Delay

Time

6000 126 7350 125

1950 133 2750 130 1200 136 1650 132

650 143 800 141

Best Quality Settings Production Settings

Cut Speed Voltage Cut Speed Voltage

inches inches inches % seconds ipm Volts ipm Volts

1/16

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

0.06

0.15 250

0.1

365 121 428 121

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

Edge Start

26 143 32 141

6-28 powermax

105

Service Manual

Hypertherm Powermax105 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Section 1

SPECIFICATIONS

Safety information

System description

Where to find information

Power supply dimensions

Component weights (105 A systems)

Powermax105 power supply ratings

Duramax 75° hand torch dimensions

Duramax 15° hand torch dimensions

Duramax 180° full-length machine torch dimensions

Duramax 180° mini machine torch dimensions

Powermax105 cutting specifications

Symbols and markings

Noise levels

IEC symbols

Section 2

POWER SUPPLY SETUP

Unpack the Powermax system

Claims

Contents

Position the power supply

Prepare the electrical power

Install a line-disconnect switch

Requirements for grounding

Power connection for the Powermax105

Three-phase power cord and plug installation

Extension cord recommendations

Extension cord specifications

Engine-driven generator recommendations

Prepare the gas supply

Additional gas filtration

Connect the gas supply

Section 3

BASIC SYSTEM OPERATIONS

Controls and indicators

Rear controls

Front controls and LEDs

Status screen

Operating the Powermax105

Connect the electrical power, gas supply, and torch lead

Attach the work lead to the power supply

Attach the work clamp to the workpiece

Turn ON the system

Set the operating mode switch

Check the indicators

Manually adjusting the gas pressure

Adjusting the current (amperage)

Electrode end-of-life detection feature

Understanding duty-cycle limitations

Section 4

HAND TORCH SETUP

Introduction

Consumable life

Hand torch components

Choose the hand torch consumables

Drag-cutting 105 A consumables

Drag-cutting 45 A, 65 A, 85 A consumables

Hand torch consumables

Gouging consumables

FineCut® consumables

Install the hand torch consumables

Connecting the torch lead

Section 5

HAND CUTTING

Using the hand torch

Operate the safety trigger

Hand torch cutting hints

Start a cut from the edge of the workpiece

Pierce a workpiece

Gouge a workpiece

Gouge profile

Varying the gouge profile

Common hand-cutting faults

Section 6

MACHINE TORCH SETUP