Hypertherm Powermax125 Service Manual
®
Powermax125
Plasma Arc Cutting System
Service Manual
808070 | Revision 1 | English
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© 2014 Hypertherm, Inc.
Powermax125
Service Manual
808070
Revision 1
English
April 2014
Hypertherm, Inc.
Hanover, NH 03755 USA
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
Safety information
Before operating any Hypertherm equipment, read the separate Safety and Compliance Manual (80669C) included
with your product for important safety information.
Contents
Electromagnetic Compatibility (EMC) ............................................................................ SC-15
Introduction ..............................................................................................................................................................................SC-15
Installation and use .................................................................................................................................................................SC-15
Assessment of area ................................................................................................................................................................SC-15
Methods of reducing emissions ..........................................................................................................................................SC-15
Mains supply ....................................................................................................................................................................SC-15
Maintenance of cutting equipment .....................................................................................................................................SC-16
Cutting cables .........................................................................................................................................................................SC-16
Equipotential bonding ....................................................................................................................................................SC-16
Earthing of the workpiece .............................................................................................................................................SC-16
Screening and shielding .......................................................................................................................................................SC-16
Warranty .................................................................................................................................. SC-17
Attention ....................................................................................................................................................................................SC-17
General .....................................................................................................................................................................................SC-17
Patent indemnity .....................................................................................................................................................................SC-18
Limitation of liability ................................................................................................................................................................SC-18
National and local codes .......................................................................................................................................................SC-18
Liability cap ..............................................................................................................................................................................SC-18
Insurance ..................................................................................................................................................................................SC-18
Transfer of rights .....................................................................................................................................................................SC-18
1 Specifications .............................................................................................................................. 19
Safety information ......................................................................................................................................................................... 19
Powermax125 System description ........................................................................................................................................... 19
Power supply dimensions ........................................................................................................................................................... 20
Component weights (125 A systems) ..................................................................................................................................... 21
Hypertherm power supply ratings ............................................................................................................................................. 22
Powermax125 Service Manual 808070 7
Contents
Duramax Hyamp 85° hand torch dimensions ......................................................................................................................... 23
Duramax Hyamp 15° hand torch dimensions ......................................................................................................................... 23
Duramax Hyamp 180° full-length machine torch dimensions ............................................................................................ 24
Duramax Hyamp 180° mini machine torch dimensions ....................................................................................................... 24
Powermax125 cutting specifications ....................................................................................................................................... 25
Symbols and markings ................................................................................................................................................................ 26
Noise levels ............................................................................................................................................................................ 27
IEC symbols ........................................................................................................................................................................... 28
2 Power Supply Setup .................................................................................................................. 29
Unpack the Powermax system .................................................................................................................................................. 29
Claims ...................................................................................................................................................................................... 29
Contents ......................................................................................................................................................................................... 30
Position the power supply .......................................................................................................................................................... 30
Prepare the electrical power ...................................................................................................................................................... 31
Install a line-disconnect switch ......................................................................................................................................... 31
Requirements for grounding .............................................................................................................................................. 31
Power connection for the Powermax125 ............................................................................................................................... 32
Three-phase power cord and plug installation .............................................................................................................. 33
Decrease output current for lower-rated power plugs ........................................................................................ 33
Extension cord recommendations ............................................................................................................................................ 35
Engine-driven generator recommendations ................................................................................................................... 35
Prepare the gas supply ............................................................................................................................................................... 36
Additional gas filtration ........................................................................................................................................................ 36
Connect the gas supply ...................................................................................................................................................... 37
Minimum inlet pressure (while gas is flowing) ........................................................................................................ 38
Gas flow rates ............................................................................................................................................................... 38
3 Basic System Operations ......................................................................................................... 39
Controls and indicators ............................................................................................................................................................... 39
Rear controls ......................................................................................................................................................................... 39
Front controls and LEDs ..................................................................................................................................................... 40
LEDs ................................................................................................................................................................................ 40
Selectors ......................................................................................................................................................................... 40
Operating mode switch ............................................................................................................................................... 41
Amperage adjustment knob ....................................................................................................................................... 41
Status screen ......................................................................................................................................................................... 41
Gas pressure indicators .............................................................................................................................................. 42
System status icons ..................................................................................................................................................... 42
Fault codes and icons .................................................................................................................................................. 42
8 Powermax125 Service Manual 808070
Contents
Operating the Powermax ............................................................................................................................................................ 44
Connect the electrical power, gas supply, and torch lead .......................................................................................... 44
Attach the work lead to the power supply ...................................................................................................................... 45
Attach the ground clamp to the workpiece .................................................................................................................... 46
Turn on the system ............................................................................................................................................................... 46
Set the operating mode switch ......................................................................................................................................... 47
Check the indicators ............................................................................................................................................................ 47
Manually adjusting the gas pressure ................................................................................................................................ 48
Adjusting the current (amperage) ..................................................................................................................................... 48
Electrode end-of-life detection feature .................................................................................................................................... 49
Understanding duty-cycle limitations ....................................................................................................................................... 50
4 Hand Torch Setup ....................................................................................................................... 51
Introduction .................................................................................................................................................................................... 51
Consumable life ............................................................................................................................................................................ 51
Hand torch components ............................................................................................................................................................. 52
Duramax Hyamp 85° hand torch ....................................................................................................................................... 52
Duramax Hyamp 15° hand torch ....................................................................................................................................... 52
Choose the hand torch consumables ...................................................................................................................................... 52
Drag-cutting 105/125 A consumables ........................................................................................................................... 53
Drag-cutting 45 A and 65 A consumables ..................................................................................................................... 53
Gouging consumables ........................................................................................................................................................ 53
FineCut consumables .......................................................................................................................................................... 53
Install the hand torch consumables .......................................................................................................................................... 54
Connecting the torch lead .......................................................................................................................................................... 55
5 Hand Cutting ................................................................................................................................ 57
Using the hand torch ................................................................................................................................................................... 57
Operate the safety trigger ........................................................................................................................................................... 58
Hand torch cutting guidelines .................................................................................................................................................... 58
Start a cut from the edge of the workpiece ............................................................................................................................ 59
Pierce a workpiece ....................................................................................................................................................................... 60
Gouge a workpiece ...................................................................................................................................................................... 62
Gouge profile ......................................................................................................................................................................... 63
Varying the gouge profile .................................................................................................................................................... 64
125 A gouging profile chart ............................................................................................................................................... 64
Common hand-cutting faults ..................................................................................................................................................... 66
Powermax125 Service Manual 808070 9
Contents
6 Machine Torch Setup ................................................................................................................ 67
Introduction .................................................................................................................................................................................... 67
Consumable life ............................................................................................................................................................................ 67
Machine torch components ....................................................................................................................................................... 68
Duramax Hyamp 180° machine torch .............................................................................................................................. 68
Duramax Hyamp 180° mini machine torch ..................................................................................................................... 68
Disassemble the machine torch ................................................................................................................................................ 69
Convert a full-length machine torch to a mini machine torch ............................................................................................. 71
Mount the torch ............................................................................................................................................................................. 72
Choose the machine torch consumables ............................................................................................................................... 73
Machine torch consumables ...................................................................................................................................................... 73
Mechanized shielded 105 A/125 A consumables ........................................................................................................ 73
Mechanized shielded 45 A and 65 A consumables ..................................................................................................... 73
Mechanized shielded with ohmic 105 A/125 A consumables .................................................................................. 74
Mechanized shielded with ohmic 45 A and 65 A consumables ................................................................................ 74
Gouging consumables ........................................................................................................................................................ 74
FineCut shielded consumables ......................................................................................................................................... 74
FineCut shielded with ohmic consumables .................................................................................................................... 75
Install the machine torch consumables ................................................................................................................................... 75
Aligning the torch ......................................................................................................................................................................... 75
Connecting the torch lead .......................................................................................................................................................... 76
Using the cut charts ..................................................................................................................................................................... 77
Estimated kerf-width compensation ................................................................................................................................. 78
Estimated kerf-width compensation – Metric (mm) .............................................................................................. 78
Estimated kerf-width compensation – English (inches) ...................................................................................... 79
125 A shielded consumables ............................................................................................................................................ 80
125 A shielded cutting – mild steel ................................................................................................................................. 81
125 A shielded cutting – stainless steel ......................................................................................................................... 82
125 A shielded cutting – aluminum ................................................................................................................................. 83
105 A shielded consumables ............................................................................................................................................ 84
105 A shielded cutting – mild steel ................................................................................................................................. 85
105 A shielded cutting – stainless steel ......................................................................................................................... 86
105 A shielded cutting – aluminum ................................................................................................................................. 87
65 A shielded consumables ............................................................................................................................................... 88
65 A shielded cutting – mild steel .................................................................................................................................... 89
65 A shielded cutting – stainless steel ........................................................................................................................... 90
65 A shielded cutting – aluminum .................................................................................................................................... 91
45 A shielded consumables ............................................................................................................................................... 92
45 A shielded cutting – mild steel .................................................................................................................................... 93
45 A shielded cutting – stainless steel ........................................................................................................................... 94
45 A shielded cutting – aluminum .................................................................................................................................... 95
10 Powermax125 Service Manual 808070
Contents
FineCut consumables .......................................................................................................................................................... 96
FineCut – mild steel ............................................................................................................................................................. 97
FineCut – stainless steel ..................................................................................................................................................... 98
7 Mechanized Cutting ................................................................................................................... 99
Connecting an optional remote-start pendant ....................................................................................................................... 99
Connecting the machine interface cable .............................................................................................................................. 100
Machine interface pinout ................................................................................................................................................... 102
Setting the five-position voltage divider ........................................................................................................................ 103
Accessing raw arc voltage ....................................................................................................................................................... 104
Connecting an optional RS-485 serial interface cable ..................................................................................................... 104
Serial port cables ................................................................................................................................................................ 105
Using the machine torch ........................................................................................................................................................... 105
Setting up the torch and table ................................................................................................................................................. 105
Understand and optimize cut quality ...................................................................................................................................... 105
Cut or bevel angle .............................................................................................................................................................. 106
Dross ..................................................................................................................................................................................... 106
Piercing a workpiece using the machine torch .................................................................................................................... 107
Common machine-cutting faults ............................................................................................................................................. 107
8 Troubleshooting and System Tests ..................................................................................... 109
Controls and indicators ............................................................................................................................................................. 109
Rear panel ............................................................................................................................................................................ 109
Front panel ............................................................................................................................................................................ 110
Status screen ............................................................................................................................................................... 110
Theory of operation .................................................................................................................................................................... 111
480 V and 600 V CSA 3-phase power supply functional description .................................................................. 111
400 V CE, 380 V CCC 3-phase power supply functional description ................................................................. 111
Sequence of operation ...................................................................................................................................................... 112
Troubleshooting preparation .................................................................................................................................................... 113
Test equipment .................................................................................................................................................................... 113
Troubleshooting procedures and sequence ................................................................................................................. 113
External inspection .............................................................................................................................................................. 115
Internal inspection ............................................................................................................................................................... 115
Initial resistance check .............................................................................................................................................................. 115
Check the power switch ................................................................................................................................................... 115
Hypertherm IGBT tester .................................................................................................................................................... 118
Indicator LEDs and device tests ..................................................................................................................................... 119
IGBT test preparation ........................................................................................................................................................ 119
IGBT device test using the Hypertherm tester ............................................................................................................ 121
Troubleshoot the Hypertherm IGBT tester ................................................................................................................... 121
Powermax125 Service Manual 808070 11
Contents
IGBT device test using a non-Hypertherm tester ............................................................................................................... 122
Fault codes ................................................................................................................................................................................... 128
Important fault icons ........................................................................................................................................................... 128
Displaying the service screen .......................................................................................................................................... 128
Run a gas test ..................................................................................................................................................................... 130
Perform a cold restart ........................................................................................................................................................ 131
Fault codes and solutions ................................................................................................................................................. 131
Fault code format – 0-00-0 ...................................................................................................................................... 131
Fault code format – 0-nn-n ...................................................................................................................................... 132
Fault code format – 1-nn-n ...................................................................................................................................... 138
Fault code format – 2-nn-n ...................................................................................................................................... 138
Fault code format – 3-nn-n ...................................................................................................................................... 139
Torch-related faults – continuity check ................................................................................................................. 142
Troubleshooting guide ............................................................................................................................................................... 143
System tests ................................................................................................................................................................................ 149
Test 1 – Voltage input ....................................................................................................................................................... 150
Test 2 – DC power bus .................................................................................................................................................... 152
Resistance check ........................................................................................................................................................ 152
Voltage check .............................................................................................................................................................. 152
Test 3 – Output diodes ..................................................................................................................................................... 154
Test 4 – Inverter temperature sensor ............................................................................................................................. 154
For operational fault codes 0-40-2 and 0-40-3 or power board faults 2-10-0 and 2-10-1 ................... 155
Test 5 – Flyback circuit (DC minor voltages) ............................................................................................................... 156
Test 6 – Torch stuck open/torch stuck closed ............................................................................................................ 158
Test 7 – Start signal ........................................................................................................................................................... 160
Test 8 – Torch cap switch ................................................................................................................................................ 161
Test 9 – Electronic regulator ........................................................................................................................................... 162
Test 10 – Pressure sensor ............................................................................................................................................... 163
Test 11 – Fan ...................................................................................................................................................................... 164
Test 12 – AUX switch ....................................................................................................................................................... 164
9 Power Supply Component Replacement ........................................................................... 165
Installing a machine interface cable for raw arc voltage .................................................................................................... 166
Disconnect the power and gas supply .................................................................................................................................. 166
Replacing the gas filter element .............................................................................................................................................. 167
Replacing the work lead connector ....................................................................................................................................... 169
Installing the optional filter kit .................................................................................................................................................. 170
Replacing the power supply cover ......................................................................................................................................... 172
Replacing the component barrier ........................................................................................................................................... 173
Replacing the end panel bracket ............................................................................................................................................ 174
12 Powermax125 Service Manual 808070
Contents
Replacing the machine interface cable with voltage divider board ................................................................................. 176
Set the voltage divider board ........................................................................................................................................... 181
Installing the machine interface cable .................................................................................................................................... 182
Installing the RS-485 serial interface cable ......................................................................................................................... 183
Replacing the power cord and strain relief ........................................................................................................................... 190
Replacing the power switch ..................................................................................................................................................... 197
Replacing the control board ..................................................................................................................................................... 201
Replacing the DSP board ......................................................................................................................................................... 203
Replacing the power board ...................................................................................................................................................... 205
Replacing the input diode bridge ............................................................................................................................................ 209
Replacing the output diode bridge ......................................................................................................................................... 210
Replacing the pilot arc IGBT ................................................................................................................................................... 211
Replacing the inverter IGBT module ...................................................................................................................................... 212
Replacing the snubber resistor ............................................................................................................................................... 213
Replacing the thermal sensor .................................................................................................................................................. 214
Replacing the fan shroud .......................................................................................................................................................... 216
Replacing the fan ........................................................................................................................................................................ 217
Replacing the pressure transducer ........................................................................................................................................ 219
Replacing the pressure switch ................................................................................................................................................ 221
Replacing the gas filter assembly ........................................................................................................................................... 223
Replacing the solenoid valve ................................................................................................................................................... 225
Replacing the gas tubing .......................................................................................................................................................... 227
Replacing the bulk capacitors ................................................................................................................................................. 229
Replacing the torch quick disconnect receptacle .............................................................................................................. 231
Replacing the work lead receptacle ....................................................................................................................................... 236
Replacing the output inductor ................................................................................................................................................. 238
Replacing the transformer ........................................................................................................................................................ 244
Replacing the PFC inductor ..................................................................................................................................................... 249
Replacing the front panel .......................................................................................................................................................... 252
Replacing the rear panel ........................................................................................................................................................... 257
10 Torch Component Replacement .......................................................................................... 265
Disconnect the power, gas supply, and torch ..................................................................................................................... 266
Hand torches ............................................................................................................................................................................... 267
Replacing the handle ......................................................................................................................................................... 269
Replacing the trigger assembly ....................................................................................................................................... 274
Replacing the torch body .................................................................................................................................................. 276
Replacing the start switch ................................................................................................................................................ 278
Replacing the cap-sensor switch ................................................................................................................................... 280
Replacing the torch lead ................................................................................................................................................... 281
Powermax125 Service Manual 808070 13
Contents
Machine torches ......................................................................................................................................................................... 284
Replacing the mounting sleeve ....................................................................................................................................... 285
Replacing the cap sensor switch .................................................................................................................................... 287
Replacing the torch body .................................................................................................................................................. 288
Replacing the coupler and positioning sleeve (full-length only) or adapter (mini only) ...................................... 289
Replacing the torch lead ................................................................................................................................................... 290
Replacing the quick disconnect housing .............................................................................................................................. 291
11 Parts ............................................................................................................................................. 293
Power supply parts .................................................................................................................................................................... 294
Exterior, front ........................................................................................................................................................................ 294
Exterior, rear ......................................................................................................................................................................... 295
Interior, power board side ................................................................................................................................................. 297
480 V, 600 V CSA ..................................................................................................................................................... 297
400 V CE/380 V CCC .............................................................................................................................................. 298
Interior, fan side ................................................................................................................................................................... 299
Interior, heatsink assembly ................................................................................................................................................ 300
Duramax Hyamp 85° hand torch replacement parts .......................................................................................................... 301
Duramax Hyamp 15° hand torch replacement parts .......................................................................................................... 302
Hand torch consumables .......................................................................................................................................................... 303
Drag cutting ......................................................................................................................................................................... 303
Gouging ................................................................................................................................................................................ 303
FineCut .................................................................................................................................................................................. 303
Duramax Hyamp 180° full-length machine torch replacement parts .............................................................................. 304
Duramax Hyamp 180° mini machine torch replacement parts ......................................................................................... 305
Machine torch consumables .................................................................................................................................................... 306
Shielded ................................................................................................................................................................................ 306
Gouging ................................................................................................................................................................................ 306
FineCut .................................................................................................................................................................................. 307
Accessory parts .......................................................................................................................................................................... 307
Powermax125 labels ................................................................................................................................................................. 308
Safety-critical parts .................................................................................................................................................................... 310
Power supply, power board side .................................................................................................................................... 310
Power supply, fan side ...................................................................................................................................................... 312
Recommended spare parts ...................................................................................................................................................... 313
12 Wiring Diagrams ....................................................................................................................... 315
Powermax generic timing chart ............................................................................................................................................... 316
Powermax125 schematic diagram ......................................................................................................................................... 317
14 Powermax125 Service Manual 808070
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.
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.
Safety and Compliance SC-15
Electromagnetic Compatibility (EMC)
Maintenance of cutting equipment
The cutting equipment must be routinely maintained
according to the manufacturer’s recommendations. All
access and service doors and covers should be closed
and properly fastened when the cutting equipment is in
operation. The cutting equipment should not be modified
in any way, except as set forth in and in accordance with
the manufacturer’s written instructions. For example, the
spark gaps of arc striking and stabilizing devices should
be adjusted and maintained according to the
manufacturer’s recommendations.
Cutting cables
The cutting cables should be kept as short as possible
and should be positioned close together, running at or
close to the floor level.
Equipotential bonding
Bonding of all metallic components in the cutting
installation and adjacent to it should be considered.
Earthing of the workpiece
Where the workpiece is not bonded to earth for electrical
safety, nor connected to earth because of its size and
position, for example, ship’s hull or building steel work, a
connection bonding the workpiece to earth may reduce
emissions in some, but not all instances. Care should be
taken to prevent the earthing of the workpiece increasing
the risk of injury to users, or damage to other electrical
equipment. Where necessary, the connection of the
workpiece to earth should be made by a direct connection
to the workpiece, but in some countries where direct
connection is not permitted, the bonding should be
achieved by suitable capacitances selected according to
national regulations.
Note: The cutting circuit may or may not be earthed for
safety reasons. Changing the earthing arrangements
should only be authorized by a person who is competent
to assess whether the changes will in crease the risk of
injury, for example, by allowing parallel cutting current
return paths which may damage the earth circuits of other
equipment. Further guidance is provided in IEC 60974-9,
Arc Welding Equipment, Part 9: Installation and Use.
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.
Screening and shielding
Selective screening and shielding of other cables and
equipment in the surrounding area may alleviate problems
of interference. Screening of the entire plasma cutting
installation may be considered for special applications.
SC-16 Safety and Compliance
Warranty
Attention
Genuine Hypertherm parts are the factory-recommended
replacement parts for your Hypertherm system. Any
damage or injury caused by the use of other than genuine
Hypertherm parts may not be covered by the Hypertherm
warranty, and will constitute misuse of the Hypertherm
Product.
You are solely responsible for the safe use of the Product.
Hypertherm does not and cannot make any guarantee or
warranty regarding the safe use of the product in your
environment.
General
Hypertherm, Inc. warrants that its Products shall be free
from defects in materials and workmanship for the specific
periods of time set forth herein and as follows: if
Hypertherm is notified of a defect (i) with respect to the
plasma power supply within a period of two (2) years from
the date of its delivery to you, with the exception of
Powermax brand power supplies, which shall be within a
period of three (3) years from the date of delivery to you,
and (ii) with respect to the torch and leads within a period
of one (1) year from its date of delivery to you, 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.
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 product
which has been incorrectly installed, modified, or
otherwise damaged.
Safety and Compliance SC-17
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.
SC-18 Safety and Compliance
Section 1
Specifications
Safety information
Before operating any Hypertherm equipment, read the separate Safety and Compliance Manual (80669C) included with
your product for important safety information.
Powermax125 System description
The Powermax125 is a highly portable, 125 A, 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 Powermax125 is recommended for metal thicknesses up to 44 mm (1-3/4 inches), can sever up to 57 mm
(2-1/4 inches), and can pierce thicknesses up to 25 mm (1 inch). FastConnect™ provides a simple push-button torch
connection to the power supply for quick torch changes.
The typical handheld Powermax125 system includes a Duramax™ Hyamp 85° hand torch with a starter consumable kit, a
box of spare electrodes and nozzles, and a work lead cable. Reference materials include: operator manual, quick setup
card, registration card, setup DVD, and safety manual.
The typical mechanized Powermax125 system includes a Duramax Hyamp 180° full-length machine torch with a starter
consumable kit, a box of spare electrodes and nozzles, 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 Parts on page 293 for a list of spare and optional parts.
Powermax125 CSA and CE power supplies ship without a plug on the power cord. See Power Supply Setup on
page 29.
CCC certified configurations do not ship with a power cord.
Powermax125 Service Manual 808070 19
1 – Specifications
508 mm
(20.0 inches)
592 mm
(23.3 inches)
274 mm
(10.8 inches)
432 mm (17.0 inches)
Powermax125 3-phase systems include the following models:
480 V CSA (480 V only)
600 V CSA (600 V only)
400 V CE (400 V only)
380 V CCC (380 V only)
To maintain CE certification, install power cord kit 228886.
Power supply dimensions
20 Powermax125 Service Manual 808070
Component weights (125 A systems)
Table 1 – Power supply weights
1 – Specifications
Voltage 480 V CSA 600 V CSA 400 V CE
Power supply 41 kg
(90 pounds)
With 7.6 m (25 foot) hand
torch and 7.6 m (25 foot)
work lead
48 kg
(106 pounds)
40 kg
(89 pounds)
48 kg
(105 pounds)
42 kg
(92 pounds)
49 kg
(108 pounds)
Table 2 – Torch weights
Hand torch 7.6 m (25 feet) 3.5 kg (7.7 pounds)
Hand torch 15 m (50 feet) 6.2 kg (13.7 pounds)
Hand torch 23 m (75 feet) 8.8 kg (19.5 pounds)
Machine torch 7.6 m (25 feet) 3.7 kg (8.2 pounds)
Machine torch 11 m (35 feet) 4.8 kg (10.6 pounds)
Machine torch 15 m (50 feet) 6.4 kg (14.2 pounds)
380 V CCC
(no power cord)
38 kg
(84 pounds)
45 kg
(100 pounds)
Machine torch 23 m (75 feet) 9.2 kg (20.3 pounds)
Table 3 – Work lead weights
Work lead 7.6 m (25 feet) 3.6 kg (8 pounds)
Work lead 15 m (50 feet) 6.6 kg (14.6 pounds)
Work lead 23 m (75 feet) 9.6 kg (21.2 pounds)
Powermax125 Service Manual 808070 21
1 – Specifications
Hypertherm power supply ratings
Rated open-circuit voltage (U0)480/600V CSA
400 V CE
380 V CCC
Output characteristic
Rated output current (I
Rated output voltage (U
1
) 30 – 125 A
2
)175VDC
2
Duty cycle at 40° C (104° F) 480/600 V CSA
400 V CE
380 VCCC
320 VDC
305 VDC
290 VDC
Drooping
100% at 125 A, 480/600 V, 3-PH
100% at 125 A, 400 V, 3-PH
100% at 125 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 0.94
– Short Circuit Ratio (CE models
R
sce
only)
EMC emissions classification
CISPR 11 (CE models only)
Input voltage (U
rated output (U
)/ Input current (I1) at
1
2 MAX I2 MAX
2
)
U1 – Volts AC rms, 3-PH R
400 V CE 250
Class A
480/600 V CSA 480/600 V, 3-PH, 50/60 Hz, 31/24 A
400 V CE
3,4
400V, 3-PH, 50/60Hz, 36A
sce
(See Power Supply Setup on
page 29.)
380 V CC 380 V, 3-PH, 50/60 Hz, 38 A
Gas type Air Nitrogen
Gas quality Clean, dry, oil-free per ISO 8573-1
99.95% pure
Class 1.2.2
Recommended gas inlet flow
rate/pressure
Cutting: 260 slpm (550 scfh, 9.2 scfm) at:
• 5.9 bar (85 psi) for 7.6 m (25 foot) and 15 m (50 foot) torches
• 6.6 bar (95 psi) for 23 m (75 foot) torches
Gouging: 212 slpm (450 scfh, 7.5 scfm) at 4.1 bar (60 psi)
1
Defined as a plot of output voltage versus output current.
2
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 or radiated disturbances.
3
This product meets the technical requirements of IEC 61000-3-3 and is not subject to conditional connection.
4
Equipment complies with IEC 61000-3-12 provided that the short-circuit power Ssc is greater than or equal to 5363 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
greater than or equal to 5363 KVA.
sc
22 Powermax125 Service Manual 808070
Duramax Hyamp 85° hand torch dimensions
31.2 cm (12.3 inches)
3.5 cm
(1.375 inch)
11.4 cm
(4.5 inches)
85°
6.8 cm
(2.68 inches)
29.5 cm (11.6 inches)
6.8 cm
(2.68 inches)
5.85 cm
(2.3 inches)
15°
3.5 cm (1.375 inch)
35.3 cm (13.9 inches)
Duramax Hyamp 15° hand torch dimensions
1 – Specifications
Powermax125 Service Manual 808070 23
1 – Specifications
3.5 cm (1.375 inches)
40.6 cm (16.0 inches)
4.4 cm (1.75 inches)
4.2 cm (1.6 inch) outer dimension,
3.6 cm (1.4 inch) flat sides
3.5 cm (1.375 inch)
18.3 cm (7.2 inches)
4.4 cm (1.75 inches)
4.2 cm (1.6 inch) outer dimension,
3.6 cm (1.4 inch) flat sides
Duramax Hyamp 180° full-length machine torch dimensions
Duramax Hyamp 180° mini machine torch dimensions
24 Powermax125 Service Manual 808070
Powermax125 cutting specifications
Handheld cut capacity (material thickness)
1 – Specifications
Recommended cut capacity at 457 mm/min (18 ipm)
Recommended cut capacity at 250 mm/min (10 ipm)
Severance capacity at 125 mm/min (5 ipm)
1
1
1
38 mm (1-1/2 inches)
44 mm (1-3/4 inches)
57 mm (2-1/4 inches)
Pierce capacity (material thickness)
Pierce capacity for handheld cutting, or mechanized cutting with
25 mm (1 inch)
programmable torch height control
Pierce capacity for mechanized cutting without programmable torch height
22 mm (7/8 inch)
control
Maximum cut speed2 (mild steel)
6mm (1/4inch) 7160 mm/min (282 ipm)
10 mm (3/8 inch) 4390 mm/min (173 ipm)
12 mm (1/2 inch) 2950 mm/min (116 ipm)
16 mm (5/8 inch) 2110 mm/min (83 ipm)
20 mm (3/4 inch) 1470 mm/min (58 ipm)
22 mm (7/8 inch) 1170 mm/min (46 ipm)
25 mm (1 inch) 940 mm/min (37 ipm)
32 mm (1-1/4 inches) 610 mm/min (24 ipm)
38 mm (1-1/2 inches) 457 mm/min (18 ipm)
Gouging capacity
Metal removal rate on mild steel (125 A) 12.5 kg/hour (27 pounds/hour)
Duramax Hyamp series torch weights (refer to Component weights (125 A systems) on page 21)
Duty cycle and voltage information (refer to Hypertherm power supply ratings on page 22)
1
Cut capacity speeds are not necessarily maximum speeds. They are the speeds that must be achieved to be rated at that
thickness.
2
Maximum cut speeds are the results of Hypertherm’s laboratory testing. Actual cutting speeds may vary based on different cutting
applications.
Powermax125 Service Manual 808070 25
1 – Specifications
s
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
The S mark indicates that the power supply and torch are suitable for operations carried out in
environments with increased hazard of electrical shock according to IEC 60974-1.
CSA mark
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 mark
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.
Eurasian Customs Union (CU) mark
CE versions of Hypertherm products that include an EAC mark of conformity meet the product safety and
EMC requirements for export to Russia, Belarus, and Kazakhstan.
GOST-TR mark
CE versions of Hypertherm products that include a GOST-TR mark of conformity meet the product safety
and EMC requirements for export to the Russian Federation.
C-Tick mark
CE versions of 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
The CE versions of Hypertherm products that include a UkrSEPRO mark of conformity meet the product
safety and EMC requirements for export to the Ukraine.
Serbian AAA mark
CE versions of Hypertherm products that include a AAA Serbian mark meet the product safety and EMC
requirements for export to Serbia.
26 Powermax125 Service Manual 808070
1 – Specifications
Noise levels
This plasma system may exceed acceptable noise levels as defined by national and local codes. Always wear proper ear
protection when cutting or gouging. Any noise measurements taken depend on the specific environment in which the
system is used. Refer to Noise can damage hearing in the Safety and Compliance Manual (80669C) included with your
system.
In addition, you can find an Acoustical Noise Data Sheet for your system in the Hypertherm downloads library at
https://www.hypertherm.com
1. Click “Downloads library.”
2. Select a product from the “Product type” menu.
3. Select “Regulatory” from the “Category” menu.
4. Select “Acoustical Noise Data Sheets” from the “Sub Category” menu.
:
Powermax125 Service Manual 808070 27
1 – Specifications
Direct current (DC)
Alternating current (AC)
Plasma torch cutting
Plate metal cutting
Expanded metal cutting
Gouging
Torc h l ock
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/amperage 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)
f
1
f
2
1~
AC
AC
IEC symbols
The following symbols may appear on the power supply data plate, control labels, switches, LEDs, and LCD screen.
28 Powermax125 Service Manual 808070
Section 2
Power Supply Setup
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. 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 (80669C)
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.
Powermax125 Service Manual 808070 29
2 – Power Supply Setup
or
or
1
2
3
4
5
6
7
8
9
10
11
1
Operator Manual
2
Quick Setup Card
3
Registration card
4
Setup DVD
5
Safety and Compliance Manual
6
Remote-start pendant (optional)
7
Torches
8
Ground clamp and work lead
9
Starter consumable kit
10
Box with extra consumables (located next to air
filter)
11
Power supply
Contents
The following illustration shows typical system components. A vinyl cap is installed on torches that ship with new
systems. Consumables are included in the starter consumable kit, and the small consumables box next to the air filter
contains spare electrodes and nozzles.
Position the power supply
Locate the power supply near an appropriate power receptacle for your installation:
480 V (3-phase, CSA certified)
600 V (3-phase, CSA certified)
400 V (3-phase, CE certified)
380 V (3-phase, CCC certified)
CSA and CE certified power supplies include a 3 m (10 foot) power cord (depending on the model). CCC certified
power supplies do not ship with a power cord. To maintain CE certification, install power cord kit 228886.
30 Powermax125 Service Manual 808070
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