Hypertherm powermax65 Operator's Manual
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Hypertherm powermax65 Operator's Manual

Plasma arc cutting systems
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Plasma arc cutting systems
Operator Manual – 806650
Revision 2

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  • Page 1 Plasma arc cutting systems Operator Manual – 806650 Revision 2...
  • Page 2 Register your new Hypertherm system Register your product on-line at www.hypertherm.com/registration for easier technical and warranty support. You can also receive updates on new Hypertherm products and a free gift as a token of our appreciation. For your records Serial number:...
  • Page 3 (P/N 806650) Revision 2 – December 2012 Hypertherm, Inc. Hanover, NH USA www.hypertherm.com email: info@hypertherm.com © 2012 Hypertherm, Inc. All Rights Reserved Hypertherm and Powermax are trademarks of Hypertherm, Inc. and may be registered in the United States and/or other countries.
  • Page 4 55 11 2409 2636 Tel 55 11 2408 0462 Fax Hypertherm (S) Pte Ltd. 82 Genting Lane Media Centre Hypertherm México, S.A. de C.V. Annexe Block #A01-01 Avenida Toluca No. 444, Anexo 1, Singapore 349567, Republic of Singapore Colonia Olivar de los Padres 65 6841 2489 Tel Delegación Álvaro Obregón...

  • Page 5: Mains Supply

    Introduction a. Other supply cables, control cables, signaling and telephone cables; above, below and adjacent to the Hypertherm’s CE-marked equipment is built in compliance cutting equipment. with standard EN60974-10. The equipment should be installed and used in accordance with the information b.

  • Page 6: Maintenance Of Cutting Equipment

    ELECTROMAGNETIC COMPATIBILITY Earthing of the workpiece Consideration should be given to shielding the supply cable of permanently installed cutting equipment, in metallic conduit or equivalent. Shielding should Where the workpiece is not bonded to earth for be electrically continuous throughout its length. The electrical safety, nor connected to earth because of its shielding should be connected to the cutting mains size and position, for example, ship’s hull or building...
  • Page 7 Products or as to if Hypertherm is notified of a defect (i) with respect to the results which may be obtained therefrom, and the power supply within a period of two (2) years from...

  • Page 8: Patent Indemnity

    You may transfer any remaining rights you may have the use of the Hypertherm product, alone and not in hereunder only in connection with the sale of all or combination with any other product not supplied by substantially all of your assets or capital stock to a Hypertherm, infringes any patent of any third party.
  • Page 9 Safety information Before operating any Hypertherm equipment, read the separate Safety and Compliance Manual (80669C) included with your product for important safety information. powermax 65/85 Operator Manual...
  • Page 10 powermax 65/85 Operator Manual...

  • Page 11: Table Of Contents

    Powermax85 cutting specifications ..............................1-13 Symbols and markings ..................................1-14 IEC symbols ......................................1-15 Section 2 Power Supply Setup Unpack the Powermax65 or Powermax85 system .........................2-2 Claims ......................................2-2 Contents ......................................2-3 Position the power supply..................................2-4 Prepare the electrical power ................................2-4 Install a line-disconnect switch ..............................2-5 Requirements for grounding ..............................2-5...
  • Page 12 Rear controls ....................................4-2 Front controls and LEDs ................................4-2 Status screen ....................................4-4 Operating the Powermax65 or Powermax85 ...........................4-6 Connect the electrical power, gas supply, and torch lead ....................4-6 Attach the work lead to the power supply ..........................4-7 Attach the work clamp to the workpiece ..........................4-8 Turn ON the system ..................................4-9...
  • Page 13 Duramax 15° hand torch replacement parts .............................6-7 Hand torch consumables ..................................6-8 Duramax 180° full-length machine torch replacement parts ......................6-9 Duramax 180° mini machine torch replacement parts ........................ 6-11 Machine torch consumables ................................6-13 Accessory parts....................................6-14 Powermax65/85 labels ..................................6-15 powermax 65/85 Operator Manual...
  • Page 14 Table of ConTenTs powermax 65/85 Operator Manual...
  • Page 15 System description ....................................1-2 Where to find information ..................................1-3 Power supply dimensions ..................................1-4 Component weights ....................................1-5 Powermax65 power supply ratings ..............................1-6 Powermax85 power supply ratings ..............................1-8 Duramax 75° hand torch dimensions .............................. 1-10 Duramax 15° hand torch dimensions .............................. 1-10 Duramax 180° full-length machine torch dimensions ........................1-11 Duramax 180°...

  • Page 16: Specifications

    The Powermax65 can cut thicknesses up to 1 inch (25 mm) with a handheld torch and pierce thicknesses up to 5/8 inch (16 mm). The Powermax85 can cut thicknesses up to 1-1/4 inches (32 mm) and pierce thicknesses up to 3/4 inch (19 mm).

  • Page 17: Where To Find Information

    SpecificationS Where to find information System specifications such as size, weight, detailed electrical specifications, and cut speeds can be found in this section. For information on: • Setup requirements, including power requirements, grounding, power cord configurations, extension cord requirements, and generator recommendations – see Section 2, Power Supply Setup. •...

  • Page 18: Power Supply Dimensions

    SpecificationS Power supply dimensions 17.0 in (432 mm) 19.0 in 9.2 in (483 mm) (234 mm) powermax 65/85 Operator Manual...

  • Page 19: Component Weights

    SpecificationS Component weights 65 A CSA 65 A CE 85 A CSA 85 A CE lbs (kg) lbs (kg) lbs (kg) lbs (kg) Power supply 54.1 (24.5) 47.0 (21.3) 59.9 (27.2) 50.4 (22.8) 65/85 A lbs (kg) Hand torch 7.6 m (25 ft) 6.8 (3.1) Hand torch 15 m (50 ft) 12.2 (5.5)

  • Page 20: Powermax65 Power Supply Ratings

    SpecificationS Powermax65 power supply ratings Rated open-circuit voltage (U CSA, 1-phase, 3-phase CSA 296 VDC CE, 3-phase 270 VDC Output characteristic Drooping Rated output current (I 20 – 65 A Rated output voltage (U 139 VDC Duty cycle at 40° C (104° F) 50% @ 65 A, 230 –...
  • Page 21 SpecificationS Defined as a plot of output voltage versus output current. Equipment complies with IEC 61000-3-12 provided that the short-circuit power S is greater than or equal to 2035 KVA at the interface point between the user’s supply and the public system. It is the responsibility of the installer or user of the equipment to ensure, by consultation with the distribution network operator if necessary, that the equipment is connected only to a supply with a short-circuit power S greater than or equal to 2035 KVA.

  • Page 22: Powermax85 Power Supply Ratings

    SpecificationS Powermax85 power supply ratings Rated open-circuit voltage (U CSA, single-phase, 3-phase 305 VDC CE, 3-phase 270 VDC Drooping Output characteristic Rated output current (I 25 – 85 A Rated output voltage (U 143 VDC Duty cycle at 40° C (104° F) 60% @ 85 A, 230 –...
  • Page 23 SpecificationS Defined as a plot of output voltage versus output current. Equipment complies with IEC 61000-3-12 provided that the short-circuit power S is greater than or equal to 2035 KVA at the interface point between the user’s supply and the public system. It is the responsibility of the installer or user of the equipment to ensure, by consultation with the distribution network operator if necessary, that the equipment is connected only to a supply with a short-circuit power S greater than or equal to 2035 KVA.

  • Page 24: Duramax 75° Hand Torch Dimensions

    SpecificationS Duramax 75° hand torch dimensions 9.9 in (25.2 cm) 75° 2.6 in angle 3.8 in (6.6 cm) (9.8 cm) 1.0 in (2.5 cm) Duramax 15° hand torch dimensions 10.2 in (25.9 cm) 15° angle 1.9 in 2.6 in (4.7 cm) (6.6 cm) 1.0 in (2.5 cm)

  • Page 25: Duramax 180° Full-Length Machine Torch Dimensions

    SpecificationS Duramax 180° full-length machine torch dimensions 15.6 in (39.6 cm) 1.4 in 1.0 in (3.5 cm) (2.5 cm) 8.1 in (20.6 cm) 1.4 in (3.6 cm) outer 12.3 in dimension, 1.3 in (31.3 cm) (3.3 cm) flat sides Duramax 180° mini machine torch dimensions 6.6 in (16.8 cm) 1.4 in...

  • Page 26: Powermax65 Cutting Specifications

    * Cut capacity speeds are not necessarily maximum speeds. They are the speeds that must be achieved to be rated at that thickness. ** Maximum cut speeds are the results of Hypertherm’s laboratory testing. Actual cutting speeds may vary based on different cutting applications.

  • Page 27: Powermax85 Cutting Specifications

    * Cut capacity speeds are not necessarily maximum speeds. They are the speeds that must be achieved to be rated at that thickness. ** Maximum cut speeds are the results of Hypertherm’s laboratory testing. Actual cutting speeds may vary based on different cutting applications.

  • Page 28: Symbols And Markings

    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.

  • Page 29: Iec Symbols

    SpecificationS IEC symbols The following symbols may appear on the power supply data plate, control labels, switches, LEDs, and LCD screen. Direct current (DC) Power is ON Alternating current Power is OFF (AC) An inverter-based power Plasma torch cutting source, either 1-phase or 3-phase Volt/amp curve, Plate metal cutting...
  • Page 30 SpecificationS powermax 1-16 65/85 Operator Manual...

  • Page 31: Power Supply Setup

    Section 2 POWER SUPPLY SETUP In this section: Unpack the Powermax65 or Powermax85 system .........................2-2 Claims ......................................2-2 Contents ......................................2-3 Position the power supply..................................2-4 Prepare the electrical power ................................2-4 Install a line-disconnect switch ..............................2-5 Requirements for grounding ..............................2-5 Power connection for the Powermax65 ............................2-6 Single-phase power cord (not for CE model) ........................2-7...

  • Page 32: Unpack The Powermax65 Or Powermax85 System

    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.

  • Page 33: Contents

    Power SuPPly SetuP Contents Verify the items in the box against the illustration. Operator Manual Quick Setup Card Registration Card Setup DVD Safety Manual Box with extra consumables (located next to air filter) Remote-start pendant (optional) powermax 65/85 Operator Manual...

  • Page 34: Position The Power Supply

    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.

  • Page 35: Install A Line-Disconnect Switch

    • Contain a power-operated mechanism that serves as an emergency stop. • Have appropriate slow-blow fuses installed. See 2-6 Power connection for the Powermax65 or 2-8 Power connection for the Powermax85 for recommended fuse sizes. Requirements for grounding To ensure personal safety, proper operation, and to reduce electromagnetic interference (EMI), the power supply must be properly grounded.

  • Page 36: Power Connection For The Powermax65

    Power connection for the Powermax65 The Powermax65 CSA model is a universal power supply that can configure itself to operate with AC voltages from 200 to 600, 1- or 3-phase. The CE model is 380/400 V, 3-phase only. The rated output is 25 – 65 A, 139 VDC.

  • Page 37: Single-Phase Power Cord (Not For Ce Model)

    The Powermax65 power supplies are shipped with an 8 AWG 4-wire power cord on CSA models. A 2.5 mm , 4-wire HAR power cord is provided on CE models. To operate the Powermax65, use a plug that meets national and local electrical codes. The plug must be connected to the power cord by a licensed electrician.

  • Page 38: Power Connection For The Powermax85

    Power SuPPly SetuP Power connection for the Powermax85 The Powermax85 CSA model is a universal power supply that can configure itself to operate with AC voltages from 200 to 600, 1- or 3-phase. The CE model is 380/400 V, 3-phase only. The rated output is 25 – 85 A, 143 VDC. CSA model Single-phase Three-phase...

  • Page 39: Single-Phase Power Cord (Not For Ce Model)

    Power SuPPly SetuP Single-phase power cord (not for CE model) To operate your Powermax85 on 1-phase power, you will need to install an appropriate power cord. Refer to 2-10 Single‑phase power cord installation for instructions. Caution: When using the Powermax85 CSA model power supply (CE model is 3-phase only) with a 1-phase power source, replace the supplied power cord with a 6AWG (16 mm ) 3-wire power cord.

  • Page 40: Single-Phase Power Cord Installation

    Power SuPPly SetuP Single-phase power cord installation Strip and prepare the power cord wires as shown below. 14.5 in (368 mm) Ground 6 in (152 mm) Route lead through strain relief and tighten Power switch Ground screw powermax 2-10 65/85 Operator Manual...

  • Page 41: Three-Phase Power Cord - Plug Installation

    Power SuPPly SetuP Three-phase power cord – plug installation The Powermax85 power supplies are shipped with an 8 AWG 4-wire power cord on CSA models. A 4 mm , 4-wire HAR power cord is provided on CE models. To operate the Powermax85, use a plug that meets national and local electrical codes.

  • Page 42: Extension Cord Specifications

    Power SuPPly SetuP Extension cord specifications < 10 ft 10 – 25 ft 25 – 50 ft 50 – 100 ft 100 – 150 ft Extension cord length (< 3 m) (3 – 7.6 m) (7.5 – 15 m) (15 – 30 m) (30 –...

  • Page 43: Engine-Driven Generator Recommendations

    Power SuPPly SetuP Engine-driven generator recommendations Generators used with the Powermax65 or Powermax85 should satisfy the following requirements: • 1-phase, 50/60 Hz, 230/240 VAC • 3-phase, 50/60 Hz, 200-600 VAC (480 VAC recommended for best performance) • 3-phase, 50/60 Hz, 380/400 VAC (400 VAC recommended for best performance)

  • Page 44: Prepare The Gas Supply

    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 128647) available from Hypertherm distributors. A 3-stage filtering system works as shown below to clean contaminants from the gas supply.

  • Page 45: Connect The Gas Supply

    Power SuPPly SetuP Connect the gas supply Connect the gas supply to the power supply using an inert-gas hose with a 3/8 inch (9.5 mm) internal diameter and a 1/4 NPT quick-disconnect coupler, or a 1/4 NPT x G-1/4 BSPP (CE units) quick-disconnect coupler. The recommended inlet pressure while gas is flowing is 85 –...
  • Page 46 Power SuPPly SetuP Minimum inlet pressure (while gas is flowing) This table shows the minimum required inlet pressure when the recommended inlet pressure is not available. Torch lead length 7.6 m (25 ft) 15 m (50 ft) 23 m (75 ft) Cutting 75 psi (5.2 bar) 80 psi (5.5 bar)
  • Page 47 Section 3 TORCH SETUP In this section: Introduction ......................................3-2 Consumable life .......................................3-2 CopperPlus™ electrode for Duramax torches........................3-2 Hand torch setup ....................................3-3 Choose the hand torch consumables .............................3-4 Hand torch consumables ................................3-5 Install the hand torch consumables ............................3-6 Machine torch setup....................................3-7 Converting a full-length machine torch to a mini machine torch ..................3-8 Mount the torch ..................................

  • Page 48: Torch Setup

    This section explains how to set up your torch and choose the appropriate consumables for the job. Consumable life How often you need to change the consumables on your Powermax65 or Powermax85 will depend on a number of factors: •...

  • Page 49: Hand Torch Setup

    Torch SeTup Hand torch setup Duramax 75° hand torch Consumables Safety trigger Duramax 15° hand torch Consumables Safety trigger powermax 65/85 Operator Manual...

  • Page 50: Choose The Hand Torch Consumables

    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.

  • Page 51: Hand Torch Consumables

    Torch SeTup Hand torch consumables Drag-cutting consumables: Powermax65 220941 Nozzle 220818 220854 220842 220857 Shield Retaining cap Electrode Swirl ring 220819 Nozzle Drag-cutting consumables: Powermax85 220941 Nozzle 220819 Nozzle 220818 220854 220842 220857 Shield Retaining cap Electrode Swirl ring 220816...

  • Page 52: Install The Hand Torch Consumables

    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.

  • Page 53: Machine Torch Setup

    Torch SeTup Machine torch setup Duramax 180° full-length machine torch Mounting sleeve Consumables Positioning sleeve Strain relief nut Torch lead Coupler Main strain Strain relief body Gear rack relief nut Duramax 180° mini machine torch Mounting sleeve Consumables Torch lead Coupler Strain relief nut Strain relief body...

  • Page 54: Converting A Full-Length Machine Torch To A Mini Machine Torch

    Torch SeTup Converting a full-length machine torch to a mini machine torch You can convert a full-length machine torch to a mini machine torch by removing the positioning sleeve. Note: If you are converting a full-length machine torch to a mini machine torch and mounting the torch at the same time, skip this section and follow the instructions in 3-10 Mount the torch.
  • Page 55 Torch SeTup Pilot wire terminal screw Wire connector for Torch head Gas supply line cap-sensor switch connection 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. 9.

  • Page 56: Mount The Torch

    Torch SeTup Mount the torch Depending on the type of cutting table you have, you may or may not need to disassemble the torch to route it through the track and mount it. If your cutting table’s track is large enough for you to thread the torch through it without removing the torch body from the lead, do so and then attach the torch to the lifter per the manufacturer’s instructions.
  • Page 57 Torch SeTup 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. 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.

  • Page 58: Choose The Machine Torch Consumables

    Machine torch consumables Mechanized shielded consumables: Powermax65 220941 Nozzle 220817 220854 220842 220857 Shield Retaining cap Electrode Swirl ring 220819 Nozzle Mechanized shielded with ohmic consumables: Powermax65 220941 Nozzle 220817 220953 220842 220857 Shield Ohmic-sensing Electrode Swirl ring 220819 retaining cap Nozzle...
  • Page 59 Torch SeTup Mechanized unshielded consumables: Powermax65 220941 Nozzle 220854 220842 220857 220955 Retaining cap Electrode Swirl ring Deflector 220819 Nozzle Mechanized shielded consumables: Powermax85 220941 Nozzle 220819 220817 220854 220842 220857 Nozzle Shield Retaining cap Electrode Swirl ring 220816 Nozzle...
  • Page 60 Torch SeTup Mechanized unshielded consumables: Powermax85 220941 Nozzle 220819 220955 220854 220842 220857 Nozzle Deflector Retaining cap Electrode Swirl ring 220816 Nozzle Gouging consumables 220798 220854 220797 220842 220857 Shield Retaining cap Nozzle Electrode Swirl ring FineCut ® shielded consumables 220948 220953 220930...

  • Page 61: Install The Machine Torch Consumables

    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.

  • Page 62: Connecting An Optional Remote-Start Pendant

    • Part number 128652: 75 foot (23 m) Remove the receptacle cover and plug the Hypertherm remote-start pendant into the receptacle on the rear of the power supply. Note: The remote-start pendant is for use only with a machine torch. It will not operate if a handheld torch is installed.

  • Page 63: Connecting An Optional Machine Interface Cable

    Torch SeTup Connecting an optional machine interface cable The Powermax65 and Powermax85 power supplies are equipped with an optional, factory-installed, five-position voltage divider that is designed to be safely connected without tools. The built-in voltage divider provides a scaled down arc voltage of 20:1, 21.1:1, 30:1, 40:1, and 50:1 (maximum output of 18 V).
  • Page 64 Note: The integration of Hypertherm equipment and customer-supplied equipment including interconnecting cords and cables, if not listed and certified as a system, is subject to inspection by local authorities at the final installation site.
  • Page 65 Torch SeTup Refer to the following table when connecting the Powermax65 or Powermax85 to a torch height controller or CNC controller with a machine interface cable. Signal Type Notes Connector External cable wires sockets Start Input Normally open. 3, 4...
  • Page 66 Torch SeTup Setting the five-position voltage divider To change the factory preset voltage divider from 50:1 to a different setting: 1. Turn OFF the power supply and disconnect the power cord. 2. Remove the power supply cover. 3. Locate the voltage divider DIP switches on the left side of the power supply. Note: The figure below shows the default setting (50:1) with the number 4 switch up.
  • Page 67 Torch SeTup Accessing raw arc voltage To access divided raw arc voltage, refer to Field Service Bulletin 807060. WARNING HIGH VOLTAGE AND CURRENT Connecting directly to the plasma circuit for access to raw arc voltage increases the risk of shock hazard, energy hazard, and fire hazard in the event of a single fault. The output voltage and the output current of the circuit are specified on the data plate.

  • Page 68: Connecting The Torch Lead

    Torch SeTup Connecting the torch lead The Powermax65 and Powermax85 are equipped with FastConnect , a quick-disconnect system for connecting and disconnecting handheld and machine torch leads. When connecting or disconnecting a torch, first turn OFF the system. To connect either torch, push the connector into the receptacle on the front of the power supply.

  • Page 69: Using The Cut Charts

    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. powermax...

  • Page 70: Estimated Kerf-Width Compensation

    Torch SeTup Estimated kerf-width compensation The widths in the tables below are for reference. The data are obtained with the “Best Quality” settings. Differences between installations and material composition may cause actual results to vary from those shown in the tables. Estimated kerf-width compensation –...
  • Page 71 Torch SeTup Estimated kerf-width compensation – English (inches) Thickness (inches) Process 22GA 18GA 14GA 10GA 3/16 Mild Steel 85A Shielded 0.068 0.071 0.073 0.078 0.090 0.095 0.100 65A Shielded 0.062 0.065 0.068 0.070 0.076 0.088 0.090 0.091 45A Shielded 0.035 0.054 0.055 0.061...

  • Page 72: 85 A Shielded Consumables

    Torch SeTup 85 A shielded consumables 220817 220854 220816 220842 220857 Shield Retaining cap Nozzle Electrode Swirl ring 220817 220953 220816 220842 220857 Shield Ohmic-sensing Nozzle Electrode Swirl ring retaining cap powermax 3-26 65/85 Operator Manual...
  • Page 73 Torch SeTup 85A Shielded Air flow rate - slpm/scfh 190 / 400 Mild Steel Cold 235 / 500 Metric Torch- Pierce Best Quality Settings Production Settings Material Initial Pierce to-Work Delay Thickness Height Cut Speed Voltage Cut Speed Voltage Distance Time seconds (mm/min)
  • Page 74 Torch SeTup 85A Shielded Air flow rate - slpm/scfh 190 / 400 Stainless Steel Cold 235 / 500 Metric Torch- Best Quality Settings Production Settings Material Pierce to-Work Initial Pierce Height Thickness Delay Time Cut Speed Voltage Cut Speed Voltage Distance seconds (mm/min)
  • Page 75 Torch SeTup 85A Shielded Air flow rate - slpm/scfh 190 / 400 Aluminum Cold 235 / 500 Metric Torch- Best Quality Settings Production Settings Material Initial Pierce Pierce to-Work Thickness Height Delay Time Cut Speed Voltage Cut Speed Voltage Distance seconds (mm/min) Volts...

  • Page 76: 65 A Shielded Consumables

    Torch SeTup 65 A shielded consumables 220817 220854 220819 220842 220857 Shield Retaining cap Nozzle Electrode Swirl ring 220817 220953 220819 220842 220857 Shield Ohmic-sensing Nozzle Electrode Swirl ring retaining cap powermax 3-30 65/85 Operator Manual...
  • Page 77 Torch SeTup 65A Shielded Air flow rate - slpm/scfh 160 / 340 Mild Steel Cold 220 / 470 Metric Best Quality Settings Production Settings Torch- Pierce Material Initial Pierce to-Work Delay Thickness Height Cut Speed Voltage Cut Speed Voltage Distance Time seconds (mm/min)
  • Page 78 Torch SeTup 65A Shielded Air flow rate - slpm/scfh 160 / 340 Stainless Steel Cold 220 / 470 Metric Torch- Best Quality Settings Production Settings Material Initial Pierce Pierce to-Work Thickness Height Delay Time Cut Speed Voltage Cut Speed Voltage Distance seconds (mm/min)
  • Page 79 Torch SeTup 65A Shielded Air flow rate - slpm/scfh 160 / 340 Aluminum Cold 220 / 470 Metric Torch- Best Quality Settings Production Settings Material Initial Pierce Pierce Delay to-Work Thickness Height Time Cut Speed Voltage Cut Speed Voltage Distance seconds (mm/min) Volts...

  • Page 80: 45 A Shielded Consumables

    Torch SeTup 45 A shielded consumables 220817 220854 220941 220842 220857 Shield Retaining cap Nozzle Electrode Swirl ring 220817 220953 220941 220842 220857 Shield Ohmic-sensing Nozzle Electrode Swirl ring retaining cap powermax 3-34 65/85 Operator Manual...
  • Page 81 Torch SeTup 45A Shielded Air flow rate - slpm/scfh 150 / 310 Mild Steel Cold 210/ 450 Metric Torch- Best Quality Settings Production Settings Material Initial Pierce Pierce Delay to-Work Thickness Height Time Cut Speed Voltage Cut Speed Voltage Distance seconds (mm/min) Volts...
  • Page 82 Torch SeTup 45A Shielded Air flow rate - slpm/scfh 150 / 310 Stainless Steel Cold 210/ 450 Metric Torch- Best Quality Settings Production Settings Material Initial Pierce Pierce to-Work Thickness Height Delay Time Cut Speed Voltage Cut Speed Voltage Distance seconds (mm/min) Volts...
  • Page 83 Torch SeTup 45A Shielded Air flow rate - slpm/scfh 150 / 310 Aluminum Cold 210/ 450 Metric Torch- Best Quality Settings Production Settings Material Initial Pierce Pierce to-Work Thickness Height Delay Time Cut Speed Voltage Cut Speed Voltage Distance seconds (mm/min) Volts (mm/min)

  • Page 84: Finecut ® Consumables

    Torch SeTup FineCut ® consumables Note: The cut charts in this section apply to both shielded and unshielded consumables. 220948 220953 220930 220842 220857 Shield Retaining cap Nozzle Electrode Swirl ring 220955 220854 220930 220842 220857 Deflector Retaining cap Nozzle Electrode Swirl ring powermax...
  • Page 85 Torch SeTup FineCut Air flow rate - slpm/scfh 155 / 330 Mild Steel Cold 215 / 460 Metric Torch- Best Quality Settings Material Pierce Delay Amps to-Work Initial Pierce Height Thickness Time Cut Speed Voltage Distance seconds (mm/min) Volts 8250 8250 8250 8250...
  • Page 86 Torch SeTup FineCut Air flow rate - slpm/scfh 155 / 330 Stainless Steel Cold 215 / 460 Metric Torch- Best Quality Settings Material Pierce Amps to-Work Initial Pierce Height Thickness Delay Time Cut Speed Voltage Distance seconds (mm/min) Volts 8250 8250 8250 8250...
  • Page 87 Torch SeTup Low Speed FineCut Air flow rate – slpm/scfh Mild Steel 155 / 330 Cold 215 / 460 Metric Torch- Recommended Material Pierce Delay Current to-Work Initial Pierce Height Thickness Time Cut Speed Voltage Distance seconds (mm/min) Volts 3800 3800 3800 3800...
  • Page 88 Torch SeTup Low Speed FineCut Air flow rate – slpm/scfh Stainless Steel 155 / 330 Cold 215 / 460 Metric Torch- Recommended Material Pierce Delay Current to-Work Initial Pierce Height Thickness Time Cut Speed Voltage Distance seconds (mm/min) Volts 3800 3800 3800 0.15...

  • Page 89: 85 A Unshielded Consumables

    Torch SeTup 85 A unshielded consumables 220955 220854 220816 220842 220857 Deflector Retaining cap Nozzle Electrode Swirl ring powermax 65/85 Operator Manual 3-43...
  • Page 90 Torch SeTup 85A Unshielded Air flow rate - slpm/scfh 190 / 400 Mild Steel Cold 235 / 500 Metric Torch- Best Quality Settings Production Settings Material Initial Pierce Pierce to-Work Thickness Height Delay Time Cut Speed Voltage Cut Speed Voltage Distance seconds (mm/min)
  • Page 91 Torch SeTup 85A Unshielded Air flow rate - slpm/scfh 190 / 400 Stainless Steel Cold 235 / 500 Metric Torch- Best Quality Settings Production Settings Material Initial Pierce Pierce Delay to-Work Thickness Height Time Cut Speed Voltage Cut Speed Voltage Distance seconds (mm/min)
  • Page 92 Torch SeTup 85A Unshielded Air flow rate - slpm/scfh 190 / 400 Aluminum Cold 235 / 500 Metric Torch- Best Quality Settings Production Settings Material Initial Pierce Pierce to-Work Thickness Height Delay Time Cut Speed Voltage Cut Speed Voltage Distance seconds (mm/min) Volts...

  • Page 93: 65 A Unshielded Consumables

    Torch SeTup 65 A unshielded consumables 220955 220854 220819 220842 220857 Deflector Retaining cap Nozzle Electrode Swirl ring powermax 65/85 Operator Manual 3-47...
  • Page 94 Torch SeTup 65A Unshielded Air flow rate - slpm/scfh 160 / 340 Mild Steel Cold 220 / 470 Metric Torch- Best Quality Settings Production Settings Material Initial Pierce Pierce Delay to-Work Thickness Height Time Cut Speed Voltage Cut Speed Voltage Distance seconds (mm/min)
  • Page 95 Torch SeTup 65A Unshielded Air flow rate - slpm/scfh 160 / 340 Stainless Steel Cold 220 / 470 Metric Torch- Best Quality Settings Production Settings Material Initial Pierce Pierce to-Work Thickness Height Delay Time Cut Speed Voltage Cut Speed Voltage Distance seconds (mm/min)
  • Page 96 Torch SeTup 65A Unshielded Air flow rate - slpm/scfh 160 / 340 Aluminum Cold 220 / 470 Metric Torch- Best Quality Settings Production Settings Material Initial Pierce Pierce to-Work Thickness Height Delay Time Cut Speed Voltage Cut Speed Voltage Distance seconds (mm/min) Volts...

  • Page 97: 45 A Unshielded Consumables

    Torch SeTup 45 A unshielded consumables 220955 220854 220941 220842 220857 Deflector Retaining cap Nozzle Electrode Swirl ring powermax 65/85 Operator Manual 3-51...
  • Page 98 Torch SeTup 45A Unshielded Air flow rate - slpm/scfh 147 / 310 Mild Steel Cold 210 / 450 Metric Torch- Best Quality Settings Production Settings Material Initial Pierce Pierce to-Work Thickness Height Delay Time Cut Speed Voltage Cut Speed Voltage Distance seconds (mm/min)
  • Page 99 Torch SeTup 45A Unshielded Air flow rate - slpm/scfh 147 / 310 Stainless Steel Cold 210 / 450 Metric Torch- Best Quality Settings Production Settings Material Initial Pierce Pierce Delay to-Work Thickness Height Time Cut Speed Voltage Cut Speed Voltage Distance seconds (mm/min)
  • Page 100 Torch SeTup 45A Unshielded Air flow rate - slpm/scfh 147 / 310 Aluminum Cold 210 / 450 Metric Torch- Best Quality Settings Production Settings Material Initial Pierce Pierce to-Work Thickness Height Delay Time Cut Speed Voltage Cut Speed Voltage Distance seconds (mm/min) Volts...

  • Page 101: Operation

    Rear controls ....................................4-2 Front controls and LEDs ................................4-2 Status screen ....................................4-4 Operating the Powermax65 or Powermax85 ...........................4-6 Connect the electrical power, gas supply, and torch lead ....................4-6 Attach the work lead to the power supply ..........................4-7 Attach the work clamp to the workpiece ..........................4-8 Turn ON the system ..................................4-9...

  • Page 102: Controls And Indicators

    OperatiOn Controls and indicators The Powermax65 and Powermax85 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. Rear controls ON (I)/OFF (O) power switch Activates the power supply and its control circuits.
  • Page 103 OperatiOn 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. •...

  • Page 104: Status Screen

    OperatiOn Status screen The status screen shows system status and fault information. Current Remote setting Torch is connected (amps) cutting Torch started Current selection cursor Fault icon Pressure selection cursor Fault code Visual pressure Pressure setting setting Gas pressure indicators In manual mode, the gas pressure is displayed in bar and psi.
  • Page 105 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.

  • Page 106: Operating The Powermax65 Or Powermax85

    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 Powermax65 and Powermax85, see Section 2, Power Supply Setup. To connect the torch, push the FastConnect connector into the receptacle on the front of the power supply You will attach the work lead in the next section.

  • Page 107: 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 65 A work lead with the Powermax65. Use an 85 A work lead with the Powermax85. The amperage is marked near the rubber boot of the work lead connector.

  • Page 108: Attach The Work Clamp To The Workpiece

    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 Powermax65 or Powermax85 with a cutting table, you can connect the work lead directly to the table instead of attaching the work clamp to the workpiece.

  • Page 109: Turn On The System

    OperatiOn Turn ON the system Set the ON/OFF switch to the ON (I) position. Set the operating mode switch Use the operating mode switch to select the type of work you want to perform. 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.

  • Page 110: Check The Indicators

    OperatiOn 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.

  • Page 111: Adjusting The Current (Amperage)

    OperatiOn 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.

  • Page 112: 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 104° F (40° C). With a Powermax65: • At 65 A, the arc can remain on for 5 minutes out of 10 minutes without causing the unit to overheat (50% duty cycle).

  • Page 113: Using The Hand Torch

    OperatiOn Using the hand torch WARNING INSTANT-ON TORCHES PLASMA ARC CAN CAUSE INJURY AND BURNS Plasma arc comes on im me di ate ly when the torch trigger is activated. The plasma arc will cut quickly through gloves and skin. • W ear correct and appropriate protective equipment.

  • Page 114: Hand Torch Cutting Hints

    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.

  • Page 115: Start A Cut From The Edge Of The Workpiece

    OperatiOn 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.

  • Page 116: Pierce A Workpiece

    OperatiOn Pierce a workpiece WARNING SPARKS AND HOT METAL CAN INJURE EYES AND BURN SKIN. When firing the torch at an angle, sparks and hot metal will spray out from the nozzle. Point the torch away from yourself and others. 1. With the work clamp attached to the workpiece, hold the torch at an approximate 30°...

  • Page 117: Gouge A Workpiece

    OperatiOn Gouge a workpiece WARNING SPARKS AND HOT METAL CAN INJURE EYES AND BURN SKIN. When firing the torch at an angle, sparks and hot metal will spray out from the nozzle. Point the torch away from yourself and others. 1. Hold the torch so that the torch tip is within 1/16 inch (1.5 mm) from the workpiece before firing the torch. 2.
  • Page 118 OperatiOn 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 Angle Operating parameters...
  • Page 119 OperatiOn 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. •...

  • Page 120: Common Hand-Cutting Faults

    OperatiOn 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. •...

  • Page 121: Using The Machine Torch

    OperatiOn Using the machine torch Since the Powermax with a machine torch can be used with a wide variety of cutting tables, track burners, pipe bevelers, and so on, you will need to refer to the manufacturer’s instructions for specifics on operating the machine torch in your configuration.
  • Page 122 OperatiOn Problem Cause Solution Negative cut angle The torch is too low. Raise the torch; or if you are using a torch height control, increase the arc voltage. Square cut The torch is too high. Lower the torch; or if you are using a torch Positive cut angle height control, decrease the arc voltage.

  • Page 123: To Pierce A Workpiece Using The Machine Torch

    Piercing will result in a shorter consumable life than with edge starts. The cut charts include a column for the recommended torch height when starting a pierce. For the Powermax65 and Powermax85, the pierce height is generally 2.5 times the cutting height. Refer to the cut charts for specifics.

  • Page 124: Common Machine-Cutting Faults

    OperatiOn Common machine-cutting faults The torch’s pilot arc will initiate, but will not transfer. Causes can be: • The work cable is not making good contact with the cutting table or the cutting table is not making good contact with the workpiece. •...

  • Page 125: Maintenance And Repair

    Section 5 MAINTENANCE AND REPAIR In this section: Perform routine maintenance ................................5-2 Inspect the consumables ..................................5-3 Basic troubleshooting ....................................5-4 Fault codes and solutions ..................................5-6 Replace the gas filter element ................................5-10 powermax 65/85 Operator Manual...

  • Page 126: Perform Routine Maintenance

    Maintenance and RepaiR Perform routine maintenance DANGER ELECTRIC SHOCK CAN KILL Disconnect the electrical power before you perform any maintenance. All work that requires removal of the power supply cover must be performed by a qualified technician. Every use: Inspect the consumables for proper installation and wear.

  • Page 127: Inspect The Consumables

    Maintenance and RepaiR Inspect the consumables Part Inspect Action Shield or The center hole for roundness. Replace the shield if the hole is no longer deflector round. The gap between the shield and the nozzle for accumulated debris. Remove the shield and clean away any material.

  • Page 128: Basic Troubleshooting

    Maintenance and RepaiR Basic troubleshooting The following table provides an overview of the most common problems that can arise when using the Powermax65 or Powermax85 and explains how to solve them. Note: Fault icons and corresponding fault codes appear in the LCD display. Refer to 5-6 Fault codes and solutions.
  • Page 129 Maintenance and RepaiR Problem Solutions The arc blows out, but re-ignites when • Inspect the consumable parts and replace them if they are worn or the torch trigger is pressed again. damaged. See 5-3 Inspect the consumables. • Replace the gas filter’s element if it is contaminated. See 5-10 Replace the gas filter element.

  • Page 130: Fault Codes And Solutions

    Maintenance and RepaiR Fault codes and solutions A label with descriptions for these common fault codes can be found inside the front cover of this manual. Peel off the label and place it on the rear of the power supply for reference. Fault Description Power...
  • Page 131 “torch stuck closed” situation. • If the consumables appear to be installed correctly, the torch may be damaged. Contact your Hypertherm distributor or authorized repair facility. 0-40 Over/under temperature • Leave the power supply on to allow the fan to cool the power supply.
  • Page 132 • If the consumables appear to be installed correctly, the torch may be damaged. Contact your Hypertherm distributor or authorized repair facility. 0-51 Start/trigger signal on at • If the power supply is turned on while the torch power up trigger is pressed, the system is disabled.
  • Page 133 Maintenance and RepaiR Fault Description Power Fault Fault Solutions code icon 0-52 Torch not connected • Plug a torch lead into the FastConnect receptacle on the front of the power supply and recycle the power switch. 0-60 AC input voltage error • Phase loss: Check all input phases and fuses.

  • Page 134: Replace The Gas Filter Element

    Maintenance and RepaiR Replace the gas filter element 1. Turn OFF the power, disconnect the power cord, and make sure the gas supply is disconnected. 2. Position the rear of the power supply so the removable gas filter bowl is easily accessible. 3.

  • Page 135: Parts

    Duramax 15° hand torch replacement parts .............................6-7 Hand torch consumables ..................................6-8 Duramax 180° full-length machine torch replacement parts ......................6-9 Duramax 180° mini machine torch replacement parts ........................ 6-11 Machine torch consumables ................................6-13 Accessory parts....................................6-14 Powermax65/85 labels ..................................6-15 powermax 65/85 Operator Manual...

  • Page 136: Power Supply Parts

    Kit: Powermax85 CSA rear panel 228653 Kit: Powermax85 CE rear panel 228642 Kit: Powermax65/85 cover screws 228666 Kit: Powermax65 CSA power supply cover 228674 Kit: Powermax65 CE power supply cover 228676 Kit: Powermax85 CSA power supply cover 228675 Kit: Powermax85 CE power supply cover...
  • Page 137 Kit: Powermax65 CE power cord 228678 Kit: Powermax85 CE power cord 228680 Kit: Powermax65/85 power cord strain relief 128650 Remote start pendant for machine torch, 7.6 m (25 ft) 128651 Remote start pendant for machine torch, 15 m (50 ft)
  • Page 138 Parts Part number Description 023206 Machine interface cable (start, stop, arc transfer signals), 7.6 m (25 ft), spade connectors 023279 Machine interface cable (start, stop, arc transfer signals), 15 m (50 ft), spade connectors 228350 Machine interface cable (start, stop, arc transfer signals) for divided arc voltage, 7.6 m (25 ft), spade connectors 228351 Machine interface cable (start, stop, arc transfer signals) for divided arc voltage, 15 m (50 ft),...
  • Page 139 (inside filter bowl) Part number Description 228686 Kit: Powermax65/85 fan subassembly 228685 Kit: Powermax65/85 air filter 228695 Kit: Powermax65/85 air filter element (inside filter bowl) 428015 Kit: AF30 air filter bowl/guard 228688 Kit: Powermax65/85 pressure switch 228687 Kit: Powermax65/85 solenoid valve 228689...

  • Page 140: Duramax 75° Hand Torch Replacement Parts

    059 indicate complete torch and lead assemblies. Part number Description 059473 Powermax65/85/105 75° hand torch assembly with 7.6 m (25 ft) lead 059474 Powermax65/85/105 75° hand torch assembly with 15 m (50 ft) lead 059475 Powermax65/85/105 75° hand torch assembly with 23 m (75 ft) lead 228954 Kit: Duramax 75°/HRT torch handle replacement...

  • Page 141: Duramax 15° Hand Torch Replacement Parts

    059 indicate complete torch and lead assemblies. Part number Description 059470 Powermax65/85/105 15° hand torch assembly with 7.6 m (25 ft) lead 059471 Powermax65/85/105 15° hand torch assembly with 15 m (50 ft) lead 059472 Powermax65/85/105 15° hand torch assembly with 23 m (75 ft) lead 228955 Kit: Duramax 15°/HRTs torch handle replacement...

  • Page 142: Hand Torch Consumables

    Parts Hand torch consumables Part number Description Drag cutting 220818 Shield: 45/65/85 A 220854 Retaining cap 45/65/85/105 A 220941 45 A Nozzle 220819 65 A Nozzle 220816 85 A Nozzle 220842 Electrode 45/65/85/105 A 220857 Swirl ring 65/85 A Gouging 220798 Gouging shield 65/85/105 A 220854...

  • Page 143: Duramax 180° Full-Length Machine Torch Replacement Parts

    Parts Duramax 180° full-length machine torch replacement parts Mounting sleeve Positioning sleeve Consumables Strain relief nut Torch lead Coupler Strain relief body Gear rack (32 pitch) Pilot wire terminal screw Front mounting ring O-ring Wire connector for cap-sensor switch Cap-sensor switch Torch head powermax 65/85 Operator Manual...
  • Page 144 059 indicate complete torch and lead assemblies. Part number Description 059476 Powermax65/85/105 180° full-length machine torch assembly with 4.6 m (15 ft) lead 059477 Powermax65/85/105 180° full-length machine torch assembly with 7.6 m (25 ft) lead 059478 Powermax65/85/105 180°...

  • Page 145: Duramax 180° Mini Machine Torch Replacement Parts

    Parts Duramax 180° mini machine torch replacement parts Note: This illustration shows the Duramax 180° machine torch. The Duramax 180° mini machine torches do not have a positioning sleeve and gear rack. Mounting sleeve Consumables Positioning sleeve Strain relief nut Torch lead Coupler Strain relief body...
  • Page 146 059 indicate complete torch and lead assemblies. Part number Description 059481 Powermax65/85/105 180° mini machine torch assembly with 4.6 m (15 ft) lead 059482 Powermax65/85/105 180° mini machine torch assembly with 7.6 m (25 ft) lead 059483 Powermax65/85/105 180°...

  • Page 147: Machine Torch Consumables

    Parts Machine torch consumables Part number Description Shielded 220817 Shield 45/65/85 A 220854 Retaining cap 45/65/85/105 A 220953 Ohmic retaining cap 45/65/85/105 A 220941 45 A Nozzle 220819 65 A Nozzle 220816 85 A Nozzle 220842 Electrode 45/65/85/105 A 220857 Swirl ring 65/85 A Unshielded 220955...

  • Page 148: Accessory Parts

    Kit: 85 A Work lead with ring terminal, 7.6 m (25 ft) 223210 Kit: 85 A Work lead with ring terminal, 15 m (50 ft) 223211 Kit: 85 A Work lead with ring terminal, 23 m (75 ft) 229370 Kit: Powermax65/85 Wheel kit assembly powermax 6-14 65/85 Operator Manual...

  • Page 149: Powermax65/85 Labels

    Parts Powermax65/85 labels Part number Description 228649 Kit: Powermax65 labels, CSA 228650 Kit: Powermax65 labels, CE 228651 Kit: Powermax85 labels, CE 228652 Kit: Powermax85 labels, CSA The label kits include the consumable label, appropriate safety labels, as well as front and side decals. The consumable and safety labels are pictured on the next page.
  • Page 150 Parts powermax 6-16 65/85 Operator Manual...

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