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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:...
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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...
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.
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...
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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...
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.
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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...
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...
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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...
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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...
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Table of ConTenTs powermax 65/85 Operator Manual...
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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°...
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).
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. •...
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)
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 –...
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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.
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 –...
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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.
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)
* 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.
* 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.
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.
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...
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...
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.
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...
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.
• 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.
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.
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.
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...
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.
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...
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.
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 –...
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)
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.
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 –...
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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)
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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 ..................................
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: •...
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.
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.
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.
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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.
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.
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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.
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.
• 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.
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).
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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.
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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...
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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.
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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.
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.
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...
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 –...
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...
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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...
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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...
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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...
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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...
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...
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.
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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. •...
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.
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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.
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.
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.
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.
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.
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.
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.
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).
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.
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.
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.
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°...
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.
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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...
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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. •...
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. •...
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.
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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.
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.
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. •...
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...
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.
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.
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.
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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.
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...
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“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.
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• 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.
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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.
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.
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...
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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)
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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),...
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(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...
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...
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...
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...
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...
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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°...
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...
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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°...
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...
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...
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.
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Parts powermax 6-16 65/85 Operator Manual...
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