Hypertherm powermax 65 Operator's Manual
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Hypertherm powermax 65 Operator's Manual

Plasma arc cutting systems
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Plasma arc cutting systems
Operator Manual – 806650
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  • Page 1 Plasma arc cutting systems Operator Manual – 806650 Revision 0...
  • 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: Operator Manual

    Revision 0 – September 2010 Hypertherm, Inc. Hanover, NH USA www.hypertherm.com email: info@hypertherm.com © Copyright 2010 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 49 6181 58 2123 (Technical Service) 55 11 2409 2636 Tel 55 11 2408 0462 Fax Hypertherm (S) Pte Ltd. 82 Genting Lane Hypertherm México, S.A. de C.V. Media Centre Avenida Toluca No. 444, Anexo 1, Annexe Block #A01-01 Colonia Olivar de los Padres Singapore 349567, Republic of Singapore Delegación Álvaro Obregón...

  • Page 5: Mains Supply

    ELECTROMAGNETIC COMPATIBILITY (EMC) EMC Introduction b. Radio and television transmitters and receivers. Hypertherm’s CE-marked equipment is built in c. Computer and other control equip ment. compliance with standard EN60974-10. The equipment should be in stalled and used in d. Safety critical equipment, for example accordance with the information be low to guarding of industrial equipment.
  • Page 6 Care should be taken to prevent the earthing of the work piece increasing the risk of injury to users, or damage to other elec tri cal equip ment. Where necessary, the con nec tion of the powermax Operator Manual 65/85 Hypertherm 4-08...
  • Page 7 - for any breach by Hypertherm of its ship, if Hypertherm is notified of a defect (i) with warranty. Distributors/OEMs may offer different respect to the power supply within a period of...
  • Page 8 Higher-level systems directives and standards. Only those versions of When a system integrator adds additional Hypertherm products with a CE Marking located equipment; such as cutting tables, motor drives, on or near the data plate have been tested for motion controllers or robots; to a Hypertherm...

  • Page 9: Patent Indemnity

    Hypertherm harmless in the event of any cause manufactured by Hypertherm or manufactured of action arising from the use of the Products. by a person other than Hypertherm not in strict conformity with Hypertherm’s specifications and National and Local codes...
  • Page 10 TAble OF CONTeNTS WARRANTY powermax Operator Manual 65/85 Hypertherm...

  • Page 11: Table Of Contents

    TAble OF CONTeNTS Section 1 Specifications 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 H65/H85 75° hand torch dimensions ......................1-10 H65s/H85s 15°...
  • Page 12 TAble OF CONTeNTS Power connection for the Powermax85 ....................... 2-8 Single-phase power cord (not for CE model) ..................... 2-9 Single-phase power cord installation ....................2-10 Three-phase power cord — plug installation.....................2-11 Extension cord recommendations ........................2-11 Extension cord specifications ......................2-12 Engine-driven generator recommendations ..................2-13 Prepare the gas supply ...........................2-14 Additional gas filtration .........................2-14 Connect the gas supply ........................2-15...
  • Page 13 TAble OF CONTeNTS Using the cut charts ............................3-25 Estimated kerf-width compensation ....................3-26 85 A shielded consumables .......................3-28 65 A shielded consumables .......................3-32 45 A shielded consumables .......................3-36 FineCut ® consumables ........................3-40 85 A unshielded consumables ......................3-43 65 A unshielded consumables ......................3-47 45 A unshielded consumables ......................3-51 Section 4 Operation...
  • Page 14 TAble OF CONTeNTS Using the machine torch ..........................4-24 Ensure the torch and table are set up correctly ................4-24 Understand and optimize cut quality ....................4-24 To pierce a workpiece using the machine torch ................4-27 Common machine-cutting faults ......................4-27 Section 5 Maintenance and Repair Perform routine maintenance ..........................
  • Page 15 Section 1 SPeCIFICATIONS In this section: 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 H65/H85 75° hand torch dimensions ......................1-10 H65s/H85s 15°...

  • Page 16: Specifications

    DVD, and safety manual. You can order additional styles of torches, consumables, and accessories – such as the plasma cutting guide – from any Hypertherm distributor. See Section 6, Parts, for a list of spare and optional parts.

  • 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 Operator Manual 65/85...

  • 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 25 ft (7.6 m) 6.8 (3.1) Hand torch 50 ft (15 m) 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.

  • 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.

  • Page 24: H65/H85 75° Hand Torch Dimensions

    SPeCIFICATIONS H65/H85 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) H65s/H85s 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: M65/M85 Full-Length Machine Torch Dimensions

    SPeCIFICATIONS M65/M85 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 M65m/M85m mini-machine torch dimensions 6.6 in (16.8 cm) 1.4 in...

  • Page 26: Powermax65 Cutting Specifications

    Duramax series torch weights (refer to “Component weights” on page 1-5) Duty cycle and voltage information (refer to “Powermax65 power supply ratings” on page 1-6) * Maximum cut speeds are the results of Hypertherm’s laboratory testing. Actual cutting speeds may vary based on different cutting applications. 1-12...

  • Page 27: Powermax85 Cutting Specifications

    Duramax series torch weights (refer to “Component weights” on page 1-5) Duty cycle and voltage information (refer to “Powermax85 power supply ratings” on page 1-8) * Maximum cut speeds are the results of Hypertherm’s laboratory testing. Actual cutting speeds may vary based on different cutting applications. powermax...

  • Page 28: Symbols And Markings

    SPeCIFICATIONS 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. Power is ON Direct current (DC) Alternating current Power is OFF (AC) An inverter-based power source, either 1-phase or Plasma torch cutting 3-phase Plate metal cutting...
  • Page 30 SPeCIFICATIONS 1-16 powermax Operator Manual 65/85...

  • 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 .......................

  • 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 Operator Manual 65/85...

  • 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

    POWeR SUPPly SeTUP Install a line-disconnect switch Use a line-disconnect switch for each power supply so that the operator can turn off the incoming power quickly in an emergency. Locate the switch so that it is easily accessible to the operator. Installation must be performed by a licensed electrician according to national and local codes.

  • Page 36: Power Connection For The Powermax65

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

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

    POWeR SUPPly SeTUP Single-phase power cord (not for Ce model) To operate your Powermax65 on 1-phase power, you will need to install an appropriate power cord. Refer to “Single-phase power cord installation” on page 2-10 for instructions. aution: When using the Powermax65 CSA model power supply (Ce model is 3-phase only) with a 1-phase power source, replace the supplied power cord with an 8 AWG (10 mm ) 3-wire...

  • 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 –...

  • 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 “Single-phase power cord installation” on page 2-10 for instructions. aution: 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 6 AWG (16 mm ) 3-wire...

  • 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 2-10 powermax Operator Manual 65/85...

  • 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 – 7.5 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) engine drive System output 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.
  • 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 25 ft (7.62 m) 50 ft (15.24 m) 75 ft (22.86 m) Cutting 75 psi (5.2 bar) 80 psi (5.5 bar)

  • Page 47: Torch Setup

    Section 3 TORCH SeTUP In this section: Introduction ................................. 3-3 Consumable life ..............................3-3 Hand torch setup ............................... 3-4 Choose the hand torch consumables ....................3-5 Hand torch consumables ........................3-6 Install the hand torch consumables ..................... 3-7 Machine torch setup............................3-8 Converting an M65/M85 torch to an M65m/M85m torch ............
  • Page 48 TORCH SeTUP Using the cut charts ............................3-25 Estimated kerf-width compensation ....................3-26 85 A shielded consumables .......................3-28 65 A shielded consumables .......................3-32 45 A shielded consumables .......................3-36 FineCut ® consumables ........................3-40 85 A unshielded consumables ......................3-43 65 A unshielded consumables ......................3-47 45 A unshielded consumables ......................3-51 powermax Operator Manual...

  • Page 49: Introduction

    TORCH SeTUP Introduction Duramax™ series handheld and machine torches are available for the Powermax65 and Powermax85 systems. The FastConnect quick-disconnect system makes it easy to remove the torch for transport or to switch from one torch to the other if your applications require the use of different torches.

  • Page 50: Hand Torch Setup

    TORCH SeTUP Hand torch setup H65/H85 Consumables Safety trigger H65s/H85s Consumables Safety trigger powermax Operator Manual 65/85...

  • Page 51: Choose The Hand Torch Consumables

    Choose the hand torch consumables Powermax systems with the Duramax series H65, H85, H65s, or H85s torch are shipped with a full set of cutting consumables pre-installed. Hypertherm also includes spare cutting electrodes and nozzles, and gouging consumables in the consumables box.

  • Page 52: 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 220818 220854 Nozzle 220842 220857 Shield Retaining cap Electrode Swirl ring 220816 Nozzle Gouging consumables 220798...

  • Page 53: 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 54: Machine Torch Setup

    TORCH SeTUP Machine torch setup M65/M85 Mounting sleeve Consumables Positioning sleeve Strain relief nut Torch lead Coupler Main strain Gear rack Strain relief body relief nut M65m/M85m Mounting sleeve Consumables Coupler Torch lead Strain relief nut Strain relief body Before using either style of machine torch, you must: •...

  • Page 55: Converting An M65/M85 Torch To An M65M/M85M Torch

    TORCH SeTUP Converting an M65/M85 torch to an M65m/M85m torch You can convert a full-length machine torch to a mini-machine torch by removing the positioning sleeve. ote: 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 “Mount the torch”...
  • Page 56 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.

  • Page 57: 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 58 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.
  • Page 59 TORCH SeTUP 13. Slide the strain relief body and strain relief nut over the torch lead. 14. If you are mounting a full-length machine torch, slide the positioning sleeve over the torch head. 15. Slide the coupler over the torch lead. 16.

  • Page 60: Choose The Machine Torch Consumables

    Powermax systems with the Duramax M65, M85, M65m, or M85m are shipped with a complete set of consumables. Hypertherm also includes spare electrodes and nozzles. In addition, an ohmic- sensing retaining cap is available for use with shielded consumables. With shielded consumables, the torch tip may touch the metal when cutting.
  • Page 61 TORCH SeTUP Mechanized unshielded consumables: Powermax65 220941 Nozzle 220955 220854 220842 220857 Deflector Retaining cap Electrode Swirl ring 220819 Nozzle Mechanized shielded consumables: Powermax85 220941 Nozzle 220819 220817 220854 220842 220857 Nozzle Shield Retaining cap Electrode Swirl ring 220816 Nozzle Mechanized shielded with ohmic consumables: Powermax85 220941 Nozzle...
  • Page 62 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 220842...

  • Page 63: 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 64: Connecting An Optional Remote-Start Pendant

    Powermax65 and Powermax85 configurations with a Duramax machine torch can include an optional 25-foot (7.6 m), 50-foot (15 m), or 75-foot (23 m) remote-start pendant. Remove the receptacle cover and plug the Hypertherm remote-start pendant into the receptacle on the rear of the power supply.

  • Page 65: Connecting An Optional Machine Interface Cable

    The voltage divider is not fault tolerant and elV outputs do not comply with safety extra low voltage (SelV) requirements for direct connection to computer products. Hypertherm offers several choices of machine interface cables for the Powermax65 and Powermax85: •...
  • Page 66 2. Remove the machine interface receptacle’s cover from the rear of the power supply. 3. Connect the Hypertherm machine interface cable to the power supply. 4. If you are using a cable with a D-sub connector on the other end, plug it into the appropriate pin connector on the torch height controller or CNC.
  • Page 67 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. Connector Cable wires Signal Type Notes sockets Green, black Start Input Normally open. 3, 4 (start 18 VDC open circuit voltage at plasma)
  • Page 68 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. ote: The figure below shows the default setting (50:1) with the number 4 switch up.
  • Page 69 TORCH SeTUP Accessing raw arc voltage You need to connect a machine interface cable (part number 228350 or 228351) to the power supply in order to access raw arc voltage. Refer to Field Service Bulletin 806180. 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.

  • Page 70: 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 71: Using The Cut Charts

    Recommended cut speeds are a good starting point for finding the best quality cut (best angle, least dross, and best cut-surface finish). Adjust the speed for your application and table to obtain the desired cut quality. ote: Hypertherm collected the data under laboratory test conditions using new consumables. powermax 3-25...

  • Page 72: Estimated Kerf-Width Compensation

    TORCH SeTUP estimated kerf-width compensation The widths in the tables below are for reference. Differences between installations and material composition may cause actual results to vary from those shown in the tables. estimated kerf-width compensation - Metric (mm) Thickness (mm) Process Mild Steel 85A Shielded...
  • Page 73 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 0.065 0.066 FineCut 0.024 0.043 0.049 0.051 85A Unshielded...

  • Page 74: 85 A Shielded Consumables

    TORCH SeTUP 85 A shielded consumables 220816 220817 220854 220842 220857 Nozzle Shield Retaining cap Electrode Swirl ring 220816 220817 220953 220842 220857 Nozzle Shield Ohmic-sensing Electrode Swirl ring retaining cap 3-28 powermax Operator Manual 65/85...
  • Page 75 TORCH SeTUP 85A Shielded Air flow rate - slpm/scfh 190 / 400 Mild Steel Cold 235 / 500 Metric Recommended Maximum Torch- Pierce Material Initial Pierce to-Work Delay Thickness Height Voltage Voltage Distance Time Speed Speed seconds (mm/min) Volts (mm/min) Volts 6800 11500...
  • Page 76 TORCH SeTUP 85A Shielded Air flow rate - slpm/scfh 190 / 400 Stainless Steel Cold 235 / 500 Metric Recommended Maximum Torch- Pierce Material Initial Pierce to-Work Delay Thickness Height Voltage Voltage Distance Time Speed Speed seconds (mm/min) Volts (mm/min) Volts 7500 11500...
  • Page 77 TORCH SeTUP 85A Shielded Air flow rate - slpm/scfh 190 / 400 Aluminum Cold 235 / 500 Metric Recommended Maximum Torch- Pierce Material Initial Pierce to-Work Delay Thickness Height Voltage Voltage Distance Time Speed Speed seconds (mm/min) Volts (mm/min) Volts 8000 11800 6500...

  • Page 78: 65 A Shielded Consumables

    TORCH SeTUP 65 A shielded consumables 220817 220854 220842 220857 220819 Shield Retaining cap Nozzle Electrode Swirl ring 220819 220817 220953 220842 220857 Nozzle Shield Ohmic-sensing Electrode Swirl ring retaining cap 3-32 powermax Operator Manual 65/85...

  • Page 79: Metric Table

    TORCH SeTUP 65A Shielded Air flow rate - slpm/scfh 160 / 340 Mild Steel Cold 220 / 470 Metric Recommended Maximum Torch- Pierce Material Initial Pierce to-Work Delay Thickness Height Voltage Voltage Distance Time Speed Speed seconds (mm/min) Volts (mm/min) Volts 6050 8800...
  • Page 80 TORCH SeTUP 65A Shielded Air flow rate - slpm/scfh 160 / 340 Stainless Steel Cold 220 / 470 Metric Recommended Maximum Torch- Pierce Material Initial Pierce to-Work Delay Thickness Height Voltage Voltage Distance Time Speed Speed seconds (mm/min) Volts (mm/min) Volts 8100 12500...
  • Page 81 TORCH SeTUP 65A Shielded Air flow rate - slpm/scfh 160 / 340 Aluminum Cold 220 / 470 Metric Recommended Maximum Torch- Pierce Material Initial Pierce to-Work Delay Thickness Height Voltage Voltage Distance Time Speed Speed seconds (mm/min) Volts (mm/min) Volts 8800 12800 7400...

  • Page 82: 45 A Shielded Consumables

    TORCH SeTUP 45 A shielded consumables 220817 220854 220941 220842 220857 Shield Retaining cap Nozzle Electrode Swirl ring 220817 220953 220842 220857 220941 Shield Ohmic-sensing Electrode Swirl ring Nozzle retaining cap 3-36 powermax Operator Manual 65/85...
  • Page 83 TORCH SeTUP 45A Shielded Air flow rate - slpm/scfh 147 / 310 Mild Steel Cold 210/ 450 Metric Recommended Maximum Torch- Pierce Material Initial Pierce to-Work Delay Thickness Height Voltage Voltage Distance Time Speed Speed seconds (mm/min) Volts (mm/min) Volts 9000 12700 9000...
  • Page 84 TORCH SeTUP 45A Shielded Air flow rate - slpm/scfh 147 / 310 Stainless Steel Cold 210/ 450 Metric Recommended Maximum Torch- Pierce Material Initial Pierce to-Work Delay Thickness Height Voltage Voltage Distance Time Speed Speed seconds (mm/min) Volts (mm/min) Volts 9000 12700 9000...
  • Page 85 TORCH SeTUP 45A Shielded Air flow rate - slpm/scfh 147 / 310 Aluminum Cold 210/ 450 Metric Recommended Maximum Torch- Pierce Material Initial Pierce to-Work Delay Thickness Height Voltage Voltage Distance Time Speed Speed seconds (mm/min) Volts (mm/min) Volts 8250 12700 6600 11500...

  • Page 86: Finecut ® Consumables

    TORCH SeTUP FineCut ® consumables ote: The cut charts in this section apply to both shielded and unshielded consumables 220948 220953 220842 220857 220930 Shield Retaining cap Electrode Swirl ring Nozzle 220955 220854 220842 220857 220930 Deflector Retaining cap Electrode Swirl ring Nozzle 3-40...
  • Page 87 TORCH SeTUP FineCut Air flow rate - slpm/scfh 155 / 330 Mild Steel Cold 215 / 460 Metric Recommended Maximum Torch- Pierce Material Initial Pierce Amps to-Work Delay Thickness Height Voltage Voltage Distance Time Speed Speed seconds (mm/min) Volts (mm/min) Volts 8250 12700...
  • Page 88 TORCH SeTUP FineCut Air flow rate - slpm/scfh 155 / 330 Stainless Steel Cold 215 / 460 Metric Recommended Maximum Torch- Pierce Material Initial Pierce Amps to-Work Delay Thickness Height Voltage Voltage Distance Time Speed Speed seconds (mm/min) Volts (mm/min) Volts 8250 12700...

  • Page 89: 85 A Unshielded Consumables

    TORCH SeTUP 85 A unshielded consumables 220816 220955 220854 220842 220857 Nozzle Deflector Retaining cap Electrode Swirl ring powermax 3-43 Operator Manual 65/85...
  • Page 90 TORCH SeTUP 85A Unshielded Air flow rate - slpm/scfh 190 / 400 Mild Steel Cold 235 / 500 Metric Recommended Maximum Torch- Pierce Material Initial Pierce to-Work Delay Thickness Height Voltage Voltage Distance Time Speed Speed seconds (mm/min) Volts (mm/min) Volts 7150 13000...
  • Page 91 TORCH SeTUP 85A Unshielded Air flow rate - slpm/scfh 190 / 400 Stainless Steel Cold 235 / 500 Metric Recommended Maximum Torch- Pierce Material Initial Pierce to-Work Delay Thickness Height Voltage Voltage Distance Time Speed Speed seconds (mm/min) Volts (mm/min) Volts 8550 14000...
  • Page 92 TORCH SeTUP 85A Unshielded Air flow rate - slpm/scfh 190 / 400 Aluminum Cold 235 / 500 Metric Recommended Maximum Torch- Pierce Material Initial Pierce to-Work Delay Thickness Height Voltage Voltage Distance Time Speed Speed seconds (mm/min) Volts (mm/min) Volts 8700 14000 7350...

  • Page 93: 65 A Unshielded Consumables

    TORCH SeTUP 65 A unshielded consumables 220819 220955 220854 220842 220857 Nozzle Deflector Retaining cap Electrode Swirl ring powermax 3-47 Operator Manual 65/85...
  • Page 94 TORCH SeTUP 65A Unshielded Air flow rate - slpm/scfh 160 / 340 Mild Steel Cold 220 / 470 Metric Recommended Maximum Torch- Pierce Material Initial Pierce to-Work Delay Thickness Height Voltage Voltage Distance Time Speed Speed seconds (mm/min) Volts (mm/min) Volts 6050 9200...
  • Page 95 TORCH SeTUP 65A Unshielded Air flow rate - slpm/scfh 160 / 340 Stainless Steel Cold 220 / 470 Metric Recommended Maximum Torch- Pierce Material Initial Pierce to-Work Delay Thickness Height Voltage Voltage Distance Time Speed Speed seconds (mm/min) Volts (mm/min) Volts 7950 12800...
  • Page 96 TORCH SeTUP 65A Unshielded Air flow rate - slpm/scfh 160 / 340 Aluminum Cold 220 / 470 Metric Recommended Maximum Torch- Pierce Material Initial Pierce to-Work Delay Thickness Height Voltage Voltage Distance Time Speed Speed seconds (mm/min) Volts (mm/min) Volts 7750 14200 6550...

  • Page 97: 45 A Unshielded Consumables

    TORCH SeTUP 45 A unshielded consumables 220941 220955 220854 220842 220857 Nozzle Deflector Retaining cap Electrode Swirl ring powermax 3-51 Operator Manual 65/85...
  • Page 98 TORCH SeTUP 45A Unshielded Air flow rate - slpm/scfh 147 / 310 Mild Steel Cold 210 / 450 Metric Recommended Maximum Torch- Pierce Material Initial Pierce to-Work Delay Thickness Height Voltage Voltage Distance Time Speed Speed seconds (mm/min) Volts (mm/min) Volts 9000 12700...
  • Page 99 TORCH SeTUP 45A Unshielded Air flow rate - slpm/scfh 147 / 310 Stainless Steel Cold 210 / 450 Metric Recommended Maximum Torch- Pierce Material Initial Pierce to-Work Delay Thickness Height Voltage Voltage Distance Time Speed Speed seconds (mm/min) Volts (mm/min) Volts 9000 12700...
  • Page 100 TORCH SeTUP 45A Unshielded Air flow rate - slpm/scfh 147 / 310 Aluminum Cold 210 / 450 Metric Recommended Maximum Torch- Pierce Material Initial Pierce to-Work Delay Thickness Height Voltage Voltage Distance Time Speed Speed seconds (mm/min) Volts (mm/min) Volts 7400 12700 4400...

  • Page 101: Operation

    Section 4 OPeRATION In this section: Controls and indicators ............................ 4-3 Rear controls ............................4-3 Front controls and LEDs ........................4-3 Status screen ............................4-6 Operating the Powermax65 or Powermax85 ....................4-9 Connect the electrical power, gas supply, and torch lead ............4-9 Attach the work lead to the power supply ..................4-10 Attach the work clamp to the workpiece ..................4-11 Turn ON the system ..........................4-12...
  • Page 102 OPeRATION Using the machine torch ..........................4-24 Ensure the torch and table are set up correctly ................4-24 Understand and optimize cut quality ....................4-24 To pierce a workpiece using the machine torch ................4-27 Common machine-cutting faults ......................4-27 powermax Operator Manual 65/85...

  • Page 103: 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 104 OPeRATION Fault leD (yellow) When illuminated, this LED indicates that there is a fault with the power supply. For information about these fault conditions and how to correct them, see “Basic troubleshooting” on page 5-4. Power ON leD (green) When illuminated, this LED indicates that the power switch has been set to I (ON) and that the safety interlocks are satisfied.
  • Page 105 OPeRATION Automatic/manual pressure setting mode selector The selector switches between automatic and manual mode. In automatic mode, the power supply automatically sets the gas pressure based upon the torch type and lead length and the adjustment knob sets only the amperage. In manual mode, the adjustment knob sets either the gas pressure or the amperage.

  • Page 106: 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 107: Remote Control

    OPeRATION Gas pressure bar When the arrow is centered in the vertical bar (the reference pressure of the automatic pressure setting), the gas pressure is set to the preset (factory-defined) value. If the pressure is higher than the preset value, the arrow appears above the mid-point of the bar. If the pressure is lower than the preset value, the arrow appears below the mid-point of the bar.
  • Page 108 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 109: Operating The Powermax65 Or Powermax85

    OPeRATION Operating the Powermax65 or Powermax85 Follow the steps below to begin cutting or gouging with the Powermax65 or Powermax85. Connect the electrical power, gas supply, and torch lead For information on connecting the proper power cord with plug to the power supply, refer to the section “Power connection for the Powermax65”...

  • Page 110: Attach The Work Lead To The Power Supply

    OPeRATION Attach the work lead to the power supply aution: 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 111: Attach The Work Clamp To The Workpiece

    OPeRATION 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 112: 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 113: 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 114: 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.

  • Page 115: Understanding Duty-Cycle Limitations

    OPeRATION 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 116: 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. •...

  • Page 117: 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 Section 6, Parts, for part numbers for the Hypertherm plasma cutting guides for cutting circles and making bevel cuts. powermax...

  • Page 118: 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 119: 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.

  • Page 120: 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.
  • Page 121 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 Standoff...
  • Page 122 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 123: 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 124: 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. However, the information in the following sections will help you optimize cut quality and maximize consumable life.
  • Page 125 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 Square cut arc voltage. The torch is too high. Lower the torch; or if you are using Positive cut angle a torch height control, decrease the arc voltage.
  • Page 126 OPeRATION High-speed dross forms when the cutting speed is too fast and the arc angles behind. It forms as a thin, linear bead of solid metal attached very close to the cut. It is more firmly attached to the bottom of the cut than at low speed and is difficult to remove. To reduce high-speed dross: •...

  • Page 127: To Pierce A Workpiece Using The Machine Torch

    OPeRATION To pierce a workpiece using the machine torch As with the hand torch, you can start a cut with the machine torch at the edge of the workpiece or by piercing the workpiece. 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.
  • Page 128 OPeRATION Dross forms on the bottom of the cut. Causes can be: • The consumables are worn and need to be replaced. For optimized performance in a mechanized application, replace the nozzle and the electrode together. • The cutting speed is not correct. See “Using the cut charts” on page 3-25 for more information.

  • Page 129: 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 Operator Manual 65/85...

  • Page 130: 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 131: Inspect The Consumables

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

  • Page 132: Basic Troubleshooting

    If you are unable to fix the problem by following this basic troubleshooting guide, or if you need further assistance: 1. Call your Hypertherm distributor or authorized Hypertherm repair facility. 2. Call the nearest Hypertherm office listed in the front of this manual. Problem Solutions The ON/OFF power switch is set to •...
  • Page 133 MAINTeNANCe AND RePAIR Problem Solutions The arc blows out, but re-ignites when • Inspect the consumable parts and replace them the torch trigger is pressed again. if they are worn or damaged. See “Inspect the consumables” on page 5-3. • Replace the gas filter’s element if it is contaminated.

  • Page 134: 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 135 ON the power supply to clear this fault. • 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 136 • 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...
  • Page 137 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 •...

  • Page 138: 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 139 MAINTeNANCe AND RePAIR The white filter element and plastic retaining nut are visible after removing the filter bowl Thumb latch Remove Install Filter bowl Helpful to lift here when replacing filter bowl powermax 5-11 Operator Manual 65/85...
  • Page 140 MAINTeNANCe AND RePAIR 5-12 powermax Operator Manual 65/85...
  • Page 141 Section 6 PARTS In this section: Power supply parts ............................6-2 Hand torch replacement parts ........................6-5 H65/H85 ..............................6-5 H65s/H85s ............................... 6-5 Hand torch consumables ........................6-8 Machine torch replacement parts ........................6-9 M65/M85/M65m/M85m ........................6-9 Machine torch consumables .......................6-12 Accessory parts..............................6-14 Powermax65/85 labels ...........................6-15 powermax...

  • Page 142: Power Supply Parts

    PARTS Power supply parts Rear panel Adjustment knob Front panel Operating mode switch Power supply cover Part number Description 228643 Kit: Powermax65/85 front panel 228645 Kit: Powermax65 CSA rear panel 228646 Kit: Powermax65 CE rear panel 228647 Kit: Powermax85 CSA rear panel 228653 Kit: Powermax85 CE rear panel 228642...
  • Page 143 PARTS Power switch Receptacle for machine interface cable or remote start pendant Power cord Base Part number Description 228691 Kit: Powermax65/85 CSA power cord 228679 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, 25 ft (7.63 m) 128651...
  • Page 144 PARTS Pressure Pressure Solenoid transducer switch valve Air filter Fan subassembly Air filter element (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 228688 Kit: Powermax65/85 pressure switch 228687 Kit: Powermax65/85 solenoid valve 228689...

  • Page 145: Hand Torch Replacement Parts

    PARTS Hand torch replacement parts H65/H85 Torch handle Torch lead Cap-sensor switch Pilot terminal screw Torch head O-ring Safety trigger Handle and spring screws H65s/H85s Torch handle Torch lead Cap-sensor switch Torch head Pilot terminal O-ring screw Handle Safety trigger screws and spring powermax...
  • Page 146 PARTS The entire hand torch and lead assembly can be replaced, or individual component parts can be replaced. Part numbers starting with 083 and 087 indicate complete torch and lead assemblies. Part number Description 083246* H65 Hand torch assembly with 10 ft (3.0 m) lead 083247* H65 Hand torch assembly with 25 ft (7.6 m) lead 083248*...
  • Page 147 PARTS Part number Description 058503 O-ring 075504 Pilot terminal screw 228719 Kit: H65/H85 Cap-sensor switch replacement 228109 Kit: H65s/H85s Cap-sensor switch replacement 228722 Kit: H65/H85 Torch lead replacement, 10 ft (3.0 m) 228723 Kit: H65/H85 Torch lead replacement, 25 ft (7.6 m) 228724 Kit: H65/H85 Torch lead replacement, 50 ft (15.2 m) 228725...

  • Page 148: Hand Torch Consumables

    PARTS Hand torch consumables Part number Description Drag cutting 220818 Shield 220854 Retaining cap 220941 45 A Nozzle 220819 65 A Nozzle 220816 85 A Nozzle 220842 Electrode 220857 Swirl ring Gouging 220798 65 A/85 A shield 220854 Retaining cap 220797 65 A/85 A nozzle 220842...

  • Page 149: Machine Torch Replacement Parts

    PARTS Machine torch replacement parts M65/M85/M65m/M85m ote: This illustration shows the M65/M85 machine torch. The M65m and M85m 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 Gear rack (32 pitch)
  • Page 150 PARTS The entire machine torch and lead assembly can be replaced, or individual component parts can be replaced. Part numbers starting with 083 and 087 indicate complete torch and lead assemblies. Part number Description 083254* M65 Machine torch assembly with 15 ft (4.6 m) lead 083255* M65 Machine torch assembly with 25 ft (7.6 m) lead 083256*...
  • Page 151 PARTS Part number Description 228736 Kit: M65/M65m/M85/M85m adapter ring (coupler) 228716 Kit: M65/M65m/M85/M85m torch main body replacement 228720 Kit: Cap-sensor switch replacement 058503 O-ring 075504 Pilot terminal screw 228730 Kit: M65/M65m/M85/M85m torch lead replacement, 15 ft (4.6 m) 228731 Kit: M65/M65m/M85/M85m torch lead replacement, 25 ft (7.6 m) 228732 Kit: M65/M65m/M85/M85m torch lead replacement, 35 ft (10.7 m) 228733...

  • Page 152: Machine Torch Consumables

    PARTS Machine torch consumables Part number Description Shielded 220817 Shield 220854 Retaining cap 220953 Ohmic retaining cap 220941 45 A Nozzle 220819 65 A Nozzle 220816 85 A Nozzle 220842 Electrode 220857 Swirl ring Unshielded 220955 Deflector 220854 Retaining cap 220941 45 A Nozzle 220819...
  • Page 153 PARTS Part number Description FineCut 45 A 220955 Deflector 220948 Shield 220854 Retaining cap 220953 Ohmic retaining cap 220930 Nozzle 220842 Electrode 220857 Swirl ring The deflector (220955) is used only with the standard retaining cap (220854). The shield (220948) is used only with the ohmic retaining cap (220953). powermax 6-13 Operator Manual...

  • Page 154: Accessory Parts

    PARTS Accessory parts Part number Description 024548 Leather torch sheathing, 25 ft (7.5 m) 127102 Basic plasma (circles and lines) cutting guide 027668 Deluxe plasma (circles and lines) cutting guide 127301 Powermax65/85 dust cover 128647 Kit: Eliminizer air filter 228570 Kit: Eliminizer air filter with cover 228624 Kit: Eliminizer filter cover...

  • Page 155: Powermax65/85 Labels

    PARTS Part number Description 223206 Kit: 85 A Work lead with magnet clamp, 25 ft (7.5 m) 223207 Kit: 85 A Work lead with magnet clamp, 50 ft (15.2 m) 223208 Kit: 85 A Work lead with magnet clamp, 75 ft (22.9 m) 223209 Kit: 85 A Work lead with ring terminal, 25 ft (7.5 m) 223210...
  • Page 156 220842 220797 220798 220854 FineCut ® 110647 Rev. B 220842 220930 220947 www.hypertherm.com/weee 220931 220854 110701 Rev. A Consumable label CE safety label Read and follow these instructions, employer safety WARNING AVERTISSEMENT practices, and material safety data sheets. Refer to ANS Z49.1, “Safety in Welding, Cutting and Allied...

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