Hypertherm Powermax105 Operator's Manual
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Hypertherm Powermax105 Operator's Manual

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807390 | Revision 2 | English

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Summary of Contents for Hypertherm Powermax105

  • Page 1 Powermax105 ® Plasma Arc Cutting Systems Operator Manual 807390 | Revision 2 | English...
  • 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 Powermax 105 Operator Manual 807390 Revision 2 – August 2015 Hypertherm Inc. Hanover, NH USA www.hypertherm.com email: info@hypertherm.com © Copyright 2015 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: Assessment Of Area

    The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place. The Hypertherm’s CE-marked equipment is built in compliance with surrounding area may extend beyond the boundaries of the premises.
  • Page 6 ElECtromagnEtiC Compatibility (EmC) Earthing of the workpiece Where the workpiece is not bonded to earth for electrical safety, nor connected to earth because of its size and position, for example, ship’s hull or building steel work, a connection bonding the workpiece to earth may reduce emissions in some, but not all instances.

  • Page 7: Patent Indemnity

    This warranty shall not apply to any Powermax brand power supplies In no event shall Hypertherm be liable to any person or entity for any that have been used with phase converters. In addition, Hypertherm incidental, consequential direct, indirect, punitive or exemplary damages...
  • Page 8 At all times you will have and maintain insurance in such quantities and types, and with coverage sufficient and appropriate to defend and to hold Hypertherm harmless in the event of any cause of action arising from the use of the products.
  • Page 9 WARNING! Before operating any Hypertherm equipment, read the safety instructions in your product’s manual and in the Safety and Compliance Manual (80669C). Failure to follow safety instructions can result in personal injury or in damage to equipment. Copies of the manuals may accompany the product in electronic and printed formats.
  • Page 10 Powermax105 Operator Manual...

  • Page 11: Table Of Contents

    Position the power supply..................................2-4 Prepare the electrical power ................................2-4 Install a line-disconnect switch ..............................2-5 Requirements for grounding ..............................2-5 Power connection for the Powermax105 ............................2-6 Three-phase power cord and plug installation ........................2-8 Extension cord recommendations ...............................2-9 Extension cord specifications ..............................2-9 Engine-driven generator recommendations ........................2-10 Prepare the gas supply ..................................
  • Page 12 Rear controls ....................................3-2 Front controls and LEDs ................................3-2 Status screen ....................................3-4 Operating the Powermax105 ................................3-6 Connect the electrical power, gas supply, and torch lead ....................3-6 Attach the work lead to the power supply ..........................3-7 Attach the work clamp to the workpiece ..........................3-8 Turn ON the system ..................................3-9...
  • Page 13 65 A Shielded cutting (Stainless Steel) ..........................6-27 65 A Shielded cutting (Aluminum) ............................6-28 45 A Shielded consumables ..............................6-29 45 A Shielded cutting (Mild Steel) ............................6-30 45 A Shielded cutting (Stainless Steel) ..........................6-31 Powermax105 Operator Manual...
  • Page 14 Using the machine torch ..................................7-8 Setting up the torch and table ................................7-8 Understand and optimize cut quality ..............................7-8 Cut or bevel angle ..................................7-8 Dross .......................................7-9 Piercing a workpiece using the machine torch ..........................7-10 Common machine-cutting faults ..............................7-11 Powermax105 Operator Manual...
  • Page 15 Duramax 15° hand torch replacement parts .............................9-7 Hand torch consumables ..................................9-8 Duramax 180° full-length machine torch replacement parts ......................9-9 Duramax 180° mini machine torch replacement parts ........................ 9-11 Machine torch consumables ................................9-13 Accessory parts....................................9-14 Powermax105 labels ................................... 9-15 Powermax105 Operator Manual...
  • Page 16 Table of ConTenTs Powermax105 Operator Manual...
  • Page 17 System description ....................................1-2 Where to find information ..................................1-3 Power supply dimensions ..................................1-4 Component weights (105 A systems) ..............................1-5 Powermax105 power supply ratings ..............................1-6 Duramax 75° hand torch dimensions ..............................1-8 Duramax 15° hand torch dimensions ..............................1-8 Duramax 180° full-length machine torch dimensions ........................1-9 Duramax 180°...

  • Page 18: Specifications

    See the Parts section for a list of spare and optional parts. Powermax105 power supplies are shipped without a plug on the power cord. See the Power Supply Setup section for more information.

  • Page 19: Where To Find Information

    Information about the controls and LEDs, steps for system operation, and hints for improving cut quality — See the Basic System Operations, Hand Cutting, and Mechanized Cutting sections. The manual also contains sections on troubleshooting and ordering parts for your system. Powermax105 Operator Manual...

  • Page 20: Power Supply Dimensions

    SpecificationS power supply dimensions 432 mm (17.0 in.) 508 mm (20.0 in.) 592 mm 274 mm (23.3 in.) (10.8 in.) Powermax105 Operator Manual...

  • Page 21: Component Weights (105 A Systems)

    Machine torch 23 m (75 ft) 8.7 kg (19.3 lbs) Work lead 7.6 m (25 ft) 2.4 kg (5.3 lbs) Work lead 15 m (50 ft) 4.4 kg (9.6 lbs) Work lead 23 m (75 ft) 6.1 kg (13.4 lbs) Powermax105 Operator Manual...

  • Page 22: Powermax105 Power Supply Ratings

    SpecificationS powermax105 power supply ratings Rated open-circuit voltage (U 200–600 V CSA 300 VDC 230–400 V CE 288 VDC 380 V CCC/230–400 V CE 288 VDC 400 V CE 292 VDC 380 V CCC 280 VDC Drooping Output characteristic Rated output current (I 30–105 A...
  • Page 23 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 4462 KVA. Powermax105 Operator Manual...

  • Page 24: Duramax 75° Hand Torch Dimensions

    75° 6.6 cm angle 9.9 cm (2.6 in.) (3.9 in.) 2.5 cm (1.0 in.) Duramax 15° hand torch dimensions 25.9 cm (10.2 in.) 15° angle 5.1 cm 6.6 cm (2.0 in.) (2.6 in.) 2.5 cm (1.0 in.) Powermax105 Operator Manual...

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

    (12.3 in.) 3.3 cm (1.3 in.) flat sides Duramax 180° mini machine torch dimensions 16.8 cm (6.6 in.) 3.5 cm 2.5 cm (1.4 in.) (1.0 in.) 8.4 cm 3.6 cm (1.4 in.) (3.3 in.) outer dimension, 3.3 cm (1.3 in.) flat sides Powermax105 Operator Manual...

  • Page 26: Powermax105 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: Symbols And Marks

    The CE versions of products that include a UkrSEPRO mark of conformity meet the product safety and EMC requirements for export to the Ukraine. Serbian aaa mark CE versions of products that include a AAA Serbian mark meet the product safety and EMC requirements for export to Serbia. Powermax105 Operator Manual 1-11...

  • Page 28: Noise Levels

    Any noise measurements taken are dependant on the specific environment in which the system is used. See also Noise can damage hearing in the Safety and Compliance Manual included with your system. Specific information by product can be found in the Hypertherm downloads library at: https://www.hypertherm.com/ Click Downloads library, select a product from the Product Type drop-down menu, select “Regulatory”...

  • Page 29: Power Supply Setup

    Position the power supply..................................2-4 Prepare the electrical power ...................................2-4 Install a line-disconnect switch ..............................2-5 Requirements for grounding .................................2-5 Power connection for the Powermax105 .............................2-6 Three-phase power cord and plug installation .........................2-8 Extension cord recommendations ................................2-9 Extension cord specifications ...............................2-9 Engine-driven generator recommendations ........................... 2-10 Prepare the gas supply ..................................

  • Page 30: Unpack The Powermax 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 31: Contents

    The following illustration shows typical system components. A vinyl cap is installed on torches that ship with new systems. Consumables are included in the consumables box. Operator Manual Quick Setup Card Registration Card Setup DVD Safety Manual Box with extra consumables (located next to air filter) Remote-start pendant (optional) Powermax105 Operator Manual...

  • Page 32: 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 33: Install A Line-Disconnect Switch

    • Contain a power-operated mechanism that serves as an emergency stop. • Have appropriate slow-blow fuses installed. See page 2-6 Power connection for the Powermax105 for recommended fuse sizes. requirements for grounding To ensure personal safety, proper operation, and to reduce electromagnetic interference (EMI), the power supply must be properly grounded.

  • Page 34: Power Connection For The Powermax105

    Power SuPPly SetuP Power connection for the Powermax105 Powermax105 3-phase systems include the following models: • The 200–600 V CSA model is a universal power supply that can automatically adjust to operate with AC voltages from 200 to 600 V. •...
  • Page 35 Input current (A) at rated output (16.8 kw) Input current (A) at arc stretch Fuse, slow-blow (A) 380 V CCC Input voltage (V) Input current (A) at rated output (16.8 kw) Input current (A) at arc stretch Fuse, slow-blow (A) Powermax105 Operator Manual...

  • Page 36: Three-Phase Power Cord And Plug Installation

    380 V CCC: 6 mm , 4-wire CCC power cord (some models ship without a power cord) To operate the Powermax105, use a plug that meets national and local electrical codes. The plug must be connected to the power cord by a licensed electrician.

  • Page 37: Extension Cord Recommendations

    6 (10) 6 (10) 6 (10) 6 (10) 230–400 V Ce Input voltage (VAC) Phase 380 V CCC/230–400 V Ce Input voltage (VAC) Phase 400 V Ce Input voltage (VAC) Phase 380 V CCC Input voltage (VAC) Phase Powermax105 Operator Manual...

  • Page 38: Engine-Driven Generator Recommendations

    Power SuPPly SetuP engine-driven generator recommendations Generators used with the Powermax105 should satisfy the following requirements: 200–600 V CSA 3-phase, 50/60 Hz, 200–600 VAC (480 VAC recommended for best performance) 230–400 V Ce 3-phase, 50/60 Hz, 230–400 VAC (400 VAC recommended for best performance) 380 V CCC/230–400 V Ce...

  • Page 39: Prepare The Gas Supply

    To address these issues, use an optional air filtration system, such as the Hypertherm Eliminizer filter kit (228890). For optimal performance, the gas should be compliant with ISO8573-1:2010, Class 1.2.2 (that is, it should have a maximum number of solid particulate per m of <20,000 for particle sizes in the...

  • Page 40: Connect The Gas Supply

    The recommended inlet pressure while gas is flowing is 5.9 – 9.3 bar (85 – 135 psi). wArnInG Do not allow the gas supply pressure to exceed 9.3 bar (135 psi). the filter bowl may explode if this pressure is exceeded. Powermax105 2-12 Operator Manual...
  • Page 41 4.5 bar (65 psi) 4.8 bar (70 psi) Gas flow rates Cutting 220 slpm (460 scfh, 7.7 scfm) at a minimum 5.9 bar (85 psi) Gouging 230 slpm (480 scfh, 8.0 scfm) at a minimum 4.8 bar (70 psi) Powermax105 Operator Manual 2-13...
  • Page 42 Power SuPPly SetuP Powermax105 2-14 Operator Manual...
  • Page 43 Rear controls ....................................3-2 Front controls and LEDs ................................3-2 Status screen ....................................3-4 Operating the Powermax105 ..................................3-6 Connect the electrical power, gas supply, and torch lead ....................3-6 Attach the work lead to the power supply ..........................3-7 Attach the work clamp to the workpiece ...........................3-8 Turn ON the system ..................................3-9...

  • Page 44: Basic System Operations

    Basic system OperatiOns controls and indicators Powermax105 power supplies have the following: ON/OFF switch, adjustment knob, automatic/manual pressure setting mode selector, current/gas selector, operating mode switch, indicator LEDs, and a status screen. These controls and indicators are described on the following pages.
  • Page 45 When in manual mode, this selector toggles between amperage and gas pressure for manual adjustments using the adjustment knob. adjustment knob This knob adjusts the amperage. When operating in manual mode, this knob can also adjust the gas pressure, overriding the automatic setting for optimized applications. Powermax105 Operator Manual...

  • Page 46: Status Screen

    Indicates that a remote control or CNC is controlling the power supply using serial communications. All local controls are disabled. electrode end-of-life detection manually disabled Indicates that the electrode end-of-life detection feature is manually disabled. Powermax105 Operator Manual...
  • Page 47 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 48: Operating The Powermax105

    Basic system OperatiOns Operating the powermax105 Follow the steps below to begin cutting or gouging with the Powermax system. Note: This section provides basic operating instructions. Before operating your Powermax in a production environment, refer to the Hand Torch Setup section or the Machine Torch Setup section.

  • Page 49: Attach The Work Lead To The Power Supply

    Use a 105 a work lead with the powermax105. the amperage is marked near the rubber boot of the work lead connector.

  • Page 50: Attach The Work Clamp To The Workpiece

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

  • Page 51: Turn On The System

    Locks the torch in the ON (fire) position. With this option selected, press the trigger to fire the torch. You can then release the trigger while continuing to cut. Press the trigger again to stop the arc. The torch goes out when transfer is lost. Powermax105 Operator Manual...

  • Page 52: Check The Indicators

    2. Press the current/gas selector until the selection cursor is opposite the gas pressure setting in the status screen. 3. Turn the adjustment knob to adjust the gas pressure to the desired level. Watch the arrow in the pressure bar as you adjust the pressure. Powermax105 3-10 Operator Manual...

  • Page 53: Adjusting The Current (Amperage)

    The electrode end-of-life detection feature on the Powermax105 protects the torch and workpiece from damage by automatically stopping power to the torch when the electrode reaches its end of life. Fault code 0-32 also displays on the front panel status screen.

  • Page 54: Understanding Duty-Cycle Limitations

    The duty cycle is the amount of time, in minutes, that a plasma arc can remain on within a 10-minute period when operating at an ambient temperature of 40° C (104° F). With a Powermax105: • At 105 A (480-600 V CSA, 400 V CE, 380 V CCC), the arc can remain on for 8 minutes out of 10 minutes without causing the unit to overheat (80% duty cycle).

  • Page 55: Hand Torch Setup

    Hand torch consumables ..................................4-4 Drag-cutting 105 A consumables ...............................4-4 Drag-cutting 45 A, 65 A, 85 A consumables ...........................4-4 Gouging consumables ...................................4-5 FineCut ® consumables ..................................4-5 HyAccess 65 A consumables ..............................4-5 Install the hand torch consumables ...............................4-6 Connecting the torch lead ..................................4-7 Powermax105 Operator Manual...

  • Page 56: Introduction

    The CopperPlus electrode (part number 220777) delivers at least two times longer consumable life over standard consumables (Hypertherm consumables designed for the system). This electrode is designed exclusively for use with Duramax torches when cutting metal 12 mm (1/2 inch) and under, and is compatible with 40 A to 105 A settings.

  • Page 57: Hand Torch Components

    Hand TorcH SeTup Hand torch components Note: Torches ship without consumables installed. duramax 75° hand torch Consumables Safety trigger duramax 15° hand torch Consumables Safety trigger Powermax105 Operator Manual...

  • Page 58: Choose The Hand Torch Consumables

    Hand TorcH SeTup choose the hand torch consumables Hypertherm includes a box of consumables with your system. Both styles of hand torches shown on the previous page use the same consumables. Hand torches use shielded consumables. Therefore, you can drag the torch tip along the metal.

  • Page 59: Gouging Consumables

    Retaining cap Nozzle Electrode Swirl ring Finecut ® consumables 220931 220854 220930 220842 220947 Shield Retaining cap Nozzle Electrode Swirl ring Hyaccess 65 a consumables 420410 Standard nozzle 420412 Gouging nozzle 420408 220857 420413 Electrode Swirl ring Retaining cap Powermax105 Operator Manual...

  • Page 60: Install The Hand Torch Consumables

    Torches ship without consumables installed. Pull off the vinyl cap before installing your consumables. With the power switch in the OFF (O) position, install the torch consumables as shown below. Swirl ring Electrode Nozzle Retaining cap Shield Powermax105 Operator Manual...

  • Page 61: Connecting The Torch Lead

    Hand TorcH SeTup connecting the torch lead The Powermax105 is 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 the torch, push the connector into the receptacle on the front of the power supply.
  • Page 62 Hand TorcH SeTup Powermax105 Operator Manual...

  • Page 63: Hand Cutting

    Operate the safety trigger ..................................5-2 Hand torch cutting hints ...................................5-3 Start a cut from the edge of the workpiece ............................5-4 Pierce a workpiece ....................................5-5 Gouge a workpiece ....................................5-6 Gouge profile ....................................5-7 Varying the gouge profile ................................5-8 Common hand-cutting faults ...................................5-8 Powermax105 Operator Manual...

  • Page 64: Using The Hand Torch

    The hand torches are equipped with a safety trigger to prevent accidental firings. When you are ready to use the torch, flip the trigger’s safety cover forward (toward the torch head) and press the red torch trigger as show below. Powermax105 Operator Manual...

  • Page 65: 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 66: Start A Cut From The Edge Of The Workpiece

    2. Press the torch’s trigger to start the arc. Pause at the edge until the arc has cut completely through the workpiece. 3. Drag the torch tip lightly across the workpiece to proceed with the cut. Maintain a steady, even pace. Powermax105 Operator Manual...

  • Page 67: Pierce A Workpiece

    3. Hold the torch in place while continuing to press the trigger. When sparks exit below the workpiece, the arc has pierced the material. 4. When the pierce is complete, drag the nozzle lightly along the workpiece to proceed with the cut. Powermax105 Operator Manual...

  • Page 68: Gouge A Workpiece

    Keep a small distance between the torch tip and the molten metal to avoid reducing consumable life or damaging the torch. Di  r ec  t ion of travel Changing the torch’s angle changes the dimensions of the gouge. Powermax105 Operator Manual...

  • Page 69: Gouge Profile

    7.1 mm (.28 in.) 6.1 mm (.24 in.) Metal removal rate on mild steel 8.8 kg/hr (19.5 lbs/hr) Typical Gouge Profile for 105 A Width Depth 7.4 mm (.29 in.) 6.4 mm (.25 in.) Metal removal rate on mild steel 9.8 kg/hr (21.7 lbs/hr) Powermax105 Operator Manual...

  • Page 70: Varying The Gouge Profile

    You are moving the torch too quickly or too slowly. The arc sputters and consumables life is shorter than expected. The cause can be: • Moisture in the gas supply. • Incorrect gas pressure. • Consumables incorrectly installed. Powermax105 Operator Manual...
  • Page 71 105 A Shielded cutting (Stainless Steel) ..........................6-19 105 A Shielded cutting (Aluminum) ............................6-20 85 A Shielded consumables ..............................6-21 85 A Shielded cutting (Mild Steel) ............................6-22 85 A Shielded cutting (Stainless Steel) ..........................6-23 85 A Shielded cutting (Aluminum) ............................6-24 Powermax105 Operator Manual...
  • Page 72 65 A Unshielded cutting (Stainless Steel) ..........................6-48 65 A Unshielded cutting (Aluminum) ............................6-49 45 A Unshielded consumables ..............................6-50 45 A Unshielded cutting (Mild Steel) ............................6-51 45 A Unshielded cutting (Stainless Steel) ..........................6-52 45 A Unshielded cutting (Aluminum) ............................6-53 Powermax105 Operator Manual...

  • Page 73: Machine Torch Setup

    The CopperPlus electrode (part number 220777) delivers at least two times longer consumable life over standard consumables (Hypertherm consumables designed for the system). This electrode is designed exclusively for use with Duramax torches when cutting metal 12 mm (1/2 inch) and under, and is compatible with 40 A to 105 A settings.

  • Page 74: Machine Torch Components

    Choose and install the consumables. • Align the torch square to the plate. • Attach the torch lead to the power supply. • Set up the power supply for remote starting with either the remote-start pendant or a machine interface cable. Powermax105 Operator Manual...

  • Page 75: Converting A Full-Length Machine Torch To A Mini Machine Torch

    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. Powermax105 Operator Manual...
  • Page 76 16. Attach the mounting sleeve to the torch body using the three screws. 17. Screw the coupler into the mounting sleeve. 18. Screw the strain relief nut into the coupler. 19. Screw the strain relief body into the strain relief nut. Powermax105 Operator Manual...

  • Page 77: Mount The Torch

    Set the torch body aside. Note: Cover the end of the gas line on the torch lead with tape to keep dirt and other contaminants from getting in the gas line when you route the lead through the track. Powermax105 Operator Manual...
  • Page 78 23. Reconnect the strain relief nut and strain relief body. 24. Attach the torch to the lifter per the manufacturer’s instructions. Powermax105 Operator Manual...

  • Page 79: Choose The Machine Torch Consumables

    220993 220854 220990 220842 220994 Shield Retaining cap Nozzle Electrode Swirl ring Mechanized shielded 45 a, 65 a, 85 a consumables 220941 Nozzle 220819 Nozzle 220817 220854 220842 220994 Shield Retaining cap Electrode Swirl ring 220816 Nozzle Powermax105 Operator Manual...

  • Page 80: Mechanized Shielded With Ohmic 105 A Consumables

    220854 220990 220842 220994 Deflector Retaining cap Nozzle Electrode Swirl ring Mechanized unshielded 45 a, 65 a, 85 a consumables 220941 Nozzle 220819 Nozzle 220955 220854 220842 220994 Deflector Retaining cap Electrode Swirl ring 220816 Nozzle Powermax105 6-10 Operator Manual...

  • Page 81: Gouging Consumables

    Electrode Swirl ring Finecut ® shielded consumables 220948 220953 220930 220842 220994 Shield Ohmic-sensing Nozzle Electrode Swirl ring retaining cap Finecut ® unshielded consumables 220955 220854 220930 220842 220994 Deflector Retaining cap Nozzle Electrode Swirl ring Powermax105 Operator Manual 6-11...

  • Page 82: Install The Machine Torch Consumables

    Refer to the Hand torch setup section. aligning the torch Mount the machine torch perpendicular to the workpiece in order to get a vertical cut. Use a square to align the torch at 0° and 90°. Torch 0° 90° Powermax105 6-12 Operator Manual...

  • Page 83: Connecting The Torch Lead

    Machine Torch SeTup connecting the torch lead The Powermax105 is 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 the torch, push the connector into the receptacle on the front of the power supply.

  • Page 84: 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. Powermax105 6-14...

  • Page 85: Estimated Kerf-Width Compensation

    105 A Unshielded 85 A Unshielded 65 A Unshielded 45 A Unshielded aluminum 105 A Shielded 85 A Shielded 65 A Shielded 45 A Shielded 105 A Unshielded 85 A Unshielded 65 A Unshielded 45 A Unshielded Powermax105 Operator Manual 6-15...
  • Page 86 0.065 0.060 105 A Unshielded 0.089 0.098 0.102 0.106 0.117 0.132 85 A Unshielded 0.075 0.075 0.075 0.080 0.082 0.088 65 A Unshielded 0.070 0.070 0.070 0.070 0.072 0.079 45 A Unshielded 0.062 0.058 0.057 0.061 Powermax105 6-16 Operator Manual...

  • Page 87: Shielded Consumables

    Machine Torch SeTup 105 a Shielded consumables 220993 220854 220990 220842 220994 Shield Retaining cap Nozzle Electrode Swirl ring 220993 220953 220990 220842 220994 Shield Ohmic-sensing Nozzle Electrode Swirl ring retaining cap Powermax105 Operator Manual 6-17...

  • Page 88: Shielded Cutting (Mild Steel)

    Best Quality Settings production Settings Material pierce to-work initial pierce height Thickness Delay Time cut Speed Voltage cut Speed Voltage Distance inches inches inches seconds Volts Volts 0.75 0.25 0.125 1.25 1-1/8 Edge Start 1-1/4 1-1/2 Powermax105 6-18 Operator Manual...

  • Page 89: Shielded Cutting (Stainless Steel)

    Best Quality Settings production Settings Material pierce to-work initial pierce height Thickness Delay Time cut Speed Voltage cut Speed Voltage Distance inches inches inches seconds Volts Volts 0.25 0.75 0.31 1.25 0.125 Edge Start 1-1/8 1-1/4 Powermax105 Operator Manual 6-19...

  • Page 90: Shielded Cutting (Aluminum)

    Torch- Best Quality Settings production Settings Material pierce to-work initial pierce height Thickness Delay Time cut Speed Voltage cut Speed Voltage Distance inches inches inches seconds Volts Volts 0.75 0.25 0.125 1.25 Edge Start 1-1/8 1-1/4 Powermax105 6-20 Operator Manual...

  • Page 91: Shielded Consumables

    Machine Torch SeTup 85 a Shielded consumables 220817 220854 220816 220842 220994 Shield Retaining cap Nozzle Electrode Swirl ring 220817 220953 220816 220842 220994 Shield Ohmic-sensing Nozzle Electrode Swirl ring retaining cap Powermax105 Operator Manual 6-21...

  • Page 92: Shielded Cutting (Mild Steel)

    Best Quality Settings production Settings Material initial pierce to-work Delay Thickness height cut Speed Voltage cut Speed Voltage Distance Time inches inches inches seconds Volts Volts 10GA 3/16 0.15 0.18 0.06 0.24 Edge Start 1-1/8 1-1/4 Powermax105 6-22 Operator Manual...

  • Page 93: Shielded Cutting (Stainless Steel)

    Torch- Best Quality Settings production Settings Material pierce to-work initial pierce height Thickness Delay Time cut Speed Voltage cut Speed Voltage Distance inches inches inches seconds Volts Volts 10GA 3/16 0.15 0.06 0.18 Edge Start Powermax105 Operator Manual 6-23...

  • Page 94: Shielded Cutting (Aluminum)

    Edge Start english Torch- Best Quality Settings production Settings Material initial pierce pierce to-work Thickness height Delay Time cut Speed Voltage cut Speed Voltage Distance inches inches inches seconds Volts Volts 0.15 0.06 0.18 Edge Start Powermax105 6-24 Operator Manual...

  • Page 95: Shielded Consumables

    Machine Torch SeTup 65 a Shielded consumables 220817 220854 220819 220842 220994 Shield Retaining cap Nozzle Electrode Swirl ring 220817 220953 220819 220842 220994 Shield Ohmic-sensing Nozzle Electrode Swirl ring retaining cap Powermax105 Operator Manual 6-25...
  • Page 96 Best Quality Settings production Settings Material initial pierce to-work Delay Thickness height cut Speed Voltage cut Speed Voltage Distance Time inches inches inches seconds Volts Volts 16GA 10GA 3/16 0.15 0.06 0.18 0.24 Edge Start Powermax105 6-26 Operator Manual...

  • Page 97: A Shielded Cutting (Stainless Steel)

    Torch- Best Quality Settings production Settings Material initial pierce pierce to-work Thickness height Delay Time cut Speed Voltage cut Speed Voltage Distance inches inches inches seconds Volts Volts 16GA 10GA 3/16 0.15 0.06 0.18 Edge Start Powermax105 Operator Manual 6-27...

  • Page 98: A Shielded Cutting (Aluminum)

    Edge Start english Torch- Best Quality Settings production Settings Material initial pierce pierce Delay to-work Thickness height Time cut Speed Voltage cut Speed Voltage Distance inches inches inches seconds Volts Volts 1/16 0.15 0.06 0.18 Edge Start Powermax105 6-28 Operator Manual...

  • Page 99: Shielded Consumables

    Machine Torch SeTup 45 a Shielded consumables 220817 220854 220941 220842 220994 Shield Retaining cap Nozzle Electrode Swirl ring 220817 220953 220941 220842 220994 Shield Ohmic-sensing Nozzle Electrode Swirl ring retaining cap Powermax105 Operator Manual 6-29...

  • Page 100: A Shielded Cutting (Mild Steel)

    Best Quality Settings production Settings Material initial pierce pierce Delay to-work Thickness height Time cut Speed Voltage cut Speed Voltage Distance inches inches inches seconds Volts Volts 26GA 22GA 18GA 16GA 14GA 0.06 0.15 12GA 10GA 3/16 Powermax105 6-30 Operator Manual...

  • Page 101: A Shielded Cutting (Stainless Steel)

    Best Quality Settings production Settings Material initial pierce pierce to-work Thickness height Delay Time cut Speed Voltage cut Speed Voltage Distance inches inches inches seconds Volts Volts 26GA 22GA 18GA 16GA 14GA 0.06 0.15 12GA 10GA 3/16 Powermax105 Operator Manual 6-31...
  • Page 102 1500 2800 english Torch- Best Quality Settings production Settings Material initial pierce pierce to-work Thickness height Delay Time cut Speed Voltage cut Speed Voltage Distance inches inches inches seconds Volts Volts 1/32 1/16 3/32 0.06 0.15 Powermax105 6-32 Operator Manual...

  • Page 103: Finecut ® Consumables

    The cut charts in this section apply to both shielded and unshielded consumables. 220948 220953 220930 220842 220994 Shield Ohmic-sensing Nozzle Electrode Swirl ring retaining cap 220955 220854 220930 220842 220994 Deflector Retaining cap Nozzle Electrode Swirl ring Powermax105 Operator Manual 6-33...
  • Page 104 6400 4800 2750 1900 english Torch- recommended Material pierce Delay current to-work initial pierce height Thickness Time cut Speed Voltage Distance inches inches seconds Volts 26GA 24GA 22GA 20GA 18GA 0.06 0.09 16GA 14GA 12GA 10GA Powermax105 6-34 Operator Manual...

  • Page 105: Finecut (Stainless Steel)

    6150 4800 2550 1050 english Torch- recommended Material pierce Delay current to-work initial pierce height Thickness Time cut Speed Voltage Distance inches inches seconds Volts 26GA 24GA 22GA 20GA 18GA 0.02 0.08 16GA 14GA 12GA 10GA Powermax105 Operator Manual 6-35...

  • Page 106: Low Speed Finecut (Mild Steel)

    Torch- Material pierce Delay current to-work initial pierce height Thickness Time cut Speed Voltage Distance inches inches seconds Volts 26GA 24GA 22GA 20GA 18GA 0.06 0.09 16GA * 14GA * 12GA 10GA *Not a dross-free cut. Powermax105 6-36 Operator Manual...

  • Page 107: Low Speed Finecut (Stainless Steel)

    0.15 3800 2900 2750 2550 1050 english Torch- recommended Material pierce Delay current to-work initial pierce height Thickness Time cut Speed Voltage Distance seconds Volts 26GA 24GA 22GA 20GA 18GA 0.02 0.08 16GA 14GA 12GA 10GA Powermax105 Operator Manual 6-37...

  • Page 108: Unshielded Consumables

    Machine Torch SeTup 105 a unshielded consumables 220955 220854 220990 220842 220994 Deflector Retaining cap Nozzle Electrode Swirl ring Powermax105 6-38 Operator Manual...

  • Page 109: Unshielded Cutting (Mild Steel)

    Torch- Best Quality Settings production Settings Material pierce to-work initial pierce height Thickness Delay Time cut Speed Voltage cut Speed Voltage Distance inches inches inches seconds Volts Volts 0.36 0.18 1.25 1-1/8 Edge Start 1-1/4 Powermax105 Operator Manual 6-39...

  • Page 110: Unshielded Cutting (Stainless Steel)

    Edge Start english Torch- Best Quality Settings production Settings Material pierce to-work initial pierce height Thickness Delay Time cut Speed Voltage cut Speed Voltage Distance inches inches inches seconds Volts Volts 0.36 0.75 0.18 Edge Start 1-1/8 Powermax105 6-40 Operator Manual...

  • Page 111: Unshielded Cutting (Aluminum)

    Torch- Best Quality Settings production Settings Material pierce to-work initial pierce height Thickness Delay Time cut Speed Voltage cut Speed Voltage Distance inches inches inches seconds Volts Volts 0.75 0.36 0.180 1.25 Edge Start 1-1/8 Powermax105 Operator Manual 6-41...

  • Page 112: Unshielded Consumables

    Machine Torch SeTup 85 a unshielded consumables 220955 220854 220816 220842 220994 Deflector Retaining cap Nozzle Electrode Swirl ring Powermax105 6-42 Operator Manual...

  • Page 113: A Unshielded Cutting (Mild Steel)

    Torch- Best Quality Settings production Settings Material initial pierce pierce to-work Thickness height Delay Time cut Speed Voltage cut Speed Voltage Distance inches inches inches seconds Volts Volts 14GA 10GA 3/16 0.20 0.08 0.24 Edge Start Powermax105 Operator Manual 6-43...
  • Page 114 Torch- Best Quality Settings production Settings Material initial pierce pierce Delay to-work Thickness height Time cut Speed Voltage cut Speed Voltage Distance inches inches inches seconds Volts Volts 14GA 10GA 3/16 0.20 0.08 0.24 Edge Start Powermax105 6-44 Operator Manual...
  • Page 115 Edge Start english Torch- Best Quality Settings production Settings Material initial pierce pierce to-work Thickness height Delay Time cut Speed Voltage cut Speed Voltage Distance inches inches inches seconds Volts Volts 3/16 0.20 0.08 0.24 Edge Start Powermax105 Operator Manual 6-45...

  • Page 116: Unshielded Consumables

    Machine Torch SeTup 65 a unshielded consumables 220955 220854 220819 220842 220994 Deflector Retaining cap Nozzle Electrode Swirl ring Powermax105 6-46 Operator Manual...

  • Page 117: A Unshielded Cutting (Mild Steel)

    Torch- Best Quality Settings production Settings Material initial pierce pierce Delay to-work Thickness height Time cut Speed Voltage cut Speed Voltage Distance inches inches inches seconds Volts Volts 16GA 10GA 0.20 3/16 0.08 0.24 Edge Start Powermax105 Operator Manual 6-47...
  • Page 118 Torch- Best Quality Settings production Settings Material initial pierce pierce to-work Thickness height Delay Time cut Speed Voltage cut Speed Voltage Distance inches inches inches seconds Volts Volts 16GA 10GA 0.20 3/16 0.08 0.24 Edge Start Powermax105 6-48 Operator Manual...
  • Page 119 Torch- Best Quality Settings production Settings Material initial pierce pierce to-work Thickness height Delay Time cut Speed Voltage cut Speed Voltage Distance inches inches inches seconds Volts Volts 1/16 0.20 3/16 0.08 0.24 Edge Start Powermax105 Operator Manual 6-49...

  • Page 120: Unshielded Consumables

    Machine Torch SeTup 45 a unshielded consumables 220955 220854 220941 220842 220994 Deflector Retaining cap Nozzle Electrode Swirl ring Powermax105 6-50 Operator Manual...

  • Page 121: A Unshielded Cutting (Mild Steel)

    Best Quality Settings production Settings Material initial pierce pierce to-work Thickness height Delay Time cut Speed Voltage cut Speed Voltage Distance inches inches inches seconds Volts Volts 26GA 22GA 18GA 16GA 14GA 0.06 0.15 12GA 10GA 3/16 Powermax105 Operator Manual 6-51...
  • Page 122 Best Quality Settings production Settings Material initial pierce pierce Delay to-work Thickness height Time cut Speed Voltage cut Speed Voltage Distance inches inches inches seconds Volts Volts 26GA 22GA 18GA 16GA 14GA 0.06 0.15 12GA 10GA 3/16 Powermax105 6-52 Operator Manual...
  • Page 123 1050 2250 english Torch- Best Quality Settings production Settings Material initial pierce pierce to-work Thickness height Delay Time cut Speed Voltage cut Speed Voltage Distance inches inches inches seconds Volts Volts 1/32 1/16 3/32 0.06 0.15 Powermax105 Operator Manual 6-53...
  • Page 124 Machine Torch SeTup Powermax105 6-54 Operator Manual...

  • Page 125: Mechanized Cutting

    Using the machine torch ..................................7-8 Setting up the torch and table ................................7-8 Understand and optimize cut quality ..............................7-8 Cut or bevel angle ...................................7-8 Dross ........................................7-9 Piercing a workpiece using the machine torch ..........................7-10 Common machine-cutting faults ................................. 7-11 Powermax105 Operator Manual...

  • Page 126: Connecting An Optional Remote-Start Pendant

    Mechanized cutting connecting an optional remote-start pendant Powermax105 configurations with a Duramax machine torch can include an optional remote-start pendant. • Part number 128650: 7.6 m (25 feet) • Part number 128651: 15.2 m (50 feet) • Part number 128652: 22.9 m (75 feet) If your power supply has the optional machine interface receptacle on the rear of the power supply, remove the receptacle cover and plug the Hypertherm remote-start pendant into the receptacle.

  • Page 127: Connecting An Optional Machine Interface Cable

    (SeLV) requirements for direct connection to computer products. Hypertherm offers several choices of machine interface cables for the Powermax105: • To use the built-in voltage divider that provides a scaled down arc voltage in addition to signals for arc transfer and plasma start: Use part number 228350 (7.6 m, 25 feet) or 228351 (15.2 m, 50 feet) for wires terminated with spade...
  • Page 128 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 129: Machine Interface Pinout

    Mechanized cutting Machine interface pinout Refer to the following table when connecting the Powermax105 to a torch height controller or CNC controller with a machine interface cable. Signal type notes connector sockets external cable wires Start (start plasma) Input Normally open.

  • Page 130: Setting The Five-Position Voltage Divider

    4. Set the DIP switches to one of the following settings and replace the power supply cover. 20:1 21.1:1 30:1 40:1 50:1 If the Hypertherm five-position voltage divider does not supply the required voltage for your application, contact your system integrator for assistance. Powermax105 Operator Manual...

  • Page 131: Accessing Raw Arc Voltage

    If your power supply is not equipped with the RS485 connector, order kit 228539, “Powermax65/85/105 RS485 board with cables”. Follow the installation instructions in the Power Supply Component Replacement section of the Service Manual. You can download the Service Manual at www.hypertherm.com (“Downloads library” link). With the RS485 connector installed: 1.

  • Page 132: Using The Machine Torch

    A positive cut angle, or bevel, results when more material is removed from the top of the cut than from the bottom. • A negative cut angle results when more material is removed from the bottom of the cut. Powermax105 Operator Manual...

  • Page 133: Dross

    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: • Decrease the cutting speed. • Decrease the torch-to-work distance. Powermax105 Operator Manual...

  • Page 134: Piercing A Workpiece Using The Machine Torch

    Piercing may 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 Powermax105, the pierce height is generally 2.5 times the cutting height. Refer to the cut charts for specifics.

  • Page 135: Common Machine-Cutting Faults

    The direction of the torch travel is incorrect. The high-quality cut is always on the right with respect to the forward motion of the torch. • The distance between the torch and the workpiece is not correct. • The cutting speed is not correct. See the cut charts in the Machine Torch Setup section. Powermax105 Operator Manual 7-11...
  • Page 136 The air quality is poor (oil or water in the air). • There might be a faulty pilot arc IGBT which can shorten nozzle life (refer to the troubleshooting sections in this manual, or call Technical Service). Powermax105 7-12 Operator Manual...

  • Page 137: Maintenance And Repair

    Section 8 Maintenance and RepaiR In this section: Perform routine maintenance ..................................8-2 Inspect the consumables ..................................8-3 Basic troubleshooting ....................................8-4 Fault codes and solutions ..................................8-6 Replace the air filter element and air filter bowl ..........................8-10 Powermax105 Operator Manual...

  • Page 138: Perform Routine Maintenance

    Replace any damaged labels. Inspect the power cord and plug. Replace if damaged. Inspect the torch lead. Replace if damaged. every 6 months: Clean the inside of the power supply with compressed air or a vacuum. Powermax105 Operator Manual...

  • Page 139: Inspect The Consumables

    The surface for damage, wear, or a If the O-ring is dry, lubricate it and the lack of lubrication. threads with a thin layer of silicone lubricant. If the O-ring is worn or damaged, replace it (058519). Powermax105 Operator Manual...

  • Page 140: 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...
  • Page 141 • Inspect the consumables for wear and replace as necessary. See 8-3 Inspect the consumables. • Check the air pressure and air quality. • Verify that the cutting mode switch is in the proper position for the cutting operation. • Verify that the correct consumables are installed. Powermax105 Operator Manual...

  • Page 142: Fault Codes And Solutions

    • Restore the gas inlet pressure and restart the power supply. • Check the torch lead for leaks or kinking. • Change consumables. 0-22 No gas input • Connect the gas source and restart the power supply. Powermax105 Operator Manual...
  • Page 143 • Change consumables. • If the consumables appear to be installed correctly, the torch may be damaged. Contact your Hypertherm distributor or authorized repair facility. 0-32 End of consumable life • Replace the electrode and nozzle. • Check the remaining consumables for wear and replace as needed.
  • Page 144 • 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 145 DSP board. 0-99 System hardware fault — • A qualified service technician must service the service required system. Contact your distributor or authorized repair facility. Indicates a major fault with the system. Powermax105 Operator Manual...

  • Page 146: Replace The Air Filter Element And Air Filter Bowl

    2. If the consumables case is positioned next to the air filter bowl, remove it first. 3. Grasp the filter bowl with your right hand. Push down the thumb latch and rotate the filter bowl approximately 45 degrees to the right. 4. Pull the filter bowl straight down to remove. Powermax105 8-10 Operator Manual...
  • Page 147 Due to a manufacturing change, your Powermax105 may have one of the two air filter bowl models shown below. The bowl styles and O-rings are not interchangeable between models. Both filter bowls use the same air filter element, but the steps to replace the element will vary for each bowl.
  • Page 148 9. Place the air filter element in the filter bowl. Twist the filter element’s top plastic part until it fastens securely to the top of the filter bowl. Note: To install the air filter bowl, skip to step 10 on page 8-14. Powermax105 8-12 Operator Manual...
  • Page 149 If the O-ring is damaged, replace it with the thinner of the two O-rings in kit 228695. Use thinner O-ring. • If the O-ring is not damaged, make sure it is lightly lubricated with silicone lubricant (027055 not included). Powermax105 Operator Manual 8-13...
  • Page 150 11. Once the bowl is seated properly, rotate the bowl 45 degrees to the left until you hear the thumb latch click into place. 12. Reconnect the gas supply hose to the power supply and check for leaks. 13. Reconnect the electrical power and turn ON the power switch. Powermax105 8-14 Operator Manual...
  • Page 151 Duramax 15° hand torch replacement parts ............................9-7 Hand torch consumables ..................................9-8 Duramax 180° full-length machine torch replacement parts ......................9-9 Duramax 180° mini machine torch replacement parts ........................9-11 Machine torch consumables ................................9-13 Accessory parts....................................... 9-14 Powermax105 labels ....................................9-15 Powermax105 Operator Manual...

  • Page 152: Power Supply Parts

    Kit: Powermax105 200-600V CSA rear panel 228868 Kit: Powermax105 230-400V CE rear panel 228869 Kit: Powermax105 400V CE/380V CCC rear panel 228905 Kit: Powermax105 CSA power supply cover with labels 228906 Kit: Powermax105 CE/CCC power supply cover with labels 108797 Adjustment knob 108732...
  • Page 153 * Filter bowl kit 428352 and 428415 only fit on air filter assembly kit 428351 (see page 9-5). † The plastic air filter bowl (kit 428352) that comes with the Powermax105 is compatible with most air systems, but the airline should be maintained clean. Organic solvents, chemicals, cutting oil, synthetic oil, alkali, and thread lock solutions may cause harmful effects to the plastic air filter bowl.
  • Page 154 Machine interface cable (start, stop, arc transfer signals) for divided arc voltage, 15 m (50 ft), D-sub connector with screws 127204 Cover for Powermax45/65/85/105 machine interface (CPC) receptacle 228539 Kit: Powermax65/85/105 RS485 board with cables 228884 Kit: Powermax105 machine interface cable, internal cable with voltage divider board (CPC port upgrade) Powermax105 Operator Manual...
  • Page 155 228688 Kit: Powermax65/85/105 pressure switch 228687** Kit: Powermax105 regulator/solenoid valve (includes tubing and screws) 228689 Kit: Powermax65/85/105 pressure transducer * Due to a manufacturing change, the new air filter assembly in kit 428351 (shown above) replaces the old air filter assembly in kit 228685.

  • Page 156: Duramax 75° Hand Torch Replacement Parts

    Kit: Duramax hand torch lead replacement, 23 m (75 ft) 128642 Kit: Start switch replacement 228314 Kit: Powermax45/65/85/105 torch quick disconnect repair (latch & spring) * The torch assembly does not include consumables. See page 9-8 for a list of consumable part numbers. Powermax105 Operator Manual...

  • Page 157: Duramax 15° Hand Torch Replacement Parts

    Kit: Duramax hand torch lead replacement, 23 m (75 ft) 128642 Kit: Start switch replacement 228314 Kit: Powermax45/65/85/105 torch quick disconnect repair (latch & spring) * The torch assembly does not include consumables. See page 9-8 for a list of consumable part numbers. Powermax105 Operator Manual...

  • Page 158: Hand Torch Consumables

    Kit: Duramax HyAccess 65 A starter kit (includes 2 HyAccess electrodes and 1 of every other consumable listed below) 420413 Duramax HyAccess retaining cap 420410 Duramax HyAccess standard nozzle 65 A 420412 Duramax HyAccess gouging nozzle 65 A 420408 Duramax HyAccess electrode 65 A 220857 Swirl ring 65 A (standard Powermax65 swirl ring) Powermax105 Operator Manual...

  • Page 159: Duramax 180° Full-Length Machine Torch Replacement Parts

    Duramax 180° full-length machine torch replacement parts Mounting sleeve Consumables Positioning sleeve Strain relief nut Torch lead Coupler Strain relief body Gear rack (32 pitch) Pilot wire terminal screw O-ring Front mounting ring Wire connector for cap-sensor switch Cap-sensor switch Torch head Powermax105 Operator Manual...
  • Page 160 Kit: Powermax65/85/105 180° full-length/mini machine torch lead replacement, 23 m (75 ft) 228314 Kit: Powermax45/65/85/105 torch quick disconnect repair (latch & spring) * The torch assembly does not include consumables. See page 9-13 for a list of consumable part numbers. Powermax105 9-10 Operator Manual...

  • Page 161: Duramax 180° Mini Machine Torch Replacement Parts

    Duramax 180° mini machine torch replacement parts Mounting sleeve Consumables Torch lead Coupler Strain relief nut Strain relief body Pilot wire terminal screw O-ring Front mounting ring Torch head Cap-sensor switch Wire connector for cap-sensor switch Powermax105 Operator Manual 9-11...
  • Page 162 Kit: Powermax65/85/105 180° full-length/mini machine torch lead replacement, 23 m (75 ft) 228314 Kit: Powermax45/65/85/105 torch quick disconnect repair (latch & spring) * The torch assembly does not include consumables. See page 9-13 for a list of consumable part numbers. Powermax105 9-12 Operator Manual...

  • Page 163: Machine Torch Consumables

    FineCut shield 220854 Retaining cap 45/65/85/105 A 220953 Ohmic retaining cap 45/65/85/105 A 220930 FineCut Nozzle 220842 Electrode 45/65/85/105 A 220994 Swirl ring 105 A The deflector (220955) is used only with the standard retaining cap (220854). Powermax105 Operator Manual 9-13...

  • Page 164: Accessory Parts

    Kit: Powermax65/85/105 air filter element 228890 Kit: Eliminizer air filter with protective metal cover for the Powermax105 101215 Kit: Eliminizer air filter protective metal cover for the Powermax105 (cover only) 223254 Kit: 105 A work lead with hand clamp, 7.6 m (25 ft) 223255...

  • Page 165: Powermax105 Labels

    Parts Powermax105 labels Part number Description 228903 Kit: Powermax105 labels, CSA 228904 Kit: Powermax105 labels, CE The label kits include the consumables label, appropriate safety labels, display panel label, power switch label, and side decals. 220990 (105 A) 220953 220993 (105 A)
  • Page 166 Parts Powermax105 9-16 Operator Manual...

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