Hypertherm Powermax45 XP Operator's Manual
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Hypertherm Powermax45 XP Operator's Manual

Plasma arc cutting system
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Powermax45 XP
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Plasma Arc Cutting System
Operator Manual
809240 | Revision 1 | English

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Summary of Contents for Hypertherm Powermax45 XP

  • Page 1 Powermax45 XP ® Plasma Arc Cutting System Operator Manual 809240 | Revision 1 | English...
  • Page 2 United States and other countries. All other trademarks are the property of their respective holders. One of Hypertherm’s long-standing core values is a focus on minimizing our impact on the environment. Doing so is critical to our, and our customers’, success.

  • Page 3: Operator Manual

    Powermax45 XP Operator Manual 809240 Revision 1 English Original instructions September 2016 Hypertherm Inc. Hanover, NH 03755 USA www.hypertherm.com...
  • Page 4 México, D.F. C.P. 01780 (Technical Service Email) 52 55 5681 8109 Tel 52 55 5683 2127 Fax South America & Central America: Hypertherm Brasil Ltda. Soporte.Tecnico@hypertherm.com (Technical Service Email) Rua Bras Cubas, 231 – Jardim Maia Guarulhos, SP – Brasil...
  • Page 5 한국어 / KOREAN product worden meegeleverd. De handleidingen, elke handleiding 경고! Hypertherm 장비를 사용하기 전에 제품 설명서와 안전 및 규정 beschikbaar in alle talen, zijn ook verkrijgbaar via de “Documentenbibliotheek” 준수 설명서 (80669C)에 나와 있는 안전 지침을 읽으십시오. 안전 지침을...
  • Page 6 Kópia návodu, ktorá je dodávaná s produktom, môže mať elektronickú alebo tlačenú podobu. Kópie návodov, vo všetkých dostupných jazykoch, sú k dispozícii aj v sekcii z „knižnice Dokumenty“ na www.hypertherm.com.
  • Page 7 Earthing of the workpiece ......................SC-16 Screening and shielding..........................SC-16 Warranty..........................SC-17 Attention ................................. SC-17 General................................SC-17 Patent indemnity............................SC-17 Limitation of liability............................SC-17 National and local codes ..........................SC-17 Liability cap..............................SC-18 Insurance................................ SC-18 Transfer of rights ............................SC-18 809240 Operator Manual Powermax45 XP...

  • Page 8: Table Of Contents

    Parts coverage..........................SC-18 1 Installation and Setup......................19 System contents..............................20 What to do if components are missing or damaged............... 21 Hypertherm plasma power supply ratings..................... 21 Cutting specifications ............................22 Recommended cut capacity – handheld................... 22 Pierce capacity ............................22 Maximum cut speeds (mild steel) ......................
  • Page 9 What to expect during and after cutting......................53 Adjust the gas pressure manually ........................54 Reset the gas pressure.......................... 56 Change the gas pressure values between psi and bar................57 Understand duty cycle to prevent overheating..................... 58 Powermax45 XP Operator Manual 809240...
  • Page 10 Procedure ............................. 77 Gouge with the machine torch ........................80 Typical gouge profiles ..........................81 Maximum Control gouging consumables (45 A) ..............81 Precision gouging consumables (10 A)................. 83 Troubleshooting tips for gouging ........................84 809240 Operator Manual Powermax45 XP...
  • Page 11 Mechanized shielded consumables with ohmic retaining cap........... 106 FineCut shielded consumables with ohmic retaining cap ............107 FineCut unshielded consumables ....................107 Consumable life..............................107 Understand and optimize cut quality ......................108 Cut or bevel angle..........................108 Dross............................... 109 Powermax45 XP Operator Manual 809240...
  • Page 12 Marking and Dimpling – Argon – Shielded....................133 10 Troubleshooting Guide......................135 Common cutting issues..........................136 Hand cutting issues..........................137 Mechanized cutting issues......................... 138 Check the gas pressure ..........................140 Check the gas quality............................141 809240 Operator Manual Powermax45 XP...
  • Page 13 75° hand torch replacement parts ....................... 164 15° hand torch replacement parts ....................... 165 Machine torch replacement parts......................... 166 Accessory parts..............................168 Powermax45 XP Labels ..........................169 Consumable labels and fault codes label..................169 CSA warning label ..........................170 CE/CCC warning label........................171 Data plate................................
  • Page 14 Contents 809240 Operator Manual Powermax45 XP...

  • Page 15: Electromagnetic Compatibility (Emc)

    Introduction Methods of reducing emissions Mains supply Hypertherm’s CE-marked equipment is built in compliance with standard EN60974-10. The equipment should be installed and used in Cutting equipment must be connected to the mains supply according to accordance with the information below to achieve electromagnetic the manufacturer’s recommendations.

  • Page 16: Earthing Of The Workpiece

    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 17: Warranty

    Hypertherm not in strict conformity herein and as follows: if Hypertherm is notified of a defect (i) with respect with Hypertherm’s specifications and in cases of designs, processes,...

  • Page 18: Waterjet Product Warranty Coverage

    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 19: Installation And Setup

    Installation and Setup The Powermax45 XP is a portable 45 A plasma cutting system that you can use for many handheld and mechanized cutting and gouging applications. The system’s automatic gas and automatic voltage features make it easy to set up and use even if you have limited plasma cutting experience.

  • Page 20: System Contents

    9 Plasma power supply 4 Work clamp with work lead  You can order additional consumables and accessories from any Hypertherm distributor. See Replacement Parts and Accessories on page 159. 809240 Operator Manual Powermax45 XP...

  • Page 21: What To Do If Components Are Missing Or Damaged

     Contact your Hypertherm distributor if any component is missing or damaged.  If you need additional assistance, call the nearest Hypertherm office listed in the front of this manual. Hypertherm plasma power supply ratings Rated open-circuit voltage (U 200 – 240 V, CSA/CE/CCC...

  • Page 22: Cutting Specifications

    * Cut capacity speeds are not necessarily maximum speeds. They are the speeds that must be achieved to be rated at that thickness. Pierce capacity Torch type Material thickness Handheld 12 mm (1/2 inch) Mechanized with a programmable torch height control 12 mm (1/2 inch) 809240 Operator Manual Powermax45 XP...

  • Page 23: Maximum Cut Speeds (Mild Steel)

    Refer to Noise can damage hearing in the Safety and Compliance Manual (80669C) included with your system. In addition, you can find an Acoustical Noise Data Sheet for your system at www.hypertherm.com: 1. Click “Documents library” near the bottom of the page.

  • Page 24: Position The Plasma Power Supply

    Its power cord is approximately 3.0 m (10 feet). Allow at least 0.25 m (10 inches)  of space around the power supply for proper ventilation. 3 m (10 feet) 809240 Operator Manual Powermax45 XP...
  • Page 25 10°. >10° Do not place the power supply  on its side. Doing so can block the louvers on the side of the cover and prevent proper air circulation needed to cool internal components. Powermax45 XP Operator Manual 809240...

  • Page 26: Power Supply Dimensions And Weight

    Work clamp with 7.6 m (25 foot) work lead 1.2 kg (2.6 pounds) Work clamp with 15 m (50 foot) work lead 2.1 kg (4.7 pounds)  For hand torch weights, see page 61. For machine torch weights, see page 89. 809240 Operator Manual Powermax45 XP...

  • Page 27: Connect To Electrical Power

    Installation and Setup Connect to electrical power Use the Hypertherm input current ratings to determine conductor sizes for power connection and installation instructions. The Hypertherm ratings are designated HYP on the data plate on the bottom of the power supply. Use the higher HYP input current value for installation purposes. See page 172 for a sample data plate.

  • Page 28: Requirements For Grounding

    The output setting to use depends on the thickness of the metal and is limited by the input power to the system.  The recommended fuse/breaker sizes account for spikes in input current that occur when you stretch the plasma arc. Stretching the plasma arc is common in some applications, such as gouging. 809240 Operator Manual Powermax45 XP...

  • Page 29: Csa/Ce/Ccc 200 V - 240 V (1-Phase)

    Input voltage 230 V Input current at rated output (45 A x 145 V = 6.5 kW) 33 A Input current at arc stretch 37 A Recommended fuse/breaker size 48 A Voltage tolerance +10% / -10% Powermax45 XP Operator Manual 809240...

  • Page 30: Ccc 380 V (3-Phase)

    480 V Input current at rated output (45 A x 145 V = 6.5 kW) 9.4 A Input current at arc stretch 17 – 12 A Recommended fuse/breaker size 20 A Voltage tolerance +20% / -15% 809240 Operator Manual Powermax45 XP...

  • Page 31: Decrease Output Current And Arc Stretch For Lower Rated Electrical Service

    19 A. Input voltage 230 V Input current at rated output (19 A x 145 V = 2.8 kW) 18 A Input current at arc stretch 19 A Voltage tolerance +10% / -10% Powermax45 XP Operator Manual 809240...

  • Page 32: Prepare The Power Cord

    3-phase (380 V / 400 V) 2.5 mm 4-wire H07RN-F power cord  Power plug not included*  * An appropriate plug must be installed on the power cord by a licensed electrician according to national and local codes. 809240 Operator Manual Powermax45 XP...

  • Page 33: Extension Cord Recommendations

    6 mm (10 AWG) Generator recommendations Generators used with this system must meet the voltage requirements in the following table and in Hypertherm plasma power supply ratings on page 21. Engine drive rating Plasma system output current Performance (arc stretch)

  • Page 34: Connect The Gas Supply

    CSA models: Tighten the 1/4 NPT fitting to 115 kg·cm (100 inch·pounds). The fitting  comes with thread sealant preapplied. CE/CCC models: Tighten the G-1/4 BSPP adapter to 104 kg·cm (90 inch·pounds).  809240 Operator Manual Powermax45 XP...

  • Page 35: Gas Supply Source

    Oil, water, vapor, and other contaminants in the gas supply can damage internal  components over time. Poor gas supply quality results in:  Reduced cut quality and cut speeds  Reduced cut thickness capability  Reduced consumable life  Powermax45 XP Operator Manual 809240...

  • Page 36: High-Pressure Gas Cylinders

    Do not use combustible fuel gases or oxidizing gases with Powermax systems. These gases can result in explosive conditions during plasma cutting operations. You can use the following gases to cut with this system. See Hypertherm plasma power supply ratings on page 21 for requirements on gas quality.

  • Page 37: Gas Flow Rates

    5.9 bar (80 psi) Torch lead length – machine torches Minimum inlet pressure 7.6 m (25 feet) 5.5 bar (80 psi) 11 m (35 feet) 5.5 bar (80 psi) 15 m (50 feet) 5.9 bar (85 psi) Powermax45 XP Operator Manual 809240...

  • Page 38: Maximum Control Gouging (26 - 45 A)

    3.8 bar (55 psi) Torch lead length – machine torches Minimum inlet pressure 7.6 m (25 feet) 3.5 bar (50 psi) 11 m (35 feet) 3.5 bar (50 psi) 15 m (50 feet) 3.8 bar (55 psi) 809240 Operator Manual Powermax45 XP...

  • Page 39: Additional Gas Filtration

     Install the filtering system between the gas supply and the power supply. Additional gas filtration may require higher pressure from the source. Water and particle Oil filter Oil vapor filter filter Gas supply Powermax45 XP Operator Manual 809240...
  • Page 40 Installation and Setup 809240 Operator Manual Powermax45 XP...

  • Page 41: Operation

    Operation Controls and indicators ON (I) / OFF (O) power switch The power switch is located on the front panel. 200 – 240 V 400 V, 480 V Powermax45 XP Operator Manual 809240...

  • Page 42: Cutting Controls

    Adjustment knob – Use this knob to set the cutting current between 10 A and 45 A in 1-unit increments. You can also use this knob to increase or decrease the gas pressure. See Adjust the gas pressure manually on page 54. 809240 Operator Manual Powermax45 XP...

  • Page 43: Indicator Leds

    Some fault conditions cause multiple LEDs to illuminate or blink at the same time. For information on what these fault conditions are and how to clear them, see Fault LEDs and fault codes on page 143. Powermax45 XP Operator Manual 809240...

  • Page 44: Disable The Torch

    “ready to fire” position, the torch emits multiple puffs of air in quick succession. This warns you that the torch is active and will fire an arc the next time the trigger is pulled. See page 45. 809240 Operator Manual Powermax45 XP...

  • Page 45: Warning Puffs Of Air

    The Torch Cap LED on the front panel illuminates when you remove the consumables or set the torch-disable switch to the yellow lock (X) position while the plasma power supply is still ON. The LED extinguishes after the torch emits the warning puffs of air. Powermax45 XP Operator Manual 809240...

  • Page 46: For Hand Torches

    Turn OFF (O) the plasma power supply.  Move the torch-disable switch to the yellow lock (X) position  (closest to the torch lead). Pull the trigger to make sure the torch does not fire a plasma arc. 809240 Operator Manual Powermax45 XP...
  • Page 47 Swirl ring Electrode Nozzle Retaining cap Shield (or deflector) Tighten to finger tight.  Do not over-tighten. Consumables are not preinstalled on new torches. Remove the vinyl cap from the torch before installing the consumables. Powermax45 XP Operator Manual 809240...

  • Page 48: Step 2 - Connect Torch Lead

    Red button To disconnect the torch,  press the red button on the connector and pull the connector out of the receptacle. 809240 Operator Manual Powermax45 XP...

  • Page 49: Step 3 - Connect Gas Supply

    CAUTION Make sure you use a work lead that is appropriate for your power supply. Use a 45 A work lead with the Powermax45 XP. The amperage is marked near the rubber boot of the work lead connector. To prevent overheating, check the work lead often to make sure it is fully seated in the receptacle.

  • Page 50: Work Clamp

    To achieve the best cut quality,  attach the work clamp as close as possible to the area being cut. CAUTION Do not attach the work clamp to the portion of the workpiece to be cut away. 809240 Operator Manual Powermax45 XP...

  • Page 51: Step 5 - Connect Electric Power And Turn On The System

    2. Turn the adjustment knob to set the output current to a maximum of 45 A. The 2-digit display shows the output current in amperage. Powermax45 XP Operator Manual 809240...

  • Page 52: Cutting Expanded Metal

    If any of the fault LEDs illuminate or blink, or if the power ON LED blinks, this indicates a fault. Correct the fault condition before continuing. See Fault LEDs and fault codes on page 143. 809240 Operator Manual Powermax45 XP...

  • Page 53: What To Expect During And After Cutting

    10 – 25 A. When the torch fires without transferring the pilot arc to the workpiece, postflow is 10 seconds even when the supply gas is argon. Fan activity – The cooling fan inside the plasma power supply runs intermittently during and after cutting in order to cool internal components. Powermax45 XP Operator Manual 809240...

  • Page 54: Adjust The Gas Pressure Manually

    In this example, we selected gouge/marking mode and set the output current to 45 A. Set the mode and  output current first because doing so can reset the gas pressure. See page 56. 809240 Operator Manual Powermax45 XP...
  • Page 55 It continues to blink until you reset the pressure. To view the gas pressure setting again, repeat step 2 above, or enter gas test mode.  See Run a gas test on page 149. Powermax45 XP Operator Manual 809240...

  • Page 56: Reset The Gas Pressure

    (26 – 45 A) You connect a different torch to the power supply.   Turning the power supply OFF and ON does not reset the gas pressure. Press the button to reset the gas pressure. 809240 Operator Manual Powermax45 XP...

  • Page 57: Change The Gas Pressure Values Between Psi And Bar

    P.U. Press-and-hold for 15 seconds to toggle between psi and bar. 2. Release the Mode button. The system will now display gas pressure values in bar instead of psi or in psi instead of bar. Powermax45 XP Operator Manual 809240...

  • Page 58: Understand Duty Cycle To Prevent Overheating

    See Decrease output current and arc stretch for lower rated electrical service on page 31. 809240 Operator Manual Powermax45 XP...

  • Page 59: Cut With The Hand Torch

    Torch on page 71.  To resolve issues with cut quality, refer to Common cutting issues on page 136. The Duramax Lock hand torches ship without consumables installed. To install the consumables, see page 46. Powermax45 XP Operator Manual 809240...

  • Page 60: Hand Torch Components, Dimensions, Weights

    102 mm (4.0 inch) 61 mm (2.4 inch) 25 mm (1.0 inch) 15° hand torch 269 mm (10.6 inch) 15° 51 mm 69 mm (2.0 inch) (2.7 inch) 25 mm (1.0 inch) 325 mm (12.8 inch) 809240 Operator Manual Powermax45 XP...

  • Page 61: Weights

    For details on marking consumables, see Marking consumables (10 – 25 A) on page 113. † When you use the following shielded and FineCut consumables, select Cut mode on the front panel. See page 51. Powermax45 XP Operator Manual 809240...

  • Page 62: Shielded Drag-Cutting Consumables

    You can expect to cut approximately the same thicknesses as with the regular shielded consumables. You may need to reduce your cut speed slightly to achieve the same cut quality. Typically, you can expect HyAccess consumables to last approximately half as long as the regular shielded consumables. 809240 Operator Manual Powermax45 XP...

  • Page 63: Copperplus™ Electrode

     1 HyAccess gouging nozzle  1 HyAccess retaining cap  1 swirl ring (standard Powermax45 XP swirl ring)  CopperPLUS™ electrode The CopperPLUS electrode (220777) delivers at least 2 times longer consumable life over standard consumables (Hypertherm consumables designed for the system). This...
  • Page 64 Maximum Control gouging consumables at 26 – 45 A. An arc stretch of 10 – 11 mm (3/8 – 1/2 inch) is recommended for gouging with the  Precision gouging consumables at 10 A– 25 A. 809240 Operator Manual Powermax45 XP...

  • Page 65: Prepare To Fire The Torch

    This warns you that the torch is active and will fire an arc the next time the trigger is pulled. See page 45. Powermax45 XP Operator Manual 809240...

  • Page 66: Hand Torch Cutting Guidelines

    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). For beveled cuts, use a bevel cutting guide. See Accessory parts on page 168. 809240 Operator Manual Powermax45 XP...

  • Page 67: 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 lightly across the workpiece to proceed with the cut. Maintain a steady, even pace. Powermax45 XP Operator Manual 809240...

  • Page 68: Pierce A Workpiece

    2. Straight pierce: Hold the torch perpendicular (90°) to the workpiece. Rolling pierce: Hold the torch at an approximate 30° angle to the workpiece with the torch tip within 1.5 mm (1/16 inch) of the workpiece before firing the torch. 30° for rolling pierce 809240 Operator Manual Powermax45 XP...
  • Page 69 4. Hold the torch in place while continuing to press the trigger. When sparks exit below the workpiece, the arc has pierced the material. 5. When the pierce is complete, drag the torch tip lightly along the workpiece to proceed with the cut. Powermax45 XP Operator Manual 809240...
  • Page 70 Cut with the Hand Torch 809240 Operator Manual Powermax45 XP...

  • Page 71: Gouge With The Hand Torch And Machine Torch

    Before you use either process, press the Mode button on the front panel to set the plasma power supply to Gouge/Marking mode. See page 51. Make sure the Gouge/Marking Mode LED is illuminated. Powermax45 XP Operator Manual 809240...

  • Page 72: Maximum Control Gouging

    Use the Maximum Control gouging consumables.   Hypertherm also offers Maximum Removal gouging consumables. At higher amperages on other Powermax systems, you can use the Maximum Removal consumables for greater metal removal rate and deeper gouge profiles. However, at 45 A with this system and torch, the Maximum Removal consumables do not offer an advantage over the Maximum Control consumables in terms of metal removal rate.

  • Page 73: Specialty Consumables

     The 428414 cutting/gouging starter kit contains: 2 HyAccess electrodes  1 HyAccess cutting nozzle  1 HyAccess gouging nozzle  1 HyAccess retaining cap  1 swirl ring (standard Powermax45 XP swirl ring)  Powermax45 XP Operator Manual 809240...

  • Page 74: How To Control The Gouge Profile

    Slow down to make the gouge wider and  – deeper. Speed up to make the gouge narrower and more shallow. Angle Speed Standoff Rotation of torch (relative to torch center line) Torch center line 809240 Operator Manual Powermax45 XP...

  • Page 75: Gouge With The Hand Torch

    Press the trigger to obtain a pilot arc. Transfer the arc to the workpiece. 40° 5. Stretch the arc as follows: Maximum Control gouging consumables: 19 – 25 mm (3/4 – 1 inch)  Precision gouging consumables: 10 – 11 mm (3/8 – 1/2 inch)  Powermax45 XP Operator Manual 809240...

  • Page 76: Remove Spot Welds

    Maintain an arc stretch of approximately 10 – 11 mm (3/8 – 1/2 inch) as you gouge  around the weld. This provides good visibility and prevents the torch tip from hitting slag, which can shorten consumable life and interrupt the gouge. 809240 Operator Manual Powermax45 XP...

  • Page 77: Procedure

    As you gouge, use very short strokes in a back-and-forth weaving motion until you have  cut through the top layer. You may need to adjust the angle of the torch slightly, depending on the thickness of the  metal. Powermax45 XP Operator Manual 809240...
  • Page 78 Gouge with the Hand Torch and Machine Torch Table 1 – Gouging around the spot weld Right-handed approach Start Spot weld Stop Start Stop Left-handed approach Start Spot weld Stop Start Stop 809240 Operator Manual Powermax45 XP...
  • Page 79 Use very short strokes in a back-and-forth weaving motion until you have removed the  spot weld.  Some scraping or grinding may be required to completely remove all remnants of the spot weld from the bottom plate. Spot weld on bottom plate Spot weld removed Powermax45 XP Operator Manual 809240...

  • Page 80: Gouge With The Machine Torch

    Rotation of the torch relative to the torch center line  Torch-to-work standoff  Speed of the torch over the workpiece  See page 74 for more details. Angle Speed Standoff Rotation of torch (relative to torch center line) Torch center line 809240 Operator Manual Powermax45 XP...

  • Page 81: Typical Gouge Profiles

    Adjust these settings as needed for your application and table to obtain the desired result. Table 2 – Mild steel (Metric) Torch angle Speed (mm/min) Depth (mm) Width (mm) Width/depth ratio 1.83 2.13 40° 3.11 1016 3.71 1.34 1.53 50° 1.81 1016 2.09 Powermax45 XP Operator Manual 809240...
  • Page 82 Table 5 – Stainless steel (English) Torch angle Speed (in/min) Depth (inches) Width (inches) Width/depth ratio 0.114 0.245 2.15 40° 0.080 0.222 2.76 0.048 0.190 3.96 0.210 0.224 1.07 50° 0.139 0.199 1.43 0.080 0.150 1.88 809240 Operator Manual Powermax45 XP...

  • Page 83: Precision Gouging Consumables (10 A)

    Adjust these settings as needed for your application and table to obtain the desired result. Table 6 – Mild steel (Metric) Speed Width/depth Torch angle Standoff (mm) Depth (mm) Width (mm) (mm/min) ratio 40° 0.05 Powermax45 XP Operator Manual 809240...

  • Page 84: Troubleshooting Tips For Gouging

     The power supply is set to Gouge/Marking mode.  Many common metal removal issues can be resolved by installing new consumables in the torch. Do not use worn or damaged consumables. See page 154. 809240 Operator Manual Powermax45 XP...
  • Page 85 • Stretch the arc to approximately 10 – 11 mm (3/8 – 1/2 inch) for better visibility visible while gouging. of the spot weld. • Make sure the Precision gouging consumables are installed. • Make sure the output current is not set above 25 A. Powermax45 XP Operator Manual 809240...
  • Page 86 Gouge with the Hand Torch and Machine Torch 809240 Operator Manual Powermax45 XP...

  • Page 87: Set Up The Machine Torch

    Automatic cooling with ambient air. Special cooling procedures are not needed.  This section provides information on: Machine torch components and dimensions  Setup details for installing the torch on X-Y tables, track burners, pipe bevelers, or other  mechanized equipment Powermax45 XP Operator Manual 809240...

  • Page 88: Machine Torch Components, Dimensions, Weights

    (1.3 inch) 310 mm (12.2 inch) * This measurement is for the outer dimension of the torch. The height of the outer torch shell is 41 mm (1.6 inch) when the torch-disable switch is included. 809240 Operator Manual Powermax45 XP...

  • Page 89: Weights

    The gear rack can be mounted on either side of the torch. If you need to remove the gear rack, remove the 2 screws that secure the rack to the torch shell.  When you install the gear rack, tighten the screws by hand. To avoid stripping the screws, do not overtighten. Gear rack Powermax45 XP Operator Manual 809240...

  • Page 90: Disassemble The Machine Torch

    The left side of the shell is the side with the screws. 4. Remove the 7 screws from the torch shell. Set the screws aside. 5. Carefully pry the left side of the shell away from the torch. 809240 Operator Manual Powermax45 XP...
  • Page 91 9. You can now route the torch body and the torch lead through the mounting system for the cutting table.  Slide the strain relief along the torch lead as needed to move it out of the way as you route the torch lead through the track. Powermax45 XP Operator Manual 809240...

  • Page 92: Assemble The Machine Torch

    Route the blue and black wires from the cap-sensor switch and the torch-disable switch outside of and below the mounting shelf. This helps to prevent the wires from getting pinched and damaged when the torch is fully assembled. 809240 Operator Manual Powermax45 XP...
  • Page 93 If you try to put the torch back together with the slider in the green “ready to fire” ( position, you can damage the torch-disable switch that is inside the shell behind the torch body. Powermax45 XP Operator Manual 809240...

  • Page 94: Align The Torch

    Mount the machine torch perpendicular to the workpiece to get a vertical cut. Use a square to align the torch at 90° angles to the workpiece. Mounting bracket Torch  Position the mounting bracket as low on the torch as possible to minimize vibration at the tip of the torch. 809240 Operator Manual Powermax45 XP...

  • Page 95: Configure Controls For Mechanized Cutting

    Configure Controls for Mechanized Cutting Machine torch setup overview Torch lead Machine interface (CPC) cable RS-485 serial cable (optional) Machine torch Workpiece Ground Work table Work lead Gas supply Powermax45 XP Operator Manual 809240...

  • Page 96: Set Up The Plasma System And Machine Torch For Mechanized Cutting

    Your plasma system must be equipped with a factory-installed (or user-installed)  CPC port with internal voltage divider board. See page 98. A CPC connection is required to fire the torch and to control the signals for arc transfer  and arc voltage. 809240 Operator Manual Powermax45 XP...

  • Page 97: Connect The Remote-Start Pendant

    8. Adjust the torch speed and output current (amperage) as needed. See the cut charts starting on page 121. Connect the remote-start pendant Powermax45 XP configurations with a Duramax Lock machine torch can include an optional remote-start pendant. The remote-start pendant enables you to remotely start and stop the machine torch.

  • Page 98: Connect The Machine Interface Cable

    (SELV) requirements for direct connection to computer products. Hypertherm offers several choices of external machine interface cables. External cables that do not use voltage divider board To use signals for arc transfer and plasma start only, use one of the following cables: 023206 (7.5 m, 25 feet)

  • Page 99: External Cables That Use Voltage Divider Board

    223354 (3.0 m, 10 feet)  223355 (6.1 m, 20 feet)  223048 (7.6 m, 25 feet)  223356 (10.7 m, 35 feet)  123896 (15 m, 50 feet)  Spade connectors CPC port CPC connector D-sub connector Powermax45 XP Operator Manual 809240...

  • Page 100: Installation Of The Machine Interface Cable

    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: a.

  • Page 101: Machine Interface Cable Signals

    2. Remove the power supply cover. 3. Locate the voltage divider DIP switches on the fan side of the power supply. This figure shows the voltage divider at the default setting (50:1) with the number 4 switch up. Powermax45 XP Operator Manual 809240...

  • Page 102: Access Raw Arc Voltage

    30:1 40:1 50:1 If the Hypertherm 5-position voltage divider does not supply the required voltage for your application, contact your system integrator for assistance. Access raw arc voltage To access divided raw arc voltage, refer to Field Service Bulletin 809520.

  • Page 103: Connect An Optional Rs-485 Serial Interface Cable

    If your power supply is not equipped with the RS-485 port, order kit 428654. Follow the installation instructions in the Powermax45 XP Service Manual (809230), which you can download from the “Documents library” at www.hypertherm.com. (Look for the link at the bottom of the page.) With the RS-485 port installed: 1.

  • Page 104: External Serial Port Cables

     223237 – RS-485 cable, unterminated, 15 m (50 feet)  223239 – RS-485 cable, 9-pin D-sub connector for Hypertherm controls, 7.6 m (25 feet)  223240 – RS-485 cable, 9-pin D-sub connector for Hypertherm controls, 15 m (50 feet) ...

  • Page 105: Cut With The Machine Torch

    Shielded consumables provide greater protection for the nozzle to minimize damage  caused from slag during piercing. Hypertherm recommends the use of shielded consumables whenever possible. If you are using unshielded consumables (for example, a deflector instead of a shield), be ...

  • Page 106: Mechanized Shielded Consumables

    Cut with the Machine Torch  Hypertherm does not recommend the use of any other consumables in the Duramax Lock machine torch except for those listed in this manual. The use of any other consumables could adversely affect system performance.

  • Page 107: Finecut Shielded Consumables With Ohmic Retaining Cap

    In general, the thicker the metal being cut, the more quickly the consumables become  worn. For best results, do not exceed the thickness specifications for this system. See page 22.  See page 154 for guidelines on when to replace worn consumables. Powermax45 XP Operator Manual 809240...

  • Page 108: Understand And Optimize Cut Quality

     The squarest cut angle is on the right side with respect to the forward motion of the torch. The left side always has some degree of cut angle. 809240 Operator Manual Powermax45 XP...

  • Page 109: Dross

    • Decrease the cutting speed. the cut as a thin, linear bead of • The arc angles behind. • Decrease the torch-to-work solid metal. It is welded to the distance. bottom of the cut and is difficult to remove. Powermax45 XP Operator Manual 809240...

  • Page 110: Pierce A Workpiece Using The Machine Torch

     system. In particular, high-strength steel with a high manganese or silicon content can reduce the maximum pierce capability. Hypertherm derives mild steel parameters on thicknesses of 12 mm (1/2 inch) or less using certified A572 Grade 50 plate. 809240...

  • Page 111: Cut Stainless Steel With F5

    Manual (80669C) for more information. You can use F5 gas to cut stainless steel with Duramax Lock torches on the Powermax45 XP. When used with a Powermax system, F5 is recommended only for cutting stainless steel to achieve to the advantages in cut quality listed below.
  • Page 112 Cut with the Machine Torch 809240 Operator Manual Powermax45 XP...

  • Page 113: Guidelines For Marking

    It may also result in deeper marks than desired and poorer results overall. 420542 220854 420415 220842 220857 Shield Retaining cap Nozzle Electrode Swirl ring 420542 220953 420415 220842 220857 Shield Ohmic retaining Nozzle Electrode Swirl ring Powermax45 XP Operator Manual 809240...

  • Page 114: Process Gas: Air Versus Argon

    3-second postflow: When the torch fires without transferring the pilot arc to the workpiece  In some dimpling applications where the plasma arc is sustained for less than 0.5 seconds  809240 Operator Manual Powermax45 XP...

  • Page 115: Types Of Marking

    Marking samples The following pictures are intended to provide only a rough approximation of the differences between marking with air versus marking with argon with this system. Argon Light marking on mild steel Powermax45 XP Operator Manual 809240...
  • Page 116 Guidelines for Marking Argon Heavy marking on mild steel Light marking on stainless steel Heavy marking on stainless steel 809240 Operator Manual Powermax45 XP...

  • Page 117: Marking, Scoring, And Dimpling Profiles

    Heavy marking / Scoring Argon Width 2.79 mm (0.11 inch) 1.22 mm (0.048 inch) Depth 0.09 mm (0.0035 inch) Less than 0.02 mm (0.001 inch) Travel speed 2.5 m/min (100 in/min) 3.2 m/min (125 in/min) Powermax45 XP Operator Manual 809240...

  • Page 118: Marking Process Guidelines

    The power supply adjusts gas pressure for you automatically. Hypertherm recommends  using these auto-gas settings for marking. Hypertherm strongly recommends that you use the Marking consumables with the power  supply set to Gouge/Marking mode and the output current set to 10 – 25 A. These settings and consumables were designed specifically for marking applications.

  • Page 119: Cornering Guidelines

    Gas pressure, if you manually adjusted the pressure to be outside the recommended range  automatically set by the system – see page 54 To optimize your marking or dimpling process and results, use the troubleshooting tips on page 120 and the cut charts starting on page 132. Powermax45 XP Operator Manual 809240...

  • Page 120: Common Marking Problems And Solutions

    • Check the cutting table parameters. If possible, increase the deceleration large. parameter. The mark becomes too • You may need to try a different method for cornering. See page 119. deep and too wide during cornering. 809240 Operator Manual Powermax45 XP...

  • Page 121: Cut Charts And Marking Charts

    Some metals, including stainless steel, may release toxic fumes when cut. Make sure your work site has adequate ventilation to ensure that the air quality level meets all local and national standards and regulations. Refer to the Safety and Compliance Manual (80669C) for more information. Powermax45 XP Operator Manual 809240...

  • Page 122: Using The Cut Charts

    “Best Quality” settings and are for reference only. Differences between installations and material composition may cause actual results to vary from those shown in the tables. Width and Depth – The marking and dimpling cut charts list the profile dimensions of the mark or  dimple. 809240 Operator Manual Powermax45 XP...
  • Page 123 Cold flow rate – Plasma is off and the system is in a steady state with gas flowing through the  torch at the default system pressure (postflow).  Hypertherm collected the cut chart data under laboratory test conditions using new consumables. Powermax45 XP Operator Manual...

  • Page 124: Mild Steel - 45 A - Air - Shielded

    14 GA 0.054 10 GA 0.057 3/16 0.06 0.15 0.059 0.061 0.069 0.077 0.082 0.086 Edge Start 0.103 0.119 Gas flow rate – slpm / scfh 151 / 320 Hot (cutflow) 184 / 390 Cold (postflow) 809240 Operator Manual Powermax45 XP...

  • Page 125: Stainless Steel - 45 A - Air - Shielded

    14 GA 0.022 10 GA 0.041 0.15 3/16 0.044 0.047 0.06 0.061 0.18 0.075 0.096 Edge Start 0.116 0.137 Gas flow rate – slpm / scfh 151 / 320 Hot (cutflow) 184 / 390 Cold (postflow) Powermax45 XP Operator Manual 809240...

  • Page 126: Aluminum - 45 A - Air - Shielded

    1/10 0.056 0.060 3/16 0.15 0.061 0.063 0.06 0.073 0.082 Edge Start 0.100 0.117 Gas flow rate – slpm / scfh 151 / 320 Hot (cutflow) 184 / 390 Cold (postflow) 809240 Operator Manual Powermax45 XP...

  • Page 127: Mild Steel - Finecut - Air - Shielded And Unshielded

    0.020 18 GA 0.06 0.15 0.043 16 GA 0.046 14 GA 0.049 12 GA 0.052 10 GA 0.051 Gas flow rate – slpm / scfh 155 / 330 Hot (cutflow) 215 / 460 Cold (postflow) Powermax45 XP Operator Manual 809240...

  • Page 128: Stainless Steel - Finecut - Air - Shielded And Unshielded

    0.017 18 GA 0.02 0.08 0.036 16 GA 0.039 14 GA 0.040 12 GA 0.049 10 GA 0.055 Gas flow rate – slpm / scfh 155 / 330 Hot (cutflow) 215 / 460 Cold (postflow) 809240 Operator Manual Powermax45 XP...

  • Page 129: Mild Steel - Finecut Low Speed - Air - Shielded And Unshielded

    0.031 16 GA* 0.029 14 GA* 0.027 12 GA 0.052 10 GA 0.051 Gas flow rate – slpm / scfh 155 / 330 Hot (cutflow) 215 / 460 Cold (postflow) * Not a dross-free cut. Powermax45 XP Operator Manual 809240...

  • Page 130: Stainless Steel - Finecut Low Speed - Air - Shielded And Unshielded

    20 GA 0.023 18 GA 0.02 0.08 16 GA 0.022 14 GA 0.021 12 GA 0.049 10 GA 0.055 Gas flow rate – slpm / scfh 155 / 330 Hot (cutflow) 215 / 460 Cold (postflow) 809240 Operator Manual Powermax45 XP...

  • Page 131: Stainless Steel - 45 A - F5 - Shielded

    0.082 0.090 Edge Start 0.098 Gas flow rate – slpm / scfh 149 / 315 Hot (cutflow) 184 / 390 Cold (postflow)  F5 is not recommended for thicknesses less than 3 mm (10 GA). Powermax45 XP Operator Manual 809240...

  • Page 132: Marking And Dimpling - Air - Shielded

    Marking 5080 0.89 0.035 <0.02 <0.001 Dimpling 0.125 — — — — — 0.89 0.035 0.09 0.0035 Gas flow rate – slpm / scfh 137 / 290 Hot (cutflow) 141 / 300 Cold (postflow) 809240 Operator Manual Powermax45 XP...

  • Page 133: Marking And Dimpling - Argon - Shielded

    0.02 0.02 4445 0.63 0.025 <0.02 <0.001 Dimpling 0.02 — — — — — 0.66 0.026 0.04 0.0015 Gas flow rate – slpm / scfh 120 / 255 Hot (cutflow) 123 / 260 Cold (postflow) Powermax45 XP Operator Manual 809240...
  • Page 134 Cut Charts and Marking Charts 809240 Operator Manual Powermax45 XP...

  • Page 135: Troubleshooting Guide

    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. WARNING INSTANT-ON TORCHES – PLASMA ARC CAN CAUSE INJURY, BURNS The plasma arc ignites immediately when you pull the torch trigger.

  • Page 136: Common Cutting Issues

    • Operate the system without using an extension cord. If you must use an extension cord, use a heavy conductor cord of the shortest possible length. See page 33. The arc sputters and • Inspect the gas filtration system for signs of moisture. See page 141. hisses. 809240 Operator Manual Powermax45 XP...

  • Page 137: Hand Cutting Issues

    • Inspect the gas filtration system for signs of contaminants that may be interfering with system performance. See page 141. • If you manually adjusted the gas pressure before this issue occurred, reset the gas pressure to the default setting. See page 56. Powermax45 XP Operator Manual 809240...

  • Page 138: Mechanized Cutting Issues

    • Make sure that the cutting table is properly grounded and is making good contact with the workpiece. • Decrease the torch-to-work distance (cut height). Refer to the cut charts starting on page 121. 809240 Operator Manual Powermax45 XP...
  • Page 139 121. • Increase the output current (amperage) on the plasma power supply. See page 51. • Inspect the torch lead. Straighten it if it is twisted or kinked. Replace it if it is damaged. Powermax45 XP Operator Manual 809240...

  • Page 140: Check The Gas Pressure

    See page 149.  If you manually adjusted the gas pressure and then started to notice issues with cut quality or cut performance, reset the gas pressure to the default setting. See page 56. 809240 Operator Manual Powermax45 XP...

  • Page 141: Check The Gas Quality

    3. Examine the O-ring at the top of the air filter bowl. Replace it if it is cracked or damaged. See page 155. 4. If you are using an external air filtration system, clean or replace any parts in it that may be contaminated. Powermax45 XP Operator Manual 809240...

  • Page 142: Cold Restarts And Quick Restarts

    If a fault occurs while using a generator, a quick restart may not clear the fault. Instead, turn OFF (O) the plasma power supply and wait 60 – 70 seconds before turning it ON (I) again. 809240 Operator Manual Powermax45 XP...

  • Page 143: Fault Leds And Fault Codes

    Operator Manual. Peel off the label and place it on the power supply or near your work area for reference. Powermax45 XP Operator Manual 809240...
  • Page 144 Retaining cap off • Turn OFF (O) the power supply. Make sure that the torch is connected to the power supply and that consumables are installed correctly. See Torch Cap fault LED on page 148. 809240 Operator Manual Powermax45 XP...
  • Page 145 • Machine torch: The plasma power supply as a “stuck start. ” was receiving a start signal when it was Blinks alternately powered ON (I). Turn off the start signal and restart the power supply. Powermax45 XP Operator Manual 809240...
  • Page 146 3-nn-n condition. • If restarting the plasma power supply does not clear the fault, a qualified service technician must service the system. Contact your distributor or authorized repair facility. 809240 Operator Manual Powermax45 XP...

  • Page 147: Gas Pressure Fault Led

    • Make sure the input gas supply is properly connected to the plasma system. • Check all the connections for the input gas supply. Make sure there are no leaks or loose connections. • Restart the plasma power supply. Powermax45 XP Operator Manual 809240...

  • Page 148: Torch Cap Fault Led

    • If the fault persists, change all of the consumables, including the swirl ring. If the consumables are in good condition and appear to be installed correctly, the torch may be damaged. Contact your distributor or authorized repair facility. 809240 Operator Manual Powermax45 XP...

  • Page 149: Generator Considerations

    Make note of the set pressure so that you can compare it to the actual pressure. “P.C. ” displays when you enter The set pressure blinks briefly. The actual pressure displays. gas test mode. Powermax45 XP Operator Manual 809240...

  • Page 150: While Gas Test Mode Is Active

    Turn the adjustment knob.  After the system exits gas test mode: The 2-digit displays shows the cutting current (amperage).  The AMPS LED illuminates.  Press button or turn knob to exit gas test mode. 809240 Operator Manual Powermax45 XP...

  • Page 151: Routine Maintenance

    Turn OFF (O) the plasma power supply.  Move the torch-disable switch to the yellow lock (X) position  (closest to the torch lead). Pull the trigger to make sure the torch does not fire a plasma arc. Powermax45 XP Operator Manual 809240...

  • Page 152: Every Use

    Make sure that instead the torch emits multiple puffs of air in quick succession. See page 45. Replace the torch-disable switch if it is not working properly. See page 159. 809240 Operator Manual Powermax45 XP...

  • Page 153: Every 3 Months

    Hand and machine torches: inspect the torch body for cracks and exposed wires. Replace any damaged parts. See page 159. Replace any damaged labels. Inspect the torch lead. Replace if damaged. See page 169. See page 159. Powermax45 XP Operator Manual 809240...

  • Page 154: Inspect The Consumables

    O-ring and the threads. The O-ring should look shiny, but there should not be any excess or built-up lubricant. If the O-ring is cracked or worn, replace Torch O-ring 809240 Operator Manual Powermax45 XP...

  • Page 155: Replace The Air Filter Bowl And Filter Element

    If you are using an external filtration system – such as the Eliminizer filter kit (128647) that Hypertherm provides – also check that filter regularly for required maintenance or cleaning. It is normal to see a small amount of water in the bottom of the filter bowl. The filter bowl automatically purges excess moisture when enough water accumulates to engage the float mechanism inside the bowl.
  • Page 156 11. Place the filter element inside the air filter bowl. Press down on the top plastic fitting until you hear it snap into place. 12. Place the air filter bowl inside the metal guard. 809240 Operator Manual Powermax45 XP...
  • Page 157 Otherwise, you may damage the threads on the bowl. 14. Reconnect the gas supply to the back of the power supply. 15. Reconnect the power cord, and set the power switch to ON (I). Powermax45 XP Operator Manual 809240...
  • Page 158 Routine Maintenance 809240 Operator Manual Powermax45 XP...

  • Page 159: Replacement Parts And Accessories

    46. For assistance with repairing or replacing internal components: 1. Call your Hypertherm distributor or authorized Hypertherm repair facility. 2. Call the nearest Hypertherm office listed in the front of this manual. Powermax45 XP Operator Manual...

  • Page 160: Plasma Supply Exterior, Front

    Shoulder strap (sold separately – not included with system) * The clips for the shoulder strap come with the system. They are also included in the replacement kit for the power supply handle. They do not come with the shoulder strap itself. 809240 Operator Manual Powermax45 XP...

  • Page 161: Plasma Supply Exterior, Rear

    Kit: Air filter bowl (polycarbonate) with metal guard (includes air filter element and O-ring) 428378 Kit: Air filter element  See page 155 for instructions on replacing the air filter bowl and the filter element. Powermax45 XP Operator Manual 809240...

  • Page 162: Machine Interface (Cpc) And Serial Interface Upgrade Kits

    Remote start pendant for machine torch, 7.6 m (25 feet) 128651 Remote start pendant for machine torch, 15 m (50 feet) 128652 Remote start pendant for machine torch, 23 m (75 feet)  The remote start pendants connect to the CPC port. 809240 Operator Manual Powermax45 XP...

  • Page 163: External Cables For Machine Interface Port And Serial Port

    Replacement Parts and Accessories External cables for machine interface port and serial port Hypertherm offers a variety of external cables that connect to the machine interface (CPC) port and the serial port. For pictures and for setup information, see: Connect the machine interface cable on page 98 ...

  • Page 164: 75° Hand Torch Replacement Parts

    Kit: Hand torch lead replacement, 15 m (50 foot) 428595 Kit: Torch-disable slider for hand torch (with yellow/green label) * The torch assembly does not include consumables. See page 61 (cutting) and page 71 (gouging) for consumable part numbers. 809240 Operator Manual Powermax45 XP...

  • Page 165: 15° Hand Torch Replacement Parts

    Kit: Hand torch lead replacement, 15 m (50 foot) 428595 Kit: Torch-disable slider for hand torch (with yellow/green label) * The torch assembly does not include consumables. See page 61 (cutting) and page 71 (gouging) for consumable part numbers. Powermax45 XP Operator Manual 809240...

  • Page 166: Machine Torch Replacement Parts

    Machine torch replacement parts Item Kit number Description 088167* Kit: Machine torch assembly with 7.6 m (25 foot) lead 088168* Kit: Machine torch assembly with 10.7 m (35 foot) lead 088169* Kit: Machine torch assembly with 15 m (50 foot) lead 428703 Kit: Removable 32-pitch gear rack (with screws) 428596...
  • Page 167 Item Kit number Description 428260 Kit: Torch quick-disconnect repair (shell with button – does not include torch lead) 428699 Kit: Machine torch lead replacement, 7.6 m (25 foot) 428710 Kit: Machine torch lead replacement, 10.7 m (35 foot) 428700 Kit: Machine torch lead replacement, 15 m (50 foot) 428705 Kit: Cap-sensor switch/torch-disable switch assembly for machine torch (includes wires and connector) 428706...

  • Page 168: Accessory Parts

    Rolling tool bag (fits power supply, torch, consumables, and some accessories) 024548 Leather torch lead cover, brown, 7.6 m (25 feet) 024877 Leather torch lead cover, black with Hypertherm logo, 7.6 m (25 feet) 127102 Basic plasma (circle) cutting guide 027668...

  • Page 169: Powermax45 Xp Labels

    Replacement Parts and Accessories Powermax45 XP Labels Kit number Description 428655 Kit: Powermax45 XP labels for 1-phase models 428656 Kit: Powermax45 XP labels for 3-phase models The label kits include: Warning labels  Decals for side panels  Consumable labels ...

  • Page 170: Csa Warning Label

    7. Do not remove, destroy, or cover this label. 7. Ne pas enlever, détruire ni couvrir cette étiquette. Replace if it is missing, damaged, or worn. La remplacer si elle est absente, endommagée ou usée. (PN 110673 Rev D) (PN 110673 Rev D) 809240 Operator Manual Powermax45 XP...

  • Page 171: Ce/Ccc Warning Label

    Become trained. Only qualified personnel should operate this equipment. Use torches specified in the manual. Keep non-qualified personnel and children away. Do not remove, destroy, or cover this label. Replace if it is missing, damaged, or worn. Powermax45 XP Operator Manual 809240...

  • Page 172: Data Plate

    Replacement Parts and Accessories Data plate The data plate on the bottom of the plasma power supply contains 2 sets of ratings: The HYP ratings are Hypertherm power supply ratings. They reflect the capability of the  system based on Hypertherm’s internal testing.

  • Page 173: 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. Powermax45 XP Operator Manual 809240...

  • Page 174: Iec Symbols

    Direct current (DC) external protective (earth) conductor Alternating current (AC) Power is ON Power is OFF Plasma torch cutting A 1-phase or 3-phase inverter-based power Gouging source AC input power Volt/amperage curve, connection “drooping” characteristic 809240 Operator Manual Powermax45 XP...

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