Hypertherm Duramax Series Operator's Manual
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Hypertherm Duramax Series Operator's Manual

Hypertherm Duramax Series Operator's Manual

Retrofit torch for powermax600, powermax800, powermax900, max42, and max43
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Duramax
Retrofit Torch
™
HRT
and MRT
for
2
2
powermax
powermax
600
,
800
,
®
®
powermax
900
, MAX42
, and MAX43
®
®
®
Operator Manual – 807530
Revision 1

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Summary of Contents for Hypertherm Duramax Series

  • Page 1 Duramax Retrofit Torch ™ and MRT powermax powermax ® ® powermax , MAX42 , and MAX43 ® ® ® Operator Manual – 807530 Revision 1...
  • Page 3 , and MAX43 ® ® ® Operator Manual (P/N 807530) Revision 1 – May 2012 Hypertherm, Inc. Hanover, NH USA www.hypertherm.com email: info@hypertherm.com © 2012 Hypertherm, Inc. All Rights Reserved Hypertherm, Powermax, and Duramax are trademarks of Hypertherm, Inc. and may be registered in the United States and/ or other countries.
  • Page 4 Rodenbacher Chaussee 6 55 11 2408 0462 Fax D-63457 Hanau-Wolfgang, Deutschland 49 6181 58 2100 Tel Hypertherm México, S.A. de C.V. 49 6181 58 2134 Fax Avenida Toluca No. 444, Anexo 1, 49 6181 58 2123 (Technical Service) Colonia Olivar de los Padres Delegación Álvaro Obregón...

  • Page 5: Electromagnetic Compatibility (Emc)

    Introduction a. Other supply cables, control cables, signaling and telephone cables; above, below and adjacent to the Hypertherm’s CE-marked equipment is built in compliance cutting equipment. with standard EN60974-10. The equipment should be installed and used in accordance with the information b.
  • Page 6 ELECTROMAGNETIC COMPATIBILITY Earthing of the workpiece Consideration should be given to shielding the supply cable of permanently installed cutting equipment, in metallic conduit or equivalent. Shielding should Where the workpiece is not bonded to earth for be electrically continuous throughout its length. The electrical safety, nor connected to earth because of its shielding should be connected to the cutting mains size and position, for example, ship’s hull or building...

  • Page 7: Warranty

    Products or as to if Hypertherm is notified of a defect (i) with respect to the results which may be obtained therefrom, and the power supply within a period of two (2) years from...
  • Page 8 You may transfer any remaining rights you may have the use of the Hypertherm product, alone and not in hereunder only in connection with the sale of all or combination with any other product not supplied by substantially all of your assets or capital stock to a Hypertherm, infringes any patent of any third party.
  • Page 9 Safety information Before operating any Hypertherm equipment, read the separate Safety and Compliance Manual (80669C) included with your product for important safety information.

  • Page 11: Table Of Contents

    Table of ConTenTs ELECTROMAGNETIC COMPATIBILITY (EMC) ....................... EMC-1 WARRANTY ................................... W-1 Safety information ..................................2 Section 1 Specifications ..................................1-1 Component weights ....................................1-2 Duramax HRT hand torch dimensions ...............................1-2 Duramax MRT full-length machine torch dimensions ........................1-2 Duramax MRT without positioning sleeve (mini torch) ........................1-2 Section 2 Torch Setup .....................................
  • Page 12 Table of ConTenTs Common hand-cutting faults ..............................3-22 Using the machine torch ..................................3-23 Ensure the torch and table are set up correctly ........................3-23 Understand and optimize cut quality ............................3-23 To pierce a workpiece using the machine torch ........................3-26 Common machine-cutting faults ..............................

  • Page 13: Specifications

    Section 1 Specifications In this section: Component weights ......................................1-2 Duramax HRT hand torch dimensions ...............................1-2 Duramax MRT full-length machine torch dimensions ..........................1-2 Duramax MRT without positioning sleeve (mini torch) ...........................1-2 Duramax Retrofit Torch Operator Manual...

  • Page 14: Component Weights

    SpecificationS Component weights Torch type Weight – kg (lbs) Hand torch 7.6 m (25 ft) 3.2 (7.1) Hand torch 15 m (50 ft) 5.7 (12.6) Machine torch 7.6 m (25 ft) 3.4 (7.5) Machine torch 15 m (50 ft) 5.9 (13.0) Duramax HRT hand torch dimensions 25.2 cm (9.9 in.)

  • Page 15: Torch Setup

    Section 2 Torch Setup In this section: Introduction ........................................2-2 Consumable life ......................................... 2-2 Hand torch setup ......................................2-2 Choose the hand torch consumables ............................... 2-3 Install the hand torch consumables ..............................2-4 Machine torch setup......................................2-5 Converting a Duramax retrofit machine torch into a mini torch ....................2-6 Mount the torch .......................................

  • Page 16: Introduction

    Torch seTup Introduction Duramax™ series handheld and machine retrofit torches are available for the Powermax600, Powermax800, Powermax900, MAX42, and MAX43 systems. The torches are cooled by ambient air and do not require special cooling procedures. This section explains how to setup your torch and choose the appropriate consumables for the job. Consumable life How often you need to change the consumables on your retrofit torch will depend on a number of factors: •...

  • Page 17: Choose The Hand Torch Consumables

    TORCH SETUP Choose the hand torch consumables Duramax retrofit torches are shipped with a full set of cutting consumables pre-installed. Hypertherm also includes spare cutting electrodes, nozzles, and gouging consumables in the consumables box, for handheld torches. Consumables for handheld cutting are shown on the next page. Notice that the retaining cap and electrode are the same for cutting, gouging, and FineCut ®...

  • Page 18: Install The Hand Torch Consumables

    Torch seTup Install the hand torch consumables WARNING INSTANT-ON TORCHES PLASMA ARC CAN CAUSE INJURY AND BURNS The plasma arc comes on im me di ate ly when the torch trigger is activated. Make sure the power is OFF before changing consumables. To operate the hand torch, a complete set of consumable parts must be installed: shield, retaining cap, nozzle, electrode, and swirl ring.

  • Page 19: Machine Torch Setup

    TORCH SETUP Machine torch setup Duramax MRT Mounting sleeve Positioning sleeve Strain relief nut Torch lead Consumables Coupler Gear rack Main strain Strain relief relief nut body Duramax MRT without positioning sleeve (mini torch) Coupler Consumables Torch lead Mounting Strain relief Strain relief sleeve body...

  • Page 20: Converting A Duramax Retrofit Machine Torch Into A Mini Torch

    Torch seTup Converting a Duramax retrofit machine torch into a mini torch You can convert a full-length machine torch to a mini-machine torch by removing the positioning sleeve. Refer to the figures on the previous page while completing the following instructions. Note: If you are converting a full-length machine torch to a mini-machine torch and mounting the torch at the same time, skip this section and follow the instructions in the next section, “Mount the torch”.
  • Page 21 TORCH SETUP 11. Slide the coupler over the torch lead. 12. Use two wrenches to tighten the gas supply line nut onto the threaded torch body fitting. 13. Secure the pilot arc wire to the torch body by tightening the pilot arc wire terminal screw. 14.

  • Page 22: Mount The Torch

    Torch seTup Mount the torch Depending on the type of cutting table you have, you may or may not need to disassemble the torch to route it through the track and mount it. If your cutting table’s track is large enough for you to thread the torch through it without removing the torch body from the lead, do so and then attach the torch to the lifter per the manufacturer’s instructions.
  • Page 23 TORCH SETUP 9. Use 1/4-inch and 3/8-inch wrenches, or two adjustable wrenches, to loosen the nut that secures the gas supply line to the torch body. 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.

  • Page 24: Choose The Machine Torch Consumables

    Choose the machine torch consumables Powermax systems with the Duramax MRT retrofit torch are shipped with a complete set of consumables. Hypertherm also includes spare electrodes and nozzles. In addition, an ohmic-sensing retaining cap is available for use with shielded consumables.
  • Page 25 TORCH SETUP Gouging consumables 220798 220854 220797 220842 220857 Shield Retaining cap Nozzle Electrode Swirl ring FineCut ® shielded 220948 220953 220930 220842 220857 Shield Retaining cap Nozzle Electrode Swirl ring FineCut ® unshielded consumables 220854 220930 220842 220857 220955 Retaining cap Nozzle Electrode...

  • Page 26: Install The Machine Torch Consumables

    Torch seTup Install the machine torch consumables WARNING INSTANT-ON TORCHES PLASMA ARC CAN CAUSE INJURY AND BURNS The plasma arc comes on im me di ate ly when the torch is activated. Make sure the power is OFF before changing the consumables. To operate the machine torch, a complete set of consumable parts must be installed: shield, retaining cap, nozzle, electrode, and swirl ring.

  • Page 27: Torch Installation

    TORCH SETUP Torch installation Torches with a quick disconnect connector 1. Turn OFF the power switch and remove the power cord from the power receptacle. 2. Disconnect the gas supply hose from the power supply. 3. Align the connector key-way on the torch lead with the receptacle on the power supply and push in until the pins seat. 4.

  • Page 28: Torches Without A Quick Disconnect Connector - Powermax600 Ce

    Torch seTup Torches without a quick disconnect connector - Powermax600 CE 1. Turn OFF the power switch and remove the power cord from the power receptacle. 2. Disconnect the gas supply hose from the power supply. Caution: Do not tighten the strain relief collar (4) onto the torch lead until the gas fitting (3) is tight, or the gas connection may leak.

  • Page 29: On/Off Pendant Connection

    TORCH SETUP ON/OFF Pendant connection Pigtail from machine On/Off pendant torch lead The Duramax MRT torch lead is supplied with a pigtail so that the on/off pendant may be used. If you want to use a different on/off switch configuration, note that the wiring configuration to the 3-socket female receptacle on the pigtail is as follows: Socket A White Wire Socket B...
  • Page 30 Torch seTup 2-16 Duramax Retrofit Torch Operator Manual...

  • Page 31: Operation

    Section 3 Operation In this section: Using the cut charts ....................................3-2 55 amp mechanized shielded consumables ..........................3-3 50 amp mechanized shielded consumables ..........................3-4 45 amp mechanized shielded consumables ..........................3-5 40 amp mechanized shielded consumables ..........................3-8 45 amp mechanized unshielded consumables ........................3-9 40 amp mechanized unshielded consumables ........................

  • Page 32: Using The Cut Charts

    The 45 amp nozzle (part number 220941) provides the best results across the 40 - 55 amp cutting range for both the mechanized shielded and unshiedled consumables. Note: Hypertherm collected the data under laboratory test conditions using new consumables. • Maximum travel speeds are the fastest travel speeds possible to cut the material without regard to cut quality.

  • Page 33: 55 Amp Mechanized Shielded Consumables

    OPERATION 55 amp mechanized shielded consumables • Torch-to-work dis t ance for the following cut chart is 1.5 mm (1/16 inch) for all cuts. 220817 220854 220941 220842 220857 Shield Retaining cap Nozzle Electrode Swirl ring 220817 220953 220941 220842 220857 Shield Ohmic-sensing Nozzle Electrode Swirl ring retaining cap Mild Steel Material Thickness Maximum Travel Speeds Optimum Travel Speeds Motion Arc Current Arc Voltage...

  • Page 34: 50 Amp Mechanized Shielded Consumables

    OPERATION 50 amp mechanized shielded consumables • Torch-to-work dis t ance for the following cut chart is 1.5 mm (1/16 inch) for all cuts. 220817 220854 220941 220842 220857 Shield Retaining cap Nozzle Electrode Swirl ring 220817 220953 220941 220857 220842 Shield Ohmic-sensing Nozzle Swirl ring Electrode retaining cap Mild Steel Material Thickness Maximum Travel Speeds Optimum Travel Speeds Motion mm/min...

  • Page 35: 45 Amp Mechanized Shielded Consumables

    OPERATION 45 amp mechanized shielded consumables 220817 220854 220941 220842 220857 Shield Retaining cap Nozzle Electrode Swirl ring 220817 220953 220941 220842 220857 Shield Ohmic-sensing Nozzle Electrode Swirl ring retaining cap 45A Shielded Air flow rate - slpm/scfh 177 / 376 Mild Steel Cold 201 / 427...
  • Page 36 OPERATION 220817 220854 220941 220842 220857 Shield Retaining cap Nozzle Electrode Swirl ring 220817 220953 220941 220857 220842 Shield Ohmic-sensing Nozzle Swirl ring Electrode retaining cap 45A Shielded Air flow rate - slpm/scfh 177 / 376 Stainless Steel Cold 201 / 427 Metric Torch- Best Quality Settings...
  • Page 37 OPERATION 220817 220854 220941 220842 220857 Shield Retaining cap Nozzle Electrode Swirl ring 220817 220953 220941 220857 220842 Shield Ohmic-sensing Nozzle Swirl ring Electrode retaining cap 45A Shielded Air flow rate - slpm/scfh 177 / 376 Aluminum Cold 201 / 427 Metric Torch- Best Quality Settings...

  • Page 38: 40 Amp Mechanized Shielded Consumables

    OPERATION 40 amp mechanized shielded consumables • Torch-to-work dis t ance for the following cut chart is 1.5 mm (1/16 inch) for all cuts. 220817 220854 220941 220842 220857 Shield Retaining cap Nozzle Electrode Swirl ring 220817 220953 220941 220857 220842 Shield Ohmic-sensing Nozzle Swirl ring Electrode retaining cap Mild Steel Motion Material Thickness Maximum Travel Speeds Optimum Travel Speeds mm/min mm/min...

  • Page 39: 45 Amp Mechanized Unshielded Consumables

    OPERATION 45 amp mechanized unshielded consumables 220842 220955 220854 220941 220857 Electrode Deflector Retaining cap Nozzle Swirl ring 45A Unshielded Air flow rate - slpm/scfh 177 / 376 Mild Steel Cold 201 / 427 Metric Torch- Best Quality Settings Production Settings Material Initial Pierce Pierce...
  • Page 40 OPERATION 220842 220955 220854 220941 220857 Electrode Deflector Retaining cap Nozzle Swirl ring 45A Unshielded Air flow rate - slpm/scfh 177 / 376 Stainless Steel Cold 201 / 427 Metric Torch- Best Quality Settings Production Settings Material Initial Pierce Pierce Delay to-Work Thickness Height...
  • Page 41 OPERATION 220842 220955 220854 220941 220857 Electrode Deflector Retaining cap Nozzle Swirl ring 45A Unshielded Air flow rate - slpm/scfh 177 / 376 Aluminum Cold 201 / 427 Metric Torch- Best Quality Settings Production Settings Material Initial Pierce Pierce to-Work Thickness Height Delay Time...

  • Page 42: 40 Amp Mechanized Unshielded Consumables

    OPERATION 40 amp mechanized unshielded consumables • Torch-to-work dis t ance for the following cut chart is 1.5 mm (1/16 inch) for all cuts. 220955 220854 220941 220842 220857 Deflector Retaining cap Nozzle Electrode Swirl ring Mild Steel Material Thickness Maximum Travel Speeds Optimum Travel Speeds Motion Current Voltage Delay mm/min mm/min Inches 13970 8966 26 GA 12294 8001...

  • Page 43: Finecut ® Consumables

    OPERATION FineCut ® consumables Note: The cut charts in this section apply to both shielded and unshielded consumables 220948 220953 220842 220857 220930 Shield Retaining cap Electrode Swirl ring Nozzle 220955 220854 220842 220857 220930 Deflector Retaining cap Electrode Swirl ring Nozzle FineCut Mild Steel...
  • Page 44 OPERATION 220948 220953 220930 220842 220857 Shield Retaining cap Nozzle Electrode Swirl ring 220955 220854 220842 220857 220930 Deflector Retaining cap Electrode Swirl ring Nozzle FineCut Stainless Steel Metric Torch- Recommended Material Pierce Delay Current to-Work Initial Pierce Height Thickness Time Cut Speed Voltage...
  • Page 45 OPERATION 220948 220953 220930 220842 220857 Shield Retaining cap Nozzle Electrode Swirl ring 220955 220854 220842 220857 220930 Deflector Retaining cap Electrode Swirl ring Nozzle Low Speed FineCut Mild Steel Metric Torch- Recommended Material Pierce Delay Current to-Work Initial Pierce Height Thickness Time Cut Speed...
  • Page 46 OPERATION 220948 220953 220930 220842 220857 Shield Retaining cap Nozzle Electrode Swirl ring 220955 220854 220842 220857 220930 Deflector Retaining cap Electrode Swirl ring Nozzle Low Speed FineCut Stainless Steel Metric Torch- Recommended Material Pierce Delay Current to-Work Initial Pierce Height Thickness Time Cut Speed...

  • Page 47: Using The Hand Torch

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

  • Page 48: Hand Torch Cutting Hints

    For straight-line cuts, use a straight edge as a guide. To cut circles, use a template or a radius cutter attachment (a circle cutting guide). See Section 4, Maintenance and Parts, for part numbers for the Hypertherm plasma cutting guides for cutting circles and making bevel cuts.

  • Page 49: Start A Cut From The Edge Of The Workpiece

    OPERATION Start a cut from the edge of the workpiece 1. With the work clamp attached to the workpiece, hold the torch nozzle perpendicular (90°) to the edge of the workpiece. 2. Press the torch’s trigger to start the arc. Pause at the edge until the arc has cut completely through the workpiece.

  • Page 50: Pierce A Workpiece

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

  • Page 51: Gouge A Workpiece

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

  • Page 52: General Guidelines For Gouging

    OPERATION General guidelines for gouging The following actions have the stated effects on the gouge profile: •  Increasing the speed of the torch will decrease width and decrease depth. •  Decreasing the speed of the torch will increase width and increase depth. • ...

  • Page 53: Using The Machine Torch

    OPERATION Using the machine torch Since the Powermax with a machine torch can be used with a wide variety of cutting tables, track burners, pipe bevelers, and so on, you will need to refer to the manufacturer’s instructions for specifics on operating the machine torch in your configuration.
  • Page 54 OPERATION Problem Cause Solution Negative cut angle The torch is too low. Raise the torch; or if you are using a torch height control, increase the Square cut arc voltage. The torch is too high. Lower the torch; or if you are using Positive cut angle a torch height control, decrease the arc voltage.
  • Page 55 OPERATION Dross Some amount of dross will always be present when cutting with air plasma. However, you can minimize the amount and type of dross by adjusting your system correctly for your application. Excess dross appears on the top edge of both pieces of the plate when the torch is too low (or voltage is too low when using a torch height control).

  • Page 56: To Pierce A Workpiece Using The Machine Torch

    OPERATION To pierce a workpiece using the machine torch As with the hand torch, you can start a cut with the machine torch at the edge of the workpiece or by piercing the workpiece. Piercing will result in a shorter consumable life than with edge starts. The pierce delay must be sufficiently long that the arc can pierce the material before the torch moves, but not so long that the arc “wanders”...
  • Page 57 OPERATION The cut angle is not square. Causes can be: • The torch is not square to the workpiece. • The consumables are worn and need to be replaced. For optimized performance in a mechanized application, replace the nozzle and the electrode together. •...
  • Page 58 OPERATION 3-28 Duramax Retrofit Torch Operator Manual...

  • Page 59: Maintenance And Parts

    Section 4 Maintenance and parts Perform routine maintenance ..................................4-2 Inspect the consumables ....................................4-3 Hand torch replacement parts – Duramax HRT 2 ....................................Machine torch replacement parts – Duramax MRT 2 .................................... Accessory parts......................................... 4-6 Duramax Retrofit Torch Operator Manual...

  • Page 60: Perform Routine Maintenance

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

  • Page 61: Inspect The Consumables

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

  • Page 62: Hand Torch Replacement Parts - Duramax Hrt 2

    MAINTENANCE AND pArTs Hand torch replacement parts – Duramax HRT Torch handle Coupler Torch lead Cap-sensor switch Pilot arc wire terminal screw Trigger start Torch body switch O-ring Safety trigger Handle and spring screws The HRT torch assembly can be replaced, or individual component parts can be replaced. The HRT torch assembly includes a variety of Duramax consumables.

  • Page 63: Machine Torch Replacement Parts - Duramax Mrt 2

    MAINTENANCE AND pArTs Machine torch replacement parts – Duramax MRT Mounting Positioning sleeve sleeve Strain relief nut Torch lead Consumables Coupler Gear rack (32 pitch) Strain relief body Pilot arc wire terminal screw Cap-sensor O-ring Torch body Wire connector for switch cap-sensor switch The MRT...

  • Page 64: Accessory Parts

    MAINTENANCE AND pArTs Accessory parts Part number Description 024548 Leather torch sheathing, 7.5 m (25 ft) 127102 Basic plasma (circles and lines) cutting guide 027668 Deluxe plasma (circles and lines) cutting guide Duramax Retrofit Torch Operator Manual...

This manual is also suitable for:

Duramax hrt2Duramax mrt2

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