Page 1 Plasma arc cutting systems Service Manual – 807120 Revision 0...
Page 2 Register your new Hypertherm system Register your product on-line at www.hypertherm.com/registration for easier technical and warranty support. You can also receive updates on new Hypertherm products and a free gift as a token of our appreciation. For your records Serial number: _____________________________________________...
Page 3: Service Manual
Revision 0 – February 2011 Hypertherm, Inc. Hanover, NH USA www.hypertherm.com email: info@hypertherm.com © Copyright 2011 Hypertherm, Inc. All Rights Reserved Hypertherm and Powermax are trademarks of Hypertherm, Inc. and may be registered in the United States and/or other countries.
Page 4 49 6181 58 2123 (Technical Service) 55 11 2409 2636 Tel 55 11 2408 0462 Fax Hypertherm (S) Pte Ltd. 82 Genting Lane Hypertherm México, S.A. de C.V. Media Centre Avenida Toluca No. 444, Anexo 1, Annexe Block #A01-01 Colonia Olivar de los Padres Singapore 349567, Republic of Singapore Delegación Álvaro Obregón...
Page 5: Assessment Of Area
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 cutting equipment. compliance with standard EN60974-10. The equipment should be installed and used in accordance with b.
Page 6: Maintenance Of Cutting Equipment
ELECTROMAGNETIC COMPATIBILITY Earthing of the workpiece Consideration should be given to shielding the supply cable of permanently installed cutting equipment, Where the workpiece is not bonded to earth for in metallic conduit or equivalent. Shielding should electrical safety, nor connected to earth because of its be electrically continuous throughout its length.
Page 7 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: Patent Indemnity
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 TABLE OF CONTENTS Safety information Before operating any Hypertherm equipment, read the separate Safety and Compliance Manual (80669C) included with your product for important safety information. powermax 65/85 Service Manual...
Page 10 TABLE OF CONTENTS powermax 65/85 Service Manual...
Page 11: Table Of Contents
TABLE OF CONTENTS Section 1 Specifications Safety information ....................................1-2 System description ....................................1-2 Where to find information ..................................1-3 Power supply dimensions ..................................1-4 Component weights ....................................1-5 Powermax65 power supply ratings ..............................1-6 Powermax85 power supply ratings ..............................1-8 H65/H85 75° hand torch dimensions ............................1-10 H65s/H85s 15°...
Page 12 TABLE OF CONTENTS Section 3 Torch Setup Introduction ......................................3-2 Consumable life .......................................3-2 Hand torch setup ....................................3-3 Choose the hand torch consumables .............................3-4 Hand torch consumables ................................3-5 Install the hand torch consumables ............................3-6 Machine torch setup....................................3-7 Converting an M65/M85 torch to an M65m/M85m torch ....................3-8 Mount the torch ..................................
Page 13 Hypertherm IGBT tester ................................5-12 Indicator LEDs and device tests ............................5-12 IGBT test preparation ................................5-13 IGBT device test using the Hypertherm tester ........................5-14 Troubleshoot the Hypertherm IGBT tester .......................... 5-14 Schematic for building an IGBT tester ..........................5-15 IGBT device test using a non-Hypertherm tester ......................
Page 14 TABLE OF CONTENTS Fault codes ......................................5-21 Displaying the service screen ..............................5-21 Important fault icons ................................. 5-22 Performing a cold restart ................................. 5-22 Fault codes and solutions ................................ 5-23 Troubleshooting guide ..................................5-32 System tests......................................5-38 Test 1 – Voltage input ................................5-39 Test 2 –...
Page 15 TABLE OF CONTENTS Section 7 Parts Power supply parts ....................................7-2 Exterior front ....................................7-2 Exterior rear ....................................7-3 Interior, power board side (200-600V CSA) .........................7-4 Interior, power board side (380/400V CE) ..........................7-5 Interior, fan side ....................................7-6 Heat sink assembly ....................................7-8 65A CSA ......................................7-8 65A CE ......................................7-9 85A CSA .....................................
Page 16 TABLE OF CONTENTS powermax 65/85 Service Manual...
Page 17 Section 1 SPECIFICATIONS In this section: Safety information ....................................1-2 System description ....................................1-2 Where to find information ..................................1-3 Power supply dimensions ..................................1-4 Component weights ....................................1-5 Powermax65 power supply ratings ..............................1-6 Powermax85 power supply ratings ..............................1-8 H65/H85 75° hand torch dimensions ............................1-10 H65s/H85s 15°...
Page 18: Specifications
SPECIFICATIONS Safety information Before you set up and operate your Hypertherm system, read the separate Safety and Compliance Manual included with your system for important safety information. System description The Powermax65 and Powermax85 are highly portable, 65-amp and 85-amp, handheld and mechanized plasma cutting systems appropriate for a wide range of applications.
Page 19: Where To Find Information
SPECIFICATIONS Where to find information System specifications such as size, weight, detailed electrical specifications, and cut speeds can be found in this section. For information on: • Setup requirements, including power requirements, grounding, power cord configurations, extension cord requirements, and generator recommendations — see Section 2, Power Supply Setup. •...
Page 20: Power Supply Dimensions
SPECIFICATIONS Power supply dimensions 17.0 in (432 mm) 19.0 in 9.2 in (483 mm) (234 mm) powermax 65/85 Service Manual...
Page 21: Component Weights
SPECIFICATIONS Component weights 65 A CSA 65 A CE 85 A CSA 85 A CE lbs (kg) lbs (kg) lbs (kg) lbs (kg) Power supply 54.1 (24.5) 47.0 (21.3) 59.9 (27.2) 50.4 (22.8) 65/85 A lbs (kg) Hand torch 25 ft (7.6 m) 6.8 (3.1) Hand torch 50 ft (15 m) 12.2 (5.5)
Page 22: Powermax65 Power Supply Ratings
SPECIFICATIONS Powermax65 power supply ratings Rated open-circuit voltage (U CSA, 1-phase, 3-phase CSA 296 VDC CE, 3-phase 270 VDC Output characteristic Drooping Rated output current (I 20 – 65 A Rated output voltage (U 139 VDC Duty cycle at 40° C (104° F) 50% @ 65 A, 230 –...
Page 23 SPECIFICATIONS Defined as a plot of output voltage versus output current. Equipment complies with IEC 61000-3-12 provided that the short-circuit power S is greater than or equal to 2035 KVA at the interface point between the user’s supply and the public system. It is the responsibility of the installer or user of the equipment to ensure, by consultation with the distribution network operator if necessary, that the equipment is connected only to a supply with a short-circuit power S greater than or equal to 2035 KVA.
Page 24: Powermax85 Power Supply Ratings
SPECIFICATIONS Powermax85 power supply ratings Rated open-circuit voltage (U CSA, single-phase, 3-phase 305 VDC CE, 3-phase 270 VDC Drooping Output characteristic Rated output current (I 25 – 85 A Rated output voltage (U 143 VDC Duty cycle at 40° C (104° F) 60% @ 85 A, 230 –...
Page 25 SPECIFICATIONS Defined as a plot of output voltage versus output current. Equipment complies with IEC 61000-3-12 provided that the short-circuit power S is greater than or equal to 2035 KVA at the interface point between the user’s supply and the public system. It is the responsibility of the installer or user of the equipment to ensure, by consultation with the distribution network operator if necessary, that the equipment is connected only to a supply with a short-circuit power S greater than or equal to 2035 KVA.
Page 26: H65/H85 75° Hand Torch Dimensions
SPECIFICATIONS H65/H85 75° hand torch dimensions 9.9 in (25.2 cm) 75° 2.6 in angle 3.8 in (6.6 cm) (9.8 cm) 1.0 in (2.5 cm) H65s/H85s 15° hand torch dimensions 10.2 in (25.9 cm) 15° angle 1.9 in 2.6 in (4.7 cm) (6.6 cm) 1.0 in (2.5 cm)
Page 27: M65/M85 Full-Length Machine Torch Dimensions
SPECIFICATIONS M65/M85 full-length machine torch dimensions 15.6 in (39.6 cm) 1.4 in 1.0 in (3.5 cm) (2.5 cm) 8.1 in (20.6 cm) 1.4 in (3.6 cm) outer 12.3 in dimension, 1.3 in (31.3 cm) (3.3 cm) flat sides M65m/M85m mini-machine torch dimensions 6.6 in (16.8 cm) 1.4 in...
Page 28: Powermax65 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 29: Powermax85 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 30: Symbols And Markings
Symbols and markings Your Hypertherm product may have one or more of the following markings on or near the data plate. Due to differences and conflicts in national regulations, not all marks are applied to every version of a product.
Page 31: Iec Symbols
SPECIFICATIONS IEC symbols The following symbols may appear on the power supply data plate, control labels, switches, LEDs, and LCD screen. Power is ON Direct current (DC) Alternating current Power is OFF (AC) An inverter-based power source, either 1-phase or Plasma torch cutting 3-phase Plate metal cutting...
Page 32 SPECIFICATIONS powermax 1-16 65/85 Service Manual...
Page 33: Power Supply Setup
Section 2 POWER SUPPLY SETUP In this section: Unpack the Powermax65 or Powermax85 system .........................2-2 Claims ......................................2-2 Contents ......................................2-3 Position the power supply..................................2-4 Prepare the electrical power ................................2-4 Install a line-disconnect switch ..............................2-5 Requirements for grounding ..............................2-5 Power connection for the Powermax65 ............................2-6 Single-phase power cord (not for CE model) ..........................2-7 Three-phase power cord —...
Page 34: Unpack The Powermax65 Or Powermax85 System
Claims for damage during shipment – If your unit was damaged during shipment, you must file a claim with the carrier. Hypertherm will furnish you with a copy of the bill of lading upon request. If you need additional assistance, call the nearest Hypertherm office listed in the front of this manual.
Page 35: Contents
POWER SUPPLY SETUP Contents Verify the items in the box against the illustration. Operator Manual Quick Setup Card Registration Card Setup DVD Safety Manual Box with extra consumables (located next to air filter) Remote-start pendant (optional) powermax 65/85 Service Manual...
Page 36: 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 37: Install A Line-Disconnect Switch
POWER SUPPLY SETUP Install a line-disconnect switch Use a line-disconnect switch for each power supply so that the operator can turn off the incoming power quickly in an emergency. Locate the switch so that it is easily accessible to the operator. Installation must be performed by a licensed electrician according to national and local codes.
Page 38: Power Connection For The Powermax65
POWER SUPPLY SETUP Power connection for the Powermax65 The Powermax65 CSA model is a universal power supply that can configure itself to operate with AC voltages from 200 to 600, 1- or 3-phase. The CE model is 380/400 V, 3-phase only. The rated output is 25 – 65 A, 139 VDC. CSA model Single-phase Three-phase...
Page 39: Single-Phase Power Cord (Not For Ce Model)
POWER SUPPLY SETUP Single-phase power cord (not for CE model) To operate your Powermax65 on 1-phase power, you will need to install an appropriate power cord. Refer to 2-10 Single- phase power cord installation for instructions. Caution: When using the Powermax65 CSA model power supply (CE model is 3-phase only) with a 1-phase power source, replace the supplied power cord with an 8 AWG (10 mm ) 3-wire power cord.
Page 40: Power Connection For The Powermax85
POWER SUPPLY SETUP Power connection for the Powermax85 The Powermax85 CSA model is a universal power supply that can configure itself to operate with AC voltages from 200 to 600, 1- or 3-phase. The CE model is 380/400 V, 3-phase only. The rated output is 25 – 85 A, 143 VDC. CSA model Single-phase Three-phase...
Page 41: Single-Phase Power Cord (Not For Ce Model)
POWER SUPPLY SETUP Single-phase power cord (not for CE model) To operate your Powermax85 on 1-phase power, you will need to install an appropriate power cord. Refer to 2-10 Single- phase power cord installation for instructions. Caution: When using the Powermax85 CSA model power supply (CE model is 3-phase only) with a 1-phase power source, replace the supplied power cord with a 6 AWG (16 mm ) 3-wire power cord.
Page 42: Single-Phase Power Cord Installation
POWER SUPPLY SETUP Single-phase power cord installation Strip and prepare the power cord wires as shown below. 14.5 in (368 mm) Ground 6 in (152 mm) Route lead through strain relief and tighten Power switch Ground screw powermax 2-10 65/85 Service Manual...
Page 43: Three-Phase Power Cord - Plug Installation
POWER SUPPLY SETUP Three-phase power cord — plug installation The Powermax85 power supplies are shipped with an 8 AWG 4-wire power cord on CSA models. A 4 mm , 4-wire HAR power cord is provided on CE models. To operate the Powermax85, use a plug that meets national and local electrical codes.
Page 44: Extension Cord Specifications
POWER SUPPLY SETUP Extension cord specifications < 10 ft 10 – 25 ft 25 – 50 ft 50 – 100 ft 100 – 150 ft Extension cord length (< 3 m) (3 – 7.5 m) (7.5 – 15 m) (15 – 30 m) (30 –...
Page 45: Engine-Driven Generator Recommendations
POWER SUPPLY SETUP Engine-driven generator recommendations Generators used with the Powermax65 or Powermax85 should satisfy the following requirements: • 1-phase, 50/60 Hz, 230/240 VAC • 3-phase, 50/60 Hz, 200-600 VAC (480 VAC recommended for best performance) • 3-phase, 50/60 Hz, 380/400 VAC (400 VAC recommended for best performance) Engine drive System output Performance...
Page 46: Prepare The Gas Supply
When site conditions introduce moisture, oil, or other contaminants into the gas line, use a 3-stage coalescing filtration system, such as the Eliminizer filter kit (part number 128647) available from Hypertherm distributors. A 3-stage filtering system works as shown below to clean contaminants from the gas supply.
Page 47: Connect The Gas Supply
POWER SUPPLY SETUP Connect the gas supply Connect the gas supply to the power supply using an inert-gas hose with a 3/8 inch (9.5 mm) internal diameter and a 1/4 NPT quick-disconnect coupler, or a 1/4 NPT x G-1/4 BSPP (CE units) quick-disconnect coupler. The recommended inlet pressure while gas is flowing is 85 - 135 psi (5.9 - 9.3 bar).
Page 48 POWER SUPPLY SETUP Minimum inlet pressure (while gas is flowing) This table shows the minimum required inlet pressure when the recommended inlet pressure is not available. Torch lead length 25 ft (7.62 m) 50 ft (15.24 m) 75 ft (22.86 m) Cutting 75 psi (5.2 bar) 80 psi (5.5 bar)
Page 49 Section 3 TORCH SETUP In this section: Introduction ......................................3-2 Consumable life .......................................3-2 Hand torch setup ....................................3-3 Choose the hand torch consumables .............................3-4 Hand torch consumables ................................3-5 Install the hand torch consumables ............................3-6 Machine torch setup....................................3-7 Converting an M65/M85 torch to an M65m/M85m torch ....................3-8 Mount the torch ..................................
Page 50: Torch Setup
TORCH SETUP Introduction Duramax™ series handheld and machine torches are available for the Powermax65 and Powermax85 systems. The FastConnect quick-disconnect system makes it easy to remove the torch for transport or to switch from one torch to the other if your applications require the use of different torches. The torches are cooled by ambient air and do not require special cooling procedures.
Page 51: Hand Torch Setup
TORCH SETUP Hand torch setup H65/H85 Consumables Safety trigger H65s/H85s Consumables Safety trigger powermax 65/85 Service Manual...
Page 52: Choose The Hand Torch Consumables
Choose the hand torch consumables Powermax systems with the Duramax series H65, H85, H65s, or H85s torch are shipped with a full set of cutting consumables pre-installed. Hypertherm also includes spare cutting electrodes and nozzles, and gouging consumables in the consumables box.
Page 53: Hand Torch Consumables
TORCH SETUP Hand torch consumables Drag-cutting consumables: Powermax65 220941 Nozzle 220818 220854 220842 220857 Shield Retaining cap Electrode Swirl ring 220819 Nozzle Drag-cutting consumables: Powermax85 220941 Nozzle 220819 220818 220854 Nozzle 220842 220857 Shield Retaining cap Electrode Swirl ring 220816 Nozzle Gouging consumables 220798...
Page 54: 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 55: Machine Torch Setup
TORCH SETUP Machine torch setup M65/M85 Mounting sleeve Consumables Positioning sleeve Strain relief nut Torch lead Coupler Main strain Gear rack Strain relief body relief nut M65m/M85m Mounting sleeve Consumables Coupler Torch lead Strain relief nut Strain relief body Before using either style of machine torch, you must: •...
Page 56: Converting An M65/M85 Torch To An M65M/M85M Torch
TORCH SETUP Converting an M65/M85 torch to an M65m/M85m torch You can convert a full-length machine torch to a mini-machine torch by removing the positioning sleeve. Note: If you are converting a full-length machine torch to a mini-machine torch and mounting the torch at the same time, skip this section and follow the instructions in 3-10 Mount the torch.
Page 57 TORCH SETUP Pilot wire terminal screw Wire connector for Torch head Gas supply line cap-sensor switch connection 7. Disconnect the wire connector for the cap-sensor switch. 8. Use a #2 Phillips screwdriver to remove the screw that secures the torch’s pilot wire to the torch body. 9.
Page 58: 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 59 TORCH SETUP 7. Disconnect the wire connector for the cap-sensor switch. 8. Use a #2 Phillips screwdriver to remove the screw that secures the torch’s pilot wire to the torch body. 9. Use 1/4-inch and 3/8-inch wrenches, or adjustable wrenches, to loosen the nut that secures the gas supply line to the torch lead.
Page 60: Choose The Machine Torch Consumables
Powermax systems with the Duramax M65, M85, M65m, or M85m are shipped with a complete set of consumables. Hypertherm also includes spare electrodes and nozzles. In addition, an ohmic-sensing retaining cap is available for use with shielded consumables. With unshielded consumables, you must keep the torch a small distance, about .08 inch (2 mm), away from the metal.
Page 61 TORCH SETUP Mechanized unshielded consumables: Powermax65 220941 Nozzle 220955 220854 220842 220857 Deflector Retaining cap Electrode Swirl ring 220819 Nozzle Mechanized shielded consumables: Powermax85 220941 Nozzle 220819 220817 220854 220842 220857 Nozzle Shield Retaining cap Electrode Swirl ring 220816 Nozzle Mechanized shielded with ohmic consumables: Powermax85 220941 Nozzle...
Page 62 TORCH SETUP Mechanized unshielded consumables: Powermax85 220941 Nozzle 220819 220955 220854 220842 220857 Nozzle Deflector Retaining cap Electrode Swirl ring 220816 Nozzle Gouging consumables 220798 220854 220797 220842 220857 Shield Retaining cap Nozzle Electrode Swirl ring FineCut ® shielded consumables 220948 220953 220842...
Page 63: Install The Machine Torch Consumables
TORCH SETUP Install the machine torch consumables WARNING INSTANT-ON TORCHES PLASMA ARC CAN CAUSE INJURY AND BURNS The plasma arc comes on im me di ate ly when the torch is activated. Make sure the power is OFF before changing the consumables. To operate the machine torch, a complete set of consumable parts must be installed: shield, retaining cap, nozzle, electrode, and swirl ring.
Page 64: Connecting An Optional Remote-Start Pendant
Part number 128651: 50 foot (15 m) • Part number 128652: 75 foot (23 m) Remove the receptacle cover and plug the Hypertherm remote-start pendant into the receptacle on the rear of the power supply. Note: The remote-start pendant is for use only with a machine torch. It will not operate if a handheld torch is installed.
Page 65: Connecting An Optional Machine Interface Cable
The voltage divider is not fault tolerant and ELV outputs do not comply with safety extra low voltage (SELV) requirements for direct connection to computer products. Hypertherm offers several choices of machine interface cables for the Powermax65 and Powermax85: •...
Page 66 2. Remove the machine interface receptacle’s cover from the rear of the power supply. 3. Connect the Hypertherm machine interface cable to the power supply. 4. If you are using a cable with a D-sub connector on the other end, plug it into the appropriate pin connector on the torch height controller or CNC.
Page 67 TORCH SETUP Refer to the following table when connecting the Powermax65 or Powermax85 to a torch height controller or CNC controller with a machine interface cable. Connector Cable wires Signal Type Notes sockets Green, black Start Input Normally open. 3, 4 (start 18 VDC open circuit voltage at plasma)
Page 68 TORCH SETUP Setting the five-position voltage divider To change the factory preset voltage divider from 50:1 to a different setting: 1. Turn OFF the power supply and disconnect the power cord. 2. Remove the power supply cover. 3. Locate the voltage divider DIP switches on the left side of the power supply. Note: The figure below shows the default setting (50:1) with the number 4 switch up.
Page 69 TORCH SETUP Accessing raw arc voltage To access divided raw arc voltage, refer to Field Service Bulletin 807060. WARNING: HIGH VOLTAGE AND CURRENT Connecting directly to the plasma circuit for access to raw arc voltage increases the risk of shock hazard, energy hazard, and fire hazard in the event of a single fault. The output voltage and the output current of the circuit are specified on the data plate.
Page 70: Connecting The Torch Lead
TORCH SETUP Connecting the torch lead The Powermax65 and Powermax85 are equipped with FastConnect , a quick-disconnect system for connecting and disconnecting handheld and machine torch leads. When connecting or disconnecting a torch, first turn OFF the system. To connect either torch, push the connector into the receptacle on the front of the power supply. To remove the torch, press the red button on the connector and pull the connector out of the receptacle.
Page 71: 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. powermax 65/85 Service Manual...
Page 72: Estimated Kerf-Width Compensation
TORCH SETUP Estimated kerf-width compensation The widths in the tables below are for reference. The data are obtained with the “Best Quality” settings. Differences between installations and material composition may cause actual results to vary from those shown in the tables. Estimated kerf-width compensation - Metric (mm) Thickness (mm) Process...
Page 73 TORCH SETUP Estimated kerf-width compensation - English (inches) Thickness (inches) Process 22GA 18GA 14GA 10GA 3/16 Mild Steel 85A Shielded 0.068 0.071 0.073 0.078 0.090 0.095 0.100 65A Shielded 0.062 0.065 0.068 0.070 0.076 0.088 0.090 0.091 45A Shielded 0.035 0.054 0.055 0.061...
Page 74: 85 A Shielded Consumables
TORCH SETUP 85 A shielded consumables 220816 220817 220854 220842 220857 Nozzle Shield Retaining cap Electrode Swirl ring 220816 220817 220953 220842 220857 Nozzle Shield Ohmic-sensing Electrode Swirl ring retaining cap powermax 3-26 65/85 Service Manual...
Page 75 TORCH SETUP 85A Shielded Air flow rate - slpm/scfh 190 / 400 Mild Steel Cold 235 / 500 Metric Torch- Pierce Best Quality Settings Production Settings Material Initial Pierce to-Work Delay Thickness Height Cut Speed Voltage Cut Speed Voltage Distance Time seconds (mm/min)
Page 76 TORCH SETUP 85A Shielded Air flow rate - slpm/scfh 190 / 400 Stainless Steel Cold 235 / 500 Metric Torch- Best Quality Settings Production Settings Material Pierce to-Work Initial Pierce Height Thickness Delay Time Cut Speed Voltage Cut Speed Voltage Distance seconds (mm/min)
Page 77 TORCH SETUP 85A Shielded Air flow rate - slpm/scfh 190 / 400 Aluminum Cold 235 / 500 Metric Torch- Best Quality Settings Production Settings Material Initial Pierce Pierce to-Work Thickness Height Delay Time Cut Speed Voltage Cut Speed Voltage Distance seconds (mm/min) Volts...
Page 78: 65 A Shielded Consumables
TORCH SETUP 65 A shielded consumables 220817 220854 220842 220857 220819 Shield Retaining cap Electrode Swirl ring Nozzle 220819 220817 220953 220842 220857 Nozzle Shield Ohmic-sensing Electrode Swirl ring retaining cap powermax 3-30 65/85 Service Manual...
Page 79 TORCH SETUP 65A Shielded Air flow rate - slpm/scfh 160 / 340 Mild Steel Cold 220 / 470 Metric Best Quality Settings Production Settings Torch- Pierce Material Initial Pierce to-Work Delay Thickness Height Cut Speed Voltage Cut Speed Voltage Distance Time seconds (mm/min)
Page 80 TORCH SETUP 65A Shielded Air flow rate - slpm/scfh 160 / 340 Stainless Steel Cold 220 / 470 Metric Torch- Best Quality Settings Production Settings Material Initial Pierce Pierce to-Work Thickness Height Delay Time Cut Speed Voltage Cut Speed Voltage Distance seconds (mm/min)
Page 81 TORCH SETUP 65A Shielded Air flow rate - slpm/scfh 160 / 340 Aluminum Cold 220 / 470 Metric Torch- Best Quality Settings Production Settings Material Initial Pierce Pierce Delay to-Work Thickness Height Time Cut Speed Voltage Cut Speed Voltage Distance seconds (mm/min) Volts...
Page 82: 45 A Shielded Consumables
TORCH SETUP 45 A shielded consumables 220817 220854 220941 220842 220857 Shield Retaining cap Nozzle Electrode Swirl ring 220817 220953 220842 220857 220941 Shield Ohmic-sensing Electrode Swirl ring Nozzle retaining cap powermax 3-34 65/85 Service Manual...
Page 83 TORCH SETUP 45A Shielded Air flow rate - slpm/scfh 150 / 310 Mild Steel Cold 210/ 450 Metric Torch- Best Quality Settings Production Settings Material Initial Pierce Pierce Delay to-Work Thickness Height Time Cut Speed Voltage Cut Speed Voltage Distance seconds (mm/min) Volts...
Page 84 TORCH SETUP 45A Shielded Air flow rate - slpm/scfh 150 / 310 Stainless Steel Cold 210/ 450 Metric Torch- Best Quality Settings Production Settings Material Initial Pierce Pierce to-Work Thickness Height Delay Time Cut Speed Voltage Cut Speed Voltage Distance seconds (mm/min) Volts...
Page 85 TORCH SETUP 45A Shielded Air flow rate - slpm/scfh 150 / 310 Aluminum Cold 210/ 450 Metric Torch- Best Quality Settings Production Settings Material Initial Pierce Pierce to-Work Thickness Height Delay Time Cut Speed Voltage Cut Speed Voltage Distance seconds (mm/min) Volts (mm/min)
Page 86: Finecut ® Consumables
TORCH SETUP FineCut ® consumables Note: The cut charts in this section apply to both shielded and unshielded consumables. 220948 220953 220930 220842 220857 Shield Retaining cap Nozzle Electrode Swirl ring 220955 220854 220842 220857 220930 Deflector Retaining cap Electrode Swirl ring Nozzle powermax...
Page 87 TORCH SETUP FineCut Air flow rate - slpm/scfh 155 / 330 Mild Steel Cold 215 / 460 Metric Torch- Best Quality Settings Material Pierce Delay Amps to-Work Initial Pierce Height Thickness Time Cut Speed Voltage Distance seconds (mm/min) Volts 8250 8250 8250 8250...
Page 88 TORCH SETUP FineCut Air flow rate - slpm/scfh 155 / 330 Stainless Steel Cold 215 / 460 Metric Torch- Best Quality Settings Material Pierce Amps to-Work Initial Pierce Height Thickness Delay Time Cut Speed Voltage Distance seconds (mm/min) Volts 8250 8250 8250 8250...
Page 89: 85 A Unshielded Consumables
TORCH SETUP 85 A unshielded consumables 220816 220955 220854 220842 220857 Nozzle Deflector Retaining cap Electrode Swirl ring powermax 65/85 Service Manual 3-41...
Page 90 TORCH SETUP 85A Unshielded Air flow rate - slpm/scfh 190 / 400 Mild Steel Cold 235 / 500 Metric Torch- Best Quality Settings Production Settings Material Initial Pierce Pierce to-Work Thickness Height Delay Time Cut Speed Voltage Cut Speed Voltage Distance seconds (mm/min)
Page 91 TORCH SETUP 85A Unshielded Air flow rate - slpm/scfh 190 / 400 Stainless Steel Cold 235 / 500 Metric Torch- Best Quality Settings Production Settings Material Initial Pierce Pierce Delay to-Work Thickness Height Time Cut Speed Voltage Cut Speed Voltage Distance seconds (mm/min)
Page 92 TORCH SETUP 85A Unshielded Air flow rate - slpm/scfh 190 / 400 Aluminum Cold 235 / 500 Metric Torch- Best Quality Settings Production Settings Material Initial Pierce Pierce to-Work Thickness Height Delay Time Cut Speed Voltage Cut Speed Voltage Distance seconds (mm/min) Volts...
Page 93: 65 A Unshielded Consumables
TORCH SETUP 65 A unshielded consumables 220819 220955 220854 220842 220857 Nozzle Deflector Retaining cap Electrode Swirl ring powermax 65/85 Service Manual 3-45...
Page 94 TORCH SETUP 65A Unshielded Air flow rate - slpm/scfh 160 / 340 Mild Steel Cold 220 / 470 Metric Torch- Best Quality Settings Production Settings Material Initial Pierce Pierce Delay to-Work Thickness Height Time Cut Speed Voltage Cut Speed Voltage Distance seconds (mm/min)
Page 95 TORCH SETUP 65A Unshielded Air flow rate - slpm/scfh 160 / 340 Stainless Steel Cold 220 / 470 Metric Torch- Best Quality Settings Production Settings Material Initial Pierce Pierce to-Work Thickness Height Delay Time Cut Speed Voltage Cut Speed Voltage Distance seconds (mm/min)
Page 96 TORCH SETUP 65A Unshielded Air flow rate - slpm/scfh 160 / 340 Aluminum Cold 220 / 470 Metric Torch- Best Quality Settings Production Settings Material Initial Pierce Pierce to-Work Thickness Height Delay Time Cut Speed Voltage Cut Speed Voltage Distance seconds (mm/min) Volts...
Page 97: 45 A Unshielded Consumables
TORCH SETUP 45 A unshielded consumables 220941 220955 220854 220842 220857 Nozzle Deflector Retaining cap Electrode Swirl ring powermax 65/85 Service Manual 3-49...
Page 98 TORCH SETUP 45A Unshielded Air flow rate - slpm/scfh 147 / 310 Mild Steel Cold 210 / 450 Metric Torch- Best Quality Settings Production Settings Material Initial Pierce Pierce to-Work Thickness Height Delay Time Cut Speed Voltage Cut Speed Voltage Distance seconds (mm/min)
Page 99 TORCH SETUP 45A Unshielded Air flow rate - slpm/scfh 147 / 310 Stainless Steel Cold 210 / 450 Metric Torch- Best Quality Settings Production Settings Material Initial Pierce Pierce Delay to-Work Thickness Height Time Cut Speed Voltage Cut Speed Voltage Distance seconds (mm/min)
Page 100 TORCH SETUP 45A Unshielded Air flow rate - slpm/scfh 147 / 310 Aluminum Cold 210 / 450 Metric Torch- Best Quality Settings Production Settings Material Initial Pierce Pierce to-Work Thickness Height Delay Time Cut Speed Voltage Cut Speed Voltage Distance seconds (mm/min) Volts...
Page 101: Operation
Section 4 OPERATION In this section: Controls and indicators ..................................4-2 Rear controls ....................................4-2 Front controls and LEDs ................................4-2 Status screen ....................................4-4 Operating the Powermax65 or Powermax85 ...........................4-6 Connect the electrical power, gas supply, and torch lead ....................4-6 Attach the work lead to the power supply ..........................4-7 Attach the work clamp to the workpiece ..........................4-8 Turn ON the system ..................................4-9 Set the operating mode switch ..............................4-9...
Page 102: Controls And Indicators
OPERATION Controls and indicators The Powermax65 and Powermax85 power supplies have the following: ON/OFF switch, adjustment knob, automatic/ manual pressure setting mode selector, current/gas selector, operating mode switch, indicator LEDs, and a status screen. Rear controls ON (I)/OFF (O) power switch Activates the power supply and its control circuits.
Page 103 OPERATION Operating mode switch The operating mode switch can be set in one of four positions: • Continuous pilot arc. Cuts expanded metal or grate. • Non-continuous pilot arc. Cuts or pierces metal plate. This is the standard setting for normal drag-cutting. •...
Page 104: Status Screen
OPERATION Status screen The status screen shows system status and fault information. Current Remote setting Torch is connected (amps) cutting Torch started Current selection cursor Fault icon Pressure selection cursor Fault code Visual pressure Pressure setting setting Gas pressure indicators In manual mode, the gas pressure is displayed in bar and psi.
Page 105 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 106: Operating The Powermax65 Or Powermax85
OPERATION Operating the Powermax65 or Powermax85 Follow the steps below to begin cutting or gouging with the Powermax65 or Powermax85. Connect the electrical power, gas supply, and torch lead For information on connecting the proper power cord with plug to the power supply, refer to Section 2, Power Supply Setup.
Page 107: Attach The Work Lead To The Power Supply
OPERATION Attach the work lead to the power supply Caution: Make sure you use a work lead that is appropriate for your power supply. Use a 65 A work lead with the Powermax65. Use an 85 A work lead with the Powermax85. The amperage is marked near the rubber boot of the work lead connector.
Page 108: Attach The Work Clamp To The Workpiece
OPERATION Attach the work clamp to the workpiece The work clamp must be connected to the workpiece while you are cutting. If you are using the Powermax65 or Powermax85 with a cutting table, you can connect the work lead directly to the table instead of attaching the work clamp to the workpiece.
Page 109: Turn On The System
OPERATION Turn ON the system Set the ON/OFF switch to the ON (I) position. Set the operating mode switch Use the operating mode switch to select the type of work you want to perform. In automatic gas mode, Smart Sense™ technology automatically adjusts the gas pressure according to the selected cutting mode and torch lead length for optimum cutting.
Page 110: Check The Indicators
OPERATION Check the indicators Verify the following: • The green power ON LED on the front of the power supply is illuminated. • The Fault LED is not illuminated. • No error icons appear in the status screen. If a fault icon appears in the status screen, or the Fault LED is illuminated, or the power ON LED is blinking, correct the fault condition before continuing.
Page 111: Adjusting The Current (Amperage)
OPERATION Adjusting the current (amperage) Turn the adjustment knob to adjust the current for your particular cutting application. If the system is in manual mode, do the following to adjust the amperage. 1. Press the current/gas selector until the selection cursor is opposite the amperage setting in the status screen. 2.
Page 112: Understanding Duty-Cycle Limitations
OPERATION Understanding duty-cycle limitations The duty cycle is the amount of time, in minutes, that a plasma arc can remain on within a 10-minute period when operating at an ambient temperature of 104° F (40° C). With a Powermax65: • At 65 A, the arc can remain on for 5 minutes out of 10 minutes without causing the unit to overheat (50% duty cycle).
Page 113: 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 114: Hand Torch Cutting Hints
For straight-line cuts, use a straight edge as a guide. To cut circles, use a template or a radius cutter attachment (a circle cutting guide). See Section 6, Parts, for part numbers for the Hypertherm plasma cutting guides for cutting circles and making bevel cuts.
Page 115: 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 116: Pierce A Workpiece
OPERATION Pierce a workpiece WARNING SPARKS AND HOT METAL CAN INJURE EYES AND BURN SKIN. When firing the torch at an angle, sparks and hot metal will spray out from the nozzle. Point the torch away from yourself and others. 1.
Page 117: Gouge A Workpiece
OPERATION Gouge a workpiece WARNING SPARKS AND HOT METAL CAN INJURE EYES AND BURN SKIN. When firing the torch at an angle, sparks and hot metal will spray out from the nozzle. Point the torch away from yourself and others. 1.
Page 118 OPERATION Gouge profile You can vary the gouge profile by varying the speed of the torch over the workpiece, varying the torch-to-work standoff distance, varying the angle of the torch to the workpiece, and varying the current output of the power supply. Speed Angle Standoff...
Page 119 OPERATION Varying the gouge profile The following actions have the stated effects on the gouge profile: • Increasing the speed of the torch will decrease width and decrease depth. • Decreasing the speed of the torch will increase width and increase depth. •...
Page 120: Common Hand-Cutting Faults
OPERATION Common hand-cutting faults The torch does not cut completely through the workpiece. The causes can be: • The cut speed is too fast. • The consumables are worn. • The metal being cut is too thick for the selected amperage. •...
Page 121: 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 122 OPERATION Problem Cause Solution Negative cut angle The torch is too low. Raise the torch; or if you are using a torch height control, increase the arc voltage. Square cut The torch is too high. Lower the torch; or if you are using a torch Positive cut angle height control, decrease the arc voltage.
Page 123: To Pierce A Workpiece Using The Machine Torch
Different material chemistries can have an adverse effect on the pierce capability of the system. In particular, high-strength steel with a high manganese or silicon content can reduce the maximum pierce capability. Hypertherm calculates mild steel parameters with certified A-36 plate. •...
Page 124: Common Machine-Cutting Faults
OPERATION Common machine-cutting faults The torch’s pilot arc will initiate, but will not transfer. Causes can be: • The work cable is not making good contact with the cutting table or the cutting table is not making good contact with the workpiece. •...
Page 125: Troubleshooting And System Tests
Hypertherm IGBT tester ................................5-12 Indicator LEDs and device tests ............................5-12 IGBT test preparation ................................5-13 IGBT device test using the Hypertherm tester ........................5-14 Troubleshoot the Hypertherm IGBT tester .......................... 5-14 Schematic for building an IGBT tester ..........................5-15 IGBT device test using a non-Hypertherm tester ......................
Page 126 TROUBLESHOOTING AND SYSTEM TESTS Fault codes ......................................5-21 Displaying the service screen ..............................5-21 Important fault icons ................................. 5-22 Performing a cold restart ................................. 5-22 Fault codes and solutions ................................ 5-23 Troubleshooting guide ..................................5-32 System tests......................................5-38 Test 1 – Voltage input ................................5-39 Test 2 –...
Page 127: Controls And Indicators
TROUBLESHOOTING AND SYSTEM TESTS Controls and indicators The Powermax65 and Powermax85 controls and indicators are described in Section 4, Operation. These figures are included for reference. ON (I)/OFF (O) power switch Activates the power supply and its control circuits. Operating mode switch Adjustment knob Status screen...
Page 128: Theory Of Operation
TROUBLESHOOTING AND SYSTEM TESTS Theory of operation General Refer to “Sequence of operation” below and Section 8, Wiring diagrams. 200-600 V CSA 1- or 3-phase power supply functional description AC power enters the system through the power switch (S1) to the input diode bridge (D50). The voltage from the bridge supplies the power factor correction (PFC) boost converter, which provides a nominal 760 VDC bus voltage.
Page 129: 380/400 V Ce 3-Phase Power Supply Functional Description
TROUBLESHOOTING AND SYSTEM TESTS 380/400 V CE 3-phase power supply functional description AC power enters the system through the power switch (S1) to the input diode bridge (D45). The voltage from the bridge provides a nominal 530 to 560 VDC bus voltage. The bus supplies voltage and current to the inverter and the flyback circuit (DC to DC converter) on the power board (PCB3).
Page 130: Sequence Of Operation
TROUBLESHOOTING AND SYSTEM TESTS Sequence of operation Power OFF • Connect the gas supply to the air fitting on the power supply. • Set the power switch (S1) to OFF (O). • Connect the work lead to the power supply and workpiece. •...
Page 131: Troubleshooting Preparation
The complexity of the circuits requires that service technicians have a working knowledge of inverter power supply theory. In addition to being technically qualified, technicians must perform all testing with safety in mind. If questions or problems arise during servicing, call the Hypertherm Technical Services team listed in the front of this manual.
Page 132 TROUBLESHOOTING AND SYSTEM TESTS DANGER ELECTRIC SHOCK CAN KILL • Turn off the power and remove the input power plug from its receptacle before removing the cover from the power supply. If the power supply is connected directly to a line disconnect box, switch the line disconnect to OFF (O).
Page 133: External Inspection
TROUBLESHOOTING AND SYSTEM TESTS External inspection 1. Inspect the exterior of the power supply for damage to the cover and external components, such as the power cord and plug. 2. Inspect the torch and the torch lead for damage. 3. Inspect the consumables for damage or wear. Internal inspection 1.
Page 134 TROUBLESHOOTING AND SYSTEM TESTS 200-600 V CSA 400 V CE 350 kΩ 500 kΩ 350 kΩ 350 kΩ 500 kΩ 500 kΩ >20 MΩ >20 MΩ Ground is Ground is at bottom at top of of heat sink heat sink powermax 5-10 65/85 Service Manual...
Page 135 The Troubleshooting guide provides most probable causes and solutions. Study the system wiring diagram and understand the theory of operation before troubleshooting. Before purchasing any major replacement component, verify the problem with Hypertherm Technical Service or the nearest Hypertherm repair facility. powermax...
Page 136: Hypertherm Igbt Tester
TROUBLESHOOTING AND SYSTEM TESTS Hypertherm IGBT tester Use the Hypertherm IGBT (insulated gate bipolar transistor) tester (part number 128883) as described in the following sections or assemble your own IGBT tester from the schematic diagram shown on page 5-15 Schematic for building an IGBT tester and use it to test the IGBTs.
Page 137: Igbt Test Preparation
TROUBLESHOOTING AND SYSTEM TESTS IGBT test preparation Before testing with the Hypertherm IGBT tester, connect the colored leads to the IGBT as shown on the next page. Note: Before an IGBT can be tested, it must be electrically isolated from all circuits. If the IGBT is installed in a power supply, remove the power board and any lead connections before testing.
Page 138: Igbt Device Test Using The Hypertherm Tester
TROUBLESHOOTING AND SYSTEM TESTS IGBT device test using the Hypertherm tester Using the Hypertherm IGBT tester, press and hold the switch in the desired position to perform each test described in the following table. Switch Position Fail Pass Battery This may mean...
Page 139: Schematic For Building An Igbt Tester
TROUBLESHOOTING AND SYSTEM TESTS Schematic for building an IGBT tester Legend 1. Collector 1 (C1) 2. Emitter 2 (E2) 3. Collector 2, Emitter 1 (C2,E1) 2.0K 4. Gate 1 (G1) 009036 5. Emitter 1 (E1) 2.0K 6. Emitter 2 (E2) 7.
Page 140: Igbt Device Test Using A Non-Hypertherm Tester
TROUBLESHOOTING AND SYSTEM TESTS IGBT device test using a non-Hypertherm tester The device tester shown on page 5-15 Schematic for building an IGBT tester has one LED and one pushbutton switch that are used in combination to perform two tests.
Page 141: 200-600V Csa Power Supply Overview
TROUBLESHOOTING AND SYSTEM TESTS 200-600V CSA power supply overview Power switch Control board Flyback circuit (S1) Digital signal processor 3uF Capacitors (DSP) board Power board Gate drive Gate drive Snubber connectors connectors resistor wires TP10 TP11 WORK LEAD TP12 Nozzle Transformer Output Electrode...
Page 142: 380/400V Ce Power Supply Overview
TROUBLESHOOTING AND SYSTEM TESTS 380/400V CE power supply overview Control board Flyback circuit Digital signal processor Power switch (S1) 3uF Capacitor (DSP) board Gate drive Power board connectors Ground MOV sub- assembly TP11 TP12 WORK LEAD TP13 Nozzle Transformer PFC inductor wires Output Electrode Test points...
Page 143: 200-600V Csa Power Supply Overview (Power Board Removed)
TROUBLESHOOTING AND SYSTEM TESTS 200-600V CSA power supply overview (power board removed) Output snubber PFC snubber Power switch (S1) resistor resistor Optional serial board Snubber resistor Input diode bridge Ground Output Inverter IGBT Inverter Pilot arc IGBT PFC IGBT diode module snubber bridge...
Page 144: 380/400V Ce Power Supply Overview (Power Board Removed)
TROUBLESHOOTING AND SYSTEM TESTS 380/400V CE power supply overview (power board removed) Output snubber Power switch (S1) resistor Optional serial board Ground Input diode bridge Output Inverter Inverter IGBT Bulk capacitors Pilot arc IGBT diode snubber module bridge resistor powermax 5-20 65/85 Service Manual...
Page 145: Fault Codes
TROUBLESHOOTING AND SYSTEM TESTS Fault codes Fault codes displayed on the LCD screen in “service mode” are in the format N-nn-n. Fault codes displayed on the LCD screen in “operator mode” have one fewer digit and appear in the format N-nn. The tables in this section show all digits. The fault priority is assigned based on the fault code value: the higher the number, the higher the fault priority.
Page 146: Important Fault Icons
TROUBLESHOOTING AND SYSTEM TESTS To move the field selector (*) between fields, press the current/gas mode selector. The asterisk indicates the selected field. You can alter the I, C, B, P, and G fields by turning the adjustment knob. To toggle between (I) Current set/read and (P) Pressure set/read, press the automatic/manual mode selector. The LED is illuminated when the Pressure set/read field is selected.
Page 147: Fault Codes And Solutions
TROUBLESHOOTING AND SYSTEM TESTS Fault codes and solutions Each table below describes a fault category and suggests solutions for each fault code. Several of the fault descriptions show a test number. If the listed solutions do not resolve the problem, refer to page 5-38 System tests and perform the indicated numbered test.
Page 148 TROUBLESHOOTING AND SYSTEM TESTS Fault Description Power Fault Fault Solutions code (System test number) icon 0-19-9 Power board hardware The inverter shuts down and does not fire protection. One or more major again for several seconds. If the fault is power board hardware faults caused by electrical noise, the fault clears (or electrical noise) detected:...
Page 149 Toggle back to “0” and exit “manual mode.” Replace the regulator if necessary. • If the problem persists, contact your Hypertherm distributor or authorized repair facility. 0-40-0 PFC/Boost IGBT module For an over-temperature fault, leave the...
Page 150 TROUBLESHOOTING AND SYSTEM TESTS Fault Description Power Fault Fault Solutions code (System test number) icon 0-50-0 Retaining cap off (Test 8) • Verify that proper consumables and retaining cap are installed. Replace damaged parts. Refer to section Torch Setup. • With the retaining cap installed, check for continuity between pins 5 and 7 at the torch connector.
Page 151 TROUBLESHOOTING AND SYSTEM TESTS Fault Description Power Fault Fault Solutions code (System test number) icon 0-98-0 Internal communication • Perform a cold restart. failure • Confirm that the connecting ribbon cable is The control board and the installed properly between the control board DSP are not communicating.
Page 152 TROUBLESHOOTING AND SYSTEM TESTS 2-nn-n These fault codes usually relate to either the DSP or the power board and can only be seen on the service screen. Fault Description Power Fault Fault Solutions code (System test number) icon 2-00-0 Analog to Digital (A/D) •...
Page 153 TROUBLESHOOTING AND SYSTEM TESTS 3-nn-n These fault codes relate to the power board and can only be seen on the service screen. Fault Description Power Fault Fault Solutions code (System test number) icon 3-00-0 DC bus voltage (Test 5) • Inspect the PFC Boost circuitry (CSA) DC bus voltage is out of •...
Page 154 TROUBLESHOOTING AND SYSTEM TESTS Fault Description Power Fault Fault Solutions code (System test number) icon 3-41-0 Drive fault If an activation signal is sent to a device and the device does not activate (machine motion relay or in-rush relay for example) this fault will occur.
Page 155 TROUBLESHOOTING AND SYSTEM TESTS Fault Description Power Fault Fault Solutions code (System test number) icon 3-51-1 Inverter saturation fault (the Upper and lower inverter IGBTs are gating inverter is over current) (being activated) in phase rather than 180° out of phase. •...
Page 156: Troubleshooting Guide
TROUBLESHOOTING AND SYSTEM TESTS Troubleshooting guide Note: Fault icons and corresponding fault codes appear in the user display for many errors. If a fault code appears, refer to page 5-21 Fault codes before using this troubleshooting guide. The following table provides an overview of the most common problems that can arise when using the Powermax65 or Powermax85 and explains how to solve them.
Page 157 TROUBLESHOOTING AND SYSTEM TESTS Problem Meaning Causes Solution • The torch or • Inspect the torch and torch lead for torch lead may damage. be damaged. The power ON LED is illuminated and no fault The start signal is • Verify that the transfer icon appears •...
Page 158 TROUBLESHOOTING AND SYSTEM TESTS Problem Meaning Causes Solution • Overused or Worn or damaged improperly • Replace consumables. consumables. installed consumables. • Electrode is not moving properly Damaged torch or in the torch or • Perform Test 6. lead assembly. the torch lead is damaged.
Page 159 TROUBLESHOOTING AND SYSTEM TESTS Problem Meaning Causes Solution • If you are cutting expanded metal, grate, • The work lead or any metal with holes, set the mode or work lead switch to continuous pilot arc mode. connection may be faulty. •...
Page 160 TROUBLESHOOTING AND SYSTEM TESTS Problem Meaning Causes Solution • The mode switch • Verify that the mode switch is set to may be set While in continuous pilot continuous pilot arc. incorrectly arc mode, the pilot arc The continuous pilot extinguishes when you •...
Page 161 TROUBLESHOOTING AND SYSTEM TESTS Problem Meaning Causes Solution • Verify that the work lead is attached to • Poor work lead the workpiece and the workpiece is free connection. of rust, paint, or other coatings. • Check the resistance across the work •...
Page 162: System Tests
Wear the proper personal protective equipment and use approved tools and measurement equipment. Before purchasing a major replacement component, verify the problem with Hypertherm Technical Service (1-800-643- 9878) or the nearest Hypertherm repair facility.
Page 163: Test 1 - Voltage Input
TROUBLESHOOTING AND SYSTEM TESTS Test 1 – Voltage input Symptom: Voltage fault (0-60-0, -1 or -2) • Check the line voltage at the power switch (S1). • Check the input voltage to the input diode bridge. The AC voltage between any 2 input wires should equal the line voltage. •...
Page 164: Test 2 - Dc Power Buss
TROUBLESHOOTING AND SYSTEM TESTS Test 2 – DC Power Buss Resistance check Note: All resistance values must be taken with the power cord disconnected and all internal power supply wires attached. • Remove the mounting screws from the bulk capacitors and pull the caps away from the power board. •...
Page 165 TROUBLESHOOTING AND SYSTEM TESTS Voltage check All voltages must be measured with the input power connected and the machine on. Note: Wear proper personal protective equipment (PPE) before testing powered equipment. All values are ±15%. • Check the inverter IGBT voltages as described below. •...
Page 166: Test 3 - Output Diodes
TROUBLESHOOTING AND SYSTEM TESTS Test 3 – Output diodes • Check the four diodes in the bridge with an ohmmeter in diode test mode. • For each diode, the value should be “open” (very high resistance) with the meter leads in one direction and 0.1V to 1.0V with the meter leads reversed.
Page 167: Test 4 - Inverter And Pfc Temperature Sensor
TROUBLESHOOTING AND SYSTEM TESTS Test 4 – Inverter and PFC temperature sensor Symptom: Fault code 0-40 appears in the operator screen. Remove power and allow the system to reach room temperature (at least 60 minutes after use). If the system has a temperature interlock, either fault code 0-40 or fault code 0-99 appears on the operator screen. Display the service screen and check the “F”...
Page 168 TROUBLESHOOTING AND SYSTEM TESTS For operational fault codes 0-40-0 and 0-40-1 or power board faults 3-11-0 and 3-11-1 (CSA only) 1. Remove PFC temperature sensor connector (J16) from power board. 2. Check the resistance between pins 1 and 2 on the plug. Resistance should be about 5.5 kΩ. 3.
Page 169 TROUBLESHOOTING AND SYSTEM TESTS For operational fault codes 0-40-2 and 0-40-3 or power board faults 2-10-0 and 2-10-1 1. Remove the inverter temperature sensor connector from the top-rear of the power board (J2 on CSA units or J4 on CE units). 2.
Page 170: Test 5 - Flyback Circuit (Dc Minor Voltages)
TROUBLESHOOTING AND SYSTEM TESTS Test 5 – Flyback circuit (DC minor voltages) Symptom: Minor voltages are not present. Note: Wear proper personal protective equipment (PPE) before testing powered equipment. The flyback circuit is the source of the minor DC voltages in the power supply. It provides +3.3 VDC, +5 VDC, +24 VDC, and +48 VDC.
Page 171 TROUBLESHOOTING AND SYSTEM TESTS If the +48 VDC value is incorrect: • Remove the fan connector (J3 for standard units or J5 for CE units) and repeat the test. • If the value is now correct, replace the fan. • If the value is still incorrect, replace the power board.
Page 172: Test 6 - Torch Stuck Open (Tso)
TROUBLESHOOTING AND SYSTEM TESTS Test 6 – Torch stuck open (TSO) Symptom: No fault occurs at power-up but an 0-30 fault displays on the operator screen when attempting to fire the torch. Confirm that all of the proper consumables are installed in the torch. In an idle (no start signal) working system with the torch and consumables installed, there should be continuity between the dual black wires connected to the center post of the pilot arc IGBT and the red wire connecting to J28.
Page 173 TROUBLESHOOTING AND SYSTEM TESTS Before continuing, turn OFF the power. If the resistance value is always less than 100 Ω, remove the torch and recheck the resistance. If the value is still less than 100 Ω: • Use an IGBT tester to check for a shorted pilot arc IGBT. •...
Page 174: Test 7 - Start Signal
TROUBLESHOOTING AND SYSTEM TESTS Test 7 – Start signal Symptom: There is no arc when the torch trigger is closed. If the start icon is displayed and there is a fault code 0-51 at power up: • Remove the torch from the system. •...
Page 175: Test 8 - Torch Cap Switch
TROUBLESHOOTING AND SYSTEM TESTS Test 8 – Torch cap switch Symptom: Fault code 0-50 and the cap-sensor switch icon appear on the operator screen. 1. Confirm that the retaining cap is in place. 2. Remove the torch from the power supply and check the resistance between Pin 5 and Pin 7 in the torch lead plug. If the resistance is very high, check for opens in the torch leads and cap sensor switch.
Page 176: Test 9 - Electronic Regulator
TROUBLESHOOTING AND SYSTEM TESTS Test 9 – Electronic regulator Symptom: Air flows continuously through the torch. 1. Turn off the machine and disconnect power. 2. Disconnect the electronic regulator control cable (J4 for CSA, J6 for CE) from the power board. •...
Page 177: Test 10 - Pressure Sensor
TROUBLESHOOTING AND SYSTEM TESTS Test 10 – Pressure sensor Symptom: The pressure sensor reading doesn’t agree with known pressures. Note: Wear proper personal protective equipment (PPE) before testing powered equipment. 1. Remove the white cover on the plug at J5 for CSA units or J7 for CE units. 2.
Page 178: Test 11 - Fan
TROUBLESHOOTING AND SYSTEM TESTS Test 11 – Fan Symptom: The fan does not operate properly. Note: Wear proper PPE protection before testing powered equipment. 1. Remove the inverter temperature sensor plug from J2 in CSA units or J4 in CE units. 2.
Page 179: Test 12 - Aux Switch
TROUBLESHOOTING AND SYSTEM TESTS Test 12 – AUX switch Symptom: The display goes blank after “Hypertherm” appears. (CSA units only). 1. Turn the machine off and disconnect the power. 2. Disconnect the auxiliary switch cable from J1 on the power board.
Page 180 TROUBLESHOOTING AND SYSTEM TESTS powermax 5-56 65/85 Service Manual...
Page 181: Component Replacement
Section 6 COMPONENT REPLACEMENT In this section: Remove and replace the power supply cover and Mylar® barrier ....................6-2 Remove the power supply cover and Mylar barrier ......................6-2 Replace the Mylar barrier ................................6-3 Replace the power supply cover ..............................6-4 Replace the power cord ..................................6-5 Replace the power cord (200 - 600 V 3-phase CSA, 400 V 3-phase CE) ..............6-5 Replace the power cord (200 - 480 V 1-phase CSA) ....................
Page 182: Remove And Replace The Power Supply Cover And Mylar® Barrier
COMPONENT REPLACEMENT Remove and replace the power supply cover and Mylar® barrier Replacing interior components requires that you remove and replace the power supply cover and Mylar barrier. This section describes these procedures. Remove the power supply cover and Mylar barrier 1.
Page 183: Replace The Mylar Barrier
COMPONENT REPLACEMENT Replace the Mylar barrier 1. Remove the metal strap at the top of the power supply and pull the front panel out slightly to make it easier to install the Mylar barrier. 2. Carefully push in the sides (1) of the Mylar barrier so that the barrier bends out slightly at the top and bottom (2). 3.
Page 184: Replace The Power Supply Cover
COMPONENT REPLACEMENT Replace the power supply cover 1. Place the cover (3) over the power supply with the slot in the cover (4) over the plastic tab in the front panel. The slot and tab ensure that the vent in the side of the cover is over the fan. Be careful not to pinch any wires. 2.
Page 185: Replace The Power Cord
COMPONENT REPLACEMENT Replace the power cord For wire sizes, see Extension cord specifications in Section 2, Power Supply Setup. Replace the power cord (200 - 600 V 3-phase CSA, 400 V 3-phase CE) This section describes the procedures for replacing the power cord on 3-phase power supplies. Remove the existing 3-phase power cord 1.
Page 186 COMPONENT REPLACEMENT 4. Pull the wires straight up to remove them from the power switch. 5. Remove the ground screw that secures the green ground wire to the heatsink. Note: For CE models, the ground screw is located at the top of the heat sink. 6.
Page 187 COMPONENT REPLACEMENT Install the new 3-phase power cord (CSA model) Black White Green Ground (GND) 1. Slide the strain relief retention nut over the wires of the new power cord and slide it back along the cord. 2. If you are replacing the old strain relief: Slide the new strain relief into the hole in the rear panel of the power supply.
Page 188 COMPONENT REPLACEMENT Install the new 3-phase power cord (CE model) In CE systems, the standard strain relief hole in the rear panel of the power supply is too big to accommodate the smaller CE power cord. Therefore, CE power cord kits contain an adapter that reduces the hole size. The kit also contains an aluminum washer to assist the strain relief nut in properly securing the strain relief inside the power supply.
Page 189 COMPONENT REPLACEMENT 2. Route the new power cord wires through the strain relief in the rear panel from inside the power supply. (The CE power cord includes a ferrite core. Therefore, you can not route the power cord through the strain relief from the outside of the power supply.) 3.
Page 190: Replace The Power Cord (200 - 480 V 1-Phase Csa)
COMPONENT REPLACEMENT Replace the power cord (200 - 480 V 1-phase CSA) To operate your Powermax on 1-phase power, you will need to install an appropriate power cord. Caution: When using the Powermax85 CSA model power supply (CE model is 3-phase only) with a 1-phase power source, replace the supplied power cord with a 6 AWG (16 mm ) 3-wire power cord.
Page 191: Replace The Work Lead
COMPONENT REPLACEMENT Replace the work lead Caution: Make sure you use a work lead that is appropriate for your power supply. Use a 65 A work lead with the Powermax65. Use an 85 A work lead with the Powermax85. The amperage is marked near the rubber boot of the work lead connector.
Page 192: Replace The Fan
COMPONENT REPLACEMENT Replace the fan Fan wire bundle Grommet Fan shroud 1. Turn OFF the power, disconnect the power cord, and disconnect the gas supply. 2. Remove the power supply cover. 3. Remove the fan shroud by pulling it straight off the fan housing. 4.
Page 193 COMPONENT REPLACEMENT 5. Pull the fan wire through the grommet to the fan side of the power supply. 6. Insert a #1 Phillips screwdriver through the holes in the fan casing to remove the retaining screw from each corner of the fan. 7.
Page 194: Replace The Air Filter Element
COMPONENT REPLACEMENT Replace the air filter element 1. Turn OFF the power, disconnect the power cord, and disconnect the gas supply. 2. Position the rear of the power supply so the removable air filter bowl is easily accessible. 3. Remove the consumables kit that ships beside the filter bowl on the rear panel. 4.
Page 195: Replace The Air Filter Subassembly
COMPONENT REPLACEMENT Replace the air filter subassembly 1. Turn OFF the power, disconnect the power cord, and disconnect the gas supply. 2. Remove the power supply cover. 3. Remove the filter bowl from the air filter at the rear of the power supply. Refer to the instructions and figure on page 6-14 Replace the air filter element.
Page 196 COMPONENT REPLACEMENT 9. Temporarily remove the filter guide from the new air filter subassembly. 10. Place the subassembly into the rear panel hole. 11. Replace the three screws that hold the gas fitting to the rear panel. Torque down the screws to 15 in-lbs (17.7 kg cm).
Page 197: Replace The Power Board
COMPONENT REPLACEMENT Replace the power board 1. Turn OFF the power, disconnect the power cord, and disconnect the gas supply. 2. Remove the power supply cover and Mylar barrier. Refer to page 6-2 Remove the power supply cover and Mylar barrier.
Page 198 COMPONENT REPLACEMENT DSP front view DSP back view powermax 6-18 65/85 Service Manual...
Page 199: Replace The Power Board (380/400V Ce)
COMPONENT REPLACEMENT Replace the power board (380/400V CE) Refer to the figure on the next page when performing the following procedure. Remove the old power board (380/400V CE) 1. Unplug the five wire connectors located at the J3, J4, J5, J6, and J7 headers on the heat sink side of the power board.
Page 200 COMPONENT REPLACEMENT 380/400V CE Power Board J7, J6, J5, J4, and J3 Board 3uF Capacitor Board mounting mounting screw Gate drive Viewing holes screw connectors Board AC input wires Inverter mounting IGBT screw screws (3) Heat sink mounting screw (located behind edge of front panel) Heat sink...
Page 201 COMPONENT REPLACEMENT Install the new power board (380/400V CE) 1. Position the left edge of the power board on a slight angle toward the front end panel, so the previously removed wire connectors will reach their intended locations. 2. If a CNC interface is installed on the power supply, plug the respective wire connectors into the J21 and J33 power board connectors.
Page 202: Replace The Power Board (200-600V Csa)
COMPONENT REPLACEMENT Replace the power board (200-600V CSA) Refer to the figure on the next page when performing the following procedure. Remove the old power board (200-600V CSA) 1. Unplug the five wire connectors located at the J1, J2, J3, J4, and J5 headers on the heatsink side of the power board.
Page 203 COMPONENT REPLACEMENT 200-600V CSA Power Board J5, J4, J3, J2, and J1 Board 3uF Capacitor 3uF Capacitor Board mounting mounting screw Gate drive Viewing screw Gate drive connectors holes connectors Board Inverter mounting IGBT Snubber screw screws (3) resistor wires Heat sink mounting screw (located behind...
Page 204 COMPONENT REPLACEMENT Install the new power board (200-600V CSA) 1. Position the left edge of the power board on a slight angle toward the front end panel, so the previously removed wire connectors will reach their intended locations. 2. If a CNC interface is installed on the power supply, plug the respective wire connectors into the J21 and J32 power board connectors.
Page 205: Install The Dsp Board
COMPONENT REPLACEMENT 15. Secure the 3uF capacitor on the left and the longer transformer wire to the board using the three inverter IGBT screws. On a Powermax85, use a #3 Phillips screwdriver to tighten the screws to 30 in-lbs (34.6 kg cm). On a Powermax65, use a #2 Phillips screwdriver to tighten the screws to 20 in-lbs (23.0 kg cm).
Page 206: Replace The Mylar Barrier And Power Supply Cover
COMPONENT REPLACEMENT DSP back view DSP front view Replace the Mylar barrier and power supply cover. 1. Replace the Mylar barrier. Refer to page 6-3 Replace the Mylar barrier. 2. Replace the power supply cover. Refer to page 6-4 Replace the power supply cover. 3.
Page 207: Replace The Control Board
COMPONENT REPLACEMENT Replace the control board 1. Turn OFF the power, disconnect the power cord, and disconnect the gas supply. 2. Remove the power supply cover and Mylar barrier. Refer to page 6-2 Remove and replace the power supply cover and Mylar®...
Page 208 COMPONENT REPLACEMENT 9. Connect the ribbon cable to the new control board. 10. Carefully slide the control board behind the front panel. 11. Tilt the bottom of the control board toward the front panel until the control board rests on the plastic tabs. Push the knob posts through the holes in the front panel.
Page 209: Replace The Heat Sink Components
COMPONENT REPLACEMENT Replace the heat sink components This section describes the procedures for replacing heat sink components for the 65A CSA, 65A CE, 85A CSA, and 85A CE models. Refer to the figures following the instructions for your particular model. 1.
Page 210: 65A Csa
COMPONENT REPLACEMENT 65A CSA When securing a component to the heat sink, gently tighten all screws and then tighten all screws to the required torque. Note: All screws listed are Phillips head, pan head, machine screws. Torque to 15 in-lbs (17.3 kg cm). M4 X 10 2SEM Torque to 20 in-lbs (23 kg cm).
Page 211 COMPONENT REPLACEMENT 65A CE When securing a component to the heat sink, gently tighten all screws and then tighten all screws to the required torque. Note: All screws listed are Phillips head, pan head, machine screws. Torque to 15 in-lbs (17.3 kg cm). M4 X 10 2SEM Torque to 20 in-lbs (23 kg cm).
Page 212: 85A Csa
COMPONENT REPLACEMENT 85A CSA When securing a component to the heat sink, gently tighten all screws and then tighten all screws to the required torque. Note: All screws listed are Phillips head, pan head, machine screws. Torque to 15 in-lbs (17.3 kg cm). M4 X 10 2SEM Torque to 20 in-lbs (23 kg cm).
Page 213 COMPONENT REPLACEMENT 85A CE When securing a component to the heat sink, gently tighten all screws and then tighten all screws to the required torque. Note: All screws listed are Phillips head, pan head, machine screws. Torque to 15 in-lbs (17.3 kg cm). M4 X 10 2SEM Torque to 20 in-lbs (23 kg cm).
Page 214 COMPONENT REPLACEMENT powermax 6-34 65/85 Service Manual...
Page 215 Section 7 PARTS In this section: Power supply parts ....................................7-2 Exterior front ....................................7-2 Exterior rear ....................................7-3 Interior, power board side (200-600V CSA) .........................7-4 Interior, power board side (380/400V CE) ..........................7-5 Interior, fan side ....................................7-6 Heat sink assembly ....................................7-8 65A CSA ......................................7-8 65A CE ......................................7-9 85A CSA .....................................
Page 216: Power Supply Parts
PARTS Power supply parts Exterior front 2 3 4 5 7 8 9 10 Item Part number Description 228649 Kit: Powermax65 labels, CSA 228650 Kit: Powermax65 labels, CE 228651 Kit: Powermax85 labels, CE 228652 Kit: Powermax85 labels, CSA 228643 Kit: Powermax65 and Powermax85 front panel 228645 Kit: Powermax65 CSA rear panel 228646...
Page 217: Exterior Rear
PARTS Exterior rear 5 6 7 1 2 3 Item Part number Description 228691 Kit: Powermax65 and Powermax85 CSA power cord 228679 Kit: Powermax65 CE power cord 228678 Kit: Powermax85 CE power cord 228680 Kit: Powermax65 and Powermax85 power cord strain relief 128650 Remote start pendant for machine torch, 25 ft (7.6 m) 128651...
Page 218: Interior, Power Board Side (200-600V Csa)
PARTS Interior, power board side (200-600V CSA) TP10 TP11 WORK LEAD TP12 Item Part number Description 228657 Kit: Powermax65 control board 228658 Kit: Powermax85 control board 228656 Kit: Powermax65 and Powermax85 DSP board 228659 Kit: Powermax65 Power board CSA 228662 Kit: Powermax85 Power board CSA 228644 Kit: Powermax65 CSA Power Switch...
Page 219: Interior, Power Board Side (380/400V Ce)
PARTS Interior, power board side (380/400V CE) TP11 TP12 WORK LEAD TP13 Item Part number Description 228657 Kit: Powermax65 control board 228658 Kit: Powermax85 control board 228656 Kit: Powermax65 and Powermax85 DSP board 228708 Kit: Powermax65 Power board CE 228672 Kit: Powermax85 Power board CE 228671 Kit: Powermax65 and Powermax85 CE Power Switch...
Page 220: Interior, Fan Side
PARTS Interior, fan side 8 9 10 21 22 23 24 powermax 65/85 Service Manual...
Page 221 PARTS Item Part number Description 228686 Kit: Powermax65 and Powermax85 fan subassembly 228694 Kit: Fan shroud 228685 Kit: Powermax65 and Powermax85 air filter 228695 Kit: Powermax65 and Powermax85 air filter element 228688 Kit: Powermax65 and Powermax85 pressure switch 228687 Kit: Powermax65 and Powermax85 regulator (solenoid valve subassembly) 228689 Kit: Powermax65 and Powermax85 pressure transducer 228663...
Page 222: Heat Sink Assembly
PARTS Heat sink assembly 65A CSA Item Part number Description 228803 Kit: Powermax65 output diode bridge 228693 Kit: Powermax65 and Powermax85 5 Ω snubber resistor with thermal grease 228704 Kit: Powermax65 inverter IGBT with thermal grease 228742 Kit: Powermax65 CSA/CE, Powermax85 CE input diode bridge with thermal grease 228692 Kit: Powermax65 pilot arc IGBT with thermal grease 228706...
Page 223 PARTS 65A CE Item Part number Description 228803 Kit: Powermax65 output diode bridge 228693 Kit: Powermax65 and Powermax85 5 Ω snubber resistor 228703 Kit: Powermax85 CSA, Powermax65 CE inverter IGBT 228742 Kit: Powermax65 CSA/CE, Powermax85 CE input diode bridge 228692 Kit: Powermax65 pilot arc IGBT 228706 Kit: Powermax65 and Powermax85 15 Ω...
Page 224: 85A Csa
PARTS 85A CSA Item Part number Description 228804 Kit: Powermax85 output diode bridge 228693 Kit: Powermax65 and Powermax85 5 Ω snubber resistor 228703 Kit: Powermax85 CSA, Powermax65 CE inverter IGBT 228741 Kit: Powermax85 CSA input diode bridge 228701 Kit: Powermax85 pilot arc IGBT 228706 Kit: Powermax65 and Powermax85 15 Ω...
Page 225 PARTS 85A CE Item Part number Description 228804 Kit: Powermax85 output diode bridge 228693 Kit: Powermax65 and Powermax85 5 Ω snubber resistor 228702 Kit: Powermax85 CE inverter IGBT 228742 Kit: Powermax85 CSA/CE, Powermax85 CE input diode bridge 228701 Kit: Powermax85 pilot arc IGBT 228706 Kit: Powermax65 and Powermax85 15 Ω...
Page 226: H65/H85 Hand Torch Replacement Parts
PARTS H65/H85 Hand torch replacement parts 7 8 9 The entire hand torch and lead assembly can be replaced, or individual component parts can be replaced. Part numbers starting with 083 and 087 indicate complete torch and lead assemblies. Item Part number Description 083247*...
Page 227: H65S/H85S Hand Torch Replacement Parts
PARTS H65s/H85s Hand torch replacement parts 7 8 9 The entire hand torch and lead assembly can be replaced, or individual component parts can be replaced. Part numbers starting with 083 and 087 indicate complete torch and lead assemblies. Item Part number Description 083251*...
Page 228: Hand Torch Consumables
PARTS Hand torch consumables Part number Description Drag cutting 220818 Shield 220854 Retaining cap 220941 45 A Nozzle 220819 65 A Nozzle 220816 85 A Nozzle 220842 Electrode 220857 Swirl ring Gouging 220798 65 A/85 A shield 220854 Retaining cap 220797 65 A/85 A nozzle 220842...
Page 229: M65/M85 Machine Torch Replacement Parts
PARTS M65/M85 Machine torch replacement parts 9 10 11 12 13 powermax 65/85 Service Manual 7-15...
Page 230 PARTS The entire machine torch and lead assembly can be replaced, or individual component parts can be replaced. Part numbers starting with 083 and 087 indicate complete torch and lead assemblies. Item Part number Description 083254* M65 Machine torch assembly with 15 ft (4.6 m) lead 083255* M65 Machine torch assembly with 25 ft (7.6 m) lead 083256*...
Page 231: M65M/M85M Machine Torch Replacement Parts
PARTS M65m/M85m Machine torch replacement parts Note: This illustration shows the M65/M85 machine torch. The M65m and M85m mini-machine torches do not have a positioning sleeve and gear rack. 7 8 9 10 powermax 65/85 Service Manual 7-17...
Page 232 PARTS The entire machine torch and lead assembly can be replaced, or individual component parts can be replaced. Part numbers starting with 083 and 087 indicate complete torch and lead assemblies. Item Part number Description 083259* M65m Mini-machine torch assembly with 15 ft (4.6 m) lead 083260* M65m Mini-machine torch assembly with 25 ft (7.6 m) lead 083261*...
Page 233: Machine Torch Consumables
PARTS Machine torch consumables Part number Description Shielded 220817 Shield 220854 Retaining cap 220953 Ohmic retaining cap 220941 45 A Nozzle 220819 65 A Nozzle 220816 85 A Nozzle 220842 Electrode 220857 Swirl ring Unshielded 220955 Deflector 220854 Retaining cap 220941 45 A Nozzle 220819...
Page 234: Accessory Parts
PARTS Accessory parts Part number Description 024548 Leather torch sheathing, 25 ft (7.5 m) 127102 Basic plasma (circles and lines) cutting guide 027668 Deluxe plasma (circles and lines) cutting guide 127301 Powermax65 and Powermax85 dust cover 128647 Kit: Eliminizer air filter 228570 Kit: Eliminizer air filter with protective metal cover 228624...
Page 235: Powermax65 And Powermax85 Labels
PARTS Powermax65 and Powermax85 labels Item Part number Description 228649 Kit: Powermax65 labels, CSA 228650 Kit: Powermax65 labels, CE 228651 Kit: Powermax85 labels, CE 228652 Kit: Powermax85 labels, CSA The label kits include the consumable label, appropriate safety labels, display panel label, power switch label, and side decals.
Page 236: Safety-Critical Parts
Genuine Hypertherm parts are the factory-recommended parts for your Hypertherm system. Any damage caused by the use of other than genuine Hypertherm parts may not be covered by the Hypertherm warranty. In addition, the parts listed below are considered safety-critical parts that must be replaced only with Hypertherm parts to maintain the warranty and all system certifications, including CE, CSA, GOST, and CCC certification.
Page 237 PARTS CSA, CE 15 16 3 4 5 6 11 12 13 14 Item Part number Description 228686 Kit: Powermax65 and Powermax85 fan subassembly 228685 Kit: Powermax65 and Powermax85 air filter 228663 Kit: Powermax65 transformer CSA 228669 Kit: Powermax65 transformer CE 228667 Kit: Powermax85 transformer CSA 228654...
Page 238: Recommended Spare Parts
PARTS Recommended spare parts Part number Description 108797 Adjustment knob 108732 Operating mode knob 223125 Kit: 65 A Work lead with hand clamp, 25 ft (7.5 m) 223035 Kit: 85 A Work lead with hand clamp, 25 ft (7.5 m) 228643 Kit: Powermax65 and Powermax85 front panel 228645...
Page 239 PARTS Part number Description 228648 Kit: Powermax65 output inductor 228665 Kit: Powermax85 output inductor 228688 Kit: Powermax65 and Powermax85 pressure switch 228687 Kit: Powermax65 and Powermax85 regulator (solenoid valve) 228686 Kit: Powermax65 and Powermax85 fan subassembly 228685 Kit: Powermax65 and Powermax85 air filter 058519 O-ring: VITON .673 X .063 228717...
Page 240 PARTS Part number Description 228737 Kit: M65/M85 positioning sleeve 228738 Kit: M65/M85 removable gear rack 228735 Kit: M65/M65m/M85/M85m front mounting sleeve 228736 Kit: M65/M65m/M85/M85m adapter ring (coupler) 228720 Kit: Cap-sensor switch replacement 228731 Kit: M65/M65m/M85/M85m torch lead replacement, 25 ft (7.6 m) 228732 Kit: M65/M65m/M85/M85m torch lead replacement, 35 ft (10.7 m) 228733...
Page 241: Cutting Timing Diagram Page 1 Of 2
Section 8 WIRING DIAGRAMS In this section: Cutting timing diagram page 1 of 2..............................8-3 Cutting timing diagram page 2 of 2..............................8-4 Electrical schematic diagram (CSA) ..............................8-5 Electrical schematic diagram (CE) ..............................8-6 powermax 65/85 Service Manual...
Page 242 WIRING DIAGRAMS powermax 65/85 Service Manual...
Page 243 REVISIONS l a i IDLE GAS UP INV ON PILOT PILOT TRANSFER POST FLOW TORCH IDLE (0x0F) (0x10) (0x11) START (0x30) (0x40) (0x60) RESET (0x0F) (0x21) (0x20) (0x70) SEQ_State Assumptions: This diagram represents most but not all possible State SEQ_Timer transitions.
Page 244 REVISIONS l a i PILOT TRANSFER PILOT (0x40) (0x30) (0x40) (0x21) SEQ_State (0x22) SEQ_Timer >=16383 Digitized EA Digitized XFR Pilot Arc Switch KNOB KNOB pilot_current_set + I_TRANSFER 2A/ms I_PILOT_HIGH_DELTA Command pilot_current_set pilot_current_set + I_PILOT_HIGH_DELTA Pilot pilot_current_set KNOB 2A/ms 1.6A 0.4A Work Lead Voltage P.O.Box 5010...
Page 245 FOR MANUFACTURING OR FABRICATION ANGULAR ±2° DRAWN BY DATE APPROVED BY DATE PURPOSES WITHOUT PERMISSION PART MUST BE FREE OF BURRS AND SHARP EDGES. BREAK SHARP EDGES IF NECESSARY FROM HYPERTHERM, INC. 05-03-10 05-04-10 WITH CHAMFER OR RADIUS .015 MAX.
Page 246 ANGULAR ±2° FOR MANUFACTURING OR FABRICATION PURPOSES WITHOUT PERMISSION PART MUST BE FREE OF BURRS AND SHARP DRAWN BY DATE APPROVED BY DATE FROM HYPERTHERM, INC. EDGES. BREAK SHARP EDGES IF NECESSARY 05-03-10 05-04-10 WITH CHAMFER OR RADIUS .015 MAX.

This manual is also suitable for:

Powermax 65

Hypertherm Powermax 85 Service Manual

Section 1

Specifications

Section 2

Power Supply Setup

Section 3

Torch Setup

Section 4

Operation

Section 5

Troubleshooting and System Tests

Table of Contents

Section 6

Component Replacement

Parts

Section 7

Wiring Diagrams

Section 8

Quick Links

Troubleshooting

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Summary of Contents for Hypertherm Powermax 85