Hypertherm Powermax 65 Manuals

Manuals and User Guides for Hypertherm Powermax 65. We have 6 Hypertherm Powermax 65 manuals available for free PDF download: Service Manual, Operator's Manual, Field Service Bulletin, User Manual

Hypertherm Powermax 65 / 85 / 105 / 125 / 65 SYNC / 85 SYNC / 105 SYNC Manual

Brand: Hypertherm | Category: Welding System | Size: 0 MB

Hypertherm Powermax 65 Service Manual (248 pages)

Plasma arc cutting systems

Brand: Hypertherm | Category: Welding System | Size: 23 MB

Assessment of Area
5
Mains Supply
5
Electromagnetic Compatibility
6
Maintenance of Cutting Equipment
6
Patent Indemnity
8
Safety Information
9
Table of Contents
11
Section 1

17
Specifications

17
Section 2

33
Power Supply Setup

33
Torch Setup

50
Section 3

50
Section 4

103
Operation

103
- Controls and Indicators
  104
  - Rear Controls
    104
  - Front Controls and Leds
    104
  - Status Screen
    106
- Operating the Powermax65 or Powermax85
  108
- Using the Hand Torch
  115
  - Operate the Safety Trigger
    115
  - Hand Torch Cutting Hints
    116
  - Start a Cut from the Edge of the Workpiece
    117
  - Pierce a Workpiece
    118
  - Gouge a Workpiece
    119
  - Common Hand-Cutting Faults
    122
- Using the Machine Torch
  123
Section 5

127
Troubleshooting and System Tests

127
- Controls and Indicators
  129
- Theory of Operation
  130
- Troubleshooting Preparation
  133
  - Test Equipment
    133
  - Troubleshooting Procedures and Sequence
    133
  - External Inspection
    135
  - Internal Inspection
    135
- Initial Resistance Check
  135
- 200 - 600 V CSA Power Supply Overview
  143
- 380/400 V CE Power Supply Overview
  144
- CSA Power Supply Overview (Power Board Removed)
  145
- 380/400 V CE Power Supply Overview (Power Board Removed)
  146
Table of Contents

147
- Fault Codes
  147
  - Displaying the Service Screen
    147
  - Important Fault Icons
    148
  - Performing a Cold Restart
    148
  - Fault Codes and Solutions
    149
- Troubleshooting Guide
  158
- System Tests
  164
  - Test 1 - Voltage Input
    165
  - Test 2 - DC Power Buss
    166
  - Test 3 - Output Diodes
    168
  - Test 4 - Inverter and PFC Temperature Sensor
    169
  - Test 5 - Flyback Circuit (DC Minor Voltages)
    172
  - Test 6 - Torch Stuck Open (TSO)
    174
  - Test 7 - Start Signal
    176
  - Test 8 - Torch Cap Switch
    177
  - Test 9 - Electronic Regulator
    178
  - Test 10 - Pressure Sensor
    179
  - Test 11 - Fan
    180
  - Test 12 - AUX Switch
    181
Section 6

183
Component Replacement

183
- Remove and Replace the Power Supply Cover and Mylar ® Barrier
  184
  - Barrier
    184
  - Remove the Power Supply Cover and Mylar Barrier
    184
  - Replace the Mylar Barrier
    185
  - Replace the Power Supply Cover
    186
- Replace the Power Cord
  187
  - Replace the Power Cord (200 - 600 V 3-Phase CSA, 400 V 3-Phase CE)
    187
  - Replace the Power Cord (200 - 480 V 1-Phase CSA)
    192
- Replace the Work Lead
  193
- Replace the Fan
  194
- Replace the Air Filter Element
  196
- Replace the Air Filter Subassembly
  197
- Replace the Power Board
  199
- Replace the Control Board
  209
- Replace the Heat Sink Components
  211
  - 65A Csa
    212
  - 85A Csa
    214
Parts

218
Section 7

218
- Power Supply Parts
  218
  - Exterior Front
    218
  - Exterior Rear
    219
  - Interior, Power Board Side (200 - 600V CSA)
    220
  - Interior, Power Board Side (380/400V CE)
    221
  - Interior, Fan Side
    222
- Heat Sink Assembly
  224
  - 65A Csa
    224
  - 85A Csa
    226
- Duramax 75° Hand Torch Replacement Parts
  228
- Duramax 15° Hand Torch Replacement Parts
  229
- Hand Torch Consumables
  230
- Duramax 180° Full-Length Machine Torch Replacement Parts
  231
- Duramax 180° Mini Machine Torch Replacement Parts
  233
- Machine Torch Consumables
  235
- Accessory Parts
  236
- Powermax65 and Powermax85 Labels
  237
- Safety-Critical Parts
  238
- Recommended Spare Parts
  240
Section 8

243
Wiring Diagrams

243

Hypertherm Powermax 65 Service Manual (246 pages)

Plasma arc cutting systems

Brand: Hypertherm | Category: Welding System | Size: 23 MB

Assessment of Area
5
Maintenance of Cutting Equipment
6
Patent Indemnity
8
Table of Contents
11
Section 1

18
Specifications

18
- Safety Information
  18
- System Description
  18
- Where to Find Information
  19
- Power Supply Dimensions
  20
- Component Weights
  21
- Powermax65 Power Supply Ratings
  22
- Powermax85 Power Supply Ratings
  24
- H65/H85 75° Hand Torch Dimensions
  26
- H65S/H85S 15° Hand Torch Dimensions
  26
- M65/M85 Full-Length Machine Torch Dimensions
  27
- M65M/M85M Mini-Machine Torch Dimensions
  27
- Powermax65 Cutting Specifications
  28
- Powermax85 Cutting Specifications
  29
- Symbols and Markings
  30
- IEC Symbols
  31
Section 2

33
Power Supply Setup

33
Section 3

50
Torch Setup

50
- Introduction
  50
- Consumable Life
  50
- Hand Torch Setup
  51
- Machine Torch Setup
  55
- Connecting the Torch Lead
  70
- Using the Cut Charts
  71
  - Estimated Kerf-Width Compensation
    72
  - 85 A Shielded Consumables
    74
  - 65 A Shielded Consumables
    78
  - 45 A Shielded Consumables
    82
  - Finecut ® Consumables
    86
  - 85 A Unshielded Consumables
    89
  - 65 A Unshielded Consumables
    93
  - 45 A Unshielded Consumables
    97
Section 4

101
Operation

101
- Controls and Indicators
  102
  - Rear Controls
    102
  - Front Controls and Leds
    102
  - Status Screen
    104
- Operating the Powermax65 or Powermax85
  106
- Using the Hand Torch
  113
  - Operate the Safety Trigger
    113
  - Hand Torch Cutting Hints
    114
  - Start a Cut from the Edge of the Workpiece
    115
  - Pierce a Workpiece
    116
  - Gouge a Workpiece
    117
  - Common Hand-Cutting Faults
    120
- Using the Machine Torch
  121
Section 5

125
Troubleshooting and System Tests

125
- Controls and Indicators
  127
- Theory of Operation
  128
- Troubleshooting Preparation
  131
  - Test Equipment
    131
  - Troubleshooting Procedures and Sequence
    131
  - External Inspection
    133
  - Internal Inspection
    133
- Initial Resistance Check
  133
- 200-600V CSA Power Supply Overview
  141
- 380/400V CE Power Supply Overview
  142
- 200-600V CSA Power Supply Overview (Power Board Removed)
  143
- 380/400V CE Power Supply Overview (Power Board Removed)
  144
Table of Contents

145
- Fault Codes
  145
  - Displaying the Service Screen
    145
  - Important Fault Icons
    146
  - Performing a Cold Restart
    146
  - Fault Codes and Solutions
    147
- Troubleshooting Guide
  156
- System Tests
  162
  - Test 1 - Voltage Input
    163
  - Test 2 - DC Power Buss
    164
  - Test 3 - Output Diodes
    166
  - Test 4 - Inverter and PFC Temperature Sensor
    167
  - Test 5 - Flyback Circuit (DC Minor Voltages)
    170
  - Test 6 - Torch Stuck Open (TSO)
    172
  - Test 7 - Start Signal
    174
  - Test 8 - Torch Cap Switch
    175
  - Test 9 - Electronic Regulator
    176
  - Test 10 - Pressure Sensor
    177
  - Test 11 - Fan
    178
  - Test 12 - AUX Switch
    179
Section 6

181
Component Replacement

181
- Remove and Replace the Power Supply Cover and Mylar® Barrier
  182
- Replace the Power Cord
  185
  - Replace the Power Cord (200 - 600 V 3-Phase CSA, 400 V 3-Phase CE)
    185
  - Replace the Power Cord (200 - 480 V 1-Phase CSA)
    190
- Replace the Work Lead
  191
- Replace the Fan
  192
- Replace the Air Filter Element
  194
- Replace the Air Filter Subassembly
  195
- Replace the Power Board
  197
- Replace the Control Board
  207
- Replace the Heat Sink Components
  209
  - 65A Csa
    210
  - 85A Csa
    212
Parts

216
Section 7

216
- Power Supply Parts
  216
  - Exterior Front
    216
  - Exterior Rear
    217
  - Interior, Power Board Side (200-600V CSA)
    218
  - Interior, Power Board Side (380/400V CE)
    219
  - Interior, Fan Side
    220
- Heat Sink Assembly
  222
  - 65A Csa
    222
  - 85A Csa
    224
- H65/H85 Hand Torch Replacement Parts
  226
- H65S/H85S Hand Torch Replacement Parts
  227
- Hand Torch Consumables
  228
- M65/M85 Machine Torch Replacement Parts
  229
- M65M/M85M Machine Torch Replacement Parts
  231
- Machine Torch Consumables
  233
- Accessory Parts
  234
- Powermax65 and Powermax85 Labels
  235
- Safety-Critical Parts
  236
- Recommended Spare Parts
  238
Wiring Diagrams

241
Section 8

241
- Cutting Timing Diagram Page 1 of 2
  241

Hypertherm Powermax 65 Operator's Manual (156 pages)

Plasma arc cutting systems

Brand: Hypertherm | Category: Welding System | Size: 12 MB

Assessment of Area
5
Mains Supply
5
Patent Indemnity
9
Table of Contents
11
Section 1

16
Specifications

16
Section 2

31
Power Supply Setup

31
Section 3

47
Torch Setup

47
- Introduction
  49
- Consumable Life
  49
- Hand Torch Setup
  50
- Machine Torch Setup
  54
- Connecting the Torch Lead
  70
- Using the Cut Charts
  71
  - Estimated Kerf-Width Compensation
    72
  - 85 A Shielded Consumables
    74
  - 65 A Shielded Consumables
    78
    
    Metric Table
    79
    
    English Table
    79
  - 45 A Shielded Consumables
    82
  - Finecut ® Consumables
    86
  - 85 A Unshielded Consumables
    89
  - 65 A Unshielded Consumables
    93
  - 45 A Unshielded Consumables
    97
Section 4

101
Operation

101
- Controls and Indicators
  103
  - Rear Controls
    103
  - Front Controls and Leds
    103
  - Status Screen
    106
    
    Remote Control
    107
    
    Fault Codes
    107
- Operating the Powermax65 or Powermax85
  109
- Using the Hand Torch
  116
  - Operate the Safety Trigger
    116
  - Hand Torch Cutting Hints
    117
  - Start a Cut from the Edge of the Workpiece
    118
  - Pierce a Workpiece
    119
  - Gouge a Workpiece
    120
  - Common Hand-Cutting Faults
    123
- Using the Machine Torch
  124
Section 5

129
Maintenance and Repair

129
- Perform Routine Maintenance
  130
- Inspect the Consumables
  131
- Basic Troubleshooting
  132
- Fault Codes and Solutions
  134
- Replace the Gas Filter Element
  138
Parts

142
Section 6

142
- Power Supply Parts
  142
- Hand Torch Replacement Parts
  145
  - H65/H85
    145
  - H65S/H85S
    145
  - Hand Torch Consumables
    148
- Machine Torch Replacement Parts
  149
  - M65/M85/M65M/M85M
    149
  - Machine Torch Consumables
    152
- Accessory Parts
  154
  - Powermax65/85 Labels
    155

Hypertherm Powermax 65 Field Service Bulletin (16 pages)

Digital Signal Processor (DSP) Board Replacement

Brand: Hypertherm | Category: Welding System | Size: 1 MB

Hypertherm Powermax 65 Field Service Bulletin (13 pages)

Wheel Kit Operation

Brand: Hypertherm | Category: Welding System | Size: 1 MB

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Hypertherm Powermax 65 Manuals

Hypertherm Powermax 65 / 85 / 105 / 125 / 65 SYNC / 85 SYNC / 105 SYNC Manual

Table of Contents

Hypertherm Powermax 65 Service Manual (248 pages)

Table of Contents

Section 1

Specifications

Section 2

Power Supply Setup

Torch Setup

Section 3

Section 4

Operation

Section 5

Troubleshooting and System Tests

Table of Contents

Section 6

Component Replacement

Parts

Section 7

Section 8

Wiring Diagrams

Hypertherm Powermax 65 Service Manual (246 pages)

Table of Contents

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

Hypertherm Powermax 65 Operator's Manual (156 pages)

Table of Contents

Section 1

Specifications

Section 2

Power Supply Setup

Section 3

Torch Setup

Section 4

Operation

Section 5

Maintenance and Repair

Parts

Section 6

Hypertherm Powermax 65 Field Service Bulletin (16 pages)

Table of Contents

Hypertherm Powermax 65 Field Service Bulletin (13 pages)

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