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Powermax105
Hypertherm Powermax105 Manuals
Manuals and User Guides for Hypertherm Powermax105. We have
12
Hypertherm Powermax105 manuals available for free PDF download: Troubleshooting Manual, Operator's Manual, Reference Manual, Cutting Manual, Field Service Bulletin, Manual
Hypertherm Powermax105 Operator's Manual (166 pages)
Brand:
Hypertherm
| Category:
Welding System
| Size: 12.11 MB
Table of Contents
Assessment of Area
5
Patent Indemnity
7
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 (105 a Systems)
21
Powermax105 Power Supply Ratings
22
Duramax 75° Hand Torch Dimensions
24
Duramax 15° Hand Torch Dimensions
24
Duramax 180° Full-Length Machine Torch Dimensions
25
Duramax 180° Mini Machine Torch Dimensions
25
Powermax105 Cutting Specifications
26
Symbols and Marks
27
Noise Levels
28
IEC Symbols
28
Section 2
29
Power Supply Setup
29
Unpack the Powermax System
30
Claims
30
Contents
31
Position the Power Supply
32
Prepare the Electrical Power
32
Install a Line-Disconnect Switch
33
Requirements for Grounding
33
Power Connection for the Powermax105
34
Three-Phase Power Cord and Plug Installation
36
Extension Cord Recommendations
37
Extension Cord Specifications
37
Engine-Driven Generator Recommendations
38
Prepare the Gas Supply
39
Additional Gas Filtration
39
Connect the Gas Supply
40
Section 3
44
Basic System Operations
44
Controls and Indicators
44
Rear Controls
44
Front Controls and Leds
44
Status Screen
46
Remote Control
46
Operating the Powermax105
48
Connect the Electrical Power, Gas Supply, and Torch Lead
48
Attach the Work Lead to the Power Supply
49
Attach the Work Clamp to the Workpiece
50
Turn on the System
51
Set the Operating Mode Switch
51
Check the Indicators
52
Manually Adjusting the Gas Pressure
52
Adjusting the Current (Amperage)
53
Electrode End-Of-Life Detection Feature
53
Understanding Duty-Cycle Limitations
54
Section 4
55
Hand Torch Setup
55
Introduction
56
Consumable Life
56
Copperplus™ Electrode for Duramax Torches
56
Hand Torch Components
57
Choose the Hand Torch Consumables
58
Hand Torch Consumables
58
Drag-Cutting 105 a Consumables
58
Drag-Cutting 45 A, 65 A, 85 a Consumables
58
Gouging Consumables
59
Finecut ® Consumables
59
Hyaccess 65 a Consumables
59
Install the Hand Torch Consumables
60
Connecting the Torch Lead
61
Section 5
63
Hand Cutting
63
Using the Hand Torch
64
Operate the Safety Trigger
64
Hand Torch Cutting Hints
65
Start a Cut from the Edge of the Workpiece
66
Pierce a Workpiece
67
Gouge a Workpiece
68
Gouge Profile
69
Varying the Gouge Profile
70
Common Hand-Cutting Faults
70
Section 6
73
Machine Torch Setup
73
Introduction
73
Consumable Life
73
Copperplus™ Electrode for Duramax Torches
73
Machine Torch Components
74
Converting a Full-Length Machine Torch to a Mini Machine Torch
75
Mount the Torch
77
Choose the Machine Torch Consumables
79
Machine Torch Consumables
79
Mechanized Shielded 105 a Consumables
79
Mechanized Shielded 45 A, 65 A, 85 a Consumables
79
Mechanized Shielded with Ohmic 105 a Consumables
80
Mechanized Shielded with Ohmic 45 A, 65 A, 85 a Consumables
80
Mechanized Unshielded 105 a Consumables
80
Mechanized Unshielded 45 A, 65 A, 85 a Consumables
80
Gouging Consumables
81
Install the Machine Torch Consumables
82
Aligning the Torch
82
Connecting the Torch Lead
83
Using the Cut Charts
84
Estimated Kerf-Width Compensation
85
Shielded Consumables
87
Shielded Cutting (Mild Steel)
88
Shielded Cutting (Stainless Steel)
89
Shielded Cutting (Aluminum)
90
Shielded Consumables
91
Shielded Cutting (Mild Steel)
92
Shielded Cutting (Stainless Steel)
93
Shielded Cutting (Aluminum)
94
Shielded Consumables
95
A Shielded Cutting (Stainless Steel)
97
A Shielded Cutting (Aluminum)
98
Shielded Consumables
99
A Shielded Cutting (Mild Steel)
100
A Shielded Cutting (Stainless Steel)
101
Finecut ® Consumables
103
Finecut (Mild Steel)
103
Finecut (Stainless Steel)
105
Low Speed Finecut (Mild Steel)
106
Low Speed Finecut (Stainless Steel)
107
Unshielded Consumables
108
Unshielded Cutting (Mild Steel)
109
Unshielded Cutting (Stainless Steel)
110
Unshielded Cutting (Aluminum)
111
Unshielded Consumables
112
A Unshielded Cutting (Mild Steel)
113
Unshielded Consumables
116
A Unshielded Cutting (Mild Steel)
117
Unshielded Consumables
120
A Unshielded Cutting (Mild Steel)
121
Section 7
125
Mechanized Cutting
125
Connecting an Optional Remote-Start Pendant
126
Connecting an Optional Machine Interface Cable
127
Page 7-6 Setting the Five-Position Voltage Divider
127
Machine Interface Pinout
129
Setting the Five-Position Voltage Divider
130
Accessing Raw Arc Voltage
131
Connecting an Optional RS485 Serial Interface Cable
131
Using the Machine Torch
132
Setting up the Torch and Table
132
Understand and Optimize Cut Quality
132
Cut or Bevel Angle
132
Dross
133
Piercing a Workpiece Using the Machine Torch
134
Common Machine-Cutting Faults
135
Section 8
137
Maintenance and Repair
137
Perform Routine Maintenance
138
Electric Shock Can Kill
138
Inspect the Consumables
139
Basic Troubleshooting
140
Fault Codes and Solutions
142
Replace the Air Filter Element and Air Filter Bowl
146
Parts
152
Section 9
152
Power Supply Parts
152
Duramax 75° Hand Torch Replacement Parts
156
Duramax 15° Hand Torch Replacement Parts
157
Hand Torch Consumables
158
Duramax 180° Full-Length Machine Torch Replacement Parts
159
Duramax 180° Mini Machine Torch Replacement Parts
161
Machine Torch Consumables
163
Accessory Parts
164
Powermax105 Labels
165
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Hypertherm Powermax105 Troubleshooting Manual (180 pages)
Brand:
Hypertherm
| Category:
Welding System
| Size: 17.72 MB
Table of Contents
Table of Contents
5
Before You Begin
11
Prepare to Troubleshoot Internal Components
13
Troubleshooting Procedures and Sequence
15
Get the Necessary Test Equipment
16
Troubleshooting Checklist
17
Do an Internal Inspection
21
Frequently Used Troubleshooting Procedures
22
Do a Cold Restart or Quick Restart
22
Do a Cold Restart
22
Do a Quick Restart
22
Examine the Gas Pressure
23
Examine the Gas Quality
24
Do a Check for Continuity
25
Do a Gas Test
26
Start and Stop a Gas Test in Automatic Gas Pressure Mode
26
Do a Gas Test in Manual Gas Pressure Mode
27
Do an Initial Resistance Check
28
Examine the Power Switch
28
Hypertherm IGBT Tester
32
Indicator Leds and Device Tests
33
IGBT Test Preparation
33
IGBT Device Test for the Hypertherm Tester
35
Troubleshooting Steps for the Hypertherm IGBT Tester
35
IGBT Device Test for a Non-Hypertherm Tester
36
Schematic to Build an IGBT Tester
38
Troubleshooting for Fault Codes
39
Fault Codes and Solutions
39
Identify Fault Icons
41
Remove Fault Code Conditions
42
Operational Faults (0-Nn-N)
42
Internal Component Faults (1-Nn-N, 2-Nn-N, 3-Nn-N)
57
Generator Considerations
62
Troubleshooting for Common Problems
63
Problems with System Performance
64
Common Cutting and Gouging Problems
72
Hand Cutting Problems
72
Hand Gouging Problems
74
Do System Tests to Identify Defective Components
75
Important Information before You Do These System Tests
75
System Tests in this Section
76
How to Attach to Ground
76
How to Get Voltage Measurements for Internal Components
77
Test 1 - Voltage Input
78
Examine the Incoming Power
78
Examine the Power Switch and the Plasma Power Supply
80
Test 2 - DC Power Bus
83
Measure the Voltage
83
Measure the Resistance
87
Test 3 - Output Diodes
90
Test 4 - Inverter Thermal Sensor and PFC Temperature Sensor
91
Identify the Fault Code
91
Procedure for Fault Codes 0-40-0, 0-40-1, 3-11-0, or 3-11-1
91
Procedure for Fault Codes 0-40-2, 0-40-3, 2-10-0, or 2-10-1
92
Test 5 - Flyback Circuit (DC Minor Voltages)
94
Test 6 - Torch Stuck Open (TSO) or Torch Stuck Closed (TSC)
98
Examine the Torch
98
Examine the Plasma Power Supply
99
Measure the Resistance at Idle and with Gas Flowing
99
Measure the Resistance with the Power off
100
Do a Check of the Pilot Arc IGBT
101
Test 7 - Start Signal
102
Test 7 - Procedure for a Hand Torch
102
Test 7 - Procedure for a Machine Torch
105
Examine the CNC and the Machine Interface Cable
105
Examine the Plasma Power Supply
106
Test 8 - Torch Cap Switch
108
Examine the Torch and Torch Lead
108
Examine the Plasma Power Supply
110
Test 9 - Solenoid Valve Electronic Regulator
112
Do a Test of the Solenoid Valve with the Gas Supply Disconnected
112
Do a Test of the Solenoid Valve after Disconnecting from the Power PCB
114
Test 10 - Solenoid Valve Pressure Sensor
115
Do a Check for Electrical Interference and Pinched Wires
115
Examine the Power Input and Solenoid Valve Coils
115
Examine the Solenoid Valve Sensor and Power PCB Sensor Input
118
Test 11 - Fan
120
Test 12 - Auxiliary (AUX) Switch
123
Test 13 - Pilot Arc IGBT
125
Test 14 - Radio Frequency (RF) Communication Errors
126
0-98-1 Fault: Cartridge or Torch
126
0-98-2 Fault: Torch or Plasma Power Supply
127
Do a Test of the Plasma Power Supply
127
Do a Test of the Torch
128
Access Service Information and Settings
133
View Current System Status
133
Go to the Main Menu Screen
135
View System Performance, Operation, and Fault Data
136
Cartridge Performance and Fault Data
136
Plasma Power Supply Performance and Operation Data
138
Cumulative Cartridge Data for the Plasma Power Supply
140
View Printed Circuit Board (PCB) and Firmware Information
142
Lcd/Control PCB Information
142
DSP PCB and Power PCB Information
143
Torch PCB Information
144
View Internal Component Faults and Radio Frequency Logs
145
Internal Component Faults
145
Radio Frequency (RF) Settings and Operation Logs
146
Cut Counter Data for Backups
147
View or Change System Settings
148
LCD Display Brightness and Contrast
148
Show Cartridge Data on the Status Screen
149
Serial Communications Parameters
150
Default Feature Configuration
153
Smart Mode Versus Basic Mode
155
Smart Mode
155
Basic Mode
155
Set System Settings to Factory Default
156
How the Plasma Power Supply Operates
157
Sequence of Operation
158
Powermax65/85 SYNC Plasma Power Supply Overviews
159
Powermax105 SYNC Plasma Power Supply Overviews
163
Theory of Operation
169
Powermax65/85 SYNC
169
200 V - 600 V CSA 1-Phase or 3-Phase Functional Description
169
380 V CCC / 400 V CE 3-Phase Functional Description
169
Powermax105 SYNC
170
200 V - 600 V CSA 3-Phase Functional Description
170
230 V - 400 V CE 3-Phase Functional Description
170
380 V CCC / 400 V CE 3-Phase Functional Description
171
System Diagrams
173
Powermax65/85 SYNC Schematic - CSA Models
175
Powermax65/85 SYNC Schematic - CE/CCC Models
176
Powermax105 SYNC Schematic - CSA Models and 230 V - 400 V CE Models
177
Powermax105 SYNC Schematic - 380 V CCC Models and 400 V CE Models
178
Timing Chart for Torch Start
179
Hypertherm Powermax105 Reference Manual (79 pages)
Serial Communication Programmer
Brand:
Hypertherm
| Category:
Motherboard
| Size: 1 MB
Table of Contents
Table of Contents
3
Getting Started
7
Hardware Requirements
7
Powermax65/85/105 SYNC Hardware Documents
8
Modbus Specifications
8
Transmission Mode and Format
8
Modbus Request and Response Message Frame Format
9
Error Response Message Frame Format
10
Example Request and Response Message
10
How to Calculate a Checksum (LRC)
12
CNC Settings on the Powermax65/85/105 SYNC
12
Powermax65/85/105 SYNC Modbus Addressing System
15
Backward Compatible with 0X2Xxx Series
15
List of Powermax65/85/105 SYNC Addresses
16
Programming Recommendations
19
Examples of Requests and Responses
20
Identify the Plasma Power Supply Type (SYNC or Older System)
20
Example Request and Response
20
Read the ID of the SYNC Torch, Torch Lead, and Plasma Power Supply
21
0X3000 (Torch and Plasma Power Supply Identification)
21
Example Request and Response
22
Read the Part Number of the Installed Cartridge
23
0X3038, 0X3039, 0X303A (Cartridge Part Number, Bytes 0 - 5)
23
Example Request and Response
25
Read the Plasma Power Supply Settings that Are Permitted for the Installed Cartridge
26
0X3001 (Permitted Operating Mode Setting)
26
0X3002, 0X3003 (Permitted Minimum and Maximum Output Current (A) Settings)
26
0X3004, 0X3005 (Permitted Minimum and Maximum Gas Pressure Settings)
26
Example Request and Response
27
Write Operating Settings and Put the Plasma Power Supply into Remote Control Mode
28
0X3080 (Operating Mode Setting)
28
0X3081 (Output Current (A) Setting)
28
0X3082 (Gas Pressure Setting)
29
Example Request and Response
29
Remote Control Mode Indicator on the Plasma Power Supply
30
Do a Check for an Active Fault
30
0X301A (Active Fault Code)
30
Example Request and Response
31
Fault Code List
32
Start and Stop a Gas Test
36
0X3180 (Coil: Gas Test)
36
Example Request and Response
37
Do a Quick Restart or Clear Fault Code 0-50-0
38
0X308E, 0X308F (Quick Restart with Approval)
38
Example Request and Response
39
Exit Remote Control Mode
40
Example Request and Response
40
Get Data from the Plasma Power Supply
41
Read the Plasma Power Supply Settings
41
0X3010 (Operating Mode)
41
0X3011 (Output Current (A) Setting)
41
0X3012 (Gas Pressure Setting)
42
Example Request and Response
42
Read the Actual Output of the Plasma Power Supply
43
0X3018 (Actual Output Current)
43
0X3019 (Actual Gas Pressure)
43
Example Request and Response
43
Read the Total Cut Counts for this Plasma Power Supply
44
0X3028 (Total Number of Torch Starts - Bytes 1 and 0)
44
0X3029 (Total Number of Starts - Bytes 3 and 2)
45
0X302A (Cumulative Pilot Arc Time - Bytes 1 and 0)
45
0X302B (Cumulative Pilot Arc Time - Bytes 3 and 2)
45
0X302C (Total Number of Arc Transfers - Bytes 1 and 0)
45
0X302D (Total Number of Arc Transfers - Bytes 3 and 2)
46
0X302E (Cumulative Arc Transfer Time - Bytes 1 and 0)
46
0X302F (Cumulative Arc Transfer Time - Bytes 3 and 2)
46
Example Request and Response
47
Read the 16-Character UID Number for the Installed Cartridge
48
0X3030 - 0X3037 (Cartridge UID, Bytes 0 - 15)
48
Example Request and Response
49
Read the Total Cut Counts for the Installed Cartridge
50
0X3040 (Total Number of Starts)
50
0X3041 (Cumulative Pilot Arc Time)
50
0X3042 (Total Number of Arc Transfers)
50
0X3043 (Cumulative Arc Transfer Time)
51
Example Request and Response
51
Read the 4 most Recent Faults for the Installed Cartridge
52
0X3044 (Fault Log 0)
52
0X3045 (Fault Log 1)
53
0X3046 (Fault Log 2)
53
0X3047 (Fault Log 3)
53
Example Request and Response
54
Read the Name of the Installed Cartridge
55
0X3048 - 0X304D (Cartridge Name, Bytes 0 - 11)
55
Example Request and Response
56
Read the Start and Motion Signal Status of the Plasma Power Supply
57
0X3100 (Coil: Start Switch Signal Status)
57
0X3101 (Coil: Motion Switch Signal Status)
57
Example Request and Response
58
Flowchart Examples
61
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Hypertherm Powermax105 Cutting Manual (76 pages)
Brand:
Hypertherm
| Category:
Flashlight
| Size: 5.74 MB
Table of Contents
Table of Contents
9
Before You Begin
13
Set up the Machine Torch
15
About the Machine Torch
15
Machine Torch Components, Dimensions, Weights
16
Components
16
Full-Length Machine Torch
16
Mini Machine Torch
17
Dimensions
17
Full-Length Machine Torch
17
Mini Machine Torch
18
Weights
18
Attach the Torch to Your Equipment
19
Minimum Bend Radius for Torch Lead
19
Remove the Gear Rack (Optional)
20
Align the Torch
20
Configure Controls for Mechanized Cutting
21
Connect a Remote-Start Pendant (Optional)
24
Connect a Machine Interface Cable (Optional)
25
Machine Interface Cables that Use the Internal Voltage Divider PCB
26
Cable Signals
27
Machine Interface Cables that Use an External Voltage Divider
27
Cable Signals
28
Access Raw Arc Voltage (Optional)
29
Machine Interface Cables for Tables with a 21.1:1 Voltage Ratio
30
Cable Signals
31
Install the Machine Interface Cable
31
Machine Interface Receptacle Sockets
32
Machine Interface Signals
33
Set the 5-Position Voltage Divider PCB
34
Connect an RS-485 Serial Interface Cable (Optional)
35
Install the RS-485 Serial Interface Cable
36
RS-485 Serial Interface Signals for Connecting to a CNC
38
RS-485 Serial Interface Signals for Troubleshooting
39
Set the Parameters on the CNC Interface Settings Screen
40
Remote Mode Indicator
41
More Information about Serial Communication Setup
42
Cut with the Machine Torch
43
Select the Cartridge
44
Use a Flushcut Specialty Cartridge
46
Get the most out of Your Cartridges
47
Signs that a Cartridge Is Near End-Of-Life
48
Show Cartridge Data on the Status Screen
49
Prepare to Fire the Torch
51
Remote Mode Indicator
53
Understand and Optimize Cut Quality
53
What Is Good Cut Quality
53
What Is a Cut Chart
54
Cutting and Piercing Guidelines
54
Cutting Guidelines
54
Piercing Guidelines
55
Understand Torch Height Control for Plasma Cutting
56
Torch Height During the Cut Cycle
57
Ohmic Contact for Initial Height Sensing
57
Learn more
58
Cut Stainless Steel with F5
59
Gouge with the Machine Torch
61
Gouging Processes
61
Change the Gouge Contour
62
Common Mechanized System Problems
65
Cutting System Problems
66
Cut Quality Problems
67
Cut Angle (Bevel)
68
Find the Cause of a Cut-Angle Problem
69
Dross
70
Gouging Problems
71
EMI Grounding and Shielding Best Practices
72
Types of Grounding and Shielding
72
Grounding and Shielding Best Practices
72
Example Grounding Diagram
75
Hypertherm Powermax105 Field Service Bulletin (40 pages)
Machine Interface Receptacle with Voltage Divider PCB
Brand:
Hypertherm
| Category:
Welding System
| Size: 5.57 MB
Hypertherm Powermax105 Field Service Bulletin (34 pages)
Power Cord and Strain Relief Replacement
Brand:
Hypertherm
| Category:
Welding System
| Size: 7.19 MB
Table of Contents
Tools and Materials Needed
3
Kit Contents
4
Remove the Power Cord
11
Install the Power Cord
14
Connect to Electrical Power
18
Outils Et Matériel Requis
19
Contenu du Kit
20
Hypertherm Powermax105 Field Service Bulletin (36 pages)
Machine Interface Receptacle with Voltage Divider PCB
Brand:
Hypertherm
| Category:
Welding System
| Size: 3.92 MB
Hypertherm Powermax105 Field Service Bulletin (28 pages)
Machine Interface for Raw Arc Voltage
Brand:
Hypertherm
| Category:
Welding System
| Size: 2.46 MB
Table of Contents
Materials and Tools
3
Kit Contents
3
Remove the Power Supply Cover and Component Barrier
4
Accessing Raw Arc Voltage
5
Replace the Component Barrier
12
Replace the Power Supply Cover
13
Hypertherm Powermax105 Field Service Bulletin (17 pages)
Cutters Machine Interface Cable Kit
Brand:
Hypertherm
| Category:
Welding System
| Size: 0.8 MB
Table of Contents
Materials and Tools
3
About the Powermax45 Voltage Divider
4
About the Powermax65/85 Voltage Divider
4
Connect the Machine Interface Cable
6
Remplacement du Câble D'interface
9
À Propos du Diviseur de Tension du Powermax45
10
Raccordement du Câble D'interface de Machine
12
Hypertherm Powermax105 Manual (14 pages)
Optional Oil Removal Air Filter Kit and Element Replacement
Brand:
Hypertherm
| Category:
Cutter
| Size: 0.43 MB
Table of Contents
Optional Air Filters
3
Tools and Materials Needed
4
Accessories (Not Included)
5
Outils Et Matériel Requis
10
Hypertherm Powermax105 Field Service Bulletin (16 pages)
Machine Interface Cable Kit
Brand:
Hypertherm
| Category:
Recording Equipment
| Size: 0.94 MB
Hypertherm Powermax105 Field Service Bulletin (12 pages)
Wheel Kit Operation
Brand:
Hypertherm
| Category:
Welding System
| Size: 1.06 MB
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