Hypertherm Powermax 105a Plasma Arc Cutting System Operator Manual

Powermax105

Operator Manual

807580 
Revision 0

English

Contents

Section 1
Specifications
Safety information
System description
Where to find information
Power supply dimensions
Component weights(105 A systems)
Powermax 105 power power supply ratings
Duramax 75º hand torch dimensions
Duramax 15º hand torch dimensions
Duramax 180º full-length machine torch dimensions
Duramax 180º mini machine torch dimensions
Powermax 105 cutting specifications
Symbols and markings
Noise levels 
IEC symbols
Section 2
Power supply setup
Unpack the powermax system

Claims

Contents

Position the power supply
Prepare the electrical power

Install a line-disconnect switch

Requirements for grounding

Power connection for the Powermax 105

Three-phase power cord and plug installation

Extension cord recommendations

Extension cord specifications

Engine-driven generator recommendations

Prepare the gas supply

Additional gas filtration

Connect the gas supply

Section 3
Basic system Operations
Controls and indicators

Rear controls

Front controls and LEDs

Status screen

Operating the Powermax 105

Connect the electrical power, gas supply, and torch lead

Attach the work lead to the power supply

Attach the work clamp to the workpiece

Turn ON the system

Set the operating mode switch

Check the indicators

Manually adjusting the gas pressure

Adjusting the currrent (amperage)

Electrode end-of-life detection feature
Understanding duty-cycle limitations
Section 4
Hand torch setup
Instruction
Consumable life
Hand torch components
Choose the hand torch consumables

Drag-cutting 105A consumables

Drag-cutting 45A, 65A, 85A consumables

Hand torch consumables

Gouging consumables

Finecut consumables

Install the hand torch consumables
Connecting the torch lead
Section 5
Hand cutting
Using the hand torch 
Operate the safety trigger
Hand torch cutting hints
Start a cut from the edge of the workpiece
Pierce a workpiece
Gouge a workpiece

Gouge profile

Varying the gouge profile

Common hand-cutting faults

Section 6
Machine torch setup
Introduction
Consumable life
Machine torch components
Converting a full-length machine torch to a mini machine torch 
Mount the torch
Choose the machine torch consumables
Machine torch consumables

Mechanized shielded 105A consumables

Mechanized shielded 45A,65a,85A consumables

Mechanized shielded with ohmic 105A consumables

Mechanized shielded with ohmic 45A,65A,85A consumables

Mechanized unshielded 105A consumables

Mechanized unshielded 45A,65A,85A consumables

Gouging consumables

Finecut shielded consumables

Finecut unshielded consumables

Install the machine torch consumables
Aligning the torch
Connecting the torch lead 
Using the cut charts

Estimated kerf-width compensation

105A shielded consumables

105A shielded cutting (Mild steel)

105A shielded cutting (Stainless steel)

105A shielded cutting(Aluminum)

85A shielded consumables

85A shielded cutting (Mild steel)

85A shielded cutting (Stainless steel)

85A shielded cutting(Aluminum)

65A shielded consumables

65A shielded cutting (Mild steel)

65A shielded cutting (Stainless steel)

65A shielded cutting(Aluminum)

45A shielded consumables

45A shielded cutting (Mild steel)

45A shielded cutting (Stainless steel)

45A shielded cutting(Aluminum)

FineCut consumables

FineCut (Mild Steel)

FineCut (Stainless Steel)

Low Speed FineCut (Mild Steel)

Low Speed FineCut (Stainless Steel)

105 A Unshielded consumables

105 A Unshielded cutting (Mild Steel)

105 A Unshielded cutting (Stainless Steel)

105 A Unshielded cutting (Aluminum)

85 A Unshielded consumables

85 A Unshielded cutting (Mild Steel)

85 A Unshielded cutting (Stainless Steel)

85 A Unshielded cutting (Aluminum)

65 A Unshielded consumables

65 A Unshielded cutting (Mild Steel)

65 A Unshielded cutting (Stainless Steel) 

65 A Unshielded cutting (Aluminum)

45 A Unshielded consumables

45 A Unshielded cutting (Mild Steel)

45 A Unshielded cutting (Stainless Steel)

45 A Unshielded cutting (Aluminum)

Section 7
Mechanized Cutting
Connecting an optional remote-start pendant
Connecting an optional machine interface cable

Machine interface pinout

Setting the five position voltage divider.

Accessing raw arc voltage
Connecting an optional RS485 serial interface cable
Using the machine torch
Setting up the torch and table
Understand and optimize cut quality

Cut or bevel angle

Dross

Piercing a workpiece using the machine torch
Common machine-cutting faults
Section 8
Troubleshooting and System Tests 
Controls and indicators
Theory of operation 

General

200-600 V CSA 3-phase power supply functional description

230-400 V CE,380 V CCC/230-400 V CE 3-phase power supply functional description

400 V CE,380 V CCC 3-phase power supply functional description

Sequence of operation

Troubleshooting preparation

Test equipment

Troubleshooting procedures and sequence 

External inspection

Internal inspection 

Initial resistance check

Check the power switch

Hypertherm IGBT tester

Indicator LEDs and device tests

IGBT test preparation

IGBT device test using the Hypertherm tester 

Troubleshoot the Hypertherm IGBT tester

Schematic for building an IGBT tester

IGBT device test using a non-Hypertherm tester

200-600 V CSA power supply overview
230-400 V CE,380 V CCC/230-400 V CE power supply overview
380 V CCC,400 V CE power supply overview
200-600 V CSA power supply overview(power board removed)
230-400 V CE,380 V CCC/230-400 V CE power supply overview(power board removed) 
380 V CCC,400 V CE power supply overview(power board removed).
Fault codes

Displaying the service screen

Important fault icons

Performing a cold restart

Fault codes and solutions

Troubleshooting guide
System tests

Test 1-Voltage input

Test 2-DC Power Buss

Test 3-Output diodes

Test 4-Inverter and PFC temperature sensor

Test 5-Flyback circuit (DC minor voltages)

Test 6-Torch stuck open (TSO)/torch stuck closed(TSC)

Test 7-Start signal

Test 8-Torch cap switch

Test 9-Electronic regulator

Test 10-Pressure sensor

Test 11-Fan

Test 12-AUX switch

Section 9
Power Supply Component Replacement 
Replacing the air filter element
Replacing the work lead connector
Installing the optional filter kit
Replacing the power supply cover
Replacing the Mylar® barrier
Installing the machine interface cable with voltage divider board
Installing the machine interface cable
Installing the RS485 serial interface cable
Replacing the power cord
Replacing the strain relief connector
Replacing the power switch
Replacing the control board
Replacing the DSP board
Replacing the power board
Replacing the input diode bridge
Replacing the output diode bridge
Replacing the pilot arc IGBT
Replacing the inverter IGBT module
Replacing the PFC IGBT module
Replacing the snubber resistor
Replacing the damper resistor
Replacing the thermal sensor
Replacing the fan shroud
Replacing the fan
Replacing the pressure transducer
Replacing the pressure switch
Replacing the air filter subassembly
Replacing the solenoid valve
Replacing the gas tubing
Replacing the bulk capacitors
Replacing the torch quick disconnect receptacle
Replacing the work lead receptacle.
Replacing the output inductor
Replacing the transformer
Replacing the PFC inductor
Replacing the front end panel
Replacing the rear end panel
Installing the machine interface cable for raw arc voltage
Section 10
Torch Component Replacement
Hand torch:Replacing the start switch
Hand torch:Replacing the cap-sensor switch
Hand torch:Replacing the handles
Hand torch:Replacing the trigger
Hand torch:Replacing the torch body
Hand torch:Replacing the torch lead
Hand torch:Replacing the quick disconnect housing
Machine torch:Replacing the mounting sleeve
Machine torch:Replacing the cap-sensor switch
Machine torch:Replacing the torch body
Machine torch:Replacing the coupler
Machine torch:Replacing the gear rack
Machine torch:Replacing the positioning sleeve
Machine torch:Replacing the torch lead
Machine torch:Replacing the quick disconnect housing
Section 11
Parts
Power supply parts

Exterior front

Exterior rear

Interior,power board side (200-600 V CSA)

Interior, power board side (230-400 V CE)

Interior,power board side (400 V CE/380 V CCC)

Interior,fan side

Heat sink assembly

200-600 V CSA heat sink components

230-400 V CE heat sink components

400 V CE/ 380 V CCC heat sink components

Duramax 75°hand torch replacement parts
Duramax 15° hand torch replacement parts
Hand torch consumables
Duramax 180° full-length machine torch replacement parts
Duramax 180° mini machine torch replacement parts
Machine torch consumables
Accessory parts
Powermax105 labels
Safety-critical parts

200-600 VCSA

230-400 V CE

400 V CE/380 VCCC

Power supply fan side

Recommended spare parts
Section 12
Wiring Diagrams
Powermax Generic Timing Chart
Schematic diagram(CSA,230-400 V CE,380 V CCC/230-400 VCE)
Schematic diagram (380 V CCC, 400 V CE)

Section 1 Specifications

Safety information

Before you set up and operate your Hypertherm system,read the separate Safety and Compliance Manua/ included with your system for important safety information.

System description

The Powermax105 is a highly portable,105-amp,handheld and mechanized plasma cutting system appropriate for a wide range of applications.The Powermax system uses air or nitrogen to cut electrically conductive metals, such as mild steel,stainless steel,or aluminum.Smart Sense technology automatically adjusts the gas pressure according to cutting mode and torch lead length for optimum cutting.

The Powermax105 can cut thicknesses up to 38 mm(1-1/2 inches) and pierce thicknesses up to 22 mm(7/8 inch). FastConnect provides a simple push-button torch connection to the power supply for quick torch changes.

The typical handheld Powermax system includes a DuramaxT series 75° hand torch with a consumables box and work lead cable.Reference materials include:operator manual, quick setup card,registration card,setup DVD,and safety manual.

The typical mechanized Powermax system includes a Duramax series 180° full-length machine torch with a consumables box,work lead cable,and remote-start pendant.Reference materials include:operator manual,quick setup card, registration card,setup DVD,and safety manual.

See your Hypertherm distributor for other system configurations.You can order additional styles of torches, consumables,and accessories such as the plasma cutting guide.See the Parts section for a list of spare and optional parts.

Powermax105 power supplies are shipped without a plug on the power cord.See the Power Supply Setup section for more information.

Note:Some CCC certified configurations do not ship with a power cord. Powermax105 3-phase systemsinclude the following models:

The 200-600 V CSA model is a universal power supply that can automatically adjust to operate with AC voltages from 200 to 600 V.

The 230-400 V CE model can automatically adjust from 230 to 400 V.

The 380 V CCC/230-400 V CE model can automatically adjust from 230 to 400 V. Note:To maintain CE certification,install power cord kit 228886.

The 400 V CE model is 400 V only. The 380 V CCC model is 380 V only.

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 configuration, extension cord requirements, and generator recommendations- See the Power Supply Setup section.

•Handheld and machine torch consumables, cut charts, and torch setup information- See the Hand Torch Setup or Machine Torch Setup section.

•Information about the controls and LEDs, steps for system operation, and hints for improving cut quality- See the basic system operations,Hand cutting, and Mechanized cutting sections.

The manual also contains sections on troubleshooting and ordering parts for your system.

Power supply demensions
Component weights (105 A systems)
 200-600V CSA230- -400 VCE400 V CE380V CCc380V CCC/230-400V CE
Power supply40 kg (88 lbs)39 kg (87 lbs)35 kg (78 lbs)With power cord 35 kg (78 lbs) No power cord 34kg (74 lbs)No power cord 36 kg (79 lbs)
With7.6 m (25 ft) hand torch and 7.6 m (25ft)45 kg (100 lbs)45 kg (100 lbs)41 kg(91lbs)With power cord 41 kg(91lbs) No power cord 39 kg (87 lbs)No power cord 42 kg (92 lbs)
Hand torch 7.6 m (25 ft)3.3kg (7.3 bs)
Hand torch 15 m (50 f)5.9 kg(13.0 lbs)
Hand torch 23 m (75 ft)8.4kg(18.5 lbs)
Machine torch 4.6 m(15ft)2.4 kg (5.4 bs)
Machine torch 7.6 m (25 ft)3.4 kg (7.6 lbs)
Machine torch 11 m (35 ft)4.5kg(10.0 lbs)
Machine torch 15 m (50 ft)6.2 kg (13.7 lbs)
Machine torch 23 m (75 ft)8.7 kg(19.3 lbs)
Work lead 7.6 m (25 ft)2.4 kg (5.3 lbs)
Work lead 15 m (50 ft)4.4 kg (9.6 lbs)
Work lead 23 m (75 f)6.1 kg(13.4 lbs)
Powermax105 power supply ratings
Rated open-circuit voltage(Uo)200-600V CSA
230-400VCE
380VCCC/230-400VCE
400VCE
380VCCC
300VDC
288VDC
288VDC
292VDC
280VDC
Output characteristicDrooping
Rated output current (,)30-105A
Rated output voltage (U)160VDC
Duty cycle at 40C(104’F)200-600VCSA
230-400VCE or 380VCCC/230-400VCE
400VCE
380VCCC
80%@105A,480-600V.3-PH
70%@105A240V,3-PH
54%@105A208V,3-PH
50%@105A200V,3-PH
100%@94A,380V,3-PH
100%@88A,240V,3-PH
100%@77A,208V,3-PH
100%@74A,200V,3-PH

80%@105A,400V,3-PH
70%@105A,230V,3-PH
100%@94A,400V,3-PH
100%@88A,230V,3-PH
80%@105A,400V,3-PH
100%@94A,400V,3-PH
80%@105A,380V,3-PH
100%@94A,380V,3-PH
Operating temperature-10Fto40C(14″to104° F)
Storage temperature-25″to 55″C(-13″to1319F)
Power factor
200-600VCSA,3-PH
230-400VCE,3-PH
380VCCC/230-400VCE,3-PH
400VCE,3-PH
380VCCC,3-PH
0.94-0.77
0.94-0.92
0.94-0.92
0.94
0.94
Rsoe- Short Circuit Ratio (CE models only)U,- Volts ACrms, 3-PH R.ce
230-400VCE 275
400VCE 230
EMC dassification CISPR11(CE models only)4Class A
Input voltage (U)/ Input current (l) at rated output (U MAx, l wx) (See the Power Supply Setup section for more information.) 200-600V CSA
380VCCC/230-400V CE23
230-400VCE23
380 V CCC
200/208/240/480/600V,3-PH.50/60Hz
58/56/49/25/22 A
230-400V.3-PH50/60Hz
50/29A
400V,3-PH,50/60Hz
28A
380V.3-PH,50V60Hz
30A
Gas typeAirNitrogen
Gas qualityClean, dry,ol-free per
ISO8573-1 Class1.2.2
99.959% pure
Recommended gas inlet flow rate/ pressureCutting:220slpm(460scfh,7.7scfm)@5.9bar(85ps)
Gouging:230 slpm (480scfh,8Oscfm)@ 4.8 bar (7Ops)
1 Defined as aplot of output voltage versus output current.

2 Equipment complies with IEC 61000-3-12provided that the short-circuit power Sg is greater than or equal to 5528 KVA at the interface point between the user’s supply and the public system.t is the responsibility of the installer or user of the equipment to ensure, by consutation with the distrbution network operator ifnecessary, that the equipment is connected only to a supply with a short-circuit power S. greater than or equal to 5528KVA

3 This product meets the technical requirements ofIEC 61000-3-3andis not subject to condtional connection
 
4 WARNING:This Cass A equipment is notintended for use in residential locations where the electrical power is provided by the public low-voltage supply system. There may be potential difficulties in ensuring electromagnefic compatibility in those locations, due to conducted as well as radiated disturbances.
 
5 Equipment complies with IEC 61000-3-12provided that the short-circuit power Sgis greater thanorequal to4462 KVA at the interface point between the user’s supply and the public system.lt is the responsibility of the installeror user of the equipment to ensure, by consultation with the distrbution network operator ifnecessary, that the equipment is connected only to asupply with ashort-circuit power Se greater than or equalto 4462KVA
Duramax 75° hand torch dimensions
Duramax 15° hand torch dimensions
Duramax 180° full-length machine torch dimensions
Duramax 180° mini machine torch dimensions
Powermax 105 cutting specifications
Handheld cut capacity (material thickness)
Recommended cut capacity at 500mm/min (20ipm)32mm(1-1/4in)
Recommended cut capacity at 250mm/min (10ipm)38mm(1-1/2 in.)
Severance capacity at125mm/min (5ipm)”50mm (2in)
Pierce capacity (material thickness)
Pierce capacity for handheld cutting or mechanized cutting with programmable torch height control22mm (7/8in)
Pierce capacity for mechanized cutting without programmable torch height control20mm (3/4 in)
Maximum cut speed- (mild steel)
6mm(1/4in)5600 mm/min(220 ipm)
12mm(1/2in)2400 mm/min (95 ipm)
20mm(3/4in)1300 mm/min (50 ipm)
25 mm(1in)760mm/min (30 ipm)
32 mm(1-1/4 in.)510 mm/min (20 ipm)
Gouging capacity
Metal removal rate on mild steel (65A)4.8 kg/hr (10.7lbs/hr)
Metal removal rate on mild steel (85A)8.8 kg/hr(19.5lbs/hr)
Metal remowal rate on mild steel (105A)9.8 kg/hr (21.7lbs/hr)
Duramax series torch weights (refer topage 1-5 Component weights (105A
systems)])
Duty cycle and voltage information (refer to page 1-6Powermax105 power
supply ratings)
*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.
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.
S mark symbol
The S mark symbolindicates that the power supply and torch are suitable for operations carried out in environments with increased hazard of electrical shock perIEC60974-1.
CSA mark
Hypertherm products with aCSA mark meet the United States and Canadian regulations for product safety. The products were evaluated, tested, and certifed by CSA-nterational Altemafvely the productmay haveamadk by one of the ather Nationally Recognized Testing Laboratories (NRTL) accredited in both the United States and Canada, such as Underwriters Laboratories, Incorporated (UL) or TOv.
CE marking
The CEmarking signifies the manufacturer’s dedaration of confomity toapplicable European directives and standards.
Only those versions of Hypertherm products with a CE marking located on or near the data plate have been tested for compliance with the European Low Voltage Directive and the European Electromagnetic Compatibity (EMC) Directive.
EMC flters needed to comply with the European EMC Directive are incorporated within versions of the product with a CE marking.
GOST-Rmark
CEversions of Hypertherm products thatincude a GOST-R mark of conformity meet the product safety and EMC requirements for export to the Russian Federation.
C-Tick mark
CE versions of Hypertherm products with a c-Tickmark comply with the EMC regulations required for salein Australia and New Zeafand.
CCCmark
The China Compulsory Certification (CCC)markindicates that the product has beentested and found compliant with
product safely regulations required for sale in China
UkrSEPRO mark
CE versions of Hypertherm products thatinclude aUkrSEPRO mark of conformity meet the product safety and EMC requirements for export to the Ukraine.
Noise levels
Acceptable noise levels as defined by national and local codes may be exceeded by this plasma system. Always wear proper ear protection when cutting or gouging. Any noise measurements taken are dependant on the specific environment in which the system is used. See also Noise can damage hearing in the Safety and Compliance Manual included with your system.
IEC symbols

The following symbols may appear on the power supply data plate, control labels, switches, LEDs, and LCD screen.

Section 2 Power Supply Setup

Unpack the Powermax system
1. Verify that all items on your order have been received in good condition. Contact yourdistributorifany parts are damaged or missing.
2. Inspect the power supply for damage that may have occurred during shipping. f there is evidence of damage, refer to Claims below. All communications regarding this equipment must include the model number and the serial number located on the back of the power supply.
3. Before you set up and operate this Hyperthem system,read the separate Safely and Compliance Manual included with your system for important safety information.
Claims
•Claims for damage during shipment -lf your unit was damaged during shipment,you must file a claim with the carrier. Hypertherm will fumish you with a copy of the bll of lading upon request.lIf you need additional assistance, call the nearest Hypertherm office listed in the front of this manual.
 
•Claims for defective or missing merchandise -lf any component is missing ordefective, contact your Hypertherm distributor. If you need additional assistance, call the nearest Hypertherm offce isted in the front of this manual.
Contents

The following illustration shows typical system components. A vinyl cap is installed on torches that ship with new systems. Consumables are included in the consumables box.

Position the power supply

Locate the power supply near an appropriate power receptacle for your installation:

•200-600 volts (3-phase,CSA certified)
 
•230-400 volts (3-phase,CE certified)
 
•380/230-400 volts (3-phase,CCc/cE certifed) without power cord
Note: To maintain CE certification, install power cord kit 228886.
 
•400 volts (3-phase,CE certifed)
 
•380 volts (3-phase,CCCcertified).
The power supply has a3 m (10ft) power cord (depending upon the model). Alow at least O.25 m (10 inches) of space around the power supply for proper ventilation.
 
The power supply is not suitable for use in rain or snow.
 
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 detemine conductor sizes for power connection and installation instructions. The HYP ratingis determined under maximum normal operating conditions and the higher HYP input current value should be used for installation purposes.
 
The madmum output voltage wil vary based on your input voltage and the circuit’s amperage. Because the current draw varies during startup, slow-blow fuses are recommended as shown in the charts on page 2-6. Slow-blow fuses can withstand currents up to 1O times the rated value forshort periods of time.
Install a line-disconnect switch
Use a line-disconnect switch for each power supply so that the operator can tum off the incoming power quickly in an emergency. Locate the switch so that itis easily accessible to the operator. Installation must be performed by a licensed electrician according to national and local codes. The interrupt level of the switch must equal or exceed the continuous rating of the fuses. In addition, the switch should:
•Isolate the electrical equipment and disconnect all live conductors from the incoming supply volage when in the OFF postion.
 
•Have one OFF and one ON position that are clearly marked with O(OFF) andI(ON).
 
•Have an external operating handle that can be locked in the OFF position.
 
•Contain a power-operated mechanism that serves as an emergency stop.
 
•Have appropriate slow-blow fuses installed. See page 2-6 Power connection for the Powermax105 for recommended fuse sizes.
Requirements for grounding
To ensure personal safety, proper operation, and toreduce electromagnetic interference (EMD, the powersupply must be properly grounded.
 
•The power supply must be grounded through the power cord according to national and local electrical codes
 
•Three-phase service must be of the 4-wire type with agreen or green/yellow wire for protective earth ground and must comply with national and local reguirements.
 
•Refer to the separate Safety and Compliance Manua included with your system for more information on grounding.
Power connection for the Powermax105
Powermax1053-phase systems include the following models:
 
•The 200-600V CSA model is a universal power supply that can automatically adjust to operate with AC voltages fom 200 to 600 V.
 
•The230-400VCE model can automatically adjust from 230to400V.
 
•The 380V CCC/230-400V CE model can automatically adjust fom 230to 400 V.
Note:To maintain CE certification, install power cord kt 228886.
 
•The 400v CE model is 400 Vonly.
 
•The380v CCC modelis 380V only.
 
The rated output is 30-105A,160VDC
200-600VCSA,
Input voltage (V)200208240480600
Ihput cument (A)at rated output(16.8kw5856492522
Input current (A)at arc stretch8282784035
Fuse,slow-blow (A)8080804040
230-400VCE
Input voltage (V)230400
Input current (A)at rated output(16,8kw)5029
Input current (A)at arc stretch8046
Fuse, slow-blow (A)8050
380V CCC/230-400V CE
Input voltage (V)230400380
Ihput cument (A)at rated output(16.8kw502930
Input current (A)at arc stretch804642
Fuse,slow-blow (A)805050
400V
Input voltage (V)400
Ihput cument (A)at rated output(16.8kw28
Input current (A)at arc stretch44
Fuse,slow-blow (A)50
380V CCC
Input voltage (V)380
Ihput cument (A)at rated output(16.8kw30
Input current (A)at arc stretch42
Fuse,slow-blow (A)50
Three-phase power cord and plug installation
Powermax105 power supplies are shipped with the following power cords:
 
•CSA models: 6 AWG 4-wire power cord
 
•230-400VCE:10mm2,4-wire HAR power cord
 
•380VCCC/230-400V CE ships without a power cord
Note:To maintain CE certification, install power cord kit 228886.
 
•400V CE:6mm2,4-wire HAR power cord
 
•380VCCC:6mm2,4-wire CCCpower cord (some models ship without apower cord)
To operate the Powermax105,usea plug that meets national and local electrical codes. The plug must be connected to the power cord by a licensed electrician.
Strip and prepare the power cord wires as shown below.
Extension cord recommendations

Any extension cord must have an appropriate wire size for the cord length and system voltage. Use a cord that meets national and local codes.

The table on the next page provides the recommended gauge sizes for various lengths and input voltages. The lengths in the tables are the length of the extension cord only; they do not include the power supply’s power cord.

Extension cord specifications
Extension cord length<3m (10ft)3-7.5m (10-25ft)7.5-15m (25-50ft)15-30m (50-100ft)30-45m(100-150ft)
200-600V CSA
Input voltage (VAC)Phasemm²(AWG)mm²(AWG)mm²(AWG)mm²(AWG)mm²(AWG)
200-240316(6)16(6)16(6)25(4)35(2)
480-60036(10)6(10)6(10)6(10)6(10)
230-400V CE
Input voltage (VAC)Phasemm²mm²mm²mm²mm²
23031616162525
40031010101010
380V CCC/230-400V CE
Input voltage (VAC)Phasemm²mm²mm²mm²mm²
23031616162525
40031010101010
38031010101010
400V CE
Input voltage (VAC)Phasemm²mm²mm²mm²mm²
40031010101010
380V CCC
Input voltage (VAC)Phasemm²mm²mm²mm²mm²
38031010101010
Engine-driven generator recommendations
Generators used with the Powermax105 should satisfy the following requirements:
 
200-600VCSA
 
3-phase, 50/60 Hz,200-600VAC(480 VAC recommended for best performance)
 
230-400VCE
 
3-phase, 50/60 Hz,230-400VAC(400 VAC recommended for best performance)
 
380VCCC/230-400VCE
 
3-phase, 50/60 Hz,230-400VAC(400VAC recommended for best performance)
 
400VCE
 
3-phase, 50/60 Hz, 400 VAC (400VAC recommended for best performance)
 
380VCCC
 
3-phase, 50/60 Hz, 380 VAC (380 VAC recommended for best performance)
Engine drive ratingSystem output currentPerformance (arc stretch)
30 kw105AFull
22.5-25105ALimited
20 kw85AFull
15kw70ALimited
15 kw65AFull
12kw65ALimited
12kw40AFull
8 kw40ALimited
8 kw30AFull
Note: Based on the generator rating, age., and condition, adjust the cutting current as needed.
 
If a fault occurs while using a generator, tuming the power switch quickly to OFF and then to ON again (sometimes called a “quick reset’) may not clear the fault. Instead, tur OFF the power supply and wait 6o to 7O seconds before turning ON again
Prepare the gas supply
The air can be supplied by a compressor or from high-pressure cylinders A high-pressure regulator must be used on either type of supply and must be capable of delivering gas to the air inlet on the power supply.
If the supply quality is poor, cut speeds decrease, cut quality deteriorates, cutting thickness capability decreases, and the life of the consumables shortens. For optimal perfomance, the gas should be compliant with ISO8573-1:2010, Class 1.2.2 (that is,it should have a maximum number of solid particulate per m3 of <20,000for particle sizes in the range of 0.1-0.5 microns, <400 for particle sizes in the range of o.5-1microns,and <1Ofor particle sizes in the range of 1-5 microns). The maximum water vapor dew point should be <-40°C(-40F.The maximum oil (aerosol, iquid, and vapor) content should be less than O.1mg/m3.
Additional gas filtration
When site conditons introduce moisture, oil, or other contaminants into the gas line,use a3-stage coalescing fltration system, such as the Eliminizer filter kit (part number 228890) available from Hypertherm distributors. A 3-stage filtering system works as shown below to clean contaminants from the gas supply.

The filter system should be installed between the gas supply and the power supply. Additional gas filtration may increase the required minumum inlet pressure.

Connect the gas supply

Connect the gas supply to the power supply using an inert-gas hose with a 9.5mm (3/8 inch)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.

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
 7.6m (25ft)15.2m(50ft)22.9 m (75ft)
Cuting5.2 bar (75 ps)5.5 bar (80 psi)5.9 bar (85 psi)
Gouging4.1 bar(60psi)4.5 bar (65 psi)4.8 bar (70 psi)
Gas fiow rates
Cuting220 slpm (460 scfh, 7.7 scfm) at a minimum 5.9 bar (85 ps)
Gouging230 slpm (480scfh,B.Oscfm)ata minimum 4.8 bar(70ps)

Section 3 Basic System Operations

Controls and indicators
Powermax105 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. These controls and indicators are described on the following pages.
Rear controls
ON (D)/OFF (O) power switch
Activates the power supply and its control circuits.
Front controls and LEDs
Fault LED (yellow)
When iluminated, this LED indicates that there is afault with the power supply.
Power ON LED (green)
When iluminated, this LED indicates that the power switch has been set tol(ON) and that the safety
interlocks are satisfied. When blinking. the power supply has afaut.
Operating mode switch
The operating mode switch can be setin one of four postions:
•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-cuting.
•Gouge. Gouges metal plate.
•Torch lock. Same as the non-continuous pilot arc mode except the torch is locked in the ON position when yourelease the trigger during a cut. The torch goes out when the transfer is lost or the torch is retriggered.
Automatic/manual pressure setting mode selector
The selector switches between automatic and manual mode. In automatic mode, the power supply
automatically sets the gas pressure based upon the torch type and lead length and the adjustment
knob sets only the amperage. In manual mode, the adjustment knob sets either the gas pressure or the
amperage. This LED is iluminated in manual mode.
Note: Manual mode should be used by experienced users who need to optimize the gas setting (overide the automatic gas setting) for aspecific cutting application.
When you switch from manual mode to automatic mode, the power supply automatically sets the gas pressure and the amperage setting is unchanged. When you switch from automatic mode to manual mode, the power supply remembers the previous manualgas pressure setting and the amperage setting is unchanged.
 
When you reset the power, the power supply remembers the previous mode, gas pressure, and amperage settings.

Current/gas selector

When in manual mode, this selector toggles between amperage and gas pressure for manual
adjustments using the adjustment knob.
Adjustment knob
This knob adjusts the amperage. When operating in manual mode, this knob can also adjust the
gas pressure, overriding the automatic setting for optimized applications.
Status screen

The status screen shows system status and faut information.

Gas pressure indicators
In manual mode, the gas pressure is displayed in bar and psi. The gas pressure bar is also a visualindicator of the gas pressure.
Gas pressure bar
When the arrow is centered in the vertical bar (the reference pressure of the automatic pressure seting), the gas pressure is set to the preset (factory-defined) value. If the pressure is higher than the preset value, the arrow appears above the mid-point of the bar. f the pressure is lower than the preset value, the arrow appears below the mid-point of the bar.
Note:In automatic mode, the power supply adjusts the pressure to the preset value. You can use manual mode to adjust the pressure to satisfy the needs of aparticular cutting job.Refer to page3-10 Manually adjusting the gas pressure.
System status icons

The screen displays icons to indicate the system’s status.

Torch started
Indicates that the torch has received a start signal.
Torch is cutting
Indicates that the cutting arc has transferred to the metal and the torch is cutting.
Remote control
Indicates that a remote control or CNC is controling the power supply using serial communications. All local controls are disabled.
Electrode end-of-ife detection manually disabled
Indicates that the electrode end-of-ife detection feature is manually disabled.
Fault codes
When a power supply or torch faut occurs, the system displays a fault codein the lower-left comer of the status screen and displays a corresponding fault icon above the code. The first digitis always zero. The other two digits identify the problem. Fault code information is induded later in this manual.
Note: Only one fault code is displayed. If more than one fault occurs at the same time,only the fault code with the highest priority is displayed.
Fault icons
The faut icons that appear on the let side of the status screen are described below.A fault code also appears to identify the fault. Refer to the troubleshooting information later in this manual.
Warning
The system continues to run.
Fault
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. Tum OFF the power, properly install the consumables, and turn ON the system again to reset the power supply.
Temperature
Indicates that the temperature of the power supply power module is outside the acceptable operating range.
Gas
Indicates that the gas is disconnected from the rear of the power supply or there is a problem with the gas supply.
Internal Serial Communications Interface
Indicates a problem with the SCl communications between the control board and the DSP board.
Operating the Powermax105
Follow the steps below to begin cutting or gouging with the Powermax system.
Note: This section provides basic operating instructions. Before operating your Powermaxina production environment, refer to the Hand Torch Setup section or the Machine Torch Setup section.
Connect the electrical power, gas supply, and torch lead
For information on connecting the proper plug to the power cord, refer to the Power Supply Setup section.
 
Plug in the power cord and connect the gas supply line. For more information about the electrical requirements and the gas supply requirements of the Powermax, see the Power Supply Setup section. To connect the torch, push the FastConnect connector into the receptacle on the front of the power supply You will attach the work lead in the next section.
Attach the work lead to the power supply
1.Insert the work lead connectorinto the receptacle on the front of the power supply.
Note: The receptacle is keyed. Align the key on the work lead connector with the opening at the top of the receptacle on the power supply.
2.Push the work lead connector all the way into the receptacle on the power supply and turn clockwise, approximately 1/4 turn, until the connectoris fully seated against the stop in order to achieve an optimal electrical connection.
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 Powermax105 with a cutting table, you can connect the work lead directly to the table instead of attaching the work clamp to the workpiece.
See your table manufacturer’s instructions.
Note the following:
 
•Ensure that the work clamp and the workpiece make good metal-to-metal contact. Remove rust, dirt, paint, coatings, and other debris to ensure the work lead makes proper contact with the workpiece.
 
•For the best cut quality, attach the work clamp as close as possible to the area being cut
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.
For cutting expanded metal, grates, metal containing holes, or any job that requires a continuous pilot arc. Using this mode to cut standard metal plate reduces consumable life.
 
For cutting or piercing metal. This is the standard setting for nomal drag-cutting.
 
For gouging metal (Note: Using this mode while cutting results in poor cut quality)
 
Locks the torch in the ON (fire) position. With this option selected, press the trigger to fire the torch. You can then release the trigger while continuing to cut. Press the tigger again to stop the arc. The torch goes out when transferis lost
Check the indicators
Verify the following:
• The green power ON LED on the front of the power supply isilluminated.
• 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 LEDisiluminated, orthe power ON LED is blinking, correct the fault condition before continuing. More troubleshooting information is included later in this manual.
Manually adjusting the gas pressure
For normal operations, the power supply automatically adjusts the gas pressure. fyou need to adjust the gas pressure for a specific application, you can use manual modeto do so.
Note: Manual mode should be used by experienced users who need to optimize the gas setting (override the automatic gas setting) fora specific cutting application.
When you switch from manual mode to automatic mode, the power supply automatically sets the gas pressure and the amperage setting is unchanged. When you switch from automatic mode to manual mode, the power supply remembers the previous manual gas pressure setting and the amperage setting is unchanged.

When you reset the power, the power supply remembers the previous mode, gas pressure, and amperage settings.

To adjust the pressure:
 
1. Press the automatic/manual pressure setting mode selector so that the LED next to the selectorilluminates. Refer to the diagram on page 3-2 Front controls and LEDs.
 
2 Press the current/gas selector until the selection cursor is opposite the gas pressure setting in the status screen.
 
3. Tum the adjustment knob to adjust the gas pressure to the desired level Watch the arrowin the pressure bar as you adjust the pressure.
Adjusting the current (amperage)

Tum 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.Tum the adjustment knob to change the amperage.
 
3. If you wish to exit manual mode, press the automatic/manual pressure setting mode selector. The LED goes off.

Note:When you exit manual mode, the gas pressure resets to the factory-optimized value.

When you switch between manual mode and automatic mode, the power supply retains the amperage setting. When you reset the power, the power supply returns to the previous mode (automatic mode or manual mode) and remembers the previous amperage setting.
Electrode end-of-life detection feature
The electrode end-of-life detection feature on the Powermax105 protects the torch and workpiece from damage by automatically stopping power to the torch when the electrode reaches its end of life. Fault code 0-32 also displays on the front panel status screen.If you have the current set below 55 A,this feature is automatically disabled without displaying the icon on the status screen.
To manually disable the feature, press the current/gas selector button (see figure below) five times on the control pane. The system must be in the auto mode and the selector presses must be less than one second apart. Re-enable the feature by repeating this procedure. An icon (see figure below) displays on the status screen when the feature is manually disabled.
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 40°C(104°F).
With a Powermax105:
 
•At 105 A(480-600VCSA,400VCE,380VCCC,the arc can remain on for 8 minutes out of 10 minutes without causing the unit to overheat (80% duty cycle).
 
•At 94A(480-600VCSA,400VCE, 380V CCC), the arc can remain on for 1O minutes out of 10(100%)
See the Specifications section for a complete list of duty cycle specifications.
 
If the duty cycle is exceeded, the power supply overheats, the temperature fault icon appears in the status screen, the arc shuts off, and the cooling fan continues to run. You can not resume cutting until the temperature fault icon disappears and the fault LED goes off.

Section 4 Hand Torch Setup

Introduction
Duramax series hand torches are available for Powermax105 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.
 
This section explains how to set up your hand torch and choose the appropriate consumables for the job.
Consumable life

How often you need to change the consumables on your torch will depend on a number of factors:

•The thickness of the metal being cut.
•The average length of the cut.
•The air quality (presence of oil, moisture, or other contaminants).
•Whether you are piercing the metal orstarting cuts from the edge.
•Proper torch-to-work distance when gouging or cutting with unshielded consumables.
•Proper pieroe height.
•Whether you are cuting in “continuous pilot arc” mode or normal mode. Cutting with a continuous pilot arc causes more consumable wear.
Under normal conditions, the nozzle wil wear out first when hand cutting. As generalrule, a set of consumables lasts approximately 1 to 3 hours of actual “arc on” time for hand cutting.
You will find more infomation about proper cutting techniques in the Hand Cutting section.
Hand Torch components

Note: Torches ship without consumables installed.

Duramax 75° hand torch
Duramax 15° hand torch
Choose the hand torch consumables
Hypertherm includes a box of consumables with your system.Bothstyles of hand torches shown on the previous page use the same consumables.
 
Hand torches use shielded consumables. Therefore, you can drag the torch tip along the metal.
 
Consumables for hand cutting are shown on the next page. Notice that the retaining cap and electrode are the same for cutting, gouging, and FineCut applications. Only the shield, nozze, and swirl ring are dfferent.
 
For the best cut quality on thin matenials (approximately 4mm/10GA or less),you may prefer to use FineCut consumables, or use a45 Anozzle and reduce the amperage to that setting.
Drag-cutting 105 A consumables
Drag-cutting 45A, 65A, 85A consumables

Hand torch consumables

Gouging consumables
Finecut consumables
Install the hand torch consumables

To operate the hand torch, a complete set of consumable parts must be installed. Pull off the vinyl cap before installing your consumables.

With the power switch in the OFF(O) position, install the torch consumables as shown below.

Connecting the torch lead
The Powermax105 is equipped with FastConnectm, aquick-disconnect system for connecting and disconnecting handheld and machine torch leads. When connecting or disconnecting atorch first turn OFF the system. To connect the 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.

Section 5 Hand Cutting

Using the hand torch
Operate the safety trigger
The hand torches are equipped with a safety trigger to prevent accidental firings. When you are ready to use the torch, fip the trigger’s safety cover forward (toward the torch head) and press the red torch trigger as show below.
Hand torch cutting hints
•Drag the torch tip lightly along the workpiece to maintain a steady cut.
 
•While cutting, make sure that sparks exit from the bottom of the workpiece. The sparks should lag slightly behind the torch as you cut (15-30°angle from vertical).
 
•If sparks spray up from the workpiece, move the torch more slowly, or set the output current higher.
•With either the Duramax 75″ hand torch or Duramax 15° hand torch, hold the torch nozzle perpendicular to the workpiece so that the nozzle is at a 90 angle to the cutting surface. Observe the cutting arc as the torch cuts.
•If you fire the torch unnecessarily, you will shorten the life of the nozzle and electrode.
•Puling, or dragging. the torch along the cutis easier than pushing it.
 
•For straight-line cuts, use a straight edge as a guide. To cut circles, use a template ora radius cutter attachment (a circle cutting guide). See the Parts section for part numbers for the Hypertherm plasma cutting guides for cutting circles and making bevel cuts.
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.
3. Drag the torch tip lightly across the workpiece to proceed
with the cut. Maintain a steady, even pace.
Gouging a workpiece
  1. Hold the torch so that the torch tip is within 1.5mm(1/16inch) from the workpiece before firing the torch.
2. Hold the torch at a 45″angle to the workpiece with a small gap between the torch tip and the workpiece. Press the trigger to obtain a pilot arc. Transfer the arc to the work piece.
3. Maintain an approximate 45″ angle to the workpiece as you feed into the gouge. Push the plasma arc in the direction of the gouge you want to create. Keep a small distance between the torch tip and the molten metal to avoid reducing consumable life or damaging the torch.
Changing the torch’s angle changes the dimensions of the gouge.
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.
Operating parameters
Speed50.8-63.5cm/min(20-25ipm)
Standoff6.4-9.5mm(1/4-3/8in)
Angle35-40*

Typical Gouge Profile for 65A

Metal removal rate on mild steel 
4.8 kg/hr(10.7lbs/hr)

Typical Gouge Profile for 85A

Metal removal rate on mild steel

8.8 kg/hr(19.5lbs/hr)

Typical Gouge Profile for 105A

Metal removal rate on mild steel
9.8 kg/hr (21.7 lbs/hr)
Varying the gouge profile
The following actions have the stated effects on the gouge profie:
 
• Increasing the speed of the torch will decrease width and decrease depth.
• Decreasing the speed of the torch will increase width and increase depth.
• Increasing the standoff of the torch will increase width and decrease depth.
• Decreasing the standoff of the torch will decrease width and increase depth.
• Increasing the angle of the torch (more vertical) will decrease width and increase depth.
• Decreasing the angle of the torch (less vertical) wil increase width and decrease depth.
• Increasing the current of the power supply will increase width and increase depth.
• Decreasing the current of the power supply will decrease width and decrease depth.
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 cutis too thick for the selected amperage.
• Gouging consumables are installed instead of drag-cutting consumables.
• The work clamp is not attached properly to the workpiece.
• The gas pressure or gas flow rate is too low.
Cut quality is poor. The causes can be:
 
• The metal being cut is too thick for the amperage.
• The wrong consumables are being used (gouging consumables are installed instead of drag-cutting consumables, for example).
• You are moving the torch too quickly or too slowly.
The arc sputters and consumables ife is shorter than expected. The cause can be:
 
• Moisture in the gas supply.
• Incorrect gas pressure.
• Consumables incorrectly installed.

Section 6 Machine Torch Setup

Introduction
Duramax series machine torches are available for Powermax105 systems. The FastConnect quick-disconnect system makes it easy to remove the torch for transport or to switch from one torch tothe other if your applications require the use of different torches. The torches are cooled by ambient air and do not require special cooling procedures.
 
This section explains how to set up your machine torch and choose the appropriate consumables for the job.
Consumable life

How often you need to change the consumables on your torch will depend on a number of factors:

• The thickness of the metal being cut.
• The average length of the cut.
• The air quality (presence of oil, moisture, or other contaminants).
• Whether you are piercing the metal or starting cuts from the edge.
• Proper torch-to-work distance when gouging or cutting with unshielded consumables.
• Proper pierce height.
• Whether you are cutting in “continuous pilot arc” mode or normal mode. Cutting with a continuous pilot arc causes more consumable wear.

Machine torch components

Duramax 180° full-length machine torch
Duramax 180° mini machine torch
Before using either style of machine torch, you must:
 
• Mount the torch on your cutting table or other equipment.
• Choose and install the consumables.
• Align the torch square to the plate.
• Attach the torch lead to the power supply.
• Set up the power supply for remote starting with either the remote-start pendant or a machine interface cable.
Converting a full-length machine torch to a mini machine torch
You can convert a full-length machine torch to amini machine torch by removing the positioning sleeve.
 
Note:If you are converting a full-length machine torch to amini machine torch and mounting the torch at the same time, skip this section and follow the instructions on page 6-7 Mountthe torch.
 
Refer to the figures on page 6-4 Machine torch components and follow these instructions.
 
Note:While disconnecting and reconnecting the torch parts, maintain the same orientation between the torch head and torch lead. Twisting the torch head in relation to the torch lead can cause damage.
1. Disconnect the torch lead from the power supply and remove the consumables from the torch.
2.Unscrew the strain relief body from the strain relief nut and slide the strain relief body back along the torch lead.
3.Unscrew the strain relief nut from the positioning sleeve and slide the nutback along the torch lead.
4. Unscrew the positioning sleeve from the coupler.
5. Unscrew the coupler from the mounting sleeve.
6. Remove the three screws from the consumables end of the mounting sleeve and slide the mounting sleeve off the front of the torch body.
7. Disconnect the wire connector for the cap-sensor switch.
8. Use a #2 Philips 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,oradjustable wrenches,to loosen the nut that secures the gas supply line to the torch lead. Set the torch body aside.
10. Slide the coupler and positioning sleeve off the front of the torch lead.
11. Slide the coupler over the torch lead.
12. Reconnect the gas line to the torch lead.
13. Reattach the torch’s pilot wire to the torch body using the screw.
14. Reconnect the cap-sensor switch’s wire connector.
15. Slide the mounting sleeve over the front of the torch body. Align the slot on the frontof the mounting sleeve (next to one of the three screw holes) with the cap-sensor plunger on the torch body.
16. Attach the mounting sleeve to the torch body using the three screws.
17. Screw the coupler into the mounting sleeve.
18. Screw the strain relief nut into the coupler.
19. Screw the strain relief body into the strain relief nut.
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.
 
Note:The Duramax machine torches can be mounted on a wide variety of X-Y tables, trackburers, pipe bevelers, and other equipment. Install the torch per the manufacturer’s instructions and follow the instructions below for disassembly if necessary.
 
If you need to disassemble and reassemble the torch, refer to the figures on page 6-4 Machine torch components and follow these instructions.
 
Note:While disconnecting and reconnecting the torch parts, maintain the same orientation between the torch head and torch lead. Twisting the torch head in relation to the torch lead can cause damage.
1. Disconnect the torch lead from the power supply and remove the consumables from the torch.
2. Unscrew the strain relief body fom the strain relef nut and slide the strain relief body back along the torch lead.
3. Unscrew the strain relief nut from the positioning sleeve (full-length machine torch) and slide the nut back along the torch lead.
4. Unscrew the positioning sleeve from the coupler.
5. Unscrew the coupler from the mounting sleeve.
6. Remove the three screws from the consumables end of the mounting sleeve and side the mounting sleeve off the front of the torch body.
7.Disconnect the wire connector for the cap-sensor switch.
8.Use a#2Phillips screwdriver to remowe 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. Set the torch body aside.
10. Slide the coupler, positioning sleeve full-length machine torch), strain relief nut,and strain relef body off the front of the torch lead.
11. If you do not need the gear rack on a full-length machine torch, slide the gear rack from the positioning sleeve toward the consumables end of the sleeve.
12. Route the torch lead through the cutting table’s track
13. Slide the strain relief body and strain relief nut over the torch lead.
14. If you are mounting aful-length machine torch, slide the positioning sleeve over the torch head if you are mounting a mini machine torch, set aside the positioning sleeve.
15. Slide the coupler over the torch lead.
16. Reconnect the gas line to the torch lead.
17. Reattach the torch’s pilot wire tothe torch body using the screw.
18. Reconnect the cap-sensor switch’s wire connector.
19. Slide the mounting sleeve over the front of the torch body. Align the slotonthe front of the mounting sleeve (next to one of the three screw holes) with the cap-sensor plunger on the torch body.
20. Attach the mounting sleeve to the torch body using the three screws
21. Screw the coupler into the mounting sleeve.
22. If you are mounting a full-length machine torch, screw the positioning sleeve into the couple. If you are mounting a mini machine torch, the strain relief nut attaches directly to the coupler in the next step.
23. Reconnect the strain relief nut and strain relief body.
24. Attach the torch to the lifter per the manufacturer’s instructions.
Choose the machine torch consumables
Powermax systems with the Duramax 180° full-length machine torch or Duramax 180 mini machine torch are shipped with a box of consumables. In addition, an ohmic-sensing retaining cap is avalable for use with shielded consumables.
 
With shielded consumables, the torch tip may touch the metal when cutting. With unshielded consumables,you must keep the torch a small distance,about 2-3mm(.08-.12inch),away from the metal. Unshielded consumables generally have a shorter life than shielded consumables. Depending upon which system you order, you may receive a starter consumable kit with a standard retaining cap or ohmic retaining cap.
 
Both styles of machine torches use the same consumables.

Machine torch consumables

Mechanized shielded 105 A consumables
Mechanized shielded 45A65A,85 A consumables
Mechanized shielded with ohmic 105 A consumables
Mechanized shielded with ohmic 45 A, 65A, 85A consumables
Mechanized unshielded 105 A consumables
Mechanized unshielded 45 A, 65A, 85A consumables
Gouging consumables
Finecut shielded consumables
Finecut unshielded consumables
Install the machine torch consumables
To operate the machine torch, a complete set of consumable parts mustbe installed: shield,retaining cap, nozzle, eledtrode, and swirl ring.
With the power switch in the OFF (O) position,install the machine torch consumables in a manner similar to the hand torch consumables. Refer to the Hand torch setup secion.
Aligning the torch
Mount the machine torch perpendicular to the workpiece in order to get a vertical cut. Use a square to align the torch at 0° and 90°.
Connecting the torch lead
The Powermax105 is equipped with FastConnectmu,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 the 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.
Using the cut charts
The following sections provide cut charts for each set of mechanized consumables. A consumable diagram with part numbers precedes each set of charts. For each consumable type, there are Metric and English charts for mild steel, stainless steel, and aluminum.
 
Each chart contains the following information:
• Amperage setting – Except for FineCut charts,the amperage setting at the top left side of the page applies to all the settings given on that page. In FineCut charts, the amperage setting for each thickness, either 45 or40 (45,40,or 3O for low speed),is included in the chart.
• Material Thickness – Thickness of the workpiece (metalplate being cut).
• Torch-to-Work Distance – For shielded consumables, the distance between the shield and the workpiece during cutting. For unshielded consumables, the distance between the nozzle and the workpiece during cutting.
• Initial Pierce Height – Distance between the shield (shielded) or the nozzle (unshielded) and the workpiece when the torch is triggered., prior to descending to the cut height.
• Pierce Delay Time – Length of time the triggered torch remains stationary at the pierce height before the torch starts the cutting motion.
• Best Quality Settings (cut speed and voltage) – Settings that provide the starting point for finding the best cut quality (best angle, least dross, best cut-surface fnish). Adjust the speed for your application and table to obtain the desired result.
• Production Settings (cut speed and voltage)-709%to 809% of the maximum speed ratings. These speeds result in the greatest number of cut parts, but not necessarly the best possible cut quality.
Note:The arc voltage increases as the consumables wear and the voltage setting should be increased to maintain the correct Torch-to-Work Distance.
Each cut chart lists hot and cold air flow rates.
 
• Hot air flow rate – Plasmais on, the system is operating at running current, and the system is ina steady state at the default system pressure (automatic mode).
• Cold air flow rate – Plasma is off and the system is in a steady state with air fowing through the torch at the default system pressure.
 
Note:Hypertherm collected the data under laboratory test conditions using new consumables.
Estimated kerf-width compensation
The widths in the tables below are for reference. The data are obtained with the “Best Quaity” 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)
ProcessThickness (mm)
0.5123681012162025
Mild Steel
105A Shielded    2.12.22.22.22.52.73.3
85 A Shielded   1.71.81.922.22.42.6 
65 A Shielded  1.61.61.81.922.22.3  
45 A Shielded1.11.11.41.51.7      
FineCut0.90.70.50.6       
Low Speed FineCut0.60.70.70.6       
105 A Unshielded    2.12.32.52.42.72.93.2
85 A Unshielded  1.71.81.92.0 2.12.12.3  
65 A Unshielded  1.61.61.71.81.92.0    
45 A Unshielded0.50.91.31.3       
Stainless Steel
105A Shielded    1.92.12.32.32.32.62.9
85 A Shielded   1.61.81.92.12.32.42.5 
65 A Shielded  1.41.51.81.92.0 2.22.4  
45 A Shielded0.91.11.51.61.8      
FineCut0.20.50.40.5       
Low Speed FineCut0.60.50.60.5       
105 A Unshielded    2.0 2.22.42.52.72.73.1
85 A Unshielded  1.71.71.81.92.12.22.4  
65 A Unshielded  1.61.61.81.81.9 2.0    
45 A Unshielded0.51.0 1.31.51.5      
Aluminum
105A Shielded    2.32.32.42.62.733.5
85 A Shielded   21.922.12.22.42.6 
65 A Shielded  1.91.91.922.12.32.5  
45 A Shielded 1.51.51.61.5      
105 A Unshielded    2.22.42.52.62.733.3
85 A Unshielded  1.91.91.9222.12.2  
65 A Unshielded  1.81.81.81.81.92   
45 A Unshielded 1.61.51.41.5      
Estimated kerf-width compensation - English (inches)
ProcessThickness (inches)
22GA18GA14GA10GA3/161/43/81/25/83/41
Mild Steel
105A Shielded     0.0830.0880.0890.1000.1010.133
85 A Shielded   0.0680.0710.0730.0780.0900.0950.100 
65 A Shielded  0.0620.0650.0680.0700.0760.0880.090 0.091 
45 A Shielded0.0350.0540.0550.0610.065 0.066     
FineCut0.0280.0260.0160.023       
Low Speed FineCut0.0260.0300.0270.023       
105 A Unshielded     0.0830.0970.0980.1070.1110.125
85 A Unshielded   0.0700.0730.0750.0800.0850.090  
65 A Unshielded  0.0620.0640.0660.0680.0750.081   
45 A Unshielded0.0200.0500.0510.054 0.057 0.059     
Stainless Steel
105A Shielded     0.0760.0890.0910.0920.0990.113
85 A Shielded   0.0650.0680.0700.0800.0940.0950.096 
65 A Shielded  0.0560.0620.0680.0730.0760.0900.093  
45 A Shielded0.0320.0550.0580.0670.069 0.069     
FineCut0.0250.0190.0140.027       
Low Speed FineCut0.0250.0230.0210.027       
105 A Unshielded     0.0800.0950.1010.1060.1040.122
85 A Unshielded  0.0660.0680.0700.0720.0800.0900.099  
65 A Unshielded  0.0610.0640.0670.0700.0720.080    
45 A Unshielded0.0200.0540.0520.0600.058 0.058     
Aluminum
105A Shielded     0.0910.0920.1020.1070.1110.138
85 A Shielded   0.0800.0780.0750.0800.0900.0950.100 
65 A Shielded  0.0730.0740.0750.0760.0830.0910.100  
45 A Shielded 0.0590.0610.065  0.060     
105 A Unshielded     0.0890.0980.1020.1060.1170.132
85 A Unshielded   0.0750.0750.0750.0800.0820.088  
65 A Unshielded  0.0700.0700.0700.0700.0720.079   
45 A Unshielded 0.0620.0580.057 0.061      
105A shielded consumables
105 A Shielded cutting (Mild Steel)
Air fiow rate -slpm/scth
Hot217/460
Cold250/530
Metric
Material ThicknessTorch-to-Work DistanceInital Pierce HeightPierce Delay TimeBest Quality SettingsProduction Settings
Cut SpeedVoltageCut SpeedVoltage
mmmmmm%seconds(mm/min)Volts(mm/min)Volts
63.26.42000.541401445090145
80.7531401453870145
1022601452790145
1216901452060148
161.0 10601491310149
20780152940152
25Edge Start550159580158
30370162410161
32350166370161
35290168320165
40190173210170
English
Material ThicknessTorch-to-Work DistanceInital Pierce HeightPierce Delay TimeBest Quality SettingsProduction Settings
Cut SpeedVoltageCut SpeedVoltage
inchesinchesinches%secondsipmVoltsipmVolts
1/40.1250.252000.5156144192145
3/80.7594145116145
1/26214676148
5/81.0 4214952149
3/43315140150
7/81.252615430157
1Edge Start2116022158
1-1/81516217160
1-1/41416615161
1-1/2917110168
105 A Shielded cutting (Stainless Steel)
Air fiow rate -slpm/scth
Hot217/460
Cold250/530
Metric
Material ThicknessTorch-to-Work DistanceInital Pierce HeightPierce Delay TimeBest Quality SettingsProduction Settings
Cut SpeedVoltageCut SpeedVoltage
mmmmmm%seconds(mm/min)Volts(mm/min)Volts
63.26.42000.548701396000141
834601414210142
1022401442670142
120.614901481860144
160.759501491080149
208.0 2501.25660154810152
25Edge Start440158530156
30340164360160
32300166320163
English
Material ThicknessTorch-to-Work DistanceInital Pierce HeightPierce Delay TimeBest Quality SettingsProduction Settings
Cut SpeedVoltageCut SpeedVoltage
inchesinchesinches%secondsipmVoltsipmVolts
1/40.1250.252000.5185139224141
3/894143112142
1/25514868145
5/80.753814943149
3/40.312501.252815334151
7/8Edge Start2215627153
11715820156
1-1/81416216159
1-1/41216613163
105 A Shielded cutting (Aluminum)
Air fiow rate -slpm/scth
Hot217/460
Cold250/530
Metric
Material ThicknessTorch-to-Work DistanceInital Pierce HeightPierce Delay TimeBest Quality SettingsProduction Settings
Cut SpeedVoltageCut SpeedVoltage
mmmmmm%seconds(mm/min)Volts(mm/min)Volts
63.26.42000.559801457090144
80.7541701495020148
1026401523280151
121.019101562450154
1612901571660155
201.2510201631190162
25Edge Start660166790165
30430173570171
32340175490173
English
Material ThicknessTorch-to-Work DistanceInital Pierce HeightPierce Delay TimeCut SpeedVoltageCut SpeedVoltage
inchesinchesinches%secondsipmVoltsipmVolts
1/40.1250.252000.5223146265145
3/80.75110151136150
1/21.0 7115691154
5/85115766155
3/41.254316250161
7/8Edge Start3416440163
12516630165
1-1/82017125169
1-1/41517520173
85A shielded consumables
85 A Shielded cutting (Mild Steel)
Air fiow rate -slpm/scth
Hot194/412
Cold236/500
Metric
Material ThicknessTorch-to-Work DistanceInital Pierce HeightPierce Delay TimeBest Quality SettingsProduction Settings
Cut SpeedVoltageCut SpeedVoltage
mmmmmm%seconds(mm/min)Volts(mm/min)Volts
31.53.82500.168001229200120
40.256501227300122
60.536001234400125
825001253100127
1016801272070128
124.53000.7 12801301600130
161.0 870134930133
2064001.5570137680136
25Edge Start350142450141
30200146300144
English
Material ThicknessTorch-to-Work DistanceInital Pierce HeightPierce Delay TimeCut SpeedVoltageCut SpeedVoltage
inchesinchesinches%secondsipmVoltsipmVolts
10 GA0.060.152500.0 250122336121
3/160.2185123220123
1/40.5 130123160126
3/87012686127
1/20.183004513156131
5/81.0 3513437133
3/40.244001.52413629135
7/8Edge Start1913922138
11314217141
1-1/8914513143
1-1/4714810146
85 A Shielded cutting (Stainless Steel)
Air fiow rate -slpm/scth
Hot194/412
Cold236/500
Metric
Material ThicknessTorch-to-Work DistanceInital Pierce HeightPierce Delay TimeBest Quality SettingsProduction Settings
Cut SpeedVoltageCut SpeedVoltage
mmmmmm%seconds(mm/min)Volts(mm/min)Volts
31.53.82500.175001229200120
40.261001227500120
60.537001224600122
824501243050124
104.530015501271900126
120.7 11001311400130
161.0 700135760134
20Edge Start480138570137
25300143370141
English
Material ThicknessTorch-to-Work DistanceInital Pierce HeightPierce Delay TimeCut SpeedVoltageCut SpeedVoltage
inchesinchesinches%secondsipmVoltsipmVolts
10 GA0.060.152500.2275122336120
3/16200122240121
1/40.5 130122164122
3/86512680125
1/20.183003613248131
5/81.0 2813530134
3/4Edge Start2013724136
7/81614019139
11114314141
85 A Shielded cutting (Aluminum)
Air fiow rate -slpm/scth
Hot194/412
Cold236/500
Metric
Material ThicknessTorch-to-Work DistanceInital Pierce HeightPierce Delay TimeBest Quality SettingsProduction Settings
Cut SpeedVoltageCut SpeedVoltage
mmmmmm%seconds(mm/min)Volts(mm/min)Volts
31.53.82500.180001229400121
40.265001238000123
60.538001264900126
826501303470129
104.530019201322500131
120.7 14501341930133
161.0 9501391200137
20Edge Start600143880141
25380146540144
English
Material ThicknessTorch-to-Work DistanceInital Pierce HeightPierce Delay TimeCut SpeedVoltageCut SpeedVoltage
inchesinchesinches%secondsipmVoltsipmVolts
1/80.060.152500.2300122360121
1/40.5 130127172127
3/880132104131
1/20.183005013568133
5/81.0 3813948137
3/4Edge Start2514237140
7/82014429142
11414620144
65A shielded consumables
65 A Shielded cutting (Mild Steel)
Air fiow rate -slpm/scth
Hot175/370
Cold209/443
Metric
Material ThicknessTorch-to-Work DistanceInital Pierce HeightPierce Delay TimeBest Quality SettingsProduction Settings
Cut SpeedVoltageCut SpeedVoltage
mmmmmm%seconds(mm/min)Volts(mm/min)Volts
21.53.82500.160501247000121
30.252001256100123
40.542501255100124
625501273240127
817001292230128
104.53000.7 11001311500129
121.2 8501341140131
166.0 4002.0 560138650136
20Edge Start350142450142
25210145270145
English
Material ThicknessTorch-to-Work DistanceInital Pierce HeightPierce Delay TimeCut SpeedVoltageCut SpeedVoltage
inchesinchesinches%secondsipmVoltsipmVolts
16 GA0.060.152500.1260123294121
10 GA190125224123
3/160.2 140126168125
1/40.5 90127116127
3/80.7 4513062129
1/20.183001.23013540132
5/80.244002.0 2313826136
3/4Edge Start1514119141
7/81214314143
1814510145
65 A Shielded cutting (Stainless Steel)
Air fiow rate -slpm/scth
Hot175/370
Cold209/443
Metric
Material ThicknessTorch-to-Work DistanceInital Pierce HeightPierce Delay TimeBest Quality SettingsProduction Settings
Cut SpeedVoltageCut SpeedVoltage
mmmmmm%seconds(mm/min)Volts(mm/min)Volts
21.53.82500.1810012510000121
30.267001258260123
40.552001256150124
624501262850126
80.7 15001291860129
104.53009601321250132
121.2 750135920134
16Edge Start500139500139
20300143370143
English
Material ThicknessTorch-to-Work DistanceInital Pierce HeightPierce Delay TimeCut SpeedVoltageCut SpeedVoltage
inchesinchesinches%secondsipmVoltsipmVolts
16 GA0.060.152500.1345124426121
10 GA240125296123
3/160.2 155126168125
1/40.5 8012696126
3/80.7 4013152131
1/20.183001.22613632135
5/8Edge Start2013920139
3/41414215142
65 A Shielded cutting (Aluminum)
Air fiow rate -slpm/scth
Hot175/370
Cold209/443
Metric
Material ThicknessTorch-to-Work DistanceInital Pierce HeightPierce Delay TimeBest Quality SettingsProduction Settings
Cut SpeedVoltageCut SpeedVoltage
mmmmmm%seconds(mm/min)Volts(mm/min)Volts
21.53.82500.1880012110000121
30.274001248260123
40.560001266150124
632001302850126
80.7 19501331860129
104.530012001361250132
121.2 1000138920134
16Edge Start650143500139
20380147370143
English
Material ThicknessTorch-to-Work DistanceInital Pierce HeightPierce Delay TimeCut SpeedVoltageCut SpeedVoltage
inchesinchesinches%secondsipmVoltsipmVolts
1/160.060.152500.1365121428121
1/8280124336124
1/40.5 105131152128
3/80.7 5013568131
1/20.183001.2 3513948138
5/8Edge Start2614332141
3/41614624144
45A shielded consumables
45 A Shielded cutting (Mild Steel)
Air fiow rate -slpm/scth
Hot177/376
Cold201/427
Metric
Material ThicknessTorch-to-Work DistanceInital Pierce HeightPierce Delay TimeBest Quality SettingsProduction Settings
Cut SpeedVoltageCut SpeedVoltage
mmmmmm%seconds(mm/min)Volts(mm/min)Volts
0.51.53.82500.0 900012812500126
1900012810800128
1.50.1900013010200129
20.366001307800129
30.4 38501334900131
422001343560131
60.5 13501372050132
English
Material ThicknessTorch-to-Work DistanceInital Pierce HeightPierce Delay TimeCut SpeedVoltageCut SpeedVoltage
inchesinchesinches%secondsipmVoltsipmVolts
26GA0.020.084000.0 350128500128
22GA350128450128
18GA0.1 350129400128
16GA350130400129
14GA0.060.152500.2 270130320129
12GA0.4190133216131
10GA100134164131
3/160.570135108132
1/40.64813773132
45 A Shielded cutting (Stainless Steel)
Air fiow rate -slpm/scth
Hot177/376
Cold201/427
Metric
Material ThicknessTorch-to-Work DistanceInital Pierce HeightPierce Delay TimeBest Quality SettingsProduction Settings
Cut SpeedVoltageCut SpeedVoltage
mmmmmm%seconds(mm/min)Volts(mm/min)Volts
0.51.53.82500.0 900013012500126
1900013010800128
1.50.1900013010200129
20.360001328660129
30.4 31001324400131
420001342600131
60.5 9001401020132
English
Material ThicknessTorch-to-Work DistanceInital Pierce HeightPierce Delay TimeCut SpeedVoltageCut SpeedVoltage
inchesinchesinches%secondsipmVoltsipmVolts
26GA0.020.084000.0 350130500129
22GA350130450129
18GA0.1 350130400130
16GA350130400130
14GA0.060.152500.2 250132360131
12GA0.4140132206131
10GA100133134134
3/160.55213558135
1/40.63014135140
45 A Shielded cutting (Aluminum)
Air fiow rate -slpm/scth
Hot177/376
Cold201/427
Metric
Material ThicknessTorch-to-Work DistanceInital Pierce HeightPierce Delay TimeBest Quality SettingsProduction Settings
Cut SpeedVoltageCut SpeedVoltage
mmmmmm%seconds(mm/min)Volts(mm/min)Volts
11.53.82500.0 825013611000136
20.1 66001369200135
30.231001396250134
40.422001414850135
60.5 15001422800137
English
Material ThicknessTorch-to-Work DistanceInital Pierce HeightPierce Delay TimeCut SpeedVoltageCut SpeedVoltage
inchesinchesinches%secondsipmVoltsipmVolts
1/320.060.152500.0 325136450136
1/160.1 325136400136
3/320.2 200136328134
1/80.4 100140224134
1/40.5 5414296137
Finecut consumables

Note: The cut charts in this section apply to both shielded and unshielded consumables.

Finecut (Mild Steel)
Air fiow rate -slpm/scth
Hot181/384
Cold191/404
Metric
Material ThicknessCurrentTorch-to-Work DistanceInital Pierce HeightPierce Delay TimeRecommended
Cut SpeedVoltage
mmAmmmm%seconds(mm/min)Volts
0.5401.52.251500.0 825078
0.6825078
0.80.1 825078
1450.2825078
1.50.4640078
2480078
30.5 275078
40.6190078
English
Material ThicknessCurrentTorch-to-Work DistanceInital Pierce HeightPierce Delay TimeRecommended
Cut SpeedVoltage
inchesAinchesinches%secondsipmVolts
26GA400.060.091500.0 32578
24GA32578
22GA0.1 32578
20GA32578
18GA450.2 32578
16GA0.425078
14GA20078
12GA0.512078
10GA9578
Finecut (Stainless Steel)
Air fiow rate -slpm/scth
Hot181/384
Cold191/404
Metric
Material ThicknessCurrentTorch-to-Work DistanceInital Pierce HeightPierce Delay TimeRecommended
Cut SpeedVoltage
mmAmmmm%seconds(mm/min)Volts
0.5400.52.0 4000.0 825068
0.6825068
0.80.1 825068
1450.15825068
1.50.4615070
2480071
30.5 255080
40.6105080
English
Material ThicknessCurrentTorch-to-Work DistanceInital Pierce HeightPierce Delay TimeRecommended
Cut SpeedVoltage
inchesAinchesinches%secondsipmVolts
26GA400.020.084000.0 32568
24GA32568
22GA0.1 32568
20GA32568
18GA450.2 32568
16GA0.424070
14GA20070
12GA0.512080
10GA0.67580
Low Speed Finecut (Mild Steel)
Air fiow rate -slpm/scth
Hot181/384
Cold191/404
Metric
Material ThicknessCurrentTorch-to-Work DistanceInital Pierce HeightPierce Delay TimeRecommended
Cut SpeedVoltage
mmAmmmm%seconds(mm/min)Volts
0.5301.52.251500.0 380069
0.6380068
0.80.1 380070
1400.2380072
1.50.4380075
245370076
30.5 275078
4 190078
English
Material ThicknessCurrentTorch-to-Work DistanceInital Pierce HeightPierce Delay TimeRecommended
Cut SpeedVoltage
inchesAinchesinches%secondsipmVolts
26GA300.060.091500.0 15078
24GA15068
22GA0.1 15070
20GA15071
18GA400.2 15073
16GA0.415075
14GA4515076
12GA0.512078
10GA9578
Low Speed Finecut (Stainless Steel)
Air fiow rate -slpm/scth
Hot181/384
Cold191/404
Metric
Material ThicknessCurrentTorch-to-Work DistanceInital Pierce HeightPierce Delay TimeRecommended
Cut SpeedVoltage
mmAmmmm%seconds(mm/min)Volts
0.5300.52.0 4000.0 380069
0.6380069
0.80.1 380069
1400.15380069
1.50.4290069
245275069
30.5 255080
40.6105080
English
Material ThicknessCurrentTorch-to-Work DistanceInital Pierce HeightPierce Delay TimeRecommended
Cut SpeedVoltage
inchesAinchesinches%secondsipmVolts
26GA300.020.084000.0 15069
24GA15069
22GA0.1 15069
20GA15069
18GA400.2 14569
16GA0.411569
14GA4511069
12GA0.512080
10GA0.67580
105A unshielded consumables
105A unshielded cutting(Mild Steel)
Air fiow rate -slpm/scth
Hot217/460
Cold250/530
Metric
Material ThicknessTorch-to-Work DistanceInital Pierce HeightPierce Delay TimeBest QualityProduction Settings
Cut SpeedVoltageCut SpeedVoltage
mmmmmm%seconds(mm/min)Volts(mm/min)Volts
64.69.2200.0 0.540401484980145
831601493770145
1023501502700145
1217001532080147
160.69801551200152
201.0 742155940154
25Edge Start500159580159
30300161370160
32260169270167
35320164350163
40160176190172
English
Material ThicknessTorch-to-Work DistanceInital Pierce HeightPierce Delay TimeRecommendedProduction Settings
Cut SpeedVoltageCut SpeedVoltage
inchesinchesinches%secondsipmVoltsipmVolts
1/40.180.362000.5 153148188145
3/891150112145
1/26215376148
5/80.6 3915548152
3/41.0 3115540153
7/81.252515630158
1Edge Start1916022159
1-1/81416117160
1-1/41316414163
105A unshielded cutting(Stainless Steel)
Air fiow rate -slpm/scth
Hot217/460
Cold250/530
Metric
Material ThicknessTorch-to-Work DistanceInital Pierce HeightPierce Delay TimeBest QualityProduction Settings
Cut SpeedVoltageCut SpeedVoltage
mmmmmm%seconds(mm/min)Volts(mm/min)Volts
64.69.2200.0 0.549701456120142
834201474210144
1020901492570146
1214101511740149
160.758801531080151
201.0 660156800155
25Edge Start420159500159
30330162370161
32300163320162
English
Material ThicknessTorch-to-Work DistanceInital Pierce HeightPierce Delay TimeRecommendedProduction Settings
Cut SpeedVoltageCut SpeedVoltage
inchesinchesinches%secondsipmVoltsipmVolts
1/40.180.362000.5 185145228142
3/888149108145
1/25215164149
5/80.8 3515343151
3/41.0 2815534154
7/8Edge Start2215726157
11615919159
1-1/81416116161
105A unshielded cutting(Aluminum)
Air fiow rate -slpm/scth
Hot217/460
Cold250/530
Metric
Material ThicknessTorch-to-Work DistanceInital Pierce HeightPierce Delay TimeBest QualityProduction Settings
Cut SpeedVoltageCut SpeedVoltage
mmmmmm%seconds(mm/min)Volts(mm/min)Volts
64.69.2200.0 0.558401487170149
80.7541101525060151
1026701543580153
121.0 20901552450154
1613301601660158
20Edge Start9801631190162
25660167770167
30500170590169
32450171520170
English
Material ThicknessTorch-to-Work DistanceInital Pierce HeightPierce Delay TimeRecommendedProduction Settings
Cut SpeedVoltageCut SpeedVoltage
inchesinchesinches%secondsipmVoltsipmVolts
1/40.180.362000.5 218149268149
3/80.75110154136153
1/21.0 7715691155
5/85116066158
3/41.254116250161
7/8Edge Start3316540164
12516729167
1-1/82016925169
85A Unshielded Consumables
85A Unshielded Cutting (Mild Steel)
Air fiow rate -slpm/scth
Hot194/412
Cold236/500
Metric
Material ThicknessTorch-to-Work DistanceInital Pierce HeightPierce Delay TimeBest QualityProduction Settings
Cut SpeedVoltageCut SpeedVoltage
mmmmmm%seconds(mm/min)Volts(mm/min)Volts
22.0 5.0 2500.0 715011710400116
30.162401189000117
40.252501187200117
60.5 34501204400119
824001213100121
1015601232070122
126.0 3000.712001261600124
16Edge Start820132930128
20540137640132
25320143400137
English
Material ThicknessTorch-to-Work DistanceInital Pierce HeightPierce Delay TimeRecommendedProduction Settings
Cut SpeedVoltageCut SpeedVoltage
inchesinchesinches%secondsipmVoltsipmVolts
14GA0.080.20 2500.1 280117416116
10GA0.2 230118328117
3/16175119220118
1/40.5 125120160119
3/86512286122
1/20.243000.64212756125
5/8Edge Start3313137128
3/42313627131
7/81814021134
11214415138
85A Unshielded Cutting (Stainless Steel)
Air fiow rate -slpm/scth
Hot194/412
Cold236/500
Metric
Material ThicknessTorch-to-Work DistanceInital Pierce HeightPierce Delay TimeBest QualityProduction Settings
Cut SpeedVoltageCut SpeedVoltage
mmmmmm%seconds(mm/min)Volts(mm/min)Volts
22.0 5.0 2500.1855011711300116
370001189660117
40.256001187800118
60.5 34001204570121
822501212970122
106.0 3000.5 14301231840124
120.710001291340128
16Edge Start650134730133
20360138570137
English
Material ThicknessTorch-to-Work DistanceInital Pierce HeightPierce Delay TimeRecommendedProduction Settings
Cut SpeedVoltageCut SpeedVoltage
inchesinchesinches%secondsipmVoltsipmVolts
14GA0.080.20 2500.1 340117452116
10GA0.2 250118352118
3/16180119249119
1/40.5 120120160121
3/86012277123
1/20.243000.63513146129
5/8Edge Start2613429133
3/41713724136
85A Unshielded Cutting (Aluminum)
Air fiow rate -slpm/scth
Hot194/412
Cold236/500
Metric
Material ThicknessTorch-to-Work DistanceInital Pierce HeightPierce Delay TimeBest QualityProduction Settings
Cut SpeedVoltageCut SpeedVoltage
mmmmmm%seconds(mm/min)Volts(mm/min)Volts
22.0 5.0 2500.1870011811200118
373501209600119
40.260001228100120
60.5 33001254930122
823501273250124
106.0 3000.5 18001282140127
120.713001381720130
16Edge Start8401391130134
20470144700138
English
Material ThicknessTorch-to-Work DistanceInital Pierce HeightPierce Delay TimeRecommendedProduction Settings
Cut SpeedVoltageCut SpeedVoltage
inchesinchesinches%secondsipmVoltsipmVolts
1/80.080.20 2500.2 280120368119
3/16200123271120
1/40.5 110126172122
3/87512788126
1/20.243000.64513562131
5/8Edge Start3413945134
3/42214332137
65A Unshielded Consumables
65A Unshielded Cutting (Mild Steel)
Air fiow rate -slpm/scth
Hot175/370
Cold209/443
Metric
Material ThicknessTorch-to-Work DistanceInital Pierce HeightPierce Delay TimeBest QualityProduction Settings
Cut SpeedVoltageCut SpeedVoltage
mmmmmm%seconds(mm/min)Volts(mm/min)Volts
22.0 5.0 2500.160501177340117
30.252001186330118
40.542501185250118
625501203560120
816201232330121
106.0 3000.7 9701271500122
12Edge Start7601291140124
16500134650129
20280138400133
English
Material ThicknessTorch-to-Work DistanceInital Pierce HeightPierce Delay TimeRecommendedProduction Settings
Cut SpeedVoltageCut SpeedVoltage
inchesinchesinches%secondsipmVoltsipmVolts
16GA0.080.20 2500.1 255116308117
10GA190118232118
3/160.2 135119172119
1/40.5 90120116120
3/80.243000.74012662122
1/2Edge Start2713040125
5/82013426129
3/41313718132
85A Unshielded Cutting (Stainless Steel)
Air fiow rate -slpm/scth
Hot175/370
Cold209/443
Metric
Material ThicknessTorch-to-Work DistanceInital Pierce HeightPierce Delay TimeBest QualityProduction Settings
Cut SpeedVoltageCut SpeedVoltage
mmmmmm%seconds(mm/min)Volts(mm/min)Volts
22.0 5.0 2500.1795011710300117
30.266001188500118
40.550501196500118
623001213070120
80.716201231900121
106.0 3000.7 9701261250122
12Edge Start710130925127
16430135500133
English
Material ThicknessTorch-to-Work DistanceInital Pierce HeightPierce Delay TimeRecommendedProduction Settings
Cut SpeedVoltageCut SpeedVoltage
inchesinchesinches%secondsipmVoltsipmVolts
16GA0.080.20 2500.1 340116437115
10GA235118304118
3/160.2 150119172121
1/40.5 75120116120
3/80.243000.73812652122
1/2Edge Start2513232129
5/81713520133
85A Unshielded Cutting (Aluminum)
Air fiow rate -slpm/scth
Hot175/370
Cold209/443
Metric
Material ThicknessTorch-to-Work DistanceInital Pierce HeightPierce Delay TimeBest QualityProduction Settings
Cut SpeedVoltageCut SpeedVoltage
mmmmmm%seconds(mm/min)Volts(mm/min)Volts
22.0 5.0 2500.1775012311300122
30.265501249500123
40.554001257640124
630001273900126
80.718001302460127
106.0 3000.7 11001331640129
12Edge Start9001351250133
16600139700136
English
Material ThicknessTorch-to-Work DistanceInital Pierce HeightPierce Delay TimeRecommendedProduction Settings
Cut SpeedVoltageCut SpeedVoltage
inchesinchesinches%secondsipmVoltsipmVolts
1/160.080.20 2500.1 325116437122
1/8250118304123
3/16175119172124
1/40.5 100120116126
3/80.243000.74512652128
1/2Edge Start3213232134
5/82413520136
45A Unshielded Consumables
45A Unshielded Cutting (Mild Steel)
Air fiow rate -slpm/scth
Hot177/376
Cold201/427
Metric
Material ThicknessTorch-to-Work DistanceInital Pierce HeightPierce Delay TimeBest QualityProduction Settings
Cut SpeedVoltageCut SpeedVoltage
mmmmmm%seconds(mm/min)Volts(mm/min)Volts
0.51.5 3.8 2500.0 900012012500120
1900012010800121
1.50.1770012010200121
20.361501197800122
30.439501214900123
423501233560124
60.514001262050124
English
Material ThicknessTorch-to-Work DistanceInital Pierce HeightPierce Delay TimeRecommendedProduction Settings
Cut SpeedVoltageCut SpeedVoltage
inchesinchesinches%secondsipmVoltsipmVolts
26GA0.060.15 2500.0 350120500120
22GA350120450120
18GA0.1 350119400121
16GA300121400121
14GA0.2250119320122
12GA0.4200120216123
10GA100123164124
3/160.585122108124
1/40.64812773124
45A Unshielded Cutting (Stainless Steel)
Air fiow rate -slpm/scth
Hot177/376
Cold201/427
Metric
Material ThicknessTorch-to-Work DistanceInital Pierce HeightPierce Delay TimeBest QualityProduction Settings
Cut SpeedVoltageCut SpeedVoltage
mmmmmm%seconds(mm/min)Volts(mm/min)Volts
0.51.5 3.8 2500.0 900012112500119
1900012110800119
1.50.1900012110200120
20.360001227800120
30.432501224900122
419001283560124
60.57001301450124
English
Material ThicknessTorch-to-Work DistanceInital Pierce HeightPierce Delay TimeRecommendedProduction Settings
Cut SpeedVoltageCut SpeedVoltage
inchesinchesinches%secondsipmVoltsipmVolts
26GA0.020.08 4000.0 350120500119
22GA350120450119
18GA0.1 350119400119
16GA300121400120
14GA0.060.15 2500.2250119320120
12GA0.4200120216120
10GA100123164121
3/160.54213188123
1/40.62513048124
45A Unshielded Cutting (Aluminum)
Air fiow rate -slpm/scth
Hot177/376
Cold201/427
Metric
Material ThicknessTorch-to-Work DistanceInital Pierce HeightPierce Delay TimeBest QualityProduction Settings
Cut SpeedVoltageCut SpeedVoltage
mmmmmm%seconds(mm/min)Volts(mm/min)Volts
11.5 3.8 2500.0 740012611000119
20.144001279200119
30.2280012910200120
40.421001327800126
60.510501352250127
English
Material ThicknessTorch-to-Work DistanceInital Pierce HeightPierce Delay TimeRecommendedProduction Settings
Cut SpeedVoltageCut SpeedVoltage
inchesinchesinches%secondsipmVoltsipmVolts
1/320.060.15 2500.0 325120500121
1/160.1 200120450122
3/320.2150119400124
1/80.4100130224125
1/40.53613672127

Section 7 Mechanized Cutting

Connecting an optional remote-start pendant
Powermax105 configurations with a Duramax machine torch caninclude an optional remote-start pendant.
 
• Part number 128650:7.6m(25feet)
 
• Part number 128651:15.2m(50feet)
 
• Part number 128652:22.9m(75 feet)
If your power supply has the optional machine interface receptacle on the rear of the power supply, remove the receptacle cover and plug the Hypertherm remote-start pendant into the receptacle.
 
Note:The remote-start pendant is for use only with a machine torch. It will not operate if a handheld torch is installed.
Connecting an optional machine interface cable
The Powermax power supply may be equipped with a factory-installed (or user-installed) five-position voltage divider board. The bult-in voltage divider provides a scaled down arc voltage of 20:1,21.1:1,30:1,40:1,or 50:1(maximum output of 15 V). An optional receptacle on the rear of the power supply (see the previous page) provides access to the scaled down arc voltage and signals for arc transfer and plasma start.
Note:The factory presets the voltage divider to 50:1.To change the voltage divider to adifferent setting, referto page 7-6 Setting the five-position voltage divider.
Hypertherm offers several choices of machine interface cables for the Powermax105:
 
• To use the buit-in voltage divider that provides ascaled down arc votage in addition to signals for arc transfer and plasma start:
 
Use part number 228350 (7.6m, 25 feet) or 228351 (15.2 m 50 feet) for wires terminated with spade connectors.
Use part number 123896 (15.2m, 50 feet) for a cable terminated with a D-sub connector. (Compatible with Hypertherm products, such as Edgel T and Sensor”PHC)
 
• To use signals for arc transfer and plasma start only,use either part number 023206(7.6m,25feet) or part number 023279(15.2m,50feeb). These cables have spade connectors as shown below.
 
Refer to page 7-5 Machine interface pinout for receptacle pinout infomation.
Note:The cover on the machine interface receptacle prevents dust and moisture from damaging the receptacle when not in use. This cover should be replaced if damaged or lost (part number 127204).
 
See the Parts section for more infomation.
Installation of the machine interface cable must be performed by a qualified service technician. To install a machine interface cable:
1. Turn OFF the power and disconnect the power cord.
2 Remove the machine interface receptacle’s cover fom 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 aD-sub connector on the other end, plug it into the appropriate pin connector on the torch height controller or CNC. Secure it with the screws on the D-sub connector.
If you are using a cable with wires and spade connectors on the other end, terminate the machine interface cable inside the electrical enclosure of the torch height controller or CNC controller to prevent unauthorized access to the connections after installation. Verify that the connections are correct and that all live parts are endosed and protected before operating the equipment.
Note:The integration of Hyperthem equipment and customer-supplied equipmentincluding interconnecting cords and cables, if not listed and certified as a system,is subject to inspection by local authorities at the final installation site.
 
The connector sockets for each type of signal available through the machine interface cable are shown in the figure on the next page. The table provides details about each signal type.
Machine interface pinout

Refer to the following table when connecting the Powermax 105 to a torch height controller or CNC controller with a machine interface cable.

SignalTypeNotesConnector socketsExternal cable wire
Start (start plasma)InputNormaly open.
18VDC open circuit woltage at START teminals. Requires dry
contact closure to activate.
3,4Green, black
Transfer (start machine motion)OutputNomally open. Dry contact closure when the arc transfers.
120VAC/1 A maximum at the
machine interface relay.
12,14Red, black
GroundGround 13 
Voltage dividerOutputDivided arc signal of 20:1,21.1:1, 30:1,40:1,50:1(provides a
maximum of 15V).
5(-),6(+)Black (-), white(+)
Setting the five-position voltage divider
To change the factory preset voltage divider from 50:1to 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.

4. Set the DIP switches to one of the following settings and replace the power supply cover.

If the Hypertherm five-position voltage divider does not supply the required voltage for your application, contact your system integrator for assistance.
Accessing raw arc voltage

To access divided raw arc voltage, refer to Field Service Bulletin 807060.

Connecting an optional RS485 serial interface cable
The RS485 serial interface connector on the back of the power supply allows you to connect an external device to your Powermax For example, you can remotely operate the Powermax withaCNC controller.
The Powermax power supply must be equipped with a factory-installed (or user-installed) RS485 serial interface connector on the rear pane. The receptacle on the rear of the power supply provides access to the RS485 board inside the power supply.
Ifyour power supply is not equipped with the RS485 connector, order kit 228539,”Powermax65/85/105 RS485 board with cables”. Follow the installation instructions in the Power Supply Component Replacement section of the Service Manual.
With the RS485 connector installed:

1. Shut off the power supply.

2.Connect the RS485 cable from your external device to the receptacle on the back of the Powermax power supply.
Using the machine torch
Since the Powermax with a machine torch can be used with a wide variety of cutting tables,track bumers, 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. However, the information in the following sections will help you optimize cut quality and maximize consumable life.
Setting up the torch and table
• Use a square to align the torch at right angles to the workpiece in two dimensions.
 
• The torch may travel more smoothly ifyou clean, check and “tune” the cutting table’s rails and drive system 
Unsteady machine motion can cause aregular, wavy pattem on the cut surface.
 
• Ensure that the torch does not touch the workpiece during cutting. Contact with the workpiece can damage the shield and nozzle and affect the cut surface.
Understand and optimize cut quality
There are several factors to consider in cut quality:
 
• Cut angle – The degree of angularity of the cut edge.
 
• Dross – The molten material that solidifies on the top or bottom of the workpiece.
 
• Straightness of the cut surface – The cut surface can be concave or convex.

The following sections explain how these factors can affect cut quality.

Cut or bevel angle
• A positive cut angle, or bevel, results when more material is removed from the top of the cut than from the bottom.
 
• A negative cut angle results when more materialis removed from the bottom of the cut.
Note:The squarest cut angle will be on the right side with respect to the forward motion of the torch. The left side will always have some degree of bevel.
To determine whether a cut-angle problem is being caused by the plasma system or the drive system,make a test cut and measure the angle of each side. Next, rotate the torch 90′ in its holder and repeat the process. If the angles are the same in both tests, the problem is in the drive system.
 
If a cut-angle problem persists after “mechanical causes” have been eliminated (see page 7-8 Setting up the torch and table), check the torch-to-work distance, especially ifthe cut angles are all positive or all negative. Also consider the material being cut: if the metal is magnetized or hardened, you are more likely to experience cut angle problems.
Dross
Some amount of dross will always be present when cutting with air plasma. However, you can minimize the amount and type of dross by adjusting your system correctly for your application.
Excess dross appears on the top edge of both pieces of the plate when the torch is too low (or voltage is too low when using a torch height control). Adjust the torch or adjust the voltage in small increments (5 volts or less) until the dross is reduced.
Low-speed dross foms when the torch’s cutting speed is too slow and the arc angles ahead. It forms as aheavy, bubbly deposit at the bottom of the cut and can be removed easily. Increase the speed to reduce this type of dross. 

High-speed dross forms when the cutting speed is too fast and the arc angles behind. it foms as athin, linear bead of solid metal attached very close to the cut. It is more firmly attached to the bottom of the cut than at low speed and is difficult to remove. To reduce high-speed dross:
• Decrease the cutting speed.
 
• Decrease the torch-to-work distance.
Piercing a workpiece using the machine torch
As with the hand torch, you can start a cut with the machine torch at the edge of the workpiece or by piercing the workpiece. Piercing may result in a shorter consumable life than with edge starts.
 
The cut charts include a column for the recommended torch height when starting a pierce. For the Powermax105, the pierce height is generally 2.5 times the cutting height. Refer to the cut charts for specifics.
The pierce delay must be long enough that the arc can pierce the material before the torch moves,but not so long that the arc “wanders” while trying to find the edge of a large hole. As consumables wear,this delay time may need to be increased. Pierce delay times given in the cut charts are based on average delay times throughout the life of the consumables.
When piercing materials close to the maximum thickness for aspecific process, consider the following important factors:
• Allow a lead-in distance approximately equal to the thickness of the material being pierced. For example, 20 mm (3/4 in) material requires a 20 mm lead-in.
 
• To avoid damage to the shield from the buildup of molten material created by the pierce, do not allow the torch to descend to cut height until it has cleared the puddle of molten material.
 
• Different material chemistries can have an adverse effect onthe pierce capablity of the system In particular, high-strength steel with a high manganese or sillicon content can reduce the maximum pierce capabilty.
Hypertherm derives mild steel parameters using certified A-36 plate.
Common machine-cutting faults
The torch’s pilot arc wil 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.
 
• The torch-to-work distance is too large.
The workpiece is not totally penetrated, and there is excessive sparking on the top of the workpiece. Causes can be:
 
• The metal surface is not clean of rust or paint.
 
• The consumables are wom and need to be replaced. For optimized performance in a mechanized application, replace the nozzle and the electrode together.
 
• The work cable is not making good contact with the cutting table or the cutting table is not making good contact with the workpiece.
• The current (amperage) is settoo low. See the Machine Torch Setup section.
 
• The cut speed is too high. See the cut charts in the Machine Torch Setup section
 
• The metal being cut exceeds the maximum capacity for the selected amperage. See the Specifications section.
Dross forms on the bottom of the cut. Causes can be:
 
• The gas setting is incorrect
 
• The consumables are worm and need to be replaced. For optimized performance in a mechanized application, replace the nozzle and the electrode together.
 
• The cutting speed is not corredt. See the cut charts in the Machine Torch Setup section.
 
• The current (amperage) is set too low. See the cut charts in the Machine Torch Setup section.
The cut angle is not square. Causes can be:
 
• The torch is not square to the work piece.
 
• The gas setting is incorrect.
 
• The consumables are wom and need to be replaced. For optimized performance inamechanized application, replace the nozzle and the electrode together.
 
• The direction of the torch travel isincorrect. The high-quality cutis always on the right with respect to the forward motion of the torch.
 
• The distance between the torch and the workpiece is not correct.
 
• The cutting speed is not correct. See the cut charts in the Machine Torch Setup section.
The consumable life is shortened. Causes can be:
 
• The gas setting is incorrect.
 
• The arc current, arc voltage,travel speed, and other variables are not set as recommended in the cut charts.
 
• Firing the arc in the air (beginning or ending the cut off of the plate surface). Starting at the edge is acceptable as long as the arc makes contact with the workpiece when started.
 
• Starting a pierce with an incorrect torch height. Refer to the cut charts for the specific initial pierce height.
 
• The pierce time is incorrect.
 
• The air quality is poor (oil or water in the air).
 
• There might be afaulty pilot arc IGBT which can shorten nozzle life (refer to the troubleshooting sections in this manual, or call Technical Service)

Section 8 Troubleshooting and System Test

Controls and Indicators

The Powermax 105 controls and indicators are described in the Basic System Operations section. These figures are included for reference.

Theory of operation

General

Refer to “Sequence of operation” below and the Wining Diagrams section.

200-600 VCSA 3-phase power supply functional description
AC power enters the system through the power switch (S1) to the input diode bridge (D38) .The voltage from the bridge supplies the power factor correction (PFC) boost converter, which provides anominal 760 VDC bus voltage.
The bus supplies voltage and current to the inverter and the flyback circuit (DCto DCcorverter) on the power board (PCB3). The power board provides noise suppression and spike protection. A “soft starf” is implemented via the power board resistors (RT4,RT5) and relays (K2,K3).
The PFC boost converter consists of an insulated gate bipolar transistor (GBT Q11),PFCchoke, and control circuit.It provides a 760 VDC bus voltage when the input AC voltage is between 200and 540 VAC.At 600VAC, the nominal bus voltage is 840VDC.
The inverter consists of a dual lGBT package (Q12),the power transformer, an output current sensor, and the control circuit. The inverter operates as a pulse-width modulated half-bridge circuit driving an isolation transformer. The output of the isolation transformer is rectified by the output bridge (D36 and D37).
The output circuitry consists of 2 current sensors located on the power board, the pilot arc IGBT (Q13), and the output choke.
The digital signal processor (PCB2) monitors and regulates the system’s operation and safety circuits. The amperage adjustment knob on the control board (PCB1) is used to set the output current tothe desired value:30-105 amps. The system compares the set-point to the output current by monitoring the current sensors and adjusting the output of the inverter IGBT module (Q12).
230-400 VCE,380VCCC/230-400VCE 3-phase power supply functional description
AC power enters the system through the power switch (S1) to the input diode bridge (D38) .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).
The power board provides noise suppression and spike protection. A “soft start” is implemented viathe power board resistors (RT4,RT5)and relay (K2).
The PFC boost converter consists of an insulated gate bipolar transistor(IGBTQ11),PFC choke, and control circuit.It provides a nominal 760 VDC bus voltage
The inverter consists of a dual IGBT package (Q12),the power transformer, a current sensor, and the control circuit.
The inverter operates as a pulse-width modulated half-bidge cirauit driving an isolation transformer. The output of the isolation transformer is rectified by the output bridge (D36 and D37).
The output circuitry consists of 2 current sensors located on the power board, the pilot arclGBT (Q13), and the output choke.
The digital signal processor (PCB2) monitors and regulates the system’s operation and safety circuits. The amperage adjustment knob on the control board (PCB1)is used to set the output currentto the desired value. 30-105 amps The system compares the set-point to the output current by monitoring the current sensors and adjusting the output of the inverter IGBT module. (Q12).
400 v cE,380 vcCC 3-phase power supply functional description
AC power enters the system through the power switch (S1) to the input diode bridge (D38). The voltage from the bridge provides a nominal 530to 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). 
The power board provides noise suppression and spike protection. A “soft start” is implemented via the power board resistors (RT4,RT5)and relay (K2).
The inverter consists of a duallGBT package (Q12),the power transformer, a current sensor, and the control circuit.
The inverter operates as a pulse-width modulated half-bridge circuit driving an isolation transformer. The output of the isolation transformer is rectified by the output bridge (D36 and D37).
The output circuitry consists of 2 current sensors located on the power board,the pilot arc IGBT (Q3), and the output choke.
The digital signal processor (PCB2) monitors and regulates the system’s operation and safety circuits. The amperage adjustment knob on the control board (PCB1) is used to set the output current to the desired value: 30-105 amps. The system compares the set-point to the output current by monitoring the current sensors and adjusting the output of the inverter lGBT module.(Q12).
Sequence of operation
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 qualfied, 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.
Test equipment
• Multimeter
 
• IGBT(insulated gate bipolar transistor) tester (partnumber 128883)
Troubleshooting procedures and sequence
When performing the troubleshooting procedures:
 
• Read the Safety and Compliance Manua (80669C) for detailed safety information.
 
• Refer to the Power Supply Component Replacement section.
 
• Refer to the Parts section.
 
• Refer to the Wiring Diagrams section.
After the problem has been located and repaired, refer to the “Sequence of operation” flow diagram in this section to test the power supply for proper operation.
External inspection
1. Inspect the exterior of the power supply fordamage to the coverand 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. Turn OFF the power, disconnect the power cord, and disconnect the gas supply.
2. Using a TORX or blade screwdriver remove the screws from the power supply cover.
3. Lift the cover off the power supply.
4. Remove the Mylar barrier from the power board side of the power supply. The Mylar barrier is flexible and can be bent slightly for removal. Be certain to replace the barrier when you are finished working on the power supply.
5.Inspect the inside of the power supply, especially on the side with the power board. Look for broken or loose wiring connections, burn and char marks, damaged components, and so on. Repair or replace as necessary.
Initial resistance check
All resistance values must be taken with the power cord disconnected and all internal power supply wires attached.
Perform the steps in Internal inspection before continuing in this section.
• If resistance values are not close (t25%) to the values given in this section, isolate the problem by removing wires attached to the resistance check points or component until the problem is found.
 
• After the problem has been located and repaired, refer to the Sequence of operation flow diagram in this section to test the power supply for proper operation.
Check the power switch
Refer to the figures and table on the following pages.
 
1.Wth the power disconnected and the torch removed from the power supply, set the ON/OFF switch (S1)to ON(I).
 
2. Check the resistance across the input leads (the leads are labeled L1,L2, andL3on the power switch).
– 200-600VCSA:resistance across the input leads = 500kΩ.
– 230-400VCE,380VCCC/230-400VCE, 400VCE,380VCCC:resistance across the input leads =
350kΩ
3. Check the resistance from the inputleads to ground to verify that it reads as open. For all power supplies, the resistance from input to ground should read as > 20MΩ
Note: With the power disconnected and the ON/OFF switch (S1)setto OFF (O),all circuits should read as open.
The electrical values shown are ±25%

4. Check the output resistance for the values shown in the table.

Measure resistance fromAll models
Work lead(J27) to nozzle(black wire)230kΩ
Work lead(J27) to electrode(red wire)9kΩ
Electrode(red wire) to nozzle(black wire)230kΩ
Output to ground>20kΩ
If no problems were found during the visual inspection or the initial resistance check, and the power supply still does not operate correctly, see the Troubleshooting guide.
Note:Troubleshooting guide later is this section 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.
Hypertherm IGBT tester
Use the Hyperthem 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 8-15 Schematic for building an IGBT tester and use it to test the IGBTs.
Indicator LEDs and device tests

Green “pass” LED

When iluminated, this LED indicates that thelGBT passed the test for an open IGBT when switch is
pressed to the right or for a short-circuited IGBT when switch is pressed to the left.
Red “fail” LED
When illuminated, this LED indicates that the IGBT faled the testfor an open IGBT when switch is
pressed to the right or for a short-circuited IGBT when switch is pressed to the left.
Red “low battery” LED
When illuminated, this LED indicates that the remaining voltage in the battery is insufficient to power the test circuitry. Replace the batery.
Note: The Hypertherm IGBT tester requires a minimum of 8 Vto power its circuitry properly.
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.
The illustrations below depict three common configurations of an lGBT. Each connection on the IGBT will be labeled with an abbreviation. They may be labeled as C,E, G or 1, 2, 3 with a schematic that shows numbers and pin functions.
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.
Troubleshoot the Hypertherm IGBT tester

1. Inspect the leads and the IGBT tester for damage.

2.Verifty that the battery voltage is greater than 8V.

3.Test the IGBT Tester, itself, as shown below. If the resuts do not match the table,replace the lead connections.

Connect leadsShort testOpen test
None
Red to black
Pass
Fail
Fail
Pass
Schematic for building an IGBT tester
IGBT device test using a non-Hypertherm tester
The device tester shown on page 8-15 Schematic for building an IGBT tester has one LED and one push-button switch that are used in combination to perform two tests.
Note: Before an IGBT can be tested,it mustbe electrically isolated from all circuits. If the lGBT is installed ina power supply, remove the power board and any lead connections before testing.
1. Inspect the IGBT for cracks or black marks. If damaged,replace the IGBT.
2. Verify that the 9 v battery reads greater than (>)8.0v.
3.Connect the test leads as shown below.
4.With the test leads connected and without pressing the push button switch, the LED should notilluminate. If the LEDis illuminated, then the IGBT is shorted. Replace the IGBT.
5. With the test leads connected, press the pushbutton switch. This time, the LED should illuminate. If theLED does not illuminate, then the IGBT is open. Replace the IGBT.
200-600V CSA power supply overview
230-400V CE, 380V CCC/230-400V CE Power supply overview
380V CCC, 400V CE Power supply overview
200-600V CSA power supply overview(power board removed)
230-400V CE, 380V CCC/230-400V CE Power supply overview(power board removed)
380V CCC, 400V CE Power supply overview(power board removed)
Fault codes
Fault codes displayed on the LCD screen in ‘service mode” are in the format N-nn-n. Faultcodes displayed on the LCD screen in ‘operator mode”have one fewer digit and appear in the format N-nn. The tables in this soction showall digits.
The fault priority is assigned based on the fault code value: the higher the number, the higher the fault priority. Only one faut code is set at one time. fmore than one fault occus at the same time, only the fault with the highest priority is set.
Displaying the service screen
For troubleshooting faults, display the service screen by simutaneously pressing the automatic/manual and current/gas mode selectors for approximately two (2) seconds. The service screen displays.
Designator

I

C

B

P

G

IP

VL

TI

TP

VB

AH

F

T

S

1-6

Description

Current set/read

LCD contrast

LCD brightness (per cent)

Pressure set/read

Gas test enable (1)disable (0)

Boost circuit current (not present on 400VCE)

Incoming AC line voltage

Inverter module temperature (C)

Boost module temperature (C), not present on 400VCE

DC bus voltage

Arc hours

Live fault code

Torch identifier (amps/H hand or M machine load length in feet)

DSP/Control board software versions

1 is the most recent fault code; 6 is the oldest fault code

Note: Fault codes beginning with zero (0-n-nn)are not recorded in the fault log.

To move the field solector () between fields, press the current gas mode selector. The asterisk indicates the selected field You can alter theL, C,B,P,and G felds by turning the adjustment knob.
To toggle between (I) Curent 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.
To exit the service screen, simultaneously press the automatic/manual and current gas mode selectors. The operator screen displays.
Important fault icons

One of the following fault icons may appear on the LCD display in operator mode:

Warning
The system continues to operate.
Fault
The system stops cutting and is able to recover when the fault is cleared.
Error
The system needs service.
Performing a cold restart
Sometimes a “cold restart” cears the fault When a cold restart is recommended in one of the Solutions below, do the following:
1.Power OFF the machine.
2.Wait 20 seconds or until the red LED near the top of the DSP board blinks once.
3.Power ON the machine.
Fault codes and solutions
Each table below describes a faut category and suggests solutions for each faut code. Several of the fault solutions show a test number. Refer to page B-42 System tests to perform the indicated numbered test.
Note: if a fault occurs while using a generator, turning the power switch quickly to OFF and then to ON again (sometimes called a “quickreset) may not clear the fault. Instead, turn OFF the power supply and wait 30 to 45 seconds before turning ON again.
0-00-0

This fault code indicates normal operations.

Fault codeDescriptionPower LEDFault LEDFault iconSolutions
0-00-0NoneOnOffNo errors
0-nn-n
These fault codes identity operational fauts. On the operator screen, thelast digitis omitted. Display the service screen for more information on faults 11,19,30,40,60,and 99.