Hypertherm power max 105 инструкция

Инструкция по эксплуатации системы плазменно-дуговой резки Powermax 105. Инструкция содержит все важные сведения для эффективной и безопасной работы с системой, включая информацию об установке, методах снижения излучения, уравнивании потенциалов и настройке источника тока и др.

Powermax 105 инструкция по эксплуатации

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Plasma arc cutting systems

Service Manual – 807580

Revision 1

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Service Manual

(P/N 807580)

Revision 1 – November 2013

Hypertherm, Inc.

Hanover, NH USA

www.hypertherm.com

email: info@hypertherm.com

© Copyright 2013 Hypertherm, Inc.

All Rights Reserved

Hypertherm and Powermax are trademarks of Hypertherm, Inc.

and may be registered in the United States and/or other countries.

powermax

105

Hypertherm Inc.

Etna Road, P.O. Box 5010

Hanover, NH 03755 USA

603-643-3441 Tel (Main Office)

603-643-5352 Fax (All Departments)

info@hypertherm.com (Main Office Email)

800-643-9878 Tel (Technical Service)

technical.service@hypertherm.com (Technical Service Email)

800-737-2978 Tel (Customer Service)

customer.service@hypertherm.com (Customer Service Email)

866-643-7711 Tel (Return Materials Authorization)

877-371-2876 Fax (Return Materials Authorization)

return.materials@hypertherm.com (RMA email)

Hypertherm Plasmatechnik GmbH

Technologiepark Hanau

Rodenbacher Chaussee 6

D-63457 Hanau-Wolfgang, Deutschland

49 6181 58 2100 Tel

49 6181 58 2134 Fax

49 6181 58 2123 (Technical Service)

Hypertherm (S) Pte Ltd.

82 Genting Lane

Media Centre

Annexe Block #A01-01

Singapore 349567, Republic of Singapore

65 6841 2489 Tel

65 6841 2490 Fax

65 6841 2489 (Technical Service)

Hypertherm (Shanghai) Trading Co., Ltd.

Unit 301, South Building

495 ShangZhong Road

Shanghai, 200231

PR China

86-21-60740003 Tel

86-21-60740393 Fax

Hypertherm Europe B.V.

Vaartveld 9

4704 SE

Roosendaal, Nederland

31 165 596907 Tel

31 165 596901 Fax

31 165 596908 Tel (Marketing)

31 165 596900 Tel (Technical Service)

00 800 4973 7843 Tel (Technical Service)

Hypertherm Japan Ltd.

Level 9, Edobori Center Building

2-1-1 Edobori, Nishi-ku

Osaka 550-0002 Japan

81 6 6225 1183 Tel

81 6 6225 1184 Fax

Hypertherm Brasil Ltda.

Rua Bras Cubas, 231 – Jardim Maia

Guarulhos, SP — Brasil

CEP 07115-030

55 11 2409 2636 Tel

55 11 2408 0462 Fax

Hypertherm México, S.A. de C.V.

Avenida Toluca No. 444, Anexo 1,

Colonia Olivar de los Padres

Delegación Álvaro Obregón

México, D.F. C.P. 01780

52 55 5681 8109 Tel

52 55 5683 2127 Fax

Hypertherm Korea Branch

#3904 Centum Leaders Mark B/D,

1514 Woo-dong, Haeundae-gu, Busan

Korea, 612-889

82 51 747 0358 Tel

82 51 701 0358 Fax

12/2/13

Compliance Information EMC-1

7/ 10

ELECTROMAGNETIC COMPATIBILITY EMC

Introduction

Hypertherm’s CE-marked equipment is built in compliance

with standard EN60974-10. The equipment should be

installed and used in accordance with the information

below to achieve electromagnetic compatibility.

The limits required by EN60974-10 may not be adequate

to completely eliminate interference when the affected

equipment is in close proximity or has a high degree of

sensitivity. In such cases it may be necessary to use other

measures to further reduce interference.

This cutting equipment is designed for use only in an

industrial environment.

Installation and use

The user is responsible for installing and using the plasma

equipment according to the manufacturer’s instructions.

If electromagnetic disturbances are detected then it shall

be the responsibility of the user to resolve the situation

with the technical assistance of the manufacturer. In some

cases this remedial action may be as simple as earthing

the cutting circuit, see Earthing of the workpiece. In other

cases, it could involve constructing an electromagnetic

screen enclosing the power source and the work

complete with associated input filters. In all cases,

electromagnetic disturbances must be reduced to the

point where they are no longer troublesome.

Assessment of area

Before installing the equipment, the user shall make an

assessment of potential electromagnetic problems in

the surrounding area. The following shall be taken into

account:

a. Other supply cables, control cables, signaling and

telephone cables; above, below and adjacent to the

cutting equipment.

b. Radio and television transmitters and receivers.

c. Computer and other control equipment.

d. Safety critical equipment, for example guarding

ofindustrial equipment.

e. Health of the people around, for example the use

ofpacemakers and hearing aids.

f. Equipment used for calibration or measurement.

g. Immunity of other equipment in the environment. User

shall ensure that other equipment being used in the

environment is compatible. This may require additional

protection measures.

h. Time of day that cutting or other activities are to be

carried out.

The size of the surrounding area to be considered

will depend on the structure of the building and other

activities that are taking place. The surrounding area may

extend beyond the boundaries of the premises.

Methods of reducing emissions

Mains supply

Cutting equipment must be connected to the mains

supply according to the manufacturer’s recommendations.

If interference occurs, it may be necessary to take

additional precautions such as filtering of the mains

supply.

EMC-2 Compliance Information

7/ 10

ELECTROMAGNETIC COMPATIBILITY

Consideration should be given to shielding the supply

cable of permanently installed cutting equipment,

in metallic conduit or equivalent. Shielding should

be electrically continuous throughout its length. The

shielding should be connected to the cutting mains

supply so that good electrical contact is maintained

between the conduit and the cutting power source

enclosure.

Maintenance of cutting equipment

The cutting equipment must be routinely maintained

according to the manufacturer’s recommendations. All

access and service doors and covers should be closed

and properly fastened when the cutting equipment is in

operation. The cutting equipment should not be modified

in any way, except as set forth in and in accordance with

the manufacturer’s written instructions. For example,

the spark gaps of arc striking and stabilizing devices

should be adjusted and maintained according to the

manufacturer’s recommendations.

Cutting cables

The cutting cables should be kept as short as possible

and should be positioned close together, running at or

close to the floor level.

Equipotential bonding

Bonding of all metallic components in the cutting

installation and adjacent to it should be considered.

However, metallic components bonded to the workpiece

will increase the risk that the operator could receive a

shock by touching these metallic components and the

electrode (nozzle for laser heads) at the same time.

The operator should be insulated from all such bonded

metallic components.

Earthing of the workpiece

Where the workpiece is not bonded to earth for

electrical safety, nor connected to earth because of its

size and position, for example, ship’s hull or building

steel work, a connection bonding the workpiece to earth

may reduce emissions in some, but not all instances.

Care should be taken to prevent the earthing of the

workpiece increasing the risk of injury to users, or

damage to other electrical equipment. Where necessary,

the connection of the workpiece to earth should be

made by a direct connection to the workpiece, but

in some countries where direct connection is not

permitted, the bonding should be achieved by suitable

capacitances selected according to national regulations.

Note: The cutting circuit may or may not be earthed for

safety reasons. Changing the earthing arrangements

should only be authorized by a person who is competent

to assess whether the changes will in crease the risk of

injury, for example, by allowing parallel cutting current

return paths which may damage the earth circuits

of other equipment. Further guidance is provided

in IEC60974-9, Arc Welding Equip ment, Part 9:

Installation and Use.

Screening and shielding

Selective screening and shielding of other cables

and equipment in the surrounding area may alleviate

problems of interference. Screening of the entire plasma

cutting installation may be considered for special

applications.

Compliance Information W-1

9/10

Attention

Genuine Hypertherm parts are the factory-

recommended replacement parts for your Hypertherm

system. Any damage or injury caused by the use of other

than genuine Hypertherm parts may not be covered by

the Hypertherm warranty, and will constitute misuse of

the Hypertherm Product.

You are solely responsible for the safe use of the

Product. Hypertherm does not and cannot make any

guarantee or warranty regarding the safe use of the

product in your environment.

General

Hypertherm, Inc. warrants that its Products shall be

free from defects in materials and workmanship for the

specific periods of time set forth herein and as follows: if

Hypertherm is notified of a defect (i)with respect to the

plasma power supply within a period of two (2) years

from the date of its delivery to you, with the exception of

Powermax brand power supplies, which shall be within

a period of three (3) years from the date of delivery

to you, and (ii)with respect to the torch and leads

within a period of one (1) year from its date of delivery

to you, and with respect to torch lifter assemblies

within a period of one (1) year from its date of delivery

to you, and with respect to Automation products

one (1) year from its date of delivery to you, with the

exception of the EDGEProCNC, EDGEProTiCNC,

MicroEDGEProCNC and ArcGlideTHC, which shall

be within a period of two (2) years from the date of

delivery to you, and (iii)with respect to HyIntensity fiber

laser components within a period of two (2) years from

the date of its delivery to you, with the exception of laser

heads and beam delivery cables, which shall be within a

period of one (1) year from its date of delivery to you.

This warranty shall not apply to any Powermax brand

power supplies that have been used with phase

converters. In addition, Hypertherm does not warranty

systems that have been damaged as a result of poor

power quality, whether from phase converters or

incoming line power. This warranty shall not apply to any

product which has been incorrectly installed, modified,

or otherwise damaged.

Hypertherm provides repair, replacement or adjustment

of the Product as the sole and exclusive remedy, if

and only if the warranty set forth herein properly is

invoked and applies. Hypertherm, at its sole option,

shall repair, replace, or adjust, free of charge, any

defective Products covered by this warranty which

shall be returned with Hypertherm’s prior authorization

(which shall not be unreasonably withheld), properly

packed, to Hypertherm’s place of business in Hanover,

New Hampshire, or to an authorized Hypertherm repair

facility, all costs, insurance and freight pre paid by the

customer. Hypertherm shall not be liable for any repairs,

replacement, or adjustments of Products covered by this

warranty, except those made pursuant to this paragraph

and with Hypertherm’s prior written consent.

The warranty set forth above is exclusive and is in

lieu of all other warranties, express, implied, statutory,

or otherwise with respect to the Products or as to

the results which may be obtained therefrom, and

all implied warranties or conditions of quality or of

merchantability or fitness for a particular purpose or

against infringement. The foregoing shall constitute the

sole and exclusive remedy for any breach by Hypertherm

of its warranty.

Distributors/OEMs may offer different or additional

warranties, but Distributors/OEMs are not authorized

togive any additional warranty protection to you or make

any representation to you purporting to be binding upon

Hypertherm.

WARRANTY

W-2 Compliance Information

9/10

WARRANTY

Patent indemnity

Except only in cases of products not manufactured by

Hypertherm or manufactured by a person other than

Hypertherm not in strict conformity with Hypertherm’s

specifications and in cases of designs, processes,

formulae, or combinations not developed or purported

to be developed by Hypertherm, Hypertherm will have

the right to defend or settle, at its own expense, any

suit or proceeding brought against you alleging that

the use of the Hypertherm product, alone and not in

combination with any other product not supplied by

Hypertherm, infringes any patent of any third party. You

shall notify Hypertherm promptly upon learning of any

action or threatened action in connection with any such

alleged infringement (and in any event no longer than

fourteen (14) days after learning of any action or threat

of action), and Hypertherm’s obligation to defend shall

be conditioned upon Hypertherm’s sole control of, and

the indemnified party’s cooperation and assistance in,

the defense of the claim.

Limitation of liability

In no event shall Hypertherm be liable to any

person or entity for any incidental, consequential

direct, indirect, punitive or exemplary damages

(including but not limited to lost profits)

regardless of whether such liability is based on

breach of contract, tort, strict liability, breach

of warranty, failure of essential purpose, or

otherwise, and even if advised of the possibility

of such damages.

National and local codes

National and local codes governing plumbing and

electrical installation shall take precedence over any

instructions contained in this manual. In no event shall

Hypertherm be liable for injury to persons or property

damage by reason of any code violation or poor work

practices.

Liability cap

In no event shall Hypertherm’s liability, if any,

whether such liability is based on breach of

contract, tort, strict liability, breach of warranties,

failure of essential purpose or otherwise, for

any claim, action, suit or proceeding (whether

in court, arbitration, regulatory proceeding or

otherwise) arising out of or relating to the use of

the Products exceed in the aggregate the amount

paid for the Products that gave rise to such claim.

Insurance

At all times you will have and maintain insurance in such

quantities and types, and with coverage sufficient and

appropriate to defend and to hold Hypertherm harmless

in the event of any cause of action arising from the use

of the products.

Transfer of rights

You may transfer any remaining rights you may have

hereunder only in connection with the sale of all or

substantially all of your assets or capital stock to a

successor in interest who agrees to be bound by all of

the terms and conditions of this Warranty. Within thirty

(30) days before any such transfer occurs, you agree to

notify in writing Hypertherm, which reserves the right of

approval. Should you fail timely to notify Hypertherm and

seek its approval as set forth herein, the Warranty set

forth herein shall be null and void and you will have no

further recourse against Hypertherm under the Warranty

or otherwise.

powermax

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Service Manual

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Safety information

Before operating any Hypertherm equipment, read the separate Safety and Compliance Manual (80669C) included

with your product for important safety information.

vi powermax

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Service Manual

Table of ConTenTs

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Service Manual

vii

Section 1

Specifications

Safety information …………………………………………………………………………………………………………………………………………………………….. 1-2

System description …………………………………………………………………………………………………………………………………………………………… 1-2

Where to find information …………………………………………………………………………………………………………………………………………………1-3

Power supply dimensions ………………………………………………………………………………………………………………………………………………… 1-4

Component weights (105 A systems) …………………………………………………………………………………………………………………………….. 1-5

Powermax105 power supply ratings ……………………………………………………………………………………………………………………………….. 1-6

Duramax 75° hand torch dimensions ………………………………………………………………………………………………………………………………. 1-8

Duramax 15° hand torch dimensions ………………………………………………………………………………………………………………………………. 1-8

Duramax 180° full-length machine torch dimensions ……………………………………………………………………………………………………… 1-9

Duramax 180° mini machine torch dimensions ……………………………………………………………………………………………………………….. 1-9

Powermax105 cutting specifications ……………………………………………………………………………………………………………………………. 1-10

Symbols and markings …………………………………………………………………………………………………………………………………………………… 1-11

Noise levels ……………………………………………………………………………………………………………………………………………………………………. 1-11

IEC symbols …………………………………………………………………………………………………………………………………………………………………… 1-12

Section 2

Power Supply Setup

Unpack the Powermax system …………………………………………………………………………………………………………………………………………. 2-2

Claims ………………………………………………………………………………………………………………………………………………………………………2-2

Contents ………………………………………………………………………………………………………………………………………………………………….. 2-3

Position the power supply…………………………………………………………………………………………………………………………………………………2-4

Prepare the electrical power …………………………………………………………………………………………………………………………………………….2-4

Install a line-disconnect switch ……………………………………………………………………………………………………………………………….2-5

Requirements for grounding …………………………………………………………………………………………………………………………………… 2-5

Power connection for the Powermax105 ………………………………………………………………………………………………………………………… 2-6

Three-phase power cord and plug installation ………………………………………………………………………………………………………. 2-8

Extension cord recommendations ……………………………………………………………………………………………………………………………………. 2-9

Extension cord specifications …………………………………………………………………………………………………………………………………. 2-9

Engine-driven generator recommendations ………………………………………………………………………………………………………… 2-10

Prepare the gas supply ………………………………………………………………………………………………………………………………………………….. 2-11

Additional gas filtration …………………………………………………………………………………………………………………………………………. 2-11

Connect the gas supply ……………………………………………………………………………………………………………………………………….. 2-12

Table of ConTenTs

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Service Manual

Section 3

Basic System Operations

Controls and indicators ……………………………………………………………………………………………………………………………………………………. 3-2

Rear controls ……………………………………………………………………………………………………………………………………………………………3-2

Front controls and LEDs …………………………………………………………………………………………………………………………………………. 3-2

Status screen …………………………………………………………………………………………………………………………………………………………..3-4

Operating the Powermax105 …………………………………………………………………………………………………………………………………………… 3-6

Connect the electrical power, gas supply, and torch lead …………………………………………………………………………………….3-6

Attach the work lead to the power supply ……………………………………………………………………………………………………………… 3-7

Attach the work clamp to the workpiece ………………………………………………………………………………………………………………..3-8

Turn ON the system ………………………………………………………………………………………………………………………………………………… 3-9

Set the operating mode switch ………………………………………………………………………………………………………………………………. 3-9

Check the indicators …………………………………………………………………………………………………………………………………………….. 3-10

Manually adjusting the gas pressure ……………………………………………………………………………………………………………………. 3-10

Adjusting the current (amperage) ………………………………………………………………………………………………………………………… 3-11

Electrode end-of-life detection feature …………………………………………………………………………………………………………………………. 3-11

Understanding duty-cycle limitations ……………………………………………………………………………………………………………………………. 3-12

Section 4

Hand Torch Setup

Introduction ……………………………………………………………………………………………………………………………………………………………………….4-2

Consumable life …………………………………………………………………………………………………………………………………………………………………4-2

Hand torch components …………………………………………………………………………………………………………………………………………………..4-3

Choose the hand torch consumables ……………………………………………………………………………………………………………………………… 4-4

Drag-cutting 105 A consumables ………………………………………………………………………………………………………………………….. 4-4

Drag-cutting 45 A, 65 A, 85 A consumables ………………………………………………………………………………………………………… 4-4

Hand torch consumables …………………………………………………………………………………………………………………………………………………. 4-5

Gouging consumables ……………………………………………………………………………………………………………………………………………. 4-5

FineCut

®

consumables …………………………………………………………………………………………………………………………………………… 4-5

Install the hand torch consumables …………………………………………………………………………………………………………………………………. 4-6

Connecting the torch lead ……………………………………………………………………………………………………………………………………………….. 4-7

Section 5

Hand Cutting

Using the hand torch ………………………………………………………………………………………………………………………………………………………… 5-2

Operate the safety trigger ………………………………………………………………………………………………………………………………………………… 5-2

Hand torch cutting hints …………………………………………………………………………………………………………………………………………………… 5-3

Start a cut from the edge of the workpiece …………………………………………………………………………………………………………………….. 5-4

Pierce a workpiece …………………………………………………………………………………………………………………………………………………………… 5-5

Gouge a workpiece ………………………………………………………………………………………………………………………………………………………….. 5-6

Gouge profile …………………………………………………………………………………………………………………………………………………………..5-7

Varying the gouge profile ………………………………………………………………………………………………………………………………………… 5-8

Common hand-cutting faults ……………………………………………………………………………………………………………………………………………. 5-8

Table of ConTenTs

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Section 6

Machine Torch Setup

Introduction ……………………………………………………………………………………………………………………………………………………………………….6-3

Consumable life …………………………………………………………………………………………………………………………………………………………………6-3

Machine torch components ……………………………………………………………………………………………………………………………………………… 6-4

Converting a full-length machine torch to a mini machine torch …………………………………………………………………………………….6-5

Mount the torch ………………………………………………………………………………………………………………………………………………………………… 6-7

Choose the machine torch consumables …………………………………………………………………………………………………………………………6-9

Machine torch consumables …………………………………………………………………………………………………………………………………………….6-9

Mechanized shielded 105 A consumables …………………………………………………………………………………………………………….6-9

Mechanized shielded 45 A, 65 A, 85 A consumables …………………………………………………………………………………………..6-9

Mechanized shielded with ohmic 105 A consumables ………………………………………………………………………………………. 6-10

Mechanized shielded with ohmic 45 A, 65 A, 85 A consumables …………………………………………………………………….. 6-10

Mechanized unshielded 105 A consumables ……………………………………………………………………………………………………… 6-10

Mechanized unshielded 45 A, 65 A, 85 A consumables ……………………………………………………………………………………. 6-10

Gouging consumables …………………………………………………………………………………………………………………………………………. 6-11

FineCut

®

shielded consumables …………………………………………………………………………………………………………………………. 6-11

FineCut

®

unshielded consumables …………………………………………………………………………………………………………………….. 6-11

Install the machine torch consumables …………………………………………………………………………………………………………………………. 6-12

Aligning the torch …………………………………………………………………………………………………………………………………………………………… 6-12

Connecting the torch lead …………………………………………………………………………………………………………………………………………….. 6-13

Using the cut charts ………………………………………………………………………………………………………………………………………………………. 6-14

Estimated kerf-width compensation …………………………………………………………………………………………………………………….. 6-15

105 A Shielded consumables ……………………………………………………………………………………………………………………………… 6-17

105 A Shielded cutting (Mild Steel) ……………………………………………………………………………………………………………………. 6-18

105 A Shielded cutting (Stainless Steel) ……………………………………………………………………………………………………………. 6-19

105 A Shielded cutting (Aluminum) …………………………………………………………………………………………………………………….. 6-20

85 A Shielded consumables ………………………………………………………………………………………………………………………………… 6-21

85 A Shielded cutting (Mild Steel) ………………………………………………………………………………………………………………………. 6-22

85 A Shielded cutting (Stainless Steel) ………………………………………………………………………………………………………………. 6-23

85 A Shielded cutting (Aluminum) ………………………………………………………………………………………………………………………. 6-24

65 A Shielded consumables ………………………………………………………………………………………………………………………………… 6-25

65 A Shielded cutting (Mild Steel) ………………………………………………………………………………………………………………………. 6-26

65 A Shielded cutting (Stainless Steel) ………………………………………………………………………………………………………………. 6-27

65 A Shielded cutting (Aluminum) ………………………………………………………………………………………………………………………. 6-28

45 A Shielded consumables ………………………………………………………………………………………………………………………………… 6-29

45 A Shielded cutting (Mild Steel) ………………………………………………………………………………………………………………………. 6-30

45 A Shielded cutting (Stainless Steel) ………………………………………………………………………………………………………………. 6-31

45 A Shielded cutting (Aluminum) ………………………………………………………………………………………………………………………. 6-32

Table of ConTenTs

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Service Manual

FineCut

®

consumables ………………………………………………………………………………………………………………………………………… 6-33

FineCut (Mild Steel) ……………………………………………………………………………………………………………………………………………… 6-34

FineCut (Stainless Steel) ……………………………………………………………………………………………………………………………………… 6-35

Low Speed FineCut (Mild Steel) …………………………………………………………………………………………………………………………. 6-36

Low Speed FineCut (Stainless Steel) …………………………………………………………………………………………………………………. 6-37

105 A Unshielded consumables ………………………………………………………………………………………………………………………….. 6-38

105 A Unshielded cutting (Mild Steel) ………………………………………………………………………………………………………………… 6-39

105 A Unshielded cutting (Stainless Steel) ………………………………………………………………………………………………………… 6-40

105 A Unshielded cutting (Aluminum) ………………………………………………………………………………………………………………… 6-41

85 A Unshielded consumables ……………………………………………………………………………………………………………………………. 6-42

85 A Unshielded cutting (Mild Steel) ………………………………………………………………………………………………………………….. 6-43

85 A Unshielded cutting (Stainless Steel) ………………………………………………………………………………………………………….. 6-44

85 A Unshielded cutting (Aluminum) …………………………………………………………………………………………………………………… 6-45

65 A Unshielded consumables ……………………………………………………………………………………………………………………………. 6-46

65 A Unshielded cutting (Mild Steel) ………………………………………………………………………………………………………………….. 6-47

65 A Unshielded cutting (Stainless Steel) ………………………………………………………………………………………………………….. 6-48

65 A Unshielded cutting (Aluminum) …………………………………………………………………………………………………………………… 6-49

45 A Unshielded consumables ……………………………………………………………………………………………………………………………. 6-50

45 A Unshielded cutting (Mild Steel) ………………………………………………………………………………………………………………….. 6-51

45 A Unshielded cutting (Stainless Steel) ………………………………………………………………………………………………………….. 6-52

45 A Unshielded cutting (Aluminum) …………………………………………………………………………………………………………………… 6-53

Section 7

Mechanized Cutting

Connecting an optional remote-start pendant ………………………………………………………………………………………………………………… 7-2

Connecting an optional machine interface cable ……………………………………………………………………………………………………………. 7-3

Machine interface pinout …………………………………………………………………………………………………………………………………………7-5

Setting the five-position voltage divider …………………………………………………………………………………………………………………. 7-6

Accessing raw arc voltage ………………………………………………………………………………………………………………………………………………..7-7

Connecting an optional RS485 serial interface cable ……………………………………………………………………………………………………. 7-7

Using the machine torch …………………………………………………………………………………………………………………………………………………..7-8

Setting up the torch and table …………………………………………………………………………………………………………………………………………. 7-8

Understand and optimize cut quality ……………………………………………………………………………………………………………………………….. 7-8

Cut or bevel angle …………………………………………………………………………………………………………………………………………………… 7-8

Dross ……………………………………………………………………………………………………………………………………………………………………….. 7-9

Piercing a workpiece using the machine torch …………………………………………………………………………………………………………….. 7-10

Common machine-cutting faults …………………………………………………………………………………………………………………………………… 7-11

Table of ConTenTs

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Section 8

Troubleshooting and System Tests

Controls and indicators ……………………………………………………………………………………………………………………………………………………. 8-3

Theory of operation ……………………………………………………………………………………………………………………………………………………………8-4

General …………………………………………………………………………………………………………………………………………………………………….8-4

200-600 V CSA 3-phase power supply functional description ……………………………………………………………………………8-4

230-400 V CE, 380 V CCC/230-400 V CE 3-phase power supply functional description ………………………………8-5

400 V CE, 380 V CCC 3-phase power supply functional description ………………………………………………………………… 8-5

Sequence of operation ……………………………………………………………………………………………………………………………………………. 8-6

Troubleshooting preparation …………………………………………………………………………………………………………………………………………….8-7

Test equipment ………………………………………………………………………………………………………………………………………………………..8-7

Troubleshooting procedures and sequence ………………………………………………………………………………………………………….. 8-7

External inspection ………………………………………………………………………………………………………………………………………………….. 8-9

Internal inspection ……………………………………………………………………………………………………………………………………………………8-9

Initial resistance check ………………………………………………………………………………………………………………………………………………………8-9

Check the power switch …………………………………………………………………………………………………………………………………………. 8-9

Hypertherm IGBT tester ………………………………………………………………………………………………………………………………………. 8-12

Indicator LEDs and device tests ………………………………………………………………………………………………………………………….. 8-12

IGBT test preparation …………………………………………………………………………………………………………………………………………… 8-13

IGBT device test using the Hypertherm tester ……………………………………………………………………………………………………. 8-14

Troubleshoot the Hypertherm IGBT tester ………………………………………………………………………………………………………….. 8-14

Schematic for building an IGBT tester ………………………………………………………………………………………………………………… 8-15

IGBT device test using a non-Hypertherm tester ……………………………………………………………………………………………….. 8-16

200-600 V CSA power supply overview ……………………………………………………………………………………………………………………… 8-17

230-400 V CE, 380 V CCC/230-400 V CE power supply overview ………………………………………………………………………… 8-18

380 V CCC, 400 V CE power supply overview …………………………………………………………………………………………………………… 8-19

200-600 V CSA power supply overview (power board removed) ……………………………………………………………………………… 8-20

230-400 V CE, 380 V CCC/230-400 V CE power supply overview (power board removed) ………………………………… 8-21

380 V CCC, 400 V CE power supply overview (power board removed) …………………………………………………………………… 8-22

Fault codes …………………………………………………………………………………………………………………………………………………………………….. 8-23

Displaying the service screen ………………………………………………………………………………………………………………………………. 8-23

Important fault icons …………………………………………………………………………………………………………………………………………….. 8-24

Performing a cold restart ……………………………………………………………………………………………………………………………………… 8-24

Fault codes and solutions …………………………………………………………………………………………………………………………………….. 8-25

Troubleshooting guide …………………………………………………………………………………………………………………………………………………… 8-36

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System tests…………………………………………………………………………………………………………………………………………………………………… 8-42

Test 1 – Voltage input ………………………………………………………………………………………………………………………………………….. 8-43

Test 2 – DC Power Buss …………………………………………………………………………………………………………………………………….. 8-44

Test 3 – Output diodes………………………………………………………………………………………………………………………………………… 8-46

Test 4 – Inverter and PFC temperature sensor …………………………………………………………………………………………………… 8-47

Test 5 – Flyback circuit (DC minor voltages) ……………………………………………………………………………………………………… 8-50

Test 6 – Torch stuck open (TSO)/torch stuck closed (TSC) …………………………………………………………………………….. 8-52

Test 7 – Start signal …………………………………………………………………………………………………………………………………………….. 8-54

Test 8 – Torch cap switch …………………………………………………………………………………………………………………………………… 8-55

Test 9 – Electronic regulator ……………………………………………………………………………………………………………………………….. 8-56

Test 10 – Pressure sensor …………………………………………………………………………………………………………………………………… 8-57

Test 11 – Fan ……………………………………………………………………………………………………………………………………………………….. 8-58

Test 12 – AUX switch ………………………………………………………………………………………………………………………………………….. 8-59

Section 9

Power Supply Component Replacement

Replacing the air filter element …………………………………………………………………………………………………………………………………………9-3

Replacing the work lead connector …………………………………………………………………………………………………………………………………. 9-3

Installing the optional filter kit …………………………………………………………………………………………………………………………………………… 9-3

Replacing the power supply cover …………………………………………………………………………………………………………………………………..9-3

Replacing the component barrier …………………………………………………………………………………………………………………………………….. 9-3

Installing the machine interface cable with voltage divider board ………………………………………………………………………………….. 9-4

Installing the machine interface cable ……………………………………………………………………………………………………………………………… 9-4

Installing the RS485 serial interface cable ……………………………………………………………………………………………………………………… 9-4

Replacing the power cord ………………………………………………………………………………………………………………………………………………..9-5

Replacing the strain relief connector ………………………………………………………………………………………………………………………………..9-5

Replacing the power switch …………………………………………………………………………………………………………………………………………….. 9-6

Replacing the control board …………………………………………………………………………………………………………………………………………….. 9-6

Replacing the DSP board ………………………………………………………………………………………………………………………………………………… 9-6

Replacing the power board ……………………………………………………………………………………………………………………………………………… 9-7

Replacing the input diode bridge …………………………………………………………………………………………………………………………………….. 9-7

Replacing the output diode bridge ………………………………………………………………………………………………………………………………….. 9-8

Replacing the pilot arc IGBT ……………………………………………………………………………………………………………………………………………. 9-8

Replacing the inverter IGBT module ……………………………………………………………………………………………………………………………….. 9-8

Replacing the PFC IGBT module …………………………………………………………………………………………………………………………………….9-9

Replacing the snubber resistor …………………………………………………………………………………………………………………………………………9-9

Replacing the damper resistor ………………………………………………………………………………………………………………………………………. 9-10

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Replacing the thermal sensor ……………………………………………………………………………………………………………………………………….. 9-10

Replacing the fan shroud ………………………………………………………………………………………………………………………………………………. 9-10

Replacing the fan …………………………………………………………………………………………………………………………………………………………… 9-11

Replacing the pressure transducer ………………………………………………………………………………………………………………………………. 9-11

Replacing the pressure switch ……………………………………………………………………………………………………………………………………… 9-11

Replacing the air filter subassembly ……………………………………………………………………………………………………………………………… 9-12

Replacing the solenoid valve …………………………………………………………………………………………………………………………………………. 9-12

Replacing the gas tubing ………………………………………………………………………………………………………………………………………………. 9-12

Replacing the bulk capacitors……………………………………………………………………………………………………………………………………….. 9-13

Replacing the torch quick disconnect receptacle ………………………………………………………………………………………………………… 9-13

Replacing the work lead receptacle ……………………………………………………………………………………………………………………………… 9-13

Replacing the output inductor ………………………………………………………………………………………………………………………………………. 9-14

Replacing the transformer ……………………………………………………………………………………………………………………………………………… 9-14

Replacing the PFC inductor ………………………………………………………………………………………………………………………………………….. 9-14

Replacing the front end panel ……………………………………………………………………………………………………………………………………….. 9-15

Replacing the rear end panel ………………………………………………………………………………………………………………………………………… 9-15

Installing the machine interface cable for raw arc voltage …………………………………………………………………………………………… 9-15

Section 10

Torch Component Replacement

Hand torch: Replacing the start switch ………………………………………………………………………………………………………………………… 10-2

Hand torch: Replacing the cap-sensor switch …………………………………………………………………………………………………………….. 10-2

Hand torch: Replacing the handles ………………………………………………………………………………………………………………………………. 10-2

Hand torch: Replacing the trigger ………………………………………………………………………………………………………………………………… 10-3

Hand torch: Replacing the torch body ………………………………………………………………………………………………………………………….. 10-3

Hand torch: Replacing the torch lead …………………………………………………………………………………………………………………………… 10-3

Hand torch: Replacing the quick disconnect housing …………………………………………………………………………………………………. 10-4

Machine torch: Replacing the mounting sleeve ……………………………………………………………………………………………………………. 10-4

Machine torch: Replacing the cap-sensor switch ………………………………………………………………………………………………………… 10-4

Machine torch: Replacing the torch body …………………………………………………………………………………………………………………….. 10-4

Machine torch: Replacing the coupler ………………………………………………………………………………………………………………………….. 10-5

Machine torch: Replacing the gear rack ……………………………………………………………………………………………………………………….. 10-5

Machine torch: Replacing the positioning sleeve …………………………………………………………………………………………………………. 10-5

Machine torch: Replacing the torch lead ……………………………………………………………………………………………………………………… 10-6

Machine torch: Replacing the quick disconnect housing ……………………………………………………………………………………………. 10-6

Table of ConTenTs

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Section 11

Parts

Power supply parts ………………………………………………………………………………………………………………………………………………………… 11-2

Exterior front …………………………………………………………………………………………………………………………………………………………. 11-2

Exterior rear …………………………………………………………………………………………………………………………………………………………… 11-3

Interior, power board side (200-600 V CSA) ……………………………………………………………………………………………………… 11-5

Interior, power board side (230-400 V CE) ………………………………………………………………………………………………………… 11-6

Interior, power board side (400 V CE/380 V CCC) …………………………………………………………………………………………… 11-7

Interior, fan side ……………………………………………………………………………………………………………………………………………………. 11-8

Heat sink assembly ……………………………………………………………………………………………………………………………………………………….11-10

200-600 V CSA heat sink components …………………………………………………………………………………………………………….11-10

230-400 V CE heat sink components ……………………………………………………………………………………………………………….11-11

400 V CE/ 380 V CCC heat sink components …………………………………………………………………………………………………11-12

Duramax 75° hand torch replacement parts ……………………………………………………………………………………………………………….. 11-13

Duramax 15° hand torch replacement parts ……………………………………………………………………………………………………………….. 11-14

Hand torch consumables ……………………………………………………………………………………………………………………………………………..11-15

Duramax 180° full-length machine torch replacement parts ………………………………………………………………………………………11-16

Duramax 180° mini machine torch replacement parts ………………………………………………………………………………………………..11-18

Machine torch consumables ………………………………………………………………………………………………………………………………………..11-20

Accessory parts…………………………………………………………………………………………………………………………………………………………….11-21

Powermax105 labels …………………………………………………………………………………………………………………………………………………….11-21

Safety-critical parts……………………………………………………………………………………………………………………………………………………….11-22

200-600 V CSA ………………………………………………………………………………………………………………………………………………….11-22

230-400 V CE …………………………………………………………………………………………………………………………………………………….11-23

400 V CE/380 V CCC ……………………………………………………………………………………………………………………………………….11-24

Power supply fan side …………………………………………………………………………………………………………………………………………11-25

Recommended spare parts ………………………………………………………………………………………………………………………………………….11-26

Section 12

Wiring Diagrams

Powermax Generic Timing Chart ………………………………………………………………………………………………………………………………….. 12-3

Schematic diagram (CSA,230-400VCE,380VCCC/230-400VCE) …………………………………………………………………. 12-4

Schematic diagram (380 V CCC, 400 V CE) ……………………………………………………………………………………………………………… 12-5

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Service Manual 1-1

Section 1

SPECIFICATIONS

In this section:

Safety information ………………………………………………………………………………………………………………………………………………………………..1-2

System description ………………………………………………………………………………………………………………………………………………………………1-2

Where to find information ……………………………………………………………………………………………………………………………………………………1-3

Power supply dimensions ……………………………………………………………………………………………………………………………………………………1-4

Component weights (105 A systems) ………………………………………………………………………………………………………………………………..1-5

Powermax105 power supply ratings …………………………………………………………………………………………………………………………………..1-6

Duramax 75° hand torch dimensions ………………………………………………………………………………………………………………………………….1-8

Duramax 15° hand torch dimensions ………………………………………………………………………………………………………………………………….1-8

Duramax 180° full-length machine torch dimensions …………………………………………………………………………………………………………1-9

Duramax 180° mini machine torch dimensions …………………………………………………………………………………………………………………..1-9

Powermax105 cutting specifications ………………………………………………………………………………………………………………………………. 1-10

Symbols and markings ………………………………………………………………………………………………………………………………………………………1-11

Noise levels ………………………………………………………………………………………………………………………………………………………………………. 1-11

IEC symbols ……………………………………………………………………………………………………………………………………………………………………… 1-12

SpecificationS

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Service Manual

Safety information

Before you set up and operate your Hypertherm system, read the separate Safety and Compliance Manual included

with your system for important safety information.

System description

The 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 Duramax™ 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 systems include 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.

SpecificationS

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Service Manual 1-3

Where to find information

System specifications such as size, weight, detailed electrical specifications, and cut speeds can be found in this

section. For information on:

• Setup requirements, including power requirements, grounding, power cord configurations, extension cord

requirements, and generator recommendations — See 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.

SpecificationS

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Service Manual

Power supply dimensions

274 mm

(10.8 in.)

592 mm

(23.3 in.)

508 mm

(20.0 in.)

432 mm

(17.0 in.)

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Service Manual 1-5

Component weights (105 A systems)

200–600 V CSA 230–400 V CE 400 V CE 380 V CCC 380 V CCC/

230–400 V CE

Power supply 40 kg (88lbs) 39 kg (87lbs) 35 kg (78lbs) With power cord

35 kg (78 lbs)

No power cord

34 kg (74 lbs)

No power cord

36 kg (79 lbs)

With 7.6 m

(25ft) hand torch

and 7.6 m (25ft)

work lead

45 kg (100lbs) 45 kg (100lbs) 41 kg (91lbs) With power cord

41 kg (91 lbs)

No power cord

39 kg (87 lbs)

No power cord

42 kg (92 lbs)

Hand torch 7.6 m (25 ft) 3.3 kg (7.3 lbs)

Hand torch 15 m (50 ft) 5.9 kg (13.0 lbs)

Hand torch 23 m (75 ft) 8.4 kg (18.5 lbs)

Machine torch 4.6 m (15 ft) 2.4 kg (5.4 lbs)

Machine torch 7.6 m (25 ft) 3.4 kg (7.6 lbs)

Machine torch 11 m (35 ft) 4.5 kg (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 ft) 6.1 kg (13.4 lbs)

SpecificationS

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Service Manual

Powermax105 power supply ratings

Rated open-circuit voltage (U

0

)

200–600 V CSA

230–400 V CE

380 V CCC/230–400 V CE

400 V CE

380 V CCC

300 VDC

288 VDC

288 VDC

292 VDC

280 VDC

Output characteristic

1

Drooping

Rated output current (I

2

) 30–105 A

Rated output voltage (U

2

) 160 VDC

Duty cycle at 40° C (104° F) 200–600 V CSA 80% @ 105 A, 480–600 V, 3-PH

70% @ 105 A 240 V, 3-PH

54% @ 105 A 208 V, 3-PH

50% @ 105 A, 200 V, 3-PH

100% @ 94 A, 480–600 V, 3-PH

100% @ 88 A, 240 V, 3-PH

100% @ 77 A, 208 V, 3-PH

100% @ 74 A, 200 V, 3-PH

230–400 V CE

or380VCCC/230–400V CE 80% @ 105 A, 400 V, 3-PH

70% @ 105 A, 230 V, 3-PH

100% @ 94 A, 400 V, 3-PH

100% @ 88 A, 230 V, 3-PH

400 V CE 80% @ 105 A, 400 V, 3-PH

100% @ 94 A, 400 V, 3-PH

380 V CCC 80% @ 105 A, 380 V, 3-PH

100% @ 94 A, 380 V, 3-PH

Operating temperature -10° to 40° C (14° to 104° F)

Storage temperature -25° to 55° C (-13° to 131° F)

Power factor

200–600 V CSA, 3-PH

230–400 V CE, 3-PH

380 V CCC/230–400 V CE, 3-PH

400 V CE, 3-PH

380 V CCC, 3-PH

0.94–0.77

0.94–0.92

0.94–0.92

0.94

0.94

R

sce

– Short Circuit Ratio (CE models only) U

1

– Volts AC rms, 3-PH R

sce

230-400 V CE

400 V CE

275

230

SpecificationS

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Service Manual 1-7

EMC classification CISPR 11 (CE models only)

4

Class A

Input voltage (U

1

)/ Input current (I

1

) at

rated output (U

2 MAX

, I

2 MAX

) (See the

Power Supply Setup section for more

information.)

200–600 V CSA 200/208/240/480/600 V, 3-PH, 50/60 Hz

58/56/49/25/22 A

380 V CCC/

230–400 V CE

2,3

230-400 V, 3-PH, 50/60 Hz

50/29 A

230–400 V CE

2,3

230-400 V, 3-PH, 50/60 Hz

50/29 A

400 V CE

3,5

400 V, 3-PH, 50/60 Hz

28 A

380 V CCC 380 V, 3-PH, 50/60 Hz

30 A

Gas type Air Nitrogen

Gas quality Clean, dry, oil-free per

ISO 8573-1 Class 1.2.2

99.95% pure

Recommended gas inlet flow rate/

pressure

Cutting: 220 slpm (460 scfh , 7.7 scfm) @ 5.9 bar (85 psi)

Gouging: 230 slpm (480 scfh, 8.0 scfm) @ 4.8 bar (70 psi)

1

Defined as a plot of output voltage versus output current.

2

Equipment complies with IEC 61000-3-12 provided that the short-circuit power S

sc

is greater than or equal to 5528

KVA at the interface point between the user’s supply and the public system. It is the responsibility of the installer or

user of the equipment to ensure, by consultation with the distribution network operator if necessary, that the equipment

is connected only to a supply with a short-circuit power S

sc

greater than or equal to 5528 KVA.

3

This product meets the technical requirements of IEC 61000-3-3 and is not subject to conditional connection.

4

WARNING: This Class A equipment is not intended 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 electromagnetic

compatibility in those locations, due to conducted as well as radiated disturbances.

5

Equipment complies with IEC 61000-3-12 provided that the short-circuit power S

sc

is greater than or equal to 4462

KVA at the interface point between the user’s supply and the public system. It is the responsibility of the installer or

user of the equipment to ensure, by consultation with the distribution network operator if necessary, that the equipment

is connected only to a supply with a short-circuit power S

sc

greater than or equal to 4462 KVA.

SpecificationS

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Service Manual

Duramax 75° hand torch dimensions

25.2 cm (9.9 in.)

9.9 cm

(3.9 in.)

75°

angle

25.9 cm (10.2 in.)

5.1 cm

(2.0 in.)

15°

angle

Duramax 15° hand torch dimensions

6.6 cm

(2.6 in.)

6.6 cm

(2.6 in.)

2.5 cm

(1.0 in.)

2.5 cm

(1.0 in.)

SpecificationS

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Service Manual 1-9

Duramax 180° full-length machine torch dimensions

39.6 cm

(15.6 in.)

2.5 cm

(1.0 in.)

2.5 cm

(1.0 in.)

3.6 cm (1.4 in.)

outer dimension,

3.3cm (1.3 in.) flat sides

3.6 cm (1.4 in.)

outerdimension,

3.3cm (1.3 in.) flatsides

31.3 cm

(12.3 in.)

20.6 cm

(8.1 in.)

3.5 cm

(1.4 in.)

3.5 cm

(1.4 in.)

Duramax 180° mini machine torch dimensions

16.8 cm

(6.6 in.)

8.4 cm

(3.3 in.)

SpecificationS

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Service Manual

Powermax105 cutting specifications

Handheld cut capacity (material thickness)

Recommended cut capacity at 500 mm/min (20 ipm)* 32 mm (1-1/4 in.)

Recommended cut capacity at 250 mm/min (10 ipm)* 38 mm (1-1/2 in.)

Severance capacity at 125 mm/min (5 ipm)* 50 mm (2 in.)

Pierce capacity (material thickness)

Pierce capacity for handheld cutting, or mechanized

cutting with programmable torch height control

22 mm (7/8 in.)

Pierce capacity for mechanized cutting without

programmable torch height control

20 mm (3/4 in.)

Maximum cut speed** (mild steel)

6 mm (1/4 in.) 5600 mm/min (220 ipm)

12 mm (1/2 in.) 2400 mm/min (95 ipm)

20 mm (3/4 in.) 1300 mm/min (50 ipm)

25 mm (1 in.) 760 mm/min (30 ipm)

32 mm (1-1/4 in.) 510 mm/min (20 ipm)

Gouging capacity

Metal removal rate on mild steel (65 A) 4.8 kg/hr (10.7 lbs/hr)

Metal removal rate on mild steel (85 A) 8.8 kg/hr (19.5 lbs/hr)

Metal removal rate on mild steel (105 A) 9.8 kg/hr (21.7 lbs/hr)

Duramax series torch weights (refer to page 1-5 Component weights (105 A

systems)] )

Duty cycle and voltage information (refer to page 1-6 Powermax105 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.

SpecificationS

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Service Manual 1-11

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 symbol indicates that the power supply and torch are suit able for operations carried out in en vi ron ments with

increased hazard of elec tri cal shock per IEC 60974-1.

CSA mark

Hypertherm products with a CSA mark meet the United States and Canadian regulations for product safety. The products

were evaluated, tested, and certified by CSA-International. Alternatively the product may have amark by one of the other

Nationally Recognized Testing Laboratories (NRTL) accredited in both the United States and Canada, such as Underwriters

Laboratories, Incorporated (UL) or TÜV.

CE marking

The CE marking signifies the manufacturer’s declaration of conformity to applicable 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 Compatibility (EMC) Directive.

EMC filters needed to comply with the European EMC Directive are incorporated within versions of the product with a

CEmarking.

GOST-R mark

CE versions of Hypertherm products that include 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-Tick mark comply with the EMC regulations required for sale inAustralia and

New Zealand.

s

CCC mark

The China Compulsory Certification (CCC) mark indicates that the product has been tested and found compliant with

product safety regulations required for sale in China.

UkrSEPRO mark

CE versions of Hypertherm products that include a UkrSEPRO 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. Specific information by product can be found in the Hypertherm downloads library at:

https://www.hypertherm.com/

Click Downloads library, select a product from the Product Type drop-down menu, select “Regulatory” from the

Category drop-down menu, and select “Acoustical Noise Data Sheets” from the Sub Category drop-down menu.

SpecificationS

1-12 powermax

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Service Manual

O

l

Direct current (DC)

The terminal for the

external protective

(earth) conductor

AC input power

connection

Plasma torch cutting

Alternating current

(AC)

An inverter-based power

source, either 1-phase or

3-phase

Power is OFF

Power is ON

f

1

f

2

1~

Power is ON (LED)

Inlet gas pressure fault

(LCD)

Missing or loose

consumables (LCD)

Power supply is out of

temperature range (LCD)

Volt/amp curve, “drooping”

characteristic

IEC symbols

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

System fault (LED)

Plate metal cutting

Expanded metal

cutting

Gouging

AC

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Service Manual 2-1

Section 2

POWER SUPPLY SETUP

In this section:

Unpack the Powermax system …………………………………………………………………………………………………………………………………………….2-2

Claims …………………………………………………………………………………………………………………………………………………………………………2-2

Contents ……………………………………………………………………………………………………………………………………………………………………..2-3

Position the power supply……………………………………………………………………………………………………………………………………………………2-4

Prepare the electrical power ……………………………………………………………………………………………………………………………………………….2-4

Install a line-disconnect switch ………………………………………………………………………………………………………………………………….2-5

Requirements for grounding ………………………………………………………………………………………………………………………………………2-5

Power connection for the Powermax105 ……………………………………………………………………………………………………………………………2-6

Three-phase power cord and plug installation ………………………………………………………………………………………………………….2-8

Extension cord recommendations ……………………………………………………………………………………………………………………………………….2-9

Extension cord specifications …………………………………………………………………………………………………………………………………….2-9

Engine-driven generator recommendations …………………………………………………………………………………………………………… 2-10

Prepare the gas supply ……………………………………………………………………………………………………………………………………………………..2-11

Additional gas filtration ……………………………………………………………………………………………………………………………………………. 2-11

Connect the gas supply ………………………………………………………………………………………………………………………………………….. 2-12

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Unpack the Powermax system

1. Verify that all items on your order have been received in good condition. Contact your distributor if any parts are

damaged or missing.

2. Inspect the power supply for damage that may have occurred during shipping. If 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 Hypertherm system, read the separate Safety and Compliance Manual included

with your system for important safety information.

Claims

 Claims for damage during shipment – If your unit was damaged during shipment, youmust file a claim

with the carrier. Hypertherm will furnish you with a copy of the bill oflading upon request. If you need additional

assistance, call the nearest Hypertherm office listed in the front of this manual.

 Claims for defective or missing merchandise – If any component is missing or defective, contact your

Hypertherm distributor. If you need additional assistance, call thenearest Hypertherm office listed in the front of

this manual.

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Service Manual 2-3

Operator Manual

Safety Manual

Quick Setup Card

Registration Card

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.

Box with extra consumables

(located next to air filter)

Setup DVD

Or

Or

Remote-start pendant (optional)

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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 certified) without power cord

Note: To maintain CE certification, install power cord kit 228886.

• 400 volts (3-phase, CE certified)

• 380 volts (3-phase, CCC certified).

The power supply has a 3 m (10 ft) power cord (depending upon the model). Allow at least 0.25 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 determine conductor sizes for power

connection and installation instructions. The HYP rating is determined under maximum normal operating conditions and

the higher HYP input current value should be used for installation purposes.

The maximum output voltage will 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 10 times the rated value for short periods of time.

Caution: Protect the circuit with appropriately sized time-delay (slow-blow) fuses and a

line-disconnect switch.

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Service Manual 2-5

Install a line-disconnect switch

Use a line-disconnect switch for each power supply so that the operator can turn off the incoming power quickly in an

emergency. Locate the switch so that it is easily accessible to the operator. Installation must be performed by a licensed

electrician according to national and local codes. 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 voltage when in the

OFF position.

• Have one OFF and one ON position that are clearly marked with O (OFF) and I (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 to reduce electromagnetic interference (EMI), the power supply 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 a green or green/yellow wire for protective earth ground

and must comply with national and local requirements.

• Refer to the separate Safety and Compliance Manual included with your system for more information on

grounding.

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Power connection for the Powermax105

Powermax105 3-phase systems include 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.

The rated output is 30–105 A, 160 VDC.

200–600 V CSA,

Input voltage (V) 200 208 240 480 600

Input current (A) at rated output (16.8 kw) 58 56 49 25 22

Input current (A) at arc stretch 82 82 78 40 35

Fuse, slow-blow (A) 80 80 80 40 40

230–400 V CE

Input voltage (V) 230 400

Input current (A) at rated output (16.8 kw) 50 29

Input current (A) at arc stretch 80 46

Fuse, slow-blow (A) 80 50

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Service Manual 2-7

380 V CCC/230–400 V CE

Input voltage (V) 230 400 380

Input current (A) at rated output (16.8 kw) 50 29 30

Input current (A) at arc stretch 80 46 42

Fuse, slow-blow (A) 80 50 50

400 V CE

Input voltage (V) 400

Input current (A) at rated output (16.8 kw) 28

Input current (A) at arc stretch 44

Fuse, slow-blow (A) 50

380 V CCC

Input voltage (V) 380

Input current (A) at rated output (16.8 kw) 30

Input current (A) at arc stretch 42

Fuse, slow-blow (A) 50

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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

• 230–400 V CE: 10 mm

2

, 4-wire HAR power cord

• 380 V CCC/230–400 V CE ships without a power cord

Note: To maintain CE certification, install power cord kit 228886.

• 400 V CE: 6 mm

2

, 4-wire HAR power cord

• 380 V CCC: 6 mm

2

, 4-wire CCC power cord (some models ship without a power cord)

To operate the Powermax105, use a 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.

L1

L3

L2

L2

L1

L3

Ground

6 mm (.25 in.)

419 mm

(16.5 in.)

203 mm

(8 in.)

CSA

Route lead through strain

relief and tighten

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Service Manual 2-9

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

< 3 m

(<10ft)

3–7.5 m

(10–25ft)

7.5–15 m

(25–50ft)

15–30 m

(50–100ft)

30–45 m

(100–150ft)

200–600 V CSA

Input voltage (VAC) Phase mm

2

(AWG) mm

2

(AWG) mm

2

(AWG) mm

2

(AWG) mm

2

(AWG)

200–240 3 16 (6) 16 (6) 16 (6) 25 (4) 35 (2)

480–600 3 6 (10) 6 (10) 6 (10) 6 (10) 6 (10)

230–400 V CE

Input voltage (VAC) Phase mm

2

mm

2

mm

2

mm

2

mm

2

230 3 16 16 16 25 25

400 3 10 10 10 10 10

380 V CCC/230–400 V CE

Input voltage (VAC) Phase mm

2

mm

2

mm

2

mm

2

mm

2

230 3 16 16 16 25 25

400 3 10 10 10 10 10

380 3 10 10 10 10 10

400 V CE

Input voltage (VAC) Phase mm

2

mm

2

mm

2

mm

2

mm

2

400 3 10 10 10 10 10

380 V CCC

Input voltage (VAC) Phase mm

2

mm

2

mm

2

mm

2

mm

2

380 3 10 10 10 10 10

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Engine-driven generator recommendations

Generators used with the Powermax105 should satisfy the following requirements:

200–600 V CSA

3-phase, 50/60 Hz, 200–600 VAC (480 VAC recommended for best performance)

230–400 V CE

3-phase, 50/60 Hz, 230–400 VAC (400 VAC recommended for best performance)

380 V CCC/230–400 V CE

3-phase, 50/60 Hz, 230–400 VAC (400 VAC recommended for best performance)

400 V CE

3-phase, 50/60 Hz, 400 VAC (400 VAC recommended for best performance)

380 V CCC

3-phase, 50/60 Hz, 380 VAC (380 VAC recommended for best performance)

Engine drive

rating

System output

current

Performance

(arcstretch)

30 kw 105 A Full

22.5–25 105 A Limited

20 kw 85 A Full

15 kw 70 A Limited

15 kw 65 A Full

12 kw 65 A Limited

12 kw 40 A Full

8 kw 40 A Limited

8 kw 30 A Full

Note: Based on the generator rating, age, and condition, adjust the cutting current as needed.

If a fault occurs while using a generator, turning the power switch quickly to OFF and then to ON again

(sometimes called a “quick reset”) may not clear the fault. Instead, turn OFF the power supply and wait 60 to

70 seconds before turning ON again.

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Service Manual 2-11

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 performance, 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 m

3

of <20,000 for particle sizes in the

range of 0.1-0.5 microns, <400 for particle sizes in the range of 0.5-1 microns, and <10 for particle sizes in the range

of 1-5 microns). The maximum water vapor dew point should be <-40° C (-40° F). The maximum oil (aerosol, liquid, and

vapor) content should be less than 0.1 mg/m

3

.

Additional gas filtration

When site conditions introduce moisture, oil, or other contaminants into the gas line, use a 3-stage coalescing filtration

system, such as the Eliminizer filter kit (part number 228890) available from Hypertherm distributors. A 3-stage filtering

system works as shown below toclean contaminants from the gas supply.

The filtering system should be installed between the gas supply and the power supply. Additional gas filtration may

increase the required minimum inlet pressure.

Gas supply

Powermax105

Water and particle filter Oil filter Oil vapor filter

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Connect the gas supply

Connect the gas supply to the power supply using an inert-gas hose with a 9.5mm (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.

The recommended inlet pressure while gas

is flowing is 5.9 – 9.3 bar (85 – 135 psi).

WARNING

Do not allow the gas supply pressure to exceed 9.3 bar (135 psi). The filter bowl may explode if this

pressure is exceeded.

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Service Manual 2-13

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

7.6 m (25 ft) 15.2 m (50 ft) 22.9 m (75 ft)

Cutting 5.2 bar (75 psi) 5.5 bar (80 psi) 5.9 bar (85 psi)

Gouging 4.1 bar (60 psi) 4.5 bar (65 psi) 4.8 bar (70 psi)

Gas flow rates

Cutting 220 slpm (460 scfh, 7.7 scfm) at a minimum 5.9 bar (85 psi)

Gouging 230 slpm (480 scfh, 8.0 scfm) at a minimum 4.8 bar (70 psi)

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Service Manual 3-1

Section 3

BASIC SYSTEM OPERATIONS

In this section:

Controls and indicators ……………………………………………………………………………………………………………………………………………………….3-2

Rear controls ………………………………………………………………………………………………………………………………………………………………3-2

Front controls and LEDs …………………………………………………………………………………………………………………………………………….3-2

Status screen ……………………………………………………………………………………………………………………………………………………………..3-4

Operating the Powermax105 ………………………………………………………………………………………………………………………………………………3-6

Connect the electrical power, gas supply, and torch lead ……………………………………………………………………………………….3-6

Attach the work lead to the power supply …………………………………………………………………………………………………………………3-7

Attach the work clamp to the workpiece …………………………………………………………………………………………………………………..3-8

Turn ON the system ……………………………………………………………………………………………………………………………………………………3-9

Set the operating mode switch ………………………………………………………………………………………………………………………………….3-9

Check the indicators ………………………………………………………………………………………………………………………………………………..3-10

Manually adjusting the gas pressure ……………………………………………………………………………………………………………………….3-10

Adjusting the current (amperage) …………………………………………………………………………………………………………………………… 3-11

Electrode end-of-life detection feature ……………………………………………………………………………………………………………………………. 3-11

Understanding duty-cycle limitations ………………………………………………………………………………………………………………………………. 3-12

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Service Manual

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 (I)/OFF (O) power switch

Activates the power supply and its control circuits.

Front controls and LEDs

Fault LED (yellow)

Power ON LED

(green)

Status screen

Automatic/manual pressure

setting mode selector

Current/gas

selector

Operating

modeswitch

Modes described

onnext page

Adjustment knob

Fault LED (yellow)

When illuminated, this LED indicates that there is a fault with the power supply.

AC

Power ON LED (green)

When illuminated, this LED indicates that the power switch has been set to I (ON) and that the safety

interlocks are satisfied. When blinking, the power supply has a fault.

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Service Manual 3-3

Operating mode switch

The operating mode switch can be set in one of four positions:

• Continuous pilot arc. Cuts expanded metal or grate.

• Non-continuous pilot arc. Cuts or pierces metal plate. This is the standard

setting for normal drag-cutting.

• Gouge. Gouges metal plate.

• Torch lock. Same as the non-continuous pilot arc mode except the torch is

locked in the ON position when you release 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 illuminated in manual mode.

Note: Manual mode should be used by experienced users who need to optimize the gas setting

(override the automatic gas setting) for a 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.

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.

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Service Manual

Status screen

The status screen shows system status and fault information.

Torch started

Fault icon

Fault code

Torch is cutting

Remote

connected

Electrode end of life

detection manually disabled

Current setting (amps)

Current selection cursor

Pressure selection cursor

Pressure

setting

Visual pressure

setting

Gas pressure indicators

In manual mode, the gas pressure is displayed in bar and psi. The gas pressure bar is also a visual indicator of the gas

pressure.

Gas pressure bar

When the arrow is centered in the vertical bar (the reference pressure of the automatic pressure setting), 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. If 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 a particular cutting job. Refer to page 3-10

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 controlling the power supply using serial communications. All local

controls are disabled.

Electrode end-of-life detection manually disabled

Indicates that the electrode end-of-life detection feature is manually disabled.

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Service Manual 3-5

Fault codes

When a power supply or torch fault occurs, the system displays a fault code in the lower-left corner of the status screen

and displays a corresponding fault icon above the code. The first digit is always zero. The other two digits identify the

problem. Fault code information is included 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 fault icons that appear on the left 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. Turn 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 SCI communications between the control board and the DSP board.

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Service Manual

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 Powermax in a 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

TM

connector into the receptacle on the front of the power supply You will attach the work lead in the next

section.

Power cord (does not

ship with plug)

Work lead

Torch lead

Gas supply

line