Hypertherm Powermax65 Service Manual Rev.1 Uživatelský manuál

Service Manual – 807120Revision 1Plasma arc cutting systems

vi powermax65/85 Service Manual

Torch SeTup3-52 powermax65/85 Service Manual45A Unshielded Air flow rate - slpm/scfhMild SteelHot 147 / 310Cold 210 / 450MetricMaterial ThicknessTorc

Torch SeTuppowermax65/85 Service Manual 3-5345A Unshielded Air flow rate - slpm/scfhStainless SteelHot 147 / 310Cold 210 / 450MetricMaterial Thicknes

Torch SeTup3-54 powermax65/85 Service Manual45A Unshielded Air flow rate - slpm/scfhAluminumHot 147 / 310Cold 210 / 450MetricMaterial ThicknessTorch-

powermax65/85 Service Manual 4-1Section 4OPERATIONIn this section:Controls and indicators ...

OperatiOn4-2 powermax65/85 Service ManualFront controls and LEDsControls and indicatorsThe Powermax65 and Powermax85 power supplies have the followin

OperatiOnpowermax65/85 Service Manual 4-3Operating mode switchThe operating mode switch can be set in one of four positions:• Continuous pilot arc.

OperatiOn4-4 powermax65/85 Service ManualGas pressure indicatorsIn manual mode, the gas pressure is displayed in bar and psi. The gas pressure bar is

OperatiOnpowermax65/85 Service Manual 4-5Fault codesWhen a power supply or torch fault occurs, the system displays a fault code in the lower-left cor

OperatiOn4-6 powermax65/85 Service ManualOperating the Powermax65 or Powermax85Follow the steps below to begin cutting or gouging with the Powermax65

OperatiOnpowermax65/85 Service Manual 4-7Work lead receptacle on power supplyKeyed opening at top of receptacle1. Insert the work lead connector int

Table of ConTenTspowermax65/85 Service Manual viiSection 1SpecificationsSafety information ...

OperatiOn4-8 powermax65/85 Service ManualAttach the work clamp to the workpieceThe work clamp must be connected to the workpiece while you are cuttin

OperatiOnpowermax65/85 Service Manual 4-9Set the operating mode switchUse the operating mode switch to select the type of work you want to perform.In

OperatiOn4-10 powermax65/85 Service ManualCheck the indicatorsVerify the following:• The green power ON LED on the front of the power supply is illu

OperatiOnpowermax65/85 Service Manual 4-11Adjusting the current (amperage)Turn the adjustment knob to adjust the current for your particular cutting

OperatiOn4-12 powermax65/85 Service ManualUnderstanding duty-cycle limitationsThe duty cycle is the amount of time, in minutes, that a plasma arc can

OperatiOnpowermax65/85 Service Manual 4-13Using the hand torchWARNINGINSTANTON TORCHESPLASMA ARC CAN CAUSE INJURY AND BURNSPlasma arc comes on im me

OperatiOn4-14 powermax65/85 Service ManualHand torch cutting hints• Drag the torch tip lightly along the workpiece to maintain a steady cut.• While

OperatiOnpowermax65/85 Service Manual 4-15Start a cut from the edge of the workpiece1. With the work clamp attached to the workpiece, hold the torch

OperatiOn4-16 powermax65/85 Service ManualPierce a workpiece1. With the work clamp attached to the workpiece, hold the torch at an approximate 30° a

OperatiOnpowermax65/85 Service Manual 4-17Gouge a workpiece1. Hold the torch so that the torch tip is within 1/16 inch (1.5 mm) from the workpiece b

Table of ConTenTsviii powermax65/85 Service ManualSection 3Torch SetupIntroduction ...

OperatiOn4-18 powermax65/85 Service ManualGouge profileYou can vary the gouge profile by varying the speed of the torch over the workpiece, varying t

OperatiOnpowermax65/85 Service Manual 4-19Varying the gouge profileThe following actions have the stated effects on the gouge profile:• Increasing t

OperatiOn4-20 powermax65/85 Service ManualCommon hand-cutting faultsThe torch does not cut completely through the workpiece. The causes can be:• The

OperatiOnpowermax65/85 Service Manual 4-21Using the machine torchSince the Powermax with a machine torch can be used with a wide variety of cutting t

OperatiOn4-22 powermax65/85 Service ManualCauseThe torch is too high.SolutionLower the torch; or if you are using a torch height control, decrease th

OperatiOnpowermax65/85 Service Manual 4-23To pierce a workpiece using the machine torchAs with the hand torch, you can start a cut with the machine t

OperatiOn4-24 powermax65/85 Service ManualCommon machine-cutting faultsThe torch’s pilot arc will initiate, but will not transfer. Causes can be:• T

powermax65/85 Service Manual 5-1Section 5TROUBLESHOOTING AND SYSTEM TESTSIn this section:Controls and indicators ...

TroubleshooTing and sysTem TesTs5-2 powermax65/85 Service ManualFault codes ...

TroubleshooTing and sysTem TesTspowermax65/85 Service Manual 5-3Fault LED (yellow)Power ON LED (green)Status screenAutomatic/manual pressure setting

Table of ConTenTspowermax65/85 Service Manual ixUsing the hand torch ...

TroubleshooTing and sysTem TesTs5-4 powermax65/85 Service ManualTheory of operationGeneralRefer to “Sequence of operation” below and Section 8, Wirin

TroubleshooTing and sysTem TesTspowermax65/85 Service Manual 5-5380/400 V CE 3-phase power supply functional descriptionAC power enters the system th

TroubleshooTing and sysTem TesTs5-6 powermax65/85 Service ManualSequence of operationPower OFF•Connectthegassupplytotheairfittingonthepow

TroubleshooTing and sysTem TesTspowermax65/85 Service Manual 5-7Troubleshooting preparationThe complexity of the circuits requires that service techn

TroubleshooTing and sysTem TesTs5-8 powermax65/85 Service ManualDANGERELECTRICSHOCKCANKILL• Turnoffthepowerandremovetheinputpowerplugf

TroubleshooTing and sysTem TesTspowermax65/85 Service Manual 5-9External inspection1. Inspect the exterior of the power supply for damage to the cov

TroubleshooTing and sysTem TesTs5-10 powermax65/85 Service Manual500kΩ200–600 V CSA500kΩ 500kΩ>20 MΩGround is at bottom of heat sinkGround is

TroubleshooTing and sysTem TesTspowermax65/85 Service Manual 5-11Measure resistance from200 – 600 V CSA power board location400 V CE power board loca

TroubleshooTing and sysTem TesTs5-12 powermax65/85 Service ManualHypertherm IGBT testerUse the Hypertherm IGBT (insulated gate bipolar transistor) te

TroubleshooTing and sysTem TesTspowermax65/85 Service Manual 5-13IGBT test preparationBefore testing with the Hypertherm IGBT tester, connect the col

Table of ConTenTsx powermax65/85 Service ManualFault codes ...

TroubleshooTing and sysTem TesTs5-14 powermax65/85 Service ManualIGBT device test using the Hypertherm testerUsing the Hypertherm IGBT tester, press

TroubleshooTing and sysTem TesTspowermax65/85 Service Manual 5-15Legend1. Collector 1 (C1)2. Emitter 2 (E2)3. Collector 2, Emitter 1 (C2,E1)4.

TroubleshooTing and sysTem TesTs5-16 powermax65/85 Service ManualIGBT device test using a non-Hypertherm testerThe device tester shown on page 5-15 S

TroubleshooTing and sysTem TesTspowermax65/85 Service Manual 5-17WORK LEADBLKBLKJ13J16J17J18J19J26J29TP12J28TP10TP11Power switch (S1)200 – 600 V CSA

TroubleshooTing and sysTem TesTs5-18 powermax65/85 Service ManualWORK LEADJ13J2J1J18J19J27J30J23J24TP13J29TP11TP12380/400 V CE power supply overviewP

TroubleshooTing and sysTem TesTspowermax65/85 Service Manual 5-19200 – 600 V CSA power supply overview (power board removed)Power switch (S1)Output s

TroubleshooTing and sysTem TesTs5-20 powermax65/85 Service Manual380/400 V CE power supply overview (power board removed)Input diode bridgeInverter I

TroubleshooTing and sysTem TesTspowermax65/85 Service Manual 5-21Fault codesFault codes displayed on the LCD screen in “service mode” are in the form

TroubleshooTing and sysTem TesTs5-22 powermax65/85 Service ManualTo move the field selector (*) between fields, press the current/gas mode selector.

TroubleshooTing and sysTem TesTspowermax65/85 Service Manual 5-230-nn-nThese fault codes identify operational faults. On the operator screen, the las

Table of ConTenTspowermax65/85 Service Manual xiSection 7PartsPower supply parts ...

TroubleshooTing and sysTem TesTs5-24 powermax65/85 Service ManualFault codeDescription(System test number)Power LEDFault LEDFault iconSolutions0-19-9

TroubleshooTing and sysTem TesTspowermax65/85 Service Manual 5-25Fault codeDescription(System test number)Power LEDFault LEDFault iconSolutions0-30-0

TroubleshooTing and sysTem TesTs5-26 powermax65/85 Service ManualFault codeDescription(System test number)Power LEDFault LEDFault iconSolutions0-50-0

TroubleshooTing and sysTem TesTspowermax65/85 Service Manual 5-27Fault codeDescription(System test number)Power LEDFault LEDFault iconSolutions0-98-0

TroubleshooTing and sysTem TesTs5-28 powermax65/85 Service Manual2-nn-nThese fault codes usually relate to either the DSP or the power board and can

TroubleshooTing and sysTem TesTspowermax65/85 Service Manual 5-293-nn-nThese fault codes relate to the power board and can only be seen on the servic

TroubleshooTing and sysTem TesTs5-30 powermax65/85 Service ManualFault codeDescription(System test number)Power LEDFault LEDFault iconSolutions3-41-0

TroubleshooTing and sysTem TesTspowermax65/85 Service Manual 5-31Fault codeDescription(System test number)Power LEDFault LEDFault iconSolutions3-51-1

TroubleshooTing and sysTem TesTs5-32 powermax65/85 Service ManualProblem Meaning Causes SolutionThe ON/OFF power switch is set to ON (I), but the pow

TroubleshooTing and sysTem TesTspowermax65/85 Service Manual 5-33Problem Meaning Causes SolutionThe power ON LED is illuminated and no fault codes ar

Table of ConTenTsxii powermax65/85 Service Manual

TroubleshooTing and sysTem TesTs5-34 powermax65/85 Service ManualProblem Meaning Causes SolutionWhen pressing the torch trigger or start switch, gas

TroubleshooTing and sysTem TesTspowermax65/85 Service Manual 5-35Problem Meaning Causes SolutionArc goes out while cuttingor intermittently willnot

TroubleshooTing and sysTem TesTs5-36 powermax65/85 Service ManualProblem Meaning Causes SolutionWhile in continuous pilot arc mode, the pilot arc ext

TroubleshooTing and sysTem TesTspowermax65/85 Service Manual 5-37Problem Meaning Causes SolutionMachine does not cut well (does not appear to be cutt

TroubleshooTing and sysTem TesTs5-38 powermax65/85 Service ManualSystem testsTest # Description Associated fault codes1 Voltage input 0-60-ALL2 DC p

TroubleshooTing and sysTem TesTspowermax65/85 Service Manual 5-39BLKBLKJ13Test 1 – Voltage inputSymptom: Voltage fault (0-60-0, -1 or -2)• Check the

TroubleshooTing and sysTem TesTs5-40 powermax65/85 Service ManualTest 2 – DC Power BussResistance checkNote: All resistance values must be taken

TroubleshooTing and sysTem TesTspowermax65/85 Service Manual 5-41WORK LEADJ13J2 J1J18J19J27J30J23J24TP13J29TP11TP12WORK LEADBLKBLKJ13J16J17J18J19J26T

TroubleshooTing and sysTem TesTs5-42 powermax65/85 Service ManualTest 3 – Output diodes• Check the four diodes in the bridge with an ohmmeter in dio

TroubleshooTing and sysTem TesTspowermax65/85 Service Manual 5-43Test 4 – Inverter and PFC temperature sensorSymptom: Fault code 0-40 appears in the

powermax65/85 Service Manual 1-1Section 1SPECIFICATIONSIn this section:Safety information ...

TroubleshooTing and sysTem TesTs5-44 powermax65/85 Service ManualFor operational fault codes 0-40-0 and 0-40-1 or power board faults 3-11-0 and 3-11-

TroubleshooTing and sysTem TesTspowermax65/85 Service Manual 5-45For operational fault codes 0-40-2 and 0-40-3 or power board faults 2-10-0 and 2-10-

TroubleshooTing and sysTem TesTs5-46 powermax65/85 Service ManualTest 5 – Flyback circuit (DC minor voltages)Symptom: Minor voltages are not present.

TroubleshooTing and sysTem TesTspowermax65/85 Service Manual 5-47If the +48 VDC value is incorrect:• Remove the fan connector (J3 for standard units

TroubleshooTing and sysTem TesTs5-48 powermax65/85 Service ManualTest 6 – Torch stuck open (TSO)Symptom: No fault occurs at power-up but an 0-30 faul

TroubleshooTing and sysTem TesTspowermax65/85 Service Manual 5-49Before continuing, turn OFF the power.If the resistance value is always less than 10

TroubleshooTing and sysTem TesTs5-50 powermax65/85 Service ManualTest 7 – Start signalSymptom: There is no arc when the torch trigger is closed.If th

TroubleshooTing and sysTem TesTspowermax65/85 Service Manual 5-51Test 8 – Torch cap switchSymptom: Fault code 0-50 and the cap-sensor switch icon app

TroubleshooTing and sysTem TesTs5-52 powermax65/85 Service ManualTest 9 – Electronic regulatorSymptom: Air flows continuously through the torch.1. T

TroubleshooTing and sysTem TesTspowermax65/85 Service Manual 5-53Test 10 – Pressure sensorSymptom: The pressure sensor reading doesn’t agree with kno

SpecificationS1-2 powermax65/85 Service ManualSafety informationBefore you set up and operate your Hypertherm system, read the separate Safety and Co

TroubleshooTing and sysTem TesTs5-54 powermax65/85 Service ManualTest 11 – FanSymptom: The fan does not operate properly.Note: Wear proper PPE pr

TroubleshooTing and sysTem TesTspowermax65/85 Service Manual 5-55Test 12 – AUX switchSymptom: The display goes blank after “Hypertherm” appears. (CSA

TroubleshooTing and sysTem TesTs5-56 powermax65/85 Service Manual

powermax65/85 Service Manual 6-1Section 6COMPONENT REPLACEMENTIn this section:Remove and replace the power supply cover and Mylar® barrier ...

Component ReplaCement6-2 powermax65/85 Service ManualRemove the power supply cover and Mylar barrierRemove and replace the power supply cover and Myl

Component ReplaCementpowermax65/85 Service Manual 6-3Replace the Mylar barrier1. Remove the metal strap at the top of the power supply and pull the

Component ReplaCement6-4 powermax65/85 Service ManualReplace the power supply cover1. Place the cover (3) over the power supply with the slot in the

Component ReplaCementpowermax65/85 Service Manual 6-5Replace the power cordFor wire sizes, see Extension cord specifications in Section 2, Power Supp

Component ReplaCement6-6 powermax65/85 Service Manual4. Pull the wires straight up to remove them from the power switch.5. Remove the ground screw

Component ReplaCementpowermax65/85 Service Manual 6-7Strain relief retention nutStrain reliefRear panel of power supplyStrain relief nut inside power

SpecificationSpowermax65/85 Service Manual 1-3Where to find informationSystem specifications such as size, weight, detailed electrical specifications

Component ReplaCement6-8 powermax65/85 Service ManualStrain relief retention nutStrain reliefRear panel of powersupplyAluminum washerStrain relief a

Component ReplaCementpowermax65/85 Service Manual 6-92. Route the new power cord wires through the strain relief in the rear panel from inside the p

Component ReplaCement6-10 powermax65/85 Service ManualReplace the power cord (200 – 480 V 1-phase CSA)To operate your Powermax on 1-phase power, you

Component ReplaCementpowermax65/85 Service Manual 6-11Replace the work leadWork lead receptacle on power supplyKeyed opening at top of receptacle1.

Component ReplaCement6-12 powermax65/85 Service Manual1. Turn OFF the power, disconnect the power cord, and disconnect the gas supply.2. Remove the

Component ReplaCementpowermax65/85 Service Manual 6-135. Pull the fan wire through the grommet to the fan side of the power supply.6. Insert a #1 P

Component ReplaCement6-14 powermax65/85 Service ManualReplace the air filter element1. Turn OFF the power, disconnect the power cord, and disconnect

Component ReplaCementpowermax65/85 Service Manual 6-15Replace the air filter subassembly1. Turn OFF the power, disconnect the power cord, and discon

Component ReplaCement6-16 powermax65/85 Service Manual9. Temporarily remove the filter guide from the new air filter subassembly.10. Place the subas

Component ReplaCementpowermax65/85 Service Manual 6-17Replace the power board1. Turn OFF the power, disconnect the power cord, and disconnect the ga

Register your new Hypertherm systemRegister your product on-line at www.hypertherm.com/registration for easier technical and warranty support. You can

SpecificationS1-4 powermax65/85 Service ManualPower supply dimensions9.2 in(234 mm)19.0 in(483 mm)17.0 in(432 mm)

Component ReplaCement6-18 powermax65/85 Service Manual14623335DSP back viewDSP front view

Component ReplaCementpowermax65/85 Service Manual 6-19Replace the power board (380/400V CE)Refer to the figure on the next page when performing the f

Component ReplaCement6-20 powermax65/85 Service Manual380/400V CE Power BoardWORK LEADJ13J2J1J18J19J27J30J23J24TP13J29TP11TP12J7, J6, J5, J4, and J3G

Component ReplaCementpowermax65/85 Service Manual 6-21Install the new power board (380/400V CE)1. Position the left edge of the power board on a sli

Component ReplaCement6-22 powermax65/85 Service ManualReplace the power board (200 – 600V CSA)Refer to the figure on the next page when performing th

Component ReplaCementpowermax65/85 Service Manual 6-23200 – 600V CSA Power BoardWORK LEADBLKBLKJ13J16J17J18J19J26J29TP12J28TP10TP11J5, J4, J3, J2, an

Component ReplaCement6-24 powermax65/85 Service ManualInstall the new power board (200 – 600V CSA)1. Position the left edge of the power board on a

Component ReplaCementpowermax65/85 Service Manual 6-2515. Secure the 3uF capacitor on the left and the longer transformer wire to the board using the

Component ReplaCement6-26 powermax65/85 Service Manual44776633DSP back view1423DSP front viewReplace the Mylar barrier and power supply cover.1. Rep

Component ReplaCementpowermax65/85 Service Manual 6-27Replace the control board1. Turn OFF the power, disconnect the power cord, and disconnect the

SpecificationSpowermax65/85 Service Manual 1-5Component weights65 A CSA 65 A CE 85 A CSA 85 A CElbs (kg) lbs (kg) lbs (kg) lbs (kg)Power supply 54.1

Component ReplaCement6-28 powermax65/85 Service Manual9. Connect the ribbon cable to the new control board.10. Carefully slide the control board beh

Component ReplaCementpowermax65/85 Service Manual 6-29Replace the heat sink componentsThis section describes the procedures for replacing heat sink c

Component ReplaCement6-30 powermax65/85 Service Manual3331165A CSA22Note: “3” on the leftWhen securing a component to the heat sink, gently tighten a

Component ReplaCementpowermax65/85 Service Manual 6-3165A CE23331Note: “3” on the leftWhen securing a component to the heat sink, gently tighten all

Component ReplaCement6-32 powermax65/85 Service Manual85A CSA2333311Note: “3” on the leftTorque to 15 in-lbs (17.3 kg cm).M4 X 10 2SEMTorque to 20 in

Component ReplaCementpowermax65/85 Service Manual 6-3385A CE23331When securing a component to the heat sink, gently tighten all screws and then tight

Component ReplaCement6-34 powermax65/85 Service Manual

powermax65/85 Service Manual 7-1Section 7PARTSIn this section:Power supply parts ...

Parts7-2 powermax65/85 Service ManualPower supply partsExterior frontItem Part number Description228649 Kit: Powermax65 labels, CSA228650 Kit: Powe

Partspowermax65/85 Service Manual 7-3Exterior rearItem Part number Description1 228691 Kit: Powermax65 and Powermax85 CSA power cord2 228679 Kit: P

SpecificationS1-6 powermax65/85 Service ManualPowermax65 power supply ratingsRated open-circuit voltage (U0)CSA, 1-phase, 3-phaseCE, 3-phaseCSA 296

Parts7-4 powermax65/85 Service ManualInterior, power board side (200 – 600V CSA)WORK LEADBLKBLKJ13J16J17J18J19J26J29TP12J28TP10TP111234567Item Part n

Partspowermax65/85 Service Manual 7-5WORK LEADJ13J2J1J18J19J27J30J23J24TP13J29TP11TP12Interior, power board side (380/400V CE)123456Item Part number

Parts7-6 powermax65/85 Service Manual1234255678 910Interior, fan side16171819201112131421 22232415

Partspowermax65/85 Service Manual 7-7Item Part number Description1 228686 Kit: Powermax65 and Powermax85 fan subassembly2 228694 Kit: Fan shroud3 2

Parts7-8 powermax65/85 Service ManualItem Part number Description1 228803 Kit: Powermax65 output diode bridge2 228693 Kit: Powermax65 and Powermax8

Partspowermax65/85 Service Manual 7-965A CEItem Part number Description1 228803 Kit: Powermax65 output diode bridge2 228693 Kit: Powermax65 and Pow

Parts7-10 powermax65/85 Service Manual85A CSA712345689Item Part number Description1 228804 Kit: Powermax85 output diode bridge2 228693 Kit: Powerma

Partspowermax65/85 Service Manual 7-1185A CEItem Part number Description1 228804 Kit: Powermax85 output diode bridge2 228693 Kit: Powermax65 and Po

Parts7-12 powermax65/85 Service ManualDuramax 75° hand torch replacement parts1234567891011Item Part number Description059473 Powermax65/85/105 75° h

Partspowermax65/85 Service Manual 7-13Duramax 15° hand torch replacement parts1234567 8 911The entire hand torch and lead assembly can be replaced, o

SpecificationSpowermax65/85 Service Manual 1-71 Defined as a plot of output voltage versus output current.2 Equipment complies with IEC 61000-3-12

Parts7-14 powermax65/85 Service ManualPart number DescriptionDrag cutting220818 Shield220854 Retaining cap220941 45 A Nozzle220819 65 A Nozzle220816

Partspowermax65/85 Service Manual 7-15Duramax 180° full-length machine torch replacement parts1234567891112 1310

Parts7-16 powermax65/85 Service ManualThe entire machine torch and lead assembly can be replaced, or individual component parts can be replaced. Part

Partspowermax65/85 Service Manual 7-17Duramax 180° mini machine torch replacement partsNote: This illustration shows the Duramax 180° machine torch

Parts7-18 powermax65/85 Service ManualThe entire machine torch and lead assembly can be replaced, or individual component parts can be replaced. Part

Partspowermax65/85 Service Manual 7-19Machine torch consumablesPart number DescriptionShielded220817 Shield220854 Retaining cap220953 Ohmic retaining

Parts7-20 powermax65/85 Service ManualAccessory partsPart number Description024548 Leather torch sheathing, brown leather, 7.6m(25 ft)024877 Leathe

Partspowermax65/85 Service Manual 7-21Item Part number Description228649 Kit: Powermax65 labels, CSA228650 Kit: Powermax65 labels, CE228651 Kit: P

Parts7-22 powermax65/85 Service ManualWORK LEADJ13J2J1J18J19J27J30J23J24TP13J29TP11TP12WORK LEADBLKBLKJ13J29J16J17J18J19J26TP12J28TP10TP11Safety-crit

Partspowermax65/85 Service Manual 7-23CSA, CE123456789101112 13 1415 16Item Part number Description1 228686 Kit: Powermax65 and Powermax85 fan subas

SpecificationS1-8 powermax65/85 Service ManualPowermax85 power supply ratingsRated open-circuit voltage (U0)CSA, single-phase, 3-phaseCE, 3-phaseCSAC

Parts7-24 powermax65/85 Service ManualRecommended spare partsPart number Description108797 Adjustment knob108732 Operating mode knob223125 Kit: 65 A

Partspowermax65/85 Service Manual 7-25Part number Description228648 Kit: Powermax65 output inductor228665 Kit: Powermax85 output inductor228688 Kit

Parts7-26 powermax65/85 Service ManualPart number Description228737 Kit: Powermax65/85/105 180° full-length machine torch/MRT positioning sleeve2287

powermax65/85 Service Manual 8-1Section 8WIRING DIAGRAMSIn this section:Cutting timing diagram page 1 of 2...

Wiring Diagrams8-2 powermax65/85 Service Manual

DRAWN BYQLIUDCBA4 3 2 1DCBA4 3 2 1DATE4/26/2010PAGE1 OF 2TITLEFILENAMECUTTING FSM FAST LOOP BY QLIU.VSDP.O.Box 5010Hanover, NH 03755-5010(603) 643-344

8-4DRAWN BYQLIUDCBA4 3 2 1DCBA4 3 2 1DATE4/26/2010PAGE2 OF 2TITLEFILENAMECUTTING FSM FAST LOOP BY QLIU.VSDP.O.Box 5010Hanover, NH 03755-5010(603) 643-

8-5Electrical schematic diagram (CSA)

8-6Electrical schematic diagram (CE)

SpecificationSpowermax65/85 Service Manual 1-91 Defined as a plot of output voltage versus output current.2 Equipment complies with IEC 61000-3-12

SpecificationS1-10 powermax65/85 Service ManualDuramax 75° hand torch dimensions9.9 in(25.2 cm)3.8 in(9.8 cm) 75° angle10.2 in(25.9 cm)1.9 in(4.7

SpecificationSpowermax65/85 Service Manual 1-11Duramax 180° full-length machine torch dimensions15.6 in(39.6 cm)1.0 in(2.5 cm)1.0 in(2.5 cm)1.4 in (3

SpecificationS1-12 powermax65/85 Service ManualPowermax65 cutting specificationsHandheld cut capacity (material thickness)Recommended cut capacity at

SpecificationSpowermax65/85 Service Manual 1-13Powermax85 cutting specificationsHandheld cut capacity (material thickness)Recommended cut capacity at

Service ManualEnglish / EnglishRevision 1 – December 2012Hypertherm, Inc.Hanover, NH USAwww.hypertherm.comemail: [email protected]© 2012 Hypertherm

SpecificationS1-14 powermax65/85 Service ManualSymbols and markingsYour Hypertherm product may have one or more of the following markings on or near

SpecificationSpowermax65/85 Service Manual 1-15IEC symbolsThe following symbols may appear on the power supply data plate, control labels, switches,

SpecificationS1-16 powermax65/85 Service Manual

powermax65/85 Service Manual 2-1Section 2POWER SUPPLY SETUPIn this section:Unpack the Powermax65 or Powermax85 system ...

Power SuPPly SetuP2-2 powermax65/85 Service ManualUnpack the Powermax65 or Powermax85 system1. Verify that all items on your order have been receive

Power SuPPly SetuPpowermax65/85 Service Manual 2-3Operator ManualSafety ManualQuick Setup CardRegistration CardContentsVerify the items in the box ag

Power SuPPly SetuP2-4 powermax65/85 Service ManualPosition the power supplyLocate the power supply near an appropriate power receptacle for your inst

Power SuPPly SetuPpowermax65/85 Service Manual 2-5Install a line-disconnect switchUse a line-disconnect switch for each power supply so that the oper

Power SuPPly SetuP2-6 powermax65/85 Service ManualPower connection for the Powermax65The Powermax65 CSA model is a universal power supply that can co

Power SuPPly SetuPpowermax65/85 Service Manual 2-7Single-phase power cord (not for CE model)To operate your Powermax65 on 1-phase power, you will nee

Hypertherm, Inc.Etna Road, P.O. Box 5010Hanover, NH 03755 USA603-643-3441 Tel (Main Office)603-643-5352 Fax (All Departments)[email protected] (Main

Power SuPPly SetuP2-8 powermax65/85 Service ManualPower connection for the Powermax85The Powermax85 CSA model is a universal power supply that can co

Power SuPPly SetuPpowermax65/85 Service Manual 2-9Single-phase power cord (not for CE model)To operate your Powermax85 on 1-phase power, you will nee

Power SuPPly SetuP2-10 powermax65/85 Service ManualSingle-phase power cord installationStrip and prepare the power cord wires as shown below.L1L2Grou

Power SuPPly SetuPpowermax65/85 Service Manual 2-11Three-phase power cord – plug installationThe Powermax85 power supplies are shipped with an 8 AWG

Power SuPPly SetuP2-12 powermax65/85 Service ManualExtension cord length< 10 ft(< 3 m)10 – 25 ft(3 – 7.6 m)25 – 50 ft(7.5 – 15 m)50 – 100 ft(15

Power SuPPly SetuPpowermax65/85 Service Manual 2-13Engine-driven generator recommendationsGenerators used with the Powermax65 or Powermax85 should sa

Power SuPPly SetuP2-14 powermax65/85 Service ManualPrepare the gas supplyThe gas supply can be shop-compressed or cylinder-compressed. A high-pressur

Power SuPPly SetuPpowermax65/85 Service Manual 2-15Connect the gas supplyConnect the gas supply to the power supply using an inert-gas hose with a 3/

Power SuPPly SetuP2-16 powermax65/85 Service ManualMinimum inlet pressure (while gas is flowing)This table shows the minimum required inlet pressure

powermax65/85 Service Manual 3-1Section 3TORCH SETUPIn this section:Introduction ...

Compliance Information EMC-17/10ELECTROMAGNETIC COMPATIBILITY EMC IntroductionHypertherm’s CE-marked equipment is built in compliance with standard

Torch SeTup3-2 powermax65/85 Service ManualIntroductionDuramax™ series handheld and machine torches are available for the Powermax65 and Powermax85 s

Torch SeTuppowermax65/85 Service Manual 3-3ConsumablesSafety triggerSafety triggerHand torch setupDuramax 75° hand torchDuramax 15° hand torchConsuma

Torch SeTup3-4 powermax65/85 Service ManualChoose the hand torch consumablesHypertherm includes a box of consumables with your system. Both styles of

Torch SeTuppowermax65/85 Service Manual 3-565A45A85A65A45AHand torch consumablesDrag-cutting consumables: Powermax65Drag-cutting consumables: Powerma

Torch SeTup3-6 powermax65/85 Service ManualInstall the hand torch consumablesTo operate the hand torch, a complete set of consumable parts must be in

Torch SeTuppowermax65/85 Service Manual 3-7Machine torch setupBefore using either style of machine torch, you must:• Mount the torch on your cutting

Torch SeTup3-8 powermax65/85 Service ManualConverting a full-length machine torch to a mini machine torchYou can convert a full-length machine torch

Torch SeTuppowermax65/85 Service Manual 3-97. Disconnect the wire connector for the cap-sensor switch.8. Use a #2 Phillips screwdriver to remove th

Torch SeTup3-10 powermax65/85 Service ManualMount the torchDepending on the type of cutting table you have, you may or may not need to disassemble th

Torch SeTuppowermax65/85 Service Manual 3-117. Disconnect the wire connector for the cap-sensor switch.8. Use a #2 Phillips screwdriver to remove t

EMC-2 Compliance Information7/10ELECTROMAGNETIC COMPATIBILITYConsideration should be given to shielding the supply cable of permanently installed cut

Torch SeTup3-12 powermax65/85 Service Manual65A45A65A45AChoose the machine torch consumablesPowermax systems with the Duramax 180° full-length machin

Torch SeTuppowermax65/85 Service Manual 3-1365A45A220955Deflector220854Retaining cap220941Nozzle220819Nozzle220857Swirl ring220842ElectrodeMechanized

Torch SeTup3-14 powermax65/85 Service ManualGouging consumables220854Retaining cap220857Swirl ring220842Electrode220798Shield220797NozzleFineCut® uns

Torch SeTuppowermax65/85 Service Manual 3-15Install the machine torch consumablesWARNINGINSTANT-ON TORCHESPLASMA ARC CAN CAUSE INJURY AND BURNSThe pl

Torch SeTup3-16 powermax65/85 Service ManualConnecting an optional remote-start pendantPowermax65 and Powermax85 configurations with a Duramax machin

Torch SeTuppowermax65/85 Service Manual 3-17Connecting an optional machine interface cableThe Powermax65 and Powermax85 power supplies are equipped w

Torch SeTup3-18 powermax65/85 Service ManualNote: The cover on the machine interface receptacle prevents dust and moisture from damaging the rece

Torch SeTuppowermax65/85 Service Manual 3-193412131456Refer to the following table when connecting the Powermax65 or Powermax85 to a torch height con

Torch SeTup3-20 powermax65/85 Service ManualSetting the five-position voltage divider To change the factory preset voltage divider from 50:1 to a dif

Torch SeTuppowermax65/85 Service Manual 3-21Accessing raw arc voltageTo access divided raw arc voltage, refer to Field Service Bulletin 807060.WARNIN

Compliance Information W-19/10AttentionGenuine Hypertherm parts are the factory-recommended replacement parts for your Hypertherm system. Any damage

Torch SeTup3-22 powermax65/85 Service ManualConnecting the torch leadThe Powermax65 and Powermax85 are equipped with FastConnectTM, a quick-disconnec

Torch SeTuppowermax65/85 Service Manual 3-23Using the cut chartsThe following sections provide cut charts for each set of mechanized consumables. A c

Torch SeTup3-24 powermax65/85 Service ManualEstimated kerf-width compensationThe widths in the tables below are for reference. The data are obtained

Torch SeTuppowermax65/85 Service Manual 3-25Estimated kerf-width compensation – English (inches)ProcessThickness (inches)22GA 18GA 14GA 10GA 3/16 1/4

Torch SeTup3-26 powermax65/85 Service Manual220817Shield220817Shield220854Retaining cap220857Swirl ring220857Swirl ring220842Electrode220842Electrode

Torch SeTuppowermax65/85 Service Manual 3-2785A Shielded Air flow rate - slpm/scfhMild SteelHot 190 / 400Cold 235 / 500MetricMaterial ThicknessTorch-

Torch SeTup3-28 powermax65/85 Service Manual85A Shielded Air flow rate - slpm/scfhStainless SteelHot 190 / 400Cold 235 / 500MetricMaterial ThicknessT

Torch SeTuppowermax65/85 Service Manual 3-2985A Shielded Air flow rate - slpm/scfhAluminumHot 190 / 400Cold 235 / 500MetricMaterial ThicknessTorch-to

Torch SeTup3-30 powermax65/85 Service Manual65 A shielded consumables65A65A220817Shield220817Shield220854Retaining cap220819Nozzle220819Nozzle220857S

Torch SeTuppowermax65/85 Service Manual 3-3165A Shielded Air flow rate - slpm/scfhMild SteelHot 160 / 340Cold 220 / 470MetricMaterial ThicknessTorch-

W-2 Compliance Information9/10WARRANTYPatent indemnityExcept only in cases of products not manufactured by Hypertherm or manufactured by a person oth

Torch SeTup3-32 powermax65/85 Service Manual65A Shielded Air flow rate - slpm/scfhStainless SteelHot 160 / 340Cold 220 / 470MetricMaterial ThicknessT

Torch SeTuppowermax65/85 Service Manual 3-3365A Shielded Air flow rate - slpm/scfhAluminumHot 160 / 340Cold 220 / 470MetricMaterial ThicknessTorch-to

Torch SeTup3-34 powermax65/85 Service Manual45 A shielded consumables45A45A220817Shield220817Shield220854Retaining cap220941Nozzle220941Nozzle220857S

Torch SeTuppowermax65/85 Service Manual 3-3545A Shielded Air flow rate - slpm/scfhMild SteelHot 150 / 310Cold 210/ 450MetricMaterial ThicknessTorch-t

Torch SeTup3-36 powermax65/85 Service Manual45A Shielded Air flow rate - slpm/scfhStainless SteelHot 150 / 310Cold 210/ 450MetricMaterial ThicknessTo

Torch SeTuppowermax65/85 Service Manual 3-3745A Shielded Air flow rate - slpm/scfhAluminumHot 150 / 310Cold 210/ 450MetricMaterial ThicknessTorch-to-

Torch SeTup3-38 powermax65/85 Service ManualFineCut® consumablesNote: The cut charts in this section apply to both shielded and unshielded consumab

Torch SeTuppowermax65/85 Service Manual 3-39FineCut Air flow rate - slpm/scfhMild SteelHot 155 / 330Cold 215 / 460MetricMaterial ThicknessAmpsTorch-t

Torch SeTup3-40 powermax65/85 Service ManualFineCut Air flow rate - slpm/scfhStainless SteelHot 155 / 330Cold 215 / 460MetricMaterial ThicknessAmpsTo

Torch SeTuppowermax65/85 Service Manual 3-41Low Speed FineCut Air flow rate – slpm/scfhMild SteelHot 155 / 330Cold 215 / 460MetricMaterial ThicknessC

powermax65/85 Service Manual vSafety informationBefore operating any Hypertherm equipment, read the separate Safety and Compliance Manual (80669C) inc

Torch SeTup3-42 powermax65/85 Service ManualLow Speed FineCut Air flow rate – slpm/scfhStainless SteelHot 155 / 330Cold 215 / 460MetricMaterial Thick

Torch SeTuppowermax65/85 Service Manual 3-4385 A unshielded consumables85A220955Deflector220854Retaining cap220857Swirl ring220842Electrode220816Nozz

Torch SeTup3-44 powermax65/85 Service Manual85A Unshielded Air flow rate - slpm/scfhMild SteelHot 190 / 400Cold 235 / 500MetricMaterial ThicknessTorc

Torch SeTuppowermax65/85 Service Manual 3-4585A Unshielded Air flow rate - slpm/scfhStainless SteelHot 190 / 400Cold 235 / 500MetricMaterial Thicknes

Torch SeTup3-46 powermax65/85 Service Manual85A Unshielded Air flow rate - slpm/scfhAluminumHot 190 / 400Cold 235 / 500MetricMaterial ThicknessTorch-

Torch SeTuppowermax65/85 Service Manual 3-4765 A unshielded consumables65A220955Deflector220854Retaining cap220857Swirl ring220842Electrode220819Nozz

Torch SeTup3-48 powermax65/85 Service Manual65A Unshielded Air flow rate - slpm/scfhMild SteelHot 160 / 340Cold 220 / 470MetricMaterial ThicknessTorc

Torch SeTuppowermax65/85 Service Manual 3-4965A Unshielded Air flow rate - slpm/scfhStainless SteelHot 160 / 340Cold 220 / 470MetricMaterial Thicknes

Torch SeTup3-50 powermax65/85 Service Manual65A Unshielded Air flow rate - slpm/scfhAluminumHot 160 / 340Cold 220 / 470MetricMaterial ThicknessTorch-

Torch SeTuppowermax65/85 Service Manual 3-5145 A unshielded consumables45A220955Deflector220854Retaining cap220857Swirl ring220842Electrode220941Nozz