Hypertherm Powermax105 Service Manual Bedienungsanleitung

Plasma arc cutting systemsService Manual – 807580Revision 1

vi powermax105 Service Manual

Machine Torch SeTup6-28 powermax105 Service Manual65 A Shielded cutting (Aluminum)Air flow rate – slpm/scfhHot 175 / 370Cold 209 / 443MetricMaterial

Machine Torch SeTuppowermax105 Service Manual 6-2945 A Shielded consumables45A45A220817Shield220854Retaining cap220941Nozzle220842Electrode220994Swir

Machine Torch SeTup6-30 powermax105 Service Manual45 A Shielded cutting (Mild Steel)Air flow rate – slpm/scfhHot 177 / 376Cold 201 / 427MetricMateria

Machine Torch SeTuppowermax105 Service Manual 6-3145 A Shielded cutting (Stainless Steel)Air flow rate – slpm/scfhHot 177 / 376Cold 201 / 427MetricMa

Machine Torch SeTup6-32 powermax105 Service Manual45 A Shielded cutting (Aluminum)Air flow rate – slpm/scfhHot 177 / 376Cold 201 / 427MetricMaterial

Machine Torch SeTuppowermax105 Service Manual 6-33FineCut® consumablesNote: The cut charts in this section apply to both shielded and unshielded con

Machine Torch SeTup6-34 powermax105 Service ManualFineCut (Mild Steel)Air flow rate – slpm/scfhHot 181 / 384Cold 191 / 404MetricMaterial ThicknessCur

Machine Torch SeTuppowermax105 Service Manual 6-35FineCut (Stainless Steel)Air flow rate – slpm/scfhHot 181 / 384Cold 191 / 404MetricMaterial Thickne

Machine Torch SeTup6-36 powermax105 Service ManualLow Speed FineCut (Mild Steel)Air flow rate – slpm/scfhHot 181 / 384Cold 191 / 404MetricMaterial Th

Machine Torch SeTuppowermax105 Service Manual 6-37Low Speed FineCut (Stainless Steel)Air flow rate – slpm/scfhHot 181 / 384Cold 191 / 404MetricMateri

Table of ConTenTspowermax105 Service Manual viiSection 1SpecificationsSafety information ...

Machine Torch SeTup6-38 powermax105 Service Manual105 A Unshielded consumables220955Deflector220854Retaining cap220990Nozzle220994Swirl ring220842Ele

Machine Torch SeTuppowermax105 Service Manual 6-39105 A Unshielded cutting (Mild Steel)Air flow rate – slpm/scfhHot 217 / 460Cold 250 / 530MetricMate

Machine Torch SeTup6-40 powermax105 Service Manual105 A Unshielded cutting (Stainless Steel)Air flow rate – slpm/scfhHot 217 / 460Cold 250 / 530Metri

Machine Torch SeTuppowermax105 Service Manual 6-41105 A Unshielded cutting (Aluminum)Air flow rate – slpm/scfhHot 217 / 460Cold 250 / 530MetricMateri

Machine Torch SeTup6-42 powermax105 Service Manual85 A Unshielded consumables85A220955Deflector220854Retaining cap220816Nozzle220842Electrode220994Sw

Machine Torch SeTuppowermax105 Service Manual 6-4385 A Unshielded cutting (Mild Steel)Air flow rate – slpm/scfhHot 194 / 412Cold 236 / 500MetricMater

Machine Torch SeTup6-44 powermax105 Service Manual85 A Unshielded cutting (Stainless Steel)Air flow rate – slpm/scfhHot 194 / 412Cold 236 / 500Metric

Machine Torch SeTuppowermax105 Service Manual 6-4585 A Unshielded cutting (Aluminum)Air flow rate – slpm/scfhHot 194 / 412Cold 236 / 500MetricMateria

Machine Torch SeTup6-46 powermax105 Service Manual65 A Unshielded consumables65A220955Deflector220854Retaining cap220819Nozzle220842Electrode220994Sw

Machine Torch SeTuppowermax105 Service Manual 6-4765 A Unshielded cutting (Mild Steel)Air flow rate – slpm/scfhHot 175 / 370Cold 209 / 443MetricMater

Table of ConTenTsviii powermax105 Service ManualSection 3Basic System OperationsControls and indicators ...

Machine Torch SeTup6-48 powermax105 Service Manual65 A Unshielded cutting (Stainless Steel)Air flow rate – slpm/scfhHot 175 / 370Cold 209 / 443Metric

Machine Torch SeTuppowermax105 Service Manual 6-4965 A Unshielded cutting (Aluminum)Air flow rate – slpm/scfhHot 175 / 370Cold 209 / 443MetricMateria

Machine Torch SeTup6-50 powermax105 Service Manual45 A Unshielded consumables45A220955Deflector220854Retaining cap220941Nozzle220842Electrode220994Sw

Machine Torch SeTuppowermax105 Service Manual 6-5145 A Unshielded cutting (Mild Steel)Air flow rate – slpm/scfhHot 177 / 376Cold 201 / 427MetricMater

Machine Torch SeTup6-52 powermax105 Service Manual45 A Unshielded cutting (Stainless Steel)Air flow rate – slpm/scfhHot 177 / 376Cold 201 / 427Metric

Machine Torch SeTuppowermax105 Service Manual 6-5345 A Unshielded cutting (Aluminum)Air flow rate – slpm/scfhHot 177 / 376Cold 201 / 427MetricMateria

Machine Torch SeTup6-54 powermax105 Service Manual

powermax105 Service Manual 7-1Section 7MECHANIZED CUTTINGIn this section:Connecting an optional remote-start pendant ...

Mechanized cutting7-2 powermax105 Service ManualConnecting an optional remote-start pendantPowermax105 configurations with a Duramax machine torch ca

Mechanized cuttingpowermax105 Service Manual 7-3Connecting an optional machine interface cableThe Powermax power supply may be equipped with a factor

Table of ConTenTspowermax105 Service Manual ixSection 6Machine Torch SetupIntroduction ...

Mechanized cutting7-4 powermax105 Service ManualNote: The cover on the machine interface receptacle prevents dust and moisture from damaging the rec

Mechanized cuttingpowermax105 Service Manual 7-53412131456Machine interface pinoutRefer to the following table when connecting the Powermax105 to a t

Mechanized cutting7-6 powermax105 Service ManualSetting the five-position voltage dividerTo change the factory preset voltage divider from 50:1 to a

Mechanized cuttingpowermax105 Service Manual 7-7Connecting an optional RS485 serial interface cableThe RS485 serial interface connector on the back o

Mechanized cutting7-8 powermax105 Service ManualUsing the machine torchSince the Powermax with a machine torch can be used with a wide variety of cut

Mechanized cuttingpowermax105 Service Manual 7-9CauseThe torch is too high.SolutionLower the torch; or if you are using a torch height control, decre

Mechanized cutting7-10 powermax105 Service ManualPiercing a workpiece using the machine torchAs with the hand torch, you can start a cut with the mac

Mechanized cuttingpowermax105 Service Manual 7-11Common machine-cutting faultsThe torch’s pilot arc will initiate, but will not transfer. Causes can

Mechanized cutting7-12 powermax105 Service ManualThe consumable life is shortened. Causes can be:• The gas setting is incorrect.• The arc current,

powermax105 Service Manual 8-1Section 8TROUBLESHOOTING AND SYSTEM TESTSIn this section:Controls and indicators ...

Table of ConTenTsx powermax105 Service ManualFineCut® consumables ...

TroubleshooTing and sysTem TesTs8-2 powermax105 Service Manual200-600 V CSA power supply overview (power board removed) ...

TroubleshooTing and sysTem TesTspowermax105 Service Manual 8-3Fault LED (yellow)Power ON LED (green)Status screenAutomatic/manual pressure setting mo

TroubleshooTing and sysTem TesTs8-4 powermax105 Service ManualTheory of operationGeneralRefer to “Sequence of operation” below and the Wiring Diagram

TroubleshooTing and sysTem TesTspowermax105 Service Manual 8-5230-400 V CE, 380 V CCC/230-400 V CE 3-phase power supply functional descriptionAC powe

TroubleshooTing and sysTem TesTs8-6 powermax105 Service ManualSequence of operation Power OFF•Connectthegassupplytotheairfittingonthepowe

TroubleshooTing and sysTem TesTspowermax105 Service Manual 8-7Troubleshooting preparationThe complexity of the circuits requires that service technic

TroubleshooTing and sysTem TesTs8-8 powermax105 Service ManualDANGER 

TroubleshooTing and sysTem TesTspowermax105 Service Manual 8-9External inspection1. Inspect the exterior of the power supply for damage to the cover

TroubleshooTing and sysTem TesTs8-10 powermax105 Service Manual500 kΩ 350 kΩ200-600 V CSA model500 kΩ 350 kΩ500 kΩ 350 kΩ>20 MΩ >20 MΩGround is

TroubleshooTing and sysTem TesTspowermax105 Service Manual 8-11J27WORKLEADJ26REDJ18ORGJ17J32J28REDMeasure resistance from All modelsWork lead (J27) t

Table of ConTenTspowermax105 Service Manual xiSection 8Troubleshooting and System TestsControls and indicators ...

TroubleshooTing and sysTem TesTs8-12 powermax105 Service ManualHypertherm IGBT testerUse the Hypertherm IGBT (insulated gate bipolar transistor) test

TroubleshooTing and sysTem TesTspowermax105 Service Manual 8-13IGBT test preparationBefore testing with the Hypertherm IGBT tester, connect the color

TroubleshooTing and sysTem TesTs8-14 powermax105 Service ManualIGBT device test using the Hypertherm testerUsing the Hypertherm IGBT tester, press an

TroubleshooTing and sysTem TesTspowermax105 Service Manual 8-15Legend1. Collector 1 (C1)2. Emitter 2 (E2)3. Collector 2, Emitter 1 (C2,E1)4. Gate

TroubleshooTing and sysTem TesTs8-16 powermax105 Service ManualIGBT device test using a non-Hypertherm testerThe device tester shown on page 8-15 Sch

TroubleshooTing and sysTem TesTspowermax105 Service Manual 8-17Work leadJ22 J21 J20 J19J27WORKLEADJ26J25+_+_REDJ18ORGJ17J32J11BRJ28TP7TP9TP8WRBPower

TroubleshooTing and sysTem TesTs8-18 powermax105 Service ManualJ22 J21 J20 J19J27WORKLEADJ26J25+_+_REDJ18ORGJ17J32J11J28TP7TP9TP8WRB230-400 V CE, 380

TroubleshooTing and sysTem TesTspowermax105 Service Manual 8-19J22 J21 J20 J19J27WORKLEADJ26J25+_+_REDJ18ORGJ17J32J11J28TP7TP9TP8WRB380 V CCC, 400 V

TroubleshooTing and sysTem TesTs8-20 powermax105 Service Manual200-600 V CSA power supply overview (power board removed)Power switch (S1)Output snubb

TroubleshooTing and sysTem TesTspowermax105 Service Manual 8-21Damper resistorPFC IGBT module230-400 V CE, 380 V CCC/230-400 V CE power supply overvi

Table of ConTenTsxii powermax105 Service ManualSystem tests...

TroubleshooTing and sysTem TesTs8-22 powermax105 Service Manual380 V CCC, 400 V CE power supply overview (power board removed)Input diode bridgeInver

TroubleshooTing and sysTem TesTspowermax105 Service Manual 8-23Fault codesFault codes displayed on the LCD screen in “service mode” are in the format

TroubleshooTing and sysTem TesTs8-24 powermax105 Service ManualTo move the field selector (*) between fields, press the current/gas mode selector. Th

TroubleshooTing and sysTem TesTspowermax105 Service Manual 8-250-nn-nThese fault codes identify operational faults. On the operator screen, the last

TroubleshooTing and sysTem TesTs8-26 powermax105 Service ManualFault codeDescription Power LEDFault LEDFault iconSolutions0-13-0 AC input unstable (l

TroubleshooTing and sysTem TesTspowermax105 Service Manual 8-27Fault codeDescription Power LEDFault LEDFault iconSolutions0-21-0 Gas flow lost while

TroubleshooTing and sysTem TesTs8-28 powermax105 Service ManualFault codeDescription Power LEDFault LEDFault iconSolutions0-32-0 End of consumable li

TroubleshooTing and sysTem TesTspowermax105 Service Manual 8-29Torch-related faults — Check for continuity between the following points:Torch FastCon

TroubleshooTing and sysTem TesTs8-30 powermax105 Service ManualFault codeDescription Power LEDFault LEDFault iconSolutions0-51-0*Start/trigger signal

TroubleshooTing and sysTem TesTspowermax105 Service Manual 8-312-nn-nThese fault codes usually relate to either the DSP or the power board and can on

Table of ConTenTspowermax105 Service Manual xiiiReplacing the thermal sensor ...

TroubleshooTing and sysTem TesTs8-32 powermax105 Service Manual3-nn-nThese fault codes can only be seen on the service screen.Fault codeDescription P

TroubleshooTing and sysTem TesTspowermax105 Service Manual 8-33Fault codeDescription Power LEDFault LEDFault iconSolutions3-20-0 Fill valveIndicates

TroubleshooTing and sysTem TesTs8-34 powermax105 Service ManualFault codeDescription Power LEDFault LEDFault iconSolutions3-41-0 Drive faultOn OnIf a

TroubleshooTing and sysTem TesTspowermax105 Service Manual 8-35Fault codeDescription Power LEDFault LEDFault iconSolutions3-51-1 Inverter saturation

TroubleshooTing and sysTem TesTs8-36 powermax105 Service ManualProblem Meaning Causes SolutionThe ON/OFF power switch is set to ON (I), but the power

TroubleshooTing and sysTem TesTspowermax105 Service Manual 8-37Problem Meaning Causes SolutionThe power ON LED is illuminated and no fault codes are

TroubleshooTing and sysTem TesTs8-38 powermax105 Service ManualProblem Meaning Causes SolutionWhen pressing the torch trigger or start switch, gas fl

TroubleshooTing and sysTem TesTspowermax105 Service Manual 8-39Problem Meaning Causes SolutionArc goes out while cuttingor intermittently willnot f

TroubleshooTing and sysTem TesTs8-40 powermax105 Service ManualProblem Meaning Causes SolutionWhile in continuous pilot arc mode, the pilot arc extin

TroubleshooTing and sysTem TesTspowermax105 Service Manual 8-41Problem Meaning Causes SolutionMachine does not cut well (does not appear to be cuttin

Table of ConTenTsxiv powermax105 Service ManualSection 11PartsPower supply parts ...

TroubleshooTing and sysTem TesTs8-42 powermax105 Service ManualSystem testsTest # Description Associated fault codes1 Voltage input 0-60-ALL2 DC pow

TROUBLESHOOTING AND SYSTEM TESTSpowermax105Service Manual 8-43 Test 1 – Voltage inputSymptom: Voltage fault (0-60-0, -1 or -2)• Check the line volta

TroubleshooTing and sysTem TesTs8-44 powermax105 Service ManualJ27WORKLEADJ26+_TP7TP9TP8WRBTest 2 – DC Power BussResistance checkNote: All resistanc

TroubleshooTing and sysTem TesTspowermax105 Service Manual 8-45J22 J21 J20 J19J27WORKLEADJ26+_+_TP7TP9TP8WRBJ22 J21 J20 J19J27WORKLEADJ26+_+_TP7TP9TP

TroubleshooTing and sysTem TesTs8-46 powermax105 Service ManualTest 3 – Output diodes• Turn OFF the power switch and disconnect the power cord.• Ch

TroubleshooTing and sysTem TesTspowermax105 Service Manual 8-47Test 4 – Inverter and PFC temperature sensorSymptom: Fault code 0-40 appears in the op

TroubleshooTing and sysTem TesTs8-48 powermax105 Service ManualFor operational fault codes 0-40-0 and 0-40-1 or power board faults 3-11-0 and 3-11-1

TroubleshooTing and sysTem TesTspowermax105 Service Manual 8-49For operational fault codes 0-40-2 and 0-40-3 or power board faults 2-10-0 and 2-10-11

TroubleshooTing and sysTem TesTs8-50 powermax105 Service ManualTest 5 – Flyback circuit (DC minor voltages)Symptom: Minor voltages are not present.No

TroubleshooTing and sysTem TesTspowermax105 Service Manual 8-51Remove the connector covers to access the pins on the top-rear of the power board.If t

powermax105 Service Manual 1-1Section 1SPECIFICATIONSIn this section:Safety information ...

TroubleshooTing and sysTem TesTs8-52 powermax105 Service ManualJ27WORKLEADJ26REDJ18ORGJ17J32J28REDJ27WORKLEADJ26REDJ18ORGJ17J32J28REDTest 6 – Torch s

TroubleshooTing and sysTem TesTspowermax105 Service Manual 8-53Install a test jumper hereJ27WORKLEADJ26REDJ18ORGJ17J32J28REDBefore continuing, turn O

TroubleshooTing and sysTem TesTs8-54 powermax105 Service ManualTest 7 – Start signalSymptom: There is no arc when the torch trigger is closed.If the

TroubleshooTing and sysTem TesTspowermax105 Service Manual 8-55Test 8 – Torch cap switchSymptom: Fault code 0-50 and the cap-sensor switch icon appea

TroubleshooTing and sysTem TesTs8-56 powermax105 Service ManualTest 9 – Electronic regulatorSymptom: Air flows continuously through the torch.1. Tur

TroubleshooTing and sysTem TesTspowermax105 Service Manual 8-57Test 10 – Pressure sensorSymptom: The pressure sensor reading doesn’t agree with known

TroubleshooTing and sysTem TesTs8-58 powermax105 Service ManualTest 11 – FanSymptom: The fan does not operate properly.Note: Wear proper PPE protect

TroubleshooTing and sysTem TesTspowermax105 Service Manual 8-59Test 12 – AUX switchSymptom: Upon power-up, fault code 0-19 displays. After 1 minute,

TroubleshooTing and sysTem TesTs8-60 powermax105 Service Manual

powermax105 Service Manual 9-1Section 9POWER SUPPLY COMPONENT REPLACEMENTIn this section:Replacing the air filter element ...

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

SpecificationS1-2 powermax105 Service ManualSafety informationBefore you set up and operate your Hypertherm system, read the separate Safety and Comp

Power SuPPly ComPonent rePlaCement9-2 powermax105 Service ManualReplacing the solenoid valve ...

Power SuPPly ComPonent rePlaCementpowermax105 Service Manual 9-3Step Task Page1. Disconnect the power and gas supply 9-162. Replace the air

Power SuPPly ComPonent rePlaCement9-4 powermax105 Service ManualStep Task Page1. Disconnect the power and gas supply 9-162. Remove the power

Power SuPPly ComPonent rePlaCementpowermax105 Service Manual 9-5Step Task Page1. Disconnect the power and gas supply 9-162. Remove the power

Power SuPPly ComPonent rePlaCement9-6 powermax105 Service ManualStep Task Page1. Disconnect the power and gas supply 9-162. Remove the power

Power SuPPly ComPonent rePlaCementpowermax105 Service Manual 9-7Step Task Page1. Disconnect the power and gas supply 9-162. Remove the power

Power SuPPly ComPonent rePlaCement9-8 powermax105 Service ManualStep Task Page1. Disconnect the power and gas supply 9-162. Remove the power

Power SuPPly ComPonent rePlaCementpowermax105 Service Manual 9-9Step Task Page1. Disconnect the power and gas supply 9-162. Remove the power

Power SuPPly ComPonent rePlaCement9-10 powermax105 Service ManualStep Task Page1. Disconnect the power and gas supply 9-162. Remove the powe

Power SuPPly ComPonent rePlaCementpowermax105 Service Manual 9-11Step Task Page1. Disconnect the power and gas supply 9-162. Remove the powe

SpecificationSpowermax105 Service Manual 1-3Where to find informationSystem specifications such as size, weight, detailed electrical specifications,

Power SuPPly ComPonent rePlaCement9-12 powermax105 Service ManualStep Task Page1. Disconnect the power and gas supply 9-162. Remove the powe

Power SuPPly ComPonent rePlaCementpowermax105 Service Manual 9-13Step Task Page1. Disconnect the power and gas supply 9-162. Remove the powe

Power SuPPly ComPonent rePlaCement9-14 powermax105 Service ManualStep Task Page1. Disconnect the power and gas supply 9-162. Remove the powe

Power SuPPly ComPonent rePlaCementpowermax105 Service Manual 9-15Step Task Page1. Disconnect the power and gas supply 9-162. Remove the powe

Power SuPPly ComPonent rePlaCement9-16 powermax105 Service ManualWARNING Disconnect electrical power before performing any mai

Power SuPPly ComPonent rePlaCementpowermax105 Service Manual 9-17Replace the air filter element1. Remove the consumables kit that ships beside the f

Power SuPPly ComPonent rePlaCement9-18 powermax105 Service ManualReplace the work lead connector1. Using a razor blade or sharp knife, slice the rub

Power SuPPly ComPonent rePlaCementpowermax105 Service Manual 9-19Install the optional filter kitBracketGas inlet fittingBracketGas inlet fittingAdapt

Power SuPPly ComPonent rePlaCement9-20 powermax105 Service Manual5. Remove the upper two T20 screws from each side of the power supply.6. Place the

Power SuPPly ComPonent rePlaCementpowermax105 Service Manual 9-21Remove the component barrier1. Remove the 16 T20 screws from the sides and top of t

SpecificationS1-4 powermax105 Service ManualPower supply dimensions274 mm (10.8 in.)592 mm (23.3 in.)508 mm (20.0 in.)432 mm (17.0 in.)

Power SuPPly ComPonent rePlaCement9-22 powermax105 Service ManualRemove the end panel bracket1. Remove the two mounting screws from the end panel br

Power SuPPly ComPonent rePlaCementpowermax105 Service Manual 9-231. Secure the voltage divider board to the right of the power supply fan by tighten

Power SuPPly ComPonent rePlaCement9-24 powermax105 Service Manual3. Route the CPC port and attached cables above the solenoid valve and over to the

Power SuPPly ComPonent rePlaCementpowermax105 Service Manual 9-25J22J27WORKLEADJ26_REDJ18ORGJ17J32J11BRJ28REDJ32J18Power board7. Route the large ca

Power SuPPly ComPonent rePlaCement9-26 powermax105 Service ManualSet the voltage divider boardCAUTION: The factory-installed internal voltage div

Power SuPPly ComPonent rePlaCementpowermax105 Service Manual 9-27Connect the machine interface cable1. Remove the machine interface receptacle’s cov

Power SuPPly ComPonent rePlaCement9-28 powermax105 Service ManualInstall the RS485 serial interface cable1. Pry up the right edge of the power switc

Power SuPPly ComPonent rePlaCementpowermax105 Service Manual 9-296. Route the long RS485 cable, along with the two existing gray cables, above the s

Power SuPPly ComPonent rePlaCement9-30 powermax105 Service Manual8. Attach the ground wire (green with yellow stripe) ring connector to the threaded

Power SuPPly ComPonent rePlaCementpowermax105 Service Manual 9-31RS485 Board J2 ConnectorDSP BoardJ7 ConnectorShort RS485 cableLong RS485 cable J1 Co

SpecificationSpowermax105 Service Manual 1-5Component weights (105 A systems)200–600 V CSA 230–400 V CE 400 V CE 380 V CCC 380 V CCC/ 230–400 V CEPow

Power SuPPly ComPonent rePlaCement9-32 powermax105 Service ManualDisconnect the gas tube1. Push in the plastic ring on the push-to-connect fitting.2

Power SuPPly ComPonent rePlaCementpowermax105 Service Manual 9-33Remove the power cord1. Remove the three mounting screws from the bottom of the rea

Power SuPPly ComPonent rePlaCement9-34 powermax105 Service Manual3. Slide the rear end panel approximately 4.0 cm (1.5 inches) away from the power s

Power SuPPly ComPonent rePlaCementpowermax105 Service Manual 9-35Strain relief retention nutStrain reliefRear panel of power supplyAluminum washerStr

Power SuPPly ComPonent rePlaCement9-36 powermax105 Service ManualReplace the power switch1. Remove the three mounting screws from the bottom of the

Power SuPPly ComPonent rePlaCementpowermax105 Service Manual 9-379. Remove the handle screw that secures the power switch handle to the post.10. Pu

Power SuPPly ComPonent rePlaCement9-38 powermax105 Service Manual18. Insert the red and black wires in the top of the auxiliary switch and tighten th

Power SuPPly ComPonent rePlaCementpowermax105 Service Manual 9-39Replace the control board1. Remove the current adjustment knob and operating mode s

Power SuPPly ComPonent rePlaCement9-40 powermax105 Service ManualRemove the DSP board1. Disconnect the DSP connector (1) from the top of the DSP boa

Power SuPPly ComPonent rePlaCementpowermax105 Service Manual 9-41Remove the power boardComplete the instructions below while referring to the applica

SpecificationS1-6 powermax105 Service ManualPowermax105 power supply ratingsRated open-circuit voltage (U0)200–600 V CSA 230–400 V CE 380 V CCC/230–4

Power SuPPly ComPonent rePlaCement9-42 powermax105 Service ManualJ6 J5J3 J2 J1J22 J21 J20 J19J27WORKLEADJ26J25+_+_REDJ18ORGJ17REDJ32J11BRJ28C152 C151

Power SuPPly ComPonent rePlaCementpowermax105 Service Manual 9-43230-400 V CE, 380 V CCC/230-400 V CE Power BoardJ6 J5J3 J2 J1REDJ18ORGJ17REDJ32J11BR

Power SuPPly ComPonent rePlaCement9-44 powermax105 Service Manual380 V CCC/400 V CE Power BoardJ6 J5J3 J2 J1REDJ18ORGJ17REDJ32J11BRJ27J28WORKLEADJ26C

Power SuPPly ComPonent rePlaCementpowermax105 Service Manual 9-45Replace the input diode bridgeComplete the instructions below while referring to the

Power SuPPly ComPonent rePlaCement9-46 powermax105 Service ManualReplace the inverter IGBT moduleComplete the instructions below while referring to t

Power SuPPly ComPonent rePlaCementpowermax105 Service Manual 9-47Replace the PFC IGBT moduleComplete the instructions below while referring to the ap

Power SuPPly ComPonent rePlaCement9-48 powermax105 Service ManualReplace the damper resistorComplete the instructions below while referring to the ap

Power SuPPly ComPonent rePlaCementpowermax105 Service Manual 9-49Replace the thermal sensorComplete the instructions below while referring to the app

Power SuPPly ComPonent rePlaCement9-50 powermax105 Service Manual200-600 V CSA heat sink componentsInput diode bridge (Kit 128746)PFC IGBT module (Ki

Power SuPPly ComPonent rePlaCementpowermax105 Service Manual 9-51230-400 V CE, 380 V CCC/230-400 V CE heat sink componentsInput diode bridge (Kit 128

SpecificationSpowermax105 Service Manual 1-7EMC classification CISPR 11 (CE models only)4Class AInput voltage (U1)/ Input current (I1) at rated outpu

Power SuPPly ComPonent rePlaCement9-52 powermax105 Service Manual380 V CCC/400 V CE heat sink componentsInput diode bridge (Kit 128746)Inverter IGBT

Power SuPPly ComPonent rePlaCementpowermax105 Service Manual 9-53Install the power boardComplete the instructions below while referring to the applic

Power SuPPly ComPonent rePlaCement9-54 powermax105 Service ManualInstall the DSP board1. Connect the ribbon cable from the control board to the conn

Power SuPPly ComPonent rePlaCementpowermax105 Service Manual 9-55Remove the fan shroud1. Grasp the fan shroud with two hands.2. Pull the fan shroud

Power SuPPly ComPonent rePlaCement9-56 powermax105 Service ManualReplace the fan1. Unplug the J1 connector from the back side of the power board.2.

Power SuPPly ComPonent rePlaCementpowermax105 Service Manual 9-57Replace the pressure transducer1. Unplug the J3 connector from the back side of the

Power SuPPly ComPonent rePlaCement9-58 powermax105 Service ManualReplace the pressure switch1. Unplug the wire terminals from the top of the pressur

Power SuPPly ComPonent rePlaCementpowermax105 Service Manual 9-59Replace the air filter subassembly1. Remove the air filter element. Refer to the &q

Power SuPPly ComPonent rePlaCement9-60 powermax105 Service Manual7. Remove the three mounting screws around the gas fitting on the rear panel.8. R

Power SuPPly ComPonent rePlaCementpowermax105 Service Manual 9-61Replace the solenoid valve1. Unplug the J6 connector from the back side of the powe

SpecificationS1-8 powermax105 Service ManualDuramax 75° hand torch dimensions25.2 cm (9.9 in.)9.9 cm (3.9 in.) 75° angle25.9 cm (10.2 in.)5.1 cm (2

Power SuPPly ComPonent rePlaCement9-62 powermax105 Service Manual8. Align and push the new solenoid valve onto the short gas tube until fully seated

Power SuPPly ComPonent rePlaCementpowermax105 Service Manual 9-63Replace the gas tubing1. Push in the plastic ring on the straight push-to-connect f

Power SuPPly ComPonent rePlaCement9-64 powermax105 Service ManualReplace the bulk capacitors1. Remove the four bulk capacitor mounting screws from t

Power SuPPly ComPonent rePlaCementpowermax105 Service Manual 9-65Replace the torch quick disconnect receptacle1. Unplug the wire connector from the

Power SuPPly ComPonent rePlaCement9-66 powermax105 Service Manual5. Disconnect the 90° push-to-connect fitting by pushing in the plastic ring (close

Power SuPPly ComPonent rePlaCementpowermax105 Service Manual 9-678. Remove the brass fitting by pushing it out through the front of the quick discon

Power SuPPly ComPonent rePlaCement9-68 powermax105 Service Manual17. Secure the nozzle wires ring terminal to the power board by tightening the scr

Power SuPPly ComPonent rePlaCementpowermax105 Service Manual 9-69Replace the work lead receptacle1. Remove the bolt securing the work cable to the w

Power SuPPly ComPonent rePlaCement9-70 powermax105 Service ManualReplace the output inductor1. Remove the screw at J28 that secures the electrode wi

Power SuPPly ComPonent rePlaCementpowermax105 Service Manual 9-714. Disconnect the 90° push-to-connect fitting by pushing in the plastic ring (close

SpecificationSpowermax105 Service Manual 1-9Duramax 180° full-length machine torch dimensions39.6 cm (15.6 in.)2.5 cm (1.0 in.)2.5 cm (1.0 in.)3.6 cm

Power SuPPly ComPonent rePlaCement9-72 powermax105 Service Manual9. Lift the output inductor out of the power supply while guiding the long inductor

Power SuPPly ComPonent rePlaCementpowermax105 Service Manual 9-7317. Carefully slide the front end panel against the power supply base.18. Tighten

Power SuPPly ComPonent rePlaCement9-74 powermax105 Service ManualReplace the transformer1. Remove the two screws securing the long transformer wires

Power SuPPly ComPonent rePlaCementpowermax105 Service Manual 9-755. Push the bottom of the fan to the left, so that it will not interfere with the r

Power SuPPly ComPonent rePlaCement9-76 powermax105 Service Manual7. Place the new transformer in the power supply, while guiding the transformer wi

Power SuPPly ComPonent rePlaCementpowermax105 Service Manual 9-77Replace the PFC inductor1. Refer to the applicable figure that follows and remove t

Power SuPPly ComPonent rePlaCement9-78 powermax105 Service ManualFigure 3 - 380 V CCC and 400 V CE models2. Remove the two mounting screws from the

Power SuPPly ComPonent rePlaCementpowermax105 Service Manual 9-793. Lift the PFC inductor out of the power supply, while carefully guiding the PFC i

Power SuPPly ComPonent rePlaCement9-80 powermax105 Service ManualReplace the front end panel1. Remove the current adjustment knob and operating mode

Power SuPPly ComPonent rePlaCementpowermax105 Service Manual 9-816. Disconnect the quick disconnect receptacle from the front end panel by removing

SpecificationS1-10 powermax105 Service ManualPowermax105 cutting specificationsHandheld cut capacity (material thickness)Recommended cut capacity at

Power SuPPly ComPonent rePlaCement9-82 powermax105 Service Manual10. Remove the three front end panel mounting screws.11. Remove the front end panel

Power SuPPly ComPonent rePlaCementpowermax105 Service Manual 9-83Control boardFront end panel - topOperating mode knobCurrent adjustment knobPower bo

Power SuPPly ComPonent rePlaCement9-84 powermax105 Service ManualReplace the rear end panel1. Remove the screw securing the ground wire(s) to the ai

Power SuPPly ComPonent rePlaCementpowermax105 Service Manual 9-85RS485 connector installedRS485 connector not installedLabel perforationPower switch

Power SuPPly ComPonent rePlaCement9-86 powermax105 Service ManualOptional RS485 connectorOptional CNC interface connectorPressure switchGround wire s

Power SuPPly ComPonent rePlaCementpowermax105 Service Manual 9-87Install the strain relief connector1. Install the strain relief connector parts ref

Power SuPPly ComPonent rePlaCement9-88 powermax105 Service ManualInstall the power cord1. Loosen the strain relief retention nut on the strain relie

Power SuPPly ComPonent rePlaCementpowermax105 Service Manual 9-89Rear end panel mounting screws7. Tighten the three supplied mounting screws in the

Power SuPPly ComPonent rePlaCement9-90 powermax105 Service ManualInstall the end panel bracket1. Align the end panel bracket positioning posts with

Power SuPPly ComPonent rePlaCementpowermax105 Service Manual 9-91Install the component barrier1. Slide the side and bottom edges of the component ba

SpecificationSpowermax105 Service Manual 1-11Symbols and markingsYour Hypertherm product may have one or more of the following markings on or near th

Power SuPPly ComPonent rePlaCement9-92 powermax105 Service ManualInstall the power supply cover1. Place the cover over the power supply, aligning th

powermax105 Service Manual 10-1Section 10TORCH COMPONENT REPLACEMENTIn this section:Hand torch: Replacing the start switch ...

Torch componenT replacemenT10-2 powermax105 Service ManualStep Task Page1. Disconnect the power, gas supply, and torch 10-72. Remove the lef

Torch componenT replacemenTpowermax105 Service Manual 10-3Step Task Page1. Disconnect the power, gas supply, and torch 10-72. Remove the le

Torch componenT replacemenT10-4 powermax105 Service ManualStep Task Page1. Disconnect the power, gas supply, and torch 10-72. Separate the t

Torch componenT replacemenTpowermax105 Service Manual 10-5Step Task Page1. Disconnect the power, gas supply, and torch 10-72. Separate the

Torch componenT replacemenT10-6 powermax105 Service ManualStep Task Page1. Disconnect the power, gas supply, and torch 10-72. Separate the t

Torch componenT replacemenTpowermax105 Service Manual 10-7WARNING Disconnect electrical power before performing any maintenan

Torch componenT replacemenT10-8 powermax105 Service ManualLeft handleStrain reliefStrain reliefLeft handleRemove the left handle1. Remove the consum

Torch componenT replacemenTpowermax105 Service Manual 10-9Right handleRight handleRemove the trigger and spring1. Compress the spring into the trig

Service Manual(P/N 807580)Revision 1 – November 2013Hypertherm, Inc. Hanover, NH USA www.hypertherm.com email: [email protected]© Copyright 2013 Hy

SpecificationS1-12 powermax105 Service ManualOlDirect current (DC)The terminal for the external protective (earth) conductorAC input power connection

Torch componenT replacemenT10-10 powermax105 Service ManualRight handleStrain reliefStrain reliefTorch leadTorch leadRight handleRemove the start swi

Torch componenT replacemenTpowermax105 Service Manual 10-11Remove the right handle1. Press the right handle away from the torch body to remove it.

Torch componenT replacemenT10-12 powermax105 Service ManualReplace the torch bodyRefer to the appropriate figure on the previous page and complete th

Torch componenT replacemenTpowermax105 Service Manual 10-13Replace the torch leadRefer to the appropriate figure on the previous page and complete t

Torch componenT replacemenT10-14 powermax105 Service ManualInstall the right handleRefer to the appropriate figures that follow and complete the foll

Torch componenT replacemenTpowermax105 Service Manual 10-15Duramax 15° hand torch handleGas hose fitting slotStart switch postsCap-sensor switch mou

Torch componenT replacemenT10-16 powermax105 Service ManualRemove the mounting sleeveRefer to the appropriate figure(s) on the following page and com

Torch componenT replacemenTpowermax105 Service Manual 10-17Duramax 180° full-length machine torchMachine torch connectionsDuramax 180° mini machine

Torch componenT replacemenT10-18 powermax105 Service ManualReplace the positioning sleeveRefer to the appropriate figure(s) on the previous page and

Torch componenT replacemenTpowermax105 Service Manual 10-19Install the torch bodyRefer to the appropriate figure(s) on page 10-17 and complete the f

powermax105 Service Manual 2-1Section 2POWER SUPPLY SETUPIn this section:Unpack the Powermax system ...

Torch componenT replacemenT10-20 powermax105 Service ManualFour screwsSpringBottom shell halfLatchTop shell halfTorch leadQuick disconnect housingStr

powermax105 Service Manual 11-1Section 11PARTSIn this section:Power supply parts ...

Parts11-2 powermax105 Service ManualPower supply partsExterior frontItem Part number Description228903 Kit: Powermax105 labels, CSA228904 Kit: Powe

PARTSpowermax105 Service Manual 11-3Exterior rearItem Part number Description1 228885 Kit: Powermax105 power cord 200-600 V CSA2 228886 Kit: Powerm

Parts11-4 powermax105 Service ManualItem Part number Description023206 Machine interface cable (start, arc transfer ground), 7.6 m (25 ft), spade con

Partspowermax105 Service Manual 11-5J22 J21 J20 J19J27WORKLEADJ26J25+_+_REDJ18ORGJ17J32J11BRJ28TP7TP9TP8WRBInterior, power board side (200-600 V CSA)

Parts11-6 powermax105 Service ManualJ22 J21 J20 J19J27WORKLEADJ26J25+_+_REDJ18ORGJ17J32J11J28TP7TP9TP8WRBInterior, power board side (230-400 V CE)124

Partspowermax105 Service Manual 11-7J22 J21 J20 J19J27WORKLEADJ26J25+_+_REDJ18ORGJ17J32J11J28TP7TP9TP8WRBInterior, power board side (400 V CE/380 V C

Parts11-8 powermax105 Service Manual12345678 9Interior, fan side1617121314151011

Partspowermax105 Service Manual 11-9Item Part number Description1 228881 Kit: Powermax105 fan subassembly2 228910 Kit: Powermax105 fan shroud3 2286

Power SuPPly SetuP2-2 powermax105 Service ManualUnpack the Powermax system1. Verify that all items on your order have been received in good conditio

Parts11-10 powermax105 Service ManualItem Part number Description1 228902 Kit: Powermax105 output diode bridge (2) with thermal grease2 228693 Kit:

Partspowermax105 Service Manual 11-11Item Part number Description1 228902 Kit: Powermax105 output diode bridge (2) with thermal grease2 228693 Kit:

Parts11-12 powermax105 Service Manual400 V CE/ 380 V CCC heat sink components715346Item Part number Description1 228902 Kit: Powermax105 output diod

Partspowermax105 Service Manual 11-13Duramax 75° hand torch replacement parts1234567891011Item Part number Description059473 Powermax65/85/105 75° ha

Parts11-14 powermax105 Service ManualDuramax 15° hand torch replacement parts1234567 8 9The entire hand torch and lead assembly can be replaced, or i

Partspowermax105 Service Manual 11-15Hand torch consumablesPart number DescriptionDrag cutting220818 Shield: 45/65/85 A220992 Shield 105 A220854 Reta

Parts11-16 powermax105 Service ManualDuramax 180° full-length machine torch replacement parts12345678910 1112 13

Partspowermax105 Service Manual 11-17The entire machine torch and lead assembly can be replaced, or individual component parts can be replaced. Part

Parts11-18 powermax105 Service ManualDuramax 180° mini machine torch replacement parts345678910 1112

Partspowermax105 Service Manual 11-19The entire machine torch and lead assembly can be replaced, or individual component parts can be replaced. Part

Power SuPPly SetuPpowermax105 Service Manual 2-3Operator ManualSafety ManualQuick Setup CardRegistration CardContentsThe following illustration shows

Parts11-20 powermax105 Service ManualMachine torch consumables* The deflector (220955) is used only with the standard retaining cap (220854). The shi

Partspowermax105 Service Manual 11-21Accessory partsPart number Description024548 Brown leather torch sheathing, 7.6 m (25 ft)024877 Black leather to

Parts11-22 powermax105 Service ManualSafety-critical partsGenuine Hypertherm parts are the factory-recommended parts for your Hypertherm system. The

Partspowermax105 Service Manual 11-23J22 J21 J20 J19J27WORKLEADJ26J25+_+_REDJ18ORGJ17J32J11J28TP7TP9TP8WRB230-400 V CE4Item Part number Description1

Parts11-24 powermax105 Service Manual4Item Part number Description1 228878 Kit: Powermax105 power board 400 V CE/380 V CCC2 228880 Kit: Powermax10

Partspowermax105 Service Manual 11-25Power supply fan side12347 8Item Part number Description1 228881 Kit: Powermax105 fan subassembly2 228685 Kit:

Parts11-26 powermax105 Service ManualRecommended spare partsPart number Description108797 Adjustment knob108732 Operating mode knob223254 Kit: 105 A

Partspowermax105 Service Manual 11-27Part number Description228959 Kit: Duramax hand torch lead replacement, 7.6 m (25 ft)228960 Kit: Duramax hand

Parts11-28 powermax105 Service Manual

powermax105 Service Manual 12-1Section 12WIRING DIAGRAMSIn this section:Powermax Generic Timing Chart ...

Power SuPPly SetuP2-4 powermax105 Service ManualPosition the power supplyLocate the power supply near an appropriate power receptacle for your instal

Wiring Diagrams12-2 powermax105 Service Manual

12-3Powermax Generic Timing ChartPowermax Service ReferenceMaximum 5 secondsUser set currentTransfer PA currentPilot arc currentTransfer threshold: 1.

12-4PMX105 CSAPMX105 230-400V CEPMX105 380V CCC/230-400V CESchematic diagram (CSA,230-400VCE,380VCCC/230-400VCE)

12-5PMX105 380V CCCPMX105 400V CESchematic diagram (380 V CCC, 400 V CE)

Power SuPPly SetuPpowermax105 Service Manual 2-5Install a line-disconnect switchUse a line-disconnect switch for each power supply so that the operat

Power SuPPly SetuP2-6 powermax105 Service ManualPower connection for the Powermax105Powermax105 3-phase systems include the following models:• The 2

Power SuPPly SetuPpowermax105 Service Manual 2-7380 V CCC/230–400 V CEInput voltage (V) 230 400 380Input current (A) at rated output (16.8 kw) 50 29

Power SuPPly SetuP2-8 powermax105 Service ManualThree-phase power cord and plug installationPowermax105 power supplies are shipped with the following

Power SuPPly SetuPpowermax105 Service Manual 2-9Extension cord recommendationsAny extension cord must have an appropriate wire size for the cord leng

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

Power SuPPly SetuP2-10 powermax105 Service ManualEngine-driven generator recommendationsGenerators used with the Powermax105 should satisfy the follo

Power SuPPly SetuPpowermax105 Service Manual 2-11Prepare the gas supplyThe air can be supplied by a compressor or from high-pressure cylinders. A hig

Power SuPPly SetuP2-12 powermax105 Service ManualConnect the gas supplyConnect the gas supply to the power supply using an inert-gas hose with a 9.5

Power SuPPly SetuPpowermax105 Service Manual 2-13Minimum inlet pressure (while gas is flowing)This table shows the minimum required inlet pressure wh

Power SuPPly SetuP2-14 powermax105 Service Manual

powermax105 Service Manual 3-1Section 3BASIC SYSTEM OPERATIONSIn this section:Controls and indicators ...

Basic system OperatiOns3-2 powermax105 Service ManualControls and indicatorsPowermax105 power supplies have the following: ON/OFF switch, adjustment

Basic system OperatiOnspowermax105 Service Manual 3-3Operating mode switchThe operating mode switch can be set in one of four positions:• Continuous

Basic system OperatiOns3-4 powermax105 Service ManualStatus screenThe status screen shows system status and fault information.Torch startedFault icon

Basic system OperatiOnspowermax105 Service Manual 3-5Fault codesWhen a power supply or torch fault occurs, the system displays a fault code in the lo

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

Basic system OperatiOns3-6 powermax105 Service ManualOperating the Powermax105Follow the steps below to begin cutting or gouging with the Powermax sy

Basic system OperatiOnspowermax105 Service Manual 3-7Attach the work lead to the power supplyCaution: Make sure you use a work lead that is appropri

Basic system OperatiOns3-8 powermax105 Service ManualAttach the work clamp to the workpieceThe work clamp must be connected to the workpiece while yo

Basic system OperatiOnspowermax105 Service Manual 3-9Turn ON the system Set the ON/OFF switch to the ON (I) position.OffOnSet the operating mode swit

Basic system OperatiOns3-10 powermax105 Service ManualCheck the indicatorsVerify the following:• The green power ON LED on the front of the power su

Basic system OperatiOnspowermax105 Service Manual 3-11Adjusting the current (amperage)Turn the adjustment knob to adjust the current for your particu

Basic system OperatiOns3-12 powermax105 Service ManualUnderstanding duty-cycle limitationsThe duty cycle is the amount of time, in minutes, that a pl

powermax105 Service Manual 4-1Section 4HAND TORCH SETUPIn this section:Introduction ...

Hand TorcH SeTup4-2 powermax105 Service ManualIntroductionDuramax™ series hand torches are available for Powermax105 systems. The FastConnectTM quick

Hand TorcH SeTuppowermax105 Service Manual 4-3ConsumablesConsumablesSafety triggerSafety triggerHand torch componentsNote: Torches ship without c

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

Hand TorcH SeTup4-4 powermax105 Service ManualChoose the hand torch consumablesHypertherm includes a box of consumables with your system. Both styles

Hand TorcH SeTuppowermax105 Service Manual 4-5105AHand torch consumablesGouging consumables220854Retaining cap220994Swirl ring220842Electrode220798Sh

Hand TorcH SeTup4-6 powermax105 Service ManualInstall the hand torch consumablesWARNING:INSTANTON TORCHESPLASMA ARC CAN CAUSE INJURY AND BURNSThe pl

Hand TorcH SeTuppowermax105 Service Manual 4-7Connecting the torch leadThe Powermax105 is equipped with FastConnectTM, a quick-disconnect system for

Hand TorcH SeTup4-8 powermax105 Service Manual

powermax105 Service Manual 5-1Section 5HAND CUTTINGIn this section:Using the hand torch ...

Hand Cutting5-2 powermax105 Service ManualUsing the hand torchWARNING:INSTANTON TORCHESPLASMA ARC CAN CAUSE INJURY AND BURNSPlasma arc comes on imme

Hand Cuttingpowermax105 Service Manual 5-3Hand torch cutting hints• Drag the torch tip lightly along the workpiece to maintain a steady cut.• While

Hand Cutting5-4 powermax105 Service ManualStart a cut from the edge of the workpiece1. With the work clamp attached to the workpiece, hold the torch

Hand Cuttingpowermax105 Service Manual 5-5Pierce a workpieceWARNING:When firing the torch at an a

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

Hand Cutting5-6 powermax105 Service ManualGouge a workpieceWARNING:When firing the torch at an an

Hand Cuttingpowermax105 Service Manual 5-7Gouge profileYou can vary the gouge profile by varying the speed of the torch over the workpiece, varying t

Hand Cutting5-8 powermax105 Service ManualVarying the gouge profileThe following actions have the stated effects on the gouge profile: Increasing t

powermax105 Service Manual 6-1Section 6MACHINE TORCH SETUPIn this section:Introduction ...

Machine Torch SeTup6-2 powermax105 Service Manual65 A Shielded cutting (Mild Steel) ...

Machine Torch SeTuppowermax105 Service Manual 6-3IntroductionDuramax™ series machine torches are available for Powermax105 systems. The FastConnectTM

Machine Torch SeTup6-4 powermax105 Service ManualMachine torch componentsDuramax 180° full-length machine torchBefore using either style of machine t

Machine Torch SeTuppowermax105 Service Manual 6-5Converting a full-length machine torch to a mini machine torchYou can convert a full-length machine

Machine Torch SeTup6-6 powermax105 Service Manual9. Use 1/4-inch and 3/8-inch wrenches, or adjustable wrenches, to loosen the nut that secures the g

Machine Torch SeTuppowermax105 Service Manual 6-7Mount the torchDepending on the type of cutting table you have, you may or may not need to disassemb

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

Machine Torch SeTup6-8 powermax105 Service Manual10. Slide the coupler, positioning sleeve (full-length machine torch), strain relief nut, and strain

Machine Torch SeTuppowermax105 Service Manual 6-9Choose the machine torch consumablesPowermax systems with the Duramax 180° full-length machine torch

Machine Torch SeTup6-10 powermax105 Service ManualMechanized shielded with ohmic 105 A consumablesMechanized shielded with ohmic 45 A, 65 A, 85 A con

Machine Torch SeTuppowermax105 Service Manual 6-11Gouging consumables220854Retaining cap220994Swirl ring220842Electrode220798Shield220991NozzleFineCu

Machine Torch SeTup6-12 powermax105 Service ManualInstall the machine torch consumablesWARNING:INSTANTON TORCHESPLASMA ARC CAN CAUSE INJURY AND BURN

Machine Torch SeTuppowermax105 Service Manual 6-13Connecting the torch leadThe Powermax105 is equipped with FastConnectTM, a quick-disconnect system

Machine Torch SeTup6-14 powermax105 Service ManualUsing the cut chartsThe following sections provide cut charts for each set of mechanized consumable

Machine Torch SeTuppowermax105 Service Manual 6-15Estimated kerf-width compensationThe widths in the tables below are for reference. The data are obt

Machine Torch SeTup6-16 powermax105 Service ManualEstimated kerf-width compensation – English (inches)ProcessThickness (inches)22GA 18GA 14GA 10GA 3/

Machine Torch SeTuppowermax105 Service Manual 6-17105 A Shielded consumables220993Shield220854Retaining cap220990Nozzle220994Swirl ring220842Electrod

powermax105 Service Manual vSafety informationBefore operating any Hypertherm equipment, read the separate Safety and Compliance Manual (80669C) inclu

Machine Torch SeTup6-18 powermax105 Service Manual105 A Shielded cutting (Mild Steel)Air flow rate – slpm/scfhHot 217 / 460Cold 250 / 530MetricMateri

Machine Torch SeTuppowermax105 Service Manual 6-19105 A Shielded cutting (Stainless Steel)Air flow rate – slpm/scfhHot 217 / 460Cold 250 / 530MetricM

Machine Torch SeTup6-20 powermax105 Service Manual105 A Shielded cutting (Aluminum)Air flow rate – slpm/scfhHot 217 / 460Cold 250 / 530MetricMaterial

MACHINE TORCH SETUPpowermax105 Service Manual 6-2185 A Shielded consumables85A85A220817Shield220953Ohmic-sensing retaining cap220816Nozzle220842Elect

Machine Torch SeTup6-22 powermax105 Service Manual85 A Shielded cutting (Mild Steel)Air flow rate – slpm/scfhHot 194 / 412Cold 236 / 500MetricMateria

Machine Torch SeTuppowermax105 Service Manual 6-2385 A Shielded cutting (Stainless Steel)Air flow rate – slpm/scfhHot 194 / 412Cold 236 / 500MetricMa

Machine Torch SeTup6-24 powermax105 Service Manual85 A Shielded cutting (Aluminum)Air flow rate – slpm/scfhHot 194 / 412Cold 236 / 500MetricMaterial

Machine Torch SeTuppowermax105 Service Manual 6-2565 A Shielded consumables65A65A220817Shield220953Ohmic-sensing retaining cap220819Nozzle220842Elect

Machine Torch SeTup6-26 powermax105 Service Manual65 A Shielded cutting (Mild Steel)Air flow rate – slpm/scfhHot 175 / 370Cold 209 / 443MetricMateria

Machine Torch SeTuppowermax105 Service Manual 6-2765 A Shielded cutting (Stainless Steel)Air flow rate – slpm/scfhHot 175 / 370Cold 209 / 443MetricMa