Hypertherm Duramax Hyamp Series User manual

Duramax™ Hyamp Long Handheld Torches
45° and 90° / 0.6 m (2 feet), 1.2 m (4 feet), and 1.8 m (6 feet)
Service Manual
808290 | Revision 1 | English

Powermax, Duramax, FastConnect, and Hypertherm are trademarks of Hypertherm Inc. and may be registered in the United States
and other countries. All other trademarks are the property of their respective holders.
Environmental stewardship is one of Hypertherm’s core values, and it is critical to our success and our customers’ success. We
are striving to reduce the environmental impact of everything we do. For more information:www.hypertherm.com/environment.
© 2018 Hypertherm Inc.
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Benefits of registration
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is required.
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Hypertherm Inc.
Hanover, NH 03755 USA
www.hypertherm.com
Duramax Hyamp Long Handheld Torches
Service Manual
808290
Revision 1
English
March 2018

Hypertherm Inc.
Etna Road, P.O. Box 5010
Hanover, NH 03755 USA
603-643-3441 Tel (Main Office)
603-643-5352 Fax (All Departments)
[email protected] (Main Office Email)
800-643-9878 Tel (Technical Service)
[email protected] (Technical Service Email)
800-737-2978 Tel (Customer Service)
customer.ser[email protected] (Customer Service Email)
866-643-7711 Tel (Return Materials Authorization)
877-371-2876 Fax (Return Materials Authorization)
[email protected] (RMA email)
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
Soporte.T[email protected] (Technical Service Email)
Hypertherm Plasmatechnik GmbH
Sophie-Scholl-Platz 5
63452 Hanau
Germany
00 800 33 24 97 37 Tel
00 800 49 73 73 29 Fax
31 (0) 165 596900 Tel (Technical Service)
00 800 4973 7843 Tel (Technical Service)
[email protected] (Technical Service Email)
Hypertherm (Singapore) Pte Ltd.
82 Genting Lane
Media Centre
Annexe Block #A01-01
Singapore 349567, Republic of Singapore
65 6841 2489 Tel
65 6841 2490 Fax
[email protected] (Marketing Email)
TechSupportAP[email protected] (Technical Service Email)
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
[e-mail] (Main Office Email)
TechSupportAP[email protected] (Technical Service Email)
Hypertherm Europe B.V.
Vaartveld 9, 4704 SE
Roosendaal, Nederland
31 165 596907 Tel
31 165 596901 Fax
31 165 596908 Tel (Marketing)
31 (0) 165 596900 Tel (Technical Service)
00 800 4973 7843 Tel (Technical Service)
[email protected]
(Technical Service Email)
Hypertherm (Shanghai) Trading Co., Ltd.
B301, 495 ShangZhong Road
Shanghai, 200231
PR China
86-21-80231122 Tel
86-21-80231120 Fax
86-21-80231128 Tel (Technical Service)
[email protected]
(Technical Service Email)
South America & Central America: Hypertherm Brasil Ltda.
Rua Bras Cubas, 231 – Jardim Maia
Guarulhos, SP – Brasil
CEP 07115-030
55 11 2409 2636 Tel
[email protected] (Technical Service Email)
Hypertherm Korea Branch
#3904. APEC-ro 17. Heaundae-gu. Busan.
Korea 48060
82 (0)51 747 0358 Tel
82 (0)51 701 0358 Fax
[email protected] (Marketing Email)
TechSupportAP[email protected]
(Technical Service Email)
Hypertherm Pty Limited
GPO Box 4836
Sydney NSW 2001, Australia
61 (0) 437 606 995 Tel
61 7 3219 9010 Fax
[email protected] (Main Office Email)
TechSupportAP[email protected]
(Technical Service Email)
Hypertherm (India) Thermal Cutting Pvt. Ltd
A-18 / B-1 Extension,
Mohan Co-Operative Industrial Estate,
Mathura Road, New Delhi 110044, India
91-11-40521201/ 2/ 3 Tel
91-11 40521204 Fax
[e-mail] (Main Office Email)
TechSupportAP[email protected]
(Technical Service Email)
1/28/16

ENGLISH
WARNING! Before operating any Hypertherm equipment, read the safety
instructions in your product’s manual and in the Safety and Compliance Manual
(80669C). Failure to follow safety instructions can result in personal injury or in
damage to equipment.
Copies of the manuals may accompany the product in electronic and printed
formats. You can also obtain copies of the manuals, in all languages available
for each manual, from the “Documents library” at www.hypertherm.com.
DEUTSCH / GERMAN
WARNUNG! Bevor Sie ein Hypertherm-Gerät in Betrieb nehmen, lesen
Sie bitte die Sicherheitsanweisungen in Ihrer Bedienungsanleitung sowie im
Handbuch für Sicherheit und Übereinstimmung (80669C). Das Nichtbefolgen
der Sicherheitsanweisungen kann zu Verletzungen von Personen oder
Schäden am Gerät führen.
Bedienungsanleitungen und Handbücher können dem Gerät in
elektronischer Form oder als Druckversion beiliegen. Alle Handbücher
und Anleitungen können in den jeweils verfügbaren Sprachen auch in der
„Dokumente-Bibliothek“ unter www.hypertherm.com heruntergeladen werden.
FRANÇAIS / FRENCH
AVERTISSEMENT! Avant d’utiliser tout équipement Hypertherm, lire les
consignes de sécurité importantes dans le manuel de votre produit et dans
le Manuel de sécurité et de conformité (80669C). Le non-respect des
consignes de sécurité peut engendrer des blessures physiques ou des
dommages à l’équipement.
Des copies de ces manuels peuvent accompagner le produit en format
électronique et papier. Vous pouvez également obtenir des copies de chaque
manuel dans toutes les langues disponibles à partir de la «Bibliothèque
de documents» sur www.hypertherm.com.
ESPAÑOL / SPANISH
¡ADVERTENCIA! Antes de operar cualquier equipo Hypertherm, leer las
instrucciones de seguridad del manual de su producto y del Manual de
Seguridad y Cumplimiento (80669C). No cumplir las instrucciones
de seguridad podría dar lugar a lesiones personales o daño a los equipos.
Pueden venir copias de los manuales en formato electrónico e impreso
junto con el producto. También se pueden obtener copias de los manuales,
en todos los idiomas disponibles para cada manual, de la “Biblioteca
de documentos” en www.hypertherm.com.
ITALIANO / ITALIAN
AVVERTENZA! Prima di usare un’attrezzatura Hypertherm, leggere le istruzioni
sulla sicurezza nel manuale del prodotto e nel Manuale sulla sicurezza e
la conformità (80669C). Il mancato rispetto delle istruzioni sulla sicurezza può
causare lesioni personali o danni all’attrezzatura.
Il prodotto può essere accompagnato da copie elettroniche e cartacee
del manuale. È anche possibile ottenere copie del manuale, in tutte le lingue
disponibili per ogni manuale, dall’“Archivio documenti” all’indirizzo
www.hypertherm.com.
NEDERLANDS / DUTCH
WAARSCHUWING! Lees voordat u Hypertherm-apparatuur gebruikt
de veiligheidsinstructies in de producthandleiding en in de Veiligheids- en
nalevingshandleiding (80669C). Het niet volgen van de veiligheidsinstructies
kan resulteren in persoonlijk letsel of schade aan apparatuur.
De handleidingen kunnen in elektronische en gedrukte vorm met het
product worden meegeleverd. De handleidingen, elke handleiding
beschikbaar in alle talen, zijn ook verkrijgbaar via de “Documentenbibliotheek”
op www.hypertherm.com.
DANSK / DANISH
ADVARSEL! Inden Hypertherm udstyr tages i brug skal
sikkerhedsinstruktionerne i produktets manual og i Manual om sikkerhed og
overholdelse af krav (80669C), gennemlæses. Følges sikkerhedsvejledningen
ikke kan det resultere i personskade eller beskadigelse af udstyret.
Kopier af manualerne kan ledsage produktet i elektroniske og trykte formater.
Du kan også få kopier af manualer, på alle sprog der er til rådighed for hver
manuel, fra “Dokumentbiblioteket” på www.hypertherm.com.
PORTUGUÊS / PORTUGUESE
ADVERTÊNCIA! Antes de operar qualquer equipamento Hypertherm, leia as
instruções de segurança no manual do seu produto e no Manual de Segurança
e de Conformidade (80669C). Não seguir as instruções de segurança pode
resultar em lesões corporais ou danos ao equipamento.
Cópias dos manuais podem acompanhar os produtos nos formatos eletrônico
e impresso. Também é possível obter cópias dos manuais em todos os idiomas
disponíveis para cada manual na “Biblioteca de documentos” em
www.hypertherm.com.
日本語 / JAPANESE
警告 ! Hypertherm 機器を操作する前に、安全に関する重要な情報につい
て、この製品説明書にある安全情報、および製品に同梱されている別冊の
「安全とコンプライアンスマニュアル」(80669C) をお読みください。安全
情報に従わないと怪我や装置の損傷を招くことがあります。
説明書のコピーは、電子フォーマット、または印刷物として製品に同梱さ
れています。各説明書は、www.hypertherm.com の「ドキュメントライブラ
リ」から各言語で入手できます。
简体中文 / CHINESE (SIMPLIFIED)
警告！ 在操作任何海宝设备之前，请阅读产品手册和 《安全和法规遵守手
册》 (80669C) 中的安全操作说明。若未能遵循安全操作说明，可能会造成
人员受伤或设备损坏。
随产品提供的手册可能提供电子版和印刷版两种格式。您也可从
“Documents library” （文档资料库）中获取每本手册所有可用语言的副本，
网址为 www.hypertherm.com.
NORSK / NORWEGIAN
ADVARSEL! Før du bruker noe Hypertherm-utstyr, må du lese
sikkerhetsinstruksjonene i produktets håndbok og i Håndboken om sikkerhet
og samsvar (80669C). Unnlatelse av å følge sikkerhetsinstruksjoner kan føre
til personskade eller skade på utstyr.
Eksemplarer av håndbøkene kan medfølge produktet i elektroniske og trykte
utgaver. Du kan også få eksemplarer av håndbøkene i alle tilgjengelige språk
for hver håndbok fra dokumentbiblioteket på www.hypertherm.com.
SVENSKA / SWEDISH
VARNING! Läs häftet säkerhetsinformationen i din produkts säkerhets- och
efterlevnadsmanual (80669C) för viktig säkerhetsinformation innan du
använder eller underhåller Hypertherm-utrustning. Underlåtenhet att följa
dessa säkerhetsinstruktionerkan resultera i personskador eller skador
på utrustningen.
Kopior av manualen kan medfölja produkten i elektronisk och tryckform.
Du hittar även kopior av manualerna i alla tillgängliga språk
i dokumentbiblioteket (Documents library) på www.hypertherm.com.
한국어 / KOREAN
경고! Hypertherm 장비를 사용하기 전에 제품 설명서와 안전 및 규정
준수 설명서 (80669C)에 나와 있는 안전 지침을 읽으십시오. 안전 지침을
준수하지 않으면 신체 부상이나 장비 손상을 초래할 수 있습니다.
전자 형식과 인쇄된 형식으로 설명서 사본이 제품과 함께 제공될
수 있습니다. www.hypertherm.com 의 'Documents library (문서라이브러리)'
에서도모든언어로이용할수있는설명서사본을얻을수있습니다.

ČESKY / CZECH
VAROVÁNÍ! Před uvedením jakéhokoliv zařízení Hypertherm do provozu
si přečtěte bezpečnostní pokyny v příručce k produktu a v Manuálu pro
bezpečnost a dodržování předpisů (80669C). Nedodržování bezpečnostních
pokynů může mít za následek zranění osob nebo poškození majetku.
Kopie příruček a manuálů mohou být součástí dodávky produktu, a to
v elektronické i tištěné formě. Kopie příruček a manuálů ve všech jazykových
verzích, v nichž byly dané příručky a manuály vytvořeny, naleznete v „Knihovně
dokumentů“ na webových stránkách www.hypertherm.com.
POLSKI / POLISH
OSTRZEŻENIE! Przed rozpoczęciem obsługi jakiegokolwiek systemu firmy
Hypertherm należy się zapoznać z instrukcjami bezpieczeństwa
zamieszczonymi w podręczniku produktu oraz w Podręczniku bezpieczeństwa
i zgodności (80669C). Nieprzestrzeganie instrukcji bezpieczeństwa może
skutkować obrażeniami ciała i uszkodzeniem sprzętu.
Do produktu mogą być dołączone kopie podręczników w formacie
elektronicznym i drukowanym. Kopie podręczników, wkażdym udostępnionym
języku, można również znaleźć w„Bibliotece dokumentów” pod adresem
www.hypertherm.com.
PУССКИЙ / RUSSIAN
БЕРЕГИСЬ! Перед работой с любым оборудованием Hypertherm
ознакомьтесь с инструкциями по безопасности, представленными
в руководстве, которое поставляется вместе с продуктом, а также
вРуководстве по безопасности и соответствию (80669J). Невыполнение
инструкций по безопасности может привести к телесным повреждениям
или повреждению оборудования.
Копии руководств, которые поставляются вместе с продуктом, могут быть
представлены в электронном и бумажном виде. Копии руководств на всех
языках, на которые переведено то или иное руководство, можно также
загрузить в разделе «Библиотека документов» на веб-сайте
www.hypertherm.com.
SUOMI / FINNISH
VAROITUS! Ennen minkään Hypertherm-laitteen käyttöä lue tuotteen
käyttöoppaassa olevat turvallisuusohjeet ja turvallisuus- ja
vaatimustenmukaisuusohje (80669C). Turvallisuusohjeiden laiminlyönti
voi aiheuttaa henkilökohtaisen loukkaantumisen tai laitevahingon.
Käyttöoppaiden kopiot voivat olla tuotteen mukana elektronisessa ja
tulostetussa muodossa. Voit saada käyttöoppaiden kopiot kaikilla kielillä
”latauskirjastosta”, joka on osoitteessa www.hypertherm.com.
БЪЛГAPCКИ / BULGARIAN
ПРЕДУПРЕЖДЕНИЕ! Преди да работите с което и да е оборудване
Hypertherm, прочетете инструкциите за безопасност в ръководството на
вашия продукт и „Инструкция за безопасност и съответствие“ (80669C).
Неспазването на инструкциите за безопасност би могло да доведе
до телесно нараняване или до повреда на оборудването.
Копия на ръководствата може да придружават продукта в електронен и в
печатен формат. Можете да получите копия на ръководствата, предлагани
на всички езици, от „Documents library“ (Библиотека за документи)
на адрес www.hypertherm.com.
ROMÂNĂ / ROMANIAN
AVERTIZARE! Înainte de utilizarea oricărui echipament Hypertherm, citiți
instrucțiunile de siguranță din cadrul manualului produsului și din cadrul
Manualului de siguranță și conformitate (80669C). Nerespectarea
instrucțiunilor de siguranță pot rezulta în vătămare personală sau în avarierea
echipamentului.
Produsul poate fi însoțit de copii ale manualului în format tipărit și electronic.
De asemenea, dumneavoastră puteţi obţine copii ale manualelor, în toate limbile
disponibile pentru fiecare manual, din cadrul secţiunii „Bibliotecă documente”
aflată pe site-ul www.hypertherm.com.
TÜRKÇE / TURKISH
UYARI! Bir Hypertherm ekipmanını çalıştırmadan önce, ürün kullanım
kılavuzunda ve Güvenlik ve Uyumluluk Kılavuzu’nda (80669C) yer alan
güvenlik talimatlarını okuyun. Güvenlik talimatlarına uyulmaması durumunda
kişisel yaralanmalar veya ekipman hasarı meydana gelebilir.
Kılavuzların kopyaları, elektronik ve basılı formatta ürünle birlikte verilebilir.
Her biri tüm dillerde yayınlanan kılavuzların kopyalarını www.hypertherm.com
adresindeki “Documents library” (Dosyalar kitaplığı) başlığından da elde
edebilirsiniz.
MAGYAR / HUNGARIAN
VIGYÁZAT! Mielőtt bármilyen Hypertherm berendezést üzemeltetne, olvassa
el a biztonsági információkat a termék kézikönyvében és a Biztonsági és
szabálykövetési kézikönyvben (80669C). A biztonági utasítások betartásának
elmulasztása személyi sérüléshez vagy a berendezés károsodásához vezethet.
A termékhez a kézikönyv példányai elektronikus és nyomtatott formában
is mellékelve lehetnek. A kézikönyvek példányai (minden nyelven) a
www.hypertherm.com weboldalon a „Documents library” (Dokumentum
könyvtár) részben is beszerezhetők.
ΕΛΛΗΝΙΚΆ / GREEK
ΠΡΟΕΙΔΟΠΟΙΗΣΗ! Πριν θέσετε σε λειτουργία οποιονδήποτε εξοπλισμό της
Hypertherm, διαβάστε τις οδηγίες ασφαλείας στο εγχειρίδιο του προϊόντος
και στο Εγχειρίδιο ασφάλειας και συμμόρφωσης (80669C). Η μη τήρηση
των οδηγιών ασφαλείας μπορεί να επιφέρει σωματική βλάβη ή ζημιά στον
εξοπλισμό.
Αντίγραφα των εγχειριδίων μπορεί να συνοδεύουν το προϊόν σε ηλεκτρονική
και έντυπη μορφή. Μπορείτε, επίσης, να λάβετε αντίγραφα των εγχειριδίων σε
όλες τις γλώσσες που διατίθενται για κάθε εγχειρίδιο από την ψηφιακή
βιβλιοθήκη εγγράφων (Documents library) στη διαδικτυακή τοποθεσία
www.hypertherm.com.
繁體中文 / CHINESE (TRADITIONAL)
警告！ 在操作任何 Hypertherm 設備前，請閱讀您產品手冊和 《安全和法務
遵從手冊》(80669C) 內的安全指示。不遵守安全指示可能會導致人身傷害
或設備損壞。
手冊複本可能以電子和印刷格式隨附產品提供。您也可以在
www.hypertherm.com 的 「文檔資料庫」內獲取所有手冊的多語種複本。
SLOVENŠČINA / SLOVENIAN
OPOZORILO! Pred uporabo katerekoli Hyperthermove opreme preberite
varnostna navodila v priročniku vašega izdelka ter v Priročniku za varnost
in skladnost (80669C). Neupoštevanje navodil za uporabo lahko povzroči
telesne poškodbe ali materialno škodo.
Izdelku so lahko priloženi izvodi priročnikov v elektronski ali tiskani obliki. Izvode
priročnikov v vseh razpoložljivih jezikih si lahko prenesete tudi iz knjižnice
dokumentov “Documents library” na naslovu www.hypertherm.com.
SRPSKI / SERBIAN
UPOZORENJE! Pre rukovanja bilo kojom Hyperthermovom opremom
pročitajte uputstva o bezbednosti u svom priručniku za proizvod i u Priručniku
o bezbednosti i usaglašenosti (80669C). Oglušavanje o praćenje uputstava
o bezbednosti može da ima za posledicu ličnu povredu ili oštećenje opreme.
Može se dogoditi da kopije priručnika prate proizvod u elektronskom
i štampanom formatu. Takođe možete da pronađete kopije priručnika, na svim
jezicima koji su dostupni za svaki od priručnika, u “Biblioteci dokumenata”
(“Documents library”) na www.hypertherm.com.
SLOVENČINA / SLOVAK
VÝSTRAHA! Pred použitím akéhokoľvek zariadenia od spoločnosti Hypertherm
si prečítajte bezpečnostné pokyny v návode na obsluhu vášho zariadenia
avManuáli o bezpečnosti a súlade s normami (80669C). V prípade
nedodržania bezpečnostných pokynov môže dôjsť k ujme na zdraví alebo
poškodeniu zariadenia.
Kópia návodu, ktorá je dodávaná s produktom, môže mať elektronickú
alebo tlačenú podobu. Kópie návodov, vo všetkých dostupných jazykoch,
sú k dispozícii aj v sekcii z „knižnice Dokumenty“ na www.hypertherm.com.

Duramax Hyamp Long Handheld Torches Service Manual 808290 7
Contents
Electromagnetic Compatibility (EMC) ............................................................................ SC-11
Introduction ..............................................................................................................................................................................SC-11
Installation and use .................................................................................................................................................................SC-11
Assessment of area ................................................................................................................................................................SC-11
Methods of reducing emissions ..........................................................................................................................................SC-11
Mains supply ....................................................................................................................................................................SC-11
Maintenance of cutting equipment .....................................................................................................................................SC-11
Cutting cables .........................................................................................................................................................................SC-11
Equipotential bonding ....................................................................................................................................................SC-11
Earthing of the workpiece .............................................................................................................................................SC-12
Screening and shielding .......................................................................................................................................................SC-12
Warranty .................................................................................................................................. SC-13
Attention ....................................................................................................................................................................................SC-13
General .....................................................................................................................................................................................SC-13
Patent indemnity .....................................................................................................................................................................SC-13
Limitation of liability ................................................................................................................................................................SC-13
National and local codes .......................................................................................................................................................SC-13
Liability cap ..............................................................................................................................................................................SC-14
Insurance ..................................................................................................................................................................................SC-14
Transfer of rights .....................................................................................................................................................................SC-14
Waterjet product warranty coverage .................................................................................................................................SC-14
Product ..............................................................................................................................................................................SC-14
Parts coverage .................................................................................................................................................................SC-14
1 Specifications .............................................................................................................................. 15
Introduction .................................................................................................................................................................................... 15
Torch configurations and weights ............................................................................................................................................. 17

8Duramax Hyamp Long Handheld Torches Service Manual 808290
Contents
45° Duramax Hyamp long handheld torch dimensions ....................................................................................................... 18
90° Duramax Hyamp long handheld torch dimensions ....................................................................................................... 19
2 Torch Setup .................................................................................................................................. 21
Consumable life ............................................................................................................................................................................ 22
Long handheld torch components ............................................................................................................................................ 23
Duramax Hyamp 45° long handheld torch ...................................................................................................................... 23
Duramax Hyamp 90° long handheld torch ...................................................................................................................... 23
Choose the hand torch consumables ...................................................................................................................................... 24
Drag-cutting 105/125 A consumables ........................................................................................................................... 24
Drag-cutting 45 A and 65 A consumables .................................................................................................................... 24
Maximum Removal gouging consumables ...................................................................................................................... 25
FineCut consumables .......................................................................................................................................................... 25
Install the hand torch consumables .......................................................................................................................................... 25
Connecting the torch lead .......................................................................................................................................................... 27
3 Operation ...................................................................................................................................... 29
Using the hand torch ................................................................................................................................................................... 29
Operate the safety trigger .......................................................................................................................................................... 30
Hand torch cutting guidelines ................................................................................................................................................... 31
Start a cut from the edge of the workpiece ............................................................................................................................ 32
Pierce a workpiece ....................................................................................................................................................................... 33
Gouge a workpiece ...................................................................................................................................................................... 35
Gouge profile ......................................................................................................................................................................... 36
Varying the gouge profile .................................................................................................................................................... 37
125 A gouging profile chart ............................................................................................................................................... 37
Common hand-cutting faults ..................................................................................................................................................... 39
4 Component Replacement ........................................................................................................ 41
Duramax Hyamp 45° long handheld torch components ..................................................................................................... 42
Duramax Hyamp 90° long handheld torch components ..................................................................................................... 43
Disconnect the power, gas supply, and torch ....................................................................................................................... 44
Replace the handle ...................................................................................................................................................................... 45
Replace the front shell ................................................................................................................................................................. 51
Replace the trigger assembly .................................................................................................................................................... 56
Replace the start switch ............................................................................................................................................................. 58
Replace the torch body ............................................................................................................................................................... 62
Replace the pilot arc wire ........................................................................................................................................................... 69
Replace the cap-sensor switch ................................................................................................................................................. 74
Replace the extension tube ........................................................................................................................................................ 77

Duramax Hyamp Long Handheld Torches Service Manual 808290 9
Contents
Replace the torch lead ................................................................................................................................................................ 78
Replace the quick disconnect housing ................................................................................................................................... 84
5 Maintenance and Parts ............................................................................................................. 87
Routine maintenance and troubleshooting ............................................................................................................................. 87
Perform routine maintenance tasks .................................................................................................................................. 88
Inspect the consumables .................................................................................................................................................... 89
Basic troubleshooting .......................................................................................................................................................... 90
Duramax Hyamp long handheld torch replacement parts ................................................................................................... 92
Full torch assembly, 45° torch ........................................................................................................................................... 92
External components, 45° torch ........................................................................................................................................ 93
Internal components, 45° torch ......................................................................................................................................... 94
Full torch assembly, 90° torch ........................................................................................................................................... 96
External components, 90° torch ........................................................................................................................................ 97
Internal components, 90° torch ......................................................................................................................................... 98
Duramax Hyamp hand torch consumables ................................................................................................................... 100
Drag cutting .................................................................................................................................................................. 100
Maximum Removal gouging ...................................................................................................................................... 100
FineCut .......................................................................................................................................................................... 100
Accessory parts .................................................................................................................................................................. 101

10 Duramax Hyamp Long Handheld Torches Service Manual 808290
Contents

Safety and compliance SC-11
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
workpiece. 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.
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.

SC-12 Safety and compliance
Electromagnetic Compatibility (EMC)
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 increase
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 Equipment,
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.

Safety and compliance SC-13
Warranty
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, with the exception of the
HPRXD short torch with integrated lead, which shall be within a period of
six (6) months from the 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 Connect CNC,
EDGE Connect T CNC, EDGE Connect TC CNC, 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.
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. Hypertherm shall not be liable for
any losses to Distributor based on down time, lost production or
lost profits. It is the intention of the Distributor and Hypertherm
that this provision be construed by a court as being the
broadest limitation of liability consistent with applicable law.
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.

SC-14 Safety and compliance
Warranty
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.
Waterjet product warranty coverage
Consumable parts are not covered by this warranty. Consumable parts
include, but are not limited to, high-pressure water seals, check valves,
cylinders, bleed-down valves, low-pressure seals, high-pressure tubing,
low- and high-pressure water filters and abrasive collection bags. All
third-party pumps, pump accessories, hoppers, hopper accessories,
dryer boxes, dryer box accessories and plumbing accessories are
covered by the respective manufacturers’ warranties and not covered by
this warranty.
Product Parts coverage
HyPrecision pumps 27 months from the ship date, or 24 months
from the date of proven installation, or
4,000 hours, whichever occurs first
PowerDredge
abrasive removal
system
15 months from the ship date or 12 months
from the date of proven installation,
whichever occurs first
EcoSift abrasive
recycling system
15 months from the ship date or 12 months
from the date of proven installation,
whichever occurs first
Abrasive metering
devices
15 months from the ship date or 12 months
from the date of proven installation,
whichever occurs first
On/off valve air
actuators
15 months from the ship date or 12 months
from the date of proven installation,
whichever occurs first
Diamond orifices 600 hours of use with the use of a thimble
filter and compliance with Hypertherm’s
water quality requirements

Duramax Hyamp Long Handheld Torches Service Manual 808290 15
Section 1
Specifications
Introduction
The Duramax Hyamp torch line includes 45° long handheld torches fitted with either 0.6 m (2 foot) or 1.2 m (4 foot)
extensions and 90° long handheld torches fitted with 0.6 m (2 foot), 1.2 m (4 foot), or 1.8 m (6 foot) extensions. The
extensions offer increased reach in difficult to access areas. You can use these long handheld torches with the following
Powermax®power supplies:
Powermax45 XP
Powermax65
Powermax85
Powermax105
Powermax125
The Duramax Hyamp long handheld torches were designed to be used with the Powermax125, but they can also be used
with the Powermax45 XP, Powermax65, Powermax85, and Powermax105 with the exception of the torches with the 46-m
(150-foot) leads.
The Duramax Hyamp long handheld torches with 46-m (150-foot) torch leads must be used with a Powermax125.
Duramax Hyamp long handheld torches with 46-m (150-foot) leads cannot be used with any other Powermax systems.
IMPORTANT: If your Powermax125 has a serial number of 125-007943 or lower, you
must install a new DSP board (428119). Make sure that the DSP board is at Revision C
or higher.
For more information about using the Duramax Hyamp long handheld torches with the
46-m (150-foot) torch leads on Powermax125 systems, see the Duramax Hyamp 46-m
(150-foot) Torch and Torch Leads Field Service Bulletin (810260).

16 Duramax Hyamp Long Handheld Torches Service Manual 808290
1 – Specifications
Hypertherm’s FastConnect™ system makes it easy to remove the torch for transport or to switch from one torch to
another if your cutting applications require the use of multiple torches. The torches are cooled by ambient air and do not
require special cooling procedures.
Duramax Hyamp long handheld torches comply with IEC 60974-7. They are not suitable for cutting under water or for use
in the rain or snow.
WARNING!
Do not submerge the torch in water while cutting. Putting the torch head under water
while there is an active arc can result in electric shock.

Duramax Hyamp Long Handheld Torches Service Manual 808290 17
1 – Specifications
Torch configurations and weights
The Duramax Hyamp long handheld torches ship in one of the configurations shown in Table 1. Table 1 lists each
configuration and its corresponding weight.
These weights do not include consumables.
Table 1
Torch configuration Weight
45° Duramax Hyamp 0.6 m (2 foot) torch with 7.6 m (25 foot) lead 4.2 kg (9.2 pounds)
45° Duramax Hyamp 0.6 m (2 foot) torch with 15.2 m (50 foot) lead 6.9 kg (15.1 pounds)
45° Duramax Hyamp 1.2 m (4 foot) torch with 7.6 m (25 foot) lead 5.2 kg (11.4 pounds)
45° Duramax Hyamp 1.2 m (4 foot) torch with 15.2 m (50 foot) lead 7.9 kg (17.3 pounds)
45° Duramax Hyamp 1.2 m (4 foot) torch with 46 m (150 foot) lead
(for Powermax125 only)
18.3 kg (40.3 pounds)
90°DuramaxHyamp0.6m(2foot)torchwith7.6m(25foot)lead 4.2kg(9.2pounds)
90°DuramaxHyamp0.6m(2foot)torchwith15.2m(50foot)lead 6.9kg(15.1pounds)
90°DuramaxHyamp1.2m(4foot)torchwith7.6m(25foot)lead 5.2kg(11.4pounds)
90°DuramaxHyamp1.2m(4foot)torchwith15.2m(50foot)lead 7.9kg(17.3pounds)
90° Duramax Hyamp 1.2 m (4 foot) torch with 46 m (150 foot) lead
(for Powermax125 only)
18.3 kg (40.3 pounds)
90°DuramaxHyamp1.8m(6foot)torchwith7.6m(25foot)lead 5.7kg(12.6pounds)
90°DuramaxHyamp1.8m(6foot)torchwith15.2m(50foot)lead 8.4kg(18.5pounds)

18 Duramax Hyamp Long Handheld Torches Service Manual 808290 1 – Specifications
45° Duramax Hyamp long handheld torch dimensions
Torch dimensions will vary depending on the type of consumables installed. This figure shows handheld shielded
consumables installed.
45°
3.5 cm
(1.4 inches)
3.5 cm
(1.4 inches)
74 cm (29 inches) with 0.6 m extension
145 cm (57 inches) with 1.2 m extension
9.6 cm
(3.8 inches)
8.0 cm
(3.2 inches)
51 cm (20 inches) with 0.6 m extension
122 cm (48 inches) with 1.2 m extension

Duramax Hyamp Long Handheld Torches Service Manual 808290 19
1 – Specifications
90° Duramax Hyamp long handheld torch dimensions
Torch dimensions will vary depending on the type of consumables installed. This figure shows handheld shielded
consumables installed.
90°
3.5 cm
(1.4 inches)
3.5 cm
(1.4 inches)
71 cm (28 inches) with 0.6 m extension
142 cm (56 inches) with 1.2 m extension
203 cm (80 inches) with 1.8 m extension
12.4cm
(4.9 inches)
8.0 cm
(3.2 inches)
51 cm (20 inches) with 0.6 m extension
122 cm (48 inches) with 1.2 m extension
183 cm (72 inches) with 1.8 m extension

20 Duramax Hyamp Long Handheld Torches Service Manual 808290
1 – Specifications