Hypertherm Powermax 125 Reference manual

Torch Alignment Guide for Bevel Cutting
Powermax125®and MAXPRO200™
Field Service Bulletin
811280
Revision 0
January 2021

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Torch Alignment Guide for Bevel Cutting
Powermax125 / MAXPRO200 Field Service Bulletin 811280 3
Introduction
Purpose
This Field Service Bulletin shows how to use the Hypertherm torch alignment guide accessory to do
bevel cutting on a track burner with a Powermax125 or a MAXPRO200.
Tools and materials needed
3/16 inch hexagonal key wrench
Digital level, or digital level application on a smartphone
Remote start pendant for the plasma cutting system if the track burner cannot start and stop
the plasma torch
Kit 528077 contents
Kit 528077 contains only the torch alignment guide and this Field Service Bulletin. Refer to
Figure 1.
WARNING
ELECTRIC SHOCK CAN KILL
Disconnect electrical power before doing installation or maintenance.
The line-disconnect switch must REMAIN in the OFF position until all
installation or maintenance steps are complete.
See the Safety and Compliance Manual (80669C) for more safety
information.
WARNING
EXPLOSION HAZARD – CUTTING WITH FLAMMABLE OR OXIDIZING GASES
Do not use flammable or oxidizing gases with Powermax systems. These gases can cause
explosive conditions during plasma cutting operations.
An example of an oxidizing gas is oxygen. Examples of flammable gases are acetylene,
propylene, methane, and pure hydrogen. Refer to the Safety and Compliance Manual
(80669C) for more information.

Torch Alignment Guide for Bevel Cutting
4811280 Field Service Bulletin Powermax125 / MAXPRO200
Figure 1 – Torch alignment guide
1
2
3
4
5
1Metric units (cm/mm)
2Torch clearance gauge for Air/Air processes
3Set screw
4English units (inches)
5Torch clearance gauge for O2/Air processes
(MAXPRO200 only)

Torch Alignment Guide for Bevel Cutting
Powermax125 / MAXPRO200 Field Service Bulletin 811280 5
Assemble the torch alignment guide
Before you use the torch alignment guide, attach the vertical piece to the horizontal piece .
Use the 2 screws given in the kit.
1
2
12

Torch Alignment Guide for Bevel Cutting
6811280 Field Service Bulletin Powermax125 / MAXPRO200
Use the torch alignment guide to put the torch in position for bevel cutting
This procedure gives general instructions for any track burner. The pictures show one example from
a common track burner. Your configuration can be different.
Hypertherm recommends that you use a track burner that is compatible with plasma cutting so that
you can get the best bevel cut results at the specified cut speeds. Use a remote start pendant for
the plasma cutting system if the track burner cannot start and stop the plasma torch.
1. Set the power to OFF (O) for the track burner and the plasma power supply.
2. Select the parameters to use for the metal thickness and the correct bevel cut angle. Use the
Powermax125 and MAXPRO200 Bevel compensation cut charts on page 11.
3. Put the torch alignment guide
on the workpiece to be cut.
Put the track down so that
it is touching the guide.
4. Examine both ends of the
track and different points in
between to make sure that
the track is touching the end
of the alignment guide. Also
make sure that the track is
parallel to the edge of the
plate.
5. When the track and the torch
alignment guide are in
position, engage the locking
mechanism on the track to
attach the track to the
workpiece. This mechanism is
different on different tracks.
Some tracks use magnets
as the locking mechanism, as
shown in this example.
6. Attach the track burner
tractor to the track. Connect
the cables for the track
burner and for the plasma
power supply. Refer to the
manufacturer instructions for
each system.
7. Adjust the X-axis arm to be approximately in the center of the tractor. Use the horizontal racker
control knob or equivalent control on your tractor.
1
2 2
1
2

Torch Alignment Guide for Bevel Cutting
Powermax125 / MAXPRO200 Field Service Bulletin 811280 7
8. Install the correct cutting consumables on the machine torch. Refer to the Powermax125 and
MAXPRO200 Bevel compensation cut charts on page 11.
9. Loosen the knobs or fasteners on the torch holder, as necessary. Put the torch in the holder and
tighten.
10. If there is a cable mount, make sure that the torch lead is correctly installed and tightened in the
cable mount.
11 . Loosen the control lever for the angle of the torch. Adjust the angle to 0°, or make sure that the
torch is squarely aligned to the workpiece. Tighten the control lever.
12. Loosen the control lever for the torch bevel angle. Adjust the torch to the correct bevel angle to
align with the settings from the bevel compensation cut charts.
a. Use a digital level to make sure that the angle of the torch is correct. If you have a
smartphone, you can also use a digital level application. In the following pictures, the digital
level is used to make sure that the torch is set to a 45° angle.
b. When the torch bevel angle is correct, tighten the control lever.
Digital level Digital level application on a smartphone

Torch Alignment Guide for Bevel Cutting
8811280 Field Service Bulletin Powermax125 / MAXPRO200
13. Move the torch alignment guide so that the correct torch clearance gauge is in front of the
torch.
One torch clearance gauge is for Air/Air processes. The other gauge is for O2/Air
processes (MAXPRO200 only). Refer to Figure 1 on page 4.
Make sure that you keep the torch alignment guide on the edge of the workpiece .
3
4
3
4

Torch Alignment Guide for Bevel Cutting
Powermax125 / MAXPRO200 Field Service Bulletin 811280 9
14. Use the bevel compensation cut charts to
find the correct edge offset value to use
for the torch clearance. Clearance is the
distance between the torch and the top of
the workpiece.
15. Put the torch clearance gauge in the
correct position, as follows:
a. Loosen the set screw .
b. Align the inside of the torch clearance
gauge with the correct position on the
ruler. Move the gauge higher or lower
on the guide, as necessary. The
position to use on the ruler is the edge
offset value from step 14.
c. For example, in the picture shown ,
the torch clearance gauge is set to an
edge offset of 1.5 inches.
d. When the torch clearance gauge is in
the correct position, tighten the set
screw.
16. Move the torch closer to the torch
clearance gauge, as follows:
a. Move the torch horizontally, as
necessary. Use the horizontal racker control knob or equivalent control on your tractor.
b. Move the torch vertically, as necessary. Loosen the knobs on the torch holder. Move the
torch closer to the torch clearance gauge and tighten the knobs.
c. If there is a torch height control knob or similar mechanism, use that to move the torch in
very small increments, as necessary. Adjust the torch height until the torch consumables
touch the torch clearance gauge.
d. Make sure that the tip of the torch is touching the torch clearance gauge and is
approximately perpendicular to the gauge, as shown.
5
6
5
6

Torch Alignment Guide for Bevel Cutting
10 811280 Field Service Bulletin Powermax125 / MAXPRO200
17. Remove the torch alignment guide from the workpiece.
18. Move the tractor as necessary until the torch consumables are centered on the edge of the
workpiece, as shown.
Start to cut
1. Set the power to ON (I) for the track burner and for the plasma power supply.
2. Use the bevel compensation cut charts to find the following values for the bevel cut:
Adjust the pierce delay setting on the tractor to use the correct pierce delay value from the
cut chart. Use the timer control knob or equivalent control on your tractor.
Adjust the speed of the tractor to use the correct cut speed value from the cut chart. Use
the speed control knob or equivalent control on your tractor.
Adjust the plasma power supply to use the correct current (A) value from the cut chart. Use
the amperage control knob on the front of the plasma power supply.
3. You are now ready to make the bevel cut. Can the track burner control both the tractor and the
plasma torch?
If yes, start the tractor to start both the plasma arc and the tractor motion.
If no, start the tractor and the plasma torch at the same time. Use a remote start pendant to
start the plasma arc.
4. Make sure that the plasma arc transfers to the workpiece and that the tractor starts the forward
motion.
5. At the end of the cut, stop the tractor as soon as the plasma arc extinguishes, if the tractor does
not stop automatically.

Torch Alignment Guide for Bevel Cutting
Powermax125 / MAXPRO200 Field Service Bulletin 811280 11
Bevel compensation cut charts
The following bevel compensation cut charts are given in metric and English units:
Powermax125 – Mild steel – Air
MAXPRO200 – Mild steel – 200 A – O2Plasma / Air Shield
MAXPRO200 – Mild steel – 200 A – Air Plasma / Air Shield
MAXPRO200 – Mild steel – 130 A – O2Plasma / Air Shield
MAXPRO200 – Mild steel – 130 A – Air Plasma / Air Shield
All of the cut chart processes in
this document are for
single-pass, V cuts .
7
7

Torch Alignment Guide for Bevel Cutting
12 811280 Field Service Bulletin Powermax125 / MAXPRO200
Powermax125 – Mild steel – Air
Metric
Bevel type Current Clearance Material
thickness Cut angle Cut speed Pierce delay Kerf offset Edge offset
Amm mm degrees mm/min seconds mm mm
V cut
105
9.1
6
22.5 2540 0.5 2.3 4.8
37.5 2540 0.6 2.7 7.3
45.0 2327 0.7 3.1 9.1
125
12
22.5 1603 0.5 2.8 7.8
37.5 1245 0.6 3.5 12.7
45.0 1028 0.7 4.1 16.1
16
22.5 994 0.7 3.1 9.8
37.5 772 1.2 3.8 16.1
45.0 638 2.1 4.5 20.5
20
22.5 686 1.4 3.4 11.7
37.5 533 2.8 4.2 19.5
45.0 440 1.0* 4.9 24.9
25
22.5 474 1.0* 3.7 14.0
37.5 368 1.0* 4.5 23.7
45.0 304 1.0* 5.2 30.2
English
Bevel type Current Clearance Material
thickness Cut angle Cut speed Pierce delay Kerf offset Edge offset
Ainches inches degrees in/min seconds inches inches
V cut
105
0.360
1/4
22.5 100.0 0.5 0.09 0.20
37.5 99.4 0.6 0.11 0.30
45.0 84.7 0.7 0.12 0.37
125
1/2
22.5 57.4 0.5 0.11 0.32
37.5 44.6 0.6 0.14 0.52
45.0 36.8 0.7 0.16 0.66
5/8
22.5 39.7 0.7 0.12 0.38
37.5 30.8 1.2 0.15 0.63
45.0 25.4 2.1 0.18 0.80
3/4
22.5 29.3 1.4 0.13 0.44
37.5 22.8 2.8 0.16 0.74
45.0 18.8 1.0* 0.19 0.94
1
22.5 18.2 1.0* 0.14 0.56
37.5 14.1 1.0* 0.18 0.95
45.0 11.7 1.0* 0.21 1.21
* Edge start only.
220976
Shield
220977
Retaining cap
220975
Nozzle
220997
Swirl ring
220971
Electrode

Torch Alignment Guide for Bevel Cutting
Powermax125 / MAXPRO200 Field Service Bulletin 811280 13
MAXPRO200 – Mild steel – 200 A – O2Plasma / Air Shield
Metric
Bevel type Current Clearance Material
thickness Cut angle Cut speed Pierce delay Kerf offset Edge offset
Amm mm degrees mm/min seconds mm mm
V cut 200 7.6
10 22.5 2540 0.5 4.0 8.1
10 37.5 2469 0.7 4.7 12.4
10 45.0 2204 0.8 5.5 15.5
12 22.5 2400 0.7 4.1 9.1
12 37.5 2049 0.9 5.1 14.3
12 45.0 1788 1.0 5.9 17.9
16 22.5 1742 1.1 4.6 11.2
16 37.5 1411 1.3 5.6 17.9
16 45.0 1176 1.5 6.5 22.5
20 22.5 1265 1.4 4.9 13.2
20 37.5 972 1.7 6.0 21.4
20 45.0 774 1.0* 6.9 26.9
25 22.5 848 1.0* 5.3 15.6
25 37.5 610 1.0* 6.3 25.5
25 45.0 459 1.0* 7.3 32.3
32 22.5 484 1.0* 5.5 18.8
32 37.5 317 1.0* 6.6 31.1
32 45.0 221 1.0* 7.5 39.5
38 22.5 299 1.0* 5.7 21.4
38 37.5 181 1.0* 6.7 35.9
44 22.5 185 1.0* 5.8 24.0
* Edge start only.
420737
Shield
220935
Retaining cap
420733
Nozzle
220488
Swirl ring
420732
Electrode
420823
Water tube

Torch Alignment Guide for Bevel Cutting
14 811280 Field Service Bulletin Powermax125 / MAXPRO200
MAXPRO200 – Mild steel – 200 A – O2Plasma / Air Shield
English
Bevel type Current Clearance Material
thickness Cut angle Cut speed Pierce delay Kerf offset Edge offset
Ainches inches degrees in/min seconds inches inches
V cut 200 0.300
0.375 22.5 100.0 0.5 0.16 0.31
0.375 37.5 100.0 0.6 0.18 0.47
0.375 45.0 91.2 0.7 0.21 0.59
0.500 22.5 89.3 0.8 0.16 0.37
0.500 37.5 75.6 1.0 0.20 0.59
0.500 45.0 65.4 1.1 0.24 0.74
0.625 22.5 69.3 1.1 0.18 0.44
0.625 37.5 56.2 1.3 0.22 0.70
0.625 45.0 46.9 1.5 0.26 0.88
0.750 22.5 53.7 1.3 0.19 0.50
0.750 37.5 41.8 1.6 0.23 0.81
0.750 45.0 33.7 1.0* 0.27 1.02
1.000 22.5 32.3 1.0* 0.21 0.62
1.000 37.5 23.1 1.0* 0.25 1.02
1.000 45.0 17.3 1.0* 0.29 1.29
1.250 22.5 19.4 1.0* 0.22 0.74
1.250 37.5 12.8 1.0* 0.26 1.22
1.250 45.0 8.9 1.0* 0.29 1.54
1.500 22.5 11.7 1.0* 0.22 0.84
1.500 37.5 7.1 1.0* 0.26 1.42
1.750 22.5 7.0 1.0* 0.23 0.95
* Edge start only.
420737
Shield
220935
Retaining cap
420733
Nozzle
220488
Swirl ring
420732
Electrode
420823
Water tube

Torch Alignment Guide for Bevel Cutting
Powermax125 / MAXPRO200 Field Service Bulletin 811280 15
MAXPRO200 – Mild steel – 200 A – Air Plasma / Air Shield
Metric
Bevel type Current Clearance Material
thickness Cut angle Cut speed Pierce delay Kerf offset Edge offset
Amm mm degrees mm/min seconds mm mm
V cut 200 9.1
10 22.5 2540 0.7 4.1 8.2
10 37.5 2540 0.8 4.8 12.4
10 45.0 2368 0.9 5.5 15.5
12 22.5 2540 0.9 4.1 9.1
12 37.5 2211 1.0 5.1 14.3
12 45.0 1944 1.1 5.9 17.9
16 22.5 1898 1.2 4.6 11.2
16 37.5 1556 1.4 5.6 17.9
16 45.0 1311 1.5 6.6 22.6
20 22.5 1403 1.5 5.0 13.2
20 37.5 1095 1.7 6.0 21.4
20 45.0 884 1.9 7.0 27.0
25 22.5 963 1.9 5.3 15.6
25 37.5 706 2.2 6.4 25.6
25 45.0 540 1.0* 7.3 32.3
32 22.5 568 1.0* 5.6 18.8
32 37.5 382 1.0* 6.7 31.2
32 45.0 271 1.0* 7.6 39.6
38 22.5 361 1.0* 5.8 21.5
38 37.5 225 1.0* 6.8 36.0
44 22.5 230 1.0* 5.8 24.1
* Edge start only.
420737
Shield
220935
Retaining cap
420734
Nozzle
220488
Swirl ring
420732
Electrode
420823
Water tube

Torch Alignment Guide for Bevel Cutting
16 811280 Field Service Bulletin Powermax125 / MAXPRO200
MAXPRO200 – Mild steel – 200 A – Air Plasma / Air Shield
English
Bevel type Current Clearance Material
thickness Cut angle Cut speed Pierce delay Kerf offset Edge offset
Ainches inches degrees in/min seconds inches inches
V cut 200 0.360
0.375 22.5 100.0 0.7 0.16 0.32
0.375 37.5 100.0 0.8 0.19 0.48
0.375 45.0 97.7 0.9 0.21 0.59
0.500 22.5 95.8 0.9 0.16 0.37
0.500 37.5 81.9 1.1 0.20 0.59
0.500 45.0 71.4 1.2 0.24 0.74
0.625 22.5 75.4 1.2 0.18 0.44
0.625 37.5 61.9 1.4 0.22 0.70
0.625 45.0 52.2 1.5 0.26 0.88
0.750 22.5 59.4 1.4 0.19 0.50
0.750 37.5 46.9 1.6 0.23 0.81
0.750 45.0 38.2 1.8 0.27 1.02
1.000 22.5 36.8 1.9 0.21 0.62
1.000 37.5 26.8 1.0* 0.25 1.02
1.000 45.0 20.4 1.0* 0.29 1.29
1.250 22.5 22.8 1.0* 0.22 0.74
1.250 37.5 15.4 1.0* 0.26 1.22
1.250 45.0 10.9 1.0* 0.30 1.55
1.500 22.5 14.1 1.0* 0.23 0.85
1.500 37.5 8.8 1.0* 0.27 1.42
1.750 22.5 8.7 1.0* 0.23 0.96
* Edge start only.
420737
Shield
220935
Retaining cap
420734
Nozzle
220488
Swirl ring
420732
Electrode
420823
Water tube

Torch Alignment Guide for Bevel Cutting
Powermax125 / MAXPRO200 Field Service Bulletin 811280 17
MAXPRO200 – Mild steel – 130 A – O2Plasma / Air Shield
Metric
Bevel type Current Clearance Material
thickness Cut angle Cut speed Pierce delay Kerf offset Edge offset
Amm mm degrees mm/min seconds mm mm
V cut 130 7.6
6 22.5 2540 0.2 3.3 5.8
6 37.5 2540 0.3 3.9 8.5
6 45.0 2540 0.4 4.4 10.4
10 22.5 2008 0.5 3.6 7.7
10 37.5 1662 0.6 4.4 12.1
10 45.0 1411 0.6 5.2 15.2
12 22.5 1595 0.6 3.8 8.8
12 37.5 1271 0.7 4.7 13.9
12 45.0 1045 0.8 5.6 17.6
16 22.5 1007 0.8 4.3 11.0
16 37.5 744 1.0* 5.5 17.8
16 45.0 573 1.0* 6.7 22.7
20 22.5 636 1.0* 4.9 13.2
20 37.5 436 1.0* 6.4 21.8
20 45.0 314 1.0* 7.9 27.9
* Edge start only.
420735
Shield
220935
Retaining cap
420828
Nozzle
220529
Swirl ring
420824
Electrode
420823
Water tube

Torch Alignment Guide for Bevel Cutting
18 811280 Field Service Bulletin Powermax125 / MAXPRO200
MAXPRO200 – Mild steel – 130 A – O2Plasma / Air Shield
English
Bevel type Current Clearance Material
thickness Cut angle Cut speed Pierce delay Kerf offset Edge offset
Ainches inches degrees in/min seconds inches inches
V cut 130 0.300
0.250 22.5 100.0 0.3 0.12 0.23
0.250 37.5 100.0 0.3 0.12 0.31
0.250 45.0 96.1 0.4 0.12 0.37
0.375 22.5 83.5 0.4 0.13 0.28
0.375 37.5 69.7 0.5 0.13 0.42
0.375 45.0 59.7 0.6 0.14 0.52
0.500 22.5 57.9 0.6 0.14 0.35
0.500 37.5 45.6 0.7 0.15 0.54
0.500 45.0 37.0 0.8 0.16 0.66
0.625 22.5 40.2 0.8 0.16 0.42
0.625 37.5 29.8 1.0* 0.17 0.65
0.625 45.0 23.0 1.0* 0.18 0.81
0.750 22.5 27.9 1.0* 0.17 0.49
0.750 37.5 19.5 1.0* 0.19 0.77
0.750 45.0 14.3 1.0* 0.21 0.96
* Edge start only.
420735
Shield
220935
Retaining cap
420828
Nozzle
220529
Swirl ring
420824
Electrode
420823
Water tube

Torch Alignment Guide for Bevel Cutting
Powermax125 / MAXPRO200 Field Service Bulletin 811280 19
MAXPRO200 – Mild steel – 130 A – Air Plasma / Air Shield
Metric
Bevel type Current Clearance Material
thickness Cut angle Cut speed Pierce delay Kerf offset Edge offset
Amm mm degrees mm/min seconds mm mm
V cut 200 9.1
6 22.5 2540 0.3 3.4 5.9
6 37.5 2540 0.3 4.0 8.6
6 45.0 2540 0.4 4.5 10.5
10 22.5 2058 0.6 3.7 7.8
10 37.5 1672 0.7 4.5 12.2
10 45.0 1397 0.8 5.3 15.3
12 22.5 1598 0.7 3.9 8.9
12 37.5 1246 0.8 4.8 14.0
12 45.0 1005 0.9 5.5 17.5
16 22.5 965 1.0 4.3 10.9
16 37.5 692 1.0* 5.1 17.4
16 45.0 519 1.0* 5.9 21.9
20 22.5 582 1.0* 4.5 12.8
20 37.5 384 1.0* 5.3 20.7
20 45.0 268 1.0* 6.1 26.1
25 22.5 310 1.0* 4.6 15.0
* Edge start only.
420735
Shield
220935
Retaining cap
420829
Nozzle
220488
Swirl ring
420824
Electrode
420823
Water tube

Torch Alignment Guide for Bevel Cutting
20 811280 Field Service Bulletin Powermax125 / MAXPRO200
MAXPRO200 – Mild steel – 130 A – Air Plasma / Air Shield
English
Bevel type Current Clearance Material
thickness Cut angle Cut speed Pierce delay Kerf offset Edge offset
Ainches inches degrees in/min seconds inches inches
V cut 130 0.360
0.250 22.5 100.0 0.3 0.13 0.24
0.250 37.5 100.0 0.4 0.16 0.35
0.250 45.0 100.0 0.4 0.18 0.43
0.375 22.5 86.0 0.5 0.14 0.30
0.375 37.5 70.6 0.6 0.17 0.46
0.375 45.0 59.5 0.7 0.20 0.58
0.500 22.5 57.6 0.7 0.16 0.36
0.500 37.5 44.2 0.9 0.19 0.58
0.500 45.0 35.2 1.0 0.22 0.72
0.625 22.5 38.6 0.9 0.17 0.43
0.625 37.5 27.7 1.0* 0.20 0.68
0.625 45.0 20.9 1.0* 0.23 0.86
0.750 22.5 25.8 1.0* 0.17 0.49
0.750 37.5 17.4 1.0* 0.21 0.78
0.750 45.0 12.4 1.0* 0.24 0.99
1.000 22.5 11.6 1.0* 0.18 0.60
* Edge start only.
420735
Shield
220935
Retaining cap
420829
Nozzle
220488
Swirl ring
420824
Electrode
420823
Water tube