Hypertherm Powermax65 User manual

Plasma arc cutting systems

Operator Manual – 806650

Revision 2

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Operator Manual

(P/N 806650)

Revision 2 – December 2012

Hypertherm, Inc.

Hanover, NH USA

www.hypertherm.com

email: [email protected]

Hypertherm and Powermax are trademarks of Hypertherm, Inc.

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

powermax

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.service@hypertherm.com (Customer Service Email)

866-643-7711 Tel (Return Materials Authorization)

877-371-2876 Fax (Return Materials Authorization)

[email protected] (RMA email)

Hypertherm Plasmatechnik GmbH

Technologiepark Hanau

Rodenbacher Chaussee 6

D-63457 Hanau-Wolfgang, Deutschland

49 6181 58 2100 Tel

49 6181 58 2134 Fax

49 6181 58 2123 (Technical Service)

Hypertherm (S) Pte Ltd.

82 Genting Lane

Media Centre

Annexe Block #A01-01

Singapore 349567, Republic of Singapore

65 6841 2489 Tel

65 6841 2490 Fax

65 6841 2489 (Technical Service)

Hypertherm (Shanghai) Trading Co., Ltd.

Unit 301, South Building

495 ShangZhong Road

Shanghai, 200231

PR China

86-21-60740003 Tel

86-21-60740393 Fax

Hypertherm Europe B.V.

Vaartveld 9

4704 SE

Roosendaal, Nederland

31 165 596907 Tel

31 165 596901 Fax

31 165 596908 Tel (Marketing)

31 165 596900 Tel (Technical Service)

00 800 4973 7843 Tel (Technical Service)

Hypertherm Japan Ltd.

Level 9, Edobori Center Building

2-1-1 Edobori, Nishi-ku

Osaka 550-0002 Japan

81 6 6225 1183 Tel

81 6 6225 1184 Fax

Hypertherm Brasil Ltda.

Rua Bras Cubas, 231 – Jardim Maia

Guarulhos, SP - Brasil

CEP 07115-030

55 11 2409 2636 Tel

55 11 2408 0462 Fax

Hypertherm México, S.A. de C.V.

Avenida Toluca No. 444, Anexo 1,

Colonia Olivar de los Padres

Delegación Álvaro Obregón

México, D.F. C.P. 01780

52 55 5681 8109 Tel

52 55 5683 2127 Fax

Hypertherm Korea Branch

#3904 Centum Leaders Mark B/D,

1514 Woo-dong, Haeundae-gu, Busan

Korea, 612-889

82 51 747 0358 Tel

82 51 701 0358 Fax

07/18/12

Compliance Information EMC-1

7/10

ELECTROMAGNETIC COMPATIBILITY EMC

Introduction

Hypertherm’s CE-marked equipment is built in compliance

with standard EN60974-10. The equipment should be

installed and used in accordance with the information

below to achieve electromagnetic compatibility.

The limits required by EN60974-10 may not be adequate

to completely eliminate interference when the affected

equipment is in close proximity or has a high degree of

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

measures to further reduce interference.

This cutting equipment is designed for use only in an

industrial environment.

Installation and use

The user is responsible for installing and using the plasma

equipment according to the manufacturer’s instructions.

If electromagnetic disturbances are detected then it shall

be the responsibility of the user to resolve the situation

with the technical assistance of the manufacturer. In some

cases this remedial action may be as simple as earthing

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

cases, it could involve constructing an electromagnetic

screen enclosing the power source and the work

complete with associated input filters. In all cases,

electromagnetic disturbances must be reduced to the

point where they are no longer troublesome.

Assessment of area

Before installing the equipment, the user shall make an

assessment of potential electromagnetic problems in

the surrounding area. The following shall be taken into

account:

a. Other supply cables, control cables, signaling and

telephone cables; above, below and adjacent to the

cutting equipment.

b. Radio and television transmitters and receivers.

c. Computer and other control equipment.

d. Safety critical equipment, for example guarding

ofindustrial equipment.

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

ofpacemakers and hearing aids.

f. Equipment used for calibration or measurement.

g. Immunity of other equipment in the environment. User

shall ensure that other equipment being used in the

environment is compatible. This may require additional

protection measures.

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

carried out.

The size of the surrounding area to be considered

will depend on the structure of the building and other

activities that are taking place. The surrounding area may

extend beyond the boundaries of the premises.

Methods of reducing emissions

Mains supply

Cutting equipment must be connected to the mains

supply according to the manufacturer’s recommendations.

If interference occurs, it may be necessary to take

additional precautions such as filtering of the mains

supply.

EMC-2 Compliance Information

7/10

ELECTROMAGNETIC COMPATIBILITY

Consideration should be given to shielding the supply

cable of permanently installed cutting equipment,

in metallic conduit or equivalent. Shielding should

be electrically continuous throughout its length. The

shielding should be connected to the cutting mains

supply so that good electrical contact is maintained

between the conduit and the cutting power source

enclosure.

Maintenance of cutting equipment

The cutting equipment must be routinely maintained

according to the manufacturer’s recommendations. All

access and service doors and covers should be closed

and properly fastened when the cutting equipment is in

operation. The cutting equipment should not be modified

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

the manufacturer’s written instructions. For example,

the spark gaps of arc striking and stabilizing devices

should be adjusted and maintained according to the

manufacturer’s recommendations.

Cutting cables

The cutting cables should be kept as short as possible

and should be positioned close together, running at or

close to the floor level.

Equipotential bonding

Bonding of all metallic components in the cutting

installation and adjacent to it should be considered.

However, metallic components bonded to the workpiece

will increase the risk that the operator could receive a

shock by touching these metallic components and the

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

The operator should be insulated from all such bonded

metallic components.

Earthing of the workpiece

Where the workpiece is not bonded to earth for

electrical safety, nor connected to earth because of its

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

steel work, a connection bonding the workpiece to earth

may reduce emissions in some, but not all instances.

Care should be taken to prevent the earthing of the

workpiece increasing the risk of injury to users, or

damage to other electrical equipment. Where necessary,

the connection of the workpiece to earth should be

made by a direct connection to the workpiece, but

in some countries where direct connection is not

permitted, the bonding should be achieved by suitable

capacitances selected according to national regulations.

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

safety reasons. Changing the earthing arrangements

should only be authorized by a person who is competent

to assess whether the changes will in crease the risk of

injury, for example, by allowing parallel cutting current

return paths which may damage the earth circuits

of other equipment. Further guidance is provided

in IEC60974-9, Arc Welding 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.

Compliance Information W-1

9/10

Attention

Genuine Hypertherm parts are the factory-

recommended replacement parts for your Hypertherm

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

than genuine Hypertherm parts may not be covered by

the Hypertherm warranty, and will constitute misuse of

the Hypertherm Product.

You are solely responsible for the safe use of the

Product. Hypertherm does not and cannot make any

guarantee or warranty regarding the safe use of the

product in your environment.

General

Hypertherm, Inc. warrants that its Products shall be

free from defects in materials and workmanship for the

specific periods of time set forth herein and as follows:

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

the power supply within a period of two (2) years from

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

Powermax brand power supplies, which shall be within

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

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

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

and with respect to torch lifter assemblies within a

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

and with respect to laser heads within a period of one

(1) year from its date of delivery to you, and with respect

to Automation products one (1) year from its date of

delivery to you, with the exception of the EDGE Pro

and MicroEDGE Pro CNCs and ArcGlide THC, which

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

delivery to you.

This warranty shall not apply to any Powermax brand

power supplies that have been used with phase

converters. In addition, Hypertherm does not warranty

systems that have been damaged as a result of poor

power quality, whether from phase converters or

incoming line power. This warranty shall not apply to any

Product which has been incorrectly installed, modified,

or otherwise damaged.

Hypertherm provides repair, replacement or adjustment

of the Product as the sole and exclusive remedy, if

and only if the warranty set forth herein properly is

invoked and applies. Hypertherm, at its sole option,

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

defective Products covered by this warranty which

shall be returned with Hypertherm’s prior authorization

(which shall not be unreasonably withheld), properly

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

New Hampshire, or to an authorized Hypertherm repair

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

customer. Hypertherm shall not be liable for any repairs,

replacement, or adjustments of Products covered by this

warranty, except those made pursuant to this paragraph

and with Hypertherm’s prior written consent.

The warranty set forth above is exclusive and is in

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

or otherwise with respect to the Products or as to

the results which may be obtained therefrom, and

all implied warranties or conditions of quality or of

merchantability or fitness for a particular purpose or

against infringement. The foregoing shall constitute the

sole and exclusive remedy for any breach by Hypertherm

of its warranty.

Distributors/OEMs may offer different or additional

warranties, but Distributors/OEMs are not authorized to

give any additional warranty protection to you or make

any representation to you purporting to be binding upon

Hypertherm.

WARRANTY

W-2 Compliance Information

9/10

WARRANTY

Patent indemnity

Except only in cases of products not manufactured by

Hypertherm or manufactured by a person other than

Hypertherm not in strict conformity with Hypertherm’s

specifications and in cases of designs, processes,

formulae, or combinations not developed or purported

to be developed by Hypertherm, Hypertherm will have

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

suit or proceeding brought against you alleging that

the use of the Hypertherm product, alone and not in

combination with any other product not supplied by

Hypertherm, infringes any patent of any third party. You

shall notify Hypertherm promptly upon learning of any

action or threatened action in connection with any such

alleged infringement (and in any event no longer than

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

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

be conditioned upon Hypertherm’s sole control of, and

the indemnified party’s cooperation and assistance in,

the defense of the claim.

Limitation of liability

In no event shall Hypertherm be liable to any

person or entity for any incidental, consequential

direct, indirect, punitive or exemplary damages

(including but not limited to lost profits)

regardless of whether such liability is based on

breach of contract, tort, strict liability, breach

of warranty, failure of essential purpose, or

otherwise, and even if advised of the possibility

of such damages.

National and local codes

National and local codes governing plumbing and

electrical installation shall take precedence over any

instructions contained in this manual. In no event shall

Hypertherm be liable for injury to persons or property

damage by reason of any code violation or poor work

practices.

Liability cap

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

whether such liability is based on breach of

contract, tort, strict liability, breach of warranties,

failure of essential purpose or otherwise, for

any claim, action, suit or proceeding (whether

in court, arbitration, regulatory proceeding or

otherwise) arising out of or relating to the use of

the Products exceed in the aggregate the amount

paid for the Products that gave rise to such claim.

Insurance

At all times you will have and maintain insurance in such

quantities and types, and with coverage sufficient and

appropriate to defend and to hold Hypertherm harmless

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

of the products.

Transfer of rights

You may transfer any remaining rights you may have

hereunder only in connection with the sale of all or

substantially all of your assets or capital stock to a

successor in interest who agrees to be bound by all of

the terms and conditions of this Warranty. Within thirty

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

notify in writing Hypertherm, which reserves the right of

approval. Should you fail timely to notify Hypertherm and

seek its approval as set forth herein, the Warranty set

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

further recourse against Hypertherm under the Warranty

or otherwise.

powermax

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Operator Manual v

Safety information

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

with your product for important safety information.

vi powermax

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Operator Manual

Table of ConTenTs

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Operator Manual vii

Section 1

Specifications

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

System description.................................................................................................................................................................................1-2

Where to find information .....................................................................................................................................................................1-3

Power supply dimensions.....................................................................................................................................................................1-4

Component weights...............................................................................................................................................................................1-5

Powermax65 power supply ratings ....................................................................................................................................................1-6

Powermax85 power supply ratings ....................................................................................................................................................1-8

Duramax 75° hand torch dimensions .............................................................................................................................................. 1-10

Duramax 15° hand torch dimensions .............................................................................................................................................. 1-10

Duramax 180° full-length machine torch dimensions.................................................................................................................. 1-11

Duramax 180° mini machine torch dimensions............................................................................................................................. 1-11

Powermax65 cutting specifications................................................................................................................................................. 1-12

Powermax85 cutting specifications................................................................................................................................................. 1-13

Symbols and markings........................................................................................................................................................................ 1-14

IEC symbols .......................................................................................................................................................................................... 1-15

Section 2

Power Supply Setup

Unpack the Powermax65 or Powermax85 system .........................................................................................................................2-2

Claims .............................................................................................................................................................................................2-2

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

Position the power supply.....................................................................................................................................................................2-4

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

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

Requirements for grounding ......................................................................................................................................................2-5

Power connection for the Powermax65 ............................................................................................................................................2-6

Single-phase power cord (not for CE model) .......................................................................................................................2-7

Three-phase power cord – plug installation ..........................................................................................................................2-7

Power connection for the Powermax85 ............................................................................................................................................2-8

Single-phase power cord (not for CE model) .......................................................................................................................2-9

Single-phase power cord installation ................................................................................................................................... 2-10

Three-phase power cord – plug installation.................................................................................................................................. 2-11

Extension cord recommendations.................................................................................................................................................... 2-11

Extension cord specifications................................................................................................................................................. 2-12

Engine-driven generator recommendations........................................................................................................................ 2-13

Prepare the gas supply....................................................................................................................................................................... 2-14

Additional gas filtration............................................................................................................................................................. 2-14

Connect the gas supply........................................................................................................................................................... 2-15

Table of ConTenTs

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Operator Manual

Section 3

Torch Setup

Introduction ..............................................................................................................................................................................................3-2

Consumable life.......................................................................................................................................................................................3-2

CopperPlus™ electrode for Duramax torches........................................................................................................................3-2

Hand torch setup....................................................................................................................................................................................3-3

Choose the hand torch consumables .....................................................................................................................................3-4

Hand torch consumables ...........................................................................................................................................................3-5

Install the hand torch consumables..........................................................................................................................................3-6

Machine torch setup...............................................................................................................................................................................3-7

Converting a full-length machine torch to a mini machine torch.......................................................................................3-8

Mount the torch.......................................................................................................................................................................... 3-10

Choose the machine torch consumables............................................................................................................................ 3-12

Machine torch consumables................................................................................................................................................... 3-12

Install the machine torch consumables ................................................................................................................................ 3-15

Aligning the torch ...................................................................................................................................................................... 3-15

Connecting an optional remote-start pendant ................................................................................................................... 3-16

Connecting an optional machine interface cable............................................................................................................... 3-17

Connecting the torch lead................................................................................................................................................................. 3-22

Using the cut charts............................................................................................................................................................................ 3-23

Estimated kerf-width compensation...................................................................................................................................... 3-24

85 A shielded consumables ................................................................................................................................................... 3-26

65 A shielded consumables ................................................................................................................................................... 3-30

45 A shielded consumables ................................................................................................................................................... 3-34

FineCut®consumables............................................................................................................................................................ 3-38

85 A unshielded consumables............................................................................................................................................... 3-43

65 A unshielded consumables............................................................................................................................................... 3-47

45 A unshielded consumables............................................................................................................................................... 3-51

Section 4

Operation

Controls and indicators .........................................................................................................................................................................4-2

Rear controls .................................................................................................................................................................................4-2

Front controls and LEDs.............................................................................................................................................................4-2

Status screen ................................................................................................................................................................................4-4

Operating the Powermax65 or Powermax85...................................................................................................................................4-6

Connect the electrical power, gas supply, and torch lead .................................................................................................4-6

Attach the work lead to the power supply..............................................................................................................................4-7

Attach the work clamp to the workpiece ................................................................................................................................4-8

Turn ON the system.....................................................................................................................................................................4-9

Set the operating mode switch.................................................................................................................................................4-9

Check the indicators................................................................................................................................................................. 4-10

Manually adjusting the gas pressure..................................................................................................................................... 4-10

Adjusting the current (amperage).......................................................................................................................................... 4-11

Understanding duty-cycle limitations.................................................................................................................................... 4-12

Table of ConTenTs

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Operator Manual ix

Using the hand torch........................................................................................................................................................................... 4-13

Operate the safety trigger ....................................................................................................................................................... 4-13

Hand torch cutting hints .......................................................................................................................................................... 4-14

Start a cut from the edge of the workpiece......................................................................................................................... 4-15

Pierce a workpiece.................................................................................................................................................................... 4-16

Gouge a workpiece .................................................................................................................................................................. 4-17

Common hand-cutting faults .................................................................................................................................................. 4-20

Using the machine torch .................................................................................................................................................................... 4-21

Ensure the torch and table are set up correctly................................................................................................................. 4-21

Understand and optimize cut quality..................................................................................................................................... 4-21

To pierce a workpiece using the machine torch ................................................................................................................ 4-23

Common machine-cutting faults............................................................................................................................................ 4-24

Section 5

Maintenance and Repair

Perform routine maintenance ...............................................................................................................................................................5-2

Inspect the consumables......................................................................................................................................................................5-3

Basic troubleshooting............................................................................................................................................................................5-4

Fault codes and solutions.....................................................................................................................................................................5-6

Replace the gas filter element .......................................................................................................................................................... 5-10

Section 6

Parts

Power supply parts.................................................................................................................................................................................6-2

Duramax 75° hand torch replacement parts.....................................................................................................................................6-6

Duramax 15° hand torch replacement parts.....................................................................................................................................6-7

Hand torch consumables......................................................................................................................................................................6-8

Duramax 180° full-length machine torch replacement parts ........................................................................................................6-9

Duramax 180° mini machine torch replacement parts ................................................................................................................ 6-11

Machine torch consumables ............................................................................................................................................................. 6-13

Accessory parts.................................................................................................................................................................................... 6-14

Powermax65/85 labels....................................................................................................................................................................... 6-15

Table of ConTenTs

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Operator Manual 1-1

Section 1

SPECIFICATIONS

In this section: