Hypertherm Duramax User Manual

30 Duramax/Duramax Hyamp Robotic Torches Service Manual 807460
2 – Torch Setup
Mount the torch
Each style of robotic torch has 2 different mounting methods to maintain consistent positioning:
1. Increment markings – These are located on each side of the positioning barrel. One set is in inches and the other set
is in centimeters.
2. Positioning holes – These are equally spaced along the anti-rotational slots on each side of the barrel.
Figure 10
The robotic torch must be correctly mounted to the robot’s arm to make sure that there is proper torch-to-work distance
throughout each cut. A robotic torch clamp with mating positioning dowels and anti-rotational tabs is available from
Hypertherm. If you choose to use an alternate torch clamp, follow the manufacturer’s instructions on how to mount the
torch in the clamp. It is the customer’s responsibility to interface between the torch clamp and the robot’s arm.
1
2
3
1 Increment markings
2 Anti-rotational slot
3 Positioning holes (3)

Hypertherm Duramax Specifications

General

Brand	Hypertherm
Model	Duramax
Category	Flashlight
Language	English

Summary

Safety Information

Electromagnetic Compatibility (EMC)

Introduction to EMC

Overview of Hypertherm's compliance with EMC standards and environmental considerations.

Installation and Use for EMC

User responsibilities for installation and resolving electromagnetic disturbances.

Area Assessment for EMC

Evaluating potential electromagnetic problems in the surrounding environment.

Reducing EMC Emissions

Methods to reduce electromagnetic interference, including mains supply and cable management.

Maintenance of Cutting Equipment for EMC

Ensuring proper maintenance for electromagnetic compatibility.

Cutting Cables and Bonding for EMC

Guidelines for positioning cutting cables and equipotential bonding.

Workpiece Earthing and Shielding

Techniques for earthing the workpiece and screening/shielding for EMC.

Warranty Information

Attention and General Warranty

Genuine parts, user responsibility for safe use, and general warranty terms.

Warranty Exclusions and Limitations

Conditions not covered by warranty and limitations of Hypertherm's liability.

Patent Indemnity and Liability Cap

Hypertherm's commitment regarding patent infringement and liability limits.

Insurance and Transfer of Rights

Customer responsibilities for insurance and conditions for transferring warranty rights.

Section 1: Specifications

Introduction to Torches

Overview of Duramax and Duramax Hyamp robotic torch lines and their applications.

Duramax Component Weights

Weights for Duramax robotic torches and lead bend radius information.

Duramax Hyamp Component Weights

Weights for Duramax Hyamp robotic torches and lead bend radius information.

Torch Dimensions

Detailed dimensions for Duramax 180° and 90° robotic torches.

Duramax 45° Robotic Torch Dimensions

Detailed dimensions for the Duramax 45° robotic torch.

Duramax Hyamp 180° Robotic Torch Dimensions

Detailed dimensions for the Duramax Hyamp 180° robotic torch.

Duramax Hyamp 90° Robotic Torch Dimensions

Detailed dimensions for the Duramax Hyamp 90° robotic torch.

Duramax Hyamp 45° Robotic Torch Dimensions

Detailed dimensions for the Duramax Hyamp 45° robotic torch.

Section 2: Torch Setup

Robotic Torch Components

Identification of key components in robotic torches.

Install the Torch

Step-by-step guide for installing the torch, including through-arm mounting.

Disassemble the Robotic Torch

Procedure for disassembling and reassembling robotic torches.

Mount the Torch

Methods for mounting the torch to the robot arm using increment markings or positioning holes.

Consumable Life Factors

Factors influencing the lifespan of torch consumables.

Choosing Duramax Consumables

Guide to selecting and identifying Duramax shielded and unshielded consumables.

Choosing Duramax Hyamp Consumables

Guide to selecting and identifying Duramax Hyamp shielded and gouging consumables.

Installing the Consumables

Procedure for installing shield, retaining cap, nozzle, electrode, and swirl ring.

Connecting the Torch Lead

Instructions for connecting and disconnecting the torch lead using the FastConnect system.

Connecting Remote-Start Pendant

Guide for connecting an optional remote-start pendant to Powermax systems.

Connecting Machine Interface Cable

Details on connecting machine interface cables for arc voltage and signals.

Machine Interface Pinout

Diagram and table detailing connector sockets and signals for machine interface cables.

Setting Voltage Divider

Procedure for changing the five-position voltage divider settings on the power supply.

Using Cut Charts

Explanation of cut chart information and its use for optimizing cutting parameters.

Section 3: Operation

Using the Robotic Torch

General guidance on operating robotic torches and optimizing performance.

Using the Duramax Robotic Teach Tool

Instructions for installing and using the torch teach tool for robot programming.

Optimize Cut Quality

Factors affecting cut quality like angle, dross, and straightness.

Piercing Workpieces

Techniques and considerations for piercing workpieces with robotic torches.

Common Machine-Cutting Faults

Troubleshooting common faults encountered during machine cutting operations.

Section 4: Component Replacement

Robotic Torch Component Overview

General overview of Duramax and Duramax Hyamp robotic torch components.

Disconnect Power, Gas, and Torch

Steps to safely disconnect the torch, power supply, and gas supply.

Replacing the Positioning Barrel

Procedure for removing and installing the positioning barrel on robotic torches.

Replacing the Torch Body

Procedure for replacing the main body of the robotic torch.

Replacing the Cap-Sensor Switch

Procedure for replacing the cap-sensor switch on the robotic torch.

Replacing the Torch Lead

Procedure for replacing the torch lead assembly.

Section 5: Maintenance and Parts

Perform Routine Maintenance

Safety precautions and general guidelines for performing maintenance.

Routine Maintenance Tasks

Scheduled maintenance tasks for every use, every 3 months, and every 6 months.

Inspect the Consumables

Guidelines for inspecting and identifying worn or damaged consumables.

Duramax Robotic Torch Replacement Parts

Part numbers for Duramax 180°, 90°, and 45° robotic torch components.

Duramax 90° Robotic Torch Parts

Part numbers for Duramax 90° robotic torch components.

Duramax 45° Robotic Torch Parts

Part numbers for Duramax 45° robotic torch components.

Duramax Hyamp Robotic Torch Replacement Parts

Part numbers for Duramax Hyamp 180°, 90°, and 45° robotic torch components.

Duramax Hyamp 180° Robotic Torch Parts

Part numbers for Duramax Hyamp 180° robotic torch components.

Duramax Hyamp 90° Robotic Torch Parts

Part numbers for Duramax Hyamp 90° robotic torch components.

Duramax Hyamp 45° Robotic Torch Parts

Part numbers for Duramax Hyamp 45° robotic torch components.

Accessory Parts

List of available accessory parts, including sheathing and teach assemblies.