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Welding System
Powermax105
Hypertherm Powermax105 User Manual
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Parts
9-16
Powermax105
Operator Manual
165
Table of Contents
Default Chapter
5
Assessment of Area
5
Patent Indemnity
7
Table of Contents
11
Section 1
18
Specifications
18
Safety Information
18
System Description
18
Where to Find Information
19
Power Supply Dimensions
20
Component Weights (105 a Systems)
21
Powermax105 Power Supply Ratings
22
Duramax 75° Hand Torch Dimensions
24
Duramax 15° Hand Torch Dimensions
24
Duramax 180° Full-Length Machine Torch Dimensions
25
Duramax 180° Mini Machine Torch Dimensions
25
Powermax105 Cutting Specifications
26
Symbols and Marks
27
Noise Levels
28
IEC Symbols
28
Section 2
29
Power Supply Setup
29
Unpack the Powermax System
30
Claims
30
Contents
31
Position the Power Supply
32
Prepare the Electrical Power
32
Install a Line-Disconnect Switch
33
Requirements for Grounding
33
Power Connection for the Powermax105
34
Three-Phase Power Cord and Plug Installation
36
Extension Cord Recommendations
37
Extension Cord Specifications
37
Engine-Driven Generator Recommendations
38
Prepare the Gas Supply
39
Additional Gas Filtration
39
Connect the Gas Supply
40
Section 3
44
Basic System Operations
44
Controls and Indicators
44
Rear Controls
44
Front Controls and Leds
44
Status Screen
46
Remote Control
46
Operating the Powermax105
48
Connect the Electrical Power, Gas Supply, and Torch Lead
48
Attach the Work Lead to the Power Supply
49
Attach the Work Clamp to the Workpiece
50
Turn on the System
51
Set the Operating Mode Switch
51
Check the Indicators
52
Manually Adjusting the Gas Pressure
52
Adjusting the Current (Amperage)
53
Electrode End-Of-Life Detection Feature
53
Understanding Duty-Cycle Limitations
54
Section 4
55
Hand Torch Setup
55
Introduction
56
Consumable Life
56
Copperplus™ Electrode for Duramax Torches
56
Hand Torch Components
57
Choose the Hand Torch Consumables
58
Hand Torch Consumables
58
Drag-Cutting 105 a Consumables
58
Drag-Cutting 45 A, 65 A, 85 a Consumables
58
Gouging Consumables
59
Finecut ® Consumables
59
Hyaccess 65 a Consumables
59
Install the Hand Torch Consumables
60
Connecting the Torch Lead
61
Section 5
63
Hand Cutting
63
Using the Hand Torch
64
Operate the Safety Trigger
64
Hand Torch Cutting Hints
65
Start a Cut from the Edge of the Workpiece
66
Pierce a Workpiece
67
Gouge a Workpiece
68
Gouge Profile
69
Varying the Gouge Profile
70
Common Hand-Cutting Faults
70
Section 6
73
Machine Torch Setup
73
Introduction
73
Consumable Life
73
Copperplus™ Electrode for Duramax Torches
73
Machine Torch Components
74
Converting a Full-Length Machine Torch to a Mini Machine Torch
75
Mount the Torch
77
Choose the Machine Torch Consumables
79
Machine Torch Consumables
79
Mechanized Shielded 105 a Consumables
79
Mechanized Shielded 45 A, 65 A, 85 a Consumables
79
Mechanized Shielded with Ohmic 105 a Consumables
80
Mechanized Shielded with Ohmic 45 A, 65 A, 85 a Consumables
80
Mechanized Unshielded 105 a Consumables
80
Mechanized Unshielded 45 A, 65 A, 85 a Consumables
80
Gouging Consumables
81
Install the Machine Torch Consumables
82
Aligning the Torch
82
Connecting the Torch Lead
83
Using the Cut Charts
84
Estimated Kerf-Width Compensation
85
Shielded Consumables
87
Shielded Cutting (Mild Steel)
88
Shielded Cutting (Stainless Steel)
89
Shielded Cutting (Aluminum)
90
Shielded Consumables
91
Shielded Cutting (Mild Steel)
92
Shielded Cutting (Stainless Steel)
93
Shielded Cutting (Aluminum)
94
Shielded Consumables
95
A Shielded Cutting (Stainless Steel)
97
A Shielded Cutting (Aluminum)
98
Shielded Consumables
99
A Shielded Cutting (Mild Steel)
100
A Shielded Cutting (Stainless Steel)
101
Finecut ® Consumables
103
Finecut (Mild Steel)
103
Finecut (Stainless Steel)
105
Low Speed Finecut (Mild Steel)
106
Low Speed Finecut (Stainless Steel)
107
Unshielded Consumables
108
Unshielded Cutting (Mild Steel)
109
Unshielded Cutting (Stainless Steel)
110
Unshielded Cutting (Aluminum)
111
Unshielded Consumables
112
A Unshielded Cutting (Mild Steel)
113
Unshielded Consumables
116
A Unshielded Cutting (Mild Steel)
117
Unshielded Consumables
120
A Unshielded Cutting (Mild Steel)
121
Section 7
125
Mechanized Cutting
125
Connecting an Optional Remote-Start Pendant
126
Connecting an Optional Machine Interface Cable
127
Page 7-6 Setting the Five-Position Voltage Divider
127
Machine Interface Pinout
129
Setting the Five-Position Voltage Divider
130
Accessing Raw Arc Voltage
131
Connecting an Optional RS485 Serial Interface Cable
131
Using the Machine Torch
132
Setting up the Torch and Table
132
Understand and Optimize Cut Quality
132
Cut or Bevel Angle
132
Dross
133
Piercing a Workpiece Using the Machine Torch
134
Common Machine-Cutting Faults
135
Section 8
137
Maintenance and Repair
137
Perform Routine Maintenance
138
Electric Shock Can Kill
138
Inspect the Consumables
139
Basic Troubleshooting
140
Fault Codes and Solutions
142
Replace the Air Filter Element and Air Filter Bowl
146
Parts
152
Section 9
152
Power Supply Parts
152
Duramax 75° Hand Torch Replacement Parts
156
Duramax 15° Hand Torch Replacement Parts
157
Hand Torch Consumables
158
Duramax 180° Full-Length Machine Torch Replacement Parts
159
Duramax 180° Mini Machine Torch Replacement Parts
161
Machine Torch Consumables
163
Accessory Parts
164
Powermax105 Labels
165
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Hypertherm Powermax105 Specifications
General
Brand
Hypertherm
Model
Powermax105
Category
Welding System
Language
English
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