Hypertherm Powermax105 User Manual

Hand Cutting
Powermax105 Operator Manual 5-5
Pierce a workpiece
WARNING:
SPARKS AND HOT METAL CAN INJURE EYES AND BURN SKIN. When firing the torch
at an angle, sparks and hot metal will spray out from the nozzle. Point the torch away
from yourself and others.
1. With the work clamp attached to the workpiece, hold the torch
at an approximate 30° angle to the workpiece with the torch
tip within 1.5 mm (1/16 inch) of the workpiece before firing the
torch.
2. Fire the torch while still at an angle to the workpiece. Slowly
rotate the torch to a perpendicular (90°) position.
3. Hold the torch in place while continuing to press the trigger.
When sparks exit below the workpiece, the arc has pierced the
material.
4. When the pierce is complete, dragthe nozzle lightly along the
workpiece to proceed with the cut.

Hypertherm Powermax105 Specifications

General

Brand	Hypertherm
Model	Powermax105
Category	Welding System
Language	English

Summary

Electromagnetic Compatibility (EMC)

Installation and Use for EMC

Methods for Reducing Emissions

Warranty Information

General Warranty Terms

Details on Hypertherm's product warranty periods and conditions.

Section 1 Specifications

Safety Information Overview

System Description

Overview of the Powermax105 plasma cutting system and its capabilities.

Power Supply Ratings

Technical specifications and ratings of the Powermax105 power supply.

Cutting Specifications

Detailed specifications for cutting capacity, speed, and gouging.

Section 2 Power Supply Setup

Unpacking the Powermax System

Power Supply Positioning

Electrical Power Preparation

Instructions for ensuring appropriate electrical power for the system.

Line-Disconnect Switch Installation

Grounding Requirements

Essential information on proper grounding for safety and performance.

Power Connection Details

Details on electrical requirements and fuse recommendations for different models.

Power Cord and Plug Installation

Extension Cord Recommendations

Engine-Driven Generator Recommendations

Gas Supply Preparation and Filtration

Steps for preparing the gas supply, including quality and filtration.

Connecting the Gas Supply

Section 3 Basic System Operations

Controls and Indicators Overview

Overview of the power supply's controls, LEDs, and status screen.

Front Controls and LEDs

Details on the adjustment knob, selectors, and indicator LEDs on the front.

Status Screen Explained

Explanation of the system status and fault information displayed on the screen.

Gas Pressure Indicators

System Status Icons

Fault Codes Explained

Understanding fault codes displayed on the status screen.

Fault Icons

Visual indicators for system faults and warnings.

Operating the Powermax105

Step-by-step guide to operating the Powermax system for cutting.

Connecting Power, Gas, and Torch

Procedures for connecting essential power, gas, and torch leads.

Attaching the Work Lead

How to properly connect the work lead to the power supply.

Attaching the Work Clamp

Correct method for attaching the work clamp to the workpiece.

Turning ON the System

Setting the Operating Mode

Checking System Indicators

Manually Adjusting Gas Pressure

Procedure for manually setting gas pressure for specific applications.

Adjusting Current (Amperage)

How to adjust the cutting current using the adjustment knob.

Electrode End-of-Life Detection

Understanding Duty-Cycle Limitations

Information on duty cycle and its impact on system operation.

Section 4 Hand Torch Setup

Hand Torch Introduction

Consumable Life Factors

Choosing Hand Torch Consumables

Guidance on selecting appropriate consumables for different cutting tasks.

Hand Torch Consumables List

List of consumables for drag-cutting, gouging, FineCut, and HyAccess.

Installing Hand Torch Consumables

Step-by-step instructions for installing consumables on the torch.

Connecting the Torch Lead

Section 5 Hand Cutting

Using the Hand Torch

Basic safety and operational guidance for using the hand torch.

Operating the Safety Trigger

Hand Torch Cutting Hints

Tips and techniques for achieving optimal hand cutting results.

Starting Cuts from the Edge

Piercing a Workpiece

Procedure for piercing material before starting a cut.

Gouging a Workpiece

Technique for performing gouging operations with the hand torch.

Gouge Profile Parameters

Varying Gouge Profile

Common Hand-Cutting Faults

Section 6 Machine Torch Setup

Machine Torch Introduction

Machine Consumable Life

Convert Full-Length to Mini Torch

Mounting the Machine Torch

Using Cut Charts

How to interpret and use cut charts for optimized mechanized cutting.

Kerf-Width Compensation

Section 7 Mechanized Cutting

Connecting Remote-Start Pendant

Connecting Machine Interface Cable

Machine Interface Pinout

Setting Voltage Divider

Connecting RS485 Serial Cable

Using the Machine Torch

Torch and Table Setup

Optimizing Cut Quality

Factors affecting cut quality and methods for optimization.

Cut or Bevel Angle

Dross Formation and Minimization

Piercing with Machine Torch

Common Machine-Cutting Faults

Troubleshooting common problems encountered in mechanized cutting.

Section 8 Maintenance and Repair

Routine Maintenance Schedule

Schedule and procedures for regular system maintenance.

Inspecting Consumables

Basic Troubleshooting Guide

Common problems and their solutions for the Powermax system.

Fault Codes and Solutions

Detailed explanations of fault codes and corrective actions.

Replacing Air Filter