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Hypertherm
Welding System
Powermax45 XP
Hypertherm Powermax45 XP User Manual
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Gouge with the Hand T
orch and Machine T
orch
4
86
80
9240
Operator Manual
Powermax45
XP
ARC WELDING SUPPLIES - 07 847 7870
85
87
Table of Contents
Default Chapter
8
Table of Contents
8
Electromagnetic Compatibility (EMC)
15
Earthing of the Workpiece
16
Warranty
17
Waterjet Product Warranty Coverage
18
Product
18
Parts Coverage
18
Liability Cap
18
Installation and Setup
19
System Contents
20
What to Do if Components Are Missing or Damaged
21
Hypertherm Plasma Power Supply Ratings
21
Cutting Specifications
22
Pierce Capacity
22
Recommended Cut Capacity - Handheld
22
Gouge Capacity
23
Maximum Cut Speeds (Mild Steel)
23
Noise Levels
23
Position the Plasma Power Supply
24
Power Supply Dimensions and Weight
26
Work Lead Weights
26
Connect to Electrical Power
27
Install a Line-Disconnect Switch
27
Requirements for Grounding
28
The System's Rated Output (Cutting Power)
28
Voltage Configurations
28
CCC 220 V (1-Phase)
29
CE 230 V (1-Phase)
29
CSA 208 V (1-Phase)
29
CSA/CE/CCC 200 V - 240 V (1-Phase)
29
CCC 380 V (3-Phase)
30
CE 400 V (3-Phase)
30
CSA 480 V (3-Phase)
30
Decrease Output Current and Arc Stretch for Lower Rated Electrical Service
31
Example: 230 V Input on 20 a Electrical Service
31
Prepare the Power Cord
32
1-Phase (200 V - 240 V)
32
3-Phase (380 V / 400 V)
32
3-Phase (480 V)
32
CE/CCC Systems
32
CSA Systems
32
Extension Cord Recommendations
33
Generator Recommendations
33
Connect the Gas Supply
34
Gas Supply Source
35
High-Pressure Gas Cylinders
36
Cutting
37
Gas Flow Rates
37
Minimum Inlet Pressure (While Gas Is Flowing)
37
Maximum Control Gouging (26 - 45 A)
38
Precision Gouging / Marking (10 - 25 A)
38
Additional Gas Filtration
39
Operation
41
Controls and Indicators
41
ON (I) / off (O) Power Switch
41
Cutting Controls
42
Indicator Leds
43
Disable the Torch
44
Warning Puffs of Air
45
For Hand Torches
46
For Machine Torches
46
Operate the Plasma System
46
Step 1 - Install Consumables and Activate Torch
46
Step 2 - Connect Torch Lead
48
Step 3 - Connect Gas Supply
49
Step 4 - Connect Work Lead and Work Clamp
49
Work Lead
49
Work Clamp
50
Step 5 - Connect Electric Power and Turn on the System
51
Step 6 - Set Mode and Adjust Output Current (Amperage)
51
Cutting Expanded Metal
52
Step 7 - Check Cut Settings and Indicator Leds
52
What to Expect During and after Cutting
53
Adjust the Gas Pressure Manually
54
Reset the Gas Pressure
56
Change the Gas Pressure Values between Psi and Bar
57
Understand Duty Cycle to Prevent Overheating
58
Cut with the Hand Torch
59
Hand Torch Components, Dimensions, Weights
60
Components
60
Dimensions
60
75° Hand Torch
60
Weights
61
Choose the Consumables
61
Finecut Consumables
62
Hyaccess Cutting Consumables
62
Shielded Drag-Cutting Consumables
62
Specialty Consumables
62
Copperplus™ Electrode
63
Consumable Life
63
Prepare to Fire the Torch
65
Hand Torch Cutting Guidelines
66
Start a Cut from the Edge of the Workpiece
67
Pierce a Workpiece
68
Gouge with the Hand Torch and Machine Torch
71
Gouging Processes
71
Maximum Control Gouging
72
Maximum Control Gouging Consumables (26 - 45 A)
72
Precision Gouging
72
Precision Gouging Consumables (10 - 25 A)
72
Hyaccess Gouging Consumables
73
Specialty Consumables
73
How to Control the Gouge Profile
74
Gouge with the Hand Torch
75
Remove Spot Welds
76
Tips
76
Procedure
77
Gouge with the Machine Torch
80
Maximum Control Gouging Consumables (45 A)
81
Typical Gouge Profiles
81
Precision Gouging Consumables (10 A)
83
Troubleshooting Tips for Gouging
84
Set up the Machine Torch
87
Machine Torch Components, Dimensions, Weights
88
Components
88
Dimensions
88
Weights
89
Mount the Torch
89
Remove the Gear Rack
89
Disassemble the Machine Torch
90
Assemble the Machine Torch
92
Align the Torch
94
Configure Controls for Mechanized Cutting
95
Machine Torch Setup Overview
95
Set up the Plasma System and Machine Torch for Mechanized Cutting
96
Connect the Remote-Start pendant
97
Connect the Machine Interface Cable
98
External Cables that Do Not Use Voltage Divider Board
98
External Cables that Use Voltage Divider Board
99
Installation of the Machine Interface Cable
100
Machine Interface Pinout
100
Machine Interface Cable Signals
101
Set the 5-Position Voltage Divider
101
Access Raw Arc Voltage
102
Connect an Optional RS-485 Serial Interface Cable
103
External Serial Port Cables
104
Remote Mode
104
Cut with the Machine Torch
105
Choose the Consumables
105
Mechanized Shielded Consumables
106
Mechanized Shielded Consumables with Ohmic Retaining Cap
106
Finecut Shielded Consumables with Ohmic Retaining Cap
107
Finecut Unshielded Consumables
107
Consumable Life
107
Understand and Optimize Cut Quality
108
Cut or Bevel Angle
108
Dross
109
Pierce a Workpiece Using the Machine Torch
110
Pierce Delay
110
Pierce Height
110
Pierce Maximum Thickness
110
Cut Stainless Steel with F5
111
Guidelines for Marking
113
Marking Consumables (10 - 25 A)
113
Process Gas: Air Versus Argon
114
How the System Handles Postflow for Marking
114
Marking Samples
115
Types of Marking
115
Marking, Scoring, and Dimpling Profiles
117
Marking Process Guidelines
118
Cornering Guidelines
119
Marking Troubleshooting Tips
119
Common Marking Problems and Solutions
120
Cut Charts and Marking Charts
121
Using the Cut Charts
122
Mild Steel - 45 a - Air - Shielded
124
Stainless Steel - 45 a - Air - Shielded
125
Aluminum - 45 a - Air - Shielded
126
Mild Steel - Finecut - Air - Shielded and Unshielded
127
Stainless Steel - Finecut - Air - Shielded and Unshielded
128
Mild Steel - Finecut Low Speed - Air - Shielded and Unshielded
129
Stainless Steel - Finecut Low Speed - Air - Shielded and Unshielded
130
Stainless Steel - 45 a - F5 - Shielded
131
Marking and Dimpling - Air - Shielded
132
Marking and Dimpling - Argon - Shielded
133
Troubleshooting Guide
135
Common Cutting Issues
136
Hand Cutting Issues
137
Mechanized Cutting Issues
138
Check the Gas Pressure
140
Check the Gas Quality
141
Cold Restarts and Quick Restarts
142
Perform a Cold Restart
142
Perform a Quick Restart
142
Fault Leds and Fault Codes
143
Gas Pressure Fault LED
147
Torch Cap Fault LED
148
Enter Gas Test Mode
149
Generator Considerations
149
Run a Gas Test
149
Exit Gas Test Mode
150
While Gas Test Mode Is Active
150
Routine Maintenance
151
Inspect the System and Torch
151
Every Use
152
Every Consumable Change or Weekly (Whichever Is more Frequent)
152
Every 3 Months
153
Inspect the Consumables
154
Replace the Air Filter Bowl and Filter Element
155
Replacement Parts and Accessories
159
Plasma Supply Exterior, Front
160
Plasma Supply Exterior, Rear
161
Machine Interface (CPC) and Serial Interface Upgrade Kits
162
External Cables for Machine Interface Port and Serial Port
163
75° Hand Torch Replacement Parts
164
15° Hand Torch Replacement Parts
165
Machine Torch Replacement Parts
166
Accessory Parts
168
Powermax45 XP Labels
169
Consumable Labels and Fault Codes Label
169
CSA Warning Label
170
CE/CCC Warning Label
171
Data Plate
172
Symbols and Marks
173
IEC Symbols
174
Other manuals for Hypertherm Powermax45 XP
Manual
14 pages
Quick Setup
4 pages
Field Service Bulletin
30 pages
4
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Hypertherm Powermax45 XP Specifications
General
Brand
Hypertherm
Model
Powermax45 XP
Category
Welding System
Language
English
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