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Questions and Answers
What is the purpose of screening and shielding in plasma cutting installations?
What is the purpose of screening and shielding in plasma cutting installations?
Using genuine Hypertherm parts is recommended to ensure warranty coverage.
Using genuine Hypertherm parts is recommended to ensure warranty coverage.
True
What is the duration of the warranty for the plasma power supply from Hypertherm?
What is the duration of the warranty for the plasma power supply from Hypertherm?
2 years
In no event shall Hypertherm's liability exceed the ______ paid for the Products that gave rise to the claim, as stated in the document.
In no event shall Hypertherm's liability exceed the ______ paid for the Products that gave rise to the claim, as stated in the document.
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What is one of Hypertherm's core values related to environmental impact?
What is one of Hypertherm's core values related to environmental impact?
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What should be considered when installing and using plasma equipment?
What should be considered when installing and using plasma equipment?
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The cutting equipment should only be used in industrial environments.
The cutting equipment should only be used in industrial environments.
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To reduce emissions, the cutting equipment must be connected to the mains supply according to the ____ recommendations.
To reduce emissions, the cutting equipment must be connected to the mains supply according to the ____ recommendations.
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Match the following components to their descriptions:
Match the following components to their descriptions:
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What type of gas can the Powermax systems use to cut electrically conductive metals?
What type of gas can the Powermax systems use to cut electrically conductive metals?
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What technology in the Powermax systems automatically adjusts gas pressure for optimum cutting?
What technology in the Powermax systems automatically adjusts gas pressure for optimum cutting?
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Match the Powermax system with its cutting specifications:
Match the Powermax system with its cutting specifications:
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FastConnect™ allows for a complicated torch connection process.
FastConnect™ allows for a complicated torch connection process.
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To operate the Powermax65 on 1-phase power, you need to install an appropriate _________.
To operate the Powermax65 on 1-phase power, you need to install an appropriate _________.
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For the Powermax65 CSA model power supply with 1-phase power, what type of power cord needs to be installed?
For the Powermax65 CSA model power supply with 1-phase power, what type of power cord needs to be installed?
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What is recommended when connecting the power cord to the Powermax65 CSA model for 1-phase power?
What is recommended when connecting the power cord to the Powermax65 CSA model for 1-phase power?
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The CE/CCC model of the Powermax65 supports both single-phase and three-phase power.
The CE/CCC model of the Powermax65 supports both single-phase and three-phase power.
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What power value must the equipment be connected to, according to the content?
What power value must the equipment be connected to, according to the content?
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What warning is given about using Class A equipment in residential locations?
What warning is given about using Class A equipment in residential locations?
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The __ cutting specifications state a recommended cut capacity of 1 in (25 mm) at 20 ipm (500 mm/min).
The __ cutting specifications state a recommended cut capacity of 1 in (25 mm) at 20 ipm (500 mm/min).
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Match the torch angle with its corresponding torch dimensions:
Match the torch angle with its corresponding torch dimensions:
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What does the 'O' symbol represent in the document in relation to 'Direct current (DC)' and 'Alternating current (AC)'?
What does the 'O' symbol represent in the document in relation to 'Direct current (DC)' and 'Alternating current (AC)'?
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What is the characteristic of the volt/amp curve for 'Plate metal cutting'?
What is the characteristic of the volt/amp curve for 'Plate metal cutting'?
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Match the following items with their corresponding descriptions:
Match the following items with their corresponding descriptions:
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What is the minimum amount of space required around the power supply for proper ventilation?
What is the minimum amount of space required around the power supply for proper ventilation?
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Slow-blow fuses are recommended due to the variable current draw during startup.
Slow-blow fuses are recommended due to the variable current draw during startup.
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Study Notes
Environmental Stewardship
- Hypertherm's core values include environmental stewardship, and the company strives to reduce its environmental impact.
Service Manual
- The Powermax65 and Powermax85 service manual has a revision number of 3 and was published in April 2018.
- The manual is published by Hypertherm Inc., located in Hanover, NH, USA.
Contact Information
- Hypertherm Inc. contact information:
- Phone: 603-643-3441 (main office)
- Fax: 603-643-5352 (all departments)
- Email: [email protected] (main office)
- Technical service: 800-643-9878 (phone) and [email protected] (email)
- Customer service: 800-737-2978 (phone) and [email protected] (email)
- Hypertherm also has offices in Europe, Asia, and Latin America, with contact information provided.
Electromagnetic Compatibility (EMC)
- Hypertherm's equipment is built in compliance with standard EN60974-10.
- The equipment should be installed and used in accordance with the manufacturer's instructions to achieve electromagnetic compatibility.
- Methods of reducing emissions include:
- Shielding the supply cable of permanently installed cutting equipment
- Earthing the cutting circuit
- Using associated input filters
- The user is responsible for resolving any electromagnetic disturbances that may occur.
Safety and Compliance
- The user is responsible for ensuring the safe use of the product in their environment.
- The user should ensure that other equipment being used in the environment is compatible with the Hypertherm product.
- Genuine Hypertherm parts are recommended to ensure the safe use of the product.
Warranty
- Hypertherm warrants its products to be free from defects in materials and workmanship for specific periods of time.
- The warranty period varies depending on the product, ranging from 6 months to 3 years.
- The warranty does not apply to products that have been used with phase converters, incorrectly installed, modified, or damaged.
- Hypertherm's liability is limited to the repair, replacement, or adjustment of defective products.
Limitation of Liability
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Hypertherm's liability is limited to the amount paid for the product that gave rise to the claim.
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Hypertherm is not liable for any incidental, consequential, direct, indirect, punitive, or exemplary damages.
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The user is responsible for maintaining insurance to defend and hold Hypertherm harmless in the event of any cause of action arising from the use of the products.### Transfer of Rights
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The transfer of rights is only allowed in connection with the sale of all or substantially all assets or capital stock to a successor in interest.
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The successor in interest must agree to be bound by all terms and conditions of the Warranty.
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Written notification to Hypertherm is required within thirty (30) days before the transfer occurs.
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Hypertherm reserves the right to approve or disapprove the transfer.
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Failure to notify Hypertherm and obtain approval will render the Warranty null and void.
Safety and Compliance
- It is essential to read the safety instructions in the product's manual and the Safety and Compliance Manual (80669C) before operating any Hypertherm equipment.
- Failure to follow safety instructions can result in personal injury or equipment damage.
- Product manuals are available in electronic and printed formats and may accompany the product.
- Copies of manuals can be obtained from the "Documents library" at www.hypertherm.com in all languages available for each manual.### Powermax65 and Powermax85 Overview
- Highly portable, handheld, and mechanized plasma cutting systems for a wide range of applications
- Use air or nitrogen to cut electrically conductive metals, such as mild steel, stainless steel, or aluminum
- Smart Sense technology automatically adjusts gas pressure according to cutting mode and torch lead length for optimum cutting
Powermax65 Specifications
- Can cut thicknesses up to 1 inch (25 mm) with a handheld torch and pierce thicknesses up to 5/8 inch (16 mm)
- Typical handheld system includes a Duramax series 75° hand torch with a consumables box and work lead cable
Powermax85 Specifications
- Can cut thicknesses up to 1-1/4 inches (32 mm) and pierce thicknesses up to 3/4 inch (19 mm)
- Typical mechanized system includes a Duramax series 180° full-length machine torch with a consumables box, work lead cable, and remote-start pendant
Component Weights
- Power supply: 54.1 lbs (24.5 kg) for 65 A CSA, 47.0 lbs (21.3 kg) for 65 A CE/CCC, 59.9 lbs (27.2 kg) for 85 A CSA, 50.4 lbs (22.8 kg) for 85 A CE/CCC
- Hand torch: 6.8 lbs (3.1 kg) for 25 ft (7.6 m), 12.2 lbs (5.5 kg) for 50 ft (15 m), 17.6 lbs (8.0 kg) for 75 ft (23 m)
- Machine torch: 7.6 lbs (3.4 kg) for 25 ft (7.6 m), 13.2 lbs (6.0 kg) for 50 ft (15 m), 18.8 lbs (8.5 kg) for 75 ft (23 m)
- Work lead: 2.8 lbs (1.3 kg) for 25 ft (7.6 m), 5.0 lbs (2.3 kg) for 50 ft (15 m), 6.9 lbs (3.1 kg) for 75 ft (23 m)
Power Supply Ratings
- Powermax65: rated open-circuit voltage (U0) of 296 VDC for CSA, 270 VDC for CE/CCC; rated output current (I2) of 20-65 A; duty cycle at 40°C (104°F) of 50% @ 65 A, 230-600 V, 1/3 PH
- Powermax85: rated open-circuit voltage (U0) of 305 VDC for CSA, 270 VDC for CE/CCC; rated output current (I2) of 25-85 A; duty cycle at 40°C (104°F) of 60% @ 85 A, 230-600 V, 3 PH
Gas Requirements
- Gas type: air or nitrogen
- Gas quality: clean, dry, oil-free per ISO 8573-1 Class 1.2.2
- Recommended gas inlet flow rate/pressure: 400 scfh, 6.7 scfm (190 slpm) @ 85 psi (5.9 bar) for cutting; 450 scfh, 7.5 scfm (210 slpm) @ 70 psi (4.8 bar) for gouging
Torches
- Duramax 75° hand torch dimensions: 9.9 in (25.2 cm) length, 2.6 in (6.6 cm) width, 3.8 in (9.8 cm) height
- Duramax 15° hand torch dimensions: 10.2 in (25.9 cm) length, 2.6 in (6.6 cm) width, 3.8 in (9.8 cm) height
- Duramax 180° full-length machine torch dimensions: 15.6 in (39.6 cm) length, 1.4 in (3.5 cm) width, 12.3 in (31.3 cm) height
- Duramax 180° mini machine torch dimensions: 6.6 in (16.8 cm) length, 1.4 in (3.5 cm) width, 3.3 in (8.4 cm) height
Cutting Specifications
- Powermax65 cutting specifications:
- Handheld cut capacity: 3/4 in (19 mm) at 20 ipm (500 mm/min), 1 in (25 mm) at 10 ipm (250 mm/min)
- Pierce capacity: 5/8 in (16 mm) for handheld cutting or mechanized cutting with torch height control, 1/2 in (12 mm) for mechanized cutting without torch height control
- Maximum cut speed: 145 ipm (4000 mm/min) for 1/4 in (6 mm), 50 ipm (1400 mm/min) for 1/2 in (12 mm), 24 ipm (600 mm/min) for 3/4 in (19 mm), 12 ipm (320 mm/min) for 1 in (25 mm)
- Powermax85 cutting specifications:
- Handheld cut capacity: 1 in (25 mm) at 20 ipm (500 mm/min), 1-1/4 in (32 mm) at 10 ipm (250 mm/min)
- Pierce capacity: 3/4 in (19 mm) for handheld cutting or mechanized cutting with torch height control, 5/8 in (16 mm) for mechanized cutting without torch height control
- Maximum cut speed: 200 ipm (5500 mm/min) for 1/4 in (6 mm), 70 ipm (2000 mm/min) for 1/2 in (12 mm), 36 ipm (900 mm/min) for 3/4 in (19 mm), 21 ipm (550 mm/min) for 1 in (25 mm), 13 ipm (330 mm/min) for 1-1/4 in (32 mm)
Symbols and Marks
- S mark: indicates suitability for operations in environments with increased hazard of electrical shock according to IEC 60974-1
- CSA mark: indicates products meet United States and Canadian regulations for product safety
- CE mark: signifies manufacturer's declaration of conformity to applicable European directives and standards
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Description
This service manual provides guidance on the maintenance and repair of Powermax65 and Powermax85 plasma arc cutting systems. It covers environmental stewardship and sustainability practices.
