Hypertherm Powermax65 Service Manual Rev.1 User Manual
Plasma arc cutting systems
This manual is related to the following products:
Table of contents
Document Outline
- Section 1
- Specifications
- Safety information
- System description
- Where to find information
- Power supply dimensions
- Component weights
- Powermax65 power supply ratings
- Powermax85 power supply ratings
- Duramax 75° hand torch dimensions
- Duramax 15° hand torch dimensions
- Duramax 180° full‑length machine torch dimensions
- Duramax 180° mini machine torch dimensions
- Powermax65 cutting specifications
- Powermax85 cutting specifications
- Symbols and markings
- IEC symbols
- Section 2
- Power Supply Setup
- Unpack the Powermax65 or Powermax85 system
- Position the power supply
- Prepare the electrical power
- Power connection for the Powermax65
- Single‑phase power cord (not for CE model)
- Three‑phase power cord – plug installation
- Power connection for the Powermax85
- Three‑phase power cord – plug installation
- Extension cord recommendations
- Prepare the gas supply
- Section 3
- Torch Setup
- Section 4
- Operation
- Controls and indicators
- Operating the Powermax65 or Powermax85
- Connect the electrical power, gas supply, and torch lead
- Attach the work lead to the power supply
- Attach the work clamp to the workpiece
- Turn ON the system
- Set the operating mode switch
- Check the indicators
- Manually adjusting the gas pressure
- Adjusting the current (amperage)
- Understanding duty-cycle limitations
- Using the hand torch
- Using the machine torch
- Section 5
- Troubleshooting and System Tests
- Controls and indicators
- Theory of operation
- Troubleshooting preparation
- Initial resistance check
- 200 – 600 V CSA power supply overview
- 380/400 V CE power supply overview
- 200 – 600 V CSA power supply overview (power board removed)
- 380/400 V CE power supply overview (power board removed)
- Fault codes
- Troubleshooting guide
- System tests
- Test 1 – Voltage input
- Test 2 – DC Power Buss
- Test 3 – Output diodes
- Test 4 – Inverter and PFC temperature sensor
- Test 5 – Flyback circuit (DC minor voltages)
- Test 6 – Torch stuck open (TSO)
- Test 7 – Start signal
- Test 8 – Torch cap switch
- Test 9 – Electronic regulator
- Test 10 – Pressure sensor
- Test 11 – Fan
- Test 12 – AUX switch
- Section 6
- Component Replacement
- Section 7
- Parts
- Power supply parts
- Heat sink assembly
- Duramax 75° hand torch replacement parts
- Duramax 15° hand torch replacement parts
- Hand torch consumables
- Duramax 180° full-length machine torch replacement parts
- Duramax 180° mini machine torch replacement parts
- Machine torch consumables
- Accessory parts
- Powermax65 and Powermax85 labels
- Safety-critical parts
- Recommended spare parts
- Section 8
- Wiring Diagrams