Hypertherm Powermax105 Service Manual User Manual

Plasma arc cutting systems

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Powermax105 Operator Manual

Table of contents

Document Outline

Section 1
Specifications
- Safety information
- System description
- Where to find information
- Power supply dimensions
- Component weights (105 A systems)
- Powermax105 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
- Powermax105 cutting specifications
- Symbols and markings
- Noise levels
- IEC symbols
Section 2
Power Supply Setup
- Unpack the Powermax system
  - Claims
  - Contents
- Position the power supply
- Prepare the electrical power
  - Install a line-disconnect switch
  - Requirements for grounding
- Power connection for the Powermax105
  - Three-phase power cord and plug installation
- Extension cord recommendations
  - Extension cord specifications
  - Engine-driven generator recommendations
- Prepare the gas supply
  - Additional gas filtration
  - Connect the gas supply
Section 3
Basic System Operations
- Controls and indicators
- Operating the Powermax105
- Electrode end-of-life detection feature
- Understanding duty-cycle limitations
Section 4
Hand Torch Setup
- Introduction
- Consumable life
- Hand torch components
- Choose the hand torch consumables
  - Drag-cutting 105 A consumables
  - Drag-cutting 45 A, 65 A, 85 A consumables
- Hand torch consumables
  - Gouging consumables
  - FineCut® consumables
- Install the hand torch consumables
- Connecting the torch lead
Section 5
Hand Cutting
- Using the hand torch
- Operate the safety trigger
- Hand torch cutting hints
- Start a cut from the edge of the workpiece
- Pierce a workpiece
- Gouge a workpiece
  - Gouge profile
  - Varying the gouge profile
- Common hand-cutting faults
Section 6
Machine Torch Setup
- Introduction
- Consumable life
- Machine torch components
- Converting a full-length machine torch to a mini machine torch
- Mount the torch
- Choose the machine torch consumables
- Machine torch consumables
- Install the machine torch consumables
- Aligning the torch
- Connecting the torch lead
- Using the cut charts
Section 7
Mechanized Cutting
- Connecting an optional remote-start pendant
- Connecting an optional machine interface cable
  - Machine interface pinout
  - Setting the five-position voltage divider
- Accessing raw arc voltage
- Connecting an optional RS485 serial interface cable
- Using the machine torch
- Setting up the torch and table
- Understand and optimize cut quality
  - Cut or bevel angle
  - Dross
- Piercing a workpiece using the machine torch
- Common machine-cutting faults
Section 8
Troubleshooting and System Tests
- Controls and indicators
- Theory of operation
- Troubleshooting preparation
- Initial resistance check
- 200-600 V CSA power supply overview
- 230-400 V CE, 380 V CCC/230-400 V CE power supply overview
- 380 V CCC, 400 V CE power supply overview
- 200-600 V CSA power supply overview (power board removed)
- 230-400 V CE, 380 V CCC/230-400 V CE power supply overview (power board removed)
- 380 V CCC, 400 V CE power supply overview (power board removed)
- Fault codes
- Troubleshooting guide
- System tests
Section 9
Power Supply Component Replacement
- Replacing the air filter element
- Replacing the work lead connector
- Installing the optional filter kit
- Replacing the power supply cover
- Replacing the Mylar® barrier
- Installing the machine interface cable with voltage divider board
- Installing the machine interface cable
- Installing the RS485 serial interface cable
- Replacing the power cord
- Replacing the strain relief connector
- Replacing the power switch
- Replacing the control board
- Replacing the DSP board
- Replacing the power board
- Replacing the input diode bridge
- Replacing the output diode bridge
- Replacing the pilot arc IGBT
- Replacing the inverter IGBT module
- Replacing the PFC IGBT module
- Replacing the snubber resistor
- Replacing the damper resistor
- Replacing the thermal sensor
- Replacing the fan shroud
- Replacing the fan
- Replacing the pressure transducer
- Replacing the pressure switch
- Replacing the air filter subassembly
- Replacing the solenoid valve
- Replacing the gas tubing
- Replacing the bulk capacitors
- Replacing the torch quick disconnect receptacle
- Replacing the work lead receptacle
- Replacing the output inductor
- Replacing the transformer
- Replacing the PFC inductor
- Replacing the front end panel
- Replacing the rear end panel
- Installing the machine interface cable for raw arc voltage
Section 10
Torch Component Replacement
- Hand torch: Replacing the start switch
- Hand torch: Replacing the cap-sensor switch
- Hand torch: Replacing the handles
- Hand torch: Replacing the trigger
- Hand torch: Replacing the torch body
- Hand torch: Replacing the torch lead
- Hand torch: Replacing the quick disconnect housing
- Machine torch: Replacing the mounting sleeve
- Machine torch: Replacing the cap-sensor switch
- Machine torch: Replacing the torch body
- Machine torch: Replacing the coupler
- Machine torch: Replacing the gear rack
- Machine torch: Replacing the positioning sleeve
- Machine torch: Replacing the torch lead
- Machine torch: Replacing the quick disconnect housing
Section 11
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
- Powermax105 labels
- Safety-critical parts
- Recommended spare parts
Section 12
Wiring Diagrams
- Powermax Generic Timing Chart
- Schematic diagram (CSA, 230‑400 V CE, 380 V CCC/230‑400 V CE)
- Schematic diagram (380 V CCC, 400 V CE)

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