Document Outline

• Contents
• Electromagnetic Compatibility (EMC)
  • Introduction
  • Installation and use
  • Assessment of area
  • Methods of reducing emissions
    • Mains supply
  • Maintenance of cutting equipment
  • Cutting cables
    • Equipotential bonding
    • Earthing of the workpiece
  • Screening and shielding
• Warranty
  • Attention
  • General
  • Patent indemnity
  • Limitation of liability
  • National and local codes
  • Liability cap
  • Insurance
  • Transfer of rights
• Specifications
  • Safety information
  • Powermax125 System description
  • Power supply dimensions
  • Component weights (125 A systems)
  • Hypertherm power supply ratings
  • Duramax Hyamp 85° hand torch dimensions
  • Duramax Hyamp 15° hand torch dimensions
  • Duramax Hyamp 180° full-length machine torch dimensions
  • Duramax Hyamp 180° mini machine torch dimensions
  • Powermax125 cutting specifications
  • Symbols and markings
    • Noise levels
    • IEC symbols
• 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 Powermax125
    • Three-phase power cord and plug installation
      • Decrease output current for lower-rated power plugs
  • Extension cord recommendations
    • Engine-driven generator recommendations
  • Prepare the gas supply
    • Additional gas filtration
    • Connect the gas supply
      • Minimum inlet pressure (while gas is flowing)
      • Gas flow rates
• Basic System Operations
  • Controls and indicators
    • Rear controls
    • Front controls and LEDs
      • LEDs
      • Selectors
      • Operating mode switch
      • Amperage adjustment knob
    • Status screen
      • Gas pressure indicators
      • System status icons
      • Fault codes and icons
  • Operating the Powermax
    • Connect the electrical power, gas supply, and torch lead
    • Attach the work lead to the power supply
    • Attach the ground 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)
  • Electrode end-of-life detection feature
  • Understanding duty-cycle limitations
• Hand Torch Setup
  • Introduction
  • Consumable life
  • Hand torch components
    • Duramax Hyamp 85° hand torch
    • Duramax Hyamp 15° hand torch
  • Choose the hand torch consumables
    • Drag-cutting 105/125 A consumables
    • Drag-cutting 45 A and 65 A consumables
    • Gouging consumables
    • FineCut consumables
  • Install the hand torch consumables
  • Connecting the torch lead
• Hand Cutting
  • Using the hand torch
  • Operate the safety trigger
  • Hand torch cutting guidelines
  • Start a cut from the edge of the workpiece
  • Pierce a workpiece
  • Gouge a workpiece
    • Gouge profile
    • Varying the gouge profile
    • 125 A gouging profile chart
  • Common hand-cutting faults
• Machine Torch Setup
  • Introduction
  • Consumable life
  • Machine torch components
    • Duramax Hyamp 180° machine torch
    • Duramax Hyamp 180° mini machine torch
  • Disassemble the machine torch
  • Convert a full-length machine torch to a mini machine torch
  • Mount the torch
  • Choose the machine torch consumables
  • Machine torch consumables
    • Mechanized shielded 105 A/125 A consumables
    • Mechanized shielded 45 A and 65 A consumables
    • Mechanized shielded with ohmic 105 A/125 A consumables
    • Mechanized shielded with ohmic 45 A and 65 A consumables
    • Gouging consumables
    • FineCut shielded consumables
    • FineCut shielded with ohmic consumables
  • Install the machine torch consumables
  • Aligning the torch
  • Connecting the torch lead
  • Using the cut charts
    • Estimated kerf-width compensation
      • Estimated kerf-width compensation – Metric (mm)
      • Estimated kerf-width compensation – English (inches)
    • 125 A shielded consumables
    • 125 A shielded cutting – mild steel
    • 125 A shielded cutting – stainless steel
    • 125 A shielded cutting – aluminum
    • 105 A shielded consumables
    • 105 A shielded cutting – mild steel
    • 105 A shielded cutting – stainless steel
    • 105 A shielded cutting – aluminum
    • 65 A shielded consumables
    • 65 A shielded cutting – mild steel
    • 65 A shielded cutting – stainless steel
    • 65 A shielded cutting – aluminum
    • 45 A shielded consumables
    • 45 A shielded cutting – mild steel
    • 45 A shielded cutting – stainless steel
    • 45 A shielded cutting – aluminum
    • FineCut consumables
    • FineCut – mild steel
    • FineCut – stainless steel
• Mechanized Cutting
  • Connecting an optional remote-start pendant
  • Connecting the machine interface cable
    • Machine interface pinout
    • Setting the five-position voltage divider
  • Accessing raw arc voltage
  • Connecting an optional RS-485 serial interface cable
    • Serial port cables
  • 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
• Troubleshooting and System Tests
  • Controls and indicators
    • Rear panel
    • Front panel
      • Status screen
  • Theory of operation
    • 480 V and 600 V CSA 3-phase power supply functional description
    • 400 V CE, 380 V CCC 3-phase power supply functional description
    • Sequence of operation
  • Troubleshooting preparation
    • Test equipment
    • Troubleshooting procedures and sequence
    • External inspection
    • Internal inspection
  • Initial resistance check
    • Check the power switch
    • Hypertherm IGBT tester
    • Indicator LEDs and device tests
    • IGBT test preparation
    • IGBT device test using the Hypertherm tester
    • Troubleshoot the Hypertherm IGBT tester
  • IGBT device test using a non-Hypertherm tester
  • Fault codes
    • Important fault icons
    • Displaying the service screen
    • Run a gas test
    • Perform a cold restart
    • Fault codes and solutions
      • Fault code format – 0-00-0
      • Fault code format – 0-nn-n
      • Fault code format – 1-nn-n
      • Fault code format – 2-nn-n
      • Fault code format – 3-nn-n
      • Torch-related faults – continuity check
  • Troubleshooting guide
  • System tests
    • Test 1 – Voltage input
    • Test 2 – DC power bus
      • Resistance check
      • Voltage check
    • Test 3 – Output diodes
    • Test 4 – Inverter temperature sensor
      • For operational fault codes 0-40-2 and 0-40-3 or power board faults 2-10-0 and 2-10-1
    • Test 5 – Flyback circuit (DC minor voltages)
    • Test 6 – Torch stuck open/torch stuck closed
    • Test 7 – Start signal
    • Test 8 – Torch cap switch
    • Test 9 – Electronic regulator
    • Test 10 – Pressure sensor
    • Test 11 – Fan
    • Test 12 – AUX switch
• Power Supply Component Replacement
  • Installing a machine interface cable for raw arc voltage
  • Disconnect the power and gas supply
  • Replacing the gas filter element
    • Remove the gas filter element
    • Install the gas filter element
  • Replacing the work lead connector
  • Installing the optional filter kit
  • Replacing the power supply cover
    • Remove the power supply cover
    • Install the power supply cover
  • Replacing the component barrier
    • Remove the component barrier
    • Install the component barrier
  • Replacing the end panel bracket
    • Remove the end panel bracket
    • Install the end panel bracket
  • Replacing the machine interface cable with voltage divider board
    • Remove the machine interface cable with voltage divider board
    • Install the machine interface cable with voltage divider board
    • Set the voltage divider board
  • Installing the machine interface cable
    • Connect the external machine cable to the CNC or THC
  • Installing the RS-485 serial interface cable
  • Disconnect the gas tube
  • Connect the gas tube
  • Replacing the power cord and strain relief
    • Remove the power cord and strain relief
    • Install the power cord and strain relief
  • Replacing the power switch
    • Remove the power switch
    • Install the power switch
  • Replacing the control board
    • Remove the control board
    • Install the control board
  • Replacing the DSP board
    • Remove the DSP board
    • Install the DSP board
  • Replacing the power board
    • Remove the power board
    • Install 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 snubber resistor
  • Replacing the thermal sensor
  • Replacing the fan shroud
    • Remove the fan shroud
    • Install the fan shroud
  • Replacing the fan
  • Replacing the pressure transducer
  • Replacing the pressure switch
  • Replacing the gas filter assembly
    • Remove the gas filter assembly
    • Install the gas filter assembly
  • Replacing the solenoid valve
    • Remove the solenoid valve
    • Install the solenoid valve
  • Replacing the gas tubing
  • Replacing the bulk capacitors
  • Replacing the torch quick disconnect receptacle
    • Remove the torch quick disconnect receptacle
    • Install the quick disconnect receptacle
  • Replacing the work lead receptacle
  • Replacing the output inductor
    • Remove the output inductor
    • Install the output inductor
  • Replacing the transformer
    • Remove the transformer
    • Install the transformer
  • Replacing the PFC inductor
    • Remove the PFC inductor
    • Install the PFC inductor
  • Replacing the front panel
    • Remove the front panel
    • Install the front panel
  • Replacing the rear panel
    • Remove the rear panel
    • Install the rear panel
• Torch Component Replacement
  • Disconnect the power, gas supply, and torch
  • Hand torches
    • Replacing the handle
    • Replacing the trigger assembly
    • Replacing the torch body
    • Replacing the start switch
    • Replacing the cap-sensor switch
    • Replacing the torch lead
  • Machine torches
    • Replacing the mounting sleeve
    • Replacing the cap sensor switch
    • Replacing the torch body
    • Replacing the coupler and positioning sleeve (full-length only) or adapter (mini only)
    • Replacing the torch lead
  • Replacing the quick disconnect housing
• Parts
  • Power supply parts
    • Exterior, front
    • Exterior, rear
    • Interior, power board side
      • 480 V, 600 V CSA
      • 400 V CE/380 V CCC
    • Interior, fan side
    • Interior, heatsink assembly
  • Duramax Hyamp 85° hand torch replacement parts
  • Duramax Hyamp 15° hand torch replacement parts
  • Hand torch consumables
    • Drag cutting
    • Gouging
    • FineCut
  • Duramax Hyamp 180° full-length machine torch replacement parts
  • Duramax Hyamp 180° mini machine torch replacement parts
  • Machine torch consumables
    • Shielded
    • Gouging
    • FineCut
  • Accessory parts
  • Powermax125 labels
  • Safety-critical parts
    • Power supply, power board side
    • Power supply, fan side
  • Recommended spare parts
• Wiring Diagrams
  • Powermax generic timing chart
  • Powermax125 schematic diagram