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
    • Rear controls
    • Front controls and LEDs
    • Status screen
  • Operating the Powermax105
    • 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)
  • 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
    • Mechanized shielded 105 A consumables
    • Mechanized shielded 45 A, 65 A, 85 A consumables
    • Mechanized shielded with ohmic 105 A consumables
    • Mechanized shielded with ohmic 45 A, 65 A, 85 A consumables
    • Mechanized unshielded 105 A consumables
    • Mechanized unshielded 45 A, 65 A, 85 A consumables
    • Gouging consumables
    • FineCut® shielded consumables
    • FineCut® unshielded consumables
  • Install the machine torch consumables
  • Aligning the torch
  • Connecting the torch lead
  • Using the cut charts
    • Estimated kerf-width compensation
    • 105 A Shielded consumables
    • 105 A Shielded cutting (Mild Steel)
    • 105 A Shielded cutting (Stainless Steel)
    • 105 A Shielded cutting (Aluminum)
    • 85 A Shielded consumables
    • 85 A Shielded cutting (Mild Steel)
    • 85 A Shielded cutting (Stainless Steel)
    • 85 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)
    • Low Speed FineCut (Mild Steel)
    • Low Speed FineCut (Stainless Steel)
    • 105 A Unshielded consumables
    • 105 A Unshielded cutting (Mild Steel)
    • 105 A Unshielded cutting (Stainless Steel)
    • 105 A Unshielded cutting (Aluminum)
    • 85 A Unshielded consumables
    • 85 A Unshielded cutting (Mild Steel)
    • 85 A Unshielded cutting (Stainless Steel)
    • 85 A Unshielded cutting (Aluminum)
    • 65 A Unshielded consumables
    • 65 A Unshielded cutting (Mild Steel)
    • 65 A Unshielded cutting (Stainless Steel)
    • 65 A Unshielded cutting (Aluminum)
    • 45 A Unshielded consumables
    • 45 A Unshielded cutting (Mild Steel)
    • 45 A Unshielded cutting (Stainless Steel)
    • 45 A Unshielded cutting (Aluminum)
• 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
    • General
    • 200-600 V CSA 3-phase power supply functional description
    • 230-400 V CE, 380 V CCC/230-400 V CE 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
    • Schematic for building an IGBT tester
    • IGBT device test using a non-Hypertherm tester
  • 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
    • Displaying the service screen
    • Important fault icons
    • Performing a cold restart
    • Fault codes and solutions
  • 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)/torch stuck closed (TSC)
    • 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 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
    • Exterior front
    • Exterior rear
    • Interior, power board side (200-600 V CSA)
    • Interior, power board side (230-400 V CE)
    • Interior, power board side (400 V CE/380 V CCC)
    • Interior, fan side
  • Heat sink assembly
    • 200-600 V CSA heat sink components
    • 230-400 V CE heat sink components
    • 400 V CE/ 380 V CCC heat sink components
  • 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
    • 200-600 V CSA
    • 230-400 V CE
    • 400 V CE/380 V CCC
    • Power supply fan side
  • 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)