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
    • Claims
    • Contents
  • Position the power supply
  • Prepare the electrical power
    • Install a line‑disconnect switch
    • Requirements for grounding
  • Power connection for the Powermax65
  • Single‑phase power cord (not for CE model)
  • Three‑phase power cord – plug installation
  • Power connection for the Powermax85
    • Single‑phase power cord (not for CE model)
    • Single‑phase power cord installation
  • Three‑phase power cord – 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
• Torch Setup
  • Introduction
  • Consumable life
    • CopperPlus™ electrode for Duramax torches
  • Hand torch setup
    • Choose the hand torch consumables
    • Hand torch consumables
    • Install the hand torch consumables
  • Machine torch setup
    • 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 an optional remote‑start pendant
    • Connecting an optional machine interface cable
  • Connecting the torch lead
  • Using the cut charts
    • Estimated kerf-width compensation
    • 85 A shielded consumables
    • 65 A shielded consumables
    • 45 A shielded consumables
    • FineCut® consumables
    • 85 A unshielded consumables
    • 65 A unshielded consumables
    • 45 A unshielded consumables
• Section 4
• Operation
  • Controls and indicators
    • Rear controls
    • Front controls and LEDs
    • Status screen
  • 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
    • Operate the safety trigger
    • Hand torch cutting hints
    • Start a cut from the edge of the workpiece
    • Pierce a workpiece
    • Gouge a workpiece
    • Common hand-cutting faults
  • Using the machine torch
    • Ensure the torch and table are set up correctly
    • Understand and optimize cut quality
    • To pierce a workpiece using the machine torch
    • Common machine-cutting faults
• Section 5
• Troubleshooting and System Tests
  • Controls and indicators
  • Theory of operation
    • General
    • 200 – 600 V CSA 1- or 3‑phase power supply functional description
    • 380/400 V CE 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
  • 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
    • 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)
    • 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
  • Remove and replace the power supply cover and Mylar® barrier
    • Remove the power supply cover and Mylar barrier
    • Replace the Mylar barrier
    • Replace the power supply cover
  • Replace the power cord
    • Replace the power cord (200 – 600 V 3‑phase CSA, 400 V 3‑phase CE)
    • Replace the power cord (200 – 480 V 1‑phase CSA)
  • Replace the work lead
  • Replace the fan
  • Replace the air filter element
  • Replace the air filter subassembly
  • Replace the power board
    • Remove the DSP board
    • Replace the power board (380/400V CE)
    • Replace the power board (200 – 600V CSA)
    • Install the DSP board
    • Replace the Mylar barrier and power supply cover.
  • Replace the control board
  • Replace the heat sink components
    • 65A CSA
    • 65A CE
    • 85A CSA
    • 85A CE
• Section 7
• Parts
  • Power supply parts
    • Exterior front
    • Exterior rear
    • Interior, power board side (200 – 600V CSA)
    • Interior, power board side (380/400V CE)
    • Interior, fan side
  • Heat sink assembly
    • 65A CSA
    • 65A CE
    • 85A CSA
    • 85A CE
  • 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
  • Cutting timing diagram page 1 of 2
  • Cutting timing diagram page 2 of 2
  • Electrical schematic diagram (CSA)
  • Electrical schematic diagram (CE)