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Hypertherm Duramax Service Manual

Robotic torches
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Duramax™ and Duramax Hyamp Robotic
Torches
45°, 90°, 180°
Service Manual
807460 | Revision 2 | English

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  • Page 1 Duramax™ and Duramax Hyamp Robotic Torches 45°, 90°, 180° Service Manual 807460 | Revision 2 | English...
  • Page 2 ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ Duramax, Powermax, FastConnect, and Hypertherm are trademarks of Hypertherm Inc. and may be registered in the United States and other countries. All other trademarks are the property of their respective holders. © 2014 Hypertherm Inc.
  • Page 3 Duramax /Duramax Hyamp Robotic Torches Service Manual 807460 Revision 2 English March 2014 Hypertherm Inc. Hanover, NH 03755 USA...
  • Page 4 55 11 2409 2636 Tel 55 11 2408 0462 Fax Hypertherm (S) Pte Ltd. 82 Genting Lane Media Centre Hypertherm México, S.A. de C.V. Annexe Block #A01-01 Avenida Toluca No. 444, Anexo 1, Singapore 349567, Republic of Singapore Colonia Olivar de los Padres 65 6841 2489 Tel Delegación Álvaro Obregón...
  • Page 5 Safety information Before operating any Hypertherm equipment, read the separate Safety and Compliance Manual (80669C) included with your product for important safety information.

  • Page 7: Table Of Contents

    Transfer of rights ..................................SC-14 1 Specifications ..........................15 Introduction ....................................15 Duramax component weights ..............................16 Duramax Hyamp component weights ............................16 Torch dimensions ..................................17 Duramax 180° robotic torch dimensions ......................... 17 Duramax/Duramax Hyamp Robotic Torches Service Manual 807460...
  • Page 8 Duramax robotic torches ..............................34 Duramax consumables ................................ 34 Duramax mechanized shielded 105 A* ........................34 Duramax mechanized shielded 45 A, 65 A, 85 A* ....................34 Duramax FineCut shielded 105 A* ........................... 34 Duramax FineCut shielded 65 A, 85 A* ........................35 *Ohmic-sensing retaining cap ...........................
  • Page 9 Piercing a workpiece using the robotic torch ........................ 50 Common machine-cutting faults ............................51 4 Component Replacement ......................53 Duramax and Duramax Hyamp robotic torch overview ......................53 Disconnect the power, gas supply, and torch ........................55 Replacing the positioning barrel ............................... 56 Replacing the torch body ................................
  • Page 10 Contents Duramax/Duramax Hyamp Robotic Torches Service Manual 807460...

  • Page 11: Electromagnetic Compatibility (Emc

    Other supply cables, control cables, signaling and telephone cables; above, below and adjacent to the cutting equipment. Hypertherm’s CE-marked equipment is built in compliance with standard EN60974-10. The equipment should be b. Radio and television transmitters and receivers. installed and used in accordance with the information c.

  • Page 12: Maintenance Of Cutting Equipment

    Electromagnetic Compatibility (EMC) Maintenance of cutting equipment Earthing of the workpiece Where the workpiece is not bonded to earth for electrical The cutting equipment must be routinely maintained safety, nor connected to earth because of its size and according to the manufacturer’s recommendations. All position, for example, ship’s hull or building steel work, a access and service doors and covers should be closed connection bonding the workpiece to earth may reduce...

  • Page 13: Warranty

    Hypertherm is notified of a defect (i) with respect to the particular purpose or against infringement. The foregoing plasma power supply within a period of two (2) years from...

  • Page 14: Patent Indemnity

    (14) days after learning of any action or threat of action), appropriate to defend and to hold Hypertherm harmless in and Hypertherm’s obligation to defend shall be the event of any cause of action arising from the use of the conditioned upon Hypertherm’s sole control of, and the...

  • Page 15: Specifications

    The torches are cooled by ambient air and do not require special cooling procedures. Duramax and Duramax Hyamp robotic torches comply with IEC 60974-7 and are not suitable for use in the rain or snow. Duramax/Duramax Hyamp Robotic Torches Service Manual 807460...

  • Page 16: Duramax Component Weights

    3.5 kg (7.8 pounds) Each Duramax Hyamp robotic torch weighs 0.46 kg/m (0.31 pounds/foot).  The recommended minimum bend radius for the Duramax Hyamp torch lead is 102 mm (4.0 inches). See Figure 2. Figure 2 – Duramax Hyamp bend radius 102 mm (4.0 inches)

  • Page 17: Torch Dimensions

    Duramax 90° robotic torch dimensions 20.1 cm (7.90 inches) 3.5 cm (1.38 inches) 90° 10.1 cm (3.97 inches)* 2.5 cm (1.0 inch) 5.41 cm (2.13 inches)* 9.78 cm (3.85 inches)* 14.2 cm (5.58 inches)* Duramax/Duramax Hyamp Robotic Torches Service Manual 807460...

  • Page 18: Duramax 45° Robotic Torch Dimensions

    Duramax Hyamp 180° robotic torch dimensions 27.1 cm (10.7 inches)* 20.8 cm (8.15 inches) 4.5 cm 3.5 cm (1.8 inches) (1.38 inches) 3.5 cm (1.38 inches) 14.1 cm (5.57 inches)* 18.5 cm (7.30 inches)* 22.9 cm (9.02 inches)* Duramax/Duramax Hyamp Robotic Torches Service Manual 807460...

  • Page 19: Duramax Hyamp 90° Robotic Torch Dimensions

    11.8 cm (4.66 inches)* 16.2 cm (6.39 inches)* 20.6 cm (8.11 inches)* * Torch dimensions will vary depending on the type of consumables installed. The preceding figures show the mechanized shielded consumables installed. Duramax/Duramax Hyamp Robotic Torches Service Manual 807460...
  • Page 20 1 – Specifications Duramax/Duramax Hyamp Robotic Torches Service Manual 807460...

  • Page 21: Torch Setup

    Choose and install the consumables.  Attach the torch lead to the power supply.  Set up the power supply for remote starting with either the remote-start pendant or a machine interface cable. Duramax/Duramax Hyamp Robotic Torches Service Manual 807460...

  • Page 22: Install The Torch

    Mount the torch on page 30. Figure 3 4.20 cm (1.65 inches) 3.68 cm (1.45 inches) 1 Disconnect button 4 Strain relief 2 Tab 5 Bottom shell 3 Top shell 6 Mounting screws (4) Duramax/Duramax Hyamp Robotic Torches Service Manual 807460...

  • Page 23: Disassemble The Robotic Torch

    See the Safety and Compliance Manual (80669C) for more safety precautions.  The instructions to disassemble and reassemble all 3 models of robotic torches are the same. The 45° robotic torch is shown in the figures that follow. Duramax/Duramax Hyamp Robotic Torches Service Manual 807460...
  • Page 24 3 Cap-sensor switch 9 Left half of the positioning barrel 4 Pilot terminal screw 10 Torch lead 5 Torch body (torch head and gas tube) 11 Strain relief 6 Gas supply tube fitting Duramax/Duramax Hyamp Robotic Torches Service Manual 807460...
  • Page 25 7. Slide the cap-sensor switch off its mounting post. Figure 6 – Duramax 45° (top) and Duramax Hyamp 45° (bottom) 1 Cap-sensor switch mounting post 3 Gas fitting flange slot...
  • Page 26 Do not get any threadlocker on the conical surface of the gas tube fitting to avoid causing damage to the torch. If any threadlocker does get on this surface, clean it off immediately. Duramax/Duramax Hyamp Robotic Torches Service Manual 807460...
  • Page 27 The wire should go slightly down into the positioning barrel. 17. Press the cap-sensor switch into its post hole and onto its mounting post. (See Figure 6.) 18. Route the cap-sensor wires below the slot for the gas hose fitting’s flange. Duramax/Duramax Hyamp Robotic Torches Service Manual 807460...
  • Page 28 1 Pilot arc wire terminal 4 Gas fitting flange 2 Cap-sensor switch 5 Strain relief 3 Cap-sensor switch connector Figure 9 – Duramax Hyamp wire routing 1 Pilot arc wire terminal 4 Gas fitting flange 2 Cap-sensor switch 5 Strain relief 3 Cap-sensor switch connector 19.
  • Page 29 23. If the O-ring on the torch body is dry, lubricate it and the threads with a thin layer of silicone lubricant.  Silicone lubricant is included in several of the replacement kits. 24. Install the consumables. 25. Reconnect the torch and gas supply, and turn ON (I) the power. Duramax/Duramax Hyamp Robotic Torches Service Manual 807460...

  • Page 30: Mount The Torch

    A robotic torch clamp with mating positioning dowels and anti-rotational tabs is available from Hypertherm. If you choose to use an alternate torch clamp, follow the manufacturer’s instructions on how to mount the torch in the clamp. It is the customer’s responsibility to interface between the torch clamp and the robot’s arm.
  • Page 31 For the recommended minimum bend radius of the torch lead, see Figure 1 or Figure 2 on page 16. If you are using Hypertherm’s robotic torch clamp (228806), complete the following instructions: 1. Mount the robotic torch clamp using one set of mounting holes (through hole or threaded).
  • Page 32 4. Verify that the anti-rotational tabs on each half of the torch clamp are aligned with the slots in the torch. 5. Loosely hand tighten the 4 screws. 6. Starting with the upper left screw, step torque the 4 screws to 17.3 kg∙cm (15 inch∙pounds) in the pattern shown below – Figure 13 Duramax/Duramax Hyamp Robotic Torches Service Manual 807460...

  • Page 33: Consumable Life

    Whether you are cutting in “continuous pilot arc” mode or normal mode. Cutting with a continuous pilot arc causes more consumable wear. You will find more information about proper cutting techniques in Operation on page 47. Duramax/Duramax Hyamp Robotic Torches Service Manual 807460...

  • Page 34: Choosing The Consumables

    Choosing the consumables Duramax robotic torches Duramax robotic torches are shipped with a consumable kit that includes enough consumables to create a complete consumable set for 65, 85, or 105 amperage shielded cutting. An ohmic-sensing retaining cap is available for use with shielded consumables, a deflector is available for unshielded cutting and FineCut ®...

  • Page 35: Duramax Finecut Shielded 65 A, 85 A

    Duramax mechanized unshielded 105 A 220955 220854 220990 220842 220994 Deflector Retaining cap Nozzle Electrode Swirl ring Duramax mechanized unshielded 45 A, 65 A, 85 A 220941 Nozzle (45 A) 220819 Nozzle (65 A) 220842 220857 220955 220854 Electrode Swirl ring...

  • Page 36: Duramax Finecut Unshielded 65 A, 85

    Duramax gouging 105 A 220798 220854 220991 220842 220994 Shield Retaining cap Nozzle Electrode Swirl ring Duramax gouging 65 A, 85 A 220798 220854 220797 220842 220857 Shield Retaining cap Nozzle Electrode Swirl ring Duramax/Duramax Hyamp Robotic Torches Service Manual 807460...

  • Page 37: Duramax Hyamp Robotic Torches

    2 – Torch Setup Duramax Hyamp robotic torches Duramax Hyamp robotic torches ship with a consumable kit that includes enough consumables to create a complete consumable set for 45, 65, 105, or 125 amperage shielded cutting. Also notice that specific consumables are not available for cutting at 85 A.

  • Page 38: Installing The Consumables

    OFF (O) position, remove the consumables, and install the new consumables by referring to Figure 14. Figure 14 Duramax Duramax Hyamp 1 Swirl ring 4 Retaining cap 2 Electrode 5 Shield 3 Nozzle Duramax/Duramax Hyamp Robotic Torches Service Manual 807460...

  • Page 39: Connecting The Torch Lead

    OFF the system. To connect the torch, push the connector into the receptacle on the front of the power supply. Figure 15 To remove the torch, press the red button on the connector and pull the connector out of the receptacle. Figure 16 Red button Duramax/Duramax Hyamp Robotic Torches Service Manual 807460...

  • Page 40: Connecting A Remote-Start Pendant

    If your power supply has the machine interface receptacle on the rear of the power supply, remove the receptacle cover and plug the Hypertherm remote-start pendant into the receptacle. If the system does not have a receptacle installed, a CPC port upgrade kit (228697 for Powermax65/85) (228884 for Powermax105/125) is available from Hypertherm.

  • Page 41: Connecting The Machine Interface Cable

    (SELV) requirements for direct connection to computer products. Hypertherm offers several choices of machine interface cables:  To use the built-in voltage divider that provides a scaled down arc voltage in addition to signals for arc transfer and plasma start: ...
  • Page 42 2. Remove the machine interface receptacle’s cover from the rear of the power supply. 3. Connect the Hypertherm machine interface cable to the power supply. 4. If you are using a cable with a D-sub connector on the other end, plug it into the appropriate pin connector on the torch height controller or CNC.

  • Page 43: Machine Interface Pinout

    120 VAC/1 A maximum at the machine interface relay. Ground Ground Voltage divider Output Divided arc signal of 20:1, 21.1:1, 5 (-), 6 (+) Black (-), white (+) 30:1, 40:1, 50:1 (provides a maximum of 16 V). Duramax/Duramax Hyamp Robotic Torches Service Manual 807460...

  • Page 44: Setting The Five-Position Voltage Divider

    4. Set the DIP switches to one of the following settings, and replace the power supply cover. 20:1 21.1:1 30:1 40:1 50:1 If the Hypertherm five-position voltage divider does not supply the required voltage for your application, contact your system integrator for assistance. Duramax/Duramax Hyamp Robotic Torches Service Manual 807460...

  • Page 45: Using The Cut Charts

    The cut charts for each set of mechanized consumables can be found in the Torch Setup section of the Operator Manual that shipped with the system. The manuals also can be downloaded from Hypertherm’s website (www.hypertherm.com) using the “Downloads library” link. A consumable diagram with part numbers precedes each set of charts. For each consumable type, there are Metric and English charts for mild steel, stainless steel, and aluminum.

  • Page 46: Duramax/Duramax Hyamp Robotic Torches Service Manual

    2 – Torch Setup Duramax/Duramax Hyamp Robotic Torches Service Manual 807460...

  • Page 47: Operation

    However, the information in the following section will help you optimize cut quality and maximize consumable life. Duramax/Duramax Hyamp Robotic Torches Service Manual 807460...

  • Page 48: Using The Duramax Robotic Teach Tool

    Using the Duramax robotic teach tool A robotic torch teach tool (229456) for only the Duramax robotic torches is available from Hypertherm to assist with programming the robot before cutting. The torch teach tool enables the system operator to program the robot’s cutting path, while visually verifying the torch will not touch the workpiece while cutting.

  • Page 49: Understand And Optimize Cut Quality

    Excess dross appears on the top edge of both pieces of the plate when the torch is too low (or voltage is too low when using a torch height control). Adjust the torch or adjust the voltage in small increments (5 volts or less) until the dross is reduced. Duramax/Duramax Hyamp Robotic Torches Service Manual 807460...

  • Page 50: Straightness Of The Cut Surface

    Different material chemistries can have an adverse effect on the pierce capability of the system. In particular, high-strength steel with a high manganese or silicon content can reduce the maximum pierce capability. Hypertherm calculates mild steel parameters with certified A-36 plate.

  • Page 51: Common Machine-Cutting Faults

    The consumable life is shortened.  The gas setting is incorrect.  The arc current, arc voltage, travel speed, and other variables are not set as recommended in the cut charts. Duramax/Duramax Hyamp Robotic Torches Service Manual 807460...
  • Page 52 The air quality is poor (oil or water in the air).  There might be a faulty pilot arc IGBT, which can shorten nozzle life.  The swirl ring or retaining cap is worn and needs to be replaced. Duramax/Duramax Hyamp Robotic Torches Service Manual 807460...

  • Page 53: Component Replacement

    The instructions to replace components in all 6 models of robotic torches (180°, 90°, and 45°) are very similar. Any differences are noted in the steps. The 45° Duramax and Duramax Hyamp robotic torches are shown in the figures that follow.
  • Page 54 3 Cap-sensor switch 9 Left half of the positioning barrel 4 Pilot terminal screw 10 Torch lead 5 Torch body (torch head and gas tube) 11 Strain relief 6 Gas supply tube fitting Duramax/Duramax Hyamp Robotic Torches Service Manual 807460...

  • Page 55: Disconnect The Power, Gas Supply, And Torch

    1. Turn the plasma power supply switch to OFF (O). 2. Turn the line disconnect switch to OFF (O). 3. Disconnect the gas supply hose from the plasma power supply. 4. Disconnect the torch from the plasma power supply. Figure 23 Duramax/Duramax Hyamp Robotic Torches Service Manual 807460...

  • Page 56: Replacing The Positioning Barrel

    4 – Component Replacement Replacing the positioning barrel Description 228856 Kit: Duramax 180° robotic torch positioning barrel replacement 228857 Kit: Duramax 90° robotic torch positioning barrel replacement 228858 Kit: Duramax 45° robotic torch positioning barrel replacement 428295 Kit: Duramax Hyamp 180° robotic torch barrel replacement 428294 Kit: Duramax Hyamp 90°...
  • Page 57 4 – Component Replacement Figure 24 – Duramax 45° (top) and Duramax Hyamp 45° (bottom) 1 Cap-sensor switch mounting post 3 Gas fitting flange slot 2 Cap-sensor switch post hole 4 Strain relief slot Install the positioning barrel 1. Lay the right half of the positioning barrel on a flat surface with the inside facing up.
  • Page 58 1 Pilot arc wire terminal 4 Gas fitting flange 2 Cap-sensor switch 5 Strain relief slot 3 Cap-sensor switch connector Figure 26 – Duramax Hyamp wire routing 1 Pilot arc wire terminal 4 Gas fitting flange 2 Cap-sensor switch 5 Strain relief slot 3 Cap-sensor switch connector 5.

  • Page 59: Replacing The Torch Body

    Kit: Duramax 90° robotic torch main body replacement 228855 Kit: Duramax 45° robotic torch main body replacement 428298 Kit: Duramax Hyamp 180° robotic torch main body replacement 428297 Kit: Duramax Hyamp 90° robotic torch main body replacement 428296 Kit: Duramax Hyamp 45° robotic torch main body replacement 1.
  • Page 60 9. Complete the following procedures: a. Install all of the torch components that you removed. See Install the positioning barrel on page 57. b. Reconnect the torch and gas supply, and turn ON (I) the power. Duramax/Duramax Hyamp Robotic Torches Service Manual 807460...

  • Page 61: Replacing The Cap-Sensor Switch

    4. Complete the following procedures: a. Install all of the torch components that you removed. See Install the positioning barrel on page 57. b. Reconnect the torch and gas supply, and turn ON (I) the power. Duramax/Duramax Hyamp Robotic Torches Service Manual 807460...

  • Page 62: Replacing The Torch Lead

    228852 Kit: Robotic torch lead replacement, 7.6 m (25 feet) 428292 Kit: Duramax Hyamp robotic torch lead replacement, 7.6 m (25 feet) 1. Complete the following procedures: a. See Disconnect the power, gas supply, and torch on page 55. b. Remove all components from the torch. See Remove the positioning barrel on page 56.
  • Page 63 8. Route the pilot arc wire under the gas tube. (See Figure 25 and Figure 26.) 9. Tighten the pilot terminal screw to 17.3 kg∙cm (15 inch∙pounds).  The wire should go slightly down into the positioning barrel. 10. Connect the cap-sensor switch. Duramax/Duramax Hyamp Robotic Torches Service Manual 807460...
  • Page 64 11. Complete the following procedures: a. Install all of the components that you removed. See Install the positioning barrel on page 57. b. Reconnect the torch and gas supply, and turn ON (I) the power. Duramax/Duramax Hyamp Robotic Torches Service Manual 807460...

  • Page 65: Maintenance And Parts

    Section 5 Maintenance and Parts Perform routine maintenance WARNING! ELECTRIC SHOCK CAN KILL Disconnect electrical power before performing any maintenance. See the Safety and Compliance Manual (80669C) for more safety precautions. Duramax/Duramax Hyamp Robotic Torches Service Manual 807460...

  • Page 66: Routine Maintenance Tasks

    Inspect the torch lead. Replace if damaged. Inspect the power cord and plug. Replace if damaged. Every 6 months: Clean the inside of the power supply with moisture-free compressed air or a vacuum. Duramax/Duramax Hyamp Robotic Torches Service Manual 807460...

  • Page 67: Inspect The Consumables

    Duramax Hyamp: If the length of the 220997 swirl ring is less than 32 mm (1.27 inches), replace it. Duramax: If the length of the 220994 or 220857 swirl ring is less than 30.5 mm (1.20 inches), replace it. The surface for damage, wear, or a lack If the O-ring is dry, lubricate it and the of lubrication.

  • Page 68: Duramax Robotic Torch Replacement Parts

    5 – Maintenance and Parts Duramax robotic torch replacement parts Duramax 180° robotic torch The entire Duramax 180° robotic torch assembly with leads can be replaced, or individual component parts can be replaced. Part Number Description 059466 Duramax 180° robotic torch assembly with leads, 7.6 m (25 feet) 228856 Kit: Duramax 180°...

  • Page 69: Duramax 90° Robotic Torch

    5 – Maintenance and Parts Duramax 90° robotic torch The entire Duramax 90° robotic torch assembly with leads can be replaced, or individual component parts can be replaced. Part Number Description 059465 90° Duramax robotic torch assembly with leads, 7.6 m (25 feet) 228857 Kit: Duramax 90°...

  • Page 70: Duramax 45° Robotic Torch

    5 – Maintenance and Parts Duramax 45° robotic torch The entire Duramax 45° robotic torch assembly with leads can be replaced, or individual component parts can be replaced. Part Number Description 059464 Duramax 45° robotic torch assembly with leads, 7.6 m (25 feet) 228858 Kit: Duramax 45°...

  • Page 71: Duramax Hyamp Robotic Torch Replacement Parts

    5 – Maintenance and Parts Duramax Hyamp robotic torch replacement parts Duramax Hyamp 180° robotic torch The entire Duramax Hyamp 180° robotic torch assembly with leads can be replaced, or individual component parts can be replaced. Part Number Description 059566 Duramax Hyamp 180°...

  • Page 72: Duramax Hyamp 90° Robotic Torch

    5 – Maintenance and Parts Duramax Hyamp 90° robotic torch The entire Duramax Hyamp 90° robotic torch assembly with leads can be replaced, or individual component parts can be replaced. Part Number Description 059565 Duramax Hyamp 90° robotic torch assembly with leads, 7.6 m (25 feet) 428294 Kit: Duramax Hyamp 90°...

  • Page 73: Duramax Hyamp 45° Robotic Torch

    5 – Maintenance and Parts Duramax Hyamp 45° robotic torch The entire Duramax Hyamp 45° robotic torch assembly with leads can be replaced, or individual component parts can be replaced. Part Number Description 059564 Duramax Hyamp 45° robotic torch assembly with leads, 7.6 m (25 feet) 428293 Kit: Duramax Hyamp 45°...

  • Page 74: Accessory Parts

    Part Number Description 024548 Brown leather torch sheathing, 7.6 m (25 feet) 024877 Black leather torch sheathing with Hypertherm logo, 7.6 m (25 feet) 228806 Kit: Robotic clamp torch assembly 229456 Duramax robotic torch teach assembly Duramax/Duramax Hyamp Robotic Torches Service Manual 807460...

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