Hypertherm Powermax125 Operator's Manual
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Hypertherm Powermax125 Operator's Manual

Plasma arc cutting system
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808080 | Revision 0 | English

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  • Page 1 Powermax125 ® Plasma Arc Cutting System Operator Manual 808080 | Revision 0 | English...
  • Page 2 ____________________________________________________________________________ ____________________________________________________________________________ Powermax, Duramax, Smart Sense, FastConnect, FineCut, 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. © 2013 Hypertherm Inc.

  • Page 3: Operator Manual

    Powermax125 Operator Manual 808080 Revision 0 English December 2013 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-16 1 Specifications ..........................17 Safety information ..................................17 Powermax125 System description ............................17 Power supply dimensions ................................18 Component weights (125 A systems) ............................. 19 Hypertherm power supply ratings ............................. 20 Powermax125 Operator Manual 808080 Revision 0...
  • Page 8 Prepare the electrical power ..............................29 Install a line-disconnect switch ............................29 Requirements for grounding .............................. 29 Power connection for the Powermax125 ..........................30 Three-phase power cord and plug installation ......................31 Extension cord recommendations ............................33 Engine-driven generator recommendations ........................33 Prepare the gas supply ................................
  • Page 9 Start a cut from the edge of the workpiece ..........................57 Pierce a workpiece ..................................58 Gouge a workpiece ..................................60 Gouge profile ..................................61 Varying the gouge profile ..............................62 125 A gouging profile chart ............................... 62 Common hand-cutting faults ..............................64 Powermax125 Operator Manual 808080 Revision 0...
  • Page 10 65 A shielded cutting – aluminum ............................ 89 45 A shielded consumables ............................... 90 45 A shielded cutting – mild steel ............................ 91 45 A shielded cutting – stainless steel ........................... 92 45 A shielded cutting – aluminum ............................ 93 Powermax125 Operator Manual 808080 Revision 0...
  • Page 11 Common machine-cutting faults ............................. 105 8 Maintenance and Repair ......................107 Perform routine maintenance ..............................107 Routine maintenance tasks ............................... 108 Inspect the Powermax125 consumables ..........................109 Basic troubleshooting ................................110 Troubleshooting guide ............................... 110 Fault codes and solutions ................................. 111 Fault codes ...................................
  • Page 12 Duramax Hyamp 180° full-length machine torch replacement parts ................125 Duramax Hyamp 180° mini machine torch replacement parts ..................126 Machine torch consumables ..............................127 Shielded ....................................127 Gouging ....................................127 FineCut ....................................128 Accessory parts ..................................128 Powermax125 labels ................................. 129 Powermax125 Operator Manual 808080 Revision 0...

  • Page 13: Electromagnetic Compatibility (Emc

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

  • Page 14: 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 15: Warranty

    Products or as to the results which Hypertherm is notified of a defect (i) with respect to the may be obtained therefrom, and all implied warranties or...

  • Page 16: Patent Indemnity

    (and in any event no longer than fourteen appropriate to defend and to hold Hypertherm harmless in (14) days after learning of any action or threat of action), the event of any cause of action arising from the use of the and Hypertherm’s obligation to defend shall be...

  • Page 17: Specifications

    The Powermax125 is recommended for metal thicknesses up to 44 mm (1-3/4 inches), can sever up to 57 mm (2-1/4 inches), and can pierce thicknesses up to 25 mm (1 inch). FastConnect™ provides a simple push-button torch connection to the power supply for quick torch changes.

  • Page 18: Power Supply Dimensions

    1 – Specifications Powermax125 3-phase systems include the following models:  480 V CSA (480 V only)  600 V CSA (600 V only)  400 V CE (400 V only)  380 V CCC (380 V only) Power supply dimensions 432 mm (17.0 inches)

  • Page 19: Component Weights (125 A Systems)

    Table 3 – Work lead weights Work lead 7.6 m (25 feet) 3.6 kg (8 pounds) Work lead 15 m (50 feet) 6.6 kg (14.6 pounds) Work lead 23 m (75 feet) 9.6 kg (21.2 pounds) Powermax125 Operator Manual 808080 Revision 0...

  • Page 20: Hypertherm Power Supply Ratings

    It is the responsibility of the installer or user of the equipment to ensure, by consultation with the distribution network operator if necessary, that the equipment is connected only to a supply with a short-circuit power S greater than or equal to 5363 KVA. Powermax125 Operator Manual 808080 Revision 0...

  • Page 21: Duramax Hyamp 85° Hand Torch Dimensions

    3.5 cm 85° (4.5 inches) (1.375 inch) Duramax Hyamp 15° hand torch dimensions 29.5 cm (11.6 inches) 15° 5.85 cm 6.8 cm (2.3 inches) (2.68 inches) 3.5 cm (1.375 inch) 35.3 cm (13.9 inches) Powermax125 Operator Manual 808080 Revision 0...

  • Page 22: Duramax Hyamp 180° Full-Length Machine Torch Dimensions

    3.6 cm (1.4 inch) flat sides Duramax Hyamp 180° mini machine torch dimensions 18.3 cm (7.2 inches) 4.4 cm (1.75 inches) 3.5 cm (1.375 inch) 4.2 cm (1.6 inch) outer dimension, 3.6 cm (1.4 inch) flat sides Powermax125 Operator Manual 808080 Revision 0...

  • Page 23: Powermax125 Cutting Specifications

    Cut capacity speeds are not necessarily maximum speeds. They are the speeds that must be achieved to be rated at that thickness. Maximum cut speeds are the results of Hypertherm’s laboratory testing. Actual cutting speeds may vary based on different cutting applications.

  • Page 24: Symbols And Markings

    Symbols and markings Your Hypertherm product may have one or more of the following markings on or near the data plate. Due to differences and conflicts in national regulations, not all marks are applied to every version of a product.

  • Page 25: Noise Levels

    Refer to Noise can damage hearing in the Safety and Compliance Manual (80669C) included with your system. In addition, you can find an Acoustical Noise Data Sheet for your system in the Hypertherm downloads library at https://www.hypertherm.com: 1.

  • Page 26: Iec Symbols

    Inlet gas pressure fault (LCD) Gouging Missing or loose consumables (LCD) AC input power connection Power supply is out of temperature range (LCD) The terminal for the external protective (earth) conductor Power is ON Power is OFF Powermax125 Operator Manual 808080 Revision 0...

  • Page 27: Power Supply Setup

    Claims for damage during shipment – If your unit was damaged during shipment, you must file a claim with the carrier. Hypertherm will furnish you with a copy of the bill of lading upon request. If you need additional assistance, call the nearest Hypertherm office listed in the front of this manual.

  • Page 28: Contents

    380 V (3-phase, CCC certified) CSA and CE certified power supplies include a 3 m (10 foot) power cord (depending on the model). CCC certified power supplies do not ship with a power cord. Powermax125 Operator Manual 808080 Revision 0...

  • Page 29: Prepare The Electrical Power

    To avoid toppling, do not set the power supply on an incline greater than 10 degrees. Prepare the electrical power Hypertherm (designated HYP on the data plate) input current ratings are used to determine conductor sizes for power connection and installation instructions. The HYP rating is determined under maximum normal operating conditions, and the higher HYP input current value should be used for installation purposes.

  • Page 30: Power Connection For The Powermax125

    2 – Power Supply Setup Power connection for the Powermax125 Powermax125 3-phase systems are available in the following fixed-voltage configurations:  480 V CSA  600 V CSA  400 V CE  380 V CCC The Hypertherm rated output is 30 – 125 A, 175 VDC.

  • Page 31: Three-Phase Power Cord And Plug Installation

    Input current (A) at rated output (21.9 kW) Input current (A) at arc stretch Fuse, slow-blow (A) Three-phase power cord and plug installation Powermax125 power supplies ship with the following power cords:  CSA models: 8 AWG 4-wire power cord (no power plug included) ...
  • Page 32 419 mm (16.5 inches) Ground 6 mm (0.25 inch) 203 mm (8 inches) Route lead through strain relief and tighten CSA/CCC power cords CE power cord (no ferrite cores) (ferrite cores on power wires and ground wire) Powermax125 Operator Manual 808080 Revision 0...

  • Page 33: Extension Cord Recommendations

    3 – 45 m (10 – 150 feet) is 10 mm (8 AWG). Engine-driven generator recommendations Generators used with the Powermax125 should satisfy the voltage requirements in the following table and in Hypertherm power supply ratings on page 20. Engine drive rating...

  • Page 34: Prepare The Gas Supply

    When site conditions introduce moisture, oil, or other contaminants into the gas line, use a 3-stage coalescing filtration system, such as the Eliminizer filter kit (228890) available from Hypertherm distributors. A 3-stage filtering system works as follows to clean contaminants from the gas supply.

  • Page 35: Connect The Gas Supply

    5.9 – 9.3 bar (85 – 135 psi). WARNING! Do not allow the gas supply pressure to exceed 9.3 bar (135 psi). The filter bowl may explode if this pressure is exceeded. Powermax125 Operator Manual 808080 Revision 0...

  • Page 36: Minimum Inlet Pressure (While Gas Is Flowing)

    • 5.9 bar (85 psi) for 7.6 m (25 foot) and 15 m (50 foot) torches • 6.6 bar (95 psi) for 23 m (75 foot) torches Gouging 212 slpm (450 scfh, 7.5 scfm) at a minimum 4.1 bar (60 psi) Powermax125 Operator Manual 808080 Revision 0...

  • Page 37: Basic System Operations

    LEDs, and a status screen. These controls and indicators are described on the following pages. Rear controls ON (I)/OFF (O) power switch – Activates the power supply and its control circuits. Powermax125 Operator Manual 808080 Revision 0...

  • Page 38: Front Controls And Leds

    When you reset the power, the power supply remembers the previous mode, gas pressure, and amperage settings. Current/gas selector – When in manual mode, this selector toggles between amperage and gas pressure for manual adjustments using the adjustment knob. Powermax125 Operator Manual 808080 Revision 0...

  • Page 39: Operating Mode Switch

    2 Torch start 8 Current selection cursor 3 Fault icon 9 Current setting (amperage) 4 Fault code 10 Electrode end of life detection manually disabled 5 Visual pressure setting 11 Remote connected 6 Pressure setting Powermax125 Operator Manual 808080 Revision 0...

  • Page 40: Gas Pressure Indicators

    Fault icon – The fault icons that appear on the left side of the status screen are described below. A fault code also appears to identify the fault. Refer to the troubleshooting information later in this manual. Warning – The system continues to run. Powermax125 Operator Manual 808080 Revision 0...
  • Page 41 Fault – The system stops cutting. If you cannot correct the problem and restart the system, contact your distributor or Hypertherm Technical Service. Error – The system requires service. Contact your distributor or Hypertherm Technical Service. Torch cap sensor – Indicates that the consumables are loose, improperly installed, or missing.

  • Page 42: Operating The Powermax

    FastConnect connector into the receptacle on the front of the power supply. You will attach the work lead in the next step. Power cord (does not Torch lead ship with plug) Gas supply line Work lead  CCC units do not ship with a power cord. Powermax125 Operator Manual 808080 Revision 0...

  • Page 43: Attach The Work Lead To The Power Supply

    Make sure you use a work lead that is appropriate for your power supply. Use a 125 A work lead with the Powermax125. The amperage is marked near the rubber boot of the work lead connector. 1. Insert the work lead connector into the receptacle on the front of the power supply.

  • Page 44: Attach The Ground Clamp To The Workpiece

    For the best cut quality, attach the ground clamp as close as possible to the area being cut. Ground clamp CAUTION! Do not attach the ground clamp to the portion of the workpiece to be cut away. Turn on the system Set the ON/OFF switch to the ON (I) position. Powermax125 Operator Manual 808080 Revision 0...

  • Page 45: Set The Operating Mode Switch

    If a fault icon appears in the status screen, or the Fault LED is illuminated, or the power ON LED is blinking, correct the fault condition before continuing. More troubleshooting information is included later in this manual. Powermax125 Operator Manual 808080 Revision 0...

  • Page 46: Manually Adjusting The Gas Pressure

    When you switch between manual mode and automatic mode, the power supply retains the amperage setting. When you reset the power, the power supply returns to the previous mode (automatic mode or manual mode) and remembers the previous amperage setting. Powermax125 Operator Manual 808080 Revision 0...

  • Page 47: Electrode End-Of-Life Detection Feature

    3. To re-enable the feature, press the current/gas selector button five times again in quick succession, less than one second apart. The icon disappears. Figure 1 – Front panel controls Electrode end-of-life detection manually disabled Current/gas selector Powermax125 Operator Manual 808080 Revision 0...

  • Page 48: Understanding Duty-Cycle Limitations

     At 125 A (480/600 V CSA, 400 V CE, 380 V CCC), the arc can remain on for 10 minutes out of 10 minutes without causing the unit to overheat (100% duty cycle). Powermax125 Operator Manual 808080 Revision 0...

  • Page 49: Hand Torch Setup

    Hand Torch Setup Introduction Duramax Hyamp series hand torches are available for Powermax125 systems. The FastConnect quick-disconnect system makes it easy to remove the torch for transport or to switch from one torch to the other if your applications require the use of different torches.

  • Page 50: Hand Torch Components

    Safety trigger Choose the hand torch consumables Hypertherm includes a starter consumable kit and a box of spare electrodes and nozzles with your system. Both styles of hand torches shown above use the same consumables. Hand torches use shielded consumables. Therefore, you can drag the torch tip along the metal.

  • Page 51: Drag-Cutting 105/125 A Consumables

    420169 (65 A) Swirl ring Electrode Nozzle Gouging consumables 420112 220977 420001 220997 220971 Shield Retaining cap Nozzle Swirl ring Electrode FineCut consumables 420152 220977 420151 420159 220971 Shield Retaining cap Nozzle Swirl ring Electrode Powermax125 Operator Manual 808080 Revision 0...

  • Page 52: Install The Hand Torch Consumables

    To operate the hand torch, a complete set of consumable parts must be installed: shield, retaining cap, nozzle, electrode, and swirl ring. Torches ship without consumables installed. Pull off the vinyl cap before installing your consumables. With the power switch in the OFF (O) position, install the Powermax125 torch consumables as shown. Electrode...

  • Page 53: Connecting The Torch Lead

    When connecting or disconnecting a torch, first turn OFF the system. To connect the torch, push the connector into the receptacle on the front of the power supply. To remove the torch, press the red button on the connector and pull the connector out of the receptacle. Red button Powermax125 Operator Manual 808080 Revision 0...
  • Page 54 4 – Hand Torch Setup Powermax125 Operator Manual 808080 Revision 0...

  • Page 55: Hand Cutting

    Keep hands, clothing, and objects away from the torch tip.  Do not hold the workpiece and keep your hands clear of the cutting path.  Never point the torch toward yourself or others. Powermax125 Operator Manual 808080 Revision 0...

  • Page 56: Operate The Safety Trigger

    With either hand torch, hold the torch nozzle perpendicular to the workpiece so that the nozzle is at a 90° angle to the cutting surface. Observe the cutting arc as the torch cuts. 90° Powermax125 Operator Manual 808080 Revision 0...

  • Page 57: Start A Cut From The Edge Of The Workpiece

    1. With the ground clamp attached to the workpiece, hold the torch nozzle perpendicular (90°) to the edge of the workpiece. 2. Press the torch’s trigger to start the arc. Pause at the edge until the arc has cut completely through the workpiece. Powermax125 Operator Manual 808080 Revision 0...

  • Page 58: Pierce A Workpiece

    1. With the ground clamp attached to the workpiece, hold the torch at an approximate 30° angle to the workpiece with the torch tip within 1.5 mm (1/16 inch) of the workpiece before firing the torch. Powermax125 Operator Manual 808080 Revision 0...
  • Page 59 3. Hold the torch in place while continuing to press the trigger. When sparks exit below the workpiece, the arc has pierced the material. 4. When the pierce is complete, drag the nozzle lightly along the workpiece to proceed with the cut. Powermax125 Operator Manual 808080 Revision 0...

  • Page 60: Gouge A Workpiece

    4. Maintain the same angle to the workpiece as you feed into the gouge. Push the plasma arc in the direction of the gouge you want to create. Keep a small distance between the torch tip and the molten metal to avoid reducing consumable life or damaging the torch. Direction of travel Powermax125 Operator Manual 808080 Revision 0...

  • Page 61: Gouge Profile

    6.4 – 10.2 mm (1/4 – 2/5 inch) 30 – 35° Angle Typical gouging profile 125 A Depth Width 7.6 mm (0.3 inch) 10 mm (0.4 inch.) Metal removal rate on mild steel 12.5 kg/hour (27 pounds/hour) Powermax125 Operator Manual 808080 Revision 0...

  • Page 62: Varying The Gouge Profile

    Torch angle (mm) (mm/min) (mm) (mm) ratio 1.06 1.16 1016 1.21 1270 1.38 30° 1.30 1.43 10.1 1016 1.50 1270 1.66 0.92 1.13 1016 1.26 1270 1.24 35° 1.12 1.30 10.1 1016 1.12 1270 1.35 Powermax125 Operator Manual 808080 Revision 0...
  • Page 63 0.40 0.19 0.29 1.50 0.17 0.28 1.66 0.30 0.27 0.92 0.23 0.26 1.13 0.25 0.18 0.22 1.26 0.17 0.21 1.24 35° 0.29 0.32 1.12 0.23 0.30 1.30 0.40 0.23 0.25 1.12 0.18 0.24 1.35 Powermax125 Operator Manual 808080 Revision 0...

  • Page 64: Common Hand-Cutting Faults

    The torch is moving too quickly or too slowly. The arc sputters and consumable life is shorter than expected. The causes can be:  Moisture in the gas supply.  Incorrect gas pressure.  Consumables incorrectly installed.  The consumables are worn. Powermax125 Operator Manual 808080 Revision 0...

  • Page 65: Machine Torch Setup

    1 to 3 hours for 125 A mechanized cutting, depending on the job. Cutting at lower amperages may yield longer consumable life. You will find more information about proper cutting techniques in Mechanized Cutting on page 97. Powermax125 Operator Manual 808080 Revision 0...

  • Page 66: Machine Torch Components

    Align the torch square to the plate.  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. Powermax125 Operator Manual 808080 Revision 0...

  • Page 67: Disassemble The Machine Torch

    3. If you are disassembling the full-length machine torch, unscrew the strain relief from the positioning sleeve. If you are disassembling the mini machine torch, unscrew the strain relief from the adapter. Slide the strain relief back along the torch lead. Powermax125 Operator Manual 808080 Revision 0...
  • Page 68 11. If you are disassembling a full-length machine torch, slide the positioning sleeve off the front of the torch lead. If you are disassembling a mini machine torch, slide the adapter off the front of the torch lead. Powermax125 Operator Manual 808080 Revision 0...

  • Page 69: Convert A Full-Length Machine Torch To A Mini Machine Torch

    4. Screw the adapter onto the coupler. 5. Reconnect the gas supply line to the torch lead. 6. Reattach the torch’s pilot wire to the torch body using the screw. 7. Reconnect the cap-sensor switch’s wire connector. Powermax125 Operator Manual 808080 Revision 0...

  • Page 70: Mount The Torch

    9. Attach the mounting sleeve to the torch body using the three screws. 10. Screw the coupler into the mounting sleeve. Powermax125 Operator Manual 808080 Revision 0...

  • Page 71: Choose The Machine Torch Consumables

    220977 220975 Swirl ring Electrode Shield Retaining cap Nozzle Mechanized shielded 45 A and 65 A consumables 220997 220971 420168 220977 420158 (45 A) Swirl ring Electrode Shield Retaining cap 420169 (65 A) Nozzle Powermax125 Operator Manual 808080 Revision 0...

  • Page 72: Mechanized Shielded With Ohmic 105 A/125 A Consumables

    420169 (65 A) Electrode retaining cap Nozzle Gouging consumables 220971 220997 420112 220977 420001 Electrode Swirl ring Shield Retaining cap Nozzle FineCut shielded consumables 220997 220971 420152 220977 420151 Swirl ring Electrode Shield Retaining cap Nozzle Powermax125 Operator Manual 808080 Revision 0...

  • Page 73: Finecut Shielded With Ohmic Consumables

    Mount the machine torch perpendicular to the workpiece in order to get a vertical cut. Use a square to align the torch at right angles to the workpiece. Mounting bracket  Position the mounting bracket as low on the torch as possible to minimize vibration at the tip of the torch. Powermax125 Operator Manual 808080 Revision 0...

  • Page 74: Connecting The Torch Lead

    When connecting or disconnecting a torch, first turn OFF the system. To connect the torch, push the connector into the receptacle on the front of the power supply. To remove the torch, press the red button on the connector and pull the connector out of the receptacle. Red button Powermax125 Operator Manual 808080 Revision 0...

  • Page 75: Using The Cut Charts

    Cold air flow rate – Plasma is off and the system is in a steady state with air flowing through the torch at the default system pressure.  Hypertherm collected the cut chart data under laboratory test conditions using new consumables. Powermax125 Operator Manual 808080 Revision 0...

  • Page 76: Estimated Kerf-Width Compensation

    Estimated kerf-width compensation The widths in the following tables are for reference. The data are obtained with the “Best Quality” settings. Differences between installations and material composition may cause actual results to vary from those shown in the tables. Estimated kerf-width compensation – Metric (mm) Thickness (mm) Process Mild steel...

  • Page 77: Estimated Kerf-Width Compensation - English (Inches)

    Estimated kerf-width compensation – English (inches) Thickness (inches) Process 22 GA 18 GA 14 GA 10 GA 3/16 1-1/4 1-1/2 Mild steel 125 A shielded 0.089 0.094 0.095 0.103 0.108 0.109 0.123 0.150 0.158 105 A shielded 0.080 0.088 0.091 0.094 0.099 0.103...

  • Page 78: 125 A Shielded Consumables

    6 – Machine Torch Setup 125 A shielded consumables 220997 220971 220976 220977 220975 Swirl ring Electrode Shield Retaining cap Nozzle 220997 220971 220976 420156 220975 Swirl ring Electrode Shield Ohmic-sensing Nozzle retaining cap Powermax125 Operator Manual 808080 Revision 0...

  • Page 79: 125 A Shielded Cutting - Mild Steel

    * You can pierce thicknesses up to 32 mm (1-1/4 inch) if your CNC software and torch height control system enable you to temporarily raise the torch in order to clear the puddle of dross that can form during the pierce. In Hypertherm’s Phoenix CNC software, for example, this function is referred to as the “puddle jump height.

  • Page 80: 125 A Shielded Cutting - Stainless Steel

    Best Quality Settings Production Settings Material Torch-to-Work Pierce Initial Pierce Height Thickness Distance Delay Time Cut Speed Voltage Cut Speed Voltage inches inches inches seconds volts volts 0.36 0.45 0.18 Edge Start 1-1/4 1-1/2 Powermax125 Operator Manual 808080 Revision 0...

  • Page 81: 125 A Shielded Cutting - Aluminum

    Best Quality Settings Production Settings Material Torch-to-Work Pierce Initial Pierce Height Thickness Distance Delay Time Cut Speed Voltage Cut Speed Voltage inches inches inches seconds volts volts 0.36 0.18 0.45 1-1/4 Edge Start 1-1/2 Powermax125 Operator Manual 808080 Revision 0...

  • Page 82: 105 A Shielded Consumables

    6 – Machine Torch Setup 105 A shielded consumables 220997 220971 220976 220977 220975 Swirl ring Electrode Shield Retaining cap Nozzle 220997 220971 220976 420156 220975 Swirl ring Electrode Shield Ohmic-sensing Nozzle retaining cap Powermax125 Operator Manual 808080 Revision 0...

  • Page 83: 105 A Shielded Cutting - Mild Steel

    Best Quality Settings Production Settings Material Torch-to-Work Pierce Initial Pierce Height Thickness Distance Delay Time Cut Speed Voltage Cut Speed Voltage inches inches inches seconds volts volts 0.36 0.75 0.75 0.18 0.45 Edge Start 1-1/4 Powermax125 Operator Manual 808080 Revision 0...

  • Page 84: 105 A Shielded Cutting - Stainless Steel

    English Best Quality Settings Production Settings Material Torch-to-Work Pierce Initial Pierce Height Thickness Distance Delay Time Cut Speed Voltage Cut Speed Voltage inches inches inches seconds volts volts 0.36 0.18 0.45 Edge Start 1-1/4 Powermax125 Operator Manual 808080 Revision 0...

  • Page 85: 105 A Shielded Cutting - Aluminum

    Best Quality Settings Production Settings Material Torch-to-Work Pierce Initial Pierce Height Thickness Distance Delay Time Cut Speed Voltage Cut Speed Voltage inches inches inches seconds volts volts 0.36 0.75 0.18 0.45 Edge Start 1-1/4 Powermax125 Operator Manual 808080 Revision 0...

  • Page 86: 65 A Shielded Consumables

    6 – Machine Torch Setup 65 A shielded consumables 420168 220977 420169 220997 220971 Shield Retaining cap Nozzle Swirl ring Electrode 420168 420156 420169 220997 220971 Shield Ohmic-sensing Nozzle Swirl ring Electrode retaining cap Powermax125 Operator Manual 808080 Revision 0...

  • Page 87: 65 A Shielded Cutting - Mild Steel

    Production Settings Material Torch-to-Work Pierce Initial Pierce Height Thickness Distance Delay Time Cut Speed Voltage Cut Speed Voltage inches inches inches seconds volts volts 16 GA 10 GA 3/16 0.15 0.06 0.18 0.24 Edge Start Powermax125 Operator Manual 808080 Revision 0...

  • Page 88: 65 A Shielded Cutting - Stainless Steel

    Production Settings Material Torch-to-Work Pierce Initial Pierce Height Thickness Distance Delay Time Cut Speed Voltage Cut Speed Voltage inches inches inches seconds volts volts 16 GA 10 GA 3/16 0.15 0.06 0.18 Edge Start Powermax125 Operator Manual 808080 Revision 0...

  • Page 89: Shielded Cutting - Aluminum

    English Best Quality Settings Production Settings Material Torch-to-Work Pierce Initial Pierce Height Thickness Distance Delay Time Cut Speed Voltage Cut Speed Voltage inches inches inches seconds volts volts 1/16 0.15 0.06 0.18 Edge Start Powermax125 Operator Manual 808080 Revision 0...

  • Page 90: 45 A Shielded Consumables

    6 – Machine Torch Setup 45 A shielded consumables 420168 220977 420158 220997 220971 Shield Retaining cap Nozzle Swirl ring Electrode 420168 420156 420158 220997 220971 Shield Ohmic-sensing Nozzle Swirl ring Electrode retaining cap Powermax125 Operator Manual 808080 Revision 0...

  • Page 91: 45 A Shielded Cutting - Mild Steel

    Distance Delay Time Cut Speed Voltage Cut Speed Voltage inches inches inches seconds volts volts 26 GA 22 GA 0.02 0.08 18 GA 16 GA 14 GA 12 GA 10 GA 0.06 0.15 3/16 Powermax125 Operator Manual 808080 Revision 0...

  • Page 92: 45 A Shielded Cutting - Stainless Steel

    Distance Delay Time Cut Speed Voltage Cut Speed Voltage inches inches inches seconds volts volts 26 GA 22 GA 0.02 0.08 18 GA 16 GA 14 GA 12 GA 10 GA 0.06 0.15 3/16 Powermax125 Operator Manual 808080 Revision 0...

  • Page 93: Shielded Cutting - Aluminum

    2795 English Best Quality Settings Production Settings Material Torch-to-Work Pierce Initial Pierce Height Thickness Distance Delay Time Cut Speed Voltage Cut Speed Voltage inches inches inches seconds volts volts 1/32 1/16 3/32 0.06 0.15 Powermax125 Operator Manual 808080 Revision 0...

  • Page 94: Finecut Consumables

    6 – Machine Torch Setup FineCut consumables 220997 220971 420152 220977 420151 Swirl ring Electrode Shield Retaining cap Nozzle 420152 420156 420151 220997 220971 Swirl ring Electrode Shield Ohmic-sensing Nozzle retaining cap Powermax125 Operator Manual 808080 Revision 0...

  • Page 95: Finecut - Mild Steel

    Initial Pierce Height Thickness Distance Time Cut Speed Voltage inches inches inches seconds volts 26 GA 24 GA 22 GA 20 GA 18 GA 0.06 0.09 16 GA 14 GA 12 GA 10 GA Powermax125 Operator Manual 808080 Revision 0...

  • Page 96: Finecut - Stainless Steel

    Initial Pierce Height Thickness Distance Time Cut Speed Voltage inches inches inches seconds volts 26 GA 24 GA 22 GA 20 GA 18 GA 0.02 0.08 16 GA 14 GA 12 GA 10 GA Powermax125 Operator Manual 808080 Revision 0...

  • Page 97: Mechanized Cutting

    Part number 128651: 15 m (50 feet)  Part number 128652: 23 m (75 feet) Remove the machine interface receptacle cover on the rear of the power supply, and plug the Hypertherm remote-start pendant into the receptacle.  The remote-start pendant is for use only with a machine torch. It will not operate if a handheld torch is installed.

  • Page 98: Connecting The Machine Interface Cable

    Connecting the machine interface cable The Powermax125 is equipped with a factory-installed five-position voltage divider board. The built-in voltage divider provides a scaled down arc voltage of 20:1, 21.1:1, 30:1, 40:1, or 50:1 (maximum output of 16 V). A receptacle on the rear of the power supply (see the previous illustration) provides access to the scaled down arc voltage and signals for arc transfer and plasma start.
  • Page 99 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 100: 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). Powermax125 Operator Manual 808080 Revision 0...

  • Page 101: 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. Powermax125 Operator Manual 808080 Revision 0...

  • Page 102: Accessing Raw Arc Voltage

    If your power supply is not equipped with the RS-485 connector, order kit 228539, “Powermax65/85/105/125 RS-485 board with cables”. Follow the installation instructions in the Power Supply Component Replacement section of the Powermax125 Service Manual (808070), which you can download from the Downloads Library at www.hypertherm.com. With the RS-485 connector installed: 1.

  • Page 103: Serial Port Cables

     223237 – RS-485 cable, unterminated, 15 m (50 feet)  223239 – RS-485 cable, 9-pin D-sub connector for Hypertherm controls, 7.6 m (25 feet)  223240 – RS-485 cable, 9-pin D-sub connector for Hypertherm controls, 15 m (50 feet)

  • Page 104: Cut Or Bevel Angle

    Low-speed dross forms when the torch’s cutting speed is too slow and the arc angles ahead. It forms as a heavy, bubbly deposit at the bottom of the cut and can be removed easily. Increase the speed to reduce this type of dross. Powermax125 Operator Manual 808080 Revision 0...

  • Page 105: Piercing A Workpiece Using The Machine Torch

    Piercing may result in a shorter consumable life than with edge starts. The cut charts include a column for the recommended torch height when starting a pierce. For the Powermax125, the pierce height is generally between 1.5 and 4 times the cut height. Refer to the cut charts for specific values.
  • Page 106  There might be a faulty pilot arc IGBT, which can shorten nozzle life (refer to Maintenance and Repair on page 107, or contact your closest Hypertherm technical service in the front of this manual).  The swirl ring or retaining cap is worn and needs to be replaced.

  • Page 107: Maintenance And Repair

    All work requiring removal of the power supply cover must be performed by a qualified technician. Read the separate Safety and Compliance Manual included with your system for more safety precautions. Powermax125 Operator Manual 808080 Revision 0...

  • Page 108: Routine Maintenance Tasks

    Inspect the screws on the machine torch that connect the torch body to the mounting sleeve. Tighten the screws, if needed. Every 6 months: Clean the inside of the power supply with moisture-free compressed air or a vacuum. Powermax125 Operator Manual 808080 Revision 0...

  • Page 109: Inspect The Powermax125 Consumables

    If the o-ring is dry, lubricate it and the of lubrication. threads with a thin layer of silicone lubricant. If the o-ring is worn or damaged, replace it. (See Parts on page 117.) Torch o-ring Powermax125 Operator Manual 808080 Revision 0...

  • Page 110: Basic Troubleshooting

    If you are unable to fix the problem by following this basic troubleshooting guide, or if you need further assistance: 1. Call your Hypertherm distributor or authorized Hypertherm repair facility. 2. Call the nearest Hypertherm office listed in the front of this manual. Troubleshooting guide...

  • Page 111: Fault Codes And Solutions

    Cutting on page 97. • Inspect the consumables for wear and replace as necessary. See Inspect the Powermax125 consumables on page 109. • Check the air pressure and air quality. • Verify that the cutting mode switch is in the proper position for the cutting operation.
  • Page 112 Contact your Hypertherm distributor or authorized repair facility. 0-32 End of consumable life • Replace the electrode and nozzle. • Check the remaining consumables for wear and replace as needed. Powermax125 Operator Manual 808080 Revision 0...
  • Page 113 DSP board. 0-99 System hardware fault – • A qualified service technician must service service required the system. Contact your distributor or authorized repair facility. Indicates a major fault with the system. Powermax125 Operator Manual 808080 Revision 0...

  • Page 114: Display The Service Screen

    (*) indicates the selected field. To exit the service screen, simultaneously press the automatic/manual and current/gas mode selectors. The operator screen displays. Designator Description Current set/read LCD contrast LCD brightness (percent) Pressure set/read Gas test enable (1)/disable (0) Powermax125 Operator Manual 808080 Revision 0...

  • Page 115: Run A Gas Test

    3. Use the adjustment knob to set the gas test field from 0 to 1. If gas does not flow, call your Hypertherm distributor or authorized Hypertherm repair facility, or call the nearest Hypertherm office listed in the front of this manual.

  • Page 116: Replace The Gas Filter Element

    12. Once the bowl is seated properly, turn the bowl 45 degrees to the left until you hear the thumb latch click into place. 13. Reconnect the gas supply hose to the power supply and check for leaks. 14. Reconnect the electrical power, and turn ON the power switch. Powermax125 Operator Manual 808080 Revision 0...

  • Page 117: Parts

    Section 9 Parts Use the Hypertherm kit numbers in this section to order replacement parts, consumables, and accessories for your power supply, hand torch, and machine torch. For instructions on installing the gas filter element in the power supply, see Replace the gas filter element on page 116.

  • Page 118: Power Supply Parts

    Kit: Adjustment knob 228866 Kit: Powermax105/Powermax125 front panel 428141 Kit: Powermax105/Powermax125 cover screws 428115 Kit: Powermax125 CSA power supply cover with labels 428116 Kit: Powermax125 CE power supply cover with labels 428247 Kit: Powermax125 CCC power supply cover with labels 428142...

  • Page 119: Exterior, Rear

    Kit: Powermax105/Powermax125 CE power cord strain relief 428121 Kit: Powermax125 power cord 480/600 V CSA 228886 Kit: Powermax105 230 – 400 V CE/Powermax125 400 V CE power cord 228539 Kit: Serial interface port, internal cables, and RS-485 board 223236 RS-485 cable, unterminated, 7.6 m (25 feet)
  • Page 120 15 m (50 feet), D-sub connector with screws 128650 Remote start pendant for machine torch, 7.6 m (25 feet) 128651 Remote start pendant for machine torch, 15 m (50 feet) 128652 Remote start pendant for machine torch, 23 m (75 feet) Powermax125 Operator Manual 808080 Revision 0...

  • Page 121: Interior, Fan Side

    228695 Kit: Powermax65/85/105/125 air filter element (inside filter bowl) 228910 Kit: Powermax105/Powermax125 fan shroud 228881 Kit: Powermax105/Powermax125 fan assembly 228689 Kit: Powermax65/85/105/125 pressure transducer 228882 Kit: Powermax105/Powermax125 regulator/solenoid valve 228688 Kit: Powermax65/85/105/125 pressure switch Powermax125 Operator Manual 808080 Revision 0...

  • Page 122: Duramax Hyamp 85° Hand Torch Replacement Parts

    Kit: Duramax 85° torch handle replacement 428260 Kit: Duramax and Duramax Hyamp torch quick disconnect repair (lead side) * The torch assembly does not include consumables. See page 124 for a list of consumable part numbers. Powermax125 Operator Manual 808080 Revision 0...

  • Page 123: Duramax Hyamp 15° Hand Torch Replacement Parts

    Kit: Duramax Hyamp 15° torch handle replacement 428260 Kit: Duramax and Duramax Hyamp torch quick disconnect repair (lead side) * The torch assembly does not include consumables. See page 124 for a list of consumable part numbers. Powermax125 Operator Manual 808080 Revision 0...

  • Page 124: Hand Torch Consumables

    220997 Duramax Hyamp swirl ring FineCut Part Number Description 420152 Duramax Hyamp FineCut shield 220977 Duramax Hyamp retaining cap 420151 Duramax Hyamp FineCut nozzle 220971 Duramax Hyamp electrode 420159 Duramax Hyamp FineCut swirl ring Powermax125 Operator Manual 808080 Revision 0...

  • Page 125: Duramax Hyamp 180° Full-Length Machine Torch Replacement Parts

    Kit: Duramax Hyamp 180° machine torch main body replacement 428149 Kit: Duramax Hyamp 180° machine torch lead replacement, 4.6 m (15 feet) 428150 Kit: Duramax Hyamp 180° machine torch lead replacement, 7.6 m (25 feet) Powermax125 Operator Manual 808080 Revision 0...

  • Page 126: Duramax Hyamp 180° Mini Machine Torch Replacement Parts

    Duramax Hyamp 180° mini machine torch assembly with 15 m (50 foot) lead 428146 Kit: Duramax Hyamp 180° mini machine torch adapter ring 428248 Kit: Duramax Hyamp 180° machine torch coupler 428145 Kit: Duramax Hyamp 180° machine torch mounting sleeve Powermax125 Operator Manual 808080 Revision 0...

  • Page 127: Machine Torch Consumables

    Duramax Hyamp electrode 220997 Duramax Hyamp swirl ring Gouging Part Number Description 420112 Duramax Hyamp gouging shield 220977 Duramax Hyamp retaining cap 420001 Duramax Hyamp gouging nozzle 220971 Duramax Hyamp electrode 220997 Duramax Hyamp swirl ring Powermax125 Operator Manual 808080 Revision 0...

  • Page 128: Finecut

    Accessory parts Part Number Description 024548 Brown leather torch sheathing, 7.6 m (25 foot) 024877 Black leather torch sheathing with Hypertherm logo, 7.6 m (25 foot) 127360 Powermax105/125 dust cover 228695 Kit: Powermax65/85/105/125 gas filter element 228890 Kit: Eliminizer gas filter with protective metal cover for the Powermax105/125...

  • Page 129: Powermax125 Labels

    428117 Kit: Powermax125 labels, CSA 428118 Kit: Powermax125 labels, CE 428257 Kit: Powermax125 labels, CCC The label kits include the consumables label, appropriate safety labels, display panel label, power switch label, and side decals. Powermax125 Operator Manual 808080 Revision 0...
  • Page 130 7. Ne pas enlever, détruire ni couvrir cette étiquette. Replace if it is missing, damaged, or worn. La remplacer si elle est absente, endommagée ou usée. (PN 110673 Rev D) (PN 110673 Rev D) CSA safety label Powermax125 Operator Manual 808080 Revision 0...

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