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Duramax Retrofit Torch
HRT, HRTs, and MRT for powermax1000 , powermax1250 , and powermax1650

Operator Manual 807190 Revision 3
Duramax Retrofit Torch

HRT, HRTs, and MRT for powermax1000 , powermax1250, and powermax1650
Operator Manual (P/N 807190)
Revision 3 May 2012
Hypertherm, Inc. Hanover, NH USA www.hypertherm.com email: info@hypertherm.com
2012 Hypertherm, Inc. All Rights Reserved Hypertherm, Powermax, and Duramax are trademarks of Hypertherm, Inc. andmayberegisteredintheUnited States and/or other countries.
Hypertherm, Inc. Etna Road, P.O. Box 5010 Hanover, NH 03755 USA 603-643-3441 Tel (Main Office) 603-643-5352 Fax (All Departments) info@hypertherm.com (Main Office Email) 800-643-9878 Tel (Technical Service) technical.service@hypertherm.com (Technical Service Email) 800-737-2978 Tel (Customer Service) customer.service@hypertherm.com (Customer Service Email) 866-643-7711 Tel (Return Materials Authorization) 877-371-2876 Fax (Return Materials Authorization) return.materials@hypertherm.com (RMA email) Hypertherm Automation 5 Technology Drive, Suite 300 West Lebanon, NH 03784 USA 603-298-7970 Tel 603-298-7977 Fax Hypertherm Plasmatechnik GmbH Technologiepark Hanau Rodenbacher Chaussee 6 D-63457 Hanau-Wolfgang, Deutschland 49 6181 58 2100 Tel 49 6181 58 2134 Fax 49 6181 58 2123 (Technical Service) Hypertherm (S) Pte Ltd. 82 Genting Lane Media Centre Annexe Block #A01-01 Singapore 349567, Republic of Singapore 65 6841 2489 Tel 65 6841 2490 Fax 65 6841 2489 (Technical Service) Hypertherm (Shanghai) Trading Co., Ltd. Unit A, 5th Floor, Careri Building 432 West Huai Hai Road Shanghai, 200052 PR China 86-21 5258 3330/1 Tel 86-21 5258 3332 Fax
Hypertherm Europe B.V. Vaartveld 9 4704 SE Roosendaal, Nederland 31 165 596907 Tel 31 165 596901 Fax 31 165 596908 Tel (Marketing) 31 165 596900 Tel (Technical Service) 00 800 4973 7843 Tel (Technical Service) Hypertherm Japan Ltd. Level 9, Edobori Center Building 2-1-1 Edobori, Nishi-ku Osaka 550-0002 Japan 81 6 6225 1183 Tel 81 6 6225 1184 Fax Hypertherm Brasil Ltda. Rua Bras Cubas, 231 Jardim Maia Guarulhos, SP - Brasil CEP 07115-030 55 11 2409 2636 Tel 55 11 2408 0462 Fax Hypertherm Mxico, S.A. de C.V. Avenida Toluca No. 444, Anexo 1, Colonia Olivar de los Padres Delegacin lvaro Obregn Mxico, D.F. C.P. 01780 52 55 5681 8109 Tel 52 55 5683 2127 Fax Hypertherm Korea Branch #3904 Centum Leaders Mark B/D, 1514 Woo-dong, Haeundae-gu, Busan Korea, 612-889 82 51 747 0358 Tel 82 51 701 0358 Fax
03/15/12
ELECTROMAGNETIC COMPATIBILITY (EMC) Introduction

Hypertherms CEmarked equipment is built in compliance with standard EN6097410. The equipment should be installed and used in accordance with the information be low to achieve electromagnetic compatibility. The limits required by EN60974-10 may not be adequate to completely eliminate interference when the affected equipment is in close proximity or has a high degree of sen sitivity. Insuch cases it may be nec essary to use other mea sures to further reduce interference. This cutting equipment is designed for use only in an industrial environment. area. The following shall be taken into account: a. Other supply cables, control cables, signalling and telephone cables; above, below and adjacent to the cutting equipment. b. Radio and television transmitters and receivers. c. Computer and other control equip ment. d. Safety critical equipment, for example guarding of industrial equipment. e. Health of the people around, for example the use of pacemakers and hearing aids. f. Equipment used for calibration or measurement. g. Immunity of other equipment in the environment. User shall ensure that other equipment being used in the environment is compatible. This may require additional protection measures. h. Time of day that cutting or other activities are to be carried out. The size of the surround ing area to be considered will depend on the structure of the building and other activities that are taking place. The surrounding area may extend beyond the bound aries of the premises.
Installation and use

The user is responsible for installing and using the plasma equipment according to the manufacturers instructions. If electromagnetic disturbances are detected then it shall be the responsibility of the user to resolve the situation with the technical assistance of the manufacturer. In some cases this remedial action may be as simple as earthing the cutting circuit, see Earthing of Workpiece. Inother cases it could involve constructing an electromagnetic screen enclosing the power source and the work complete with associated input filters. In all cases electromagnetic disturbances must be reduced to the point where they are no longer troublesome.
Methods of reducing emissions

Mains supply
Cutting equipment must be connected to the mains supply according to the manufacturers recommendations. If interference occurs, it may be necessary to take additional precautions
Assessment of area
Before installing the equipment the user shall make an assessment of potential electromagnetic problems in the surrounding
Compliance Information
EMC-1
9/10
Electromagnetic compatibility (emc)
such as filtering of the mains supply. Consideration should be given to shielding the supply cable of permanently installed cutting equipment, in metallic conduit or equivalent. Shielding should be electrically continuous throughout its length. The shielding should be connected to the cutting mains supply so that good electrical contact is maintained between the conduit and the cutting pow er source enclosure.
Earthing of workpiece
Where the workpiece is not bonded to earth for electrical safety, nor connected to earth because of its size and position, for example, ships hull or building steelwork, a connection bonding the work piece to earth may reduce emis sions in some, but not all instances. Careshould be taken to prevent the earthing ofthe workpiece increasing the risk of injury to users, or damage to other electrical equipment. Where necessary, the connection of the workpiece to earth should be made by a direct connection to the workpiece, but in some countries where direct connection is not permitted, the bonding should be achieved by suitable capacitances selected according to national regulations. Note: the cutting circuit may or may not be earthed for safety reasons. Changing the earthing arrangements should only be authorized by a person who is competent to assess whether the changes will increase the risk of injury, for example, by allowing parallel cutting current return paths which may damage the earth cir cuits of other equipment. Further guidance is provided in IEC 60974-9, Arc Welding Equip ment, Part 9: Installation and Use.
Maintenance of cutting equipment

The cutting equipment must be routinely maintained according to the manufacturers recommendations. All access and service doors and covers should be closed and properly fastened when the cutting equipment is in operation. The cutting equipment should not be modified in any way except as set forth in and in accordance with the manufacturers written instructions. For example, the spark gaps of arc striking and stabilizing devices should be adjusted and maintained according to the manufacturers recommendations.
Cutting cables
The cutting cables should be kept as short aspossible and should be positioned close together, running at or close to the floor level.
Equipotential bonding
Bonding of all metallic components in the cutting installation and adjacent to it should be considered. However, metallic com po nents bonded to the workpiece will increase the risk that the operator could receive a shock by touching these metallic components and the electrode (nozzle for laser heads) at the same time. The operator should be insulated from all such bonded metallic components.
Screening and shielding

Selective screening and shielding of other cables and equipment in the surrounding area may alleviate problems of interference. Screening of the entire plasma cutting installation may be con sid ered for special applications.
EMC-2
9/10
WARRANTY
Attention
Genuine Hypertherm parts are the factoryrecommended replacement parts for your Hypertherm system. Any damage or injury caused by the use of other than genuine Hypertherm parts may not be covered by the Hypertherm warranty, and will constitute misuse of the Hypertherm Product. You are solely responsible for the safe use of the Product. Hypertherm does not and cannot make any guarantee or warranty regarding the safe use of the product in your environment.
This warranty shall not apply to any Powermax brand power supplies that have been used with phase converters. In addition, Hypertherm does not warranty systems that have been damaged as a result of poor power quality, whether from phase converters or incoming line power. This warranty shall not apply to any Product which has been incorrectly installed, modified, or otherwise damaged. Hypertherm provides repair, replacement or adjustment of the Product as the sole and exclusive remedy, if and only if the warranty set forth herein properly is invoked and applies. Hypertherm, at its sole option, shall repair, replace, or adjust, free of charge, any defective Products covered by this warranty which shall be returned with Hypertherms prior authorization (which shall not be unreasonably withheld), properly packed, to Hypertherms place of business in Hanover, New Hampshire, or to an authorized Hypertherm repair facility, all costs, insurance and freight pre paid by the customer. Hypertherm shall not be liable for any repairs, replacement, or adjustments of Products covered by this warranty, except those made pursuant to this paragraph and with Hypertherms prior written consent. The warranty set forth above is exclusive and is in lieu of all other warranties, express, implied, statutory, or otherwise with respect to the Products or as to the results which may be obtained therefrom, and all implied warranties or conditions of quality or of merchantability or fitness for a particular purpose or against infringement. The foregoing shall constitute the sole and exclusive remedy for any breach by Hypertherm of its warranty.
General
Hypertherm, Inc. warrants that its Products shall be free from defects in materials and workmanship for the specific periods of time set forth herein and as follows: if Hypertherm is notified of a defect (i) with respect to the power supply within a period of two (2) years from the date of its delivery to you, with the exception of Powermax brand power supplies, which shall be within a period of three (3) years from the date of delivery to you, and (ii) with respect to the torch and leads within a period of one (1) year from its date of delivery to you, and with respect to torch lifter assemblies within a period of one (1) year from its date of delivery to you, and with respect to laser heads within a period of one (1) year from its date of delivery to you, and with respect to Automation products one (1) year from its date of delivery to you, with the exception of the EDGE Pro CNC and ArcGlide THC, which shall be within a period of two (2) years from the date of delivery to you.
W-1
9/10
Warranty
Distributors/OEMs may offer different or additional warranties, but Distributors/OEMs are not authorized to give any additional warranty protection to you or make any representation to you purporting to be binding upon Hypertherm.
Limitation of liability
In no event shall Hypertherm be liable to any person or entity for any incidental, consequential direct, indirect, punitive or exemplary damages (including but not limited to lost profits) regardless of whether such liability is based on breach of contract, tort, strict liability, breach of warranty, failure of essential purpose, or otherwise, and even if advised of the possibility of such damages.
Patent indemnity
Except only in cases of products not manufactured by Hypertherm or manufactured by a person other than Hypertherm not in strict conformity with Hypertherms specifications and in cases of designs, processes, formulae, or combinations not developed or purported to be developed by Hypertherm, Hypertherm will have the right to defend or settle, at its own expense, any suit or proceeding brought against you alleging that the use of the Hypertherm product, alone and not in combination with any other product not supplied by Hypertherm, infringes any patent of any third party. You shall notify Hypertherm promptly upon learning of any action or threatened action in connection with any such alleged infringement (and in any event no longer than fourteen (14) days after learning of any action or threat of action), and Hypertherms obligation to defend shall be conditioned upon Hypertherms sole control of, and the indemnified partys cooperation and assistance in, the defense of the claim.
National and local codes

National and local codes governing plumbing and electrical installation shall take precedence over any instructions contained in this manual. In no event shall Hypertherm be liable for injury to persons or property damage by reason of any code violation or poor work practices.
Liability cap
In no event shall Hypertherms liability, if any, whether such liability is based on breach of contract, tort, strict liability, breach of warranties, failure of essential purpose or otherwise, for any claim, action, suit or proceeding (whether in court, arbitration, regulatory proceeding or otherwise) arising out of or relating to the use of the Products exceed in the aggregate the amount paid for the Products that gave rise to such claim.
Insurance
At all times you will have and maintain insurance in such quantities and types, and with coverage sufficient and appropriate to defend and to hold Hypertherm harmless in the event of any cause of action arising from the use of the products.
W-2
9/10
Warranty
Transfer of rights
You may transfer any remaining rights you may have hereunder only in connection with the sale of all or substantially all of your assets or capital stock to a successor in interest who agrees to be bound by all of the terms and conditions of this Warranty. Within thirty (30) days before any such transfer occurs, you agree to notify in writing Hypertherm, which reserves the right of approval. Should you fail timely to notify Hypertherm and seek its approval as set forth herein, the Warranty set forth herein shall be null and void and you will have no further recourse against Hypertherm under the Warranty or otherwise.
W-3
9/10
Warranty
W-4
9/10
Safety information
Before operating any Hypertherm equipment, read the separate Safety and Compliance Manual (80669C) included with your product for important safety information.
Table of Contents
ELECTROMAGNETIC COMPATIBILITY (EMC) .....................................................................EMC-1 WARRANTY.........................................................................................................................................W-1 Safety information.................................................................................................................................. 1 Section 1 Specifications.......................................................................................................................................1-1 Component weights........................................................................................................................................... 1-2 Duramax HRT hand torch dimensions........................................................................................................... 1-2 Duramax HRTs hand torch dimensions......................................................................................................... 1-2 Duramax MRT full-length machine torch dimensions................................................................................. 1-3 Duramax MRT without positioning sleeve (mini torch)............................................................................... 1-3 Section 2 Torch Setup...........................................................................................................................................2-1 Introduction.......................................................................................................................................................... 2-2 Consumable life................................................................................................................................................... 2-2 Hand torch setup................................................................................................................................................ 2-3 Choose the hand torch consumables................................................................................................. 2-3 Hand torch consumables....................................................................................................................... 2-4 Install the hand torch consumables...................................................................................................... 2-5 Machine torch setup.......................................................................................................................................... 2-6 Converting a Duramax retrofit machine torch into a mini torch..................................................... 2-7 Mount the torch......................................................................................................................................... 2-9 Choose the machine torch consumables.........................................................................................2-12 Machine torch consumables................................................................................................................2-12 Install the machine torch consumables.............................................................................................2-15 Aligning the torch...................................................................................................................................2-15 Torch installation...............................................................................................................................................2-16 Section 3 Operation...............................................................................................................................................3-1 Using the cut charts........................................................................................................................................... 3-2 Estimated kerf-width compensation..................................................................................................... 3-2 100 amp mechanized shielded cutting for Powermax1650.......................................................... 3-5 85 amp mechanized shielded cutting for Powermax1650............................................................. 3-7 80 amp mechanized shielded cutting for Powermax1250/1650...............................................3-11
Duramax Retrofit Torch Operator Manual
Table of Contents
65 amp mechanized shielded cutting for Powermax1250/1650...............................................3-13 60 amp mechanized shielded cutting for Powermax1000/1250/1650....................................3-17 45 amp mechanized shielded cutting for Powermax1000/1250/1650....................................3-19 100 amp mechanized unshielded cutting for Powermax1650....................................................3-23 85 amp mechanized unshielded cutting for Powermax1650......................................................3-25 65 amp mechanized unshielded cutting for Powermax1250/1650...........................................3-29 45 amp mechanized unshielded cutting for Powermax1000/1250/1650...............................3-33 FineCut consumables for Powermax1000/1250/1650.............................................................3-37 Using the hand torch........................................................................................................................................3-42 Operate the safety trigger....................................................................................................................3-42 Hand torch cutting hints.......................................................................................................................3-43 Start a cut from the edge of the workpiece.....................................................................................3-44 Pierce a workpiece.................................................................................................................................3-45 Gouge a workpiece...............................................................................................................................3-46 Common hand-cutting faults...............................................................................................................3-49 Using the machine torch.................................................................................................................................3-50 Ensure the torch and table are set up correctly..............................................................................3-50 Understand and optimize cut quality..................................................................................................3-50 To pierce a workpiece using the machine torch.............................................................................3-53 Common machine-cutting faults.........................................................................................................3-53 Section 4 Maintenance and parts......................................................................................................................4-1 Perform routine maintenance........................................................................................................................... 4-2 Inspect the consumables.................................................................................................................................. 4-3 Hand torch replacement parts......................................................................................................................... 4-4 Machine torch replacement parts................................................................................................................... 4-6 Accessory parts.................................................................................................................................................. 4-7
ii
Section 1 Specifications
In this section:
Component weights........................................................................................................................................... 1-2 Duramax HRT hand torch dimensions........................................................................................................... 1-2 Duramax HRTs hand torch dimensions......................................................................................................... 1-2 Duramax MRT full-length machine torch dimensions................................................................................. 1-3 Duramax MRT without positioning sleeve (mini torch)............................................................................... 1-3
1-1
Specifications
Component weights
Torch type Hand torch 25 ft (7.6 m) Hand torch 50 ft (15 m) Machine torch 25 ft (7.6 m) Machine torch 50 ft (15 m) Weight lbs (kg) 7.1 (3.2) 12.5 (5.7) 7.6 (3.4) 13.2 (6.0)
Duramax HRT hand torch dimensions

9.9 in (25.2 cm)
3.8 in (9.8 cm)
75 angle 1.0 in (2.5 cm)
2.6 in (6.6 cm)
Duramax HRTs hand torch dimensions

10.2 in (25.9 cm) 15 angle
1.9 in (4.7 cm)
2.6 in (6.6 cm) 1.0 in (2.5 cm)
1-2
Specifications
Duramax MRT full-length machine torch dimensions

15.6 in (39.6 cm) 1.0 in (2.5 cm) 1.4 in (3.5 cm)
8.1 in (20.6 cm) 12.3 in (31.3 cm)
1.4 in (3.6 cm) outer dimension, 1.3 in (3.3cm) flat sides
Duramax MRT without positioning sleeve (mini torch)

6.6 in (16.8 cm) 1.0 in (2.5 cm) 1.4 in (3.5 cm)
3.3 in (8.4 cm)
1.4 in (3.6 cm) outer dimension, 1.3 in (3.3cm) flat sides
1-3
Specifications
1-4
Section 2 Torch Setup
In this section:
Introduction.......................................................................................................................................................... 2-2 Consumable life................................................................................................................................................... 2-2 Hand torch setup................................................................................................................................................ 2-3 Choose the hand torch consumables................................................................................................. 2-3 Hand torch consumables....................................................................................................................... 2-4 Install the hand torch consumables...................................................................................................... 2-5 Machine torch setup.......................................................................................................................................... 2-6 Converting a Duramax retrofit machine torch into a mini torch..................................................... 2-7 Mount the torch......................................................................................................................................... 2-9 Choose the machine torch consumables.........................................................................................2-12 Machine torch consumables................................................................................................................2-12 Install the machine torch consumables.............................................................................................2-15 Aligning the torch...................................................................................................................................2-15 Torch installation...............................................................................................................................................2-16
2-1
Torch setup
Introduction
Duramax series handheld and machine retrofit torches are available for the Powermax1000, Powermax1250, and Powermax1650 systems. The ETR (Easy Torch Removal) 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. The torches are cooled by ambient air and do not require special cooling procedures. This section explains how to setup your torch and choose the appropriate consumables for the job.
Consumable life
How often you need to change the consumables on your retrofit torch will depend on a number of factors: Thickness of the material the thicker the material being cut, the more often consumables need to be changed. Average length of cut the longer the average cut, the more often consumables need to be changed. Type of cutting handheld cutting will require more consumable changes than machine cutting. Air quality the presence of oil, moisture, or other contaminants will reduce consumable life. Piercing / edge starting piercing the metal causes more consumable wear then starting cuts from the edge of the metal. Proper torch-to-work distance when gouging or cutting with unshielded consumables, maintaining proper torch-to-work distance will result in better consumable life. Proper pierce height maintaining proper pierce height will result in better consumable life. Cutting in continuous pilot arc mode or normal cutting mode cutting with a continuous pilot arc causes more consumable wear than cutting in normal cutting mode.
You will find more information about proper cutting techniques in Section 3, Operation.
2-2
TORCH SETUP
Hand torch setup

Duramax HRT
Consumables
Safety trigger
Duramax HRTs
Consumables Safety trigger
Choose the hand torch consumables

Duramax retrofit torches are shipped with a full set of cutting consumables pre-installed. Hypertherm also includes spare cutting electrodes, nozzles, and gouging consumables in the consumables box, for handheld torches. Consumables for handheld cutting are shown on the next page. Notice that the retaining cap and electrode are the same for cutting, gouging, and FineCut applications. Only the shield, nozzle, and swirl ring are different. For the best cut quality on thin materials, you may prefer to use FineCut consumables, or use a 45A nozzle and reduce the current setting to 45 amps.
2-3
Torch setup Hand torch consumables

Drag-cutting consumables: Powermax1000/1250/1650
45A
220941 Nozzle
65A
220818 Shield 220854 Retaining cap 220992 Shield
220819 Nozzle 220842 Electrode

85A
220857 Swirl ring
220816 Nozzle
00A 1
220994 Swirl ring
220990 Nozzle
Gouging consumables: Powermax1000/1250/1650

65A 85A
220797 Nozzle 220798 Shield 220854 Retaining cap 220842 Electrode

00A 1
220857 Swirl ring
220991 Nozzle
220994 Swirl ring
FineCut consumables: Powermax1000/1250/1650
220931 Shield
220854 Retaining cap
220930 Nozzle
220842 Electrode
220947 Swirl ring
Powermax1000 Use 45-65 A consumables Powermax1250 Use 45-85 A consumables Powermax1650 Use 45-100 A consumables
2-4
TORCH SETUP Install the hand torch consumables warning Instant-On Torches PLASMA ARC CAN CAUSE INJURY AND BURNS
The plasma arc comes on im me di ate ly when the torch trigger is activated. Make sure the power is OFF before changing consumables.
To operate the hand torch, a complete set of consumable parts must be installed: shield, retaining cap, nozzle, electrode, and swirl ring. With the power switch in the OFF (O) position, install the torch consumables asshown below.
Swirl ring Electrode Nozzle Retaining cap
Shield
2-5
Torch setup
Machine torch setup

Duramax MRT
Mounting sleeve Coupler
Consumables
Positioning sleeve
Strain relief nut
Torch lead
Gear rack
Main strain relief nut
Strain relief body
Duramax MRT without positioning sleeve (mini torch)

Mounting sleeve Coupler Torch lead
Consumables
Strain relief nut
Strain relief body
Before using either style of machine torch, you must: Mount the torch on your cutting table or other equipment. Choose and install the consumables. Align the torch. 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.
2-6
TORCH SETUP Converting a Duramax retrofit machine torch into a mini torch
You can convert a full-length machine torch to a mini-machine torch by removing the positioning sleeve. Note: f you are converting a full-length machine torch to a mini-machine torch and I mounting the torch at the same time, skip this section and follow the instructions in Mount the torch on page 2-9.
Refer to the figures in the section Machine torch setup on page 2-6 and follow these instructions. Note: hile disconnecting and reconnecting the torch parts, maintain the same orientation W between the torch head and torch lead. Twisting the torch head in relation to the torch lead can cause damage.
1. Disconnect the torch lead from the power supply and remove the consumables from the torch. 2. Unscrew the strain relief body from the strain relief nut and slide the strain relief body back along the torch lead. 3. Unscrew the strain relief nut from the positioning sleeve and slide the nut back along the torch lead. 4. Unscrew the positioning sleeve from the coupler. 5. Unscrew the coupler from the mounting sleeve. 6. Remove the three screws from the consumables end of the mounting sleeve and slide the mounting sleeve off the front of the torch body.
2-7
Torch setup
Pilot wire terminal screw
Torch head
Gas supply line connection
Wire connector for cap-sensor switch
7. Disconnect the wire connector for the cap-sensor switch. 8. Use a #2 Phillips screwdriver to remove the screw that secures the torchs pilot wire to the torch body. 9. Use 1/4-inch and 3/8-inch wrenches, or adjustable wrenches, to loosen the nut that secures the gas supply line to the torch lead. Set the torch body aside. 10. Slide the coupler and positioning sleeve off the front of the torch lead. 11. Slide the coupler over the torch lead. 12. Reconnect the gas line to the torch lead. 13. Reattach the torchs pilot wire to the torch body using the screw. 14. Reconnect the cap-sensor switchs wire connector. 15. Slide the mounting sleeve over the front of the torch body. Align the slot on the front of the mounting sleeve (next to one of the three screw holes) with the cap-sensor plunger on the torch body. 16. Attach the mounting sleeve to the torch body using the three screws. 17. Screw the coupler into the mounting sleeve. 18. Screw the strain relief nut into the coupler. 19. Screw the strain relief body into the strain relief nut.
2-8
TORCH SETUP Mount the torch

Depending on the type of cutting table you have, you may or may not need to disassemble the torch to route it through the track and mount it. If your cutting tables track is large enough for you to thread the torch through it without removing the torch body from the lead, do so and then attach the torch to the lifter per the manufacturers instructions. Note: he Duramax machine torches can be mounted on a wide variety of X-Y tables, track T burners, pipe bevelers, and other equipment. Install the torch per the manufacturers instructions and follow the instructions below for disassembly if necessary.
If you need to disassemble and reassemble the torch, refer to the figures in the section Machine torch setup on page 2-6 and follow these instructions. Note: hile disconnecting and reconnecting the torch parts, maintain the same orientation W between the torch head and torch lead. Twisting the torch head in relation to the torch lead can cause damage.
1. Disconnect the torch lead from the power supply and remove the consumables from the torch. 2. Unscrew the strain relief body from the strain relief nut and slide the strain relief body back along the torch lead. 3. Unscrew the strain relief nut from the positioning sleeve (full-length machine torch) and slide the nut back along the torch lead. 4. Unscrew the positioning sleeve from the coupler. 5. Unscrew the coupler from the mounting sleeve. 6. Remove the three screws from the consumables end of the mounting sleeve and slide the mounting sleeve off the front of the torch body.
2-9
Torch setup
Pilot wire terminal screw
Torch head
Gas supply line connection
7. Disconnect the wire connector for the cap-sensor switch. 8. Use a #2 Phillips screwdriver to remove the screw that secures the torchs pilot wire to the torch body. 9. Use 1/4-inch and 3/8-inch wrenches, or adjustable wrenches, to loosen the nut that secures the gas supply line to the torch lead. Set the torch body aside. Note: over the end of the gas line on the torch lead with tape to keep dirt and other C contaminants from getting in the gas line when you route the lead through the track.
10. Slide the coupler, positioning sleeve (full-length machine torch), strain relief nut, and strain relief body off the front of the torch lead. 11. If you do not need the gear rack on a full-length machine torch, slide the gear rack from the positioning sleeve toward the consumables end of the sleeve. 12. Route the torch lead through the cutting tables track.
2-10
TORCH SETUP
13. Slide the strain relief body and strain relief nut over the torch lead. 14. If you are mounting a full-length machine torch, slide the positioning sleeve over the torch head. 15. Slide the coupler over the torch lead. 16. Reconnect the gas line to the torch lead. 17. Reattach the torchs pilot wire to the torch body using the screw. 18. Reconnect the cap-sensor switchs wire connector. 19. Slide the mounting sleeve over the front of the torch body. Align the slot on the front of the mounting sleeve (next to one of the three screw holes) with the cap-sensor plunger on the torch body. 20. Attach the mounting sleeve to the torch body using the three screws. 21. Screw the coupler into the mounting sleeve. 22. If you are mounting a full-length machine torch, screw the positioning sleeve into the coupler. 23. Reconnect the strain relief nut and strain relief body. 24. Attach the torch to the lifter per the manufacturers instructions.
2-11
Torch setup Choose the machine torch consumables

Powermax systems with the Duramax MRT retrofit torch are shipped with a complete set of consumables. Hypertherm also includes spare electrodes and nozzles. In addition, an ohmicsensing retaining cap is available for use with shielded consumables. With shielded consumables, the torch tip may touch the metal when cutting. With unshielded consumables, you must keep the torch a small distance, about .08 inch (2 mm), away from the metal. Unshielded consumables generally have a shorter life than shielded consumables.
Machine torch consumables

Mechanized shielded consumables: Powermax1000/1250/1650
220941 Nozzle
65A
220817 Shield 220854 Retaining cap 220993 Shield

85A
220816 Nozzle
00A 1
220990 Nozzle
45A
220857 Swirl ring
220994 Swirl ring
2-12
TORCH SETUP
Mechanized shielded with ohmic consumables: Powermax1000/1250/1650
45A
220941 Nozzle
65A
220817 Shield 220953 Ohmic-sensing retaining cap

85A
220857 Swirl ring
220993 Shield
220816 Nozzle
00A 1
220994 Swirl ring
220990 Nozzle
Mechanized unshielded consumables: Powermax1000/1250/1650

45A
220941 Nozzle
65A
220819 Nozzle 220955 Deflector 220854 Retaining cap 220842 Electrode

85A
220857 Swirl ring
220816 Nozzle
00A 1
220994 Swirl ring
220990 Nozzle
2-13
Torch setup
Gouging consumables: Powermax1000/1250/1650
65A 85A
220797 Nozzle 220798 Shield 220854 Retaining cap 220842 Electrode

00A 1
220857 Swirl ring
220991 Nozzle
220994 Swirl ring
FineCut shielded consumables: Powermax1000/1250/1650
220948 Shield
220930 Nozzle
220842 Electrode
220857 Swirl ring
FineCut unshielded consumables: Powermax1000/1250/1650
220955 Deflector
220930 Nozzle
220842 Electrode
220857 Swirl ring
2-14
TORCH SETUP Install the machine torch consumables

WARNING
INSTANT-ON TORCHES PLASMA ARC CAN CAUSE INJURY AND BURNS The plasma arc comes on im me di ate ly when the torch is activated. Make sure the power is OFF before changing the consumables. To operate the machine torch, a complete set of consumable parts must be installed: shield, retaining cap, nozzle, electrode, and swirl ring. With the power switch in the OFF (O) position, install the machine torch consumables in a manner similar to the hand torch consumables. Refer to Install the hand torch consumables on page 2-5.
Aligning the torch

Mount the machine torch perpendicular to the workpiece in order to get a vertical cut. Use a square to align the torch at 0 and 90.
Torch
90
2-15
Torch setup
Torch installation
1. Turn OFF the power.
OFF
ON
2. Remove the power cord from the power receptacle.
3. Open the Easy Torch Removal (ETR) door and route the lead through the end cap.
AMPS 40 30 80 60
100
AC
50
60 4.0
70
80
PSI
5.0
6.0 BAR
_ +
ETR door End cap
2-16
TORCH SETUP
4. Align the marks on the strain relief.
5. Pull back the quick-release collar and insert the leads gas fitting.
Quick-release collar
6. Slide the quick-release collar forward to lock the gas fitting in place. Make sure that the gas fitting is secure.
7. Make sure that the red dot on the connector is on top, then plug in the electrical connector. Close the ETR door.
2-17
Torch setup
2-18
Section 3 Operation
In this section:
Using the cut charts........................................................................................................................................... 3-2 Estimated kerf-width compensation..................................................................................................... 3-2 100 amp mechanized shielded cutting for Powermax1650.......................................................... 3-5 85 amp mechanized shielded cutting for Powermax1650............................................................. 3-7 80 amp mechanized shielded cutting for Powermax1250/1650...............................................3-11 65 amp mechanized shielded cutting for Powermax1250/1650...............................................3-13 60 amp mechanized shielded cutting for Powermax1000/1250/1650....................................3-17 45 amp mechanized shielded cutting for Powermax1000/1250/1650....................................3-19 100 amp mechanized unshielded cutting for Powermax1650....................................................3-23 85 amp mechanized unshielded cutting for Powermax1650......................................................3-25 65 amp mechanized unshielded cutting for Powermax1250/1650...........................................3-29 45 amp mechanized unshielded cutting for Powermax1000/1250/1650...............................3-33 FineCut consumables for Powermax1000/1250/1650.............................................................3-37 Using the hand torch........................................................................................................................................3-42 Operate the safety trigger....................................................................................................................3-42 Hand torch cutting hints.......................................................................................................................3-43 Start a cut from the edge of the workpiece.....................................................................................3-44 Pierce a workpiece.................................................................................................................................3-45 Gouge a workpiece...............................................................................................................................3-46 Common hand-cutting faults...............................................................................................................3-49 Using the machine torch.................................................................................................................................3-50 Ensure the torch and table are set up correctly..............................................................................3-50 Understand and optimize cut quality..................................................................................................3-50 To pierce a workpiece using the machine torch.............................................................................3-53 Common machine-cutting faults.........................................................................................................3-53
3-1
OPERATION
Using the cut charts

The following sections provide cut charts for each set of mechanized consumables. A consumable diagram with part numbers precedes each section. The arc voltage increases as the consumables wear and the voltage setting should be increased to maintain the correct Torch-to-Work Distance. Note: ypertherm collected the data under laboratory test conditions using new H consumables.
Estimated kerf-width compensation

The widths in the tables on the following two pages are for reference. The data is obtained with the Best Quality settings. Differences between installations and material composition may cause actual results to vary from those shown in the tables.
3-2
OPERATION
Estimated kerf-width compensation Metric (mm)
Thickness (mm) Process 0.5 1 2 3 6 2.0 1.7 1.7 1.6 1.4 1.1 0.7 1.1 0.7 1.4 1.3 1.7 1.6 0.5 0.9 1.3 1.6 1.4 1.5 1.3 1.8 1.6 1.3 Stainless Steel 1.9 1.6 1.7 1.4 1.5 0.9 0.6 1.1 0.6 1.5 1.4 1.7 1.6 0.5 1.0 1.3 1.5 1.5 1.6 1.5 1.7 1.6 1.5 Aluminum 1.8 1.8 1.5 2.1 2.0 1.7 1.9 1.5 1.5 1.5 1.9 1.8 1.6 1.5 1.9 1.5 1.6 1.9 1.8 1.4 1.9 1.7 1.9 1.5 1.5 1.9 1.8 1.5 2.0 1.8 2.0 1.9 2.1 2.0 2.2 2.1 2.0 1.7 2.0 1.5 2.1 2.1 1.8 2.1 1.6 2.1 2.2 1.8 2.3 1.6 2.1 2.4 1.8 2.5 1.6 2.3 2.6 1.9 1.8 2.1 1.9 2.2 2.0 2.4 1.8 1.7 1.8 1.6 1.8 1.9 1.9 1.8 1.9 1.7 2.0 2.1 1.8 2.0 1.8 2.1 2.3 1.9 2.2 1.8 2.2 2.4 2.1 2.4 2.0 2.3 2.5 2.2 1.9 1.7 2.0 1.8 2.1 1.9 2.1 2.0 2.3 1.8 1.7 1.8 1.6 1.7 8 2.1 1.9 1.8 1.9 1.6 10 2.2 2.0 1.8 2.0 1.7 12 2.2 2.2 1.8 2.2 1.8 16 2.3 2.4 2.0 2.3 1.9 20 2.7 2.6 2.3 Mild Steel
100 A Shielded 85 A Shielded 80 A Shielded 65 A Shielded 60 A Shielded 45 A Shielded FineCut 85 A Unshielded 65 A Unshielded 45 A Unshielded 100 A Shielded 85 A Shielded 80 A Shielded 65 A Shielded 60 A Shielded 45 A Shielded FineCut 85 A Unshielded 65 A Unshielded 45 A Unshielded 100 A Shielded 85 A Shielded 80 A Shielded 65 A Shielded 60 A Shielded 45 A Shielded 85 A Unshielded 65 A Unshielded 45 A Unshielded
3-3
OPERATION
Estimated kerf-width compensation English (inches)
Thickness (inches) Process 22 GA 18 GA 14 GA 10 GA 3/16 1/4 0.079 0.068 0.062 0.055 0.035 0.024 0.054 0.043 0.055 0.049 0.062 0.020 0.050 0.051 0.065 0.057 0.061 0.051 0.070 0.064 0.054 0.073 0.066 0.057 0.075 0.068 0.059 0.074 0.068 0.062 0.035 0.024 0.054 0.043 0.055 0.049 0.062 0.020 0.050 1/32 0.051 1/16 0.065 0.061 0.051 0.070 0.064 0.054 1/8 0.080 0.069 0.073 0.064 0.059 0.061 0.070 0.062 0.058 0.074 0.061 0.065 0.075 0.070 0.057 0.075 0.070 0.075 0.073 0.066 0.057 3/16 0.078 0.075 0.068 0.059 1/4 0.083 0.075 0.065 0.076 0.057 0.060 0.075 0.070 0.061 0.080 0.072 0.082 0.079 0.088 3/8 0.085 0.080 0.072 0.083 0.061 1/2 0.080 0.090 0.069 0.091 0.063 5/8 0.084 0.095 0.075 0.100 0.065 3/4 0.089 0.100 0.080 0.075 0.085 0.081 0.090 0.071 0.068 0.065 0.073 0.066 0.070 0.065 0.066 0.079 0.078 0.072 0.076 0.069 0.083 0.090 0.077 0.088 0.073 0.087 0.095 0.082 0.090 0.080 0.090 0.100 0.088 0.091 0.088 0.080 0.075 0.085 0.081 0.090 0.071 0.068 0.068 0.060 0.065 0.073 0.068 0.070 0.063 0.066 3/8 0.085 0.078 0.071 0.076 0.067 1/2 0.085 0.090 0.073 0.088 0.071 5/8 0.089 0.095 0.078 0.090 0.076 3/4 0.107 0.100 0.088 0.091 0.084 Mild Steel
100 A Shielded 85 A Shielded 80 A Shielded 65 A Shielded 60 A Shielded 45 A Shielded FineCut 85 A Unshielded 65 A Unshielded 45 A Unshielded 100 A Shielded 85 A Shielded 80 A Shielded 65 A Shielded 60 A Shielded 45 A Shielded FineCut 85 A Unshielded 65 A Unshielded 45 A Unshielded
Stainless Steel
Aluminum
100 A Shielded 85 A Shielded 80 A Shielded 65 A Shielded 60 A Shielded 45 A Shielded 85 A Unshielded 65 A Unshielded 45 A Unshielded
3-4
OPERATION 100 amp mechanized shielded cutting for Powermax1650
00A 1
220993 Shield
220990 Nozzle
220842 Electrode
220994 Swirl ring
00A 1
220993 Shield
220953 Ohmic-sensing retaining cap
220990 Nozzle
220842 Electrode
220994 Swirl ring
Recommended cut speeds are a good starting point for finding the best quality cut (best angle, least dross, and best cut-surface finish). Adjust the speed for your application and table to obtain the desired cut quality. Maximum cut speeds are the fastest speeds possible to cut material without regard to cut quality.
3-5
OPERATION
Note:
Mild steel
Arc current Arc voltage 153 155 159 100 160 161 163 167 Pierce delay 0.5 0.5 1.0 1.0 1.5 NA Material thickness in 1/4 3/8 1/2 5/8 3/4 1 1 1/4 mm 6.4 9.5 12.7 15.9 19.0 25.4 31.8 Recommended cut speed ipm 135 77 57 40 26 18 12 mm/min 3429 1955 1447 1016 660 457 305 Maximum cut speed ipm 208 119 88 61 47 28 19 mm/min 5283 3022 2235 1549 1193 711 482
Torch-to-work dis tance for the following cut chart is 1/8 in (3.2 mm) for all cuts.
Stainless steel
Arc current Arc voltage 154 156 161 100 162 164 166 169 Pierce delay 0.5 0.5 1.0 1.0 1.5 NA Material thickness in 1/4 3/8 1/2 5/8 3/4 1 1 1/4 mm 6.4 9.5 12.7 15.9 19.0 25.4 31.8 Recommended cut speed ipm 150 79 52 34 25 15 9 mm/min 3810 2006 1320 863 635 381 228 Maximum cut speed ipm 231 122 79 52 39 23 14 mm/min 5867 3099 2006 1320 990 584 355
Aluminum
Arc current Arc voltage 154 157 100 160 161 162 165 Pierce delay 0.5 0.5 1.0 1.0 1,5 NA Material thickness in 1/4 3/8 1/2 5/8 3/4 1 mm 6.4 9.5 12.7 15.9 19.0 25.4 Recommended cut speed ipm 164 92 70 50 33 21 mm/min 4165 2336 1778 1270 838 533 Maximum cut speed ipm 253 142 108 77 57 33 mm/min 6426 3606 2743 1955 1447 838
3-6
OPERATION 85 amp mechanized shielded cutting for Powermax1650
85A
220817 Shield
220816 Nozzle
220842 Electrode
220857 Swirl ring
85A
220817 Shield
220816 Nozzle
220842 Electrode
220857 Swirl ring
Best Quality Settings (cut speed and voltage) Settings that provide the starting point for finding the best cut quality (best angle, least dross, best cut-surface finish). Adjust the speed for your application and table to obtain the desired result. Production Settings (cut speed and voltage) 80% of the maximum speed ratings. These speeds result in the greatest number of cut parts, but not necessarily the best possible cut quality.
3-7
OPERATION
85 A Shielded Mild Steel Metric Material Thickness mm 3 4 6 8 10 12 16 20 25 30 English Material Thickness in 10 GA 3/16 1/4 3/8 1/2 5/8 3/4 7/8 1 1-1/8 1-1/4 Edge Start 0.06 0.18 0.24 300 400 0.15 250 Torchto-Work Distance in Initial Pierce Height in % Best Quality Settings Pierce Delay Time Cut Speed Voltage seconds 0.0 0.2 0.5 1.0 1.5 ipm 250 185 130 70 45 35 24 19 13 9 7 Volts 122 123 123 126 131 134 136 139 142 145 148 Production Settings Cut Speed ipm 336 220 160 86 56 37 29 22 17 13 10 Voltage Volts 121 123 126 127 131 133 135 138 141 143 146 1.5 4.5 6.0 300 400 Edge Start 3.8 250 0.5 0.7 1.0 1.5 Torchto-Work Distance mm Initial Pierce Height mm % Best Quality Settings Pierce Delay Time Cut Speed Voltage seconds 0.1 0.2 mm/min 6800 5650 3600 2500 1680 1280 870 570 350 200 Volts 122 122 123 125 127 130 134 137 142 146 Production Settings Cut Speed mm/min 9200 7300 4400 3100 2070 1600 930 680 450 300 Voltage Volts 120 122 125 127 128 130 133 136 141 144
3-8
OPERATION
85 A Shielded Stainless Steel Metric Material Thickness mm 3 4 6 8 10 12 16 20 25 English Material Thickness in 10 GA 3/16 1/4 3/8 1/2 5/8 3/4 7/8 1 Edge Start 0.06 0.18 300 0.15 250 0.5 1.0 Torchto-Work Distance in Initial Pierce Height in % Pierce Delay Time seconds 0.2 Best Quality Settings Cut Speed ipm 275 200 130 65 36 28 20 16 11 Voltage Volts 122 122 122 126 132 135 137 140 143 Production Settings Cut Speed ipm 336 240 164 80 48 30 24 19 14 Voltage Volts 120 121 122 125 131 134 136 139 141 Edge Start 1.5 4.5 300 0.7 1.0 3.8 250 Torchto-Work Distance mm Initial Pierce Height mm % Pierce Delay Time seconds 0.1 0.2 0.5 Best Quality Settings Cut Speed mm/min 7500 6100 3700 2450 1550 1100 700 480 300 Voltage Volts 122 122 122 124 127 131 135 138 143 Production Settings Cut Speed mm/min 9200 7500 4600 3050 1900 1400 760 570 370 Voltage Volts 120 120 122 124 126 130 134 137 141
3-9
OPERATION
85 A Shielded Aluminum Metric Material Thickness mm 3 4 6 8 10 12 16 20 25 English Material Thickness in 1/8 1/4 3/8 1/2 5/8 3/4 7/8 1 Edge Start 0.06 0.18 300 0.15 250 0.5 1.0 Torchto-Work Distance in Initial Pierce Height in % Best Quality Settings Pierce Delay Time Cut Speed Voltage seconds 0.2 ipm 300 130 80 50 38 25 20 14 Volts 122 127 132 135 139 142 144 146 Production Settings Cut Speed ipm 360 172 104 68 48 37 29 20 Voltage Volts 121 127 131 133 137 140 142 144 Edge Start 1.5 4.5 300 0.7 1.0 3.8 250 Torchto-Work Distance mm Initial Pierce Height mm % Best Quality Settings Pierce Delay Time Cut Speed Voltage seconds 0.1 0.2 0.5 mm/min 8000 6500 3800 2650 1920 1450 950 600 380 Volts 122 123 126 130 132 134 139 143 146 Production Settings Cut Speed mm/min 9400 8000 4900 3470 2500 1930 1200 880 540 Voltage Volts 121 123 126 129 131 133 137 141 144
3-10
OPERATION 80 amp mechanized shielded cutting for Powermax1250/1650
220817 Shield
220816 Nozzle
220817 Shield
220816 Nozzle
85A
220842 Electrode
220857 Swirl ring
85A
220842 Electrode
220857 Swirl ring
3-11
OPERATION
Note:
Mild steel
Arc current Arc voltage 132 134 137 80 140 145 148 150 156 N/A 1.0 0.50 Pierce delay 0.25 Material thickness in 3/16 1/4 3/8 1/2 5/8 3/4 7/8 1 mm 4.8 6.4 9.5 12.7 15.9 19.0 22.2 25.4 Recommended cutspeed ipm 140 105 61 39 26 20 15 10 mm/min 3556 2667 1549 991 660 508 381 254 Maximum cut speed ipm 216 161 94 60 40 31 23 16 mm/min 5486 4089 2388 1524 1016 787 584 406
Stainless steel
Arc current Arc voltage 134 136 139 80 142 145 150 153 Pierce delay 0.25 0.50 0.75 1.0 N/A Material thickness in 3/16 1/4 3/8 1/2 5/8 3/4 1 mm 4.8 6.4 9.5 12.7 15.9 19.0 25.4 Recommended cutspeed Maximum cut speed
ipm
140 103 54 33 22 16 9
mm/min
3556 2616 1372 838 559 406 229
ipm
216 158 83 50 34 24 14
mm/min
5486 4013 2108 1270 864 610 356
Aluminum
Arc current Arc voltage 134 139 80 143 146 154 Pierce delay 0.25 Material thickness in 1/8 1/4 3/8 1/2 3/4 mm 3.2 6.4 9.5 12.7 19.0 Recommended cutspeed ipm 295 114 60 37 19 mm/min 7493 2896 1524 940 483 Maximum cut speed ipm 454 176 121 75 37 mm/min 11532 4470 3073 1905 940
0.75 N/A
3-12
OPERATION 65 amp mechanized shielded cutting for Powermax1250/1650
65A
220817 Shield
220819 Nozzle
220842 Electrode
220857 Swirl ring
65A
220817 Shield
220819 Nozzle
220842 Electrode
220857 Swirl ring
3-13
OPERATION
65 A Shielded Mild Steel
Metric Material Thickness mm 2 3 4 6 8 10 12 16 20 25 English Material Thickness in 16 GA 10 GA 3/16 1/4 3/8 1/2 5/8 3/4 7/8 1 Edge Start 0.06 0.18 0.24 300 400 0.15 250 Torchto-Work Distance in Initial Pierce Height in % Pierce Delay Time seconds 0.1 0.2 0.5 0.7 1.2 2.0 Best Quality Settings Cut Speed ipm 260 190 140 90 45 30 23 15 12 8 Voltage Volts 123 125 126 127 130 135 138 141 143 145 Production Settings Cut Speed ipm 294 224 168 116 62 40 26 19 14 10 Voltage Volts 121 123 125 127 129 132 136 141 143 145 1.5 4.5 6.0 300 400 Edge Start 3.8 250 0.5 0.7 1.2 2.0 Torchto-Work Distance mm Initial Pierce Height mm % Pierce Delay Time seconds 0.1 0.2 Best Quality Settings Cut Speed mm/min 6050 5200 4250 2550 1700 1100 850 560 350 210 Voltage Volts 124 125 125 127 129 131 134 138 142 145 Production Settings Cut Speed mm/min 7000 6100 5100 3240 2230 1500 1140 650 450 270 Voltage Volts 121 123 124 127 128 129 131 136 142 145
3-14
OPERATION
65 A Shielded Stainless Steel Metric Material Thickness mm 2 3 4 6 8 10 12 16 20 English Material Thickness in 16 GA 10 GA 3/16 1/4 3/8 1/2 5/8 3/4 0.06 0.18 300 Edge Start 0.15 250 Torchto-Work Distance in Initial Pierce Height in % Best Quality Settings Pierce Delay Time Cut Speed Voltage seconds 0.1 0.2 0.5 0.7 1.2 ipm 345 240 155 80 40 26 20 14 Volts 124 125 126 126 131 136 139 142 Production Settings Cut Speed ipm 426 296 168 96 52 32 20 15 Voltage Volts 121 123 125 126 131 135 139 142 1.5 4.5 300 Edge Start 3.8 250 Torchto-Work Distance mm Initial Pierce Height mm % Best Quality Settings Pierce Delay Time Cut Speed Voltage seconds 0.1 0.2 0.5 0.7 1.2 mm/min 8100 6700 5200 2450 1500 960 750 500 300 Volts 125 125 125 126 129 132 135 139 143 Production Settings Cut Speed mm/min 10000 8260 6150 2850 1860 1250 920 500 370 Voltage Volts 121 123 124 126 129 132 134 139 143
3-15
OPERATION
65 A Shielded Aluminum Metric Material Thickness mm 2 3 4 6 8 10 12 16 20 English Material Thickness in 1/16 1/8 1/4 3/8 1/2 5/8 3/4 0.06 0.18 300 Edge Start 0.15 250 Torchto-Work Distance in Initial Pierce Height in % Pierce Delay Time seconds 0.1 0.5 0.7 1.2 Best Quality Settings Cut Speed ipm 365 280 105 50 35 26 16 Voltage Volts 121 124 131 135 139 143 146 Production Settings Cut Speed ipm 428 336 152 68 48 32 24 Voltage Volts 121 124 128 131 138 141 144 1.5 4.5 300 Edge Start 3.8 250 Torchto-Work Distance mm Initial Pierce Height mm % Pierce Delay Time seconds 0.1 0.2 0.5 0.7 1.2 Best Quality Settings Cut Speed mm/min 8800 7400 6000 3200 1950 1200 1000 650 380 Voltage Volts 121 124 126 130 133 136 138 143 147 Production Settings Cut Speed mm/min 10300 8800 7350 4400 2750 1650 1330 800 560 Voltage Volts 122 124 125 128 130 132 136 141 145
3-16
OPERATION 60 amp mechanized shielded cutting for Powermax1000/1250/1650
65A
220817 Shield
220819 Nozzle
220842 Electrode
220857 Swirl ring
65A
220817 Shield
220819 Nozzle
220842 Electrode
220857 Swirl ring
3-17
OPERATION
Note:
Mild steel
Arc current Arc voltage 134 134 138 60 141 141 147 153 1.50 Pierce delay 0 0.25 0.75 Material thickness in 16 Ga 10 Ga 1/4 3/8 1/2 5/8 3/4 mm 1.5 3.4 6.4 9.5 12.7 15.9 19.0 Recommended cutspeed ipm 502 211 86 41 27 20 14 mm/min 12751 5359 2184 1041 686 512 363 Maximum cut speed ipm 627 264 132 63 42 31 22 mm/min 15926 6706 3353 1600 1067 787 559
Stainless steel
Arc current Arc voltage 134 136 139 60 145 146 149 154 2.00 Pierce delay 0 0.25 0.50 0.75 Material thickness in 16 Ga 10 Ga 1/4 3/8 1/2 5/8 3/4 mm 1.5 3.4 6.4 9.5 12.7 15.9 19.0 Recommended cutspeed Maximum cut speed
ipm
406 159 72 34 23 17 12
mm/min
10312 4039 1829 864 584 429 297
ipm
625 244 110 53 35 26 18
mm/min
15875 6198 2794 1346 889 660 457
Aluminum
Arc current Arc voltage 135 138 60 141 146 149 153 Pierce delay 0 0.25 0.75 1.50 Material thickness in 1/16 1/8 1/4 3/8 1/2 5/8 mm 1.6 3.2 6.4 9.5 12.7 15.9 Recommended cutspeed ipm 433 260 94 48 30 21 mm/min 10995 6604 2388 1219 762 545 Maximum cut speed ipm 666 400 145 74 51 33 mm/min 16916 10160 3683 1880 1295 838
3-18
OPERATION 45 amp mechanized shielded cutting for Powermax1000/1250/1650
45A
220817 Shield
220941 Nozzle
220842 Electrode
220857 Swirl ring
45A
220817 Shield
220941 Nozzle
220842 Electrode
220857 Swirl ring
3-19
OPERATION
45 A Shielded Mild Steel Metric Material Thickness mm 0.5 1 1.5 2 3 4 6 English Material Thickness in 26 GA 22 GA 18 GA 16 GA 14 GA 12 GA 10 GA 3/16 1/4 0.06 0.15 250 0.02 0.08 400 0.1 0.2 0.4 0.5 0.6 Torchto-Work Distance in Initial Pierce Height in % Pierce Delay Time seconds 0.0 Best Quality Settings Cut Speed ipm 350 350 350 350 270 190 100 70 48 Voltage Volts 128 128 129 130 130 133 134 135 137 Production Settings Cut Speed ipm 500 450 400 400 320 216 164 108 73 Voltage Volts 128 128 128 129 129 131 131 132 132 1.5 3.8 250 Torchto-Work Distance mm Initial Pierce Height mm % Pierce Delay Time seconds 0.0 0.1 0.3 0.4 0.5 Best Quality Settings Cut Speed mm/min 9000 9000 9000 6600 3850 2200 1350 Voltage Volts 128 128 130 130 133 134 137 Production Settings Cut Speed mm/min 12500 10800 10200 7800 4900 3560 2050 Voltage Volts 126 128 129 129 131 131 132
3-20
OPERATION
45 A Shielded Stainless Steel Metric Material Thickness mm 0.5 1 1.5 2 3 4 6 English Material Thickness in 26 GA 22 GA 18 GA 16 GA 14 GA 12 GA 10 GA 3/16 1/4 0.06 0.15 250 0.02 0.08 400 0.1 0.2 0.4 0.5 0.6 Torchto-Work Distance in Initial Pierce Height in % Pierce Delay Time seconds 0.0 Best Quality Settings Cut Speed ipm 350 350 350 350 250 140 100 52 30 Voltage Volts 130 130 130 130 132 132 133 135 141 Production Settings Cut Speed ipm 500 450 400 400 360 206 134 58 35 Voltage Volts 129 129 130 130 131 131 134 135 140 1.5 3.8 250 Torchto-Work Distance mm Initial Pierce Height mm % Pierce Delay Time seconds 0.0 0.1 0.3 0.4 0.5 Best Quality Settings Cut Speed mm/min 9000 9000 9000 6000 3100 2000 900 Voltage Volts 130 130 130 132 132 134 140 Production Settings Cut Speed mm/min 12500 10800 10200 8660 4400 2600 1020 Voltage Volts 129 130 130 131 132 134 139
3-21
OPERATION
45 A Shielded Aluminum Metric Material Thickness mm 1 2 3 4 6 English Material Thickness in 1/32 1/16 3/32 1/8 1/4 0.06 0.15 250 Torchto-Work Distance in Initial Pierce Height in % Best Quality Settings Pierce Delay Time Cut Speed Voltage seconds 0.0 0.1 0.2 0.4 0.5 ipm 325 325 200 100 54 Volts 136 136 136 140 142 Production Settings Cut Speed ipm 450 400 328 224 96 Voltage Volts 136 136 134 134 137 1.5 3.8 250 Torchto-Work Distance mm Initial Pierce Height mm % Best Quality Settings Pierce Delay Time Cut Speed Voltage seconds 0.0 0.1 0.2 0.4 0.5 mm/min 8250 6600 3100 2200 1500 Volts 136 136 139 141 142 Production Settings Cut Speed mm/min 11000 9200 6250 4850 2800 Voltage Volts 136 135 134 135 137
3-22
OPERATION 100 amp mechanized unshielded cutting for Powermax1650
00A 1
220955 Deflector
220990 Nozzle
220842 Electrode
220994 Swirl ring
3-23
OPERATION
Note:
Mild steel
Arc current Arc voltage 136 139 142 100 146 150 155 160 Pierce delay 0.5 0.5 1.0 1.0 1.5 NA Material thickness in 1/4 3/8 1/2 5/8 3/4 1 1 1/4 mm 6.4 9.5 12.7 15.9 19.0 25.4 31.8 Recommended cutspeed ipm 137 79 59 37 28 17 10 mm/min 3479 2006 1498 939 711 431 254 Maximum cut speed ipm 210 122 91 57 43 26 16 mm/min 5334 3098 2311 1447 1092 660 406
Stainless steel
Arc current Arc voltage Pierce delay Material thickness in 1/4 3/8 1/2 5/8 3/4 1 1 1/4 mm 6.4 9.5 12.7 15.9 19.0 25.4 31.8 Recommended cutspeed Maximum cut speed
ipm 157 85 53 33 22 14 7
mm/min 3987 2159 1346 838 558 355 177
ipm 241 131 81 51 33 22 11
mm/min 6121 3327 2057 1295 838 558 279
136 139 142 100 146 150 155 161

Aluminum
Arc current Arc voltage 137 139 100 142 147 150 154
0.5 0.5 1.0 1.0 1.5 NA
Pierce delay 0.5 0.5 1.0 1.0 1.5 NA
Material thickness in 1/4 3/8 1/2 5/8 3/4 1 mm 6.4 9.5 12.7 15.9 19.0 25.4
Recommended cutspeed
Maximum cut speed
ipm
166 99 70 50 33 20
mm/min
4216 2514 1778 1270 838 508
ipm
255 153 107 77 51 31
mm/min
6477 3886 2717 1955 1295 787
3-24
OPERATION 85 amp mechanized unshielded cutting for Powermax1650
85A
220955 Deflector
220816 Nozzle
220842 Electrode
220857 Swirl ring
3-25
OPERATION
85 A Unshielded Mild Steel
Metric Material Thickness mm 2 3 4 6 8 10 12 16 20 25 English Material Thickness in 14 GA 10 GA 3/16 1/4 3/8 1/2 5/8 3/4 7/8 1 Edge Start 0.08 0.24 300 0.20 250 Torchto-Work Distance in Initial Pierce Height in % Pierce Delay Time seconds 0.1 0.2 0.5 0.6 Best Quality Settings Cut Speed ipm 280 230 175 125 65 42 33 23 18 12 Voltage Volts 117 118 119 120 122 127 131 136 140 144 Production Settings Cut Speed ipm 416 328 220 160 86 56 37 27 21 15 Voltage Volts 116 117 118 119 122 125 128 131 134 138 Edge Start 2.0 6.0 300 5.0 250 Torchto-Work Distance mm Initial Pierce Height mm % Pierce Delay Time seconds 0.0 0.1 0.2 0.5 0.7 Best Quality Settings Cut Speed mm/min 7150 6240 5250 3450 2400 1560 1200 820 540 320 Voltage Volts 117 118 118 120 121 123 126 132 137 143 Production Settings Cut Speed mm/min 10400 9000 7200 4400 3100 2070 1600 930 640 400 Voltage Volts 116 117 117 119 121 122 124 128 132 137
3-26
OPERATION
85 A Unshielded Stainless Steel Metric Material Thickness mm 2 3 4 6 8 10 12 16 20 English Material Thickness in 14 GA 10 GA 3/16 1/4 3/8 1/2 5/8 3/4 0.08 0.24 300 Edge Start 0.20 250 Torchto-Work Distance in Initial Pierce Height in % Pierce Delay Time seconds 0.1 0.2 0.5 0.6 Best Quality Settings Cut Speed ipm 340 250 180 120 60 35 26 17 Voltage Volts 117 118 119 120 122 131 134 137 Production Settings Cut Speed ipm 452 352 249 160 77 46 29 24 Voltage Volts 116 118 119 121 123 129 133 136 2.0 6.0 300 Edge Start 5.0 250 Torchto-Work Distance mm Initial Pierce Height mm % Pierce Delay Time seconds 0.1 0.2 0.5 0.5 0.7 Best Quality Settings Cut Speed mm/min 8550 7000 5600 3400 2250 1430 1000 650 360 Voltage Volts 117 118 118 120 121 123 129 134 138 Production Settings Cut Speed mm/min 11300 9660 7800 4570 2970 1840 1340 730 570 Voltage Volts 116 117 118 121 122 124 128 133 137
3-27
OPERATION
85 A Unshielded Aluminum Metric Material Thickness mm 2 3 4 6 8 10 12 16 20 English Material Thickness in 1/8 3/16 1/4 3/8 1/2 5/8 3/4 0.08 0.24 300 Edge Start 0.20 250 0.5 0.6 Torchto-Work Distance in Initial Pierce Height in % Pierce Delay Time seconds 0.2 Best Quality Settings Cut Speed ipm 280 200 110 75 45 34 22 Voltage Volts 120 123 126 127 135 139 143 Production Settings Cut Speed ipm 368 271 172 88 62 45 32 Voltage Volts 119 120 122 126 131 134 137 2.0 6.0 300 Edge Start 5.0 250 Torchto-Work Distance mm Initial Pierce Height mm % Pierce Delay Time seconds 0.1 0.2 0.5 0.5 0.7 Best Quality Settings Cut Speed mm/min 8700 7350 6000 3300 2350 1800 1300 840 470 Voltage Volts 118 120 122 125 127 128 133 139 144 Production Settings Cut Speed mm/min 11200 9600 8100 4930 3250 2140 1720 1130 700 Voltage Volts 118 119 120 122 124 127 130 134 138
3-28
OPERATION 65 amp mechanized unshielded cutting for Powermax1250/1650
65A
220955 Deflector
220819 Nozzle
220842 Electrode
220857 Swirl ring
3-29
OPERATION
65 A Unshielded Mild Steel Metric Material Thickness mm 2 3 4 6 8 10 12 16 20 English Material Thickness in 16 GA 10 GA 3/16 1/4 3/8 1/2 5/8 3/4 Edge Start 0.08 0.20 250 Torchto-Work Distance in Initial Pierce Height in % Best Quality Settings Pierce Delay Time Cut Speed Voltage seconds 0.1 0.2 0.5 0.24 300 0.7 ipm 255 190 135 90 40 27 20 13 Volts 116 118 119 120 126 130 134 137 Production Settings Cut Speed ipm 308 232 172 116 62 40 26 18 Voltage Volts 117 118 119 120 122 125 129 132 Edge Start 2.0 6.0 300 0.7 5.0 250 0.5 Torchto-Work Distance mm Initial Pierce Height mm % Best Quality Settings Pierce Delay Time Cut Speed Voltage seconds 0.1 0.2 mm/min 6050 5200 4250 2550 1620 970 760 500 280 Volts 117 118 118 120 123 127 129 134 138 Production Settings Cut Speed mm/min 7340 6330 5250 3560 2230 1500 1140 650 400 Voltage Volts 117 118 118 120 121 122 124 129 133
3-30
OPERATION
65 A Unshielded Stainless Steel Metric Material Thickness mm 2 3 4 6 8 10 12 16 English Material Thickness in 16 GA 10 GA 3/16 1/4 3/8 1/2 5/8 0.08 0.24 300 Edge Start 0.20 250 Torchto-Work Distance in Initial Pierce Height in % Pierce Delay Time seconds 0.1 0.2 0.5 0.7 Best Quality Settings Cut Speed ipm 340 235 150 75 38 25 17 Voltage Volts 116 118 120 121 125 132 135 Production Settings Cut Speed ipm 437 304 194 100 52 32 20 Voltage Volts 115 118 120 121 122 129 133 2.0 6.0 300 Edge Start 5.0 250 Torchto-Work Distance mm Initial Pierce Height mm % Pierce Delay Time seconds 0.1 0.2 0.5 0.7 0.7 Best Quality Settings Cut Speed mm/min 7950 6600 5050 2300 1400 920 710 430 Voltage Volts 117 118 119 121 123 126 130 135 Production Settings Cut Speed mm/min 10300 8500 6500 3070 1900 1250 925 500 Voltage Volts 116 117 119 121 122 123 127 133
3-31
OPERATION
65 A Unshielded Aluminum Metric Material Thickness mm 2 3 4 6 8 10 12 16 English Material Thickness in 1/16 1/8 3/16 1/4 3/8 1/2 5/8 0.08 0.24 300 Edge Start 0.5 0.7 0.20 250 0.1 Torchto-Work Distance in Initial Pierce Height in % Pierce Delay Time seconds Best Quality Settings Cut Speed ipm 325 250 175 100 45 32 24 Voltage Volts 122 124 125 127 132 136 138 Production Settings Cut Speed ipm 476 360 245 128 68 44 28 Voltage Volts 122 123 124 126 128 134 136 2.0 6.0 300 Edge Start 5.0 250 Torchto-Work Distance mm Initial Pierce Height mm % Pierce Delay Time seconds 0.1 0.2 0.5 0.7 0.7 Best Quality Settings Cut Speed mm/min 7750 6550 5400 3000 1800 1100 900 600 Voltage Volts 123 124 125 127 130 133 135 139 Production Settings Cut Speed mm/min 11300 9500 7640 3900 2460 1640 1250 700 Voltage Volts 122 123 124 126 127 129 133 136
3-32
OPERATION 45 amp mechanized unshielded cutting for Powermax1000/1250/1650
45A
220955 Deflector
220941 Nozzle
220842 Electrode
220857 Swirl ring
3-33
OPERATION
45 A Unshielded Mild Steel Metric Material Thickness mm 0.5 1 1.5 2 3 4 6 English Material Thickness in 26 GA 22 GA 18 GA 16 GA 14 GA 12 GA 10 GA 3/16 1/4 0.06 0.15 250 Torchto-Work Distance in Initial Pierce Height in % Best Quality Settings Pierce Delay Time Cut Speed Voltage seconds 0.0 0.1 0.2 0.4 0.5 0.6 ipm 350 350 350 300 250 200 100 85 48 Volts 120 120 119 121 119 120 123 122 127 Production Settings Cut Speed ipm 500 450 400 400 320 216 164 108 73 Voltage Volts 120 120 121 121 122 123 124 124 124 1.5 3.8 250 Torchto-Work Distance mm Initial Pierce Height mm % Best Quality Settings Pierce Delay Time Cut Speed Voltage seconds 0.0 0.1 0.3 0.4 0.5 mm/min 9000 9000 7700 6150 3950 2350 1400 Volts 120 120 120 119 121 123 126 Production Settings Cut Speed mm/min 12500 10800 10200 7800 4900 3560 2050 Voltage Volts 120 121 121 122 123 124 124
3-34
OPERATION
45 A Unshielded Stainless Steel Metric Material Thickness mm 0.5 1 1.5 2 3 4 6 English Material Thickness in 26 GA 22 GA 18 GA 16 GA 14 GA 12 GA 10 GA 3/16 1/4 0.06 0.15 250 0.02 0.08 400 0.1 0.2 0.4 0.5 0.6 Torchto-Work Distance in Initial Pierce Height in % Pierce Delay Time seconds 0.0 Best Quality Settings Cut Speed ipm 350 350 350 350 300 150 100 42 25 Voltage Volts 120 120 118 121 122 121 125 131 130 Production Settings Cut Speed ipm 500 450 400 400 400 224 140 88 48 Voltage Volts 119 119 119 120 120 120 121 123 124 1.5 3.8 250 Torchto-Work Distance mm Initial Pierce Height mm % Pierce Delay Time seconds 0.0 0.1 0.3 0.4 0.5 Best Quality Settings Cut Speed mm/min 9000 9000 9000 6000 3250 1900 700 Voltage Volts 121 121 121 122 123 128 130 Production Settings Cut Speed mm/min 12500 10800 10200 9600 4750 3000 1450 Voltage Volts 119 119 120 120 120 122 124
3-35
OPERATION
45 A Unshielded Aluminum Metric Material Thickness mm 1 2 3 4 6 English Material Thickness in 1/32 1/16 3/32 1/8 1/4 0.06 0.15 250 Torchto-Work Distance in Initial Pierce Height in % Pierce Delay Time seconds 0.0 0.1 0.2 0.4 0.5 Best Quality Settings Cut Speed ipm 325 200 150 100 36 Voltage Volts 126 126 127 130 136 Production Settings Cut Speed ipm 450 400 328 224 72 Voltage Volts 121 122 124 125 127 1.5 3.8 250 Torchto-Work Distance mm Initial Pierce Height mm % Pierce Delay Time seconds 0.0 0.1 0.2 0.4 0.5 Best Quality Settings Cut Speed mm/min 7400 4400 2800 2100 1050 Voltage Volts 126 127 129 132 135 Production Settings Cut Speed mm/min 11000 9200 6250 4700 2250 Voltage Volts 121 123 125 126 127
3-36
OPERATION FineCut consumables for Powermax1000/1250/1650

Note: The cut charts in this section apply to both shielded and unshielded consumables
220948 Shield
220930 Nozzle
220842 Electrode
220857 Swirl ring
220955 Deflector
220930 Nozzle
220842 Electrode
220857 Swirl ring
Best Quality Settings (cut speed and voltage) Settings that provide the starting point for finding the best cut quality (best angle, least dross, best cut-surface finish). Adjust the speed for your application and table to obtain the desired result.
3-37
OPERATION
FineCut Mild Steel Metric Material Thickness mm 0.5 0.6 0.8 1 1.5 2 3 4 English Material Thickness Amps A 26 GA 24 GA 22 GA 20 GA 18 GA 16 GA 14 GA 12 GA 10 GA 45 0.06 0.09 150 40 0.1 0.2 0.4 0.5 Torchto-Work Distance in Initial Pierce Height in % Pierce Delay Time seconds 0.0 Best Quality Settings Cut Speed ipm 325 325 325 325 325 250 200 120 95 Voltage Volts 78 78 78 78 78 78 78 78 78 45 1.5 2.25 150 40 Amps A Torchto-Work Distance mm Initial Pierce Height mm % Pierce Delay Time seconds 0.0 0.1 0.2 0.4 0.5 0.6 Best Quality Settings Cut Speed mm/min 8250 8250 8250 8250 6400 4800 2750 1900 Voltage Volts 78 78 78 78 78 78 78 78
3-38
OPERATION
FineCut Stainless Steel Metric Material Thickness mm 0.5 0.6 0.8 1 1.5 2 3 4 English Material Thickness Amps A 26 GA 24 GA 22 GA 20 GA 18 GA 16 GA 14 GA 12 GA 10 GA 45 0.02 0.08 400 40 0.1 0.2 0.4 0.5 0.6 Torchto-Work Distance in Initial Pierce Height in % Pierce Delay Time seconds 0.0 Best Quality Settings Cut Speed ipm 325 325 325 325 325 240 200 120 75 Voltage Volts 68 68 68 68 68 70 70 80 80 45 0.5 2.0 400 40 Amps A Torchto-Work Distance mm Initial Pierce Height mm % Pierce Delay Time seconds 0.0 0.1 0.15 0.4 0.5 0.6 Best Quality Settings Cut Speed mm/min 8250 8250 8250 8250 6150 4800 2550 1050 Voltage Volts 68 68 68 68 70 71 80 80
3-39
OPERATION
Low Speed FineCut Mild Steel
Metric Material Thickness mm 0.5 0.6 0.8 1* 1.5 * 2 3 4 45 40 1.5 2.25 150 30 Amps A Torchto-Work Distance mm Initial Pierce Height mm % Pierce Delay Time seconds 0 0.1 0.2 0.4 0.5 0.6 Recommended Cut Speed (mm/min) 3800 3800 3800 3800 3800 3700 2750 1900 Voltage Volts 69 68 70 72 75 76 78 78
English Material Thickness Amps A 26GA 24GA 22GA 20GA 18GA * 16GA * 14GA 12GA 10GA 45 40 0.06 0.09 150 30 0.1 0.2 0.4 0.5 Torchto-Work Distance in Initial Pierce Height in % Pierce Delay Time seconds 0.0 Recommended Cut Speed ipm 150 150 150 150 150 150 150 120 95 Voltage Volts 70 68 70 71 73 75 76 78 78
Note:
*Not a dross-free cut.
3-40
OPERATION
Low Speed FineCut Stainless Steel Metric Material Thickness mm 0.5 0.6 0.8 1 1.5 2 3 4 45 40 0.5 2.0 400 30 Amps A Torchto-Work Distance mm Initial Pierce Height mm % Pierce Delay Time seconds 0 0.1 0.15 0.4 0.5 0.6 Recommended Cut Speed (mm/min) 3800 3800 3800 3800 2900 2750 2550 1050 Voltage Volts 69 69 69 69 69 69 80 80
English Material Thickness Amps A 26GA 24GA 22GA 20GA 18GA 16GA 14GA 12GA 10GA 45 40 0.02 0.08 400 30 0.1 0.2 0.4 0.5 0.6 Torchto-Work Distance in Initial Pierce Height in % Pierce Delay Time seconds 0.0 Recommended Cut Speed ipm 150 150 150 150 145 115 110 120 75 Voltage Volts 69 69 69 69 69 69 69 80 80
3-41
OPERATION
Using the hand torch

Instant-On Torches PLASMA ARC CAN CAUSE INJURY AND BURNS Plasma arc comes on im me di ate ly when the torch trigger is activated. The plasma arc will cut quickly through gloves and skin. Wear correct and appropriate protective equipment. Keep 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.
WARNING
Operate the safety trigger

The hand torches are equipped with a safety trigger to prevent accidental firings. When you are ready to use the torch, flip the triggers safety cover forward (toward the torch head) and press the red torch trigger as show below.
3-42
OPERATION Hand torch cutting hints

Drag the torch tip lightly along the workpiece to maintain a steady cut. While cutting, make sure that sparks exit from the bottom of the workpiece. The sparks should lag slightly behind the torch as you cut (15 30 angle from vertical). If sparks spray up from the workpiece, move the torch more slowly, or set the output current higher.
With hand torches, 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
If you fire the torch unnecessarily, you will shorten the life of the nozzle and electrode.
Pulling, or dragging, the torch along the cut is easier than pushing the torch. For straight-line cuts, use a straight edge as a guide. To cut circles, use a template or a radius cutter attachment (a circle cutting guide). See Section 4, Maintenance and Parts, for part numbers for the Hypertherm plasma cutting guides for cutting circles and making bevel cuts.
3-43
OPERATION Start a cut from the edge of the workpiece
1. With the work clamp attached to the workpiece, hold the torch nozzle perpendicular (90) to the edge of the workpiece.
2. Press the torchs trigger to start the arc. Pause at the edge until the arc has cut completely through the workpiece.
3. Drag the torch tip lightly across the workpiece to proceed with the cut. Maintain a steady, even pace.
3-44
OPERATION Pierce a workpiece WARNING

SPARKS AND HOT METAL CAN INJURE EYES AND BURN SKIN. When firing the torch at an angle, sparks and hot metal will spray out from the nozzle. Point the torch away from yourself and others.
1. With the work clamp attached to the workpiece, hold the torch at an approximate 30 angle to the workpiece with the torch tip within 1/16 inch (1.5 mm) of the workpiece before firing the torch.
2. Fire the torch while still at an angle to the workpiece. Slowly rotate the torch to a perpendicular (90) position.
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, dragthe nozzle lightly along the workpiece to proceed with the cut.
3-45
OPERATION Gouge a workpiece WARNING

SPARKS AND HOT METAL CAN INJURE EYES AND BURN SKIN. When firing the torch at an angle, sparks and hot metal will spray out from the nozzle. Point the torch away from yourself and others.
1. Hold the torch so that the torch tip is within 1/16 inch (1.5 mm) from the workpiece before firing the torch.
45
2. Hold the torch at a 45 angle to the workpiece with a small gap between the torch tip and the workpiece. Press the trigger to obtain a pilot arc. Transfer the arc to the work piece.
Direction of travel
3. Maintain an approximate 45 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. Changing the torchs angle changes the dimensions of the gouge.
3-46
OPERATION
Gouge profile You can vary the gouge profile by varying the speed of the torch over the workpiece, varying the torch-to-work standoff distance, varying the angle of the torch to the workpiece, and varying the current output of the power supply.
Speed
Angle
Standoff
Typical Gouge Profile for 60A / 65A Operation

Width 0.26 in (6.6 mm) Depth 0.14 in (3.6 mm)
Operating parameters
Speed Standoff Angle
20-25 ipm (50.8-63.5 cm/min) 1/4-3/8 in (6.4-9.5 mm) 35-40
Typical Gouge Profile for 80A / 85A Operation

20-25 ipm (50.8-63.5 cm/min) 1/4-3/8 in (6.4-9.5 mm) 35-40
3-47
OPERATION
Typical Gouge Profile for 100 A Operation
20-25 ipm (50.8-63.5 cm/min) 1/4-3/8 in (6.4-9.5 mm) 35-40
Varying the gouge profile The following actions have the stated effects on the gouge profile: Increasing the speed of the torch will decrease width and decrease depth. Decreasing the speed of the torch will increase width and increase depth. Increasing the standoff of the torch will increase width and decrease depth. Decreasing the standoff of the torch will decrease width and increase depth. Increasing the angle of the torch (more vertical) will decrease width and increase depth. Decreasing the angle of the torch (less vertical) will increase width and decrease depth. Increasing the current of the power supply will increase width and increase depth. Decreasing the current of the power supply will decrease width and decrease depth.
3-48
OPERATION Common hand-cutting faults

The torch does not cut completely through the workpiece. The causes can be: The cut speed is too fast. The consumables are worn. The metal being cut is too thick for the selected amperage. Gouging consumables are installed instead of drag-cutting consumables. The work clamp is not attached properly to the workpiece. The gas pressure or gas flow rate is too low. The metal being cut is too thick for the amperage. The wrong consumables are being used (gouging consumables are installed instead of drag-cutting consumables, for example). You are moving the torch too quickly or too slowly. Moisture in the gas supply. Incorrect gas pressure. Consumables incorrectly installed.
Cut quality is poor. The causes can be:
The arc sputters and consumables life is shorter than expected. The cause can be:
3-49
OPERATION
Using the machine torch

Since the Powermax with a machine torch can be used with a wide variety of cutting tables, track burners, pipe bevelers, and so on, you will need to refer to the manufacturers instructions for specifics on operating the machine torch in your configuration. However, the information in the following sections will help you optimize cut quality and maximize consumable life.
Ensure the torch and table are set up correctly

Use a square to align the torch at right angles to the workpiece in two dimensions. The torch may travel more smoothly if you clean, check and tune the cutting tables rails and drive system. Unsteady machine motion can cause a regular, wavy pattern on the cut surface. Ensure that the torch does not touch the workpiece during cutting. Contact with the workpiece can damage the shield and nozzle and affect the cut surface.
Understand and optimize cut quality

There are several factors to consider in cut quality: Cut angle The degree of angularity of the cut edge. Dross The molten material that solidifies on the top or bottom of the workpiece. Straightness of the cut surface The cut surface can be concave or convex.
The following sections explain how these factors can affect cut quality. Cut or bevel angle A positive cut angle, or bevel, results when more material is removed from the top of the cut than from the bottom. A negative cut angle results when more material is removed from the bottom of the cut.
3-50
OPERATION
Problem
Cause
Solution
Negative cut angle

Square cut
The torch is too low.
Raise the torch; or if you are using a torch height control, increase the arc voltage. Lower the torch; or if you are using a torch height control, decrease the arc voltage.
Positive cut angle
The torch is too high.
Note:
he squarest cut angle will be on the right side with respect to the forward motion of T the torch. The left side will always have some degree of bevel.
To determine whether a cut-angle problem is being caused by the plasma system or the drive system, make a test cut and measure the angle of each side. Next, rotate the torch 90 in its holder and repeat the process. If the angles are the same in both tests, the problem is in the drive system. If a cut-angle problem persists after mechanical causes have been eliminated (see Ensure the torch and table are set up correctly on page 3-49), check the torch-to-work distance, especially if the cut angles are all positive or all negative. Also consider the material being cut: if the metal is magnetized or hardened, you are more likely to experience cut angle problems. Dross Some amount of dross will always be present when cutting with air plasma. However, you can minimize the amount and type of dross by adjusting your system correctly for your application. 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. Low-speed dross forms when the torchs 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.
3-51
OPERATION
High-speed dross forms when the cutting speed is too fast and the arc angles behind. It forms as a thin, linear bead of solid metal attached very close to the cut. It is more firmly attached to the bottom of the cut than at low speed and is difficult to remove. To reduce highspeed dross: Decrease the cutting speed. Decrease the torch-to-work distance. Note: ross is more likely to form on warm or hot metal than on cool metal. For example, D the first cut in a series of cuts usually produces the least dross. As the workpiece heats up, more dross can accumulate on subsequent cuts. Worn or damaged consumables may produce excess dross. Straightness of the cut surface A typical plasma cut surface is slightly concave.
The cut surface may become more concave, or convex. Correct torch height is required to keep the cut surface acceptably close to straight. Worn consumables also affect the straightness of the cut. A strongly concave cut surface occurs when the torch-to-work distance is too low. Increase the torch-to-work distance to straighten the cut surface. A convex cut surface occurs when the torch-to-work distance is too great or the cutting current is too high. First, try lowering the torch, then reduce the cutting current.
3-52
OPERATION To pierce a workpiece using the machine torch

As with the hand torch, you can start a cut with the machine torch at the edge of the workpiece or by piercing the workpiece. Piercing will result in a shorter consumable life than with edge starts. The pierce delay must be sufficiently long that the arc can pierce the material before the torch moves, but not so long that the arc wanders while trying to find the edge of a large hole. When piercing maximum thicknesses, the ring of dross that forms during the pierce may become high enough to contact the torch when the torch begins to move after the pierce is complete. Remove the dross if the torch will contact it during the cut.
Common machine-cutting faults

The torchs pilot arc will initiate, but will not transfer. Causes can be: The work cable is not making good contact with the cutting table or the cutting table is not making good contact with the workpiece. The torch-to-work distance is too large.
The workpiece is not totally penetrated, and there is excessive sparking on the top of the workpiece. Causes can be: The consumables are worn and need to be replaced. For optimized performance in a mechanized application, replace the nozzle and the electrode together. The work cable is not making good contact with the cutting table or the cutting table is not making good contact with the workpiece. The current (amperage) is set too low. See Using the cut charts on page 3-3 for more information. The cut speed is too high. See Using the cut charts on page 3-3 for more information. The metal being cut exceeds the maximum capacity for the selected amperage.
3-53
OPERATION
Dross forms on the bottom of the cut. Causes can be: The consumables are worn and need to be replaced. For optimized performance in a mechanized application, replace the nozzle and the electrode together. The cutting speed is not correct. See Using the cut charts on page 3-3 for more information. The current (amperage) is set too low. See Using the cut charts on page 3-3 for more information. The torch is not square to the workpiece. The consumables are worn and need to be replaced. For optimized performance in a mechanized application, replace the nozzle and the electrode together. The direction of the torch travel is incorrect. The high-quality cut is always on the right with respect to the forward motion of the torch. The distance between the torch and the workpiece is not correct. The cutting speed is not correct. See Using the cut charts on page 3-3 for more information. The arc current, arc voltage, travel speed, and other variables are not set as recommended in the cut charts. Firing the arc in the air (beginning or ending the cut off of the plate surface). Starting at the edge is acceptable as long as the arc makes contact with the workpiece when started. Starting a pierce with an incorrect torch height. Refer to the cut charts for the specific initial pierce height.
The cut angle is not square. Causes can be:
The consumables life is shortened. Causes can be:
3-54
Section 4 Maintenance and parts
In this section:
Perform routine maintenance........................................................................................................................... 4-2 Inspect the consumables.................................................................................................................................. 4-3 Hand torch replacement parts......................................................................................................................... 4-4 Machine torch replacement parts................................................................................................................... 4-6 Accessory parts.................................................................................................................................................. 4-7
4-1
MAINTENANCE AND parts
Perform routine maintenance

DANGER ELECTRIC SHOCK CAN KILL
Disconnect the electrical power before you perform any maintenance. Allwork that requires removal of the power supply cover must be performed by a qualified technician.
Every use:
AC
Inspect the consumables for proper installation and wear.
Check indicator lights and fault icons. Correct any fault conditions.
Every 3 months:
Replace any damaged labels.
Inspect the trigger for damage. Inspect the torch body for cracks and exposed wires. Replace any damaged parts.
Inspect the power cord and plug. Replace if damaged.
Inspect the torch lead. Replace if damaged.
Every 6 months:
Or
Clean the inside of the power supply with compressed air or a vacuum.
4-2
Inspect the consumables

Part Shield or deflector Inspect The center hole for roundness. The gap between the shield and the nozzle for accumulated debris. Nozzle The center hole for roundness. Action Replace the shield if the hole is no longer round. Remove the shield and clean away any material. Replace nozzle if the center hole is not round.
Good Electrode
Worn Replace electrode if the surface is worn or the pit depth is greater than 1/16 inch (1.6mm) deep. Replace swirl ring if the surface is damaged or worn or any of the gas holes are blocked.
Max. 1/16 in (1.6 mm)
Swirl ring
The surface inside the swirl ring for damage or wear and the gas holes for blockages.
Torch o-ring
The surface for damage, If the o-ring is dry, wear, or a lack of lubrication. lubricate it and the threads with a thin layer of silicone lubricant. If the o-ring is worn or damaged, replace it.
4-3
Hand torch replacement parts

Duramax HRT
Torch handle Coupler Torch lead Cap-sensor switch Pilot terminal screw Torch head O-ring Safety trigger and spring Handle screws Trigger start switch
The entire hand torch and lead assembly can be replaced, or individual component parts can be replaced. Part number 005252 058519 075504 075714 228954 228719 228721 228952 228953 228788* 228789* 228792 228950
Description Trigger start switch O-ring Pilot terminal screw Handle screws, #4 x 1/2 slotted TORX pan head, S/B Kit: Duramax 75/ HRT Torch handle replacement Kit: Duramax 75/HRT Cap-sensor switch replacement Kit: Duramax 15/Duramax 75/HRT/HRTs Safety trigger with spring replacement Kit: HRT/HRTs Torch lead replacement, 25 ft (7.6 m), coupler with 1/2 in. (12.7 mm) threads Kit: HRT/HRTs Torch lead replacement, 50 ft (15.2 m), coupler with 1/2 in. (12.7 mm) threads Kit: HRT Hand torch assembly with 25 ft (7.6 m) lead Kit: HRT Hand torch assembly with 50 ft (15.2 m) lead Kit: HRT Torch main body replacement, coupler with 3/8 in. (9.5 mm) threads Kit: HRT Torch main body replacement, coupler with 1/2 in. (12.7 mm) threads
* The torch assembly also includes a variety of Duramax consumables.
4-4
Duramax HRTs
Torch handle Coupler Torch lead Cap-sensor switch Torch head O-ring Pilot terminal screw Safety trigger and spring Trigger start switch Handle screws
The entire hand torch and lead assembly can be replaced, or individual component parts can be replaced. Part number 005252 058519 075504 075714 228955 228109 228721 228952 228953 228807* 228808* 228809 228951
Description Trigger start switch O-ring Pilot terminal screw Handle screws, #4 x 1/2 slotted TORX pan head, S/B Kit: Duramax 15/ HRTs Torch handle replacement Kit: Duramax 15/HRTs Cap-sensor switch replacement Kit: Duramax 15/Duramax 75/HRT/HRTs Safety trigger with spring replacement Kit: HRT/HRTs Torch lead replacement, 25 ft (7.6 m), coupler with 1/2 in. (12.7 mm) threads Kit: HRT/HRTs Torch lead replacement, 50 ft (15.2 m), coupler with 1/2 in. (12.7 mm) threads Kit: HRTs Hand torch assembly with 25 ft (7.6 m) lead Kit: HRTs Hand torch assembly with 50 ft (15.2 m) lead Kit: HRTs Torch main body replacement, coupler with 3/8 in. (9.5 mm) threads Kit: HRTs Torch main body replacement, coupler with 1/2 in. (12.7 mm) threads
4-5
Machine torch replacement parts

Duramax MRT
Consumables
Mounting sleeve Coupler
Positioning sleeve
Strain relief nut
Torch lead
Gear rack (32 pitch)
Strain relief body
Pilot wire terminal screw O-ring
Front mounting ring
Torch head
Cap-sensor switch
4-6

The entire machine torch and lead assembly can be replaced, or individual component parts can be replaced.
Part number 058519 075504 228720 228735 228736 228737 228738 228786 228787 228790* 228791* 228793 Description O-ring Pilot terminal screw Kit: Cap-sensor switch replacement Kit: M65/M65m/M85/M85m/MRT front mounting sleeve Kit: M65/M65m/M85/M85m/MRT adapter ring (coupler) Kit: M65/M85/MRT positioning sleeve Kit: M65/M85/MRT removable gear rack Kit: MRT torch lead replacement, 25 ft (7.6 m) Kit: MRT torch lead replacement, 50 ft (15.2 m) Kit: MRT Machine torch assembly with 25 ft (7.6 m) lead Kit: MRT Machine torch assembly with 50 ft (15.2 m) lead Kit: MRT torch main body replacement
Accessory parts
Part number 024548 127102 027668 Description Leather torch sheathing, 25 ft (7.5 m) Basic plasma (circles and lines) cutting guide Deluxe plasma (circles and lines) cutting guide
4-7
4-8

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Duramax Retrofit Torch

HRT, HRTs, and MRT for powermax1000 , powermax1250 , and powermax1650

Operator Manual 807190 Revision 3

Duramax Retrofit Torch

Revision 3 May 2012

Hypertherm, Inc. Hanover, NH USA www.hypertherm.com email: info@hypertherm.com

ELECTROMAGNETIC COMPATIBILITY (EMC) Introduction

Installation and use

Methods of reducing emissions

Electromagnetic compatibility (emc)

Maintenance of cutting equipment

Screening and shielding

National and local codes

Duramax Retrofit Torch Operator Manual

Duramax Retrofit Torch Operator Manual

Duramax Retrofit Torch Operator Manual

Duramax HRT hand torch dimensions

3.8 in (9.8 cm)

75 angle 1.0 in (2.5 cm)

2.6 in (6.6 cm)

Duramax HRTs hand torch dimensions

1.9 in (4.7 cm)

2.6 in (6.6 cm) 1.0 in (2.5 cm)

Duramax Retrofit Torch Operator Manual

Duramax MRT full-length machine torch dimensions

8.1 in (20.6 cm) 12.3 in (31.3 cm)

1.4 in (3.6 cm) outer dimension, 1.3 in (3.3cm) flat sides

Duramax MRT without positioning sleeve (mini torch)

3.3 in (8.4 cm)

1.4 in (3.6 cm) outer dimension, 1.3 in (3.3cm) flat sides

Duramax Retrofit Torch Operator Manual

Duramax Retrofit Torch Operator Manual

Section 2 Torch Setup

Duramax Retrofit Torch Operator Manual

Duramax Retrofit Torch Operator Manual

Hand torch setup

Consumables Safety trigger

Choose the hand torch consumables

Duramax Retrofit Torch Operator Manual

Torch setup Hand torch consumables

220818 Shield 220854 Retaining cap 220992 Shield

220819 Nozzle 220842 Electrode

220857 Swirl ring

220994 Swirl ring

Gouging consumables: Powermax1000/1250/1650

220797 Nozzle 220798 Shield 220854 Retaining cap 220842 Electrode

220857 Swirl ring

220994 Swirl ring

FineCut consumables: Powermax1000/1250/1650

220854 Retaining cap

220947 Swirl ring

Duramax Retrofit Torch Operator Manual

Swirl ring Electrode Nozzle Retaining cap

Duramax Retrofit Torch Operator Manual

Machine torch setup

Strain relief nut

Main strain relief nut

Strain relief body

Duramax MRT without positioning sleeve (mini torch)

Strain relief nut

Strain relief body

Duramax Retrofit Torch Operator Manual

Duramax Retrofit Torch Operator Manual

2. Remove the power cord from the power receptacle.