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Operator and instruction manuals (15)

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Service manuals (3)

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Specifications

For full specifications, reference the manual.

Cut and gouge capacities

Cut capacity Thickness Cut speed
Recommended 32 mm (1-1/4″) 500 mm/min (20 ipm)
  38 mm (1-1/2″) 250 mm/min (10 ipm)
Severance (hand cutting) 50 mm (2″) 125 mm/min (5 ipm)
Pierce* 22 mm (7/8″)  

*Pierce rating for handheld use or with automatic torch height control

 

Gouge capacity Metal removal rate Groove profile
Typical gouge 8,6 kg (19.1 lbs.) per hour 6,6 mm D x 6,0 mm W (0.26″ D x 0.24″ W)

General specifications

Specifications - CSA

Input voltages (± 10%)

200–600 V, 3-PH, 50/60 Hz

Input current @ 16.8 kW

200/208/240/480/600 V, 3-PH 58/56/49/25/22 A

Output current

30–105 A

Rated output voltage

160 VDC

Duty cycle @ 40° C (104° F)

70% @ 105 A, 240 V, 3-PH

80% @ 105 A, 480–600 V, 3-PH

100% @ 94 A, 480–600 V, 3-PH

100% @ 88 A, 240 V, 3-PH

Open circuit voltage (OCV)

300 VDC

Weight with 7,6 m (25′) torch

230-400 V: 42.7 kg (94 lbs.)

CSA – for use in the Americas and Asia, except China

 

Specifications - CE/CCC

Input voltages (± 10%)

200-600 V, 3-PH, 50/60 Hz

Input current @ 16.8 kW

380-400 V, 3-PH, 50/60 Hz

Output current

30–105 A

Rated output voltage

160 VDC

Duty cycle @ 40° C (104° F)

70% @ 105 A, 240 V, 3-PH

80% @ 105 A, 400 V, 3-PH

100% @ 94 A, 400 V, 3-PH

100% @ 88 A, 230 V, 3-PH

Open circuit voltage (OCV)

288 VDC

Weight with 7,6 m (25′) torch

230-400 V: 42.7 kg (94 lbs.)

39.4 kg (87 lbs.)

CE – for use in Europe, Australia & New Zealand - RCM, Serbia, UK – UKCA, Ukraine, and other countries where accepted. CCC – for use in China.

 

Dimensions with handles

592 mm D; 274 mm W; 508 mm H (23.3″ D; 10.8″ W; 20.0″ H)

Gas supply

Clean, dry, oil-free air or nitrogen

Recommended inlet gas flow rate

Cutting: 260 I/min @ 6.2 bar (550 scfh, 9.1 scfm @ 90 psi)

Gouging: 260 I/min @ 4.8 bar (550 scfh, 9.1 scfm @ 70 psi)

Input power cable length

3 m (10′)

Power supply type

Inverter–IGBT

Engine drive requirement

30 kW or 37.5 kVA for full 105 A output

Electrical efficiency

91%

Recyclability

100%

Warranty

Power supply: 6-year, Torch: 1-year

 

Consumables

Please contact an authorized Hypertherm distributor to place your consumables order.

CARTRIDGE-105-Drag-Fine-Hand

Drag cutting and FineCut for hand torches

Hypertherm cartridges

Process

Cartridge

Hyamp

528162

105 A

428937

85 A

428935

65 A

428931

45 A

428927

30-45 A FineCut® hand cutting

428928

These cartridges have different dimensions as compared to traditional consumables which need to be factored when using cutting templates and guides.

Drag cartridge:

DragCut cartridge with dimensions to factor when using cutting templates and guides

FineCut cartridge:

FineCut cartridge with dimensions to factor when using cutting templates and guides

CARTRIDGE-105-Mech-standoff-Fine

Mechanized and FineCut for machine torches

Hypertherm cartridges

Process

Cartridge

Hyamp

528161

105 A

428936

85 A

428934

65 A

428930

45 A

428925

FineCut® mechanized cutting

428926

Ohmic ring kit

428895

(contains 3 #420580 ohmic rings)

Mechanized cartridges can be used on hand torches if a stand-off is desired.

CARTRIDGE-105-MaxControlRemoval-Mech

Max removal and max control gouging

Hypertherm cartridges

Process

Cartridge

Max removal gouging 105 A

428938

Max removal gouging 45–85 A

428932

Max control gouging 105 A

428939

Max control gouging 45–85 A

428933

CARTRIDGE-105-FlushCut

FlushCut

Hypertherm cartridges

Process

FlushCut™

105 A

428954

85 A

428953

65 A

428952

CARTRIDGE-65-HyAccess

HyAccess cartridges

Hypertherm cartridges

Process

HyAccess™

Drag cutting 65 A

428984

Gouging 65 A

428987

Mechanized cutting 65 A

528079

CARTRIDGE-105-HYPILOT-mechanized

Hypertherm cartridges

Process

HyPilot

Mechanized cutting 105 A

528157

Replacement parts

For complete list of replacement parts, view the manual. Please contact an authorized Hypertherm distributor to place your parts order.

Plasma power supply exterior, front

Exterior, front for Powermax SYNC

Item

Part number

Description

1

528009

Kit: Powermax65 SYNC plasma power supply cover with labels, CSA (no screws included)

1

528010

Kit: Powermax65 SYNC plasma power supply cover with labels, CE/CCC (no screws included)

1

528011

Kit: Powermax85 SYNC plasma power supply cover with labels, CSA (no screws included)

1

528012

Kit: Powermax85 SYNC plasma power supply cover with labels, CE/CCC (no screws included)

1

528013

Kit: Powermax105 SYNC plasma power supply cover with labels, CSA (no screws included)

1

528014

Kit: Powermax105 SYNC plasma power supply cover with labels, CE/CCC (no screws included)

2

428143

Kit: Adjustment knob only

3

428141

Kit: Replacement screws (16) for plasma power supply cover

Plasma power supply exterior, rear

Exterior, rear for Powermax SYNC

Item

Part number

Description and kit contents

1

428352

Kit: Air filter bowl, polycarbonate (comes with plasma power supply, includes the O-ring but not the filter element)

011124

Air filter bowl, polycarbonate

2*

428415

Kit: Air filter bowl, nylon (optional – for work sites with oily air) (includes the O-ring but not the filter element)

011128

Air filter bowl, nylon

3

228695

Kit: Air filter element and O-ring (compatible with both filter bowl types)

011093

Air filter element

011125

O-ring

4

428685

Kit: Gas inlet fittings

015145

British Pipe Thread adapter G-1/4 BSPP with 1/4 NPT threads

015337

Industrial interchange quick-disconnect nipple with 1/4 NPT threads

 

027055

Silicone lubricant, 0.25 ounces

   *   The polycarbonate filter bowl that comes with the plasma power supply is compatible with most gas supply systems, but it is important to keep the gas line clean. Organic solvents, chemicals, cutting oil, synthetic oil, alkali, and thread lock solutions can cause damage to the polycarbonate filter bowl over time. You can use the optional nylon bowl (428415) if conditions at your work site make it difficult to prevent harsh chemicals from getting into the gas line.

Power cord and strain relief

Power cord and strain relief for Powermax SYNC

Item

Part number

Description and kit contents

5

228885

Kit: Powermax105 SYNC power cord with strain relief, CSA models, 3 m (10 foot)

229443

Power cord assembly 105 A CSA

108697

Strain relief

104675

Aluminum locknut

5

228886

Kit: Powermax105 SYNC power cord with strain relief, 230 V – 400 V CE models, 3 m (10 foot)

229449

Power cord assembly 105 A, 230 V – 400 V CE

108691

Strain relief

104675

Aluminum locknut

6

428949

Kit: Powermax105 SYNC power cord with strain relief, 380 V CCC / 400 V CE models, 3 m (10 foot)

429052

Power cord assembly 105 A, 380 V CCC / 400 V CE

108795

Strain relief

104629

Strain relief adapter

075819

Aluminum washer

7

228915

Kit: Strain relief for Powermax105 SYNC power cords, CSA models

108697

Strain relief

104675

Aluminum locknut

7

228913

Kit: Strain relief for Powermax105 SYNC power cords, 230 V – 400 V CE models

108691

Strain relief

104675

Aluminum locknut

8

228914

Kit: Strain relief for Powermax105 SYNC power cords, 380 V CCC / 400 V CE models

108795

Strain relief

075819

Aluminum washer

Rear panel

Rear panel for Powermax SYNC

Item

Part number

Description and kit contents

9

528006

Kit: Powermax105 SYNC plasma power supply rear panel with screws and CPC port cover

010586

Label: Protect earth

075807

Screw: M5 X 16, flat head (3)

101197

Plasma power supply rear panel

108867

CPC port cover

210008

Label: Power switch 105 A

 

CSA, CE, or CCC data plate for Powermax105 SYNC (preapplied)

Plasma power supply interior, rear

Interior, rear of Powermax SYNC

Item

Part number

Description and kit contents

1

228644

Kit: Powermax65 SYNC power switch CSA

005257

Power switch

075760

Screw:#8 X 1/2, flat head (4)

108858

Power switch handle

110711

Label: Power switch 65 A/85 A

1

228655

Kit: Powermax85 SYNC power switch CSA

003206

Power switch

075760

Screw: #8 X 1/2, flat head (4)

108858

Power switch handle

110711

Label: Power switch 65 A/85 A

1

228671

Kit: Powermax65/85 SYNC power switch CE/CCC

005650

Power switch

075760

Screw: #8 X 1/2, flat head (4)

108858

Power switch handle

110711

Label: Power switch 65 A/85 A

1

228879

Kit: Powermax105 SYNC power switch CSA and CE 230 V – 400 V

003206

Power switch

075760

Screw: #8 X 1/2, flat head (4)

108858

Power switch handle

210008

Label: Power switch 105 A

1

228880

Kit: Powermax105 SYNC power switch CE 400 V / CCC 380 V

005257

Power switch

075760

Screw: #8 X 1/2, flat head (4)

108858

Power switch handle

210008

Label: Power switch 105 A

Plasma power supply interior, fan side

Interior, fan side of Powermax SYNC

Item

Part number

Description and kit contents

1

428942

Kit: Air filter assembly (includes air filter, air filter bowl, air filter element, and O-ring)

429017

Air filter assembly

104990

Tubing: 8 mm outer diameter X 1.75 inches

104487

Tubing: 8 mm outer diameter X 3.3 inches (optional – not shown)

2

528053

Kit: Solenoid valve (includes gas tubes and screws)

429061

Solenoid valve

101508

Bracket

104488

Tubing: 5/16 inch outer diameter X 7.75 inches

104632

Tubing: 5/16 inch outer diameter X 12 inches

104990

Tubing: 8 mm outer diameter X 1.75 inches

075711

Screw: M4 X 12, pan head

3

528017

Kit: 90° gas tube fitting

015921

90° gas tube fitting

4

528065

Kit: Powermax65/85/105 SYNC Gas tubes

104487

Tubing: 8 mm outer diameter X 3.3 inches (optional – not shown)

104488

Tubing: 5/16 inch outer diameter X 7.75 inches

104632

Tubing: 5/16 inch outer diameter X 12 inches

104990

Tubing: 8 mm outer diameter X 1.75 inches

Fan and fan shroud

Fan and fan shroud for Powermax SYNC

Item

Part number

Description and kit contents

5

428992

Kit: Powermax105 SYNC Fan assembly

429072

Fan assembly

075650

Screw: M4 X 0.7 X 16-9, pan head (3)

6

228910

Kit: Powermax105 SYNC Fan shroud

101199

Fan shroud

Plasma power supply interior, front

Interior, front for Powermax SYNC

Item

Part number

Description and kit contents

1

528026

Kit: Control PCB and adjustment knob

141472

Control PCB

108797

Adjustment knob

075418

Screw: #4 X 1/4, pan head (3)

2

428068

Kit: Ribbon cable for control PCB, 14 cm (5.5 inches)

223024

Ribbon cable that connects the control PCB to the DSP PCB

3

428070

Kit: Powermax65/85 SYNC work lead receptacle

228364

Work lead receptacle

3

228912

Kit: Powermax105 SYNC work lead receptacle

228800

Work lead receptacle

4

528024

Kit: Powermax65/85 SYNC torch quick-disconnect receptacle

229884

Torch quick-disconnect receptacle housing

015920

Torch quick-disconnect receptacle

075899

Retention nut

075693

Screw: #6 X 1/2, pan head (4)

108076

Grommet

4

528025

Kit: Powermax105 SYNC torch quick-disconnect receptacle

229885

Torch quick-disconnect receptacle housing

015920

Torch quick-disconnect receptacle

075899

Retention nut

075693

Screw: #6 X 1/2, pan head(4)

108076

Grommet

Front panel

Front panel for Powermax SYNC

Item

Part number

Description and kit contents

5

528005

Kit: Powermax105 SYNC plasma power supply front panel with screws

002540

Gasket: LCD 65 A/85 A

075807

Screw: M5 X 16, flat head (2)

101063

Panel: Lens 65 A/85 A/105 A/125 A

101459

Panel: Plasma power supply front

210570

Label: Display panel 105 A

210596

Label: Hypertherm logo

Plasma power supply interior, power PCB side

Interior, power PCB side for Powermax SYNC

Item

Part number

Description and kit contents

1

228705

Kit: Powermax65/85 SYNC component barrier

1

228895

Kit: Powermax105 SYNC component barrier

2

528029

Kit: Powermax65 SYNC power PCB CSA

075534

Screw: #6 X 5/16, pan head (4)

141440

Power PCB, 65 A CSA

2

528030

Kit: Powermax65 SYNC power PCB CE/CCC

075534

Screw: #6 X 5/16, pan head (4)

141477

Power PCB 65 A CE/CCC

2

528031

Kit: Powermax85 SYNC power PCB CSA

075534

Screw: #6 X 5/16, pan head (4)

141443

Power PCB 85 A CSA

2

528032

Kit: Powermax85 SYNC power PCB CE/CCC

075534

Screw: #6 X 5/16, pan head (4)

141453

Power PCB 85 A CE/CCC

2

528033

Kit: Powermax105 SYNC power PCB CSA

075534

Screw: #6 X 5/16, pan head (4)

141458

Power PCB 105 A CSA

2

528034

Kit: Powermax105 SYNC power PCB CE 230 V – 400 V

075534

Screw: #6 X 5/16, pan head (4)

141409

Power PCB 105 A CE 230 V – 400 V

2

528035

Kit: Powermax105 SYNC power PCB CE 400 V / CCC 380 V

075534

Screw: #6 X 5/16, pan head (4)

141460

Power PCB 105 A CE 400 V / CCC 380 V

Capacitors and DSP PCB

Capacitors and DSP PCB for Powermax SYNC

Item

Part number

Description and kit contents

3

428066

Kit: Power PCB capacitor

075569

Screw: M6 X 14-12.5, pan head (2)

075570

Screw: M5 X 14-12, pan head (2)

109930

Capacitor: 3uF, 850 VDC

4

528028

Kit: DSP PCB

075766

Screw: M3 X 16, pan head (2)

108855

2-pin jumper (preinstalled on PCB)

141421

DSP PCB

210775

Label: “Save system data before you install this part” (not shown)

5

228683

Kit: Powermax65 SYNC bulk capacitor CSA

075570

Screw: M5 X 14-12, pan head (4)

109935

Capacitor: 2200uF, 500 VDC (2)

5

228684

Kit: Powermax65 SYNC bulk capacitor CE / CCC

075570

Screw: M5 X 14-12, pan head (4)

109947

Capacitor: 3300uF, 400 VDC (2)

5

228681

Kit: Powermax85 SYNC bulk capacitor CSA

075570

Screw: M5 X 14-12, pan head (4)

109797

Capacitor: 3300uF, 500 VDC (2)

5

228682

Kit: Powermax85 SYNC bulk capacitor CE / CCC

075570

Screw: M5 X 14-12, pan head (4)

109948

Capacitor: 4400uF, 400 VDC (2)

5

228888

Kit: Powermax105 SYNC bulk capacitors CSA and CE 230 V – 400 V

075567

Screw: M6 X 16-12.5, pan head (4)

209016

Capacitor: 3300uF, 500 VDC (2)

5

228889

Kit: Powermax105 SYNC bulk capacitors CE 400 V / CCC 380 V

075567

Screw: M6 X 16-12, pan head (4)

209017

Capacitor: 5200uF, 400 VDC (2)

Plasma power supply interior, heatsink

Part number

Description

128836

Thermal grease, 0.125 ounce

105 A heatsink diode bridges

105 A heatsink diode bridges for Powermax105 SYNC

Item

Part number

Description and kit contents

1

228902

Kit: Powermax105 SYNC output diode bridge

209027

Output diode bridge (2)

075569

Screw: M6 X 14-12.5, pan head (6)

075851

M6 X 18.5±0.5-12.5, pan head (4)

128836

Thermal grease, 0.125 ounce

2

528048

Kit: Powermax105 SYNC input diode bridge

209174

Input diode bridge

075567

Screw: M6 X 16-12.5, pan head (2)

105 A heatsink IGBTs and thermal sensor

105 A heatsink IGBTs and thermal sensor for Powermax105 SYNC

Item

Part number

Description and kit contents

3

528044

Kit: Powermax105 SYNC pilot arc IGBT

109319

Pilot arc IGBT

223739

Pilot arc cable

075570

Screw: M5 X 14-12, pan head (2)

075851

Screw: M6 X 18.5±0.5-12.5, pan head (2)

128836

Thermal grease, 0.125 ounce

4

528046

Kit: Powermax105 SYNC inverter IGBT

209445

Pilot arc IGBT

223738

PFC IGBT cable (2)

075569

Screw: M6 X 14-12.5, pan head (3)

075851

Screw: M6 X 18.5±0.5 12.5, pan head (4)

128836

Thermal grease, 0.125 ounce

5

428990

Kit: Thermal sensor (switch)

209569

Transducer

075524

Screw: M5 X 16, pan head

075851

Screw: M6 X 18.5±0.5 12.5, pan head

6

528047

Kit: Powermax105 SYNC PFC IGBT, CSA and CE 230 V – 400 V

109802

PFC IGBT

223738

PFC IGBT cable (2)

075567

Screw: M6 X 16-12.5, pan head (4)

075569

Screw: M6 X 14-12.5, pan head (3)

128836

Thermal grease, 0.125 ounce

IGBT tester

Part number

Description

128883

IGBT tester

105 A heatsink resistors

105 A heatsink resistors for Powermax105 SYNC

Item

Part number

Description and kit contents

7

228898

Kit: Powermax105 SYNC snubber resistor, 15 Ω, 200 W

209045

Snubber resistor, 15 Ω, 200 W

108868

Standoff (2)

075526

Screw: M4 X 10, pan head (2)

128836

Thermal grease, 0.125 ounce

8

228693

Kit: Snubber resistor, 5 Ω, 120 W, CSA and CE 230 V – 400 V

109799

Snubber resistor, 5 Ω, 120 W

108868

Standoff (2)

075526

Screw: M4 X 10, pan head (2)

128836

Thermal grease, 0.125 ounce

9

228894

Kit: Damper resistor, CSA and CE 230 V – 400 V

229458

Damper resistor

075529

Screw: M3 X 10, pan head (2)

128836

Thermal grease, 0.125 ounce

10

228897

Kit: Powermax105 SYNC snubber resistor, 5 Ω, 200 W

209044

Snubber resistor, 5 Ω, 200W

108868

Standoff (2)

075526

Screw: M4 X 10, pan head (2)

128836

Thermal grease, 0.125 ounce

Power supply interior, magnetics

Power supply interior, magnetics for Powermax105 SYNC

Item

Part number

Description and kit contents

1

228661

Kit: Powermax65 SYNC PFC inductor CSA

014345

Inductor: PFC

075697

Screw: M5 X 0.8 X 10-10, pan head (2)

1

228670

Kit: Powermax65 SYNC PFC inductor CE / CCC

014348

Inductor: PFC

075697

Screw: M5 X 0.8 X 10-10, pan head (2)

1

228668

Kit: Powermax85 SYNC PFC inductor CSA

014337

Inductor: PFC

075697

Screw: M5 X 0.8 X 10-10, pan head (2)

1

228664

Kit: Powermax85 SYNC PFC inductor CE / CCC

014341

Inductor: PFC

075697

Screw: M5 X 0.8 X 10-10, pan head (2)

1

228873

Kit: Powermax105 SYNC PFC inductor CSA and CE 230 V – 400 V

014353

Inductor: PFC

075569

Screw: M6 X 14-12.5, pan head (2)

1

228874

Kit: Powermax105 SYNC PFC inductor CE 400 V / CCC 380 V

014357

Inductor: PFC

075569

Screw: M6 X 14-12.5, pan head (2)

2

228663

Kit: Powermax65 SYNC transformer CSA

014346

Transformer

075697

Screw: M5 X 0.8 X 10-10, pan head (2)

2

228669

Kit: Powermax65 SYNC transformer CE / CCC

014349

Transformer

075697

Screw: M5 X 0.8 X 10-10, pan head (2)

2

228667

Kit: Powermax85 SYNC transformer CSA

014338

Transformer

075697

Screw: M5 X 0.8 X 10-10, pan head (2)

2

228654

Kit: Powermax85 SYNC transformer CE / CCC

014342

Transformer

075697

Screw: M5 X 0.8 X 10-10, pan head (2)

2

228871

Kit: Powermax105 SYNC transformer CSA and CE 230 V – 400 V

014354

Transformer

075569

Screw: M6 X 14-12.5, pan head (2)

2

228872

Kit: Powermax105 SYNC transformer CE 400 V / CCC 380 V

014358

Transformer

075569

Screw: M6 X 14-12.5, pan head (2)

3

528036

Kit: Powermax65 SYNC output inductor

014439

Output inductor

075697

Screw: M5 X 0.8 X 10-10, pan head (2)

3

528037

Kit: Powermax85 SYNC output inductor

014440

Output inductor

075697

Screw: M5 X 0.8 X 10-10, pan head (2)

3

528038

Kit: Powermax105 SYNC output inductor

014441

Out put inductor

075569

Screw: M6 X 14-12.5, pan head (2)

Accessories

Hypertherm cartridge reader

The Hypertherm cartridge reader provides a simple process for reviewing data stored in Hypertherm cartridges. Data analysis helps customers understand cartridge utilization and identify operator training opportunities.

Read more

Powermax EtherCAT Interface for EDGE Connect

The Powermax® EtherCAT® Interface is an all-in-one adapter that allows a digital connection between the Powermax equipment and the EDGE® Connect CNC. This allows faster equipment setup, an intuitive operator interface, and access to real-time diagnostics information.

Read more

Robotic torch clamp kit

The robotic torch clamp kit is designed to simplify integration of Powermax® robotic torches on robots. The clamp fits perfectly with the torch dimensions and securely holds the torch during cutting applications.

Read more

Field service bulletins (10)

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Technical support