Powermax plasma cutters: how to eliminate failure with preventative maintenance

Today, we outline the five areas of your Powermax plasma cutter that you need to inspect and clean regularly to optimize performance and prevent future cutting problems.

The five areas of the Powermax that need routine inspections are:

1. Torch body

2. Torch lead

3. Consumables

4. Filter

5. Interior of the plasma cutter

Before you begin your Powermax preventative maintenance   

Before you perform any preventive maintenance checks on your plasma cutter, make sure you turn the power switch off, disconnect the power cord, and disconnect the gas supply. Never disassemble your Powermax while it is on.

Powermax routine maintenance 

 

Inspecting the plasma torch body and lead

You should inspect the plasma torch body and lead every three months.  

To inspect the torch body, first remove the retaining cap and the consumables. Set those aside.

Examine the condition of the O-ring on the torch main body. If it appears dry, apply a small amount of Hypertherm lubricant. Examine the O-ring for rips, cracks, or tears. If it appears damaged or broken, replace it with a new Hypertherm O-ring and apply a small amount of lubricant before continuing.

1. Inspect the torch body for cracks and exposed wires. If the torch is cracked or wires are exposed, discontinue using the torch and replace damaged parts.

2. Inspect the brass threads of the torch body for any signs of damage. Replace any damaged parts.

3. Rotate the torch and locate the electrode seat inside the main torch body. Examine the electrode seat for any pitting that may have occurred over time.

4. Examine the vent holes. The main torch body has three vent holes that may become blocked with slag or debris. If you see signs of any debris, clean the vent holes with clean compressed air.

5. Inspect the safety trigger and confirm that it is working properly. Do not use a torch that does not have a working safety trigger.

6. Follow the torch lead from the base of the handle to the quick disconnect plug looking for any cuts or cracks. Do not continue use if the torch lead is cut or cracked.

7. If any of the parts of the torch body or lead are damaged or defective, contact your local Hypertherm distributor for the correct replacement parts.

 

Inspecting Powermax consumables 

Powermax consumables should be inspected daily.

1. Start by checking the external retaining cap for burns or cracks from prolonged usage.

2. Inspect the electrode and nozzle as a pair because they wear evenly:

   • Start by examining the back of the electrode for excessive pitting.

   • Check the pit depth of the hafnium in the center of the electrode. The pit depth should be no greater than one point six millimeters or one-sixteenth of an inch.

   • A non-round orifice on the nozzle indicates excessive wear.

3. Examine the swirl ring surface:

   • The swirl ring surface should not show signs of excessive wear or cracks.

   • The gas holes should not be deformed or blocked.

4. When assembling the torch components, the retaining cap should be finger tightened only. Overtightening the retaining cap can damage the swirl ring by compressing it.

5. If any of the consumables have cracks, excessive wear, burns, excessive pitting, or deformations, replace the damaged parts with new genuine Hypertherm consumables.

6. Refer to your Hypertherm Operator Manual for proper reinstallation of the consumable set.

 

Inspecting the filter and bowl

1. Remove the filter and bowl. Depending on the machine you are using, the procedure may differ, but how you inspect these components will remain the same. For further information on how to remove the filter and bowl for your specific Powermax machine, refer to your Hypertherm Operator Manual.

2. After the filter and bowl are removed, inspect the filter element for dirt, oil, or debris. Replace the filter if you find any of these contaminants.

3. Wipe away any oil or condensation from the filter bowl with a clean dry towel.

4. Inspect the O-ring at the top of the filter bowl. If the O-ring is cracked or torn, replace it with a new Hypertherm O-ring. Note: the size of the O-ring will differ depending on the type of filter bowl your machine is using. Consult your Hypertherm Operator Manual for O-ring replacement and filter bowl installation instructions.

 

Inspecting and cleaning the inside of the plasma cutter

You should inspect and clean the inside of the plasma cutter every six months.

1. To begin, you need to remove the cover of your Powermax machine:

   • To access the inside of Powermax30, 30 XP, 45, and 45 XP, remove the two Phillips-head screws on each side of the handle. You may need to gently pull up on the handle to remove the screws. Gently tilt the tops of the front and rear panels away from the unit to pull the handle out. Slide the cover off.

   • To access the inside of the Powermax65, 85, 105, and 125, remove the torx screws from each side of the machine. Once you have removed the screws, the cover of the machine should slide straight up.

2. The inside of Hypertherm Powermax systems is divided into two sides, a clean side and a dirty side:

   • The clean side does not need to be cleaned.

   • The dirty side of the machine may collect debris while in use. Use a vacuum to clean any dirt that may have collected. After vacuuming, use compressed air to blow away remnants making sure to blow the remnants in a safe direction.

3. After cleaning, replace the cover, handle, and screws following the instructions for the Powermax model you are using.

4. Reconnect the input power, input gas line, and turn the power switch to the “on” position.

 

You are now ready to cut!

Routine inspections and maintenance are essential to avoid unexpected and costly cutting problems. Investing just a few minutes each day will prevent expensive cutting disruptions, ensuring you get the high-quality cuts and optimized performance you expect from your Powermax plasma system.

View more how-to videos that can help you get more from your plasma system.

If you are experiencing problems with your Powermax system, contact your Hypertherm distributor or authorized repair facility for assistance.