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Service Manual
DESCRIPTION & SPECIFICATIONS
INTRODUCTION
The Powermax800 plasma cutting system uses an inverter power supply to provide a smooth DC
output voltage producing excellent cut and gouge quality on mild steel, stainless steel, aluminum and
other metals. The Powermax800 power supply provides constant-current output variable from 20 to
50 amps, for optimum performance on all thicknesses of metal up to 1/2 inch (12 mm) thick. At 50
amps, the Powermax800 can cut metals up to 3/4 inch (20 mm) thick and will sever metals up to 1
inch (25 mm) thick.
Air is the primary plasma gas, providing low operating cost combined with high-speed performance.
Cylinder air or shop air can be used as long as it is clean, dry and oil-free. When properly set and
maintained, the pressure regulator and gas filter on the power supply ensure that the correct pressure
and flow rate is supplied to the system at the proper quantity and quality. The Powermax800 can also
cut with nitrogen when extended electrode life is a priority.
This service manual provides information for qualified service technicians to troubleshoot and repair
the power supply and torch. Sections 4 and 5 contain in-depth parts lists of the Powermax800
systems. This manual also provides a detailed list of safety practices, so that the system can be
safely tested and maintained. READ THE SAFETY SECTION (Section 1) FIRST!
The Powermax800 operator manual provides setup and daily operating instructions.
Figure 2-1 Powermax800 Hand Plasma Cutting System*
* Single-phase 208/240/480V power supply shown.
See Section 5 for part numbers and descriptions of
other Powermax800 power supplies.
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