Hypertherm SmartSYNC Robotic Torch Page 37 Operator'S Manual Download

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Troubleshooting and Maintenance Tasks

SmartSYNC Robotic Torches

Operator Manual

811450

Cartridge life is shorter
than expected.

• Do a check of the gas pressure and the gas supply hose. Refer to the

Powermax65/85/105 SYNC Operator Manual

(810470).

• Do not start or stop cuts off of the surface of the workpiece. Starting at the edge of

the workpiece is permitted if the arc makes contact with the workpiece when
started.

• Examine the torch lead. Make it straight if it is twisted or kinked. Replace it if it is

damaged.

• Make sure that the output current, arc voltage, cut speed, and other cut settings

are correct. Refer to the

Powermax65/85/105 SYNC Cut Charts Guide

(810500MU).

• Use the correct torch height for piercing. Refer to the

Powermax65/85/105 SYNC

Cut Charts Guide

(810500MU) for the initial pierce height.

• Make sure that the pierce delay time is correct. Refer to the

Powermax65/85/105

SYNC Cut Charts Guide

(810500MU).

• Examine the gas filtration system for signs of contaminants that. Refer to the

Powermax65/85/105 SYNC Operator Manual

(810470).

• Examine the cut data on the Cartridge Data screen and the Power Supply Data

screen. Refer to the

Powermax65/85/105 SYNC Operator Manual

(810470). Also

refer to

Cartridge maintenance

on page 44.

• A faulty pilot arc IGBT can decrease cartridge life. Contact your Hypertherm

distributor or authorized repair facility, or contact the nearest Hypertherm office
shown in the front of this manual.

Problem

Solutions

Summary of Contents for SmartSYNC Robotic Torch

Page 1: ...SmartSYNC Robotic Torches Operator Manual 811450 REVISION 0 ENGLISH ...

Page 2: ...countries All other trademarks are the property of their respective holders Environmental stewardship is one of Hypertherm s core values and it is critical to our success and our customers success We are striving to reduce the environmental impact of everything we do For more information www hypertherm com environment 2022 Hypertherm Inc ...

Page 3: ...Hypertherm Inc Hanover NH 03755 USA www hypertherm com SmartSYNC Robotic Torches Operator Manual 811450 REVISION 0 ENGLISH Original instructions November 2022 ...

Page 4: ...agen 100 3317 DM Dordrecht Nederland 31 165 596907 Tel 31 165 596901 Fax 31 165 596908 Tel Marketing 31 0 165 596900 Tel Technical Service 00 800 4973 7843 Tel Technical Service technicalservice emeia hypertherm com Technical Service Hypertherm Shanghai Trading Co Ltd B301 495 ShangZhong Road Shanghai 200231 PR China 86 21 80231122 Tel 86 21 80231120 Fax 86 21 80231128 Tel Technical Service techsu...

Page 5: ... vesileikkauksen turvallisuuden ja vaatimustenmukaisuuden käsikirja 80943C ja radiotaajuusvaroitusten käsikirja 80945C Käyttöoppaiden kopiot voivat olla tuotteen mukana sähköisessä ja tulostetussa muodossa Sähköiset kopiot ovat myös verkkosivustollamme Monet käyttöoppaat ovat myös saatavissa useilla kielillä www hypertherm com docs FR FRANÇAIS FRENCH AVERTISSEMENT Avant d utiliser tout équipement ...

Page 6: ...ránke www hypertherm com docs SL SLOVENŠČINA SLOVENIAN OPOZORILO Pred uporabo katerekoli Hyperthermove opreme preberite varnostna navodila v priročniku vašega izdelka v Priročniku za varnost in skladnost 80669C v Priročniku za varnost in skladnost sistemov rezanja z vodnim curkom 80943C in v Priročniku Opozorilo o radijskih frekvencah 80945C Izvodi priročnikov so lahko izdelku priloženi v elektron...

Page 7: ...mation 13 2 Specifications 15 About the robotic torch 15 Robotic torch components dimensions weights 16 Components 16 Dimensions 16 180 robotic torch 16 90 robotic torch 17 45 robotic torch 17 Weights 17 3 Mount the Robotic Torch 19 Minimum bend radius 20 Mount with a Hypertherm robotic torch clamp 228806 20 Connect the torch lead 23 ...

Page 8: ...27 Select the cartridge 27 Cutting guidelines 28 Piercing guidelines 29 Gouging processes 30 Change the gouge contour 31 5 Troubleshooting and Maintenance Tasks 35 Cutting system problems 36 Cut quality problems 38 Cut angle bevel 38 Dross 39 Gouging problems 40 Routine maintenance 41 Every use 42 Every 3 months 43 Cartridge maintenance 44 ...

Page 9: ... 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 surrounding 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 boundaries of the ...

Page 10: ...es 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 c...

Page 11: ...erly packed to Hypertherm s 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 Hypertherm s prior written consent The warranty set forth ab...

Page 12: ...ein shall be null and void and you will have no further recourse against Hypertherm under the Warranty or otherwise Waterjet product warranty coverage Consumable parts are not covered by this warranty Consumable parts include but are not limited to high pressure water seals check valves cylinders bleed down valves low pressure seals high pressure tubing low and high pressure water filters and abra...

Page 13: ... Cut Charts Guide 810500MU Powermax65 85 105 SYNC Mechanized Cutting Guide 810480 Safety and Compliance Manual 80669C For replacement part numbers for robotic torches torch accessories and cartridges refer to the Powermax65 85 105 SYNC Parts Guide 810490 You can find these documents on the USB memory stick that came with your plasma power supply Technical documentation is also available at www hyp...

Page 14: ...Where to Find More Information 1 14 811450 Operator Manual SmartSYNC Robotic Torches ...

Page 15: ...e torch lead length Communication of Hypertherm cartridge usage information to the plasma power supply including cartridge end of life detection Refer to the Powermax65 85 105 SYNC Operator Manual 810470 for more information The FastConnect quick disconnect system to easily remove the torch for transport or to change from one torch to another For information about the thicknesses that you can cut ...

Page 16: ...omponents A SmartSYNC 180 robotic torch is shown Dimensions 180 robotic torch 1 2 6 5 3 4 7 1 Hypertherm cartridge 2 Shell 3 Increment markings 4 Anti rotational slot 5 Strain relief for torch lead 6 Torch lead 7 Positioning holes 3 32 mm 1 25 inch 35 mm 0 3 mm 1 37 inch 0 01 inch 235 mm 9 25 inch 180 mm 7 08 inch ...

Page 17: ...86 mm 7 33 inch 139 mm 5 47 inch 100 mm 3 93 inch 32 mm 1 25 inch 32 mm 1 25 inch 35 mm 0 3 mm 1 37 inch 0 01 inch 214 mm 8 43 inch 139 mm 5 47 inch 76 mm 2 98 inch Torch Weight 180 robotic torch with 4 6 m 15 foot lead 2 1 kg 5 lb 180 robotic torch with 7 6 m 25 foot lead 3 1 kg 7 lb 180 robotic torch with 15 m 50 foot lead 5 7 kg 13 lb Without a Hypertherm cartridge installed ...

Page 18: ...foot lead 3 5 kg 8 lb 90 robotic torch with 15 m 50 foot lead 6 5 kg 14 lb 90 robotic torch with 23 m 75 foot lead 9 6 kg 21 lb Without a Hypertherm cartridge installed Torch Weight 45 robotic torch with 7 6 m 25 foot lead 3 5 kg 8 lb 45 robotic torch with 15 m 50 foot lead 6 5 kg 14 lb 45 robotic torch with 23 m 75 foot lead 9 6 kg 21 lb Without a Hypertherm cartridge installed ...

Page 19: ...Mount with a Hypertherm robotic torch clamp 228806 on page 20 If you use an alternate torch clamp comply with the manufacturer s instructions on how to mount the torch in the clamp For information about how to configure the Powermax power supply for remote operation refer to the Powermax65 85 105 SYNC Mechanized Cutting Guide 810480 NOTICE SENSITIVE ELECTRONICS AND OTHER COMPONENTS INSIDE THE TORC...

Page 20: ...um bend radius of 76 mm 3 0 inches Mount with a Hypertherm robotic torch clamp 228806 1 Mount the torch clamp to the robot arm using mounting holes or NOTICE MINIMUM BEND RADIUS KINKING AND OTHER DAMAGE CAN OCCUR Do not bend the torch lead too far 76 mm 3 0 in 1 2 7 62 mm 0 30 inch 19 05 mm 0 75 inch 2 1 1 1 4 5 mm 0 18 inch unthreaded holes 2 M4 x 0 7 threaded holes ...

Page 21: ...n the torch with the rear half of the clamp using either the increment markings or the positioning holes If you are using the increment markings remove the positioning dowel Push the dowel through the clamp 4 Make sure that the anti rotational tabs on each half of the torch clamp are aligned with the slot in the torch 1 2 1 2 5 2 6 3 4 1 1 2 3 4 5 6 ...

Page 22: ...front half of the clamp to the rear half of the clamp with the 4 screws 6 Tighten the 4 screws to 1 7 N m 15 lbf in in the order shown 1 2 3 2 3 1 NOTICE Do not tighten the screws too much If you tighten the screws too much you can cause damage to the internal components of the torch 2 4 1 3 ...

Page 23: ...r supply to OFF O before you connect or disconnect a torch To connect a hand torch or machine torch push the connector into the receptacle on the front of the plasma power supply The connector makes a click when it is fully engaged To disconnect the torch push the red button on the connector and pull the connector out of the receptacle Red button ...

Page 24: ...Mount the Robotic Torch 3 24 811450 Operator Manual SmartSYNC Robotic Torches ...

Page 25: ...ion gives information to help you do the following Use the robotic teach tool Select the correct Hypertherm cutting or gouging cartridge Pierce and cut metal Optimize cut quality Gouge metal To troubleshoot cutting system problems refer to Troubleshooting and Maintenance Tasks on page 35 ...

Page 26: ...e that the torch will not touch the workpiece while cutting Contact with the workpiece while cutting can cause damage to the cartridge and the cut surface The torch teach tool has a spring loaded tip so that you can simulate different cartridge lengths and stand off distances To install the torch teach tool do the following steps 1 Set the power switch on the plasma power supply to OFF O 2 Remove ...

Page 27: ...ness of the material that you want to cut Make sure that the cartridge that you select is an amperage supported by the plasma power supply For example if you have a Powermax85 SYNC select an 85 A 65 A or 45 A cartridge not a 105 A cartridge Cartridge Type Purpose Standard cut gray Use these standard cartridges for the widest range of cutting applications FineCut gray Use these cartridges to get a ...

Page 28: ...he workpiece Do all cutting system maintenance tasks as scheduled Refer to Troubleshooting and Maintenance Tasks on page 35 Do not fire the torch unnecessarily It decreases cartridge life Starting at the edge of the workpiece is permitted if the arc makes contact with the workpiece when started Prevent lead outs that move away from the workpiece and stretch the plasma arc Metric material thickness...

Page 29: ...hat the arc can pierce the material before the torch moves but not so long that the pierce hole enlarges and causes the arc to wander or extinguish before the torch starts to move Pierce delay times given in the cut charts use average delay times throughout the life of the cartridges If necessary as the cartridge wears increase the pierce delay time Pierce height Pierce height is the distance betw...

Page 30: ...ers the following gouging cartridges Cartridge Type Purpose Maximum Control gouging green Use these cartridges for more precise metal removal shallow gouge contours and light metal washing Maximum Removal gouging green Use these cartridges for aggressive metal removal deep gouge contours and extreme metal washing ...

Page 31: ... 31 Change the gouge contour The width and the depth of the gouge contour are a result of the following factors Adjust these factors in combination to get the gouge that you want Standoff arc stretch Angle of the torch Turn of the torch Torch center line Speed Output current A ...

Page 32: ...u can stretch the arc Hypertherm recommends that you keep amperage and arc stretch consistent The lowest and highest possible amperage setting relates to the plasma power supply and the Hypertherm cartridge you are using Angle of the torch to the workpiece Put the torch in a more upright position to make the gouge narrower and deeper Tilt down the torch so that it is closer to the workpiece to mak...

Page 33: ...the output current A of the plasma power supply The higher the amperage the longer that you can stretch the arc Hypertherm recommends that you keep amperage and arc stretch consistent Keep at least a small distance between the torch tip and the molten metal to increase cartridge life and prevent damage to the torch Speed of the torch Increase the speed of the torch movement to make the gouge narro...

Page 34: ...Operate the Robotic Torch 4 34 811450 Operator Manual SmartSYNC Robotic Torches ...

Page 35: ...complying with the recommendations in this chapter or if further aid is necessary do the following 1 Get the serial number for your system from the data plate that is on the rear panel 2 Speak to your Hypertherm distributor or authorized repair facility 3 Speak to the nearest Hypertherm office shown in the front of this manual Refer to the Powermax65 85 105 SYNC Parts Guide 810490 for information ...

Page 36: ...ge Replace it if it is worn or damaged A higher rate of 0 30 0 faults is typical as a cartridge gets near end of life Refer to the Powermax65 85 105 SYNC Operator Manual 810470 Decrease your cut speed Restart the plasma power supply Does it correctly recognize the type of cartridge installed Does it correctly set the amperage and operating mode to align with the cartridge If it does not look at th...

Page 37: ...Powermax65 85 105 SYNC Cut Charts Guide 810500MU Use the correct torch height for piercing Refer to the Powermax65 85 105 SYNC Cut Charts Guide 810500MU for the initial pierce height Make sure that the pierce delay time is correct Refer to the Powermax65 85 105 SYNC Cut Charts Guide 810500MU Examine the gas filtration system for signs of contaminants that Refer to the Powermax65 85 105 SYNC Operat...

Page 38: ...e top The cutting speed is too slow The torch is too low The amperage is too high Increase the cutting speed in small increments 125 mm min or 5 in min or less Lift the torch in small increments 2 mm or 1 16 in Decrease the amperage in 10 A increments No bevel square cut This is good cut quality Positive bevel More material is removed from the top of the cut than from the bottom The cartridge is w...

Page 39: ...ts on the bottom of the cut and is heavy and bubbly The cutting speed is too slow The torch is too low Or if you are using a torch height control arc voltage is too low The amperage is too high Increase the cutting speed in small increments 125 mm min or 5 in min or less Lift the torch in small increments 2 mm or 1 16 in Or if you are using a torch height control increase the arc voltage in small ...

Page 40: ...pright position The torch tip hits the molten metal slag Increase the arc stretch standoff Keep the torch tip pointed in the direction of the gouge that you want to make The gouge has too much depth Tilt the torch down so that it is closer to the workpiece Increase the arc stretch standoff Increase the gouging speed Decrease the output current A The gouge does not have enough depth Put the torch i...

Page 41: ...ll work that requires removal of the plasma power supply outer cover or panels must be done by a qualified technician Refer to the Safety and Compliance Manual 80669C for more safety information WARNING RISK OF BURNS AND ELECTRIC SHOCK USE INSULATED GLOVES Always put on insulated gloves when changing the cartridges The cartridges get very hot during cutting and can cause severe burns Touching the ...

Page 42: ...Refer to Cartridge maintenance on page 44 To prevent overheating do the following Examine the work lead connector to make sure that it is fully connected to the plasma power supply and is not loose Make sure that you turn the connector clockwise approximately 1 4 turn until the connector is fully engaged and locked in position Do a check of the plug on the work lead When a plug is replaced damage ...

Page 43: ... Parts Guide 810490 Examine the torch for cracks and exposed wires Have a qualified service technician replace any damaged parts Contact your distributor or authorized repair facility Examine the labels Replace any damaged labels Refer to the Powermax65 85 105 SYNC Parts Guide 810490 Examine the torch lead Have a qualified service technician replace it if it is damaged Contact your distributor or ...

Page 44: ...zle or shield Carefully remove molten metal that causes a blockage of the holes in the shield that are necessary for airflow Do not push the unwanted material inside the nozzle or shield Examine the O ring on the torch body If the O ring is cracked or worn replace it If the O ring is dry or if it is not easy to install the cartridge apply a thin layer of silicone lubricant on the O ring and the th...

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