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Troubleshoot Common Problems

6

118

810470

Operator Manual

Powermax65/85/105 SYNC

Start here: troubleshooting checklist

When a troubleshooting problem occurs, go through the following checklist first. It is necessary to
complete these steps before doing the recommendations in the rest of this chapter.

As you do this checklist, record any problems or questions. If you cannot find a solution to the
problem by 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 on common replacement parts.

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Summary of Contents for SYNC Powermax 105

Page 1: ...Powermax65 85 105 SYNC Operator Manual 810470 REVISION 3 ENGLISH ...

Page 2: ...o www hypertherm com registration for easy and fast registration If you experience any problems with the product registration process please contact registration hypertherm com For your records Serial number __________________________________________________________________________ Purchase date __________________________________________________________________________ Distributor ________________...

Page 3: ...Hypertherm Inc Hanover NH 03755 USA www hypertherm com Powermax65 85 105 SYNC Operator Manual 810470 REVISION 3 ENGLISH Original instructions May 2021 ...

Page 4: ...pertherm 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 F...

Page 5: ...nuales disponibles en varios idiomas en www hypertherm com docs ET EESTI ESTONIAN HOIATUS Enne Hyperthermi mis tahes seadme kasutamist lugege läbi toote kasutusjuhendis olevad ohutusjuhised ning Ohutus ja vastavusjuhend 80669C Veejoa ohutuse ja vastavuse juhend 80943C ja Raadiosageduse hoiatusjuhend 80945C Ohutusjuhiste eiramine võib põhjustada vigastusi ja kahjustada seadmeid Juhiste koopiad võiv...

Page 6: ...ários idiomas em www hypertherm com docs RO ROMÂNĂ ROMANIAN AVERTIZARE Înainte de utilizarea oricărui echipament Hypertherm citiți instrucțiunile de siguranță din manualul produsului manualul de siguranță și conformitate 80669C manualul de siguranță și conformitate Waterjet 80943C și din manualul de avertizare privind radiofrecvența 80945C Produsul poate fi însoțit de copii ale manualelor în forma...

Page 7: ... formatta ürünle birlikte verilebilir Elektronik kopyalar web sitemizde de yer alır Kılavuzların birçoğu www hypertherm com docs adresinde birçok dilde mevcuttur VI TIẾNG VIỆT VIETNAMESE CẢNH BÁO Trước khi vận hành bất kỳ thiết bị Hypertherm nào hãy đọc các hướng dẫn an toàn trong hướng dẫn sử dụng sản phẩm của bạn Sổ tay An toàn và Tuân thủ 80669C Sổ tay An toàn và Tuân thủ Tia nước 80943C và Hướ...

Page 8: ......

Page 9: ...em components 22 What to do if components are missing or damaged 23 System configurations 23 Hypertherm plasma power supply ratings 24 Powermax65 SYNC 24 Powermax85 SYNC 26 Powermax105 SYNC 28 Find system specifications on the data plate 30 Find the part number for your system 31 Critical raw materials 31 Symbols and marks 32 IEC symbols 33 Acoustical noise levels 34 Radio frequency identification...

Page 10: ...5 SYNC 43 Powermax105 SYNC 44 Prepare the power cord and plug 45 Install the power plug 45 Install the power cord if necessary 45 Install a 1 phase power cord CSA systems only if necessary 47 Use an extension cord if necessary 47 Powermax65 SYNC systems 48 Powermax85 SYNC systems 49 Powermax105 SYNC systems 50 Use a generator if necessary 51 Powermax65 SYNC and Powermax85 SYNC systems 52 Powermax1...

Page 11: ... the hand torch 73 Amperage settings by plasma power supply and cartridge 74 Use the machine torch 75 What occurs during and after cutting 75 Temperature control 75 Hand torch LED behavior 75 Adjust the gas pressure manually 76 Go back to automatic gas pressure mode 77 Adjust the operating mode manually 77 Cut expanded metal 78 Go back to automatic setting of the operating mode 78 Monitor cartridg...

Page 12: ...yAccess specialty cartridges 106 Get the most out of your cartridges 107 Signs that a cartridge is near end of life 108 Hand torch components dimensions and weights 109 Components 109 Dimensions 110 75 torch 110 15 torch 110 Weights 110 5 Gouge with the Hand Torch 111 Select the correct gouging cartridge 111 Gouge with the hand torch 112 Change the gouge contour 114 6 Troubleshoot Common Problems ...

Page 13: ...3 Cartridge Data screen 154 Power Supply Data screen 156 Cartridge History screen 158 LCD Control PCB Information screen 159 DSP PCB and Power PCB Information screen 160 Torch PCB Information screen 161 Radio Frequency RF Data screen 162 Cut Counters Transfer screen 163 CNC Interface Settings screen 164 7 Complete Regular Maintenance Tasks 165 Examine the plasma power supply and torch 165 Every us...

Page 14: ...Contents 14 810470 Operator Manual Powermax65 85 105 SYNC ...

Page 15: ...t 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 16: ...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 17: ...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 18: ...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 19: ...shooting information For related information refer to the following documents Safety and Compliance Manual 80669C Powermax65 85 105 SYNC Cut Charts Guide 810500MU Powermax65 85 105 SYNC Parts Guide 810490 Powermax65 85 105 SYNC Mechanized Cutting Guide 810480 You can find these documents on the USB memory stick that came with your plasma power supply Technical documentation is also available at ww...

Page 20: ...Where to Find Information 1 20 810470 Operator Manual Powermax65 85 105 SYNC ...

Page 21: ...s to cut stainless steel Gouge with 2 gouging processes Maximum Removal and Maximum Control Adjust the output current A from the SmartSYNC hand torch Use a single piece cartridge instead of a set of consumables Automatically set the operating mode output current A and gas pressure related to the type of SmartSYNC torch and Hypertherm cartridge that you install Record cartridge information so that ...

Page 22: ...1 2 3 4 5 6 1 Documentation USB memory stick with technical and safety documentation Quick Setup Guide Quick Reference Guide Cut Charts Guide Fault codes label 2 Plasma power supply 3 Region specific gas inlet fitting 4 Power cord with no power plug 5 Remote start pendant optional mechanized configurations only 6 Work lead with work clamp C clamp or ring terminal 7 15 or 75 hand torch with lead or...

Page 23: ...or missing or damaged merchandise Speak to your Hypertherm distributor or authorized repair facility or speak to the nearest Hypertherm office shown in the front of this manual System configurations The Powermax65 SYNC Powermax85 SYNC and Powermax105 SYNC systems are universal plasma power supplies that automatically adjust to operate with various AC voltages The following system configurations ar...

Page 24: ... C to 40 C 14 F to 104 F Storage temperature 25 C to 55 C 13 F to 131 F Power factor 200 V 480 V CSA 1 phase 0 99 0 97 200 V 600 V CSA 3 phase 0 94 0 73 380 V CCC 400 V CE 3 phase 0 94 Idle state power consumption CE systems 28 W Power source efficiency at rated maximum output power CE systems 91 2 Rsce Short Circuit Ratio CE CCC systems only U1 Volts AC rms 3 phase 400 VAC Rsce 296 4 EMC emission...

Page 25: ...difficulties in delivering electromagnetic compatibility in those locations because of conducted as well as radiated disturbances Equipment complies with IEC 61000 3 12 if the short circuit power Ssc is greater than or equal to 6 160 KVA at the interface point between the operator s supply and the public system It is the responsibility of the installer or operator of the equipment to make sure by ...

Page 26: ...ing temperature 10 C to 40 C 14 F to 104 F Storage temperature 25 C to 55 C 13 F to 131 F Power factor 200 V 480 V CSA 1 phase 0 99 0 96 200 V 600 V CSA 3 phase 0 94 0 76 380 V CCC 400 V CE 3 phase 0 94 Idle state power consumption CE systems 26 W Power source efficiency at rated maximum output power CE systems 91 9 Rsce Short Circuit Ratio CE CCC systems only U1 Volts AC rms 3 phase 400 VAC Rsce ...

Page 27: ...difficulties in delivering electromagnetic compatibility in those locations because of conducted as well as radiated disturbances Equipment complies with IEC 61000 3 12 if the short circuit power Ssc is greater than or equal to 4 353 KVA at the interface point between the operator s supply and the public system It is the responsibility of the installer or operator of the equipment to make sure by ...

Page 28: ...200 V 3 phase 100 at 94 A 480 V 600 V 3 phase 100 at 88 A 240 V 3 phase 100 at 77 A 208 V 3 phase 100 at 74 A 200 V 3 phase 230 V 400 V CE 80 at 105 A 400 V 3 phase 70 at 105 A 230 V 3 phase 100 at 94 A 400 V 3 phase 100 at 88 A 230 V 3 phase 380 V CCC 80 at 105 A 380 V 3 phase 100 at 94 A 380 V 3 phase 400 V CE 80 at 105 A 400 V 3 phase 100 at 94 A 400 V 3 phase Operating temperature 10 C to 40 C...

Page 29: ... Class A equipment is not intended for use in residential locations where the public low voltage supply system supplies the electrical power There can be difficulties in delivering electromagnetic compatibility in those locations because of conducted as well as radiated disturbances Equipment complies with IEC 61000 3 12 if the short circuit power Ssc is greater than or equal to 4 730 KVA at the i...

Page 30: ...ngs are the minimum ratings that the system must get to meet the requirements of IEC standard 60974 1 CSA CE and CCC data plates differ slightly Sample CSA data plate Sample CE CCC data plate 1 2 4 3 1 2 4 3 1 Serial number bar code and date made 2 Plasma cutting ratings 3 Plasma gouging ratings 4 Plasma power supply ratings HYP Hypertherm internal rating IEC International Electrotechnical Commiss...

Page 31: ...umber for your system The part number for your plasma power supply is near the top of the data plate Critical raw materials Critical raw material Components that contain more than 1 gram Antimony Torch leads Borate All printed circuit boards Magnesium Heatsinks metal covers Silicon metal Heatsinks metal covers ...

Page 32: ...dio Equipment Directive RED and the Restriction of Hazardous Substances RoHS Directive See the European CE Declaration of Conformity for details Eurasian Customs Union CU mark CE versions of products that include an EAC mark of conformity meet the product safety and EMC requirements for export to Russia Belarus and Kazakhstan GOST TR mark CE versions of products that include a GOST TR mark of conf...

Page 33: ...g diodes LEDs and liquid crystal display LCD screen if applicable Direct current DC Alternating current AC Plasma torch cutting Plate metal cutting Expanded metal cutting Gouging AC input power connection The terminal for the external protective earth conductor Power is ON Power is OFF An inverter based power source either 1 phase or 3 phase Volt amperage curve drooping characteristic f1 f2 1 ...

Page 34: ...d Refer to Noise can damage hearing in the Safety and Compliance Manual 80669C In addition you can find an Acoustical Noise Data Sheet for your system at www hypertherm com docs In the search box enter data sheet Radio frequency identification RFID specifications The Hypertherm RFID near field wireless communication system contains the following components A passive RFID tag in the Hypertherm cart...

Page 35: ...owermax65 SYNC Powermax85 SYNC Powermax105 SYNC For handheld cutting or mechanized cutting with programmable torch height control 16 mm 5 8 in 19 mm 3 4 in 22 mm 7 8 in For mechanized cutting without programmable torch height control 13 mm 1 2 in 16 mm 5 8 in 19 mm 3 4 in Maximum cut speed Material thickness Powermax65 SYNC Powermax85 SYNC Powermax105 SYNC 6 mm 1 4 in 3 683 mm min 145 in min 5 080...

Page 36: ...emoval rate on mild steel 4 0 kg hr 8 8 lb hr 8 2 kg hr 18 2 lb hr 8 6 kg hr 19 1 lb hr Maximum Control metal removal rate on mild steel 2 3 kg hr 5 1 lb hr 4 8 kg hr 10 6 lb hr 7 2 kg hr 15 9 lb hr WARNING CHANCE OF ELECTRIC SHOCK Never cut under water or submerge the torch in water Electric shock can cause serious injury WARNING TOXIC FUMES CAN CAUSE INJURY OR DEATH Some metals including stainle...

Page 37: ...70 37 Put the plasma power supply on a stable level surface before using The plasma power supply can tip over if set at an angle greater than 10 Do not put the plasma power supply on its side Doing so can cause a blockage of the air circulation necessary to keep internal components cool 10 ...

Page 38: ...1 Powermax65 SYNC and Powermax85 SYNC weights with power cords For hand torch weights refer to Weights on page 110 For machine torch weights refer to the Powermax65 85 105 SYNC Mechanized Cutting Guide 810480 Powermax65 SYNC Powermax85 SYNC 200 V 600 V CSA 380 V CCC 400 V CE 200 V 600 V CSA 380 V CCC 400 V CE 24 3 kg 54 lb 20 6 kg 45 lb 27 2 kg 60 lb 23 5 kg 52 lb 233 mm 9 2 inches 483 mm 19 inche...

Page 39: ...chine torch weights refer to the Powermax65 85 105 SYNC Mechanized Cutting Guide 810480 200 V 600 V CSA 230 V 400 V CE 380 V CCC 400 V CE 39 7 kg 88 lb 39 5 kg 87 lb 36 2 kg 80 lb Work lead Powermax65 SYNC Powermax85 SYNC Powermax105 SYNC 7 6 m 25 ft 1 3 kg 2 9 lb 1 6 kg 3 6 lb 2 3 kg 5 1 lb 15 m 50 ft 2 3 kg 5 0 lb 3 0 kg 6 5 lb 4 2 kg 9 25 lb 23 m 75 ft 3 1 kg 6 9 lb 4 2 kg 9 25 lb 6 1 kg 13 4 l...

Page 40: ...ding to national and local codes The interrupt level of the switch must equal or be more than the continuous rating of the fuses The switch must also do the following Isolate the electrical equipment and disconnect all live conductors from the incoming supply voltage when in the OFF position Have one OFF and one ON position that are clearly marked with O OFF and I ON Have an external operating han...

Page 41: ...ts for the systems are as follows To calculate the cutting power in watts W multiply the maximum output amperage A by the maximum rated output voltage VDC For example 65 A x 139 VDC 9035 W 9 0 kW Voltage configurations The plasma power supply automatically adjusts for correct operation at the current input voltage You do not have to change or rewire components But you must do the following Install...

Page 42: ...139 VDC 9 0 kW 52 A 50 A 44 A 22 A Input current during arc stretch 74 A 74 A 38 A Fuse time delay 80 A 80 A 40 A All models have a voltage tolerance of 10 15 Input voltage at 50 Hz 60 Hz 200 V 208 V 230 V 240 V 400 V 480 V 600 V Input current at rated output 65 A 139 VDC 9 0 kW 32 A 31 A 27 A 15 A 13 A Input current during arc stretch 45 A 45 A 27 A 23 A Fuse time delay 50 A 50 A 30 A 25 A All mo...

Page 43: ...delay 100 A 100 A 50 A All models have a voltage tolerance of 10 15 Input voltage at 50 Hz 60 Hz 200 V 208 V 230 V 240 V 400 V 480 V 600 V Input current at rated output 85 A 143 VDC 12 2 kW 42 A 40 A 35 A 21 A 18 A 17 A Input current during arc stretch 60 A 60 A 38 A 31 A 30 A Fuse time delay 60 A 60 A 40 A 30 A 30 A All models have a voltage tolerance of 10 15 Input voltage at 50 Hz 60 Hz 380 V 4...

Page 44: ...uring arc stretch 82 A 82 A 78 A 40 A 35 A Fuse time delay 80 A 80 A 80 A 40 A 40 A All models have a voltage tolerance of 10 15 Input voltage at 50 Hz 60 Hz 230 V 400 V Input current at rated output 105 A x 160 VDC 16 8 kW 50 A 29 A Input current during arc stretch 80 A 46 A Fuse time delay 80 A 50 A All models have a voltage tolerance of 10 15 Input voltage at 50 Hz 60 Hz CCC 380 V CE 400 V Inpu...

Page 45: ...le rubber insulated black neoprene jacketed multi conductor IEC60245 4 EN50525 European power cord with CE printed on the cord The H07RN F cord used by Hypertherm also has CCC certification to GB T 5013 4 with CCC printed on the cord Install the power cord if necessary If your work site makes it necessary to install a different power cord than the one that comes with the system refer to Figure 3 o...

Page 46: ... Bulletins Powermax65 85 SYNC Power Cord and Strain Relief Replacement 807020 Powermax105 SYNC Power Cord and Strain Relief Replacement 810420 L1 L2 L3 CSA power cord no ferrite cores CE CCC power cord ferrite cores on power wires and ground wire 419 mm 16 5 inches M5 10 terminal ring approximately 12 mm 0 5 inch long 65 85 102 mm 4 inches 105 152 mm 6 inches L1 L2 L3 Ground Strain relief ...

Page 47: ...ax65 85 SYNC Power Cord and Strain Relief Replacement Field Service Bulletin 807020 for instructions Use an extension cord if necessary Use an extension cord that meets the following requirements Is an approved wire gauge for the cord length and plasma power supply voltage Complies with national and local codes Extension cords can cause the machine to receive less input voltage than the output of ...

Page 48: ...2 8 AWG 16 mm2 6 AWG 25 mm2 4 AWG 480 1 4 mm2 12 AWG 4 mm2 12 AWG 4 mm2 12 AWG 6 mm2 10 AWG 6 mm2 10 AWG 200 240 3 6 mm2 10 AWG 6 mm2 10 AWG 6 mm2 10 AWG 10 mm2 8 AWG 16 mm2 6 AWG 400 480 3 4 mm2 12 AWG 4 mm2 12 AWG 4 mm2 12 AWG 4 mm2 12 AWG 4 mm2 12 AWG 600 3 4 mm2 12 AWG 4 mm2 12 AWG 4 mm2 12 AWG 4 mm2 12 AWG 4 mm2 12 AWG Extension cord length 3 m 10 ft 3 m 7 5 m 10 ft 25 ft 7 5 m 15 m 25 ft 50 ...

Page 49: ...2 6 AWG 25 mm2 4 AWG 35 mm2 2 AWG 480 1 6 mm2 10 AWG 6 mm2 10 AWG 6 mm2 10 AWG 10 mm2 8 AWG 10 mm2 8 AWG 200 240 3 10 mm2 8 AWG 10 mm2 8 AWG 10 mm2 8 AWG 16 mm2 6 AWG 25 mm2 4 AWG 400 480 3 6 mm2 10 AWG 6 mm2 10 AWG 6 mm2 10 AWG 6 mm2 10 AWG 6 mm2 10 AWG 600 3 6 mm2 10 AWG 6 mm2 10 AWG 6 mm2 10 AWG 6 mm2 10 AWG 6 mm2 10 AWG Extension cord length 3 m 10 ft 3 m 7 5 m 10 ft 25 ft 7 5 m 15 m 25 ft 50 ...

Page 50: ... AWG 25 mm2 4 AWG 35 mm2 2 AWG 480 600 3 6 mm2 10 AWG 6 mm2 10 AWG 6 mm2 10 AWG 6 mm2 10 AWG 6 mm2 10 AWG Extension cord length 3 m 10 ft 3 m 7 5 m 10 ft 25 ft 7 5 m 15 m 25 ft 50 ft 15 m 30 m 50 ft 100 ft 30 m 45 m 100 ft 150 ft Input voltage VAC Phase Extension cord gauge 230 3 16 mm2 16 mm2 16 mm2 25 mm2 25 mm2 400 3 10 mm2 10 mm2 10 mm2 10 mm2 10 mm2 Extension cord length 3 m 10 ft 3 m 7 5 m 1...

Page 51: ...rent A and operating mode if necessary on page 72 Use one of the following recommended generators when full arc stretch is necessary such as for many gouging applications These generators let spikes in input current occur when you stretch the plasma arc 15 kW generator for Powermax65 SYNC 20 kW generator for Powermax85 SYNC 30 kW generator for Powermax105 SYNC If a fault occurs set the power switc...

Page 52: ...se an adapter to connect the plasma power supply s 3 wire power cord plug NEMA 6 50P to the 4 wire connector on the generator Refer to Install a 1 phase power cord CSA systems only if necessary on page 47 for more information Table 11 Engine drive requirements CSA 1 phase 50 Hz 60 Hz 230 VAC 240 VAC 3 phase 50 Hz 60 Hz 200 VAC 600 VAC CE CCC 3 phase 50 Hz 60 Hz 380 VAC 400 VAC Engine drive rating ...

Page 53: ... Table 13 Engine drive requirements 200 V 600 V CSA 3 phase 50 Hz 60 Hz 200 VAC 600 VAC 230 V 400 V CE 3 phase 50 Hz 60 Hz 230 VAC 400 VAC 380 V CCC 400 V CE 3 phase 50 Hz 60 Hz 380 VAC 400 VAC Engine drive rating Plasma power supply output current Performance arc stretch 30 kW 105 A Full 22 5 kW 25 kW 105 A Decreased 20 kW 85 A Full 15 kW 70 A Decreased 15 kW 65 A Full 12 kW 65 A Decreased 12 kW ...

Page 54: ...Make sure that the correct gas inlet fitting is installed CSA models come with an industrial interchange quick disconnect nipple with 1 4 NPT threads To install tighten the fitting to 115 kg cm 100 in lb The fitting comes with thread sealant applied CE CCC models come with a British Pipe Thread adapter G 1 4 BSPP with 1 4 NPT threads To install tighten the adapter to 104 kg cm 90 in lb WARNING EXP...

Page 55: ...ons 5 0 microns Maximum water vapor pressure dewpoint 3 C 37 F Maximum oil concentration 0 1 mg m3 for aerosol liquid and vapor Important Any air compressors that supply air to the cutting system must remove oil prior to air delivery Speak to your air compressor manufacturer if you operate the cutting system in temperatures colder than 3 C 37 F or if you are unsure that the air compressor can comp...

Page 56: ...filtration if necessary on page 60 High pressure gas cylinders WARNING GAS CYLINDERS CAN EXPLODE IF DAMAGED Gas cylinders contain gas under high pressure If damaged a cylinder can explode For high pressure regulators comply with the manufacturer s guidelines for safe installation operation and maintenance Before plasma cutting with compressed gas read the safety instructions in the Safety and Comp...

Page 57: ...o the following Refer to the manufacturer s specifications for installation and maintenance procedures of high pressure regulators Make sure that the cylinder has an adjustable high pressure regulator with the following capabilities Gas outlet pressures up to 9 3 bar 135 psi Never use more than the maximum gas pressure of 9 3 bar 135 psi The following gas flow rates Powermax65 85 SYNC 236 L min 50...

Page 58: ...of operating mode cartridge type and torch lead length If your inlet gas pressure goes below these levels while gas is flowing a fault condition can occur A pressure related fault code on the LCD screen can be for a notification or for a condition that stops the cutting process Hypertherm recommends that you do the recommended steps to troubleshoot the fault Refer to Fault codes on page 130 and Ex...

Page 59: ...6 2 bar 90 psi Torch lead length 7 6 m 25 ft 15 m 50 ft 23 m 75 ft Powermax65 SYNC Powermax85 SYNC Powermax105 SYNC 4 1 bar 60 psi 4 5 bar 65 psi 4 8 bar 70 psi Torch lead length 7 6 m 25 ft 15 m 50 ft 23 m 75 ft Powermax65 SYNC Powermax85 SYNC Powermax105 SYNC 4 1 bar 60 psi 4 5 bar 65 psi 4 8 bar 70 psi Process Powermax65 SYNC and Powermax85 SYNC Powermax105 SYNC Cutting 210 slpm 450 scfh 7 5 sc...

Page 60: ...essary Refer to Examine the air filter bowl and filter element on page 171 The built in air filter must not take the place of sufficient external filtration If you work in an environment that is extremely warm and humid or if work site conditions introduce oil vapors or other contaminants into the gas line install an external filtration system that cleans the gas supply before it gets into the pla...

Page 61: ...Procedure Field Service Bulletin 804180 Kit 428719 The oil removal air filter removes oil oil vapor and dirt from the gas supply For more information refer to the Optional Oil Removal Air Filter Kit and Element Replacement Field Service Bulletin 809610 For additional parts related to these filter kits refer to the Powermax65 85 105 SYNC Parts Guide 810490 If you use both external filters install t...

Page 62: ...Install and Set Up the Plasma Power Supply 2 62 810470 Operator Manual Powermax65 85 105 SYNC ...

Page 63: ...line to the fitting on the back of the plasma power supply Refer to page 54 For gas supply requirements refer to Gas supply source on page 55 2 Make sure that the plasma power supply s power cord is correctly connected to electrical power according to national and local codes Refer to Connect to electrical power on page 40 and Prepare the power cord and plug on page 45 ...

Page 64: ...ower 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 65: ...ed and locked in position NOTICE INCORRECT WORK LEADS CAN CAUSE AN UNSTABLE PLASMA ARC Work leads are approved for specific amperages lengths and connectors Make sure that you use a work lead that is approved for your plasma power supply Refer to the Powermax65 85 105 SYNC Parts Guide 810490 The amperage of a work lead is identified near the rubber boot of the work lead connector Keyed opening at ...

Page 66: ...orkpiece or cutting table Attach the work clamp as close as possible to the area being cut Step 3 Install the cartridge NOTICE Do not attach the work clamp under water If the plasma power supply is below the work clamp water can get into the plasma power supply through the work lead and cause severe damage Do not attach the work clamp to the portion of the workpiece to be cut away WARNING INSTANT ...

Page 67: ... or when it is necessary to move the plasma power supply or torch while the plasma power supply is ON Torch LOCK position The yellow label with the X shows that the torch is not prepared to fire Point the torch away from yourself and others and pull the trigger to make sure that it does not fire When the torch is locked the Fault LED comes on and the Torch Cap Sensor icon and 0 50 1 fault code sho...

Page 68: ...low lock X position 3 If this is a new torch remove the vinyl cap from the torch 4 Install the correct Hypertherm cartridge for your cutting or gouging application Cutting and piercing with a hand torch Refer to Select the correct cutting cartridge on page 96 Gouging with a hand torch Refer to Select the correct gouging cartridge on page 111 Cutting piercing and gouging with a machine torch Refer ...

Page 69: ...h lock switch is set to the green ready to fire position when you set the power switch to ON the hand torch puts out a puff of air Refer to Warning puffs of air hand torches on page 70 If the torch lock switch is set to the yellow lock X position when you set the power switch to ON the 0 50 0 or 0 50 1 fault code and Torch Cap Sensor icon show on the status screen Refer to Fault code and LED behav...

Page 70: ...ondition before you continue Refer to Fault codes on page 130 Warning puffs of air hand torches The following happens on SmartSYNC hand torches the first time that you try to fire the torch after moving the torch lock switch to the yellow lock X position and then back to the green ready to fire position This feedback is a warning It does not identify a fault condition It tells you that the torch i...

Page 71: ...fault code and Torch Cap Sensor icon show After you install the cartridge and set the torch lock switch to the green ready to fire position the Fault LED goes off and the fault code changes to 0 50 2 Hand torch After the torch puts out the warning puffs of air the 0 50 2 fault code goes off Machine torch The 0 50 2 fault code shows for approximately 1 second and then goes off When you set the torc...

Page 72: ...a scale identifies the lowest and highest possible amperage setting related to the plasma power supply and Hypertherm cartridge 2 Make sure that the operating mode is correct for your application The plasma power supply automatically sets the operating mode related to the type of Hypertherm cartridge that you install When you install a Hypertherm cutting cartridge the plasma power supply goes to C...

Page 73: ...rrent A related to the type of Hypertherm cartridge that you install For example when you install a 65 A Hypertherm cartridge the plasma power supply sets the output current to 65 A If necessary you can adjust the output current A from the SmartSYNC hand torch Push the button on the amperage adjustment control to move the current setting from one preset amperage to another The amperage for each se...

Page 74: ...tridge type 45 A 65 A 45 A 65 A 35 A 60 A 25 A 55 A 20 A 45 A 35 A 25 A 20 A Cartridge type 45 A 65 A 85 A 45 A 65 A 85 A 35 A 55 A 75 A 30 A 50 A 65 A 25 A 45 A 55 A 35 A 45 A 25 A 35 A 25 A Cartridge type 45 A 65 A 85 A 105 A 45 A 65 A 85 A 105 A 35 A 55 A 75 A 95 A 30 A 50 A 65 A 85 A 45 A 55 A 65 A 35 A 45 A 55 A 30 A 35 A 45 A 30 A 30 A 7 1 2 3 4 5 6 7 1 2 3 4 5 6 7 1 2 3 4 5 6 ...

Page 75: ...tinues to flow from the torch to decrease the temperature of the cartridge This is referred to as postflow Fan activity The cooling fan inside the plasma power supply automatically comes on as necessary during and after cutting to decrease the temperature of internal components Hand torch LED behavior Green torch is prepared to cut Yellow torch is locked or there is a fault condition LED OFF syste...

Page 76: ...k switch to the green ready to fire position 2 Push and hold until the green LED next to the button comes on to go into manual gas pressure mode approximately 2 seconds 3 If necessary push until the selection cursor points to the gas pressure setting 4 Turn the adjustment knob to adjust the gas pressure to the necessary level The arrow next to the pressure bar moves up and down as you adjust the p...

Page 77: ...d the amperage setting stays the same When you do a quick restart or a cold restart of the plasma power supply in manual gas pressure mode the plasma power supply keeps the last manual gas pressure and amperage that you set unless you install a different type of cartridge Adjust the operating mode manually The plasma power supply automatically sets the operating mode related to the type of Hyperth...

Page 78: ...rating mode the plasma power supply keeps that setting until you install a different type of Hypertherm cartridge or you install a different torch Do not set the operating mode when the torch lock switch is in the yellow lock X position When you unlock the torch the plasma power supply automatically sets the operating mode to match the type of cartridge installed If you manually set the operating ...

Page 79: ... 1 Push and hold for 2 seconds to go to the main menu screen 2 Turn the adjustment knob to go to Push to select it 3 Turn the adjustment knob to go to and push to select it The Cartridge Data screen CARTRIDGE DATA 1 shows 4 When you are done push the button to go back to the status screen The following fields show the use data for the installed Hypertherm cartridge STA This field shows the total n...

Page 80: ... can show the cartridge data for pilot arc starts STA and arc transfer time XT on the status screen When you set the STA XT field to on these values stay on the status screen until you set the STA XT field to off 1 Push and hold for 2 seconds to go to the main menu screen 2 Turn the adjustment knob to go to Push to select it 3 Turn the adjustment knob to go to and push to select it The LCD Display...

Page 81: ...Operate the Plasma System 3 Powermax65 85 105 SYNC Operator Manual 810470 81 7 Push to go back to the status screen The STA and XT fields now show on the screen ...

Page 82: ... the cartridge end of life condition as follows The 0 32 0 fault code shows when the system first senses that the Hypertherm cartridge is at end of life The LED on the hand torch also changes to red To remove the fault code install a new cartridge If you restart the system and try to use the same cartridge the 0 32 1 fault code shows to remind you that the cartridge is at end of life The LED on th...

Page 83: ...d the plasma power supply overheats the following occurs The plasma arc stops The temperature fault icon comes on The cooling fan inside the plasma power supply continues to operate When the plasma power supply overheats do the following Leave the plasma power supply on to let the fan cool the plasma power supply Wait for the temperature fault icon to go off before you start to cut again Decrease ...

Page 84: ... go to Push to select it 3 Turn the adjustment knob to go to and push to select it The LCD Display screen LCD DISPLAY shows 4 Turn the adjustment knob to adjust the value in the field to increase or decrease the brightness of the LCD screen Push to enter the value 0 Darkest setting 9 Brightest setting 5 Adjust the value in the field to increase or decrease the contrast of the LCD screen 0 Lowest c...

Page 85: ...knob to increase or decrease the gas pressure Refer to Adjust the gas pressure manually on page 76 Fault LED yellow When this LED is on it shows that there is a fault condition with the plasma power supply This LED also comes on when the torch is set to the yellow lock X position Refer to page 67 Automatic manual gas pressure setting mode selector Push and hold this button until the green LED come...

Page 86: ...nded Metal mode Refer to page 77 for more information When you install a Hypertherm gouging cartridge Cut mode and Expanded Metal mode are not available When you install a Hypertherm cutting cartridge Gouge mode is not available Expanded Metal mode Use this mode with a Hypertherm cutting cartridge to cut expanded metal with a continuous pilot arc Refer to page 78 Cut mode Use this mode with a Hype...

Page 87: ...e adjustment knob on the plasma power supply or the amperage adjustment control on the hand torch to change the output current Installing a Hypertherm cartridge of a different amperage also changes the current setting Non default configuration This icon shows that at least one default system setting has been changed Remote control This icon shows that a CNC or other controller is controlling the p...

Page 88: ... shows a visual indicator of the gas pressure when you are in manual gas pressure mode The midpoint of the vertical bar identifies the automatic pressure setting that is set by the plasma power supply The arrow shows the manual pressure setting as follows When you increase the gas pressure from the set value the arrow goes above the midpoint When you decrease the gas pressure from the set value th...

Page 89: ...d other information about the Hypertherm cartridge and the plasma power supply Refer to page 90 System information Select this icon to go to service related information about printed circuit boards PCBs in the plasma power supply and in the SmartSYNC torch Refer to page 91 Service Select this icon to go to service related information about fault codes radio frequency RF settings and logs and cut c...

Page 90: ...talled on the torch Refer to Monitor cartridge data on page 79 Plasma power supply data Select this icon to see data about plasma power supply use and performance Refer to Power Supply Data screen on page 156 Cartridge history Select this icon to see cumulative cartridge start data for the life of the plasma power supply Refer to Cartridge History screen on page 158 Back Select this icon to go bac...

Page 91: ...r supply s LCD control PCB DSP and power PCB information Select this icon to see service related information about the plasma power supply s power PCB and the firmware on the DSP PCB Torch information Select this icon to see service related information about the SmartSYNC torch that is connected to the plasma power supply Refer to Torch PCB Information screen on page 161 Back Select this icon to g...

Page 92: ...een on page 146 The plasma power supply does not show operational fault codes 0 nn n on this screen Radio frequency information Select this icon to see service related information about radio frequency RF settings and logs This information is for qualified service technicians Cut counters transfer Select this icon to do a transfer of cut counter data before installing a new DSP PCB This feature is...

Page 93: ... 84 or Show cartridge data on the status screen on page 80 CNC interface settings Select this icon to see the node address given to this Powermax plasma power supply if applicable Refer to CNC Interface Settings screen on page 164 System configuration settings Select this icon to set system features to on or off such as the low gas pressure detection feature Refer to Adjust system settings on the ...

Page 94: ...Operate the Plasma System 3 94 810470 Operator Manual Powermax65 85 105 SYNC ...

Page 95: ...g It also makes it easier to cut overhead or in areas that are not easy to reach SmartSYNC hand torch features include the following A control on the torch that lets you adjust the output current A from the torch refer to Adjust the amperage from the hand torch on page 73 Automatic setting of operating mode amperage and gas pressure related to the Hypertherm cartridge that you install the torch ty...

Page 96: ...hile cutting you can use the gray mechanized cutting cartridges on your SmartSYNC hand torch For information on gouging processes and cartridges refer to Gouge with the Hand Torch on page 111 Plasma power supplies are shipped with a starter set of Hypertherm cartridges Cartridge Type Purpose Drag cutting yellow Use these cartridges to drag the torch on the workpiece drag cut for the widest range o...

Page 97: ...ition Pull the trigger to make sure that the torch does not fire a plasma arc WARNING INSTANT ON TORCHES STAY CLEAR OF PLASMA ARC The plasma arc will cut quickly through gloves and skin Put on correct and approved protective equipment Keep hands clothing and objects away from the torch tip Do not hold the workpiece Keep your hands clear of the cutting path Never point the torch toward yourself or ...

Page 98: ...to Expanded Metal mode push the button When you install a cutting cartridge Gouge mode is not available 2 Make sure that the torch lock switch is in the green ready to fire position The first time that you pull the torch trigger after you set the torch to the ready to fire position multiple puffs of air quickly come from the torch This is a warning that the torch is active and will fire an arc the...

Page 99: ... the tip of the cartridge Start the cut from the edge of the workpiece when possible to decrease this damage and to optimize cartridge life 1 With the work clamp attached to the workpiece hold the torch tip perpendicular 90 to the edge of the workpiece 2 Pull the torch s trigger to start the arc Stay at the edge until the arc has cut completely through the workpiece ...

Page 100: ...Cut with the Hand Torch 4 100 810470 Operator Manual Powermax65 85 105 SYNC 3 Drag the torch lightly across the workpiece to continue with the cut Keep a smooth stable pace ...

Page 101: ...ng pierce Rolling pierce Use a rolling pierce to cut a workpiece that is 8 mm 5 16 inch or thicker or if a straight pierce does not pierce the workpiece 1 Attach the work clamp to the workpiece 2 Straight pierce Hold the torch perpendicular 90 to the workpiece Rolling pierce Hold the torch at an approximate 30 angle to the workpiece with the torch tip touching the workpiece before firing the torch...

Page 102: ...rigger to start the arc while still at an angle to the workpiece then move the torch up to the perpendicular 90 position 4 Hold the torch in position while continuing to pull the trigger When sparks go out below the workpiece the arc has pierced the material 5 When the pierce is complete drag the torch tip lightly across the workpiece to continue with the cut 1 2 3 ...

Page 103: ...rd cartridge WARNING ARC RAYS CAN BURN EYES AND SKIN When you use FlushCut cartridges wear a face shield that covers your entire face Use a shield with a shade 10 lens Plasma arc rays produce intense visible and invisible ultraviolet and infrared rays that can burn eyes and skin WARNING INSTANT ON TORCHES PLASMA ARC CAN CAUSE INJURY BURNS Ignition of the plasma arc occurs immediately when you pull...

Page 104: ...ip of the cartridge onto the flat workpiece 2 Make sure that the flat side of the tip of the cartridge is flush with the flat workpiece Adjust as necessary 3 Fully install the cartridge 4 Optional To do metal washing decrease the output current A as necessary 5 Unlock the torch 6 Put the flat side of the tip of the cartridge 3 mm 6 mm 1 8 inch to 1 4 inch from the vertical workpiece ...

Page 105: ...e Keep a standoff of 3 mm 6 mm 1 8 inch to 1 4 inch from the vertical workpiece Keep a smooth stable pace 9 If it is necessary to adjust the flat side of the tip of the cartridge to complete the cut lock the torch before you touch the cartridge 1 2 3 WARNING RISK OF BURNS AND ELECTRIC SHOCK USE INSULATED GLOVES Always put on insulated gloves when changing the cartridges The cartridges get very hot...

Page 106: ...ch as you cut 15 30 angle from vertical Hold the torch tip perpendicular to the workpiece so that the head of the torch is at a 90 angle to the cutting surface Observe the cutting arc as the torch cuts If you fire the torch unnecessarily you shorten the life of the cartridge For straight line cuts use a straight edge as a guide To cut circles use a template or a radius cutter attachment a circle c...

Page 107: ... workpieces that you cut should be equal to or less than the thickness specified for this system and cartridge Refer to Cutting specifications on page 35 For best results do not cut material that is thicker than what is specified for this system and cartridge Expanded metal cutting and pilot arc time Expanded metal has a slotted or mesh pattern Cutting expanded metal wears out cartridges more quic...

Page 108: ...aults As a cartridge wears unwanted material can collect inside the cartridge and cause 0 30 0 faults to occur Refer to page 130 In some conditions you can remove this material by carefully shaking the cartridge Examine the crown The crown is the square copper piece inside of the cartridge Push down the crown and then release the spring tension A crown in good condition goes back to its start posi...

Page 109: ...85 105 SYNC Operator Manual 810470 109 Hand torch components dimensions and weights Components 1 2 3 4 5 6 7 1 Amperage adjustment control 2 Torch lock switch 3 Shell 4 Cartridge 5 Safety trigger 6 Strain relief for torch lead 7 Torch lead ...

Page 110: ...torch with 7 6 m 25 foot lead 3 2 kg 7 lb Hand torch with 15 m 50 foot lead 5 9 kg 13 lb Hand torch with 23 m 75 foot lead 8 2 kg 18 lb Without a cartridge installed 267 mm 10 5 inch 75 99 mm 3 9 inch 70 mm 2 75 inch 32 mm 1 25 inch 260 mm 10 2 inch 268 mm 10 5 inch 320 mm 12 6 inch 51 mm 2 0 inch 15 32 mm 1 25 inch 68 mm 2 7 inch ...

Page 111: ...or more precise metal removal shallow gouge profiles and light metal washing A slower gouging speed is recommended but the diffuse plasma arc gives better visibility than Maximum Removal cartridges If you are learning to gouge start with Maximum Control cartridges Maximum Removal gouging green Use these cartridges for aggressive metal removal deep gouge profiles and extreme metal washing A faster ...

Page 112: ...s gouging cartridge can also be used When you install a gouging cartridge the system goes to Gouge mode and the Gouge LED comes ON refer to Hand torch LED behavior on page 75 When you install a gouging cartridge Cut mode and Expanded Metal mode are not available 2 Before firing the torch hold the torch at approximately a 40 45 angle to the workpiece with the torch tip approximately 6 mm 12 mm 1 4 ...

Page 113: ... 4 in 5 Keep this position as you push the plasma arc in the direction of the gouge that you want to create 6 Change the position of the torch as necessary to get the gouge contour that you want Refer to Change the gouge contour on page 114 Keep at least a small distance between the torch tip and the molten metal to increase cartridge life and prevent damage to the torch Direction of travel ...

Page 114: ...tour 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 Figure 6 Factors that change the gouge contour Standoff arc stretch Angle of the torch Turn of the torch Torch center line Speed Output current A ...

Page 115: ... 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 Refer to Amperage settings by plasma power supply and cartridge on page 74 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 c...

Page 116: ...he 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 narrow...

Page 117: ...ver or panels must be done by a qualified technician Refer to the Safety and Compliance Manual 80669C for more safety information WARNING INSTANT ON TORCHES PLASMA ARC CAN CAUSE INJURY BURNS Ignition of the plasma arc occurs immediately when you pull the torch trigger Before changing the cartridge one of the following steps is necessary Whenever possible complete the first step Set the power switc...

Page 118: ...ecklist record any problems or questions If you cannot find a solution to the problem by 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 fro...

Page 119: ...5 105 SYNC Mechanized Cutting Guide 810480 For example keep the torch lead and work lead together by using cable ties or intertwining them like a twisted pair Also keep the routing of the torch lead and work lead separate from the shielded cables and from all other components of the mechanized cutting system Does other industrial equipment share the same ground as the plasma power supply This can ...

Page 120: ...other power source Is there any visible damage to the power cord Are any wires exposed or frayed Examine the power cord wires in the power plug or line disconnect box Are any of the wires shorted Is the power plug correct for the power cord For example do not install a 1 phase power plug on a 3 phase power cord Refer to Prepare the power cord and plug on page 45 Powermax65 85 SYNC CSA plasma power...

Page 121: ...he work clamp have good metal to metal contact If not remove any rust paint or other debris that causes interference Examine the torch and torch lead Is the torch lead connected correctly to the plasma power supply Refer to page 64 The torch lead connector makes a click when it is fully connected Examine the torch lead Are any wires exposed or frayed Is the lead twisted or kinked Examine the torch...

Page 122: ...s than 15 m 50 feet Use an internal diameter of 13 mm 1 2 inch for hoses that are 15 m 30 m 50 feet 100 feet Is sufficient gas pressure getting to the plasma power supply Refer to page 125 Are you able to keep gas pressure constant while you are cutting Do a gas test to see if the plasma power supply s actual output gas pressure is lower than the set pressure by more than an acceptable quantity Th...

Page 123: ...er is on at the main power panel or at the line disconnect switch box Make sure that the circuit breaker did not open trip Make sure that the line voltage is not too low more than 15 below the rated voltage Refer to page 24 and page 41 The LCD screen on the front panel is too bright or too dark Very hot environments can make the LCD screen darker Very cold environments can make the LCD screen brig...

Page 124: ...ing a generator a quick restart does not always remove the fault Do a cold restart instead The system changes the output current A or the operating mode after I set them Set the torch lock switch to the ready to fire position before you adjust the amperage or operating mode The system does not keep those settings while the torch lock switch is in the yellow lock X position When you set the torch l...

Page 125: ...re 15 m 30 m 50 feet 100 feet use an internal diameter of 13 mm 1 2 inch or greater Pressure setting The plasma power supply adjusts gas pressure automatically but you can adjust the gas pressure manually if necessary Refer to page 76 If you manually adjust the gas pressure and then start to see problems with cut quality or cut performance set the gas pressure back to the default setting Refer to ...

Page 126: ...arm and humid or if work site conditions let oil vapor or other contaminants into the gas line install an external filtration system that cleans the gas supply before it gets into the plasma power supply Refer to page 60 To keep a clean gas line 1 Examine the air filter element in the plasma power supply s built in air filter Replace it if it is contaminated Refer to page 171 2 Clean the air filte...

Page 127: ...gher rate of 0 30 0 faults is typical as a cartridge gets near end of life Refer to Signs that a cartridge is near end of life on page 108 and Cartridge maintenance on page 170 Examine the gas filtration system for signs of moisture Refer to page 126 Cartridge life is shorter than expected Examine the gas pressure and the gas supply hose Refer to page 125 Examine the gas filtration system for sign...

Page 128: ...g mode for the Hypertherm cartridge If it does not look at the LCD screen Do you see the non default configuration icon at right If yes there is possibly a system configuration setting that you must change Refer to page 151 If no there is possibly a problem with the Hypertherm cartridge torch or plasma power supply Speak to your distributor or authorized repair facility Make sure that the torch is...

Page 129: ...o back to smart mode the fault LED on the torch changes to green Refer to Smart mode versus basic mode on page 151 Problem Solution Problem Solution The arc goes out during gouging Decrease the arc stretch standoff Put the torch in a more upright 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 wan...

Page 130: ...n one fault occurs at the same time the fault code with the highest importance shows The Power Supply Log screen shows the 10 most recent faults Refer to page 146 The status LED on the SmartSYNC hand torch also shows the fault status The gouge does not have enough width Tilt the torch down so that it is closer to the workpiece Increase the arc stretch standoff Decrease the gouging speed Increase o...

Page 131: ...he SmartSYNC torch is in the yellow lock X position Refer to page 71 It also identifies fault conditions in which the Hypertherm cartridge is loose incorrectly installed or missing To remove the fault condition correctly install the Hypertherm cartridge Temperature This icon identifies fault conditions in which the plasma power supply is outside the range of permitted operating temperatures Refer ...

Page 132: ...hese faults do not show on the Power Supply Log screen An operational fault code can be for a notification or for a condition that stops the cutting process Hypertherm recommends that you do the steps in the following table for all fault codes that occur Troubleshooting all faults helps you to get optimal cut quality and consumable life Cartridge Communications This icon identifies faults with wir...

Page 133: ...ing There is a problem with the remote control or the software interface to the system The system cannot interpret the operating mode output current or gas pressure information coming from the controller Examine the programming code for incorrect process variables Repair the controller 0 11 1 The remote control output current A is incorrect or not permitted for the installed cartridge The permitte...

Page 134: ...ee if the plasma power supply s actual output gas pressure is lower than the set pressure by more than an acceptable quantity The set pressure is the gas pressure that the system sets to align with the type of cartridge and torch installed Refer to Do a gas test on page 147 Have a qualified service technician examine the solenoid valve inside the plasma power supply Speak to your distributor or au...

Page 135: ...e the system automatically adjusts the following settings to prevent possible damage to the workpiece and cartridge It sets the output current to 45 A It sets the operating mode to Cut mode It sets the output gas pressure to cut pressure If necessary you can manually change these settings to cut without a data connection 0 14 1 Flashes yellow The cartridge is not recognized This fault shows when a...

Page 136: ...e fault to go away and continue to cut If you use serial communications this fault can occur temporarily on the CNC when you set the plasma power supply to OFF O Wait for 1 minute for the fault to go away on its own If this fault continues to occur it can identify a possible hardware fault with an internal component A hardware fault shows as a 1 nn n 2 nn n or 3 nn n fault code A qualified service...

Page 137: ...sma power supply s actual output gas pressure is lower than the set pressure by more than an acceptable quantity The set pressure is the gas pressure that the system sets to align with the type of cartridge and torch installed Refer to page 147 If there is no apparent problem with the inlet gas supply examine the air filter bowl and air filter element in the plasma power supply Clean or replace as...

Page 138: ... is not worn or damaged Refer to Signs that a cartridge is near end of life on page 108 and Cartridge maintenance on page 170 Hand torch Move the torch lock switch to the yellow lock X position then move the torch lock switch to the green ready to fire position Fire the torch 1 time to get the warning puffs of air This can clean away unwanted material that has collected around the tip of the cartr...

Page 139: ...or correction insulated gate bipolar transistor PFC IGBT is too cold This is applicable to CSA and to Powermax105 SYNC 230 V 400 V CE models only These fault codes stop the system from operating Do the following You can continue to use the system when its internal temperature is no longer too hot or too cold Hypertherm recommends that you operate the system only in external temperatures between 10...

Page 140: ...e cartridge while the power switch on the plasma power supply is set to ON I Do a quick restart In some conditions this fault code can show when the torch is not connected Make sure that the torch lead is correctly connected to the FastConnect receptacle on the front of the plasma power supply Do a quick restart If the Hypertherm cartridge is in good condition and is installed correctly the torch ...

Page 141: ...e the fault Mini machine torch This fault code is not applicable to the mini machine torch 0 51 0 Yellow Yellow The plasma power supply was receiving a signal to start cutting at the same time that the power switch was set to ON I With a machine torch this condition is sometimes referred to as a stuck start This fault code stops the system from operating Do the following A quick restart is necessa...

Page 142: ...the following A cold restart is necessary The input line voltage is too low more than 15 below the rated voltage Have an electrical technician examine the line and increase the voltage Refer to page 24 and page 41 If applicable disconnect the system from generator power or set the generator mode feature to on Refer to Troubleshoot power related problems with generators on page 145 0 60 2 Yellow Ye...

Page 143: ...ode feature to on Refer to Troubleshoot power related problems with generators on page 145 0 98 0 Yellow Yellow An internal communication failure occurred between the LCD control PCB and the DSP PCB This fault code can stop the system from operating in some conditions You can continue to cut but the controls on the front panel are not available Hypertherm recommends that you do the following Set t...

Page 144: ...ew Hypertherm cartridge does not remove the fault condition a component in the SmartSYNC torch has possible damage A qualified service technician must examine the torch Speak to your distributor or authorized repair facility 0 98 2 Flashes yellow A communication failure occurred between the torch and the plasma power supply This fault code does not stop the system from operating Hypertherm recomme...

Page 145: ... setting to on This setting is on the Feature Configuration screen FEATURE CONFIG Hypertherm recommends that only experienced operators change this setting This setting decreases the system s sensitivity to changes in current and voltage from incoming power Refer to page 149 Make sure that you set the GEN field to off when you are not using a generator If you continue to have problems with input l...

Page 146: ...Select on the main menu screen 2 Select to go to the POWER SUPPLY LOG screen 3 Turn the adjustment knob to move through the list This field shows the list of fault codes numbered 0 9 starting with the most recent faults XT This field shows when each fault occurred The value is a timestamp in hours HH minutes MM and seconds SS HH MM SS This value is related to the XT field on the Power Supply Data ...

Page 147: ...puffs of air 3 Make sure that the correct operating mode is selected for the process that you want to examine Cut mode Gouge mode or Expanded Metal mode 4 Push and hold the operating mode button for 2 seconds until the gas test screen shows Gas flows continuously from the torch when the plasma power supply is in gas test mode WARNING CHANCE OF BURNS AND CUTS Point the torch away from you before do...

Page 148: ...erating mode button to stop the gas test and go back to the status screen Gas stops flowing from the torch 7 If the output gas pressure was too low in step 5 examine the inlet pressure from the gas supply source For inlet pressure requirements refer to Gas supply source on page 55 Do a gas test in manual gas pressure mode If the plasma power supply is in manual gas pressure mode when you start a g...

Page 149: ...tus screen By default this screen is locked To change any of the settings on this screen you must first unlock the screen using the icon 1 Push and hold for 2 seconds to go to the main menu screen 2 Select on the main menu screen 3 Select to go to the FEATURE CONFIG screen 4 Turn the adjustment knob to go to the field 5 Push to select the field 6 Turn the adjustment knob to set the field to the un...

Page 150: ...this field to off the system no longer shows the 0 32 0 or 0 32 1 fault codes when the cartridge gets to end of life Refer to page 82 This field is on by default But the system temporarily sets the feature to off when any one of the following conditions occurs You install a FineCut hand cutting cartridge You set the output current below 40 A for any Hypertherm cartridge GFL Do not use this setting...

Page 151: ...system does many things for you automatically including the following It sets the operating mode and the output current A to the correct settings for your Hypertherm cartridge For example if you install a 65 A gouging cartridge the system automatically goes into Gouge mode and sets the amperage to 65 A It records use data for the Hypertherm cartridge and for the plasma power supply You can see car...

Page 152: ...e time for approximately 2 seconds until the FACTORY RESET message shows 2 Turn the adjustment knob to go to and push to select it The system goes back to factory default settings as follows The brightness contrast and CNC interface fields go back to their default settings All of the fields on the Feature Configuration FEATURE CONFIG screen go back to their default settings The non default configu...

Page 153: ...B and Power PCB Information screen on page 160 Torch PCB Information screen on page 161 Radio Frequency RF Data screen on page 162 Cut Counters Transfer screen on page 163 CNC Interface Settings screen on page 164 For information on fault codes refer to See recent fault codes Power Supply Log screen on page 146 1 To go to the main menu screen push and hold for 2 seconds 2 Turn the adjustment knob ...

Page 154: ...own and see the CARTRIDGE DATA 2 screen P N This field shows the part number nnnnnn and the version X of the Hypertherm cartridge NAM This field shows the Hypertherm cartridge type C HAND Standard cutting cartridge for hand torch C HFNC FineCut cartridge for hand torch C MECH Standard cutting cartridge for machine torch C MFNC FineCut cartridge for machine torch C FLUSH FlushCut cartridge G RMVL M...

Page 155: ... in its life XFR This field shows the total number of arc transfers that the Hypertherm cartridge has done in its life PT This field shows the cumulative pilot arc time in hours minutes and seconds HH MM SS that the Hypertherm cartridge has had in its life XT This field shows the cumulative arc transfer time in hours minutes and seconds HH MM SS that the Hypertherm cartridge has had in its life F0...

Page 156: ... output gas pressure in psi F This field shows the active fault code if any VL This field shows the input voltage VB This field shows the bus voltage VBUS VO This field shows the arc voltage IP This field shows the boost PFC IGBT current in amperage This field shows on the screen for CSA and for Powermax105 SYNC 230 V 400 V CE models only TP This field shows the boost PFC IGBT temperature in Celsi...

Page 157: ...ansfers the plasma power supply has done in its life PT This field shows the cumulative pilot arc time in hours minutes and seconds HH MM SS that the plasma power supply has had in its life XT This field shows the cumulative arc transfer time in hours minutes and seconds HH MM SS that the plasma power supply has had in its life ...

Page 158: ...life while in Expanded Metal mode This field shows the total number of Hypertherm cutting cartridge starts that the plasma power supply has done in its life while in Cut mode This field shows the total number of Hypertherm gouging cartridge starts that the plasma power supply has done in its life This field shows the total number of pilot arc starts that the plasma power supply has done while cart...

Page 159: ...cartridge was used LCD Control PCB Information screen Go to the LCD Control PCB Information screen LCD CTRL BD INFO to see service related information about the firmware on the plasma power supply s LCD control PCB The technical information on this screen is for qualified service technicians to refer to when troubleshooting 1 Select on the main menu screen 2 Select to go to the LCD CTRL BD INFO sc...

Page 160: ...nformation screen DSP PWR BD INFO to see service related information about the plasma power supply s power PCB and the firmware on the digital signal processing DSP PCB The technical information on this screen is for qualified service technicians to refer to when troubleshooting 1 Select on the main menu screen 2 Select to go to the DSP PWR BD INFO screen ...

Page 161: ...for qualified service technicians to refer to when troubleshooting The plasma power supply cannot show torch information for a non SmartSYNC torch 1 Select on the main menu screen 2 Select to go to the TORCH BD INFO screen TYP This field shows the torch type followed by the length of the torch lead in feet SH SmartSYNC hand torch SM SmartSYNC machine torch BH Hand torch and the plasma power supply...

Page 162: ...reen Go to the Radio Frequency Data screen RF DATA to see service related information about radio frequency RF settings and logs The technical information on this screen is for qualified service technicians to refer to when troubleshooting 1 Select on the main menu screen 2 Select to go to the RF DATA screen ...

Page 163: ...OUNTERS to do a transfer of the plasma power supply s cut counter data before installing a new DSP PCB This screen is for qualified service technicians For instructions on how to use this screen refer to the Powermax65 85 105 SYNC DSP PCB Replacement Field Service Bulletin 810950 1 Select on the main menu screen 2 Select to go to the CUT COUNTERS screen ...

Page 164: ...NC Interface Settings screen CNC INTERFACE to set parameters for serial communication This screen is for qualified service technicians For instructions on how to use this screen refer to the Powermax65 85 105 SYNC Mechanized Cutting Guide 810480 1 Select on the main menu screen 2 Select to go to the CNC INTERFACE screen ...

Page 165: ...lectric power before doing installation or maintenance You can get a serious electric shock if electric power is not disconnected Electric shock can seriously injure or kill you All 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 ...

Page 166: ...if the plasma power supply is ON and the torch lock switch is not in the yellow lock X position WARNING INSTANT ON TORCHES PLASMA ARC CAN CAUSE INJURY BURNS Ignition of the plasma arc occurs immediately when you pull the torch trigger Before changing the cartridge one of the following steps is necessary Whenever possible complete the first step Set the power switch on the plasma power supply to OF...

Page 167: ...of life on page 108 and Cartridge maintenance on page 170 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 ...

Page 168: ...ine torch Send a START STOP command from the CNC Make sure that the torch does not fire Unlock the torch Move the torch lock switch to the green ready to fire position Point the torch away from yourself and others Hand torch Pull the trigger 1 time Make sure that the torch does not fire Make sure that multiple puffs of air quickly come from the torch instead Refer to Warning puffs of air hand torc...

Page 169: ... the trigger for damage Hand and machine torches Examine the torch body for cracks and exposed wires Have a qualified service technician replace any damaged parts Speak to 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 d...

Page 170: ...aterial inside the nozzle 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...

Page 171: ...r when enough water collects to engage the float mechanism inside the bowl To manually drain water from the bowl remove the nut at the bottom of the bowl with your hand To prevent damage to the plastic nut do not use a wrench or other tool Remove the air filter bowl and filter element 1 Set the power switch on the plasma power supply to OFF O 2 Disconnect the power cord from electrical power 3 Dis...

Page 172: ... to go through the gas line in the plasma power supply and torch Over time contamination can cause damage to internal components Make sure that the O ring is not cracked or damaged Clean the air filter bowl by removing any oil dirt or other contaminants Yellow material on the filter bowl often shows that oil is getting into the gas supply line 2 3 2 3 2 Example of a dirty air filter bowl NOTICE DI...

Page 173: ...ry warm and humid Replace the filter element when it is dirty or starts to deteriorate Refer to the Powermax65 85 105 SYNC Parts Guide 810490 Also refer to Replace the air filter bowl O ring and filter element on page 173 Replace the air filter bowl O ring and filter element 1 To replace the filter element twist and pull the plastic fittings away from the filter element approximately a 1 4 turn Se...

Page 174: ...n on the top plastic fitting until you hear a click Install the air filter bowl and filter element 1 Vertically align the filter bowl and push it up into the receptacle in the rear panel 2 Turn the filter bowl 45 degrees to the left until you hear a click 3 Reconnect the gas supply to the rear of the plasma power supply 4 Reconnect the power cord ...

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