Hypertherm Powermax65 SYNC Plasma Cutter User Guide

Hypertherm Powermax65 SYNC Plasma Cutter

WARNING

READ THE SAFETY INFORMATION Before operating or maintaining any Hypertherm equipment, read the Safety and Compliance Manual and the Operator Manual for important safety information.

The system comes with the following product documentation:

• Quick Setup Guide (810520MU)
• Cut Charts Guide (810500MU)
• USB memory stick:
  • Operator Manual (810470)
  • Safety and Compliance Manual (80669C)
  • Mechanized Cutting Guide (810480)
  • Parts Guide (810490)

Hand cutting

Much of this Quick Reference Guide is specific to hand cutting. For information on mechanized cutting, refer to the Mechanized Cutting Guide.

Select the cartridge

• This system uses a single-piece cartridge instead of a set of consumables that contains 4 or 5 separate parts.
• Standard hand cutting cartridges: drag cut for the widest range of hand cutting and piercing applications.
• FineCut® cartridges: get a narrower kerf on thin mild steel and stainless steel up to 3 mm (10 gauge).
• Maximum Removal gouging cartridges: for aggressive metal removal, deep gouge contours, and extreme metal washing.
• Maximum Control gouging cartridges: for more precise metal removal, shallower gouge contours, and light metal washing.
• Standard mechanized cutting cartridges: for use on machine torches for the widest range of mechanized cutting applications.
• FlushCut® cartridges: remove lugs, bolts, pad eyes, and other attachments without piercing or damaging the workpiece below.

Hand cutting cartridges

Gouging cartridges

Mechanized cutting cartridges

FlushCut cartridges

Recommended cut capacity – handheld

Powermax65 SYNC

Powermax85 SYNC

Powermax105 SYNC

Operate the system

Before you use the system

1. Connect the gas supply to the plasma power supply.
2. Connect the plasma power supply to electrical power.

Step 1 – Connect the torch lead

Step 2 – Connect the work lead and work clamp

Step 3 – Install the cartridge

SmartSYNC™ torches have a switch that locks the torch. This prevents the torch from firing even if the plasma power supply is ON. The SmartSYNC mini machine torch does not have a switch that locks the torch.

Lock the torch before you install a new cartridge

Step 4 – Set the power switch to ON (I)

Step 5 – Unlock and fire the torch

1. Unlock the torch
2. Hand torches only: Pull the torch trigger 1 time to get warning puffs of air. The plasma power supply makes a pressure-release sound with each puff of air.
3. Pull the torch trigger again to fire a plasma arc.

Step 6 – Adjust the output current (A) if necessary

The output current (A) is set automatically. If necessary, you can adjust it. Unlock the torch before you change the amperage, the operating mode, or the gas pressure.

Adjust the amperage using the hand torch

Push the button to increase and decrease the amperage.

Adjust the amperage using the plasma power supply

Use the front panel controls

Use the menu screens

1. Push and hold for 2 seconds to go to the main menu screen.
2. Turn to go to an icon on the screen. Push to select it.
3. Select to go to use data and other information about the Hypertherm cartridge and the plasma power supply.
4. Select to go to service-related information about printed circuit boards (PCBs) in the plasma power supply and in the SmartSYNC torch.
5. Select to go to service-related information about fault codes, radio frequency (RF) settings and logs, and cut counter transfers.
6. Select to go to system settings that you can change, such as the brightness and contrast of the LCD screen.

Refer to the Operator Manual for more information on all screens, fields, and settings.

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Use the LED indicators on the SmartSYNC hand torch

The SmartSYNC hand torch shows you when the torch is prepared to cut. It also shows you when you are in Cut mode or Gouge mode.

Use the Powermax SYNC system

When you install a Hypertherm cartridge on a SmartSYNC torch, the system does the following things for you:

• Sets the operating mode and the output current (A) automatically. For example, if you install a 65 A gouging cartridge, the system automatically goes to Gouge mode and sets the amperage to 65 A.
• Records use data for the cartridge and for the plasma power supply.
• Sets the gas pressure automatically.

Cut, pierce, and gouge metal

Attach the work clamp to the workpiece before cutting.

Cut

1. Start at the edge of the workpiece. Hold the torch at a 90° angle to the workpiece.
2. Fire the torch. Stay at the edge until the plasma arc cuts through the workpiece.
3. Drag the torch lightly across the workpiece. Keep a stable pace. No standoff is required.

Rolling pierce

1. Hold the torch at an approximate 30° angle. Put the tip of the torch on the workpiece.
2. Pull the trigger to start the plasma arc. Tilt the torch up until it is at a 90° angle to the workpiece.
3. Hold the torch in position until the plasma arc pierces fully through the workpiece.

Gouge

1. Hold the torch at an approximate 40° – 45° angle with the torch tip 6 mm – 12 mm (1/4 in. – 1/2 in.) from the workpiece.
2. Pull the trigger to get a pilot arc. Transfer the arc to the workpiece.
3. Stretch the plasma arc to 25 mm – 32 mm (1 in. – 1-1/4 in.). As you gouge, change the position of the torch to get the gouge contour that you want. Refer to the Operator Manual for details.

Troubleshoot common problems

Identify when to install a new cartridge

The system tells you when a Hypertherm cartridge is at end-of-life. Look for these fault codes. This feature helps to prevent damage to the torch. You can choose to replace the cartridge before it gets to this condition if the cut quality is no longer satisfactory.

0-32-0| ****| This 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. Hypertherm strongly recommends that you install a new cartridge.

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0-32-1| ****| This fault code shows when you install a used Hypertherm cartridge that had the 0-32-0 fault before. The LED on the hand torch also flashes yellow. The 0-32-1 fault code reminds you that the cartridge is at end-of-life. Hypertherm strongly recommends that you install a new cartridge.

When it is necessary to replace a cartridge, replace the full cartridge with a new one.

Do not try to disassemble the cartridge

No maintenance is necessary on the cartridge except possibly to remove molten metal from the tip of the cartridge. The cartridge end-of-life detection feature is disabled when one of the following conditions occurs:

• You install a FineCut hand cutting cartridge.
• You set the output current below 40 A for any type of Hypertherm cartridge.

Identify probelms with cut quality

Optimal cut quality

What to look for

• Easy-to-see lag lines with an angle of 10° – 15°
• Minimal dross
• Square edges
• No top splatter
• No discoloration

Too much of a bevel angle

Possible cause

• Torch is not at a 90° angle to the workpiece
• Amperage is too low
• Speed is too fast
• Worn cartridge

Solution

• Align the torch at a 90° angle to the workpiece
• Increase the amperage
• Decrease the speed
• Install a new cartridge

Hardened dross

Possible cause

• Speed is too fast
• Amperage is too low

Solution

• Decrease the speed
• Increase the amperage

Identify common system problems

Many common problems with Powermax® systems can be solved by doing the following checks. For a more complete list of problems like these, refer to Start here: troubleshooting checklist in the Operator Manual.

• Examine the cartridge:
  • Is the cartridge installed correctly?
  • Is the cartridge worn or damaged?
• Examine the gas supply line:
  • Are there any signs of contamination from oil, water, or dirt? It is extremely important to keep a clean, dry gas line.
  • Are there any signs of leaks?
  • Are any of the hoses twisted or kinked?
  • Are you able to keep sufficient gas pressure while cutting? Do a gas test if needed. Refer to Do a gas test in the Operator Manual.
• Examine the power cord:
  • Are the power cord wires connected correctly and fully tightened in the plasma power supply and in the power plug or line-disconnect box?
  • Is the ground wire connected correctly?
  • Is the power plug correct for the power cord?
• Examine the work lead and work clamp:
  • Is the work lead connected correctly to the plasma power supply?
  • Is the work clamp connected to the workpiece that you are cutting? Does it have good metal-to-metal contact?
• Examine the torch and torch lead:
  • Is the torch lead twisted or kinked?
  • Is the O-ring on the torch head dry, cracked, or damaged?
  • Is the mechanized cutting system correctly grounded and shielded? For best practices, refer to the Mechanized Cutting Guide.
  • If you see a fault code and fault icon on the LCD screen, refer to Fault codes in the Operator Manual for more information.

In some conditions, restarting the plasma power supply can remove a fault condition.

References

• Plasma, waterjet and laser cutting systems from Hypertherm
• hypertherm.com/patents
• Hypertherm Associates
• Hypertherm Associates

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