Hypertherm SYNC Powermax 105 Manuals (2024)

Table of Contents

9

15

17

19

21

• Make Sure that You Have All the System 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

    • Critical Raw Materials

      31

    • Find the Part Number for Your System

      31

    • Symbols and Marks

      32

    • IEC Symbols

      33

    • Acoustical Noise Levels

      34

    • Radio Frequency Identification (RFID) Specifications

      34

  • Cutting Specifications

    35

    • Maximum Cut Speeds (Mild Steel)

      35

    • Recommended Cut Capacity - Hand Cutting

      35

    • Recommended Pierce Capacity

      35

    • Gouge Capacity

      36

  • Set up the Plasma Power Supply

    36

    • Plasma Power Supply Dimensions and Weights

      38

    • Powermax65 SYNC and Powermax85 SYNC

      38

    • Powermax105 SYNC

      39

    • Work Lead Weights

      39

  • Connect to Electrical Power

    40

    • Install a Line-Disconnect Switch

      40

    • Rated Output (Cutting Power) of the Plasma Power Supply

      41

    • Requirements for Grounding

      41

    • Voltage Configurations

      41

    • Powermax65 SYNC

      42

    • Powermax85 SYNC

      43

    • Powermax105 SYNC

      44

  • Prepare the Power Cord and Plug

    45

    • Install the Power Cord (if Necessary)

      45

    • Install the Power Plug

      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

    • Powermax105 SYNC Systems

      53

  • Connect the Gas Supply

    54

    • Gas Supply Source

      55

    • High-Pressure Gas Cylinders

      56

    • Inlet Gas Pressure Requirements (While Gas Is Flowing)

      58

    • Maximum Inlet Pressure

      58

    • Minimum Inlet Pressure

      58

    • Optimum Inlet Pressure

      58

    • Cutting

      59

    • Maximum Control Gouging

      59

    • Maximum Removal Gouging

      59

    • Recommended Gas Inlet Flow Rates

      59

    • Add Additional Gas Filtration (if Necessary)

      60

63

• Make Sure that the Plasma Power Supply Is Connected to Gas and Power

  63

• Step 1 - Connect the Torch Lead

  64

• Step 2 - Connect the Work Lead and Work Clamp

  65

  • Work Lead

    65

  • Work Clamp

    66

  • Step 3 - Install the Cartridge

    66

    • Lock the Torch

      67

    • Install the Cartridge

      68

  • Step 4 - Set the Power Switch to on (I)

    69

  • Step 5 - Unlock the Smartsync Torch

    70

    • Warning Puffs of Air (Hand Torches)

      70

    • Fault Code and LED Behavior

      71

  • Step 6 - Adjust the Output Current (A) and Operating Mode if Necessary

    72

  • Step 7 - Use the Smartsync Torch

    73

    • Adjust the Amperage from the Hand Torch

      73

    • Use 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

    • Hand Torch LED Behavior

      75

    • Temperature Control

      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 Cartridge Data

    79

    • Monitor Data for Individual Cartridges

      79

    • Show Cartridge Data on the Status Screen

      80

  • When to Replace the Cartridge (Fault Code 0-32-N)

    82

    • Conditions When Cartridge End-Of-Life Detection Is Disabled

      82

  • Prevent Overheating

    83

    • Decrease Arc Stretch

      83

  • Adjust Brightness and Contrast

    84

  • Controls and Indicators on the Plasma Power Supply

    85

    • Cutting Controls

      85

    • Status Screen

      87

    • Fault Codes and Fault Icons

      88

    • Gas Pressure Indicators

      88

    • Main Menu Screen

      89

    • Cartridge and Power Supply Data Submenu

      90

    • System Information Submenu

      91

    • Service Information Submenu

      92

    • System Settings Submenu

      93

95

• About the Hand Torch

  95

• Select the Correct Cutting Cartridge

  96

• Prepare to Fire the Torch

  97

• Start a Cut from the Edge of the Workpiece

  99

• Pierce a Workpiece

  101

• Use a Flushcut Specialty Cartridge

  103

• Guidelines for Hand Torch Cutting

  106

  • Guidelines for Hyaccess 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

    • 75° Torch

      110

    • Dimensions

      110

    • Weights

      110

111

• Select the Correct Gouging Cartridge

  111

• Gouge with the Hand Torch

  112

• Change the Gouge Contour

  114

117

• Start Here: Troubleshooting Checklist

  118

• Common Problems

  123

  • Cold Restarts and Quick Restarts

    124

    • Do a Cold Restart

      124

    • Do a Quick Restart

      124

    • Examine the Gas Pressure

      125

    • Examine the Gas Quality

      126

  • Common Cutting and Gouging Problems

    127

    • Hand Cutting Problems

      127

    • Hand Gouging Problems

      129

  • Fault Codes

    130

    • Identify Fault Icons

      131

    • Operational Faults (0-Nn-N)

      132

    • Remove Fault Code Conditions

      132

    • Internal Component Faults (1-Nn-N, 2-Nn-N, 3-Nn-N)

      145

    • Troubleshoot Power-Related Problems with Generators

      145

    • See Recent Fault Codes (Power Supply Log Screen)

      146

  • Do a Gas Test

    147

    • Start and Stop a Gas Test in Automatic Gas Pressure Mode

      147

    • Do a Gas Test in Manual Gas Pressure Mode

      148

  • Adjust System Settings on the Feature Configuration Screen

    149

    • Basic Mode

      151

    • Smart Mode

      151

    • Smart Mode Versus Basic Mode

      151

    • Set System Settings to Factory Default

      152

  • See System Information

    153

    • 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

165

• Examine the Plasma Power Supply and Torch

  165

  • Every Use

    167

  • Every Cartridge Change or Weekly (Whichever Is more Frequent)

    168

  • Every 3 Months

    169

  • Cartridge Maintenance

    170

  • Examine the Air Filter Bowl and Filter Element

    171

    • Drain Water from the Bowl (if Necessary)

      171

    • Remove the Air Filter Bowl and Filter Element

      171

    • Examine the Air Filter Bowl and O-Ring

      172

    • Examine the Filter Element

      173

    • Replace the Air Filter Bowl, O-Ring, and Filter Element

      173

    • Install the Air Filter Bowl and Filter Element

      174