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Welding System
SYNC Powermax 85
Hypertherm SYNC Powermax 85 User Manual
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Operate the Plasma System
3
Powermax65/85
/1
05
SY
N
C
Operator
Manual
81
0
4
70
81
7.
Push
to go back to the status scree
n. T
he
ST
A
and
XT
fields now show on the screen.
80
82
Table of Contents
Default Chapter
9
Default Chapter
9
Table of Contents
9
Electromagnetic Compatibility (EMC)
15
Warranty
17
1 Where to Find Information
19
2 Install and Set up the Plasma Power Supply
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
3 Operate the Plasma System
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
4 Cut with the Hand Torch
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
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
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
7 Complete Regular Maintenance Tasks
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
Other manuals for Hypertherm SYNC Powermax 85
Quick Reference Guide
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Hypertherm SYNC Powermax 85 Specifications
General
Brand
Hypertherm
Model
SYNC Powermax 85
Category
Welding System
Language
English
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