Hypertherm SYNC Powermax65 Cutting Manual
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Hypertherm SYNC Powermax65 Cutting Manual

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Powermax65/85/105 SYNC
Mechanized Cutting Guide
810480 – REVISION 2
ENGLISH

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  • Page 1 ™ Powermax65/85/105 SYNC Mechanized Cutting Guide 810480 – REVISION 2 ENGLISH...
  • Page 2 United States and other countries. All other trademarks are the property of their respective holders. Environmental stewardship is one of Hypertherm’s core values, and it is critical to our success and our customers’ success. We are striving to reduce the environmental impact of everything we do. For more information: www.hypertherm.com/environment.
  • Page 3 Powermax65/85/105 SYNC Mechanized Cutting Guide 810480 REVISION 2 ENGLISH Original instructions February 2021 Hypertherm, Inc. Hanover, NH 03755 USA www.hypertherm.com...
  • Page 4 Mathura Road, New Delhi 110044, India HTJapan.info@hypertherm.com (Main Office Email) 91-11-40521201/ 2/ 3 Tel TechSupportAPAC@hypertherm.com (Technical Service Email) 91-11 40521204 Fax HTIndia.info@hypertherm.com (Main Office Email) TechSupportAPAC@hypertherm.com (Technical Service Email) For training and education resources, go to the Hypertherm Cutting Institute (HCI) online at www.hypertherm.com/hci.
  • Page 5 στο www.hypertherm.com/docs. DE (DEUTSCH/GERMAN) HU (MAGYAR/HUNGARIAN) WARNUNG! Bevor Sie ein Hypertherm-Gerät in Betrieb nehmen, lesen Sie VIGYÁZAT! Mielőtt bármilyen Hypertherm berendezést üzemeltetne, bitte die Sicherheitsanweisungen in Ihrer Bedienungsanleitung, das Handbuch olvassa el a biztonsági információkat a termék kézikönyvében, a Biztonsági für Sicherheit und Übereinstimmung (80669C), das Handbuch für Sicherheit...
  • Page 6 доступны на нашем веб-сайте. Целый ряд руководств доступны на нескольких языках по ссылке www.hypertherm.com/docs. KO (한국어 /KOREAN) 경고! Hypertherm 장비를 사용하기 전에 제품 설명서와 안전 및 규정 준수 SK (SLOVENČINA/SLOVAK) 설명서(80669C), 워터젯 안전 및 규정 준수 설명서(80943C) 그리고 무선 VÝSTRAHA! Pred použitím akéhokoľvek zariadenia od spoločnosti Hypertherm 주파수...
  • Page 7 VI (TI ẾNG VI Ệ T/VIETNAMESE) คํ า เตื อ น! ก อ นการใช ง านอุ ป กรณ ข อง Hypertherm ทั ้ ง หมด โปรดอ า นคํ า แนะนํ า ด า น CẢNH BÁO! Trước khi vận hành bất kỳ thiết bị Hypertherm nào, hãy đọc các hướng dẫn an toàn trong hướng dẫn sử...

  • Page 9: Table Of Contents

    Contents 1 Before You Begin........................13 2 Set Up the Machine Torch....................... 15 About the machine torch ........................... 15 Machine torch components, dimensions, weights ..................16 Components............................. 16 Full-length machine torch ......................16 Mini machine torch........................17 Dimensions ............................... 17 Full-length machine torch ......................
  • Page 10 Contents Machine interface cables that use an external voltage divider ............. 27 Cable signals..........................28 Access raw arc voltage (optional)................... 29 Machine interface cables for tables with a 21.1:1 voltage ratio ..........30 Cable signals..........................31 Install the machine interface cable...................... 31 Machine interface receptacle sockets..................
  • Page 11 Contents 5 Gouge with the Machine Torch....................61 Gouging processes ............................61 Change the gouge contour..........................62 6 Common Mechanized System Problems................65 Cutting system problems ..........................66 Cut quality problems ............................67 Cut angle (bevel)............................. 68 Find the cause of a cut-angle problem .................. 69 Dross................................
  • Page 12 Contents 810480 Mechanized Cutting Guide Powermax65/85/105 SYNC...

  • Page 13: Before You Begin

    Safety and Compliance Manual (80669C)  You can find these documents on the USB memory stick that came with your plasma power supply. Technical documentation is also available at www.hypertherm.com/docs.  Technical documentation is current as of the date of its release.
  • Page 14 Before You Begin 810480 Mechanized Cutting Guide Powermax65/85/105 SYNC...

  • Page 15: Set Up The Machine Torch

    Automatic setting of operating  mode, amperage, and gas pressure based on the Hypertherm cartridge that you install, the torch type, and the torch lead length Communication of Hypertherm cartridge usage information to the plasma power supply, ...

  • Page 16: Machine Torch Components, Dimensions, Weights

    You cannot change a full-length machine torch into a mini machine torch, or change a mini machine torch into a full-length machine torch. Components Full-length machine torch 1 Torch lead 4 Hypertherm cartridge 2 Strain relief for torch lead 5 Shell 3 Torch-lock switch 6 32-pitch removable gear rack...

  • Page 17: Mini Machine Torch

    Set Up the Machine Torch Mini machine torch 1 Torch lead 3 Shell 2 Strain relief for torch lead 4 Hypertherm cartridge Dimensions Full-length machine torch 368 mm (14.5 inch) 35 mm* (1.37 inch*) 32 mm (1.25 inch) 212 mm (8.3 inch) 312 mm (12.3 inch)

  • Page 18: Mini Machine Torch

    Machine torch with 15 m (50 foot) lead 5.8 kg (13 lb) Machine torch with 23 m (75 foot) lead 8.3 kg (18 lb) * Without a Hypertherm cartridge installed. Mini machine torch with torch lead Torch Weight* Mini machine torch with 4.6 m (15 foot) lead 2.1 kg (5 lb)

  • Page 19: Attach The Torch To Your Equipment

    Set Up the Machine Torch Attach the torch to your equipment You can put the machine torch on a wide variety of X-Y tables, track burners, pipe bevelers, and other equipment. To install the torch, refer to the instructions of the equipment manufacturer. SENSITIVE ELECTRONICS AND OTHER COMPONENTS INSIDE THE TORCH.

  • Page 20: Remove The Gear Rack (Optional)

    Set Up the Machine Torch Remove the gear rack (optional) The gear rack can be attached to either side of the full-length machine torch. If you must remove the gear rack, remove the 2 screws that attach the rack to the torch shell. ...

  • Page 21: Configure Controls For Mechanized Cutting

    Configure Controls for Mechanized Cutting This section explains how to set up the following optional external controls for a Powermax65/85/105 SYNC in a mechanized cutting system using serial communications. Ohmic contact wire CNC / THC Machine interface (CPC) cable Torch lead (optional) RS-485 serial interface cable...
  • Page 22 • Quick resets EDGE Pro ® CNC hardware requirements: Hypertherm’s EDGE Pro CNC communicates with plasma power supplies using serial communications. To connect an EDGE Pro with a Powermax65/85/105 SYNC, use the serial connectors that are already installed on the EDGE Pro.
  • Page 23 Configure Controls for Mechanized Cutting The following are the general steps to set up a mechanized cutting system. For more information about plasma power supply setup, refer to the Powermax65/85/105 SYNC Operator Manual (810470). 1. Attach the work lead from the plasma power supply to the cutting table or to the workpiece you are cutting.

  • Page 24: Connect A Remote-Start Pendant (Optional)

    Configure Controls for Mechanized Cutting 7. Make sure that the plasma power supply is automatically set to Cut mode or Gouge mode to align with the Hypertherm cartridge that you installed. To change from Cut mode to Expanded Metal mode, push the ...

  • Page 25: Connect A Machine Interface Cable (Optional)

    Configure Controls for Mechanized Cutting Connect a machine interface cable (optional)  Before you begin, make sure that the plasma power supply has a factory-installed (or user-installed) machine interface receptacle on the rear panel. Refer to the Machine Interface Receptacle with Voltage Divider PCB Field Service Bulletin (806980).

  • Page 26: Machine Interface Cables That Use The Internal Voltage Divider Pcb

    In these systems, the machine interface cable supplies signals for arc transfer and plasma start only. Hypertherm offers machine interface cables for mechanized cutting systems that use the internal voltage divider PCB and mechanized cutting systems that use an external voltage divider.

  • Page 27: Cable Signals

    Configure Controls for Mechanized Cutting Cable signals Spade connectors Machine interface connector D-sub connector Connectors Machine interface Signal D-sub pin number Spade wire color pin number Green Plasma start Black Arc transfer Black 5 (-) (Electrode) 15 (-) Black (-) Voltage divider 6 (+) (Work) 8 (+)

  • Page 28: Cable Signals

    Configure Controls for Mechanized Cutting The ends of these cables have wires that are terminated with spade connectors. Cables are available in multiple lengths. Refer to the Powermax65/85/105 SYNC Parts Guide (810490). Machine interface receptacle Machine interface connector Spade connectors Cable signals Machine interface...

  • Page 29: Access Raw Arc Voltage (Optional)

    Configure Controls for Mechanized Cutting Access raw arc voltage (optional) If the mechanized cutting system does not use the voltage divider PCB in the plasma power supply, then you must set up an external voltage divider to access the raw arc voltage of the plasma power supply directly.

  • Page 30: Machine Interface Cables For Tables With A 21.1:1 Voltage Ratio

    Configure Controls for Mechanized Cutting Machine interface cables for tables with a 21.1:1 voltage ratio Hypertherm offers machine interface cables that are designed specifically for PlasmaCAM cutting tables, for which a voltage ratio of 21.1:1 is necessary. These cables can be used with mechanized cutting systems for which a voltage ratio of 21.1:1 is necessary.

  • Page 31: Cable Signals

    1. Set the power switch on the plasma power supply to OFF (O), and disconnect the power cord. 2. Remove the cover of the machine interface receptacle from the rear of the plasma power supply. 3. Connect the Hypertherm machine interface cable to the machine interface receptacle. Powermax65/85/105 SYNC...

  • Page 32: Machine Interface Receptacle Sockets

    * * The integration of Hypertherm equipment and customer-supplied equipment including interconnecting cords and cables, if not listed and certified as a system, is subject to inspection by local authorities at the final installation site.

  • Page 33: Machine Interface Signals

    Configure Controls for Mechanized Cutting Machine interface signals Refer to the following table for the cable signal information when connecting the plasma power supply to a torch height controller or CNC with a machine interface cable. Spade connectors Internal wires Machine interface receptacle Voltage divider D-sub connector...

  • Page 34: Set The 5-Position Voltage Divider Pcb

    (THC) system determines the correct setting to use. If you are unsure which setting to use, or if the Hypertherm 5-position voltage divider PCB does not supply the necessary voltage signal for your application, speak to your Hypertherm distributor or authorized repair facility, or speak to the nearest Hypertherm office shown in the front of this manual.

  • Page 35: Connect An Rs-485 Serial Interface Cable (Optional)

    Configure Controls for Mechanized Cutting 3. Find the voltage divider PCB DIP switches on the fan side of the plasma power supply. 21.1 30 40 50 ALL DOWN = 20 21.1 30 40 50 ALL DOWN = 20 This figure shows the voltage divider PCB at the factory default setting (50:1) with switch 4 in the up position.

  • Page 36: Install The Rs-485 Serial Interface Cable

    9-pin D-sub connector EDGE Pro CNC hardware requirements: Hypertherm’s EDGE Pro CNC communicates with plasma power supplies using serial communications. To connect an EDGE Pro with a Powermax65/85/105 SYNC, use the serial connectors that are already installed on the EDGE Pro.
  • Page 37 * * The integration of Hypertherm equipment and customer-supplied equipment including interconnecting cords and cables, if not listed and certified as a system, is subject to inspection by local authorities at the final installation site.

  • Page 38: Rs-485 Serial Interface Signals For Connecting To A Cnc

    Configure Controls for Mechanized Cutting RS-485 serial interface signals for connecting to a CNC Refer to the following table for the cable signal information when connecting the plasma power supply to a CNC with a serial interface cable.  The plasma power supply includes termination resistors. Unterminated serial connector 9-pin D-sub connector...

  • Page 39: Rs-485 Serial Interface Signals For Troubleshooting

    Configure Controls for Mechanized Cutting RS-485 serial interface signals for troubleshooting Refer to the following table for the cable signal information when troubleshooting serial connection problems between the plasma power supply and the CNC. Internal wires Unterminated serial connector Serial connector 9-pin D-sub connector D-sub Powermax internal wires and serial connector...

  • Page 40: Set The Parameters On The Cnc Interface Settings Screen

    Configure Controls for Mechanized Cutting Set the parameters on the CNC Interface Settings screen Use the CNC Interface Settings screen (CNC INTERFACE) to set parameters for serial communication. 1. Select on the main menu screen. 2. Select to go to the CNC INTERFACE screen. 3.

  • Page 41: Remote Mode Indicator

    Select one of the following values for parity checking: Even (default) No parity checking Notice: Use No parity checking for Hypertherm’s EDGE Pro CNC. Select one of the following values for stop bit: 1 stop bit (default) Notice: Use 1 for Hypertherm’s EDGE Pro CNCs.

  • Page 42: More Information About Serial Communication Setup

    A CNC can also request a gas test and a quick reset on a Powermax65/85/105 SYNC. For more information, refer to the Powermax65/85/105 SYNC Serial Communication Protocol and Implementation Guide (810400). Technical documentation is available at www.hypertherm.com/docs. 810480 Mechanized Cutting Guide Powermax65/85/105 SYNC...

  • Page 43: Cut With The Machine Torch

    Cut with the Machine Torch This section gives information to help you do the following: Select the correct Hypertherm cutting cartridge  Optimize cut quality  Understand torch height control  Pierce metal  Cut stainless steel with F5 gas ...

  • Page 44: Select The Cartridge

     use these cartridges on a hand torch, keep a standoff while cutting. Plasma power supplies are shipped with a starter set of Hypertherm cartridges.  For a full list of the cutting and gouging cartridges available refer to the ...
  • Page 45 Cut with the Machine Torch  Make sure that the cartridge that you select is an amperage supported by the plasma power supply. For example, if you have a Powermax85 SYNC, select an 85 A, 65 A, or 45 A cartridge, not a 105 A cartridge. Select the best cartridge for the material you want to cut Metric material thickness (mm) FineCut...

  • Page 46: Use A Flushcut Specialty Cartridge

    Cut with the Machine Torch Use a FlushCut specialty cartridge FlushCut cartridges can remove lugs, bolts, pad eyes, and other attachments without piercing or damaging the workpiece below. You can also use FlushCut cartridges for metal washing. FlushCut cartridges supply an angled plasma arc that lets you cut very close to the base material without leaving a large amount of remaining material to grind off.

  • Page 47: Get The Most Out Of Your Cartridges

    Cut with the Machine Torch Get the most out of your cartridges How often you must change the Hypertherm cartridge on your machine torch depends on the following: Gas supply quality  It is extremely important to keep the gas supply line clean and dry. Oil, water, vapor, and ...

  • Page 48: Signs That A Cartridge Is Near End-Of-Life

    Cut with the Machine Torch Signs that a cartridge is near end-of-life Usually, the best indication of when to install a new cartridge is when the cut quality is no longer satisfactory. When it is necessary to replace a cartridge, replace the full cartridge with a new one. Do not try to disassemble the cartridge.

  • Page 49: Show Cartridge Data On The Status Screen

    Cut with the Machine Torch For more information, refer to the following sections: Understand and optimize cut quality on page 53  Understand torch height control for plasma cutting on page 56  Common Mechanized System Problems on page 65 ...
  • Page 50 Cut with the Machine Torch 810480 Mechanized Cutting Guide Powermax65/85/105 SYNC...

  • Page 51: Prepare To Fire The Torch

    Cut with the Machine Torch Prepare to fire the torch WARNING INSTANT-ON TORCHES – PLASMA ARC CAN CAUSE INJURY, BURNS The plasma arc ignites immediately when you send a START / STOP command from the CNC. Before changing the cartridge, one of the following actions must be taken. Whenever possible, complete the first action.
  • Page 52 Full-length machine torch: move the torch-lock switch to the yellow lock (X) position.  2. Install the correct Hypertherm cartridge. Tighten 1/4 turn. 3. Do one of the following: Mini machine torch: set the power switch on the plasma power supply to ON (I).

  • Page 53: Remote Mode Indicator

    Cut with the Machine Torch 4. Make sure that the plasma power supply is automatically set to Cut mode or Gouge mode to align with the Hypertherm cartridge that you installed. To change from Cut mode to Expanded Metal mode, push the ...

  • Page 54: What Is A Cut Chart

    To help you find the parameters that will give you the cut quality that you want for a particular job, Hypertherm gives you a starting point: a set of parameters for each mechanized cutting cartridge and type and thickness of metal. These sets of parameters are known as cut charts.

  • Page 55: Piercing Guidelines

    You can keep unwanted results to a minimum, increase the number of pierces, and get maximum cartridge life when you use the pierce and cut height settings that Hypertherm recommends in the cut charts. Refer to the Powermax65/85/105 SYNC Cut Charts Guide (810500MU) and the...

  • Page 56: Understand Torch Height Control For Plasma Cutting

    Torch height is the distance between the torch and the workpiece. Arc voltage is the corresponding voltage of the plasma arc between the torch and the workpiece. You use the Hypertherm cut charts to set the initial torch height and arc voltage that will give you the cut quality that you want. To keep the cut quality consistent and get the longest cartridge life, you must monitor and adjust the torch height and arc voltage during cutting.

  • Page 57: Torch Height During The Cut Cycle

    Cut with the Machine Torch Torch height during the cut cycle Automated torch height control systems must sense the surface of the workpiece before each cut cycle. This is known as initial height sensing (IHS). After IHS, the system lifts the torch to the pierce height.

  • Page 58: Learn More

    CNCs, THCs, and machine motion for light industrial tables, a recorded webinar on the  Hypertherm website at www.hypertherm.com/webinars Height Control Theory, an on-demand online course at the Hypertherm Cutting Institute  (HCI) at www.hypertherm.com/hci  These resources are in English only.

  • Page 59: Cut Stainless Steel With F5

    Refer to the Safety and Compliance Manual (80669C) for more information. You can use F5 gas to cut stainless steel with the Powermax65/85/105 SYNC. Hypertherm recommends using F5 gas only for cutting stainless steel. Plasma cutting with F5 gives smooth, shiny cuts with silver edges that are close to the original color of the metal.
  • Page 60 Cut with the Machine Torch 810480 Mechanized Cutting Guide Powermax65/85/105 SYNC...

  • Page 61: Gouge With The Machine Torch

    (green) metal washing. Plasma power supplies are shipped with a starter set of Hypertherm cartridges. For a full list of the cutting and gouging cartridges available, refer to the Powermax65/85/105 SYNC Parts Guide (810490). ...

  • Page 62: Change The Gouge Contour

    Gouge with the Machine Torch For help installing the cartridge, refer to Prepare to fire the torch on page 51. Change the gouge contour The width and the depth of the gouge contour are a result of the following factors. Adjust these factors in combination to get the gouge that you want.
  • Page 63 Arc stretch is related to the output current (A) of the plasma power supply. The higher  the amperage, the longer that you can stretch the arc. Hypertherm recommends that you keep amperage and arc stretch consistent. The lowest and highest possible amperage setting relates to the plasma power supply ...
  • Page 64 Arc stretch is related to the output current (A) of the plasma power supply. The higher  the amperage, the longer that you can stretch the arc. Hypertherm recommends that you keep amperage and arc stretch consistent. Keep at least a small distance between the torch tip and the molten metal to increase ...

  • Page 65: Common Mechanized System Problems

    Common Mechanized System Problems This section explains the following common problems and how to solve them: Cutting system problems  Cut quality problems, such as cut angle (bevel) and dross  Gouging problems  Grounding or shielding problems   This section is a supplement to the troubleshooting information in the Powermax65/85/105 SYNC Operator Manual (810470).

  • Page 66: Cutting System Problems

    Common Mechanized System Problems Cutting system problems Problem Solutions The plasma arc sputters or • Make sure that the cartridge is installed correctly. hisses, or you lose the • Examine the cartridge. Replace it if it is worn or damaged. A higher rate of 0-30-0 plasma arc.

  • Page 67: Cut Quality Problems

    Get the most out of your cartridges on page 47. • A faulty pilot arc IGBT can shorten cartridge life. Speak to your Hypertherm distributor or authorized repair facility, or speak to the nearest Hypertherm office shown in the front of this manual.

  • Page 68: Cut Angle (Bevel)

    Common Mechanized System Problems Cut angle (bevel) Cut angle (bevel) Causes Solution Negative bevel • The cutting speed is too slow. • Increase the cutting speed in small increments (125 mm/min or More material is removed • The torch is too low. Or, if you are 5 in/min or less).

  • Page 69: Find The Cause Of A Cut-Angle Problem

    Common Mechanized System Problems Find the cause of a cut-angle problem 1. Make a test cut.  Use a square for the test cuts. It makes it easier to find which side is affected by the cut-angle problem and if that side moved with the rotation of the torch.

  • Page 70: Dross

    Common Mechanized System Problems Dross Dross (slag) is molten metal that is the result of the cut process and that hardens on the bottom of the part. There is always some amount of dross when cutting with plasma. To keep the amount and type of dross to a minimum, adjust your system correctly for your application.

  • Page 71: Gouging Problems

     automatically sets the operating mode to Gouge mode. There is a condition in which the operating mode does not automatically set to Gouge mode even if a Hypertherm gouging cartridge is used. Refer to the Powermax65/85/105 SYNC Operator Manual (810470).

  • Page 72: Emi Grounding And Shielding Best Practices

    Insufficient grounding exposes operators to dangerous voltages. Insufficient grounding also  increases the risk of equipment failure and unnecessary downtime. Ideally a ground should be zero ohms resistance, but Hypertherm’s field experience shows that less than 1 ohm 810480 Mechanized Cutting Guide...
  • Page 73 If you are installing an external voltage divider PCB, attach it as closely as possible to where  the arc voltage is sampled. If a Hypertherm voltage divider PCB is used, you must supply galvanic isolation to prevent ground loops. The processed signal must go through a twisted shielded cable.
  • Page 74 Common Mechanized System Problems All other signals (analog, digital, serial, and encoder) must go through twisted pairs inside a  shielded cable. Connectors on these cables must have a metal housing. The shield, not the drain, must connect to the metal housing of the connector at each end of the cable. Never put the shield or the drain through the connector on the pins.

  • Page 75: Example Grounding Diagram

     This example is based on practices in North America. Other regions can have different local or national electrical codes. Hypertherm recommends that you consult your local and national electrical codes to make sure that the grounding and shielding practices that you use satisfy the requirements for your location.
  • Page 76 Common Mechanized System Problems 810480 Mechanized Cutting Guide Powermax65/85/105 SYNC...

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