Hypertherm Powermax65 SYNC Reference Manual
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Hypertherm Powermax65 SYNC Reference Manual

Serial communication programmer
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Serial Communication Programmer
Reference Guide
Powermax65/85/105 SYNC™
Reference Guide
810400
Revision 1
June 2021

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Summary of Contents for Hypertherm Powermax65 SYNC

  • Page 1 Serial Communication Programmer Reference Guide Powermax65/85/105 SYNC™ Reference Guide 810400 Revision 1 June 2021...
  • Page 2 (Technical Service Email) © 2021 Hypertherm, Inc. All rights reserved. Powermax, SYNC, and Hypertherm are trademarks of Hypertherm, Inc. and may be registered in the United States and other countries. All other trademarks are the property of their respective holders.

  • Page 3: Table Of Contents

    Contents Getting started............................... 7 Hardware requirements ........................... 7 Powermax65/85/105 SYNC hardware documents .............. 8 Modbus specifications ..........................8 Transmission mode and format ....................8 Modbus request and response message frame format............9 Error response message frame format................... 10 Example request and response message................10 How to calculate a checksum (LRC)..................
  • Page 4 Serial Communication Programmer Reference Guide Read the plasma power supply settings that are permitted for the installed cartridge ..26 0x3001 (permitted operating mode setting)................. 26 0x3002, 0x3003 (permitted minimum and maximum output current (A) settings)..26 0x3004, 0x3005 (permitted minimum and maximum gas pressure settings)....26 Example request and response....................
  • Page 5 Serial Communication Programmer Reference Guide 0x302C (total number of arc transfers – bytes 1 and 0)........... 45 0x302D (total number of arc transfers – bytes 3 and 2) ........... 46 0x302E (cumulative arc transfer time – bytes 1 and 0)............. 46 0x302F (cumulative arc transfer time –...
  • Page 6 Serial Communication Programmer Reference Guide 810400 Reference Guide Powermax65/85/105 SYNC...

  • Page 7: Getting Started

    Hardware requirements Using a Powermax65/85/105 SYNC plasma power supply in a CNC / THC mechanized system requires all of the following hardware. SmartSYNC machine torch with torch lead and Hypertherm cartridges. RS-485 serial interface connector, board, and cables.  This hardware provides access to cut mode, amperage, gas pressure, and more.

  • Page 8: Powermax65/85/105 Sync Hardware Documents

    Connect external serial interface and machine interface cables You can find these documents on the USB memory stick that came with your plasma power supply, or with the hardware kits. Technical documentation is also available at www.hypertherm.com/docs. Modbus specifications Transmission mode and format...

  • Page 9: Modbus Request And Response Message Frame Format

    Serial Communication Programmer Reference Guide Modbus request and response message frame format Start Node Address Function Data 1 character 2 characters 2 characters 0 up to 2x252 characters 2 characters 2 characters <CR><LF> Each segment is explained as follows. Segment Description Start All messages must start with a colon (:).

  • Page 10: Error Response Message Frame Format

    Serial Communication Programmer Reference Guide Error response message frame format The plasma power supply sends an error response message to the CNC when it detects an error in the request data and when an error occurs during processing of the request. The format of the error response message is similar to the request and response message format, with the following differences.
  • Page 11 Serial Communication Programmer Reference Guide The following is the response from the plasma power supply: :010408007900790000000001<CR><LF> Start Node Address Function Data Segment Value Description Start Start of message Node Address Plasma power supply node address (confirmed) Function Read Registers (confirmed) Data Quantity of bytes in the Data segment (0x08 = 8) 0079...

  • Page 12: How To Calculate A Checksum (Lrc)

    Serial Communication Programmer Reference Guide How to calculate a checksum (LRC) Modbus ASCII requires a longitudinal redundancy check (LRC, also called a checksum) on each message. For example, in the following request message, the LRC is 83. :01043044000483<CR><LF> Start Node Address Function Data 3044...
  • Page 13 Serial Communication Programmer Reference Guide 6. Push to select the new value. Stop bits Baud rate (can be changed) (cannot be changed) Parity (can be changed) Data bits (cannot be changed) Powermax65/85/105 SYNC Reference Guide 810400...
  • Page 14 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 15: Powermax65/85/105 Sync Modbus Addressing System

    Powermax65/85/105 SYNC supports the 0x2xxx series of Modbus addresses that was used for older Powermax plasma power supplies, as shown in Table 1. But Hypertherm strongly recommends that you use the 0x3xxx series with the Powermax65/85/105 SYNC. Older Powermax plasma power supplies include Powermax65/85/105/125 and Powermax45 XP.

  • Page 16: List Of Powermax65/85/105 Sync Addresses

    Serial Communication Programmer Reference Guide List of Powermax65/85/105 SYNC addresses SYNC Recommended Modbus Address Description Unit Function (hex) Address Request: Read the ID of the SYNC torch, torch lead, and plasma power supply 0x3000 Torch and plasma power supply identification 04 (Read Registers) High byte: torch ID Low byte: SYNC ID...
  • Page 17 Serial Communication Programmer Reference Guide SYNC Recommended Modbus Address Description Unit Function (hex) Address Request: Read the 16-character unique identification (UID) number for the installed cartridge 0x3030 UID (bytes 0 and 1) 04 (Read Registers) 0x3031 UID (bytes 2 and 3) 04 (Read Registers) 0x3032 UID (bytes 4 and 5)
  • Page 18 Serial Communication Programmer Reference Guide SYNC Recommended Modbus Address Description Unit Function (hex) Address Request: Write operating settings and put the plasma power supply into remote control mode 0x3080 Operating mode setting 10 (Write Multiple Registers) 0x2093 0x3081 Output current (A) setting Amperes 10 (Write Multiple Registers) 0x2094...

  • Page 19: Programming Recommendations

    Registers. It is not necessary to use Modbus function code 03 (Read Holding Registers) for holding registers. Hypertherm supports this usage to simplify Modbus programming. Send a single request for multiple registers at one time, when possible, for faster and ...

  • Page 20: Examples Of Requests And Responses

    Serial Communication Programmer Reference Guide Examples of requests and responses Identify the plasma power supply type (SYNC or older system) To identify the type of plasma power supply, and therefore the addressing system and features that are available, the CNC must use the following Modbus function code: 43/14 (2B/0E) (Read Device Identification) ...

  • Page 21: Read The Id Of The Sync Torch, Torch Lead, And Plasma Power Supply

    Serial Communication Programmer Reference Guide Response from plasma power supply: :012B0E0481000101010630383133333504<CR><LF> Value Description Start of message Plasma power supply node address (confirmed) 2B0E Read Device Identification (confirmed) 04810001010106 For more information on this segment, refer to Section 6.21 43/14 (0x2B/0x0E) Read Device Identification in the Modbus Application Protocol Specification at modbus.org.

  • Page 22: Example Request And Response

    Plasma Power Supply Type 0x00 Powermax65 SYNC 200 V – 600 V CSA 0x01 Powermax65 SYNC 380 V CCC / 400 V CE 0x02 Powermax85 SYNC 200 V – 600 V CSA 0x03 Powermax85 SYNC 380 V CCC / 400 V CE 0x08 Powermax105 SYNC 200 V –...

  • Page 23: Read The Part Number Of The Installed Cartridge

    Serial Communication Programmer Reference Guide Response from plasma power supply: :0104020508EC<CR><LF> Value Description Start of message Plasma power supply node address (confirmed) Read Registers (confirmed) Quantity of bytes in the Data segment (0x02 = 2) 0508 High byte = 05 = 0x05 = machine torch with 35-foot – 50-foot lead Low byte = 08 = 0x08 = Powermax105 SYNC 200 V –...
  • Page 24 Serial Communication Programmer Reference Guide Table 5 – Machine torch cartridge type Part Number Cartridge Type 343238393336 (hex) Cut: 105 A cartridge 428936 (ASCII) 343238393334 (hex) Cut: 85 A cartridge 428934 (ASCII) 343238393330 (hex) Cut: 65 A cartridge 428930 (ASCII) 343238393235 (hex) Cut: 45 A cartridge 428925 (ASCII)

  • Page 25: Example Request And Response

    Serial Communication Programmer Reference Guide Example request and response Request from CNC: :01043038000390<CR><LF> Value Description Start of message Plasma power supply node address Read Registers 3038 First register address 0003 Quantity of registers to read (0x0003 = 3): • 0x3038 (part number, bytes 0 and 1) •...

  • Page 26: Read The Plasma Power Supply Settings That Are Permitted For The Installed Cartridge

    Serial Communication Programmer Reference Guide Read the plasma power supply settings that are permitted for the installed cartridge To read the plasma power supply settings that are permitted for the installed cartridge, the CNC reads the values in the following registers: 0x3001 (permitted operating mode setting) ...

  • Page 27: Example Request And Response

    Serial Communication Programmer Reference Guide Example request and response Request from CNC: :010430010005C5<CR><LF> Value Description Start of message Plasma power supply node address Read Registers 3001 First register address 0005 Quantity of registers to read (0x0005 =5): • 0x3001 (permitted operating mode setting) •...

  • Page 28: Write Operating Settings And Put The Plasma Power Supply Into Remote Control Mode

     This write request is not necessary if you let the Powermax65/85/105 SYNC automatically set the operating settings. Hypertherm strongly recommends that you let the Powermax65/85/105 SYNC set the operating settings. Refer to Programming recommendations on page 19. To override automatic settings and put the Powermax65/85/105 SYNC into remote control mode,...

  • Page 29: 0X3082 (Gas Pressure Setting)

    Serial Communication Programmer Reference Guide 0x3082 (gas pressure setting) Description: Sets the gas pressure in psi. To have the plasma power supply set the gas pressure automatically: Write a value of zero (0x0000) to address 0x3082. The plasma power supply will automatically set the gas pressure for optimum cutting related to the operating mode, the torch type, the cartridge type, and the length of the torch lead.

  • Page 30: Remote Control Mode Indicator On The Plasma Power Supply

    Serial Communication Programmer Reference Guide Response from plasma power supply: :0110308000033C<CR><LF> Value Description Start of message Plasma power supply node address (confirmed) Write Multiple Registers (confirmed) 3080 First register address (confirmed) 0003 Quantity of registers to write (confirmed) <CR><LF> Refer also to Exit remote control mode on page 40. Remote control mode indicator on the plasma power supply When the Powermax65/85/105 SYNC enters remote control mode, an indicator shows on the...

  • Page 31: Example Request And Response

    Serial Communication Programmer Reference Guide Example request and response Request from CNC: :0104301A0001B0<CR><LF> Value Description Start of message Plasma power supply node address Read Registers 301A First register address (0x301A) 0001 Quantity of registers to read (0x0001 = 1): • 0x301A (active fault code) <CR><LF>...

  • Page 32: Fault Code List

    Powermax65/85/105 SYNC Troubleshooting Guide (810430). Hypertherm recommends that you do all the recommended steps for all fault codes that occur, including notifications that do not stop the cutting process. Troubleshooting all faults helps you to get optimal cut quality and consumable life.
  • Page 33 Serial Communication Programmer Reference Guide Fault Code Fault Code Steps Required to (hex) (decimal) Description Remove? 00C8 (Fault code 0-20-0) The gas pressure is lower than the minimum pressure for the selected process, operating mode, torch, lead length, and cartridge type. 00D2 (Fault code 0-21-0) The gas flow stopped during cutting (an excessive...
  • Page 34 Serial Communication Programmer Reference Guide Fault Code Fault Code Steps Required to (hex) (decimal) Description Remove? 01F6 (Fault code 0-50-2) The torch-lock switch is set to the green “ready to fire” ( ) position, but the torch is not prepared to fire. 01F7 (Fault code 0-50-3) The system is reading data from the cartridge.
  • Page 35 Serial Communication Programmer Reference Guide Fault Code Fault Code Steps Required to (hex) (decimal) Description Remove? 0834 2100 (Fault code 2-10-0) The inverter IGBT temperature sensor is open. 0835 2101 (Fault code 2-10-1) The inverter IGBT temperature sensor short-circuited. 083E 2110 (Fault code 2-11-0) The pressure sensor is open.

  • Page 36: Start And Stop A Gas Test

    Serial Communication Programmer Reference Guide Fault Code Fault Code Steps Required to (hex) (decimal) Description Remove? 0D66 3430 (Fault code 3-43-0) The inverter capacitors are not balanced. 0D71 3441 (Fault code 3-44-1) The boost PFC IGBT current is too high. 0DB7 3511 (Fault code 3-51-1)

  • Page 37: Example Request And Response

    Serial Communication Programmer Reference Guide Example request and response Request from CNC to start a gas test: :01053180FF004A<CR><LF> Value Description Start of message Plasma power supply node address Write Single Coil 3180 Coil address (0x3180) FF00 Value to write to coil address 0x3180 (0xFF00 = ON) <CR><LF>...

  • Page 38: Do A Quick Restart Or Clear Fault Code 0-50-0

    Serial Communication Programmer Reference Guide Response from plasma power supply: :01053180000049<CR><LF> Value Description Start of message Plasma power supply node address (confirmed) Write Single Coil (confirmed) 3180 Coil address (0x3180) (confirmed) 0000 Value to write to coil address 0x3180 (0x0000 = OFF) (confirmed) <CR><LF>...

  • Page 39: Example Request And Response

    Serial Communication Programmer Reference Guide Example request and response Request from CNC: :0110308E0002040404061805<CR><LF> Value Description Start of message Plasma power supply node address Write Multiple Registers 308E First register address (0x308E) 0002 Quantity of registers to write (0x002 = 2): •...

  • Page 40: Exit Remote Control Mode

    Serial Communication Programmer Reference Guide Exit remote control mode To exit remote control mode, the CNC must write a value of zero (0x0000) to the following registers (the same registers used to enter remote control mode): 0x3080 (operating mode setting) ...

  • Page 41: Get Data From The Plasma Power Supply

    Serial Communication Programmer Reference Guide When the Powermax65/85/105 SYNC exits remote control mode, the remote mode indicator no longer shows on the LCD display. Refer to page 30.  You can also stop remote control mode by setting the power switch on the Powermax65/85/105 SYNC to the OFF (O) position and waiting approximately 1 minute.

  • Page 42: 0X3012 (Gas Pressure Setting)

    Serial Communication Programmer Reference Guide 0x3012 (gas pressure setting) Description: Reads the hexadecimal value for the gas pressure setting in psi. Convert the hexadecimal value to decimal, and then divide that decimal value by 128 to get the gas pressure (psi). Encoding or scaling: 16-bit, fixed-point binary with 1-bit sign at MSB and 7-bit decimal at LSB Unit:...

  • Page 43: Read The Actual Output Of The Plasma Power Supply

    Serial Communication Programmer Reference Guide Read the actual output of the plasma power supply To read the actual output of the plasma power supply, the CNC reads the values in the following registers: 0x3018 (actual output current)  0x3019 (actual gas pressure) ...

  • Page 44: Read The Total Cut Counts For This Plasma Power Supply

    Serial Communication Programmer Reference Guide Response from plasma power supply: :010404104023DDA7<CR><LF> Value Description Start of message Plasma power supply node address (confirmed) Read Registers (confirmed) Quantity of bytes in the Data segment (0x04 = 4) 1040 0x1040 = 4160/64 = 65 A 23DD 0x23DD = 9181/128 = 72 psi <CR><LF>...

  • Page 45: 0X3029 (Total Number Of Starts - Bytes 3 And 2)

    Serial Communication Programmer Reference Guide 0x3029 (total number of starts – bytes 3 and 2) Description: Reads the hexadecimal value of the high word (bytes 3 and 2) for the total number of torch starts that the plasma power supply has done in its life. You will need to interchange the hexadecimal values for 0x3028 and 0x3029, and then convert the result to decimal.

  • Page 46: 0X302D (Total Number Of Arc Transfers - Bytes 3 And 2)

    Serial Communication Programmer Reference Guide 0x302D (total number of arc transfers – bytes 3 and 2) Description: Reads the hexadecimal value of the high word (bytes 3 and 2) for the total number of arc transfers that the plasma power supply has done in its life. You will need to interchange the hexadecimal values for 0x302C and 0x302D, and then convert the result to decimal.

  • Page 47: Example Request And Response

    Serial Communication Programmer Reference Guide Example request and response Request from CNC: :0104302800089B<CR><LF> Value Description Start of message Plasma power supply node address Read Registers 3028 First register address (0x3028) 0008 Quantity of registers to read (0x0008 = 8): • 0x3028 (total number of torch starts – bytes 1 and 0) •...

  • Page 48: Read The 16-Character Uid Number For The Installed Cartridge

    Serial Communication Programmer Reference Guide Read the 16-character UID number for the installed cartridge To read the unique identification (UID) number for the installed cartridge, the CNC reads the values in the following registers: 0x3030 (UID, bytes 0 and 1) ...

  • Page 49: Example Request And Response

    Serial Communication Programmer Reference Guide Example request and response Request from CNC: :01043030000893<CR><LF> Value Description Start of message Plasma power supply node address Read Registers 3030 First register address (0x3030) 0008 Quantity of registers to read (0x0008 = 8): • 0x3030 (UID, bytes 0 and 1) •...

  • Page 50: Read The Total Cut Counts For The Installed Cartridge

    Serial Communication Programmer Reference Guide Read the total cut counts for the installed cartridge To read the total cut counts for the installed cartridge, the CNC reads the values in the following registers: 0x3040 (total number of starts)  0x3041 (cumulative pilot arc time) ...

  • Page 51: 0X3043 (Cumulative Arc Transfer Time)

    Serial Communication Programmer Reference Guide 0x3043 (cumulative arc transfer time) Description: Reads the hexadecimal value for the cumulative arc transfer time in seconds that the cartridge has had in its life. Each count equals 2 seconds. Convert the hexadecimal value to decimal, and multiply by 2. Encoding or scaling: 16-bit unsigned binary number Unit:...

  • Page 52: Read The 4 Most Recent Faults For The Installed Cartridge

    Serial Communication Programmer Reference Guide Response from plasma power supply: :01040800D6000900D3098FA9<CR><LF> Value Description Start of message Plasma power supply node address (confirmed) Read Registers (confirmed) Quantity of bytes in the Data segment (0x08 = 8) 00D6 0x00D6 = 214 starts 0009 0x0009 = 9 seconds of pilot arc 00D3...

  • Page 53: 0X3045 (Fault Log 1)

    Serial Communication Programmer Reference Guide 0x3045 (fault log 1) Description: Reads the hexadecimal value of the fault code for the second most-recent fault for the installed cartridge. If there is no fault, this reads a value of 0x0000 (0-00-0). Convert the hexadecimal value to decimal. Refer to Fault code list on page 32 for the complete list of possible fault codes.

  • Page 54: Example Request And Response

    Serial Communication Programmer Reference Guide Example request and response Request from CNC: :01043044000483<CR><LF> Value Description Start of message Plasma power supply node address Read Registers 3044 First register address (0x3044) 0004 Quantity of registers to read (0x0004 = 4): • 0x3044 (fault log 0) •...

  • Page 55: Read The Name Of The Installed Cartridge

    Serial Communication Programmer Reference Guide Read the name of the installed cartridge To read the name of the installed cartridge, the CNC reads the values in the following registers: 0x3048 (name, bytes 0 and 1)  0x3049 (name, bytes 2 and 3) ...

  • Page 56: Example Request And Response

    Serial Communication Programmer Reference Guide Example request and response Request from CNC: :0104304800067D<CR><LF> Value Description Start of message Plasma power supply node address Read Registers 3048 First register address 0006 Quantity of registers to read (0x0006 = 6): • 0x3048 (name, bytes 0 and 1) •...

  • Page 57: Read The Start And Motion Signal Status Of The Plasma Power Supply

    Serial Communication Programmer Reference Guide Read the Start and Motion signal status of the plasma power supply To read the status of the plasma power supply, the CNC reads the following coils: 0x3100 (coil: Start switch status)  signal 0x3101 (coil: Motion switch status) ...

  • Page 58: Example Request And Response

    Serial Communication Programmer Reference Guide Example request and response Request from CNC to read 1 coil: :010131000001CC<CR><LF> Value Description Start of message Plasma power supply node address Read Coil 3100 Coil address (0x3100) 0001 Quantity of coils to read (0x0001 = 1): •...
  • Page 59 Serial Communication Programmer Reference Guide Response from plasma power supply: :01010103FA<CR><LF> Value Description Start of message Plasma power supply node address (confirmed) Read Coil (confirmed) Quantity of bytes in the Data segment (0x01 = 1) 0x03 = 11 (binary) = •...
  • Page 60 Serial Communication Programmer Reference Guide 810400 Reference Guide Powermax65/85/105 SYNC...

  • Page 61: Flowchart Examples

    Flowchart Examples This section contains examples of how you can program your CNC using the information in this guide. Examples for Powermax65/85/105 SYNC and older plasma power supplies are included. Older Powermax plasma power supplies include Powermax65/85/105/125 and Powermax45 XP. Example Page Figure 1 –...
  • Page 62 Figure 1 – Operator selects the plasma power supply type (SYNC / older) ENTER ON THE CNC GUI SETUP SCREEN, USER MANUALLY SELECTS THE POWERMAX FAMILY AND MODEL CONNECTED. SYNC OLDER CNC USES APPROPRIATE ADDRESSING. COMMUNICATE USING COMMUNICATE USING OLDER 0x2xxx POWERMAX SYNC 0x3xxx ADDRESSING.
  • Page 63 Serial Communication Programmer Reference Guide Figure 2 – CNC automatically selects the plasma power supply type (SYNC / older) EXAMPLE REQUEST :012B0E0401C1 ENTER 01 = MODBUS ID 2B = ENCAPSULATED INTERFACE TRANSPORT 0E = READ DEVICE ID 04 = REQUEST ONE SPECIFIC ID OBJECT 01 = STARTING ADDRESS IF NO C1 = LRC...
  • Page 64 Serial Communication Programmer Reference Guide Figure 3 – CNC requests plasma power supply and torch lead information SYNC OLDER REQUEST SYNC POWER SUPPLY ID, REQUEST POWERMAX LEAD LENGTH TORCH TYPE, LEAD LENGTH AND MAX CURRENT CAPABILITY ENTER ENTER REGISTER READ 0x3000 READ TORCH LENGTH INDEX.
  • Page 65 Figure 5 – CNC reads and sets permitted cut mode, amperage, and gas pressure SYNC OLDER ENTER ENTER READ CARTRIDGE PN. DETERMINE NEXT CUT MODE, AMPS REGISTER READ 0x3038-0x303B AND PRESSURE BY CUT CHART, OPERATOR INPUT, OR G-CODE DETERMINE NEXT CUT MODE, AMPS AND PRESSURE READ CURRENT SET LOW AND HIGH.
  • Page 66 Serial Communication Programmer Reference Guide Figure 6 – CNC requests SYNC plasma power supply and cartridge data READ TORCH TYPE/LENGTH ID, CARTRIDGE MIN/MAX AMPS AND PRESSURE. REGISTER READ 0x3000-0x3005 READ CARTRIDGE NAME. REGISTER READ 0x3048-304D READ CARTRIDGE CUMULATIVE STARTS, PILOT TIME, TRANSFERS, TRANSFER TIME.
  • Page 67 Serial Communication Programmer Reference Guide Figure 7 – CNC starts and stops a gas test OLDER SYNC ENTER ENTER TO TURN GAS ON TO TURN GAS ON COIL WRITE 0xFF00 TO 0x3180 COIL WRITE 0xFF00 TO 0x0832 READ ACTUAL PRESSURE. READ ACTUAL PRESSURE.
  • Page 68 Serial Communication Programmer Reference Guide Figure 8 – Serial communications during SYNC quick restart and cold restart (fault 0-19-9) ENTER USER SWITCHES THE POWER SUPPLY OFF LCD GOES BLANK, SERIAL COMMUNICATIONS CONTINUE FAULT RESPONSE 0-19-9 (USER HAS SWITCHED OFF POWER, OR PCB FAULT) HAS THE USER SWITCHED POWER SUPPLY BACK ON, AND...
  • Page 69 Figure 9 – Continue cutting after SYNC restart, cartridge change, or cartridge fault SYNC ENTER READ CARTRIDGE PART NUMBER. REGISTER READ 0x3038-0x303A SAME PART NUMBER AS PREVIOUS CARTRIDGE? POWER SUPPLY USES PRIOR PARAMETERS CNC SETS NEW USE CNC CUSTOM SYNC SETS (CARTRIDGE NOMINAL OR CUSTOM PARAMETERS PARAMETERS...
  • Page 70 Serial Communication Programmer Reference Guide Figure 10 – Clear SYNC cap-off fault 0-50-0 with a quick restart SYNC 0-50-0 FAULT CNC DISPLAYS 0-50-0 CAP OFF FAULT MESSAGE. INSTRUCTS USER TO INSTALL A CARTRIDGE. USER PRESSES A SOFT KEY TO RESTART THE POWERMAX. CNC DISPLAYS A CONFIRMATION DIALOGUE.
  • Page 71 Serial Communication Programmer Reference Guide Figure 11 – Continuously check for SYNC faults / plasma power supply readiness SYNC ENTER FIX THE PROBLEM POWER SUPPLY OR MAJOR FAULT FAULT CHECK FOR DETECTED 1-SECOND IF CARTRIDGE-RELATED, REFER TO FAULT. MINOR OR INTERVAL CARTRIDGE-CHANGE EXAMPLES REGISTER READ...
  • Page 72 Figure 12 – SYNC faults that clear with the next Start signal SYNC ENTER 0-32-0 CARTRIDGE IS 0-32-1 CARTRIDGE 0-20-0 INLET AIR 0-22-0 0-30-0 TSO OR 0-30-1 TSC 0-12-1 OUTPUT GAS AT END OF LIFE. INSTALLED WAS PRESSURE IS TOO NO GAS INPUT.
  • Page 73 Figure 13 – SYNC faults that require action to continue to cut SYNC ENTER 0-50-0 CARTRIDGE IS OFF FAULT TYPICAL CARTRIDGE CHANGE, 0-98-1 CARTRIDGE 0-11-1 REMOTE AMPERAGE 0-11-2 REMOTE PRESSURE 0-14-1 CARTRIDGE NOT (CARTRIDGE REMOVED WITHOUT 0-50-1 TORCH IS LOCKED 0-98-2 TORCH REQUESTED IS TOO HIGH OR LOW REQUESTED IS TOO HIGH OR LOW...
  • Page 74 Serial Communication Programmer Reference Guide Figure 14 – Request data from older Powermax plasma power supplies OLDER ENTER REQUEST DATA READ READ INSTANTANEOUS READ ARC TIME. TORCH LENGTH INDEX. SYSTEM PRESSURE. REGISTER READ COIL READ 0x0808 AND READ LATEST FAULT. REGISTER READ 0x204C 0x209E AND 0x209F 0x0809...
  • Page 75 Figure 15 – Operator or CNC does gas test to check air supply capacity SYNC (CNC AUTOMATES GAS TEST) SYNC OR OLDER (OPERATOR DOES GAS TEST) ENTER BEGIN READ POWER SUPPLY ACCESS THE LCD POWER SUPPLY EXAMPLE REQUEST ACTIVE PRESSURE SET POINT DATA MENU.
  • Page 76 Figure 16 – Behavior when SYNC tries to read the cartridge after cartridge installation SYNC ENTER USER INSTALLS A NEW CARTRIDGE QUICK RESTART USING THE MOVE THE LOCK SWITCH COLD POWER ON MAIN POWER SWITCH OR TO THE UNLOCKED CNC COMMAND POSITION FAULT 0-50-3 CARTRIDGE READ IN PROGRESS.
  • Page 77 Figure 17 – (Mech/mini) Cartridge cannot send data to the power supply (fault 0-14-0) SYNC - MECH/MINI (CLEAR THE FAULT OR SET PARAMETERS MANUALLY) ENTER FAULT CODE 0-14-0 MINI/ROBOTIC TORCH CARTRIDGE CANNOT SEND 0-14-1 DATA TO THE POWER SUPPLY OR 0-98-1 OR 0-98-2 POWERMAX DEFAULTS TO 45A, CUT MODE, SYSTEM PRESSURE...
  • Page 78 Figure 18 – (Hand torch) Cartridge cannot send data to the power supply (fault 0-14-0) SYNC - HAND TORCH (CLEAR THE FAULT OR SET PARAMETERS MANUALLY) ENTER FAULT CODE 0-14-0 CARTRIDGE CANNOT SEND DATA TO THE POWER SUPPLY POWERMAX DEFAULTS TO 45A, CUT MODE, SYSTEM PRESSURE CUT NOT ALLOWED UNTIL USER ACTION...

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