Hypertherm SmartSYNC Robotic Torch Operator's Manual
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Hypertherm SmartSYNC Robotic Torch Operator's Manual

Hypertherm SmartSYNC Robotic Torch Operator's Manual

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SmartSYNC
Robotic Torches
™
Operator Manual
811450 – REVISION 0
ENGLISH

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Summary of Contents for Hypertherm SmartSYNC Robotic Torch

  • Page 1 SmartSYNC Robotic Torches ™ Operator Manual 811450 – REVISION 0 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 ™ SmartSYNC Robotic Torches Operator Manual 811450 REVISION 0 ENGLISH Original instructions November 2022 Hypertherm, Inc. Hanover, NH 03755 USA www.hypertherm.com...
  • Page 4 31 165 596901 Fax 31 165 596908 Tel (Marketing) 31 (0) 165 596900 Tel (Technical Service) 00 800 4973 7843 Tel (Technical Service) technicalservice.emeia@hypertherm.com (Technical Service) For training and education resources, go to the Hypertherm Cutting Institute (HCI) online at www.hypertherm.com/hci.
  • Page 5 Salinan elektronik juga tersedia di situs web kami. Berbagai manual tersedia dalam beberapa bahasa di www.hypertherm.com/docs. DE (DEUTSCH/GERMAN) WARNUNG! Bevor Sie ein Hypertherm-Gerät in Betrieb nehmen, lesen Sie bitte die IT (ITALIANO/ITALIAN) Sicherheitsanweisungen in Ihrer Bedienungsanleitung, das Handbuch für Sicherheit AVVERTENZA! Prima di usare un’attrezzatura Hypertherm, leggere le istruzioni sulla...
  • Page 6 NO (NORSK/NORWEGIAN) SV (SVENSKA/SWEDISH) ADVARSEL! Før du bruker noe Hypertherm-utstyr, må du lese VARNING! Läs häftet säkerhetsinformationen i din produkts säkerhets- och sikkerhetsinstruksjonene i produktets håndbok, håndboken om sikkerhet og efterlevnadsmanual (80669C), säkerhets- och efterlevnadsmanualen för Waterjet samsvar (80669C), håndboken om vannjet sikkerhet og samsvar (80943C), (80943C) och varningsmanualen för radiofrekvenser (80945C) för viktig...

  • Page 7: Table Of Contents

    45° robotic torch ......................... 17 Weights ..............................17 3 Mount the Robotic Torch......................19 Minimum bend radius ............................20 Mount with a Hypertherm robotic torch clamp (228806) ................. 20 Connect the torch lead ............................23 SmartSYNC Robotic Torches Operator Manual...
  • Page 8 Contents 4 Operate the Robotic Torch...................... 25 Use the robotic teach tool..........................26 Cutting processes .............................. 27 Select the cartridge ..........................27 Cutting guidelines ........................... 28 Piercing guidelines..........................29 Gouging processes ............................30 Change the gouge contour........................31 5 Troubleshooting and Maintenance Tasks ................35 Cutting system problems ..........................

  • Page 9: Electromagnetic Compatibility (Emc)

    Introduction Methods of reducing emissions Mains supply Hypertherm’s CE-marked equipment is built in compliance with standard EN60974-10. The equipment should be installed and used in Cutting equipment must be connected to the mains supply according to accordance with the information below to achieve electromagnetic the manufacturer’s recommendations.
  • Page 10 Electromagnetic Compatibility (EMC) Earthing of the workpiece Where the workpiece is not bonded to earth for electrical safety, nor connected to earth because of its size and position, for example, ship’s hull or building steel work, a connection bonding the workpiece to earth may reduce emissions in some, but not all instances.

  • Page 11: Warranty

    Hypertherm not in strict conformity herein and as follows: if Hypertherm is notified of a defect (i) with respect with Hypertherm’s specifications and in cases of designs, processes,...
  • Page 12 At all times you will have and maintain insurance in such quantities and types, and with coverage sufficient and appropriate to defend and to hold Hypertherm harmless in the event of any cause of action arising from the use of the products.

  • Page 13: Where To Find More Information

    Powermax65/85/105 SYNC Parts Guide (810490). 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 Where to Find More Information 811450 Operator Manual SmartSYNC Robotic Torches...

  • Page 15: Specifications

    The FastConnect™ quick-disconnect system to easily remove the torch for transport or to  change from one torch to another. For information about the thicknesses that you can cut and pierce with a SmartSYNC robotic torch, refer to the Cutting processes on page 27.

  • Page 16: Robotic Torch Components, Dimensions, Weights

    Specifications Robotic torch components, dimensions, weights Components  A SmartSYNC 180° robotic torch is shown. 1 Hypertherm cartridge 5 Strain relief for torch lead 2 Shell 6 Torch lead 3 Increment markings 7 Positioning holes (3) 4 Anti-rotational slot Dimensions 180°...

  • Page 17: 90° Robotic Torch

    2.1 kg (5 lb) 180° robotic torch with 7.6 m (25 foot) lead 3.1 kg (7 lb) 180° robotic torch with 15 m (50 foot) lead 5.7 kg (13 lb) * Without a Hypertherm cartridge installed. SmartSYNC Robotic Torches Operator Manual 811450...
  • Page 18 90° robotic torch with 15 m (50 foot) lead 6.5 kg (14 lb) 90° robotic torch with 23 m (75 foot) lead 9.6 kg (21 lb) * Without a Hypertherm cartridge installed. 45° robotic torch with torch lead Torch Weight* 45°...

  • Page 19: Mount The Robotic Torch

    A robotic torch clamp with mating positioning dowels and anti-rotational tabs is available from Hypertherm. Refer to Mount with a Hypertherm robotic torch clamp (228806) on page 20. If you use an alternate torch clamp, comply with the manufacturer’s instructions on how to mount the torch in the clamp.

  • Page 20: Minimum Bend Radius

    Do not bend the torch lead around a radius that is less than the minimum bend radius of 76 mm (3.0 inches). 76 mm (3.0 in.) Mount with a Hypertherm robotic torch clamp (228806) 1. Mount the torch clamp to the robot arm using mounting holes 19.05 mm (0.75 inch) 7.62 mm...
  • Page 21 Mount the Robotic Torch 2. Disconnect the front half of the clamp by removing the 4 screws 3. Align the torch with the rear half of the clamp using either the increment markings or the positioning holes  If you are using the increment markings, remove the positioning dowel .
  • Page 22 Mount the Robotic Torch 5. Attach the front half of the clamp to the rear half of the clamp with the 4 screws 6. Tighten the 4 screws to 1.7 N∙m (15 lbf∙in) in the order shown. Do not tighten the screws too much. If you tighten the screws too much, you can cause damage to the internal components of the torch.

  • Page 23: Connect The Torch Lead

    Mount the Robotic Torch Connect the torch lead Always set the power  switch on the plasma power supply to OFF (O) before you connect or disconnect a torch. To connect a hand torch  Red button or machine torch, push the connector into the receptacle on the front of the plasma power supply.
  • Page 24 Mount the Robotic Torch 811450 Operator Manual SmartSYNC Robotic Torches...

  • Page 25: Operate The Robotic Torch

    Operate the Robotic Torch This section gives information to help you do the following: Use the robotic teach tool  Select the correct Hypertherm cutting or gouging cartridge  Pierce and cut metal  Optimize cut quality  Gouge metal ...

  • Page 26: Use The Robotic Teach Tool

    Operate the Robotic Torch Use the robotic teach tool A robotic torch teach tool (429054) is available from Hypertherm to help with programming the robot before cutting. Run your program with the torch teach tool installed on the torch to visually make sure that the torch will not touch the workpiece while cutting.

  • Page 27: Cutting Processes

    Operate the Robotic Torch Cutting processes Select the cartridge Hypertherm offers the following types of cutting cartridges for robotic torches: Cartridge Type Purpose Use these standard cartridges for Standard cut the widest range of cutting (gray) applications. Use these cartridges to get a FineCut ®...

  • Page 28: Cutting Guidelines

    Operate the Robotic Torch Select the best cartridge for the material you that you want to cut Metric material thickness (mm) FineCut 45 A 65 A 85 A 105 A English material thickness (in.) 0.02 0.06 1-1/4 1-1/2 FineCut 45 A 65 A 85 A 105 A...

  • Page 29: 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 30: Gouging Processes

    Operate the Robotic Torch Gouging processes Hypertherm offers the following gouging cartridges: Cartridge Type Purpose Use these cartridges for more Maximum Control precise metal removal, shallow gouging gouge contours, and light metal (green) washing. Use these cartridges for Maximum Removal...

  • Page 31: Change The Gouge Contour

    Operate the Robotic Torch 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. Angle of the torch Torch center line Turn of the torch Speed...
  • Page 32 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 33 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 34 Operate the Robotic Torch 811450 Operator Manual SmartSYNC Robotic Torches...

  • Page 35: Troubleshooting And Maintenance Tasks

    1. Get the serial number for your system from the data plate that is on the rear panel. 2. Speak to your Hypertherm distributor or authorized repair facility. 3. Speak to the nearest Hypertherm office shown in the front of this manual. ...

  • Page 36: Cutting System Problems

    Troubleshooting and Maintenance Tasks 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 37 Cartridge maintenance on page 44. • A faulty pilot arc IGBT can decrease cartridge life. Contact your Hypertherm distributor or authorized repair facility, or contact the nearest Hypertherm office shown in the front of this manual. SmartSYNC Robotic Torches...

  • Page 38: Cut Quality Problems

    Troubleshooting and Maintenance Tasks Cut quality problems The following are problems that you can have when the appearance of a cut is not satisfactory: Cut angle (bevel) – The degree of angularity of the cut edge.  Dross – The molten material that becomes solid on the top or bottom of the workpiece. ...

  • Page 39: Dross

    Troubleshooting and Maintenance Tasks 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 40: Gouging Problems

    When you install a Hypertherm gouging cartridge, the plasma power supply  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. Problem...

  • Page 41: Routine Maintenance

    Troubleshooting and Maintenance Tasks Routine maintenance WARNING ELECTRIC SHOCK CAN KILL Disconnect electric power before doing installation or maintenance. You can get a serious electric shock if electric power is not disconnected. Electric shock can seriously injure or kill you. All work that requires removal of the plasma power supply outer cover or panels must be done by a qualified technician.

  • Page 42: Every Use

    Troubleshooting and Maintenance Tasks Every use Plasma power supply Torch Examine the indicator LEDs and correct any fault conditions. Examine the cartridge for correct installation and Refer the Powermax65/85/105 SYNC Operator Manual for wear. Refer to Cartridge maintenance (810470). page 44. To prevent overheating, do the following: •...

  • Page 43: Every 3 Months

    Troubleshooting and Maintenance Tasks Every 3 months Plasma power supply Torch Examine the power cord and plug. Replace them if they Examine the torch for cracks and exposed wires. are damaged. Refer to the Powermax65/85/105 SYNC Have a qualified service technician replace any Parts Guide (810490).

  • Page 44: Cartridge Maintenance

    Troubleshooting and Maintenance Tasks Cartridge maintenance To help keep a cartridge operating correctly, do the following: Carefully remove molten metal that might collect  on the cartridge. Do not push the unwanted material inside the nozzle or shield Carefully remove molten metal that causes a ...

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