Hypertherm Powermax45 SYNC Operator's Manual
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Hypertherm Powermax45 SYNC Operator's Manual

Hypertherm Powermax45 SYNC Operator's Manual

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Powermax45 SYNC
®
Operator Manual
811470 – REVISION 2
ENGLISH

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Summary of Contents for Hypertherm Powermax45 SYNC

  • Page 1 Powermax45 SYNC ® Operator Manual 811470 – 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 Powermax45 SYNC Operator Manual 811470 REVISION 2 ENGLISH Original instructions June 2024 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

    2 Install and Set Up the Plasma Power Supply............... 17 Make sure that you have all the system components ..................18 What to do if components are missing or damaged................19 Hypertherm plasma power supply ratings......................19 Find system specifications on the data plate ..................21 Find the part number for your system....................22 Critical raw materials ..........................22...
  • Page 8 Use the hand torch ..........................54 What occurs during and after cutting....................54 Temperature control........................54 Controls and indicators on the plasma power supply .................55 Cutting and gouging controls .......................55 Indicator LEDs ............................56 Controls and indicators on the hand torch ....................57 811470 Operator Manual Powermax45 SYNC...
  • Page 9 Change the output current (A) of the plasma power supply............82 Change the angle of the torch to the workpiece ................82 Change the turn of the torch .........................83 Change the torch-to-work standoff / arc stretch................83 Change the speed of the torch......................84 Powermax45 SYNC Operator Manual 811470...
  • Page 10 Examine the air filter bowl and O-ring ....................120 Examine the filter element ........................121 Replace the air filter bowl, O-ring, and filter element ..............121 Install the air filter bowl and filter element ..................122 811470 Operator Manual Powermax45 SYNC...

  • Page 11: 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 12 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 13: 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 14 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 15: Where To Find Information

    Where to Find Information This operator manual includes the following information for the Powermax45 SYNC plasma power supply and SmartSYNC™ hand torches: Specifications, ratings, and installation and setup information  Operating instructions for the plasma power supply and torch ...
  • Page 16 Where to Find Information 811470 Operator Manual Powermax45 SYNC...

  • Page 17: Install And Set Up The Plasma Power Supply

    Install and Set Up the Plasma Power Supply The Powermax45 SYNC is a portable 45 A plasma cutting system that you can use for many handheld and mechanized cutting and gouging applications. The system’s automatic gas and automatic voltage features make it easy to set up and use even if you have limited plasma cutting experience.

  • Page 18: Make Sure That You Have All The System Components

    4 Work clamp with work lead • Radio Equipment Directive (810600MU) 5 Remote-start pendant (optional – mechanized configurations only) • Fault code labels (811490MU) • Powermax45 SYNC Getting Started 6 Power cord* Guide (811550MU) 7 Region-specific gas inlet fitting (may not be 2 SmartSYNC...

  • Page 19: What To Do If Components Are Missing Or Damaged

    Refer to page 21 for a sample data plate. Get a copy of the bill of lading from Hypertherm. For additional assistance, contact the  nearest Hypertherm office listed in the front of this manual. Claims for missing or damaged merchandise ...
  • Page 20 (Ssc) greater than or equal to 1003 KVA. F5 is only recommended to cut stainless steel. ‡ 811470 Operator Manual Powermax45 SYNC...

  • Page 21: Find System Specifications On The Data Plate

    Find system specifications on the data plate The data plate on the bottom of the plasma power supply contains 2 sets of ratings: The HYP ratings are Hypertherm plasma power supply ratings. They show the capability of  the system related to Hypertherm’s internal testing.

  • Page 22: Find The Part Number For Your System

    Critical raw materials Critical raw material Components that contain more than 1 gram Antimony Torch leads Bauxite Heatsinks, metal covers Borate All printed circuit boards Magnesium Heatsinks, metal covers Silicon metal Heatsinks, metal covers Strontium Fans 811470 Operator Manual Powermax45 SYNC...

  • Page 23: Symbols And Marks

    The RoHS mark indicates that the product meets the requirements of the European Restriction of Hazardous Substances (RoHS) Directive. United Kingdom Conformity Assessed mark CE versions of products that include a UKCA mark of conformity meet the product safety, EMC, RF, and RoHS requirements for export to the UK. Powermax45 SYNC Operator Manual 811470...

  • Page 24: International Electrotechnical Commission (Iec) Symbols

    Direct current (DC) external protective (earth) conductor Alternating current (AC) Power is ON Plasma torch cutting Power is OFF Gouging An inverter-based power source, either 1-phase or 3-phase AC input power connection Volt/amperage curve, “drooping” characteristic 811470 Operator Manual Powermax45 SYNC...

  • Page 25: Acoustical Noise Levels

    In addition, you can find an Acoustical Noise Data Sheet for your system at www.hypertherm.com/docs. In the search box, enter data sheet. Radio frequency identification (RFID) specifications The Hypertherm RFID near-field wireless communication system contains these components: A passive RFID tag in the Hypertherm cartridge ...

  • Page 26: Maximum Cut Speeds (Mild Steel)

    Install and Set Up the Plasma Power Supply Maximum cut speeds (mild steel) Maximum cut speeds are the results of Hypertherm’s laboratory testing. Actual cutting speeds may be different for different cutting applications. Material thickness Maximum cut speed 6 mm (1/4 inch)

  • Page 27: Put The Plasma Power Supply Into The Correct Position

    >0.25 m (10 inches) near the line-disconnect switch or near an approved power receptacle for your installation. Keep at least 0.25 m (10 inches)  of space around the plasma power supply for sufficient ventilation. Powermax45 SYNC Operator Manual 811470...
  • Page 28 10°. >10° Do not put the plasma power  supply on its side. Doing so can cause a blockage of the air circulation necessary to keep internal components cool. 811470 Operator Manual Powermax45 SYNC...

  • Page 29: Plasma Power Supply Dimensions And Weight

    Work clamp with 15 m (50 foot) work lead 2.1 kg (4.7 lb)  For hand torch weights, refer to page 75. For machine torch weights, refer to the Powermax45/65/85/105 SYNC Mechanized Cutting Guide (810480). Powermax45 SYNC Operator Manual 811470...

  • Page 30: Connect To Electrical Power

    10 times the rated value for short periods of time. Do not use phase converters to supply 3-phase power to your Powermax plasma power supply. Hypertherm does not warranty systems that have been damaged as a result of poor power quality from phase converters or incoming line power.

  • Page 31: Requirements For Grounding

    The plasma power supply automatically adjusts for correct operation at the current input voltage. You do not have to change or rewire components. But you must do these tasks: Install the Hypertherm cartridge in the torch. Refer to Step 4 – Install the cartridge ...

  • Page 32: Csa/Ce/Ccc 200 V - 240 V (1-Phase)

    Input voltage 230 V Input current at rated output (45 A x 155 V = 6.9 kW) 34 A Input current during arc stretch 37 A Fuse (time-delay) 48 A Voltage tolerance +20% to -15% 811470 Operator Manual Powermax45 SYNC...

  • Page 33: Ccc 380 V (3-Phase)

    480 V Input current at rated output (45 A x 145 V = 6.5 kW) 10 A Input current during arc stretch 12 A – 17 A Fuse (time-delay) 20 A Voltage tolerance +20% to -15% Powermax45 SYNC Operator Manual 811470...

  • Page 34: Decrease Output Current And Arc Stretch For Lower Rated Electrical Service

    19 A. Input voltage 230 V Input current at rated output (19 A x 155 V = 2.9 kW) 18 A Input current during arc stretch 19 A Voltage tolerance +20% to -15% 811470 Operator Manual Powermax45 SYNC...

  • Page 35: Prepare The Power Cord And Plug

    ** Style H07RN-F cord is a harmonized, heavy-duty, flexible, rubber-insulated, black-neoprene-jacketed multi-conductor IEC60245-4 / EN50525 European power cord with CE printed on the cord. The H07RN-F cord used by Hypertherm also has a CCC certification to GB/T 5013.4, with CCC printed on the cord. Powermax45 SYNC...

  • Page 36: Extension Cord Recommendations

    Use a generator (if necessary) When you use a generator, make sure that you: Only use a generator that meets Hypertherm plasma power supply ratings on page 19.  Adjust the output current (A) if necessary related to the rating, age, and condition of the ...

  • Page 37: Adapter For 4-Wire 1-Phase Connections (Csa 1-Phase Models Only)

    Install and Set Up the Plasma Power Supply Generators used with this system must meet the voltage requirements in the table below and in the Hypertherm plasma power supply ratings on page 19. Plasma power supply Engine drive rating Performance (arc stretch)
  • Page 38 (3/8 inch). Hoses that are too small can cause problems with cut quality and cut performance. 3. Connect the gas hose to the gas inlet fitting . Refer to Inlet gas pressure requirements (while gas is flowing) on page 40. 811470 Operator Manual Powermax45 SYNC...

  • Page 39: Gas Supply Source

    Install and Set Up the Plasma Power Supply Gas supply source Hypertherm recommends that air compressors supply air that meets these requirements of ISO Standard 8573-1:2010 Class 1.4.2*: Maximum particle count in 1.0 m • 20,000 at 0.1 microns – 0.5 microns •...

  • Page 40: High-Pressure Gas Cylinders

     Open each cylinder valve just long enough to blow out any dust that is possibly present. Connect the supply hose correctly to the cylinder.  Inlet gas pressure requirements (while gas is flowing)  811470 Operator Manual Powermax45 SYNC...

  • Page 41: Maximum Inlet Pressure

    Speak to the filter manufacturer about gas pressure requirements. Hypertherm recommends that you install an inline pressure gauge at the gas inlet on the back of the plasma power supply. Use this gauge to monitor the gas pressure at the plasma power supply, after all external filtration.
  • Page 42 For the recommended gas inlet flow rate and pressure, refer to Inlet gas pressure requirements (while gas is flowing) on page 40. Hypertherm offers the following optional external filter kits: Kit 128647: The Eliminizer moisture removal air filter removes water and dirt from the gas ...
  • Page 43 Install and Set Up the Plasma Power Supply If you use both external filters, install them in the order shown in Figure 1 to prevent damage to the gas line and equipment. Figure 1 – Optional Hypertherm external filters Powermax45 SYNC Operator Manual 811470...
  • Page 44 Install and Set Up the Plasma Power Supply 811470 Operator Manual Powermax45 SYNC...

  • Page 45: Operate The Plasma System

    2. Connect the gas supply line to the fitting on the back of the plasma power supply. Refer to page For gas supply requirements, refer to Inlet gas pressure requirements (while gas is flowing)  on page 40. Powermax45 SYNC Operator Manual 811470...

  • Page 46: Step 2 - Connect The Torch Lead

    The connector makes a click when it is fully engaged. To disconnect the torch,  push the red button the connector and pull the connector out of the receptacle. 811470 Operator Manual Powermax45 SYNC...

  • Page 47: Step 3 - Connect The Work Lead And Work Clamp

    LOOSE WORK LEADS CAN OVERHEAT Anytime you move the work lead or the plasma power supply, examine the work lead connector to make sure that it is fully and tightly connected to the plasma power supply. Powermax45 SYNC Operator Manual 811470...

  • Page 48: Work Clamp

    Set the power switch on the plasma power supply to OFF (O).  Move the torch-lock switch to the yellow lock (X) position. Pull the trigger to make  sure that the torch does not fire a plasma arc. 811470 Operator Manual Powermax45 SYNC...

  • Page 49: Lock The Torch

    ON. Use this switch to lock the torch when it is not in use, when you change the Hypertherm cartridge, or when you move the plasma power supply or torch while the plasma power supply is ON.

  • Page 50: Install The Cartridge

    77. Tighten 1/4 turn to install. Cut expanded metal To cut expanded metal, install a Hypertherm cutting cartridge. The system does not require a dedicated mode for cutting expanded metal.  Expanded metal has a slotted or mesh pattern. Cutting expanded metal causes cartridges to wear more quickly because a continuous pilot arc is necessary.

  • Page 51: Step 5 - Set The Power Switch To On (I)

    If the torch-lock switch is set  to the yellow lock (X) position when you set the power switch to ON, the Torch Cap LED on the front panel comes on. 200 V – 240 V Powermax45 SYNC Operator Manual 811470...

  • Page 52: Step 6 - Unlock The Smartsync Torch

    The plasma power supply makes a pressure-release sound that you can hear with each puff of air. This feedback is a warning. It does not identify a fault condition. It tells you that the torch is unlocked and will fire a plasma arc the next time that you pull the trigger. 811470 Operator Manual Powermax45 SYNC...

  • Page 53: Change A Cartridge

    After you install the cartridge and set the torch-lock switch to the green “ready to fire” ( position, the Torch Cap LED extinguishes. Hand torch: After the torch puts out the warning puffs of air, the 0-50-2 code extinguishes. Powermax45 SYNC Operator Manual 811470...

  • Page 54: Step 7 - Use The Smartsync Torch

    Always let postflow complete before you remove a cartridge. Fan activity – The cooling fan inside the plasma power supply automatically comes on as necessary during and after cutting to decrease the temperature of internal components. 811470 Operator Manual Powermax45 SYNC...

  • Page 55: Controls And Indicators On The Plasma Power Supply

    AMPS LED (green) – When illuminated, this LED indicates that the 2-digit display shows the cutting current (amperage). When the 2-digit display shows other values, such as gas pressure or a fault code, the AMPS LED is not illuminated. Powermax45 SYNC Operator Manual 811470...

  • Page 56: Indicator Leds

    When illuminated, this fault LED indicates that the system’s temperature is outside the permitted operating range. Refer to Fault icons and fault codes on page 96. Service LED This LED is used by qualified service technicians for troubleshooting the plasma power supply. 811470 Operator Manual Powermax45 SYNC...

  • Page 57: Controls And Indicators On The Hand Torch

    Changing the operating settings from their defaults is recommended only for experienced operators. The plasma power supply automatically sets the gas pressure and current based on the Hypertherm cartridge type, operating mode, the torch type, and the length of the torch lead.

  • Page 58: Adjust The Output Current Manually

    Adjust the output current from the hand torch 1. Push the button on the amperage adjustment control to move the current setting from one preset amperage to another. 811470 Operator Manual Powermax45 SYNC...

  • Page 59: Adjust The Gas Pressure Manually

    The selected mode  flashes to let you know that the gas pressure has been manually adjusted. It continues to flash until you reset the pressure. To see the gas pressure setting again, repeat step  Powermax45 SYNC Operator Manual 811470...

  • Page 60: Go Back To Automatic Settings Mode

    When you change from manual gas pressure mode to automatic gas pressure mode:  The plasma power supply automatically sets the gas pressure related to the Hypertherm  cartridge. The amperage setting stays the same.

  • Page 61: Monitor Cartridge Data

    Monitor cartridge data Monitor data for individual cartridges Each Hypertherm cartridge contains data about how it has been used. You can monitor this data if necessary using the Hypertherm Cartridge Reader kit (528083). For example, you can compare data between Hypertherm cartridges if one cartridge had significantly better life than a different cartridge, or if you want to calculate the average cartridge life over a period of time.

  • Page 62: Decrease Arc Stretch

    If you operate the plasma power supply on a lower rated electrical service, stretching the plasma arc for long periods can cause the plasma power supply to overheat more quickly and can cause the circuit breaker to open (trip). 811470 Operator Manual Powermax45 SYNC...

  • Page 63: Cut And Mark With The Hand Torch

    For gouging information, refer to Gouge with the Hand Torch on page 77.  To correct problems with cut quality, refer to Common problems and solutions on page 89.  Powermax45 SYNC Operator Manual 811470...

  • Page 64: About The Hand Torch

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

  • Page 65: Select The Correct Cutting Cartridge

    Cut and Mark with the Hand Torch Select the correct cutting cartridge Hypertherm offers the following types of hand-cutting cartridges, which can be used with both the 15° and the 75° SmartSYNC hand torches: Cartridge Type Purpose Use these cartridges to drag the...

  • Page 66: Prepare To Fire The Torch

    Touching the cartridges can also cause electric shock if the plasma power supply is ON and the torch-lock switch is not in the yellow lock (X) position. 811470 Operator Manual Powermax45 SYNC...
  • Page 67 1. Install the correct cartridge. Refer to Step 4 – Install the cartridge on page 48. When you install a Hypertherm cutting cartridge, the system goes to Cut mode  When you install a cutting cartridge, Gouge mode is not available.

  • Page 68: Start A Cut From The Edge Of The Workpiece

    1. With the work clamp attached to the workpiece, hold the torch tip perpendicular (90°) to the edge of the workpiece. 2. Pull the torch’s trigger to start the arc. Stay at the edge until the arc has cut completely through the workpiece. 811470 Operator Manual Powermax45 SYNC...
  • Page 69 Cut and Mark with the Hand Torch 3. Drag the torch lightly across the workpiece to continue with the cut. Keep a smooth, stable pace. Powermax45 SYNC Operator Manual 811470...

  • Page 70: Pierce A Workpiece

    The hand torch can pierce interior features on metal. The type of pierce that you do relates to the thickness of the workpiece and the pierce capacity of the Powermax45 SYNC. Refer to Pierce capacity on page 25.
  • Page 71 4. Hold the torch in position while continuing to pull the trigger. When sparks are coming from below the workpiece, the arc has pierced the material. 5. When the pierce is complete, drag the torch tip lightly across the workpiece to continue with the cut. Powermax45 SYNC Operator Manual 811470...

  • Page 72: Guidelines For Hand Torch Cutting

    Set the plasma power supply output current to 9 A through 19 A.  A current setting of 9 A will give you the lightest mark. A current setting of 19 A will give  the heaviest mark. 811470 Operator Manual Powermax45 SYNC...

  • Page 73: Get The Most Out Of Your Cartridges

    Fire the torch only when necessary to keep pilot arc time to a minimum.  Frequent pilot arcs cause the nozzle in the cartridge to wear more quickly. You can see  the cumulative pilot arc time for a cartridge using the Hypertherm Cartridge Reader kit (528083). Arc stretch when cutting ...

  • Page 74: Signs That A Cartridge Is Near End-Of-Life

    If you do a lot of piercing, it is possible to see black marks on the retaining cap. Usually this is not a sign that the cartridge is at end-of-life. Continue to cut with the cartridge until the cut quality is no longer satisfactory. 811470 Operator Manual Powermax45 SYNC...

  • Page 75: Hand Torch Components, Dimensions, And Weights

    Cut and Mark with the Hand Torch Hand torch components, dimensions, and weights Components 1 Amperage-adjustment control 5 Safety trigger 2 Torch-lock switch 6 Strain relief for torch lead 3 Shell 7 Torch lead 4 Cartridge Powermax45 SYNC Operator Manual 811470...

  • Page 76: Dimensions

    51 mm (2.0 inch) 15° 68 mm (2.7 inch) 32 mm (1.25 inch) 320 mm (12.6 inch) Weights Torch Weight* Hand torch with 7.6 m (20 foot) lead 2.4 kg (5.2 lb) * Without a cartridge installed. 811470 Operator Manual Powermax45 SYNC...

  • Page 77: Gouge With The Hand Torch

    Point the torch away from yourself and others. Always put on correct protective equipment including gloves and eye protection. Hypertherm offers the following gouging cartridge, which you can use with both the 15° and the 75° SmartSYNC hand torches. Cartridge Type...

  • Page 78: Prepare To Fire The Torch

    Touching the cartridges can also cause electric shock if the plasma power supply is ON and the torch-lock switch is not in the yellow lock (X) position. 811470 Operator Manual Powermax45 SYNC...
  • Page 79 1. Install the gouging cartridge. Refer to Step 4 – Install the cartridge on page 48. When you install a Hypertherm gouging cartridge, the system goes to Gouge mode  When you install a gouging cartridge, Cut mode is not available.

  • Page 80: Start A Gouge At An Angle To The Workpiece

    (1/4 in. – 1/2 in.) 2. Pull the trigger to get a pilot arc. Transfer the arc to the workpiece. 3. Stretch the arc to 25 mm – 32 mm (1 in. – 1-1/4 in.). 811470 Operator Manual Powermax45 SYNC...
  • Page 81 5. Change the position of the torch as necessary to get the gouge contour that you want. Refer to Guidelines for hand torch gouging on page 82. Keep at least a small distance between the torch tip and the molten metal to increase cartridge life and prevent damage to the torch. Powermax45 SYNC Operator Manual 811470...

  • Page 82: Guidelines For Hand Torch Gouging

    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. Change the angle of the torch to the workpiece Put the torch in a more upright position to make the gouge narrower and deeper .

  • Page 83: Change The Turn Of The Torch

    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 84: Change The Speed Of The Torch

    Change the speed of the torch Increase the speed of the torch movement to make the gouge narrower and more  shallow . Decrease the speed of the torch movement to make the gouge wider and deeper 811470 Operator Manual Powermax45 SYNC...

  • Page 85: Troubleshoot Common Problems

    Set the power switch on the plasma power supply to OFF (O).  Move the torch-lock switch to the yellow lock (X) position. Pull the trigger to make  sure that the torch does not fire a plasma arc. Powermax45 SYNC Operator Manual 811470...

  • Page 86: Start Here: Troubleshooting Checklist

    1. Get the serial number for your system from the data plate that is on the bottom of the plasma power supply. 2. Speak to your Hypertherm distributor or authorized repair facility. 3. Speak to the nearest Hypertherm office shown in the front of this manual.  Refer to the Powermax45/65/85/105 SYNC Parts Guide (810490) for information on common replacement parts.
  • Page 87 Is the status LED on the torch solid yellow or red? Is the status LED flashing yellow? Refer to page Are there any signs of damage to the torch trigger? Are the trigger and safety latch operating correctly? Is the torch-lock switch operating correctly? Refer to page Powermax45 SYNC Operator Manual 811470...
  • Page 88 Signs that a cartridge is near end-of-life page 74. Is the Hypertherm cartridge installed correctly? Refer to page Did you select the correct Hypertherm cartridge for the job that you are doing? Refer to page 65 page Examine the gas supply...

  • Page 89: Common Problems And Solutions

    Troubleshoot Common Problems Common problems and solutions Problem Solution The cut quality is • Examine the Hypertherm cartridge. Replace it if it is worn or damaged. unsatisfactory. Refer to Signs that a cartridge is near end-of-life on page 74 and...

  • Page 90: Cold Restarts And Quick Restarts

    2. Immediately set the power switch on the plasma power supply to ON (I).  If a fault occurs while you are using a generator, a quick restart does not always remove the fault. Do a cold restart instead. 811470 Operator Manual Powermax45 SYNC...

  • Page 91: Examine The Gas Pressure

    The gas pressure should be stable. For optimum system performance, make sure that the inlet gas pressure stays between 7.6 bar – 8.3 bar (110 psi – 120 psi) while gas is flowing. Powermax45 SYNC Operator Manual 811470...

  • Page 92: Examine The Gas Quality

    3. Examine the O-ring at the top of the air filter bowl. Replace it if it has cracks or other damage. 4. If you use an external air filtration system, clean or replace any parts in it that are possibly dirty. 811470 Operator Manual Powermax45 SYNC...

  • Page 93: Common Cutting And Gouging Problems

    The plasma arc sputters or • Make sure that the Hypertherm cartridge is installed correctly. hisses, or you lose the • Examine the Hypertherm cartridge. Replace it if it is worn or damaged. plasma arc. Refer to Signs that a cartridge is near end-of-life...

  • Page 94: Gouging Problems

    Troubleshoot Common Problems Problem Solution The torch does not cut fully • Examine the Hypertherm cartridge. Replace it if it is worn or damaged. through the workpiece. Refer to Signs that a cartridge is near end-of-life on page 74 and...
  • Page 95 • Tilt the torch down so that it is closer to the workpiece. enough width. • Increase the arc stretch (standoff). • Decrease the gouging speed. • Increase output current (A). Refer to Guidelines for hand torch gouging page 82. Powermax45 SYNC Operator Manual 811470...

  • Page 96: Fault Icons And Fault Codes

    Troubleshoot Common Problems Fault icons and fault codes The Powermax45 SYNC power supply shows faults using a combination of fault icons and fault code numbers. Some faults are shown by the icons only, others are shown by the icons and a fault code number.

  • Page 97: Fault Codes

    This is an example of the 0-50-2 fault code: The status LED on the SmartSYNC hand torch also shows the fault status. Yellow = a 0-nn-n Red = a 0-32-0, fault code, or the 1-nn-n, 2-nn-n, or torch is locked 3-nn-n fault code Powermax45 SYNC Operator Manual 811470...

  • Page 98: Remove Fault Code Conditions

    An operational fault code can be for a notification or for a condition that stops the cutting process. Hypertherm recommends that you do the steps in the following table for all faults that occur. Troubleshooting all faults helps you to get optimal cut quality and consumable life.
  • Page 99 • Examine all the connections for the input operating mode, torch, lead gas supply. Make sure that there are no length, or Hypertherm leaks or loose connections. cartridge type. • Make sure that the incoming gas supply...
  • Page 100 Start the following: signal is received. • If the Hypertherm cartridge became loose Yellow or was removed while the plasma power supply was ON and the torch-lock switch was set to the green “ready to fire”...
  • Page 101 • This fault also shows when a cartridge is not installed correctly. Remove the Hypertherm cartridge and install it correctly. • If the Hypertherm cartridge is in good condition and is installed correctly, the torch has possible damage. Speak to your distributor or authorized repair facility.
  • Page 102 3-phase models. voltage at the power source and at the plasma power supply. • If applicable, disconnect the system from generator power. Yellow • Do a cold restart. Refer to page Flashes 811470 Operator Manual Powermax45 SYNC...
  • Page 103 0-11-2 The remote control gas pressure is incorrect or not permitted. The permitted gas pressure relates to the selected process and operating mode, and to the installed torch, torch lead, and cartridge. Powermax45 SYNC Operator Manual 811470...
  • Page 104 • Sets the output current to 45 A. • Sets the operating mode to Cut mode. • Sets the output gas pressure to cut pressure. If necessary, you can manually change these settings to cut without a data connection. 811470 Operator Manual Powermax45 SYNC...
  • Page 105 • Machine torch: Move the torch-lock switch Yellow to the green “ready to fire” ( ) position. Fire the torch to get a plasma arc. • Mini machine torch: This fault code is not applicable to the mini machine torch. Powermax45 SYNC Operator Manual 811470...
  • Page 106 0-50-2 fault code after 0-50-3 goes away. Fire the torch 1 time to get the warning puffs of air. The 0-50-2 fault code goes away. The torch is now prepared to fire a plasma arc. 811470 Operator Manual Powermax45 SYNC...
  • Page 107 Hypertherm cartridge is not Cartridge: sending data to the system, Yellow • Make sure that the Hypertherm cartridge is so the system cannot installed correctly. collect data about the • Make sure that the cartridge. The problem can...
  • Page 108 Speak to your distributor or authorized repair facility. You can continue to cut or gouge, but you must set the output current (A) and the operating mode manually. 811470 Operator Manual Powermax45 SYNC...

  • Page 109: Internal Component Faults (1-Nn-N, 2-Nn-N, 3-Nn-N)

    1. Make sure the correct mode is selected for the process you want to validate (Cut or Gouge). 2. Press-and-hold the Mode button for approximately 5 seconds. 3. Release the Mode button when the 2-digit display shows P.C.  P.C. indicates pressure check. Powermax45 SYNC Operator Manual 811470...

  • Page 110: While Gas Test Mode Is Active

    While gas test mode is active Air flows continuously from the torch tip  The 2-digit display shows the output gas pressure  The AMPS LED remains off.  811470 Operator Manual Powermax45 SYNC...

  • Page 111: Exit Gas Test Mode

    You can do one of the two actions below to exit gas test mode: Press the Mode button.  Turn the adjustment knob  After the system exits gas test mode: The 2-digit display shows the cutting current (amperage).  The AMPS LED illuminates.  Powermax45 SYNC Operator Manual 811470...

  • Page 112: Troubleshoot Torch Stuck Open (Tso) Fault Codes That Occur During Postflow

    If you continue to have problems with input line voltage, disconnect the plasma power  supply from the generator, and connect it to a power receptacle with sufficient power. Refer to page 36 for generator specifications.  811470 Operator Manual Powermax45 SYNC...

  • Page 113: Complete Regular Maintenance Tasks

    All work that requires removal of the plasma power supply outer cover or panels must be done by a qualified technician. Refer to the Safety and Compliance Manual (80669C) for more safety information. Powermax45 SYNC Operator Manual 811470...
  • Page 114 Set the power switch on the plasma power supply to OFF (O).  Move the torch-lock switch to the yellow lock (X) position. Pull the trigger to make  sure that the torch does not fire a plasma arc. 811470 Operator Manual Powermax45 SYNC...

  • Page 115: Each Use

    • Do a check of the plug on the work lead. When a plug is replaced, damage to the wire inside the plug can occur. If the plug on the work lead has been replaced, look for damage. Powermax45 SYNC Operator Manual 811470...

  • Page 116: With Each Cartridge Change Or Each Week (Whichever Is More Frequent)

    Refer to Warning puffs of air page 52. Have a qualified service technician replace the torch-lock switch if it is not working correctly. Speak to your distributor or authorized repair facility. 811470 Operator Manual Powermax45 SYNC...

  • Page 117: At 3 Month Intervals

    Examine the labels. Replace any damaged labels. Refer Examine the torch lead. Have a qualified service to the Powermax45/65/85/105 SYNC Parts Guide technician replace it if it is damaged. Speak to your (810490). distributor or authorized repair facility. Powermax45 SYNC Operator Manual 811470...

  • Page 118: Cartridge Maintenance

    O-ring and the threads. Make sure that the O-ring is shiny, but do not apply too much lubricant. Figure 3 – Components to examine O-ring Holes for airflow Nozzle Shield Castellations 811470 Operator Manual Powermax45 SYNC...

  • Page 119: Examine The Air Filter Bowl And Filter Element

    5. Remove the air filter bowl from the metal guard. 6. Gently pry the filter element out of the filter bowl. Be careful not to damage the O-ring the top of the bowl. Powermax45 SYNC Operator Manual 811470...

  • Page 120: Examine The Air Filter Bowl And O-Ring

    O-ring, and filter element on page 121. If you use an external filtration system, such as the Eliminizer filter kit, also do a check of that  filter regularly for necessary maintenance or cleaning. 811470 Operator Manual Powermax45 SYNC...

  • Page 121: Examine The Filter Element

    , and put the new O-ring at the top of the filter bowl. 5. Put the filter element inside the air filter bowl. Push down on the top plastic fitting until you hear a click. Powermax45 SYNC Operator Manual 811470...

  • Page 122: Install The Air Filter Bowl And Filter Element

    2. Hand tighten the filter bowl by turning it to the right. 3. Reconnect the gas supply to the rear of the plasma power supply. 4. Reconnect the power cord. 811470 Operator Manual Powermax45 SYNC...

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