Hypertherm Automation Family Instruction Manual (IM)

Cut with Powermax® on an EDGE® Connect CNC

Powermax45 XP/65/85/105/125® and
Powermax65/85/105 SYNC

®

Manual Addendum

810290
Revision 0
June 2022

Hypertherm, Inc.

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Hanover, NH 03755 USA
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[e-mail] (Main Office)

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[e-mail] (Technical Service)

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[e-mail] (Customer Service)

Hypertherm México, S.A. de C.V.

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[e-mail] (Technical Service)

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[e-mail] (Technical Service)

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[e-mail] (Marketing)
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[e-mail] (Technical Service)

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Sydney NSW 2001, Australia
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61 7 3219 9010 Fax
[e-mail] (Main Office)
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91-11-40521201/ 2/ 3 Tel
91-11 40521204 Fax
[e-mail] (Main Office)
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© 2022 Hypertherm, Inc. All rights reserved. 100% Associate-owned.
EDGE, ProNest, Sensor, SYNC, SmartSYNC, Phoenix, Powermax, and Hypertherm are trademarks of Hypertherm, Inc. and may be registered in the United States and/or

other countries. All other trademarks are the property of their respective holders.
Environmental stewardship is one of Hypertherm’s core values.www.hypertherm.com/environment

Contents

1 Introduction ................................................................................................................................. 5

Purpose .................................................................................................................................................................... 5

Hardware and software requirements ............................................................................................................... 6

Before you begin .................................................................................................................................................... 6

More Powermax information ................................................................................................................................ 7

2 Set Up a CNC with Powermax .................................................................................................. 8

Make sure that the lifter is set up........................................................................................................................ 8

Select the tools installed and the processes used (Special Setups screen) .......................................... 8

Set up the stations (Station Configuration screen)........................................................................................ 9

Station Configuration guidelines ............................................................................................................... 10

Fixed-function digital I/O ............................................................................................................................. 11

Fixed-function digital inputs................................................................................................................. 11

Fixed-function digital outputs.............................................................................................................. 11

Fixed-function analog input......................................................................................................................... 11

3 Use Phoenix to Cut with Powermax...................................................................................... 12

Geometry without a part program .................................................................................................................... 12

Part programs........................................................................................................................................................ 13

Part programs with embedded process variables................................................................................. 13

Basic part programs without embedded process variables................................................................ 14

Manual Mode versus Program Mode........................................................................................................ 14

Powermax Cut with a Powermax on an EDGE Connect CNC 810290 3

Contents

Cut a part program ....................................................................................................................................... 15

Part program file types.......................................................................................................................... 15

Cut with guidance (CutPro Wizard).................................................................................................. 15

Cut without guidance (Files soft key)................................................................................................ 15

Override cut chart parameters .......................................................................................................................... 16

Cut Charts screen overrides ...................................................................................................................... 16

Change a parameter on the Cut Charts screen .................................................................................... 17

Process screen overrides............................................................................................................................ 18

4 Troubleshooting and Diagnostics .......................................................................................... 19

Make sure that the Powermax is ready............................................................................................................ 19

Set up watch windows........................................................................................................................................ 20

See and record fixed-function digital I/O ....................................................................................................... 21

See process data for Powermax....................................................................................................................... 22

About the Plasma Process screen............................................................................................................ 22

See Powermax information ................................................................................................................................ 24

Current Powermax settings ....................................................................................................................... 24

Firmware and current voltage .................................................................................................................... 25

Faults .............................................................................................................................................................. 25

Reset Powermax SYNC ............................................................................................................................. 25

More information .......................................................................................................................................... 25

See system errors and failures at the CNC ................................................................................................... 26

Status messages .......................................................................................................................................... 26

Error dialogs .................................................................................................................................................. 26

System Errors watch window ................................................................................................................... 26

See cartridge data ............................................................................................................................................... 27

Cartridge identification ............................................................................................................................... 27

Cartridge statistics ...................................................................................................................................... 27

Faults .............................................................................................................................................................. 27

Monitor cartridge life............................................................................................................................................ 28

Plasma Cartridge watch window............................................................................................................... 28

Read the estimated cartridge usage data........................................................................................ 28

How cartridge life is estimated ........................................................................................................... 29

Automatically update maximum consumable life.................................................................................... 29

Monitor and do tests of gas pressure ............................................................................................................. 30

Do a test of the gas pressure..................................................................................................................... 30

Monitor gas pressure ................................................................................................................................... 30

4 810290 Manual Addendum Powermax

Purpose

This addendum to the EDGE® Connect Installation and Setup Manual (809340) gives information
to help you do the following:

Introduction

 Set up Phoenix

 Use Phoenix to cut parts with one or more Powermax plasma power supplies.

 Find Powermax diagnostic information shown in Phoenix.

Some of the instructions given in this manual are only applicable when the



Powermax plasma power supply is connected to the EDGE Connect
CNC through the Powermax EtherCAT Interface. Refer to the Hardware

and software requirements on page 6.

®

to cut with one or more Powermax plasma power supplies.

Powermax Cut with a Powermax on an EDGE Connect CNC 810290 5

Introduction

1

Hardware and software requirements

A cutting system with the following equipment is necessary to use the information in this document:

 EDGE Connect CNC with Phoenix

 ProNest

 ProNest CNC Archives 1.6.0.0 or later

 Sensor™ THC torch height control

 Powermax EtherCAT Interface assembly

 One or more of the following Powermax plasma power supplies:

 Powermax65/85/105 SYNC

 Powermax45 XP/65/85/105/125

®

CNC Nesting Software 13.1.4.7599 or later

®

®

10.19.2 or later

®



Before you begin

Before you set up Phoenix to cut with a Powermax, do all of the following:

 Review the Hardware and software requirements.

 Connect your Powermax plasma power supply to the EDGE Connect CNC. To use the

information in this document, connect your Powermax plasma power supply to the CNC
serially through the Powermax EtherCAT Interface. Refer to Powermax EtherCAT Interface
Installation for EDGE Connect (810330) available at www.hypertherm.com/docs.



 Configure the EtherCAT network. Refer to Powermax EtherCAT Interface Installation for

EDGE Connect (810330) available at www.hypertherm.com/docs.

Each Powermax EtherCAT Interface supports one Powermax plasma
power supply, to a maximum of four Powermax EtherCAT interfaces per
EtherCAT network.

You can also connect your Powermax discretely using the procedure in
the operator manual for your plasma power supply. Some of the
functionality described in this manual is not available with a discrete
connection.

 Review the following settings on the Powermax plasma power supply:

 Baud rate and parity – The factory default setting for baud rate (19200) and parity

(Even) are compatible with the Powermax EtherCAT Interface.

 Arc voltage ratio – Make sure that the arc voltage ratio on your Powermax plasma

power supply is set to the factory default setting of 50:1. Refer to Figure 1 on page 7.

6 810290 Cut with a Powermax on an EDGE Connect CNC Powermax

1

Figure 1 – The DIP switches on the voltage divider PCB are set to the factory default of 50:1.

For more information, refer to the following Field Service Bulletins:



 Powermax45 XP Machine Interface Receptacle with Voltage Divider PCB

(809940)

 Machine Interface Receptacle with Voltage Divider PCB (806980)

More Powermax information

For Powermax technical support, refer to the manual for your Powermax plasma power supply:

 Powermax65/85/105 SYNC Operator Manual (810470)

Introduction

 Powermax65/85/105 SYNC Mechanized Cutting Guide (810480)

 Powermax45 XP Operator Manual (809240)

 Powermax65/85 Operator Manual (806650)

 Powermax105 Operator Manual (807390)

 Powermax125 Operator Manual (808080)

 Safety and Compliance Manual (80669C)

Technical documentation is available at www.hypertherm.com/docs.

Powermax Cut with a Powermax on an EDGE Connect CNC 810290 7

Set Up a CNC with Powermax

Make sure that the lifter is set up

Hypertherm CNCs support the Sensor™ THC, which is an integrated Z axis that supplies linear
motion and automatic voltage tracking. If you are using a Sensor THC, refer to the “Sensor THC
setup” procedure in the Torch Height Control (THC) section of the EDGE
and Setup Manual (809340).

Set up the Sensor THC before you select a cutting tool in the Station



Configuration screen or you will not see Sensor THC as a selection when
assigning the cutting tool.

®

Connect Installation

If you are not using a Sensor THC:

 Go to the Machine Setups screen (Setups > Password > Machine Setups) and set the

number of Sensor THCs installed to 0.

 Go to the Station Configuration screen (Setups > Password > Station Configuration) to

select Other or None for a lifter based on your configuration.

For more information, refer to the EDGE

®

Connect Installation and Setup Manual (809340).

Select the tools installed and the processes used (Special Setups screen)

Before you can assign your stations and get access to the necessary Process screens in Phoenix,
you first need to make selections on the Special Setups screen.

1. In Phoenix, select Setups > Password > Special Setups.

2. Make the applicable plasma or marker selections. Refer to Table 1 on page 9.

Powermax Cut with a Powermax on an EDGE Connect CNC 810290 8

Set Up a CNC with Powermax

2

Table 1 – Plasma process selections on the Special Setups screen

When you have... and... Select...

One or two torches One cutting process

One torch One cutting/marking* process

Two torches Two cutting processes

Two torches Two cutting/marking* processes

* Powermax45 XP is the only Powermax model that supports marking.

** You cannot assign Marker 2 without having Marker 1 also assigned. Otherwise, Marker 2 will be deleted

automatically when Phoenix restarts.

3. Select OK to save your changes.

Now you can assign your stations and go to the necessary Process screens.

Set up the stations (Station Configuration screen)

When you set up a station, Phoenix automatically customizes the Process screen, enables the cut
charts, and assigns fixed-function digital I/O.

Plasma 1

Plasma 1
Marker 1*

Plasma 1 and Plasma 2

Plasma 1 and Plasma 2
Marker 1

and Marker 2**

1. Select Setups > Password > Station Configuration.

2. Make the applicable selections for your cutting setup.

a. To see examples of station assignments, refer to Table 2.

b. For more information, refer to Station Configuration guidelines on page 10.

3. Select OK to save your changes.

Powermax Cut with a Powermax on an EDGE Connect CNC 810290 9

Set Up a CNC with Powermax

2

Table 2 – Example Powermax selections on the Station Configuration screen

When you
have...

A single torch One cutting process Station 1:

A single torch One cutting and one

Two torches One cutting process Station 1:

and... Select...

• Lifter: Sensor THC

• Plasma 1: Powermax

• Plasma 2: None

• Marker 1: None

• Marker 2: None

Station 1:

marking* process

• Lifter: Sensor THC

• Plasma 1: Powermax45 XP

• Plasma 2: None

• Marker 1: Powermax45 XP*

• Marker 2: None

• Lifter: Sensor THC

• Plasma 1: Powermax

• Plasma 2: None

• Marker 1: None

• Marker 2: None

Station 2:

• Lifter: None

• Plasma 1: None

• Plasma 2: None

• Marker 1: None

• Marker 2: None

Station 2:

• Lifter: None

• Plasma 1: None

• Plasma 2: None

• Marker 1: None

• Marker 2: None

Station 2:

• Lifter: Sensor THC 2

• Plasma 1: Powermax

• Plasma 2: None

• Marker 1: None

• Marker 2: None

* Powermax45 XP is the only Powermax model that supports marking. Select None for Marker 1 and Marker 2

when using other Powermax models.

Station Configuration guidelines

Table 2 shows common examples of station setups. More plasma power supplies can be assigned

to other stations. It is important to understand the following when setting up stations:

 The EDGE Connect CNC supports a maximum of 4 Powermax EtherCAT Interfaces.

 When installing a Powermax EtherCAT interface with one or more EtherCAT plasma power

supplies, make sure the XPR or HPR is before the Powermax EtherCAT interface.

 Do not mix XPR and HPR plasma power supplies on the same EtherCAT network.

 On the Station Configuration screen in Phoenix, set up the EtherCAT plasma power

supplies first, starting with Station 1. Set up tools with discrete connections on remaining
stations.

 It is not necessary to select Oxyfuel systems in the Station Configuration screen. Oxyfuel cut

charts become available after you select Oxyfuel as a Tool Installed in the Special Setups
screen (Setups > Password > Special Setups).

For more information, select the Help soft key or refer to Station Setup in the EDGE Connect
Installation and Setup Manual (809340). Technical documentation is available at

www.hypertherm.com/docs.

10 810290 Cut with a Powermax on an EDGE Connect CNC Powermax

2

Fixed-function digital I/O

When using a Powermax EtherCAT Interface, fixed-function digital I/O is automatically assigned
after 512. Phoenix uses your selections in the Station Configuration screen to identify what value to
use.

Phoenix lets you see and record fixed-function digital I/O using the I/O



watch window and Oscilloscope. Refer to page 21.

Fixed-function digital inputs

 Cut Sense – This input tells the CNC that the torch has transferred the arc to the

workpiece.

 Nozzle Contact Sense – This input is used during initial height sense (IHS) to find the

surface of the workpiece.

Fixed-function digital outputs

 Cut Control – This output starts the Plasma Start input of the Powermax. Cut Control turns

on and stays on until the M08 (Cut Off) command is executed in the part program.

Set Up a CNC with Powermax

Fixed-function analog input

Powermax Arc Voltage is a fixed-function analog input that is automatically assigned at 33 when
using a Sensor THC.

Powermax Cut with a Powermax on an EDGE Connect CNC 810290 11

Use Phoenix to Cut with Powermax

Figure 2 – Shape Library in Phoenix

This section tells you how to use Phoenix software to cut with one or more Powermax plasma power
supplies. You can use Phoenix to cut:

 Part programs – Refer to Part programs on page 13.

 Geometry without a part program – Refer to the next paragraph.

Geometry without a part program

ProNest CNC is pre-installed on every EDGE Connect CNC to allow you to cut and nest
geometric shapes without the need to supply your own part program.

With ProNest CNC, you can load shapes
from two locations:

 Phoenix Shape Library of default

parts (shown at the right)

 Computer-aided design (CAD) files

(*.dxf, *.dwg, *.dgn, or *.cam) that you
load into Phoenix

To use ProNest CNC, refer to Field Service
Bulletin 809560 available at

www.hypertherm.com/docs.

Powermax Cut with a Powermax on an EDGE Connect CNC 810290 12

3

Part programs

(ProNest Version 13.1.4.7599)
G21
G91
M01
(Set Powermax to 85A)
(CutPro Wizard - Load Material: Mild
Steel;1219.2mm x

2438.4mm;6.mm)

M36 T1
M37 T1

G00X68.324Y140.729

G59 V502 F69
G59 V503 F1
G59 V504 F85
G59 V505 F21
G59 V507 F29 G59
G59 V600 F128
G59 V601 F0.2
G59 V602 F120
G59 V603 F3.2
G59 V604 F120

G43X1.7
G41
M07 HS
M51
F3560
G01X4.752Y-4.752
G02Y-125.724I-62.862J-62.862
G01X-62.862Y62.862
G01X62.862Y62.862
M50
G01X2.376Y2.376
M08

Example of a part program with

embedded process variables

1

3

2

4

Phoenix allows you to cut part programs with and without embedded process variables.

 To learn more about part programs, refer to the information that follows on this page.

 To cut a part program, refer to Cut a part program on page 15.

Part programs with embedded process variables

Part programs created with Computer-Aided Manufacturing
(CAM) software often contain the types of codes described
below.

1M36 T#

2M37* T#

3 G59 5##

4 G59 6##

* If your part program has an M37 code, you must also enable

the station in Program Mode from the Soft Operator Console

Powermax Cut with a Powermax on an EDGE Connect CNC 810290 13

(Soft Op Con). Refer to page 14.

The example part program on the right shows process codes
for a Powermax SYNC that is assigned to Station 1 with the
Plasma 1 process.



For a complete list of specific process variables for
Powermax, refer to the EDGE Connect Programmer

Reference (809550) available at

www.hypertherm.com/docs.

Use Phoenix to Cut with Powermax

Allows the part program to select process
parameters in the cut charts, where T selects the
process (Plasma 1/Plasma 2 or Marker 1/Marker 2).

Enables a station, where T selects the station
number for the Powermax.*

Selects the Torch Type, Current, and Gas
parameters for the material you are cutting.

Updates Torch Height Control variables (such as
Arc Voltage, Pierce Time, Pierce Height, and Cut
Height) if a Sensor THC is set up.

There are specific G59 V5## and V6## codes for
a Powermax if it is installed on different stations and
using alternative processes (such as
Plasma1/Plasma2 or Marker1/Marker2).

Use Phoenix to Cut with Powermax

3

G20
G91
G99 X1 Y0 I0 J0
G41
M07
G01 X0 Y5
G01 X5 Y0
G01 X0 Y-5
G01 X-5 Y0
M08
G40

Example of a basic part program

Basic part programs without embedded process variables

Basic part programs do not contain an M37 (Station Select)
code or embedded process variables (G59 codes).

If you have a basic part program, make sure to:

 Manually select process parameters from the cut

charts in Phoenix before you cut the part.

 Enable the station in Manual Mode on the Soft

Operator Console (Soft Op Con). Refer to the next
section.

Manual Mode versus Program Mode

Before you can begin to cut, you must enable the assigned station in either Manual Mode or
Program (Automatic) Mode.

On the CNC’s standard Soft Op Con, select from the station modes that follow:

Station mode* Select this mode if... Before you select this mode...

Disable

Station

Manual Your part program does NOT contain an

Program

(Automatic)

* The color of the mode you select changes from gray to green when you select it.

The station is not ready for operation.

M37 (Station Select) code and the station is
ready to operate.

You want to jog the torch, Go to Home, or do
rip cutting.

Your part program contains an M37 (Station
Select) code and the station is ready to
operate.

Manually select a cut chart process in
Phoenix.

Enable the Program Code settings that
follow on the Setups > Cutting screen.

• EIA G59 Code Override**

• Process Select Override

• EIA Kerf Override

• EIA F-Code Override

• Station Select Override

** Enabling EIA G59 code overrides is only useful if your part program contains G59 codes. If your part

14 810290 Cut with a Powermax on an EDGE Connect CNC Powermax

program does NOT contain G59 codes, make sure to manually select a cut chart process in Phoenix.

3

Cut a part program

Start cutting Stop cutting

Regardless of whether your part program contains embedded process variables, you can choose to
cut with or without cutting setup guidance from the CutPro Wizard.

Part program file types

The default file extension for Phoenix parts programs is *.txt. Hypertherm ProNest parts have the
*.cnc extension. Refer to your CAM software for the file extension it uses and enter the extension on
the Special Setups screen.

If your file is a *.dxf, *.dwg, *.dgn, or *.cam, refer to page 12.

Cut with guidance (CutPro Wizard)

Use the CutPro Wizard to cut a part program if you would like to see prompts that help you to cut
your part program. The CutPro Wizard guides you to load a part, install consumables, select cut
charts, and align a part to a plate.

If you do not need step-by-step guidance, refer to Cut without guidance



(Files soft key).

Use Phoenix to Cut with Powermax

1. On the Soft Op Con, select the applicable station mode (Program or Manual ) for your
part program. Refer to page 14.

2. Go to the Main screen in Phoenix and select CutPro Wizard on the right-side of the
screen.

3. Follow the instructions and prompts on the CutPro Wizard dialogs that appear next.

Cut without guidance (Files soft key)

If you do not need help to cut your part program, cut the part with these steps.

1. Press (Files > Load from Disk) and choose the part program.

If necessary, you can override cut chart and process parameters. Refer to



page 16.

2. On the Soft Op Con, select the applicable station mode (Program or Manual ) for your
part program. Refer to page 14.

3. Select Start to cut.

Powermax Cut with a Powermax on an EDGE Connect CNC 810290 15

Use Phoenix to Cut with Powermax

3

1

2

1

*

3

2

*

*

Override cut chart parameters

If necessary, you can override the standard cut chart parameters on two screens:

 Cut Charts screen (Setups > Process > Plasma 1 [or 2] > Plasma 1 [or 2] Cut Chart)

 Process screen (Setups > Process > Plasma 1 [or 2])

Before you make one-time changes to parameters on the Process screen, edit the parameters on
the Cut Chart screen. Overrides made on the Cut Chart screen automatically update related values
on the Process screen.

If you are manually overriding values in an advanced part program with



G59 codes, make sure that the EIA G59 Code Override setting is
enabled in Setups > Cutting.

Cut Charts screen overrides

You can override the parameters on the Cut Charts screen shown in Figure 3. Powermax cut charts
include editable Gas Pressure (psi) values to use with different torch lead lengths.

For more information about specific cut chart parameters, select Help .

Figure 3 – Cut Charts screen for Powermax

* Some selections are set automatically. Refer to the next page.

16 810290 Cut with a Powermax on an EDGE Connect CNC Powermax

3

For Powermax SYNC, the following selections are set automatically:

3

 Gas Pressure

 Maximum Process Current

 Specific Material

 Cut Chart Type

 FineCut, if you install a C MFNC cartridge

 Gouge, if you install a G CNTL or G RMVL cartridge

 None, if you install a standard mechanized cutting cartridge

Change a parameter on the Cut Charts screen

1. Delete a default value and enter a new value. The override value shows in blue font.

Creep Time and Cut Height Delay cannot be edited on this screen. To



edit these values, go to the Process screen.

2. Select OK to exit the screen.

Use Phoenix to Cut with Powermax

3. Select Yes when asked if you want to save changes to the cut chart.

After completing steps 1-3 above, the overrides that you have just made stay in effect until the next
time that you save changes to those values or load a new part program. The overrides automatically
update applicable values on the Process screen.

If necessary, you can restore the factory cut chart values with the Reset Process soft key. Refer
to Figure 3 on page 16.

Powermax Cut with a Powermax on an EDGE Connect CNC 810290 17

Use Phoenix to Cut with Powermax

3

1

2

3

4

123

4

2

Process screen overrides

After you customize parameters on the Cut Charts screen, you can make one-time overrides to the
parameters on the Process screen (refer to Figure 4).

Figure 4 – Process screen when Sensor THC is set up

Some values come directly from the cut chart . Other values are calculated from a combination of
cut chart values and other Phoenix settings .

Gas Pressure and Cut Mode settings are set automatically for Powermax SYNC. A gouging
cartridge can only be used in Gouge mode, but a cutting cartridge can be used in Normal or CPA
mode. In addition, the maximum Set Arc Current is limited by the cartridge. For more information,
select Help .

To change a value that is calculated from a combination of cut chart values and Phoenix settings :

1. Clear the checkbox and delete the value.

2. Enter a new value. The override value shows in blue font.

3. When you are done editing the Process screen, select OK to save your changes and exit.

Clearing the checkbox breaks the link to the cut chart and other Phoenix



settings. The override value is kept as is until you change it again on the
Process screen or re-select the checkbox to put back the default value.

18 810290 Cut with a Powermax on an EDGE Connect CNC Powermax

Troubleshooting and Diagnostics

This section tells you how to do the following:

 Check Powermax readiness.

 Set up watch windows to monitor: Input/Output, System Errors, Process Data, and

Cartridge Life on SmartSYNC torches.

 See and record fixed-function digital I/O.

 See process data for Powermax.

 See Powermax system errors and failures at the CNC.

 See cartridge data (for Powermax SYNC).

 Monitor cartridge life (for Powermax SYNC).

 Monitor and do tests of gas flows.

Make sure that the Powermax is ready

Before sending a process to the Powermax, make sure that the following conditions are satisfied:

 The Powermax plasma power supply is set to ON.

 The fieldbus is running. (If the gantry moves when you jog the torch, then the fieldbus is

enabled.)

 The tool’s station is enabled in Phoenix. Refer to “Enable Station I/O” in the EDGE Connect

Installation and Setup Manual (809340).

 There are no Powermax errors.

 The hardware and software requirements on page 6 are satisfied.

Powermax Cut with a Powermax on an EDGE Connect CNC 810290 19

Troubleshooting and Diagnostics

4

Set up watch windows

You can set up watch windows to show on the Main screen to give you feedback during cutting.

To set up a watch window, select Setups > Watch.

You can customize a maximum of 10 watch windows. When monitoring Powermax information from
the CNC, Hypertherm recommends that you set up watch windows for:

 Input/Output

 System Errors

 Process Data

 Plasma Cartridge (Refer to Monitor cartridge life on page 28.)

Figure 5 – Example of the Watch Window Setup screen

For more information about the Watch Window Setup screen, select Help .

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See and record fixed-function digital I/O

The automatically assigned fixed-function I/O for Powermax are shown on page 11.

There are two methods you can use to monitor fixed-function digital I/O in Phoenix.

 To set up an Input/Output watch window, go to Setups > Watch and refer to Figure 5 on

page 20.

 To make an Oscilloscope log to help you understand an issue with an input or output, go to

Setups > Diagnostics > Oscilloscope and refer to Figure 6.

Figure 6 – Example of the Oscilloscope screen for Powermax

Troubleshooting and Diagnostics

For more information about the Oscilloscope screen, select Help .

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See process data for Powermax

To see process data for Powermax, do the following:

 Set up a Process Data watch window (Setups > Watch). Refer to the example in Figure 5

on page 20.

 Go to the Plasma Process screen (Setups > Process > Plasma 1).

About the Plasma Process screen

From the Process screen, you can customize and control the plasma process.

If a Sensor THC has been set up, then the Process screen includes torch height control options as
shown in Figure 7.

Figure 7 – Plasma Process screen with Sensor THC

If a Sensor THC has not been set up and you have selected Other or None as the Lifter in the
Station Configuration screen, then the Process screen includes fewer options. Refer to Figure 8 on
page 23.

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Figure 8 – Plasma Process screen without Sensor THC

For information about changing values on the Process screen, refer to Process screen overrides on
page 18.

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1

(Only available for Powermax SYNC)

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2

3

5

1 Current settings

2 Firmware and current voltage
3 Faults

4 Reset Powermax SYNC (quick restart)

5 Help

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See Powermax information

If you have a Powermax EtherCAT Interface, the Powermax sends information to Phoenix about its
current settings, firmware and current voltage, as well as recent faults.

To see Powermax System Information, select Setups > Diagnostics > Powermax System.

Figure 9 – Powermax System Information screen

Current Powermax settings

The upper-left of the Powermax System Information screen (shown in Figure 9) shows the following
Powermax settings:

 Cut Mode – The cut mode that is set by the CNC and sent to the Powermax (Normal,

Continuous Pilot Arc [CPA], or Gouge).

 Set Arc Current – The current level (amperes) that is set by the CNC and sent to the

Powermax.

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 Gas Pressure – The gas pressure (psi) that is set by the CNC and sent to the Powermax.

2

3

4

5

The CNC uses the gas pressure from the cut chart or the part program.

 Torch Lead Length – The CNC uses the torch lead length to determine the correct range

for the gas pressure. The gas pressure and lead lengths are stored in the cut charts.

You can change some of these current settings on the Process screen. Refer to page 18.

Firmware and current voltage

The lower-left of the Powermax System Information screen shows information about the Powermax
control and digital signal processing (DSP) firmware. Refer to Figure 9 on page 24.

The following information is also shown:

 Tot al Arc On Time (hours) – The time (hours) that the Powermax has been on and

producing an arc for the life of the plasma power supply.

 AC Input Voltage – The supply voltage as measured by the Powermax sensors.

 DC Bus Voltage – The internal DC voltage as measured by the Powermax sensors.

Troubleshooting and Diagnostics

Faults

The right side of the Powermax System Information screen shows recent faults. Refer to Figure 9 on
page 24.

Resolve faults by following the steps in the operator manual for your plasma power supply. Technical
documentation is available at www.hypertherm.com/docs.

Reset Powermax SYNC

When troubleshooting faults for a Powermax SYNC, you can do a quick restart of the plasma power
supply from the CNC by choosing the Reset Powermax SYNC soft key.

More information

To learn more about the fields on the Powermax System Information screen, select Help .

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See system errors and failures at the CNC

System errors at the CNC can show in Phoenix as status messages, error dialogs, and messages in
the System Errors watch window. Refer to Figure 10.

Figure 10 – Example of a status message, error dialog box, and System Errors watch window

1

Status messages

Status messages show as blue text below the part preview on the Main screen. These messages
show in order of priority and show the sequence of events on the cutting system.

Error dialogs

Error dialogs show in Phoenix when the cutting system is not operating correctly.

Faults and errors cause the arc to stop and cutting motion to pause. This prevents damage to the
cutting system, unsatisfactory cut quality, and a decline in productivity. The dialog box also shows a
message when cutting is paused for an error that does not stop cutting.

System Errors watch window

Messages in the System Errors watch window show system errors and failures. To set up the
System Errors watch window, select Setups > Watch. Refer to Figure 5 on page 20.

For more information, refer to the EDGE Connect Installation and Setup Manual (809340).

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See cartridge data

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3

1

123

If you are cutting with a SmartSYNC torch on a Powermax65/85/105 SYNC system, you can see
data about the cartridge that is currently installed. Select Setups > Diagnostics > Powermax
System > Cartridge Data.

Troubleshooting and Diagnostics

Figure 11 – Cartridge Data screen

Cartridge identification

The upper-left of the Cartridge Data screen shows information to identify the cartridge type
(including the part number to replace the cartridge). Refer to Figure 11.

Cartridge statistics

On the left of the screen, you can also see data about the total usage over the life of the cartridge.
You can set up a watch window to help you to monitor cartridge life. Refer to page 28.

Faults

On the lower-left of the screen, you can see recent operational faults that occurred while cutting or
gouging with this cartridge.

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20 40

100 200

1

Minutes used or pierces completedMinutes or pierces remaining

To resolve faults, refer to the operator manual for your plasma power supply. Technical
documentation is available at www.hypertherm.com/docs.

Monitor cartridge life

To monitor cartridge life for Powermax SYNC, set up a Plasma Cartridge watch window in the
Upper or Middle Location (Setups > Watch). Refer to Set up watch windows on page 20.

Plasma Cartridge watch window

To see a Plasma Cartridge watch window that you have set up, go to the Main screen in Phoenix.

Figure 12 – Example of a Plasma Cartridge watch window

Read the estimated cartridge usage data

The Minutes gauge (top bar) in the Plasma Cartridge watch window shows the Arc Transfer Time
over the life of the cartridge.

In Figure 12 shown above, the maximum life of the installed cartridge is approximately 40 minutes of
Arc Transfer Time.

 Minutes used – The red part of the Minutes gauge shows approximately how long the

installed cartridge has been used for in its life in minutes.

Example: The cartridge shown in Figure 12 above has been used for approximately 8
minutes of Arc Transfer Time.

 Minutes remaining – The green bar on the Minutes gauge shows an estimate of the

available Arc Transfer Time that remains on the Plasma 1 cartridge.

Example: In Figure 12, the green part of the Minutes gauge shows that the Plasma 1
cartridge has approximately 32 minutes of Arc Transfer Time remaining.

For information about how the estimated cartridge usage data is calculated, refer to How cartridge

life is estimated on page 29.

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How cartridge life is estimated

The minutes value in the Plasma Cartridge watch window is an estimate that is calculated as
follows.

minutes used (in red) = actual cumulative Arc Transfer Time + (minutes/pierce* x
number of pierces completed)

* Where the minutes/pierce value in the above calculation is taken from the estimates that you supplied on the

Change Consumables screen. Refer to Figure 13.

Figure 13 – Maximum Cartridge Life settings on the Change Consumables screen

Cartridge life can vary by cartridge type and cutting application. You must



go to the Change Consumables screen to supply estimates of the
Plasma - Max Cartridge Life values for your cartridge, unless you use
enable automatic updates. Refer to Automatically update maximum

consumable life.

Examples:

 If a cartridge has completed 20 pierces and used 6 minutes of Arc Transfer Time, then the

red part of the Minutes gauge on the Plasma Cartridge watch window shows:

(0.1 x 20) + 6 = 8 minutes of use.

 With a “0” in the minutes/pierce field, the minutes life gauge in the Plasma Cartridge watch

window is only the Arc Transfer Time.

 If each pierce in a nest takes an average of “.1” minutes (or 6 seconds) away from total

consumable life, then type “.1” in the minutes/pierce field in the Change Consumables
screen (Plasma 1 or 2 Cut Chart > Change Consumables).

If you complete 50 pierces, then Phoenix automatically adds 5 minutes to the Arc Transfer
Time that is shown as used (in red) in the Plasma Cartridge watch window.

Automatically update maximum consumable life

Hypertherm recommends enabling the Auto Update Max Consumable Life option in the Special
Setups screen (Setups > Password > Special Setups).

When enabled, this feature monitors the cartridge or consumable life beyond the user-defined
setpoint on the Change Consumables screen and uses that maximum value as the new setpoint.

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Monitor and do tests of gas pressure

Do a test of the gas pressure

To identify a problem with the gas pressure:

1. Select Setups > Diagnostics > Powermax System > Gas Test.

2. Wait while the gas flow turns ON.

3. Compare the measured gas pressure in blue text with the gas pressure set by the CNC .

Refer to Figure 14.

Figure 14 – Gas Test screen for Powermax SYNC

If the measured pressure is out of range from the set Gas Pressure , then an error shows in
the Last Fault field .

Resolve faults by following the steps in the operator manual for your plasma power supply. Technical
documentation is available at www.hypertherm.com/docs.

Monitor gas pressure

To monitor the measured gas pressure from the Main screen in Phoenix, set up a watch window.
Refer to page 20.

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