Hypertherm Manual Family Operator Manual (OM)

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Powermax65/85/105 SYNC

Operator Manual

810470 – REVISION 4

ENGLISH

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5 Safety: Registration allows us to contact you in the unlikely event a safety or quality notification

is required.

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Hypertherm Cutting Institute.

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insurance loss.

Go to www.hypertherm.com/registration for easy and fast registration.

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Maintenance notes: ______________________________________________________________________

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Powermax, SYNC, SmartSYNC, FastConnect, and Hypertherm are trademarks of Hypertherm, Inc. and may be registered in the United States and other countries. All other trademarks are the property of their respective holders.

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.

Powermax65/85/105 SYNC

Operator Manual

810470

REVISION 4

ENGLISH

Original instructions

May 2022

Hypertherm, Inc.

Hanover, NH 03755 USA

www.hypertherm.com

Hypertherm, Inc.

21 Great Hollow Road, P.O. Box 5010 Hanover, NH 03755 USA 603-643-3441 Tel (Main Office) 603-643-5352 Fax (All Departments) info@hypertherm.com (Main Office)

800-643-9878 Tel (Technical Service)

technical.service@hypertherm.com (Technical Service)

800-737-2978 Tel (Customer Service)

customer.service@hypertherm.com (Customer Service)

Hypertherm México, S.A. de C.V.

52 55 5681 8109 Tel 52 55 5681 7978 Tel soporte.tecnico@hypertherm.com (Technical Service)

Hypertherm Plasmatechnik GmbH

Sophie-Scholl-Platz 5 63452 Hanau Germany 00 800 33 24 97 37 Tel 00 800 49 73 73 29 Fax

31 (0) 165 596900 Tel (Technical Service) 00 800 4973 7843 Tel (Technical Service)

technicalservice.emeia@hypertherm.com (Technical Service)

Hypertherm (Singapore) Pte Ltd.

Solaris @ Kallang 164 164 Kallang Way #03-13 Singapore 349248, Republic of Singapore 65 6841 2489 Tel 65 6841 2490 Fax marketing.asia@hypertherm.com (Marketing) techsupportapac@hypertherm.com (Technical Service)

Hypertherm Japan Ltd.

Level 9, Edobori Center Building 2-1-1 Edobori, Nishi-ku Osaka 550-0002 Japan 81 6 6225 1183 Tel 81 6 6225 1184 Fax htjapan.info@hypertherm.com (Main Office) techsupportapac@hypertherm.com (Technical Service)

Hypertherm Europe B.V.

Vaartveld 9, 4704 SE Roosendaal, Nederland 31 165 596907 Tel 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)

Hypertherm (Shanghai) Trading Co., Ltd.

B301, 495 ShangZhong Road Shanghai, 200231 PR China 86-21-80231122 Tel 86-21-80231120 Fax

86-21-80231128 Tel (Technical Service)

techsupport.china@hypertherm.com (Technical Service)

South America & Central America: Hypertherm Brasil Ltda.

Rua Bras Cubas, 231 – Jardim Maia Guarulhos, SP – Brasil CEP 07115-030 55 11 2409 2636 Tel tecnico.sa@hypertherm.com (Technical Service)

Hypertherm Korea Branch

#3904. APEC-ro 17. Heaundae-gu. Busan. Korea 48060 82 (0)51 747 0358 Tel 82 (0)51 701 0358 Fax marketing.korea@hypertherm.com (Marketing) techsupportapac@hypertherm.com (Technical Service)

Hypertherm Pty Limited

GPO Box 4836 Sydney NSW 2001, Australia 61 7 3103 1695 Tel 61 7 3219 9010 Fax au.sales@hypertherm.com (Main Office) techsupportapac@hypertherm.com (Technical Service)

Hypertherm (India) Thermal Cutting Pvt. Ltd

A-18 / B-1 Extension, Mohan Co-Operative Industrial Estate, Mathura Road, New Delhi 110044, India 91-11-40521201/ 2/ 3 Tel 91-11 40521204 Fax htindia.info@hypertherm.com (Main Office) technicalservice.emeia@hypertherm.com (Technical Service)

For training and education resources, go to the Hypertherm Cutting Institute (HCI) online at

www.hypertherm.com/hci.

ENGLISH

WARNING! Before operating any Hypertherm equipment, read the safety instructions in your product’s manual, the Safety and Compliance Manual (80669C),

Waterjet Safety and Compliance Manual (80943C), and Radio Frequency Warning Manual (80945C). Failure to follow safety instructions can result in personal injury

or in damage to equipment. Copies of the manuals can come with the product in electronic and printed formats.

Electronic copies are also on our website. Many manuals are available in multiple languages at www.hypertherm.com/docs.

BG (БЪЛГAPCКИ/BULGARIAN)

ПРЕДУПРЕЖДЕНИЕ! Преди да работите с което и да е оборудване Hypertherm, прочетете инструкциите за безопасност в ръководството на вашия продукт, „Инструкция за безопасност и съответствие“ (80669C), „Инструкция за безопасност и съответствие на Waterjet“ (80943С) и „Инструкция за предупреждение за радиочестота“ (80945С).

Продуктът може да е съпроводен от копия на ръководствата в електронен и в печатен формат. Тези в електронен формат са достъпни също на уебсайта ни. Много ръководства са налице на няколко езика на адрес www.hypertherm.com/docs.

CS (ČESKY/CZECH)

VAROVÁNÍ! Před uvedením jakéhokoli zařízení Hypertherm do provozu si přečtěte bezpečnostní pokyny v příručce k produktu a v Manuálu pro bezpečnost

a dodržování předpisů (80669C), Manuálu pro bezpečnost a dodržování předpisů při řezání vodním paprskem (80943C) a Manuálu varování ohledně rádiových frekvencí (80945C).

Kopie příruček mohou být součástí dodávky produktu, a to v elektronické i tištěné formě. Elektronické kopie jsou k dispozici i na našich webových stránkách. Mnoho příruček je k dispozici v různých jazycích na stránce www.hypertherm.com/docs.

DA (DANSK/DANISH)

ADVARSEL! Inden Hypertherm udstyr tages i brug skal sikkerhedsinstruktionerne i produktets manual og i Manual om sikkerhed og overholdelse af krav (80669C), Manual om sikkerhed og overholdelse af krav for vandstråleskæring (80943C), og Manual om radiofrekvensadvarsel (80945C), gennemlæses.

Kopier af manualerne kan leveres med produktet i elektronisk og trykt format. Elektroniske kopier findes også på vores hjemmeside. Mange manualer er tilgængelige på flere sprog på www.hypertherm.com/docs.

DE (DEUTSCH/GERMAN)

WARNUNG! Bevor Sie ein Hypertherm-Gerät in Betrieb nehmen, lesen Sie bitte die Sicherheitsanweisungen in Ihrer Bedienungsanleitung, das Handbuch für Sicherheit

und Übereinstimmung (80669C), das Handbuch für Sicherheit und Compliance bei Wasserstrahl-Schneidanlagen (80943C) und das Handbuch für HochfrequenzWarnung (80945C).

Bedienungsanleitungen und Handbücher können dem Gerät in elektronischer Form oder als Druckversion beiliegen. In elektronischer Form liegen sie auch auf unserer Website vor. Viele Handbücher stehen in verschiedenen Sprachen auf

www.hypertherm.com/docs zur Verfügung.

ES (ESPAÑOL/SPANISH)

¡ADVERTENCIA! Antes de operar cualquier equipo Hypertherm, lea las instrucciones de seguridad del manual de su producto, del Manual de seguridad

y cumplimiento (80669C), del Manual de seguridad y cumplimiento en corte con chorro de agua (80943C) y del Manual de advertencias de radiofrecuencia

(80945C). El producto puede incluir copias de los manuales en formato digital e impreso.

Las copias digitales también están en nuestra página web. Hay diversos manuales disponibles en varios idiomas en www.hypertherm.com/docs.

ET (EESTI/ESTONIAN)

HOIATUS! Enne Hyperthermi mis tahes seadme kasutamist lugege läbi toote kasutusjuhendis olevad ohutusjuhised ning Ohutus- ja vastavusjuhend (80669C), Veejoa ohutuse ja vastavuse juhend (80943C) ja Raadiosageduse hoiatusjuhend (80945C). Ohutusjuhiste eiramine võib põhjustada vigastusi ja kahjustada seadmeid.

Juhiste koopiad võivad tootega kaasas olla elektrooniliselt või trükituna. Elektroonilised koopiad on saadaval ka meie veebilehel. Paljud kasutusjuhendid on erinevates keeltes saadaval veebilehel www.hypertherm.com/docs.

FI (SUOMI/FINNISH)

VAROITUS! Ennen minkään Hypertherm-laitteen käyttöä lue tuotteen käyttöoppaassa olevat turvallisuusohjeet, turvallisuuden ja vaatimustenmukaisuuden

käsikirja (80669C), vesileikkauksen turvallisuuden ja vaatimustenmukaisuuden käsikirja (80943C) ja radiotaajuusvaroitusten käsikirja (80945C).

Käyttöoppaiden kopiot voivat olla tuotteen mukana sähköisessä ja tulostetussa muodossa. Sähköiset kopiot ovat myös verkkosivustollamme. Monet käyttöoppaat ovat myös saatavissa useilla kielillä www.hypertherm.com/docs.

FR (FRANÇAIS/FRENCH)

AVERTISSEMENT! Avant d’utiliser tout équipement Hypertherm, lire les consignes de sécurité dumanuel de votre produit, duManuel de sécurité et de conformité (80669C), du Manuel de sécurité et de conformité du jet d’eau (80943C) et du Manuel d'avertissement relatif aux radiofréqunces (80945C).

Les exemplaires des manuels qui accompagnent le produit peuvent être sous forme électronique ou papier. Les manuels sous forme électronique se trouvent également sur notre site Internet. Plusieurs manuels sont offerts en plusieurs langues à www.hypertherm.com/docs.

GR (ΕΛΛΗΝΙΚΆ/GREEK)

ΠΡΟΕΙΔΟΠΟΙΗΣΗ! Πριν θέσετε σε λειτουργία οποιονδήποτε εξοπλισμό της Hypertherm, διαβάστε τις οδηγίες ασφαλείας στο εγχειρίδιο του προϊόντος και στο

εγχειρίδιο ασφάλειας και συμμόρφωσης (80669C), στο εγχειρίδιο ασφάλειας και συμμόρφωσης του waterjet (80943C) και στο εγχειρίδιο προειδοποιήσεων για τις ραδιοσυχνότητες (80945C).

Το προϊόν μπορεί να συνοδεύεται από αντίγραφα των εγχειριδίων σε ηλεκτρονική και έντυπη μορφή. Τα ηλεκτρονικά αντίγραφα υπάρχουν επίσης στον ιστότοπό μας. Πολλά εγχειρίδια είναι διαθέσιμα σε διάφορες γλώσσες στο

www.hypertherm.com/docs.

HU (MAGYAR/HUNGARIAN)

VIGYÁZAT! Mielőtt bármilyen Hypertherm berendezést üzemeltetne, olvassa el a biztonsági információkat a termék kézikönyvében, a Biztonsági

és szabálykövetési kézikönyvben (80669C), a Vízsugaras biztonsági és szabálykövetési kézikönyvben (80943C) és a Rádiófrekvenciás figyelmeztetéseket tartalmazó kézikönyvben (80945C).

A termékhez a kézikönyv példányai elektronikus és nyomtatott formában is mellékelve lehetnek. Az elektronikus példányok webhelyünkön is megtalálhatók. Számos kézikönyv áll rendelkezésre több nyelven a www.hypertherm.com/docs weboldalon.

ID (BAHASA INDONESIA/INDONESIAN)

PERINGATAN! Sebelum mengoperasikan peralatan Hypertherm, bacalah petunjuk keselamatan dalam manual produk Anda, Manual Keselamatan dan Kepatuhan (80669C), Manual Keselamatan dan Kepatuhan Jet Air (80943C), dan Manual Peringatan Frekuensi Radio (80945C). Kegagalan mengikuti petunjuk keselamatan dapat menyebabkan cedera pribadi atau kerusakan pada peralatan.

Produk mungkin disertai salinan manual atau petunjuk dalam format elektronik maupun cetak. Salinan elektronik juga tersedia di situs web kami. Berbagai manual tersedia dalam beberapa bahasa di www.hypertherm.com/docs.

IT (ITALIANO/ITALIAN)

AVVERTENZA! Prima di usare un’attrezzatura Hypertherm, leggere le istruzioni sulla sicurezza nel manuale del prodotto, nel Manuale sulla sicurezza e la conformità (80669C), nel Manuale sulla sicurezza e la conformità Waterjet (80943C) e nel Manuale di avvertenze sulla radiofrequenza(80945C).

Copie del manuale possono accompagnare il prodotto in formato cartaceo o elettronico. Le copie elettroniche sono disponibili anche sul nostro sito web. Molti manuali sono disponibili in diverse lingue all’indirizzo www.hypertherm.com/docs.

JA (日本語/JAPANESE)

警告 ! Hypertherm 機器を操作する前に、この製品説明書にある安全情報、「安全とコンプライアンスマニュアル」 (80669C) 、「ウォータージェットの安全とコンプライアンス」 (80943C)、「高周波警告」 (80945C) をお読みください。

説明書のコピーは、電子フォーマット、または印刷物として製品に同梱されています。電子コピーは当社ウェブサイトにも掲載されています。説明書の多くは www.hypertherm.com/docs にて複数の言語でご用意しています。

KO (뼑뼑霢꽩 KOREAN)

陲隕+\SHUWKHUP녚ꟹꌱꩡ끞뼍韥놹꾅뇑븽꫙ꐺ꫑꿵껽놹ꗄ鞑뇊늵ꯍ ꫙ꐺ꫑&낁뫥뇤껽놹ꗄ鞑뇊늵ꯍ꫙ꐺ꫑&鞭ꍡ隕ꓩ꫕늱볁ꯍ 陲隕꫙ꐺ꫑&꾅驍꿵넽鱉껽놹덵렝냹넲냱겢겑꿙

놹녅뿊겒隱넭ꭹ鷑뿊겒냱ꈑ꫙ꐺ꫑ꩡꚭ넩뇑븽隱뼝颍뇑險鷕ꯍ넽걪鱽鲙 놹녅ꩡꚭ鵹+\SHUWKHUP낮ꩡ넩뱭꾅꫑ꚩ겙ꯍ넽냱ꐥ꫙ꐺ꫑ꩡꚭ냵

www.hypertherm.com/docs꾅꫑꾡ꆡ꽭꽩ꈑ뇑險鷞鱽鲙

NE (NEDERLANDS/DUTCH)

WAARSCHUWING! Lees voordat u Hypertherm-apparatuur gebruikt de veiligheidsinstructies in de producthandleiding, in de Veiligheids-

en nalevingshandleiding (80669C) in de Veiligheids- en nalevingshandleiding voor waterstralen (80943C) en in de Waarschuwingshandleiding radiofrequentie

(80945C). De handleidingen kunnen in elektronische en gedrukte vorm met het product worden

meegeleverd. Elektronische versies zijn ook beschikbaar op onze website. Veel handleidingen zijn in meerdere talen beschikbaar via www.hypertherm.com/docs.

NO (NORSK/NORWEGIAN)

ADVARSEL! Før du bruker noe Hypertherm-utstyr, må du lese sikkerhetsinstruksjonene i produktets håndbok, håndboken om sikkerhet og samsvar (80669C), håndboken om vannjet sikkerhet og samsvar (80943C), og håndboken om radiofrekvensadvarsler (80945C).

Eksemplarer av håndbøkene kan følge med produktet i elektronisk og trykt form. Elektroniske eksemplarer finnes også på nettstedet vårt. Mange håndbøker er tilgjengelig i flere språk på www.hypertherm.com/docs.

PL (POLSKI/POLISH)

OSTRZEŻENIE! Przed rozpoczęciem obsługi jakiegokolwiek systemu firmy Hypertherm należy się zapoznać z instrukcjami bezpieczeństwa zamieszczonymi w podręczniku produktu, w podręczniku bezpieczeństwa i zgodności (80669C), podręczniku bezpieczeństwa i zgodności systemów strumienia wody (80943C) oraz podręczniku z ostrzeżeniem o częstotliwości radiowej (80945C).

Do produktu mogą być dołączone podręczniki użytkownika wformie elektronicznej idrukowanej. Kopie elektroniczne znajdują się również wnaszej witrynie internetowej. Wiele podręczników jest dostępnych wróżnych językach pod adresem

www.hypertherm.com/docs.

PT (PORTUGUÊS/PORTUGUESE)

ADVERTÊNCIA! Antes de operar qualquer equipamento Hypertherm, leia as instruções de segurança no manual do seu produto, no Manual

de Segurança e de Conformidade (80669C), no Manual de Segurança e de Conformidade do Waterjet (80943C) e no Manual de Advertência de radiofrequência (80945C).

Cópias dos manuais podem vir com o produto nos formatos eletrônico e impresso. Cópias eletrônicas também são encontradas em nosso website. Muitos manuais estão disponíveis em vários idiomas em www.hypertherm.com/docs.

RO (ROMÂNĂ/ROMANIAN)

AVERTIZARE! Înainte de utilizarea oricărui echipament Hypertherm, citiți instrucțiunile de siguranță din manualul produsului, manualul de siguranță și conformitate (80669C), manualul de siguranță și conformitate Waterjet (80943C) și din manualul de avertizare privind radiofrecvența (80945C).

Produsul poate fi însoțit de copii ale manualelor în format tipărit și electronic. Exemplarele electronice sunt disponibile și pe site-ul nostru web. Numeroase manuale sunt disponibile în mai mult limbi la adresa:

www.hypertherm.com/docs.

RU (PУССКИЙ/RUSSIAN)

БЕРЕГИСЬ! Перед работой с любым оборудованием Hypertherm ознакомьтесь с инструкциями по безопасности, представленными в руководстве, которое поставляется вместе с продуктом, в Руководстве по безопасности и

соответствию (80669С), в Руководстве по безопасности и соответствию для водоструйной резки (80943C) и Руководстве по предупреждению о радиочастотном излучении (80945С).

Копии руководств, которые поставляются вместе с продуктом, могут быть представлены в электронном и бумажном виде. Электронные копии также доступны на нашем веб-сайте. Целый ряд руководств доступны на нескольких языках по ссылке www.hypertherm.com/docs.

SK (S LOVENČINA/SLOVAK)

VÝSTRAHA! Pred použitím akéhokoľvek zariadenia od spoločnosti Hypertherm si prečítajte bezpečnostné pokyny v návode na obsluhu vášho zariadenia a v Manuáli

o bezpečnosti a súlade s normami (80669C), Manuáli o bezpečnosti a súlade snormami pre systém rezania vodou (80943C) avManuáli sinformáciami orádiofrekvencii (80945C).

Návod na obsluhu sa dodáva spolu sproduktom velektronickej atlačenej podobe. Jeho elektronický formát je dostupný aj na našej webovej stránke. Mnohé znávodov na obsluhu sú dostupné vo viacjazyčnej mutácii na stránke

www.hypertherm.com/docs.

SL (S LOVENŠČINA/S LOVENIAN)

OPOZORILO! Pred uporabo katerekoli Hyperthermove opreme preberite varnostna navodila v priročniku vašega izdelka, v Priročniku za varnost in skladnost (80669C), v Priročniku za varnost in skladnost sistemov rezanja z vodnim curkom (80943C) in v Priročniku Opozorilo o radijskih frekvencah (80945C).

Izvodi priročnikov so lahko izdelku priloženi v elektronski in tiskani obliki. Elektronski izvodi so na voljo tudi na našem spletnem mestu. Številni priročniki so na voljo v različnih jezikih na naslovu www.hypertherm.com/docs.

SR (SRPSKI/SERBIAN)

UPOZORENJE! Pre rukovanja bilo kojom Hyperthermovom opremom pročitajte uputstva o bezbednosti u svom priručniku za proizvod, Priručniku o bezbednosti

i usaglašenosti (80669C), Priručniku o bezbednosti i usaglašenosti Waterjet tehnologije (80943C) i Priručniku sa upozorenjem o radio-frekvenciji (80945C).

Уз производ се испоручују копије приручника у електронском или штампаном формату. Електронске копије су такође доступне на нашем веб-сајту. Многи приручници су доступни на више језика на адреси www.hypertherm.com/docs.

SV (SVENSKA/SWEDISH)

VARNING! Läs häftet säkerhetsinformationen i din produkts säkerhets- och efterlevnadsmanual (80669C), säkerhets- och efterlevnadsmanualen för Waterjet

(80943C) och varningsmanualen för radiofrekvenser (80945C) för viktig säkerhetsinformation innan du använder eller underhåller Hypertherm-utrustning.

Kopior av manualerna kan medfölja produkten i elektroniskt och tryckt format. Elektroniska kopior finns också på vår webbplats. Många manualer finns på flera språk på www.hypertherm.com/docs.

THࡗࡩࡠࡩࡷࡎ࡙THAI

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Electromagnetic Compatibility (EMC).................................................................................. 13

Warranty..................................................................................................................................... 15

1 Where to Find Information...................................................................................................... 17

2 Install and Set Up the Plasma Power Supply...................................................................... 19

Make sure that you have all the system components ................................................................................. 20

What to do if components are missing or damaged....................................................................... 21

System configurations........................................................................................................................................ 21

Hypertherm plasma power supply ratings..................................................................................................... 22

Powermax65 SYNC ............................................................................................................................... 22

Powermax85 SYNC ............................................................................................................................... 24

Powermax105 SYNC ............................................................................................................................. 26

Find system specifications on the data plate ................................................................................... 28

Find the part number for your system................................................................................................. 29

Critical raw materials.............................................................................................................................. 29

Symbols and marks................................................................................................................................. 30

IEC symbols ................................................................................................................................. 31

Acoustical noise levels............................................................................................................... 32

Radio frequency identification (RFID) specifications ......................................................... 32

Powermax65/85/105 SYNC Operator Manual 810470 7

Contents

Cutting specifications ........................................................................................................................................ 33

Recommended cut capacity – hand cutting..................................................................................... 33

Recommended pierce capacity........................................................................................................... 33

Maximum cut speeds (mild steel)........................................................................................................ 33

Gouge capacity ....................................................................................................................................... 34

Set up the plasma power supply..................................................................................................................... 34

Plasma power supply dimensions and weights ............................................................................... 36

Powermax65 SYNC and Powermax85 SYNC..................................................................... 36

Powermax105 SYNC ................................................................................................................. 37

Work lead weights ...................................................................................................................... 37

Connect to electrical power ............................................................................................................................. 38

Install a line-disconnect switch............................................................................................................ 38

Requirements for grounding................................................................................................................. 40

Rated output (cutting power) of the plasma power supply........................................................... 40

Voltage configurations ........................................................................................................................... 40

Powermax65 SYNC.................................................................................................................... 41

Powermax85 SYNC.................................................................................................................... 42

Powermax105 SYNC ................................................................................................................. 43

Prepare the power cord and plug ................................................................................................................... 44

Install the power plug............................................................................................................................. 44

Install the power cord (if necessary)................................................................................................... 44

Install a 1-phase power cord (CSA systems only) (if necessary)................................................ 46

Use an extension cord (if necessary) ................................................................................................. 46

Powermax65 SYNC systems................................................................................................... 47

Powermax85 SYNC systems................................................................................................... 48

Powermax105 SYNC systems ................................................................................................. 49

Use a generator (if necessary)............................................................................................................. 50

Powermax65 SYNC and Powermax85 SYNC systems..................................................... 51

Powermax105 SYNC systems ................................................................................................. 52

Connect the gas supply .................................................................................................................................... 53

Gas supply source.................................................................................................................................. 54

High-pressure gas cylinders..................................................................................................... 55

Inlet gas pressure requirements (while gas is flowing) .................................................................. 57

Maximum inlet pressure ............................................................................................................. 57

Optimum inlet pressure ............................................................................................................. 57

Minimum inlet pressure.............................................................................................................. 57

Cutting........................................................................................................................................... 58

Maximum Control gouging........................................................................................................ 58

Maximum Removal gouging...................................................................................................... 58

Recommended gas inlet flow rates..................................................................................................... 58

Add additional gas filtration (if necessary) ........................................................................................ 59

8 810470 Operator Manual Powermax65/85/105 SYNC

Contents

3 Operate the Plasma System................................................................................................... 61

Make sure that the plasma power supply is connected to gas and power........................................... 61

Step 1 – Connect the torch lead .................................................................................................................... 62

Step 2 – Connect the work lead and work clamp ...................................................................................... 63

Work lead.................................................................................................................................................. 63

Work clamp............................................................................................................................................... 64

Step 3 – Install the cartridge............................................................................................................................ 64

Lock the torch .......................................................................................................................................... 65

Install the cartridge ................................................................................................................................. 66

Step 4 – Set the power switch to ON (I)...................................................................................................... 67

Step 5 – Unlock the SmartSYNC torch ........................................................................................................ 68

Warning puffs of air (hand torches) .................................................................................................... 68

Fault code and LED behavior............................................................................................................... 69

Step 6 – Adjust the output current (A) and operating mode if necessary ............................................ 70

Step 7 – Use the SmartSYNC torch.............................................................................................................. 71

Use the hand torch ................................................................................................................................. 71

Adjust the amperage from the hand torch............................................................................. 71

Amperage settings by plasma power supply and cartridge.............................................. 72

Use the machine torch........................................................................................................................... 73

What occurs during and after cutting ............................................................................................................ 73

Temperature control................................................................................................................................ 73

Hand torch LED behavior...................................................................................................................... 73

Adjust the gas pressure manually ................................................................................................................... 74

Go back to automatic gas pressure mode........................................................................................ 75

Adjust the operating mode manually .............................................................................................................. 75

Cut expanded metal ............................................................................................................................... 76

Go back to automatic setting of the operating mode..................................................................... 76

Monitor cartridge data........................................................................................................................................ 77

Monitor data for individual cartridges ................................................................................................. 77

Show cartridge data on the status screen........................................................................................ 78

When to replace the cartridge (fault code 0-32-n) .................................................................................... 80

Conditions when cartridge end-of-life detection is disabled........................................................ 81

Prevent overheating............................................................................................................................................ 81

Decrease arc stretch.............................................................................................................................. 82

Adjust brightness and contrast........................................................................................................................ 83

Controls and indicators on the plasma power supply................................................................................ 84

Cutting controls....................................................................................................................................... 84

Status screen........................................................................................................................................... 86

Gas pressure indicators ............................................................................................................ 87

Fault codes and fault icons....................................................................................................... 87

Powermax65/85/105 SYNC Operator Manual 810470 9

Contents

Main menu screen................................................................................................................................... 88

Cartridge and Power Supply Data submenu........................................................................ 89

System Information submenu ................................................................................................... 90

Service Information submenu................................................................................................... 91

System Settings submenu ........................................................................................................ 92

4 Cut with the Hand Torch.......................................................................................................... 93

About the hand torch.......................................................................................................................................... 94

Select the correct cutting cartridge................................................................................................................ 95

Prepare to fire the torch..................................................................................................................................... 96

Start a cut from the edge of the workpiece .................................................................................................. 98

Pierce a workpiece ........................................................................................................................................... 100

Use a FlushCut specialty cartridge............................................................................................................... 102

Guidelines for hand torch cutting.................................................................................................................. 105

Get the most out of your cartridges............................................................................................................. 106

Signs that a cartridge is near end-of-life ......................................................................................... 107

Hand torch components, dimensions, and weights................................................................................. 108

Components.......................................................................................................................................... 108

Dimensions ............................................................................................................................................ 109

75° torch..................................................................................................................................... 109

15° torch..................................................................................................................................... 109

Drag cut cartridge..................................................................................................................... 110

FineCut cartridge ...................................................................................................................... 110

Weights ................................................................................................................................................... 110

5 Gouge with the Hand Torch................................................................................................... 111

Select the correct gouging cartridge .......................................................................................................... 111

Gouge with the hand torch............................................................................................................................ 112

Change the gouge contour............................................................................................................................ 114

6 Troubleshoot Common Problems.......................................................................................... 117

Start here: troubleshooting checklist........................................................................................................... 118

Common problems .......................................................................................................................................... 123

Cold restarts and quick restarts ....................................................................................................... 125

Do a cold restart....................................................................................................................... 125

Do a quick restart..................................................................................................................... 125

Examine the gas pressure .................................................................................................................. 126

Examine the gas quality ...................................................................................................................... 127

Common cutting and gouging problems.................................................................................................... 128

Hand cutting problems ....................................................................................................................... 128

Hand gouging problems..................................................................................................................... 130

10 810470 Operator Manual Powermax65/85/105 SYNC

Contents

Fault codes........................................................................................................................................................ 132

Identify fault icons ................................................................................................................................ 133

Remove fault code conditions........................................................................................................... 134

Operational faults (0-nn-n) .................................................................................................... 134

Internal component faults (1-nn-n, 2-nn-n, 3-nn-n)........................................................ 147

Troubleshoot power-related problems with generators .............................................................. 148

Troubleshoot 0-30-0 fault codes that occur during postflow.................................................... 149

See recent fault codes (Power Supply Log screen).................................................................... 150

Do a gas test..................................................................................................................................................... 151

Start and stop a gas test in automatic gas pressure mode ....................................................... 151

Do a gas test in manual gas pressure mode ................................................................................. 152

Adjust system settings on the Feature Configuration screen................................................................ 153

Smart mode versus basic mode....................................................................................................... 155

Smart mode ............................................................................................................................... 155

Basic mode................................................................................................................................ 156

Set system settings to factory default............................................................................................. 156

See system information .................................................................................................................................. 158

Cartridge Data screen ........................................................................................................................ 160

Power Supply Data screen................................................................................................................ 162

Cartridge History screen .................................................................................................................... 164

LCD/Control PCB Information screen............................................................................................ 165

DSP PCB and Power PCB Information screen ........................................................................... 166

Torch PCB Information screen.......................................................................................................... 167

Radio Frequency (RF) Data screen ................................................................................................. 168

Cut Counters Transfer screen........................................................................................................... 169

CNC Interface Settings screen ........................................................................................................ 170

7 Complete Regular Maintenance Tasks ............................................................................... 171

Examine the plasma power supply and torch............................................................................................ 171

Every use................................................................................................................................................ 173

Every cartridge change or weekly (whichever is more frequent)................................................ 174

Every 3 months ..................................................................................................................................... 175

Cartridge maintenance ................................................................................................................................... 176

Examine the air filter bowl and filter element ............................................................................................. 177

Drain water from the bowl (if necessary)........................................................................................ 177

Remove the air filter bowl and filter element.................................................................................. 177

Examine the air filter bowl and O-ring ............................................................................................. 178

Examine the filter element .................................................................................................................. 179

Replace the air filter bowl, O-ring, and filter element .................................................................. 179

Install the air filter bowl and filter element ...................................................................................... 180

Powermax65/85/105 SYNC Operator Manual 810470 11

Contents

12 810470 Operator Manual Powermax65/85/105 SYNC

Electromagnetic Compatibility (EMC)

Introduction

Hypertherm’s CE-marked equipment is built in compliance with standard EN60974-10. The equipment should be installed and used in accordance with the information below to achieve electromagnetic compatibility.

The limits required by EN60974-10 may not be adequate to completely eliminate interference when the affected equipment is in close proximity or has a high degree of sensitivity. In such cases it may be necessary to use other measures to further reduce interference.

This cutting equipment is designed for use only in an industrial environment.

Installation and use

The user is responsible for installing and using the plasma equipment according to the manufacturer’s instructions.

If electromagnetic disturbances are detected then it shall be the responsibility of the user to resolve the situation with the technical assistance of the manufacturer. In some cases this remedial action may be as simple as earthing the cutting circuit, see Earthing of the workpiece. In other cases, it could involve constructing an electromagnetic screen enclosing the power source and the work complete with associated input filters. In all cases, electromagnetic disturbances must be reduced to the point where they are no longer troublesome.

Methods of reducing emissions

Mains supply

Cutting equipment must be connected to the mains supply according to the manufacturer’s recommendations. If interference occurs, it may be necessary to take additional precautions such as filtering of the mains supply.

Consideration should be given to shielding the supply cable of permanently installed cutting equipment, in metallic conduit or equivalent. Shielding should be electrically continuous throughout its length. The shielding should be connected to the cutting mains supply so that good electrical contact is maintained between the conduit and the cutting power source enclosure.

Maintenance of cutting equipment

The cutting equipment must be routinely maintained according to the manufacturer’s recommendations. All access and service doors and covers should be closed and properly fastened when the cutting equipment is in operation. The cutting equipment should not be modified in any way, except as set forth in and in accordance with the manufacturer’s written instructions. For example, the spark gaps of arc striking and stabilizing devices should be adjusted and maintained according to the manufacturer’s recommendations.

Cutting cables

Assessment of area

Before installing the equipment, the user shall make an assessment of potential electromagnetic problems in the surrounding area. The following shall be taken into account:

a. Other supply cables, control cables, signaling and telephone

cables; above, below and adjacent to the cutting equipment.

b. Radio and television transmitters and receivers. c. Computer and other control equipment. d. Safety critical equipment, for example guarding of industrial

equipment.

e. Health of the people around, for example the use of

pacemakers and hearing aids.

f. Equipment used for calibration or measurement.

g. Immunity of other equipment in the environment. User shall

ensure that other equipment being used in the environment is compatible. This may require additional protection measures.

h. Time of day that cutting or other activities are to be carried

out.

The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place. The surrounding area may extend beyond the boundaries of the premises.

The cutting cables should be kept as short as possible and should be positioned close together, running at or close to the floor level.

Equipotential bonding

Bonding of all metallic components in the cutting installation and adjacent to it should be considered.

However, metallic components bonded to the workpiece will increase the risk that the operator could receive a shock by touching these metallic components and the electrode (nozzle for laser heads) at the same time.

The operator should be insulated from all such bonded metallic components.

Safety and compliance 13

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. Care should be taken to prevent the earthing of the workpiece increasing the risk of injury to users, or damage to other electrical equipment. Where necessary, the connection of the workpiece to earth should be made by a direct connection to the workpiece, but in some countries where direct connection is not permitted, the bonding should be achieved by suitable capacitances selected according to national regulations.

Note: The cutting circuit may or may not be earthed for safety reasons. Changing the earthing arrangements should only be authorized by a person who is competent to assess whether the changes will increase the risk of injury, for example, by allowing parallel cutting current return paths which may damage the earth circuits of other equipment. Further guidance is provided in IEC 60974-9, Arc Welding Equipment, Part 9: Installation and Use.

Screening and shielding

Selective screening and shielding of other cables and equipment in the surrounding area may alleviate problems of interference. Screening of the entire plasma cutting installation may be considered for special applications.

14 Safety and compliance

Warranty

Attention

Genuine Hypertherm parts are the factory-recommended replacement parts for your Hypertherm system. Any damage or injury caused by the use of other than genuine Hypertherm parts may not be covered by the Hypertherm warranty, and will constitute misuse of the Hypertherm Product.

You are solely responsible for the safe use of the Product. Hypertherm does not and cannot make any guarantee or warranty regarding the safe use of the product in your environment.

General

Hypertherm, Inc. warrants that its Products shall be free from defects in materials and workmanship for the specific periods of time set forth herein and as follows: if Hypertherm is notified of a defect (i) with respect to the plasma power supply within a period of two (2) years from the date of its delivery to you, with the exception of Powermax brand power supplies, which shall be within a period of three (3) years from the date of delivery to you, and (ii) with respect to the torch and leads within a period of one (1) year from its date of delivery to you, with the exception of the HPRXD short torch with integrated lead, which shall be within a period of six (6) months from the date of delivery to you, and with respect to torch lifter assemblies within a period of one (1) year from its date of delivery to you, and with respect to Automation products one (1) year from its date of delivery to you, with the exception of the EDGE Connect CNC, EDGE Connect T CNC, EDGE Connect TC CNC, EDGE Pro CNC, EDGE Pro Ti CNC, MicroEDGE Pro CNC, and ArcGlide THC, which shall be within a period of two (2) years from the date of delivery to you, and (iii) with respect to HyIntensity fiber laser components within a period of two (2) years from the date of its delivery to you, with the exception of laser heads and beam delivery cables, which shall be within a period of one (1) year from its date of delivery to you.

All third-party engines, engine accessories, alternators, and alternator accessories are covered by the respective manufacturers’ warranties and not covered by this warranty.

This warranty shall not apply to any Powermax brand power supplies that have been used with phase converters. In addition, Hypertherm does not warranty systems that have been damaged as a result of poor power quality, whether from phase converters or incoming line power. This warranty shall not apply to any product which has been incorrectly installed, modified, or otherwise damaged.

The warranty set forth above is exclusive and is in lieu of all other warranties, express, implied, statutory, or otherwise with respect to the Products or as to the results which may be obtained therefrom, and all implied warranties or conditions of quality or of merchantability or fitness for a particular purpose or against infringement. The foregoing shall constitute the sole and exclusive remedy for any breach by Hypertherm of its warranty.

Distributors/OEMs may offer different or additional warranties, but Distributors/OEMs are not authorized to give any additional warranty protection to you or make any representation to you purporting to be binding upon Hypertherm.

Patent indemnity

Except only in cases of products not manufactured by Hypertherm or manufactured by a person other than Hypertherm not in strict conformity with Hypertherm’s specifications and in cases of designs, processes, formulae, or combinations not developed or purported to be developed by Hypertherm, Hypertherm will have the right to defend or settle, at its own expense, any suit or proceeding brought against you alleging that the use of the Hypertherm product, alone and not in combination with any other product not supplied by Hypertherm, infringes any patent of any third party. You shall notify Hypertherm promptly upon learning of any action or threatened action in connection with any such alleged infringement (and in any event no longer than fourteen (14) days after learning of any action or threat of action), and Hypertherm’s obligation to defend shall be conditioned upon Hypertherm’s sole control of, and the indemnified party’s cooperation and assistance in, the defense of the claim.

Limitation of liability

In no event shall Hypertherm be liable to any person or entity for any incidental, consequential direct, indirect, punitive or exemplary damages (including but not limited to lost profits) regardless of whether such liability is based on breach of contract, tort, strict liability, breach of warranty, failure of essential purpose, or otherwise, and even if advised of the possibility of such damages. Hypertherm shall not be liable for any losses to Distributor based on down time, lost production or lost profits. It is the intention of the Distributor and Hypertherm that this provision be construed by a court as being the broadest limitation of liability consistent with applicable law.

Hypertherm provides repair, replacement or adjustment of the Product as the sole and exclusive remedy, if and only if the warranty set forth herein properly is invoked and applies. Hypertherm, at its sole option, shall repair, replace, or adjust, free of charge, any defective Products covered by this warranty which shall be returned with Hypertherm’s prior authorization (which shall not be unreasonably withheld), properly packed, to Hypertherm’s place of business in Hanover, New Hampshire, or to an authorized Hypertherm repair facility, all costs, insurance and freight pre paid by the customer. Hypertherm shall not be liable for any repairs, replacement, or adjustments of Products covered by this warranty, except those made pursuant to this paragraph and with Hypertherm’s prior written consent.

National and local codes

National and local codes governing plumbing and electrical installation shall take precedence over any instructions contained in this manual. In no event shall Hypertherm be liable for injury to persons or property damage by reason of any code violation or poor work practices.

Safety and compliance 15

Warranty

Liability cap

In no event shall Hypertherm’s liability, if any, whether such liability is based on breach of contract, tort, strict liability, breach of warranties, failure of essential purpose or otherwise, for any claim, action, suit or proceeding (whether in court, arbitration, regulatory proceeding or otherwise) arising out of or relating to the use of the Products exceed in the aggregate the amount paid for the Products that gave rise to such claim.

Insurance

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.

Transfer of rights

You may transfer any remaining rights you may have hereunder only in connection with the sale of all or substantially all of your assets or capital stock to a successor in interest who agrees to be bound by all of the terms and conditions of this Warranty. Within thirty (30) days before any such transfer occurs, you agree to notify in writing Hypertherm, which reserves the right of approval. Should you fail timely to notify Hypertherm and seek its approval as set forth herein, the Warranty set forth herein shall be null and void and you will have no further recourse against Hypertherm under the Warranty or otherwise.

Waterjet product warranty coverage

Product Parts coverage

HyPrecision pumps 27 months from the ship date, or 24 months

from the date of proven installation, or 4,000 hours, whichever occurs first

PowerDredge abrasive removal system

EcoSift abrasive recycling system

Abrasive metering devices

On/off valve air actuators

Diamond orifices 600 hours of use with the use of a thimble

Consumable parts are not covered by this warranty. Consumable parts include, but are not limited to, high-pressure water seals, check valves, cylinders, bleed-down valves, low-pressure seals, high-pressure tubing, low- and high-pressure water filters and abrasive collection bags. All third-party pumps, pump accessories, hoppers, hopper accessories, dryer boxes, dryer box accessories and plumbing accessories are covered by the respective manufacturers’ warranties and not covered by this warranty.

15 months from the ship date or 12 months from the date of proven installation, whichever occurs first

filter and compliance with Hypertherm’s water quality requirements

16 Safety and compliance

Where to Find Information

This operator manual includes the following information for the Powermax65/85/105 SYNC plasma power supplies and SmartSYNC™ hand torches:

 Specifications, ratings, and installation and setup information  Operating instructions for the plasma power supply and torch  Instructions for cutting, piercing, and gouging  Maintenance and troubleshooting information

For related information, refer to the following documents:

 Safety and Compliance Manual (80669C)  Powermax65/85/105 SYNC Cut Charts Guide (810500MU)  Powermax65/85/105 SYNC Parts Guide (810490)  Powermax65/85/105 SYNC Mechanized Cutting Guide (810480)

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.



Subsequent revisions are possible. Refer to www.hypertherm.com/docs for the most recent revisions of released documents.

Powermax65/85/105 SYNC Operator Manual 810470 17

Where to Find Information

18 810470 Operator Manual Powermax65/85/105 SYNC

Install and Set Up the Plasma Power Supply

The Powermax65 SYNC, Powermax85 SYNC, and Powermax105 SYNC are portable plasma power supplies that you can use for many handheld and mechanized cutting and gouging applications.

Powermax SYNC systems include the following capabilities:

 Use air or nitrogen to cut electrically conductive

metals, such as mild steel, stainless steel, or aluminum

 Use F5 gas to cut stainless steel  Gouge with 2 gouging processes: Maximum

Removal and Maximum Control

 Adjust the output current (A) from the

SmartSYNC hand torch

 Use a single-piece cartridge instead of a set of consumables  Automatically set the operating mode, output current (A), and gas pressure related to the

type of SmartSYNC torch and Hypertherm cartridge that you install

 Record cartridge information so that you can monitor cartridge life, and be notified when you

need to install a new cartridge

 Lock the SmartSYNC torches without setting the plasma power supply to OFF  Quickly change SmartSYNC torches with the FastConnect™ system (quick-disconnect)

Powermax65/85/105 SYNC Operator Manual 810470 19

Install and Set Up the Plasma Power Supply

1 Documentation:

• USB memory stick with technical and safety documentation

•Quick Setup Guide

• Quick Reference Guide

• Cut Charts Guide

• Fault codes label

2 Plasma power supply

3 Region-specific gas inlet fitting 4 Power cord with no power plug 5 Remote-start pendant (optional – mechanized

configurations only)

6 Work lead with work clamp, C clamp, or ring

terminal

7 15° or 75° hand torch with lead or 180° full-length

machine torch with lead

8 Starter set of cartridges

Make sure that you have all the system components

For a full list of the cutting and gouging cartridges available refer to the



20 810470 Operator Manual Powermax65/85/105 SYNC

Powermax65/85/105 SYNC Parts Guide (810490).

What to do if components are missing or damaged

 Claims for damage during shipment

 Send a claim to the carrier if your system was damaged during shipment.  Get the system’s model number and serial number from the data plate on the rear of the

plasma power supply. Refer to Find system specifications on the data plate on page 28 for a sample data plate.

 Get a copy of the bill of lading from Hypertherm.

 Claims for missing or damaged merchandise

 Speak to your Hypertherm distributor or authorized repair facility, or speak to the nearest

Hypertherm office shown in the front of this manual.

System configurations

The Powermax65 SYNC, Powermax85 SYNC, and Powermax105 SYNC systems are universal plasma power supplies that automatically adjust to operate with various AC voltages. The following system configurations are available:

Install and Set Up the Plasma Power Supply

Model Configurations AC Voltages

Powermax65 SYNC

and

Powermax85 SYNC

Powermax105 SYNC

200 V – 600 V CSA

380 V CCC / 400 V CE 380 V / 400 V (3-phase)

200 V – 600 V CSA 200 V – 600 V (3-phase)

230 V – 400 V CE 230 V – 400 V (3-phase)

380 V CCC / 400 V CE 380 V / 400 V (3-phase)

200 V – 480 V (1-phase)

200 V – 600 V (3-phase)

NOTICE

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.

Powermax65/85/105 SYNC Operator Manual 810470 21

Install and Set Up the Plasma Power Supply

Hypertherm plasma power supply ratings

Powermax65 SYNC

Rated open-circuit voltage (U0)

CSA, 1-phase, 3-phase 296 VDC CSA

CE/CCC, 3-phase 270 VDC CE/CCC

Output characteristic* Drooping

Rated output current (I

Rated output voltage (U

) 20 A – 65 A

) 139 VDC

Duty cycle at 40°C (104°F)**

CSA 50% at 65 A, 230 V – 600 V, 1-/3-phase

40% at 65 A, 200 V – 208 V, 1-/3-phase 100% at 46 A, 230 V – 600 V, 1-/3-phase

CE/CCC 50% at 65 A, 380 V/400 V, 3-phase

100% at 46 A, 380 V/400 V, 3-phase

Operating temperature -10°C to 40°C (14°F to 104°F)

Storage temperature -25°C to 55°C (-13°F to 131°F)

Power factor

200 V – 480 V CSA, 1-phase 0.99 – 0.97

200 V – 600 V CSA, 3-phase 0.94 – 0.73

380 V CCC/400 V CE, 3-phase 0.94

Idle state power consumption (CE systems) 28 W

Power source efficiency at rated maximum

91.2%

output power (CE systems)

– Short Circuit Ratio (CE/CCC systems only)

sce

– Volts AC rms, 3-phase 400 VAC

296.4

sce

EMC emissions classification CISPR 11 (CE/CCC systems only)*** Class A

Input voltage (U

) / Input current (I1) at rated output (U

2MAXI2MAX

)

(Refer to Connect to electrical power on page 38)

†, ††

CSA, 1-phase, 50 Hz/60 Hz CSA, 3-phase, 50 Hz/60 Hz CE/CCC

200 V: 208 V: 240 V: 480 V:

22 810470 Operator Manual Powermax65/85/105 SYNC

52 A 50 A 44 A 22 A

200 V: 208 V: 240 V: 480 V: 600 V:

32 A 31 A 27 A 13 A 13 A

, 3-phase, 50 Hz/60 Hz

380 V: 400 V:

15.5 A 15 A

Install and Set Up the Plasma Power Supply

Gas type Air Nitrogen F5

Gas quality Clean, dry, oil-free per

99.95% pure 99.98% pure

ISO8573-1 Class 1.4.2 Refer to page 54.

†††

(F5 = 95% nitrogen [N hydrogen [H

])

Recommended gas inlet flow rates

Cutting 210 slpm (450 scfh, 7.5 scfm) at a minimum 5.9 bar (85 psi)

Maximum Removal gouging 210 slpm (450 scfh, 7.5 scfm) at a minimum 4.8 bar (70 psi)

Maximum Control gouging 210 slpm (450 scfh, 7.5 scfm) at a minimum 4.8 bar (70 psi)

* Defined as a plot of output voltage versus output current.

** Refer to the data plate on the rear of the plasma power supply for more information on duty cycle and for

IEC ratings.

*** WARNING: This Class A equipment is not intended for use in residential locations where the public low voltage

supply system supplies the electrical power. There can be difficulties in delivering electromagnetic compatibility in those locations, because of conducted as well as radiated disturbances.

†

Equipment complies with IEC 61000-3-12 if the short-circuit power Ssc is greater than or equal to 6,160 KVA at the interface point between the operator’s supply and the public system. It is the responsibility of the installer or operator of the equipment to make sure, by consultation with the distribution network operator if necessary, that the equipment is connected only to a supply with a short-circuit power S

††

Equipment complies with IEC 61000-3-11 if the supply impedance, Zmax, is 0.201 or less. It is the responsibility of the installer or operator of the equipment to make sure, by consultation with the distribution network operator if necessary, that the equipment is connected only to a supply with a impedance of 0.201 or less.

†††

F5 recommended only for cutting stainless steel. Refer to Cut stainless steel with F5 in the Powermax65/85/105 SYNC Mechanized Cutting Guide (810480).

greater than or equal to 6,160 KVA.

], 5%

Powermax65/85/105 SYNC Operator Manual 810470 23

Install and Set Up the Plasma Power Supply

Powermax85 SYNC

Rated open-circuit voltage (U0)

CSA, 1-phase, 3-phase 305 VDC CSA

CE/CCC, 3-phase 270 VDC CE/CCC

Output characteristic* Drooping

Rated output current (I

Rated output voltage (U

) 25 A – 85 A

) 143 VDC

Duty cycle at 40°C (104°F)**

CSA 60% at 85 A, 230 V – 600 V, 3-phase

60% at 85 A, 480 V, 1-phase 50% at 85 A, 240 V, 1-phase 50% at 85 A 200 V – 208 V, 3-phase 40% at 85 A 200 V – 208 V, 1-phase 100% at 66 A, 230 V – 600 V, 1-/3-phase

CE/CCC 60% at 85 A, 380 V/400 V, 3-phase

100% at 66 A, 380 V/400 V, 3-phase

Operating temperature -10°C to 40°C (14°F to 104°F)

Storage temperature -25°C to 55°C (-13°F to 131°F)

Power factor

200 V – 480 V CSA, 1-phase 0.99 – 0.96

200 V – 600 V CSA, 3-phase 0.94 – 0.76

380 V CCC/400 V CE, 3-phase 0.94

Idle state power consumption (CE systems) 26 W

Power source efficiency at rated maximum output

91.9%

power (CE systems)

– Short Circuit Ratio (CE/CCC systems only)

sce

– Volts AC rms, 3-phase 400 VAC

209.4

sce

EMC emissions classification CISPR 11 (CE/CCC systems only)*** Class A

Input voltage (U

) / Input current (I1) at rated output (U

2MAXI2MAX

(Refer to Connect to electrical power on page 38.)

CSA, 1-phase, 50 Hz/60 Hz CSA, 3-phase, 50 Hz/60 Hz CE/CCC

200 V: 208 V: 240 V:

480 V:

70 A 68 A 58 A 29 A

200 V: 208 V: 240 V: 480 V: 600 V:

42 A 40 A 35 A 18 A 17 A

†, ††

380 V: 400 V:

)

, 3-phase, 50 Hz/60 Hz

20.5 A

19.5 A

24 810470 Operator Manual Powermax65/85/105 SYNC

Install and Set Up the Plasma Power Supply

Gas type Air Nitrogen F5

Gas quality Clean, dry, oil-free per

ISO8573-1 Class 1.4.2

Refer to page 54.

99.95% pure 99.98% pure (F5 = 95% nitrogen [N

5% hydrogen [H

Recommended gas inlet flow rates

Cutting 210 slpm (450 scfh, 7.5 scfm) at a minimum 5.9 bar (85 psi)

Maximum Removal gouging 210 slpm (450 scfh, 7.5 scfm) at a minimum 4.8 bar (70 psi)

Maximum Control gouging 210 slpm (450 scfh, 7.5 scfm) at a minimum 4.8 bar (70 psi)

* Defined as a plot of output voltage versus output current.

** Refer to the data plate on the rear of the plasma power supply for more information on duty cycle and for

IEC ratings.

*** WARNING: This Class A equipment is not intended for use in residential locations where the public low voltage

supply system supplies the electrical power. There can be difficulties in delivering electromagnetic compatibility in those locations, because of conducted as well as radiated disturbances.

†

Equipment complies with IEC 61000-3-12 if the short-circuit power Ssc is greater than or equal to 4,353 KVA at the interface point between the operator’s supply and the public system. It is the responsibility of the installer or operator of the equipment to make sure, by consultation with the distribution network operator if necessary, that the equipment is connected only to a supply with a short-circuit power S

††

†††

F5 recommended only for cutting stainless steel. Refer to Cut stainless steel with F5 in the Powermax65/85/105 SYNC Mechanized Cutting Guide (810480).

greater than or equal to 4,353 KVA.

†††

])

Powermax65/85/105 SYNC Operator Manual 810470 25

Install and Set Up the Plasma Power Supply

Powermax105 SYNC

Rated open-circuit voltage (U0)

200 V – 600 V CSA 300 VDC

230 V – 400 V CE 288 VDC

380 V CCC 286 VDC

400 V CE 286 VDC

Output characteristic*Drooping

Rated output current (I

Rated output voltage (U

Duty cycle at 40°C (104°F)**

200 V – 600 V CSA 80% at 105 A, 480 V – 600 V, 3-phase

230 V – 400 V CE 80% at 105 A, 400 V, 3-phase

) 30 A – 105 A

) 160 VDC

380 V CCC 80% at 105 A, 380 V, 3-phase

400 V CE 80% at 105 A, 400 V, 3-phase

70% at 105 A 240 V, 3-phase 54% at 105 A 208 V, 3-phase 50% at 105 A, 200 V, 3-phase 100% at 94 A, 480 V – 600 V, 3-phase 100% at 88 A, 240 V, 3-phase 100% at 77 A, 208 V, 3-phase 100% at 74 A, 200 V, 3-phase

70% at 105 A, 230 V, 3-phase 100% at 94 A, 400 V, 3-phase 100% at 88 A, 230 V, 3-phase

100% at 94 A, 380 V, 3-phase

100% at 94 A, 400 V, 3-phase

Operating temperature -10°C to 40°C (14°F to 104°F)

Storage temperature -25°C to 55°C (-13°F to 131°F)

Power factor

200 V – 600 V CSA, 3-phase 0.94 – 0.77

230 V – 400 V CE, 3-phase 0.94 – 0.92

380 V CCC, 3-phase 0.94

400 V CE, 3-phase 0.94

Idle state power consumption (CE systems)

230 V – 400 V CE

400 V CE

26 810470 Operator Manual Powermax65/85/105 SYNC

40 W 27 W

Power source efficiency at rated maximum output power (CE systems)

Install and Set Up the Plasma Power Supply

230 V – 400 V CE

– Short Circuit Ratio (CE/CCC systems only)

sce

– Volts AC rms, 3-phase 230 V – 400 V 400 V

400 V CE

91.0%

91.9%

235.4 176.9

sce

EMC emissions classification CISPR 11 (CE/CCC systems only)*** Class A

Input voltage (U

) / Input current (I1) at rated output (U

2MAXI2MAX

)

(Refer to Connect to electrical power on page 38.)

CSA, 3-phase, 50 Hz/60 Hz CE

†,††,

3-phase, 50 Hz/60 Hz CE

††, †††

/CCC, 3-phase,

50 Hz/60 Hz

200 V: 208 V: 240 V: 480 V: 600 V:

58 A 56 A 49 A 25 A 22 A

230 V: 400 V:

50 A 29 A

380 V: 400 V:

Gas type Air Nitrogen F5‡

Gas quality Clean, dry, oil-free per

ISO8573-1 Class 1.4.2

Refer to page 54.

99.95% pure 99.98% pure (F5 = 95% nitrogen [N

5% hydrogen [H

30 A 28 A

])

Recommended gas inlet flow rates

Cutting 260 slpm (550 scfh, 9.1 scfm) at a minimum 6.2 bar (90 psi)

Maximum Removal gouging 260 slpm (550 scfh, 9.1 scfm) at a minimum 4.8 bar (70 psi)

Maximum Control gouging 260 slpm (550 scfh, 9.1 scfm) at a minimum 4.8 bar (70 psi)

* Defined as a plot of output voltage versus output current.

** Refer to the data plate on the rear of the plasma power supply for more information on duty cycle and for

IEC ratings.

*** WARNING: This Class A equipment is not intended for use in residential locations where the public low voltage

supply system supplies the electrical power. There can be difficulties in delivering electromagnetic compatibility in those locations, because of conducted as well as radiated disturbances.

†

Equipment complies with IEC 61000-3-12 if the short-circuit power Ssc is greater than or equal to 4,730 KVA at the interface point between the operator’s supply and the public system. It is the responsibility of the installer or operator of the equipment to make sure, by consultation with the distribution network operator if necessary, that the equipment is connected only to a supply with a short-circuit power S

††

This product complies with the technical requirements of IEC 61000-3-3 and is not subject to conditional connection.

†††

Equipment complies with IEC 61000-3-12 if the short-circuit power Ssc is greater than or equal to 2,114 KVA at the interface point between the operator’s supply and the public system. It is the responsibility of the installer or operator of the equipment to make sure, by consultation with the distribution network operator if necessary, that the equipment is connected only to a supply with a short-circuit power S

‡ F5 recommended only for cutting stainless steel. Refer to Cut stainless steel with F5 in the

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

greater than or equal to 4,730 KVA.

greater than or equal to 2,114 KVA.

Powermax65/85/105 SYNC Operator Manual 810470 27

Install and Set Up the Plasma Power Supply

Sample CSA

data plate

Sample

CE/CCC data

plate

1 Serial number, bar code, and date made

2 Plasma cutting ratings

3 Plasma gouging ratings

4 Plasma power supply ratings

HYP = Hypertherm internal rating

IEC = International Electrotechnical Commission

rating

= Input current (A)

= Conventional welding current (A)

PF = Power factor

U0 = Rated no load voltage (V)

U1 = Input voltage (V)

U2 = Conventional welding voltage (V)

X = Duty cycle (%)

Find system specifications on the data plate

The data plate on the rear 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.

 The IEC ratings are the minimum ratings that the system must get to meet the requirements

of IEC standard 60974-1.

CSA, CE, and CCC data plates differ slightly.

28 810470 Operator Manual Powermax65/85/105 SYNC

Find the part number for your system

The part number for your plasma power supply is near the top of the data plate.

Install and Set Up the Plasma Power Supply

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

Powermax65/85/105 SYNC Operator Manual 810470 29

Install and Set Up the Plasma Power Supply

Symbols and marks

Your product may have one or more of the following marks on or near the data plate. Because of differences and conflicts in national regulations, not all marks are applied to every version of a product.

S mark

The S mark indicates that the power supply and torch are suitable for operations carried out in environments with increased hazard of electrical shock according to IEC 60974-1.

CSA mark

Products with a CSA mark meet the United States and Canadian regulations for product safety. The products were evaluated, tested, and certified by CSA-International. Alternatively, the product may have a mark by one of the other Nationally Recognized Testing Laboratories (NRTL) accredited in both the United States and Canada, such as UL or TÜV.

CE mark

The CE marking signifies the manufacturer’s declaration of conformity to applicable European directives and standards. Only those versions of products with a CE marking located on or near the data plate comply with European Directives. Applicable directives may include the European Low Voltage Directive, the European Electromagnetic Compatibility (EMC) Directive, the Radio Equipment Directive (RED), and the Restriction of Hazardous Substances (RoHS) Directive. See the European CE Declaration of Conformity for details.

Eurasian Customs Union (CU) mark

CE versions of products that include an EAC mark of conformity meet the product safety and EMC requirements for export to Russia, Belarus, and Kazakhstan.

GOST-TR mark

CE versions of products that include a GOST-TR mark of conformity meet the product safety and EMC requirements for export to the Russian Federation.

RCM mark

CE versions of products with an RCM mark comply with the EMC and safety regulations required for sale in Australia and New Zealand.

CCC mark

The China Compulsory Certification (CCC) mark indicates that the product has been tested and found compliant with product safety regulations required for sale in China.

UkrSEPRO mark

The CE versions of products that include a UkrSEPRO mark of conformity meet the product safety and EMC requirements for export to the Ukraine.

Serbian AAA mark

CE versions of products that include a AAA Serbian mark meet the product safety and EMC requirements for export to Serbia.

RoHS mark

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.

30 810470 Operator Manual Powermax65/85/105 SYNC

Install and Set Up the Plasma Power Supply

Direct current (DC)

Alternating current (AC)

Plasma torch cutting

Plate metal cutting

Expanded metal cutting

Gouging

AC input power connection

The terminal for the external protective (earth) conductor

Power is ON

Power is OFF

An inverter-based power source, either 1-phase or 3-phase

Volt/amperage curve, “drooping” characteristic

IEC symbols

The following symbols can appear on the data plate, control labels, switches, light-emitting diodes (LEDs), and liquid-crystal display (LCD) screen, if applicable.

Powermax65/85/105 SYNC Operator Manual 810470 31

Install and Set Up the Plasma Power Supply

Acoustical noise levels

This plasma system can make more than the permitted acoustical noise levels as defined by national and local codes. Always put on correct ear protection when cutting or gouging. Any acoustical noise measurements taken are related to the specific environment in which the system is used. Refer to Noise can damage hearing in the Safety and Compliance Manual (80669C).

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 the following components:

 A passive RFID tag in the Hypertherm cartridge  A wireless radio transceiver on the printed circuit board (PCB) in the SmartSYNC torch:

 Operating frequency: 13.56 MHz  Protocol: ISO/IEC 15693  Maximum range: 8 mm (0.32 inch)  Maximum transmit power: 104 mW

32 810470 Operator Manual Powermax65/85/105 SYNC

Install and Set Up the Plasma Power Supply

Cutting specifications

Recommended cut capacity – hand cutting

Material thickness

Recommended capacity Powermax65 SYNC Powermax85 SYNC Powermax105 SYNC

Cut capacity at 500 mm/min (20 in/min)*

Cut capacity at 250 mm/min (10 in/min)*

Severance capacity at 125 mm/min (5 in/min)*

* Cut capacity speeds are not necessarily maximum speeds. They are the speeds that are required to be rated at that

thickness.

19 mm (3/4 in.) 25 mm (1 in.) 32 mm (1-1/4 in.)

25 mm (1 in.) 32 mm (1-1/4 in.) 38 mm (1-1/2 in.)

32 mm (1-1/4 in.) 38 mm (1-1/2 in.) 51 mm (2 in.)

Recommended pierce capacity

Material thickness

Pierce capacity Powermax65 SYNC Powermax85 SYNC Powermax105 SYNC

For handheld cutting, or mechanized cutting with programmable torch height control

For mechanized cutting without programmable torch height control

16 mm (5/8 in.) 19 mm (3/4 in.) 22 mm (7/8 in.)

13 mm (1/2 in.) 16 mm (5/8 in.) 19 mm (3/4 in.)

Maximum cut speeds (mild steel)

Maximum cut speed*

Material thickness Powermax65 SYNC Powermax85 SYNC Powermax105 SYNC

6 mm (1/4 in.) 3,683 mm/min (145 in/min) 5,080 mm/min (200 in/min) 5,588 mm/min (220 in/min)

13 mm (1/2 in.) 1,270 mm/min (50 in/min) 1,778 mm/min (70 in/min) 2,413 mm/min (95 in/min)

19 mm (3/4 in.) 610 mm/min (24 in/min) 914 mm/min (36 in/min) 1,270 mm/min (50 in/min)

25 mm (1 in.) 305 mm/min (12 in/min) 533 mm/min (21 in/min) 762 mm/min (30 in/min)

32 mm (1-1/4 in.) Not applicable 330 mm/min (13 in/min) 508 mm/min (20 in/min)

* Maximum cut speeds are the results of Hypertherm’s laboratory testing. Actual cutting speeds can be different

related to different cutting applications.

Powermax65/85/105 SYNC Operator Manual 810470 33

Install and Set Up the Plasma Power Supply

Clearance:

>0.25 m (10 inches)

3m (10ft)

Gouge capacity

65 A 85 A 105 A

Maximum Removal metal removal rate on mild steel

Maximum Control metal removal rate on mild steel

4.0 kg/hr (8.8 lb/hr) 8.2 kg/hr (18.2 lb/hr) 8.6 kg/hr (19.1 lb/hr)

2.3 kg/hr (5.1 lb/hr) 4.8 kg/hr (10.6 lb/hr) 7.2 kg/hr (15.9 lb/hr)

Set up the plasma power supply

CHANCE OF ELECTRIC SHOCK

Never cut under water or submerge the torch in water. Electric shock can cause serious injury.

WARNING

TOXIC FUMES CAN CAUSE INJURY OR DEATH

Some metals, including stainless steel, can release toxic fumes when cut. Make sure that your work site has sufficient ventilation to make sure that the air quality level meets all local and national standards and regulations. Refer to the Safety and Compliance Manual (80669C) for more information.

 Do not use the plasma power supply in rain

or snow.

 Put the plasma power supply near the

line-disconnect switch or near an approved power receptacle for your installation. The plasma power supply has a 3 m (10 ft) power cord.

 Keep at least 0.25 m (10 inches) of space

around the plasma power supply for sufficient ventilation.

34 810470 Operator Manual Powermax65/85/105 SYNC

 Put the plasma power supply on a stable,

>10°

level surface before using. The plasma power supply can tip over if set at an angle greater than 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.

Install and Set Up the Plasma Power Supply

Powermax65/85/105 SYNC Operator Manual 810470 35

Install and Set Up the Plasma Power Supply

233 mm

(9.2 inches)

483 mm

(19 inches)

430 mm

(17 inches)

354 mm (13.9 inches)

Plasma power supply dimensions and weights

Powermax65 SYNC and Powermax85 SYNC

Figure 1 – Powermax65 SYNC and Powermax85 SYNC dimensions

Table 1 – Powermax65 SYNC and Powermax85 SYNC weights with power cords

Powermax65 SYNC Powermax85 SYNC

200 V – 600 V CSA 380 V CCC / 400 V CE 200 V – 600 V CSA 380 V CCC / 400 V CE

24.3 kg (54 lb) 20.6 kg (45 lb) 27.2 kg (60 lb) 23.5 kg (52 lb)

For hand torch weights, refer to Weights on page 110. For machine torch



weights, refer to the Powermax65/85/105 SYNC Mechanized Cutting Guide (810480).

36 810470 Operator Manual Powermax65/85/105 SYNC

Powermax105 SYNC

274 mm

(10.8 inches)

592 mm

(23.3 inches)

508 mm

(20 inches)

436 mm (17 inches)

Install and Set Up the Plasma Power Supply

Figure 2 – Powermax105 SYNC dimensions

Table 2 – Powermax105 SYNC weight with power cord

200 V – 600 V CSA 230 V – 400 V CE 380 V CCC / 400 V CE

39.7 kg (88 lb) 39.5 kg (87 lb) 36.2 kg (80 lb)

Work lead weights

Work lead Powermax65 SYNC Powermax85 SYNC Powermax105 SYNC

7.6 m (25 ft) 1.3 kg (2.9 lb) 1.6 kg (3.6 lb) 2.3 kg (5.1 lb)

15 m (50 ft) 2.3 kg (5.0 lb) 3.0 kg (6.5 lb) 4.2 kg (9.25 lb)

23 m (75 ft) 3.1 kg (6.9 lb) 4.2 kg (9.25 lb) 6.1 kg (13.4 lb)



For hand torch weights, refer to Weights on page 110. For machine torch weights, refer to the Powermax65/85/105 SYNC Mechanized Cutting Guide (810480).

Powermax65/85/105 SYNC Operator Manual 810470 37

Install and Set Up the Plasma Power Supply

Connect to electrical power

Use the Hypertherm input current ratings to select conductor sizes for power connection and installation instructions. The Hypertherm ratings are designated HYP on the data plate on the rear of the plasma power supply. Use the higher HYP input current value for installation purposes. Refer to

Find system specifications on the data plate on page 28 for a sample data plate.

NOTICE

Protect the circuit with appropriately sized time-delay fuses and a line-disconnect switch.

The maximum output voltage changes related to input voltage and the circuit’s amperage. Because the current draw changes during startup, time-delay fuses are recommended. Time-delay fuses are resistant to currents up to 10 times the rated value for short periods of time.

NOTICE

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.

Install a line-disconnect switch

 Use a line-disconnect switch for

each plasma power supply so that the operator can stop the incoming power quickly in an emergency.

 Put the switch in a location that it is

easily accessible to the operator. Installation must be done by a licensed electrician according to national and local codes.

 The interrupt level of the switch

must equal or be more than the continuous rating of the fuses.

 The switch must also do the

following:

 Isolate the electrical equipment

and disconnect all live conductors from the incoming supply voltage when in the OFF position.

 Have one OFF and one ON position that are clearly marked with O (OFF) and I (ON).  Have an external operating handle that can be locked in the OFF position.

38 810470 Operator Manual Powermax65/85/105 SYNC

Install and Set Up the Plasma Power Supply

 Contain a power-operated mechanism that operates as an emergency stop.  Have approved time-delay fuses installed. Refer to Voltage configurations on page 40

for recommended fuse sizes.

Powermax65/85/105 SYNC Operator Manual 810470 39

Install and Set Up the Plasma Power Supply

Requirements for grounding

To make sure of personal safety and correct operation, and to decrease electromagnetic interference (EMI), the plasma power supply must be correctly grounded.

 The plasma power supply must be grounded through the power cord according to

national and local electrical codes.

 1-phase service must be of the 3-wire type with a green or green/yellow wire for the

protective earth ground and must comply with national and local requirements. Do not use a 2-wire service.

 3-phase service must be of the 4-wire type with a green or green/yellow wire for protective

earth ground and must comply with national and local requirements.

Refer to the Safety and Compliance Manual (80669C) for more information on grounding.

For mechanized cutting systems, refer to EMI grounding and shielding best practices in the Powermax65/85/105 SYNC Mechanized Cutting Guide (810480).

Rated output (cutting power) of the plasma power supply

Wattage output shows a plasma power supply’s cutting power more than its amperage output. The rated outputs for the systems are as follows:

Powermax65 SYNC Powermax85 SYNC Powermax105 SYNC

Maximum output amperage 20 A – 65 A 25 A – 85 A 30 A – 105 A

Maximum rated output voltage 139 VDC 143 VDC 160 VDC

Cutting power 9.0 kW 12.2 kW 16.8 kW

To calculate the cutting power in watts (W), multiply the maximum output amperage (A) by the maximum rated output voltage (VDC). For example:

65 A x 139 VDC = 9035 W (9.0 kW)

Voltage configurations

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 the following:

 Install the Hypertherm cartridge in the torch. Refer to Step 3 – Install the cartridge on

page 64.

 Make sure that the output current (A) is correct for the cartridge that you installed. If

necessary, turn the adjustment knob on the front panel to adjust the output current. Refer to

Step 6 – Adjust the output current (A) and operating mode if necessary on page 70.

40 810470 Operator Manual Powermax65/85/105 SYNC

Install and Set Up the Plasma Power Supply

To operate the plasma power supply at full output and at its rated duty cycle (refer to Prevent

overheating on page 81), you must make your electrical service the correct size. The following

tables show the maximum rated output for typical input voltages. The output setting that you use relates to the thickness of the workpiece and the limit of the input power to the plasma power supply.

The recommended fuse sizes let spikes in input current occur when you



stretch the plasma arc. Stretching the plasma arc is common in some applications, such as gouging.

Powermax65 SYNC

CSA configurations (1-phase)

Input voltage at 50 Hz/60 Hz* 200 V – 208 V 230 V – 240 V 480 V

Input current at rated output (65 A × 139 VDC = 9.0 kW) 52 A / 50 A 44 A 22 A

Input current during arc stretch 74 A 74 A 38 A

Fuse (time-delay) 80 A 80 A 40 A

* All models have a voltage tolerance of +10% / -15%.

CSA configurations (3-phase)

Input voltage at 50Hz/60Hz* 200V– 208V 230V– 240V 400V 480V – 600V

Input current at rated output (65 A × 139 VDC = 9.0 kW)

Input current during arc stretch 45 A 45 A 27 A 23 A

Fuse (time-delay) 50 A 50 A 30 A 25 A

* All models have a voltage tolerance of +10% / -15%.

32 A / 31 A 27 A 15 A 13 A

CE/CCC configurations (3-phase)

Input voltage at 50 Hz/60 Hz* 380 V 400 V

Input current at rated output (65 A × 139 VDC = 9.0 kW) 15.5 A 15 A

Input current during arc stretch 27 A 27 A

Fuse (time-delay) 30 A 30 A

* All models have a voltage tolerance of +10% / -15%.

Powermax65/85/105 SYNC Operator Manual 810470 41

Install and Set Up the Plasma Power Supply

Powermax85 SYNC

CSA configurations (1-phase)

Input voltage at 50 Hz/60 Hz* 200 V – 208 V 230 V – 240 V 480 V

Input current at rated output (85 A × 143 VDC = 12.2 kW) 70 A / 68 A 58 A 29 A

Input current during arc stretch 98 A 98 A 50 A

Fuse (time-delay) 100 A 10 0 A 50 A

* All models have a voltage tolerance of +10% / -15%.

CSA configurations (3-phase)

Input voltage at 50 Hz/60 Hz* 200 V – 208 V 230 V – 240 V 400 V 480 V 600 V

Input current at rated output (85 A × 143 VDC = 12.2 kW)

Input current during arc stretch 60 A 60 A 38 A 31 A 30 A

Fuse (time-delay) 60 A 60 A 40 A 30 A 30 A

* All models have a voltage tolerance of +10% / -15%.

42 A / 40 A 35 A 21 A 18 A 17 A

CE/CCC configurations (3-phase)

Input voltage at 50 Hz/60 Hz* 380 V 400 V

Input current at rated output (85 A × 143 VDC = 12.2 kW) 20.5 A 19.5 A

Input current during arc stretch 38 A 38 A

Fuse (time-delay) 40 A 40 A

* All models have a voltage tolerance of +10% / -15%.

42 810470 Operator Manual Powermax65/85/105 SYNC

Install and Set Up the Plasma Power Supply

Powermax105 SYNC

CSA configurations (3-phase)

Input voltage at 50Hz/60Hz* 200V 208V 240V 480V 600V

Input current at rated output (105 A x 160 VDC = 16.8 kW)

Input current during arc stretch 82 A 82 A 78 A 40 A 35 A

Fuse (time-delay) 80 A 80 A 80 A 40 A 40 A

* All models have a voltage tolerance of +10% / -15%.

58 A 56 A 49 A 25 A 22 A

230 V – 400 V CE configurations (3-phase)

Input voltage at 50Hz/60Hz* 230V 400V

Input current at rated output (105 A x 160 VDC = 16.8 kW) 50 A 29 A

Input current during arc stretch 80 A 46 A

Fuse (time-delay) 80 A 50 A

* All models have a voltage tolerance of +10% / -15%.

380 V CCC / 400 V CE configurations (3-phase)

Input voltage at 50 Hz/60 Hz* CCC 380 V CE 400 V

Input current at rated output (105 A x 160 VDC = 16.8 kW) 30 A 28 A

Input current during arc stretch 42 A 44 A

Fuse (time-delay) 50 A 50 A

* All models have a voltage tolerance of +10% / -15%.

Powermax65/85/105 SYNC Operator Manual 810470 43

Install and Set Up the Plasma Power Supply

Prepare the power cord and plug

Install the power plug

A 3 m (10 foot) 3-phase power cord with the following specifications is included with all Powermax65 SYNC, Powermax85 SYNC, and Powermax105 SYNC plasma power supplies. Refer to Figure 3 on page 45.

This power cord does not come with a plug. To operate the plasma power supply, you must first have a licensed electrician install an approved plug on the power cord – or connect the power cord to a line-disconnect switch – according to all national and local electrical codes.

Model Configurations Power cord

Powermax65 SYNC

Powermax85 SYNC

Powermax105 SYNC

* 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 CCC certification to GB/T 5013.4, with CCC printed on the cord.

200 V – 600 V CSA 8 AWG 4-wire

380 V CCC / 400 V CE 2.5 mm

200 V – 600 V CSA 8 AWG 4-wire

380 V CCC / 400 V CE 4 mm

200 V – 600 V CSA 6 AWG 4-wire

230 V – 400 V CE 10 mm

380 V CCC / 400 V CE 6 mm

Install the power cord (if necessary)

If your work site makes it necessary to install a different power cord than the one that comes with the system, refer to Figure 3 on page 45 for instructions on how to prepare the power cord wires and to connect them correctly in the plasma power supply.

, 4-wire style H07RN-F*

, 4-wire HAR

, 4-wire H07RN-F* and HAR

44 810470 Operator Manual Powermax65/85/105 SYNC

CSA power cord

(no ferrite cores)

CE/CCC power cord

(ferrite cores on power wires and ground wire)

419 mm (16.5 inches)

M5 / #10 terminal ring, approximately 12 mm (0.5 inch) long

65/85

10 2 m m

(4 inches)

105

152 mm

(6 inches)

L1 L2 L3

Ground

Strain relief

Install and Set Up the Plasma Power Supply

Figure 3 – Install a power cord

For more instructions, refer to one of the following Field Service Bulletins:

 Powermax65/85 SYNC Power Cord and Strain Relief Replacement (807020)  Powermax105 SYNC Power Cord and Strain Relief Replacement (810420)

Powermax65/85/105 SYNC Operator Manual 810470 45

Install and Set Up the Plasma Power Supply

Install a 1-phase power cord (CSA systems only) (if necessary)

You can operate a Powermax65/85 SYNC CSA plasma power supply on 1-phase power, but the Powermax65/85 SYNC CE/CCC plasma power supply is 3-phase only.

To operate a Powermax65 SYNC CSA plasma power supply on 1-phase power, install a 10 mm (8 AWG) 3-wire power cord. To operate a Powermax85 SYNC CSA plasma power supply on 1-phase power, install a 16 mm by a licensed electrician.

Refer to the Powermax65/85 SYNC Power Cord and Strain Relief Replacement Field Service Bulletin (807020) for instructions.

(6 AWG) 3-wire power cord. The power cord must be connected

Use an extension cord (if necessary)

Use an extension cord that meets the following requirements:

 Is an approved wire gauge for the cord length and plasma power supply voltage  Complies with national and local codes

Extension cords can cause the machine to receive less input voltage than



the output of the circuit. This can put a limit on the operation of your plasma power supply.

The following tables give the recommended gauge sizes for various lengths and input voltages.

The lengths in the tables are the length of the extension cord only; they do



not include the plasma power supply’s power cord.

46 810470 Operator Manual Powermax65/85/105 SYNC

Powermax65 SYNC systems

Install and Set Up the Plasma Power Supply

Table 3 – 65 A CSA

Extension cord length

< 3 m

(< 10 ft)

3 m – 7.5 m

(10 ft – 25 ft)

7. 5 m – 1 5 m

(25 ft – 50 ft)

(50 ft – 100 ft)

Input voltage (VAC) Phase Extension cord gauge

200 – 240 1

480 1

200 – 240 3

400/480 3

600 3

10 m m

(8 AWG)

4mm

(12 AWG)

6mm

(10 AWG)

4mm

(12 AWG)

4mm

(12 AWG)

10 m m2

(8 AWG)

4mm2

(12 AWG)

6mm2

(10 AWG)

4mm2

(12 AWG)

4mm2

(12 AWG)

10 m m2

(8 AWG)

4mm2

(12 AWG)

6mm2

(10 AWG)

4mm2

(12 AWG)

4mm2

(12 AWG)

Table 4 – 65 A CE/CCC

Extension cord length

< 3 m

(< 10 ft)

3 m – 7.5 m

(10 ft – 25 ft)

7. 5 m – 1 5 m

(25 ft – 50 ft)

(50 ft – 100 ft)

Input voltage (VAC) Phase Extension cord gauge

380 3 4 mm

400 3 4 mm

4mm

15 m – 30 m

16 mm2

(6 AWG)

6mm2

(10 AWG)

10 m m2

(8 AWG)

4mm2

(12 AWG)

4mm2

(12 AWG)

15 m – 30 m

4mm

30 m – 45 m

(100 ft – 150 ft)

25 mm2

(4 AWG)

6mm2

(10 AWG)

16 mm2

(6 AWG)

4mm2

(12 AWG)

4mm2

(12 AWG)

30 m – 45 m

(100 ft – 150 ft)

4mm

Powermax65/85/105 SYNC Operator Manual 810470 47

Install and Set Up the Plasma Power Supply

Powermax85 SYNC systems

Table 5 – 85 A CSA

Extension cord length

< 3 m

(< 10 ft)

3 m – 7.5 m

(10 ft – 25 ft)

7.5 m – 15 m (25 ft – 50 ft)

(50 ft – 100 ft)

Input voltage (VAC) Phase Extension cord gauge

200 – 240 1

480 1

200 – 240 3

400/480 3

600 3

16 mm

(6 AWG)

6mm

(10 AWG)

10 m m

(8 AWG)

6mm

(10 AWG)

6mm

(10 AWG)

16 mm2

(6 AWG)

6mm2

(10 AWG)

10 mm2

(8 AWG)

6mm2

(10 AWG)

6mm2

(10 AWG)

16 mm2

(6 AWG)

6mm2

(10 AWG)

10 m m2

(8 AWG)

6mm2

(10 AWG)

6mm2

(10 AWG)

Table 6 – 85 A CE/CCC

Extension cord length

< 3 m

(< 10 ft)

3 m – 7.5 m

(10 ft – 25 ft)

7. 5 m – 1 5 m

(25 ft – 50 ft)

(50 ft – 100 ft)

Input voltage (VAC) Phase Extension cord gauge

380 3 6 mm

400 3 6 mm

6mm

15 m – 30 m

25 mm2

(4 AWG)

10 mm2

(8 AWG)

16 mm2

(6 AWG)

6mm2

(10 AWG)

6mm2

(10 AWG)

15 m – 30 m

6mm

30 m – 45 m

(100 ft – 150 ft)

35 mm2

(2 AWG)

10 m m2

(8 AWG)

25 mm2

(4 AWG)

6mm2

(10 AWG)

6mm2

(10 AWG)

30 m – 45 m

(100 ft – 150 ft)

6mm

48 810470 Operator Manual Powermax65/85/105 SYNC

Powermax105 SYNC systems

Install and Set Up the Plasma Power Supply

Table 7 – 200 V – 600 V CSA

Extension cord length

< 3 m

(< 10 ft)

3 m – 7.5 m

(10 ft – 25 ft)

7. 5 m – 1 5 m

(25 ft – 50 ft)

(50 ft – 100 ft)

Input voltage (VAC) Phase Extension cord gauge

200 – 240 3

480 – 600 3

16 mm

(6 AWG)

6mm

(10 AWG)

16 mm2

(6 AWG)

6mm2

(10 AWG)

16 mm2

(6 AWG)

6mm2

(10 AWG)

Table 8 – 230 V – 400 V CE

Extension cord length

< 3 m

(< 10 ft)

3 m – 7.5 m

(10 ft – 25 ft)

7. 5 m – 1 5 m

(25 ft – 50 ft)

(50 ft – 100 ft)

Input voltage (VAC) Phase Extension cord gauge

230 3 16 mm

400 3 10 mm

16 mm

10 m m

16 mm

10 m m

Table 9 – 380 V CCC / 400 V CE

Extension cord length

< 3 m

(< 10 ft)

3 m – 7.5 m

(10 ft – 25 ft)

7. 5 m – 1 5 m

(25 ft – 50 ft)

(50 ft – 100 ft)

15 m – 30 m

25 mm2

(4 AWG)

6mm2

(10 AWG)

15 m – 30 m

25 mm

10 m m

15 m – 30 m

30 m – 45 m

(100 ft – 150 ft)

35 mm2

(2 AWG)

6mm2

(10 AWG)

30 m – 45 m

(100 ft – 150 ft)

25 mm

10 m m

30 m – 45 m

(100 ft – 150 ft)

Input voltage (VAC) Phase Extension cord gauge

380 3 10 mm

400 3 10 mm

10 m m

Powermax65/85/105 SYNC Operator Manual 810470 49

Install and Set Up the Plasma Power Supply

Use a generator (if necessary)

Make sure that you do the following when you use a generator:

 Only use a generator that meets the plasma power supply’s requirements. Refer to

Powermax65 SYNC and Powermax85 SYNC systems on page 51 and Powermax105 SYNC systems on page 52.

 Adjust the output current (A) if necessary related to the rating, age, and condition of the

generator. Refer to Step 6 – Adjust the output current (A) and operating mode if necessary on page 70.

 Use one of the following recommended generators when full arc stretch is necessary, such

as for many gouging applications. These generators let spikes in input current occur when you stretch the plasma arc.

 15 kW generator for Powermax65 SYNC  20 kW generator for Powermax85 SYNC  30 kW generator for Powermax105 SYNC

 If a fault occurs, set the power switch on the plasma power supply to OFF (O). Wait

approximately 1 minute before you set the power switch to ON (I).



Problems with input line voltage (fault codes 0-13-0, 0-60-n, and 0-61-0) can occur more frequently with some generators. Refer to Troubleshoot

power-related problems with generators on page 148.

50 810470 Operator Manual Powermax65/85/105 SYNC

Install and Set Up the Plasma Power Supply

Powermax65 SYNC and Powermax85 SYNC systems

Generators used with a Powermax65 SYNC or Powermax85 SYNC must meet the requirements in

Ta bl e 10 and Tab le 1 1.

Table 10 – Voltage requirements

CSA

CE/CCC 3-phase: 50 Hz/60 Hz, 380 VAC / 400 VAC

* A 4-wire 1-phase connection (for example, NEMA 14-50R) is necessary for some generators. In this

condition, use an adapter to connect the plasma power supply’s 3-wire power cord plug (NEMA 6-50P) to the 4-wire connector on the generator. Refer to Install a 1-phase power cord (CSA systems only) (if

necessary) on page 46 for more information.

Engine drive rating

20 kW 85 A Full

15 kW 70 A Decreased

15 kW 65 A Full

12 kW 65 A Decreased

12 kW 40 A Full

8 kW 40 A Decreased

8 kW 30 A Full

1-phase: 50 Hz/60 Hz, 230 VAC / 240 VAC* 3-phase: 50 Hz/60 Hz, 200 VAC – 600 VAC

Table 11 – Engine drive requirements

Plasma power supply output

current

Performance (arc stretch)

Powermax65/85/105 SYNC Operator Manual 810470 51

Install and Set Up the Plasma Power Supply

Powermax105 SYNC systems

Generators used with the Powermax105 SYNC must meet the requirements in Ta bl e 12 and

Ta bl e 1 3.

Table 12 – Voltage requirements

200 V – 600 V CSA 3-phase, 50 Hz/60 Hz, 200 VAC – 600 VAC

230 V – 400 V CE 3-phase, 50 Hz/60 Hz, 230 VAC – 400 VAC

380VCCC / 400 V CE 3-phase, 50Hz/60Hz, 380VAC / 400VAC

Table 13 – Engine drive requirements

Engine drive rating

30 kW 105 A Full

22.5 kW – 25 kW 105 A Decreased

20 kW 85 A Full

15 kW 70 A Decreased

15 kW 65 A Full

12 kW 65 A Decreased

12 kW 40 A Full

8 kW 40 A Decreased

8 kW 30 A Full

Plasma power supply output

current

Performance (arc stretch)

52 810470 Operator Manual Powermax65/85/105 SYNC

Connect the gas supply

123

EXPLOSION HAZARD

The filter bowl in the plasma power supply can explode if the gas pressure is more than

9.3 bar (135 psi). Never use more than the maximum gas pressure of 9.3 bar (135 psi).

Refer to the figure on page 54.

1. Get an inert-gas hose with the correct internal diameter .

 For hoses that are less than 15 m (50 feet), use an internal diameter of 10 mm (3/8 inch)

or greater.

 For hoses that are 15 m – 30 m (50 feet – 100 feet), use an internal diameter of 13 mm

(1/2 inch) or greater.

Install and Set Up the Plasma Power Supply

WARNING

Do not use hoses with an internal diameter less than 10 mm



(3/8 inch). Hoses that are too small can cause problems with cut quality and cut performance.

2. Make sure that the correct gas inlet fitting is installed.

 CSA models come with an industrial interchange quick-disconnect nipple with 1/4 NPT

threads . To install, tighten the fitting to 115 kg·cm (100 in·lb). The fitting comes with thread sealant applied.

 CE/CCC models come with a British Pipe Thread adapter G-1/4 BSPP with 1/4 NPT

threads . To install, tighten the adapter to 104 kg·cm (90 in·lb).

NOTICE

PTFE TAPE CAN CAUSE CLOGG ED VALVES, REG U LATORS, AND TORCHES

Never use PTFE tape on any joint preparation. Use only a liquid or paste thread sealant on male threads.

Powermax65/85/105 SYNC Operator Manual 810470 53

Install and Set Up the Plasma Power Supply

3. Connect the gas hose to the gas inlet fitting. Refer to Inlet gas pressure requirements (while gas

is flowing) on page 57.

Gas supply source

Hypertherm recommends that air compressors supply air that meets the following requirements of

ISO Standard 8573-1:2010 Class 1.4.2*:

Maximum particle count in 1.0 m

Maximum water vapor pressure dewpoint: 3°C (37°F)**

Maximum oil concentration: 0.1 mg/m

* Important: Any air compressors that supply air to the cutting system must remove oil prior to air delivery.

** Speak to your air compressor manufacturer if you operate the cutting system in temperatures colder than 3°C (37°F)

or if you are unsure that the air compressor can comply with the ISO standard for air quality.

: • 20,000 at 0.1 microns – 0.5 microns

• 400 at 0.5 microns – 1.0 microns

• 10 at 1.0 microns – 5.0 microns

(for aerosol, liquid, and vapor)

NOTICE

DIRTY, OILY AIR CAN CAUSE DAMAGE TO THE AIR FILTER BOWL

Synthetic lubricants containing esters that are used in some air compressors can cause damage to the polycarbonates in the air filter bowl. Add additional gas filtration if necessary.

54 810470 Operator Manual Powermax65/85/105 SYNC

 Use shop-compressed gas or cylinder-compressed gas.

 Use a high-pressure regulator on either type of gas supply. The regulator must be able

to deliver gas to the air inlet on the plasma power supply at the specified flow rate and specified pressure.

 Use only clean, moisture-free gas.

 Oil, water, vapor, and other contaminants in the gas supply can cause damage to

internal components over time.

 Poor gas supply quality causes:

 Decreased cut quality and cut speeds  Decreased cut thickness capability  Decreased consumable life

To address these problems, use an optional air filtration system. Refer to Add additional

gas filtration (if necessary) on page 59.

High-pressure gas cylinders

Install and Set Up the Plasma Power Supply

WARNING

GAS CYLINDERS CAN EXPLODE IF DAMAGED

Gas cylinders contain gas under high pressure. If damaged, a cylinder can explode. For high pressure regulators, comply with the manufacturer’s guidelines for safe

installation, operation, and maintenance. Before plasma cutting with compressed gas, read the safety instructions in the Safety and

Compliance Manual (80669C). Failure to comply with safety instructions can cause personal injury or equipment damage.

WARNING

EXPLOSION HAZARD – CUTTING WITH FLAMMABLE OR OXIDIZING GASES

Do not use flammable or oxidizing gases with Powermax systems. These gases can cause explosive conditions during plasma cutting operations.

An example of an oxidizing gas is oxygen. Examples of flammable gases are acetylene, propylene, methane, and pure hydrogen. Refer to the Safety and Compliance Manual (80669C) for more information.

Powermax65/85/105 SYNC Operator Manual 810470 55

Install and Set Up the Plasma Power Supply

You can use the following gases to cut with this plasma power supply. Refer to Hypertherm plasma

power supply ratings on page 21 for requirements on gas quality.

 Air  Nitrogen

 Do NOT use oxygen to cut with Powermax systems

 F5 (stainless steel only)

 Refer to the Powermax65/85/105 SYNC Mechanized Cutting Guide (810480).

If you use high-pressure gas cylinders as the gas supply, then do the following:

 Refer to the manufacturer’s specifications for installation and maintenance procedures of

high-pressure regulators.

 Make sure that the cylinder has an adjustable high-pressure regulator with the following

capabilities:

 Gas outlet pressures up to 9.3 bar (135 psi). Never use more than the maximum gas

pressure of 9.3 bar (135 psi).

 The following gas flow rates:

 Powermax65/85 SYNC: 210 slpm (450 scfh)  Powermax105 SYNC: 260 slpm (550 scfh)

 Make sure that the cylinder valves are clean and free of oil, grease, and other contaminants.

Open each cylinder valve just long enough to blow out any dust that is possibly present.

 Connect the supply hose correctly to the cylinder.

56 810470 Operator Manual Powermax65/85/105 SYNC

Inlet gas pressure requirements (while gas is flowing)

The following inlet gas pressure specifications apply for air, nitrogen, and F5 gases.

Maximum inlet pressure

Never exceed the maximum gas pressure of 9.3 bar (135 psi).

WARNING

EXPLOSION HAZARD

The filter bowl in the plasma power supply can explode if the gas pressure is more than

9.3 bar (135 psi). Never use more than the maximum gas pressure of 9.3 bar (135 psi).

Optimum inlet pressure

Install and Set Up the Plasma Power Supply

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.

Keep the inlet gas pressure at the optimum range to make sure that system performance is good for all the combinations of plasma power supply, torch lead length, and cutting and gouging processes that you use.

Minimum inlet pressure

The following tables show the minimum inlet gas pressure requirements for each Powermax SYNC system. Use the correct pressure for your combination of operating mode, cartridge type, and torch lead length.

If your inlet gas pressure goes below these levels while gas is flowing, a fault condition can occur. A pressure-related fault code on the LCD screen can be for a notification or for a condition that stops the cutting process. Hypertherm recommends that you do the recommended steps to troubleshoot the fault. Refer to Fault codes on page 132 and Examine the gas pressure on page 126.

Additional gas filtration installed between the gas supply and the plasma power supply can have an effect on gas pressure and gas flow. 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.

Powermax65/85/105 SYNC Operator Manual 810470 57

Install and Set Up the Plasma Power Supply

Cutting

Torc h lea d le n gt h

7.6 m (25 ft) 15.2 m (50 ft) 22.9 m (75 ft)

Powermax65 SYNC Powermax85 SYNC

Powermax105 SYNC 5.5 bar (80 psi) 5.9 bar (85 psi) 6.2 bar (90 psi)

5.2 bar (75 psi) 5.5 bar (80 psi) 5.9 bar (85 psi)

Maximum Control gouging

Torc h lea d le n gt h

7.6 m (25 ft) 15 m (50 ft) 23 m (75 ft)

Powermax65 SYNC Powermax85 SYNC Powermax105 SYNC

4.1 bar (60 psi) 4.5 bar (65 psi) 4.8 bar (70 psi)

Maximum Removal gouging

Torc h lea d le n gt h

7.6 m (25 ft) 15 m (50 ft) 23 m (75 ft)

Powermax65 SYNC Powermax85 SYNC Powermax105 SYNC

4.1 bar (60 psi) 4.5 bar (65 psi) 4.8 bar (70 psi)

Recommended gas inlet flow rates

Process

Cutting 210 slpm (450 scfh, 7.5 scfm) at a

Maximum Removal gouging 210 slpm (450 scfh, 7.5 scfm) at a

Maximum Control gouging 210 slpm (450 scfh, 7.5 scfm) at a

Refer to the Powermax65/85/105 SYNC Cut Charts Guide (810500MU) for flow rates specific to each cutting process specified (related to the type of metal, the type of gas, and the output current).

Powermax65 SYNC and

Powermax85 SYNC

minimum 5.9 bar (85 psi)

minimum 4.8 bar (70 psi)

Powermax105 SYNC

260 slpm (550 scfh, 9.1 scfm) at a minimum 6.2 bar (90 psi)

260 slpm (550 scfh, 9.1 scfm) at a minimum 4.8 bar (70 psi)

58 810470 Operator Manual Powermax65/85/105 SYNC

Add additional gas filtration (if necessary)

Air filter bowl

Gas supply Water and

particle filter

Oil filter Plasma power

supply

Oil vapor filter

It is extremely important to keep a clean, dry gas line to do the following:

 Prevent oil, water, dirt, and other contaminants from causing damage to internal

components.

 Get optimal cut quality and consumable life.

Dirty, oily air is the root cause of many common problems that occur in Powermax systems, and in some conditions it can void the warranty on the plasma power supply and on the torch. Refer to the gas quality recommendations in the ratings tables that start on page 21.

The plasma power supply contains a built-in air filter. Regularly do a check of the filter element inside the air filter bowl and replace as necessary. Refer to Examine the air filter bowl and filter

element on page 177.

Install and Set Up the Plasma Power Supply

The built-in air filter must not take the place of sufficient external filtration. If you work in an environment that is extremely warm and humid, or if work site conditions introduce oil, vapors, or other contaminants into the gas line, install an external filtration system that cleans the gas supply before it gets into the plasma power supply.

A 3-stage coalescing filtration system is recommended. A 3-stage filtering system works as follows to clean contaminants from the gas supply.

The filtering system must be installed between the gas supply and the plasma power supply.

Additional gas filtration can make higher pressure from the gas supply



necessary. For the recommended gas inlet flow rate and pressure, refer to

Inlet gas pressure requirements (while gas is flowing) on page 57.

Powermax65/85/105 SYNC Operator Manual 810470 59

Install and Set Up the Plasma Power Supply

Hypertherm offers the following optional external filter kits:

 Kit 128647: The Eliminizer moisture removal air filter removes water and dirt from the gas

supply. For more information, refer to the Optional Air Filter Kit and Element Replacement Procedure Field Service Bulletin (804180).

 Kit 428719: The oil removal air filter removes oil, oil vapor, and dirt from the gas supply.

For more information, refer to the Optional Oil Removal Air Filter Kit and Element Replacement Field Service Bulletin (809610).

For additional parts related to these filter kits, refer to the



Powermax65/85/105 SYNC Parts Guide (810490).

If you use both external filters, install them in the order shown in Figure 4 to prevent damage to the gas line and equipment.

Figure 4 – Optional Hypertherm external filters

60 810470 Operator Manual Powermax65/85/105 SYNC

Operate the Plasma System

Make sure that the plasma power supply is connected to gas and power

1. Connect the gas supply line to the fitting on the back of the plasma power supply. Refer to

page 53.

 For gas supply requirements, refer to Gas supply source on page 54.

2. Make sure that the plasma power supply’s power cord is correctly connected to electrical power according to national and local codes. Refer to Connect to electrical power on page 38, and

Prepare the power cord and plug on page 44.

Powermax65/85/105 SYNC Operator Manual 810470 61

Operate the Plasma System

Red button

Step 1 – 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

or machine torch, push the connector into the receptacle on the front of the plasma power supply. The connector makes a click when it is fully engaged.

 To disconnect the torch,

push the red button on the connector and pull the connector out of the receptacle.

62 810470 Operator Manual Powermax65/85/105 SYNC

Operate the Plasma System

Keyed opening at the top of the work lead receptacle

Step 2 – Connect the work lead and work clamp

NOTICE

INCORRECT WORK LEADS CAN CAUSE AN UNSTABLE PLASMA ARC

Work leads are approved for specific amperages, lengths, and connectors. Make sure that you use a work lead that is approved for your plasma power supply. Refer to the Powermax65/85/105 SYNC Parts Guide (810490). The amperage of a work lead is identified near the rubber boot of the work lead connector.

Work lead

1. Put the work lead connector in the receptacle on the front of the plasma power supply. Align the key on the connector with the opening at the top of the receptacle.

2. Push the work lead connector all the way into the receptacle. Turn the connector clockwise approximately 1/4 turn until the connector is fully engaged and locked in position.

NOTICE

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 connected to the plasma power supply and is not loose.

Powermax65/85/105 SYNC Operator Manual 810470 63

Operate the Plasma System

Work clamp

NOTICE

Do not attach the work clamp under water. If the plasma power supply is below the work clamp, water can get into the plasma power supply through the work lead and cause severe damage.

Do not attach the work clamp to the portion of the workpiece to be cut away.

 Hand cutting: The work clamp must be connected to the workpiece that you are cutting.  Mechanized cutting: If you are using this plasma power supply with a mechanized cutting

system, you can connect the work clamp directly to the cutting table or to the workpiece you are cutting. Refer to your equipment manufacturer’s instructions.

 Make sure that the work clamp

makes good metal-to-metal contact with the workpiece or cutting table.

 Remove rust, dirt, paint, coatings,

and other debris so that the work clamp makes sufficient contact with the workpiece or cutting table.

 Attach the work clamp as close as

possible to the area being cut.

Step 3 – Install the cartridge

INSTANT-ON TORCHES – PLASMA ARC CAN CAUSE INJURY, BURNS

Ignition of the plasma arc occurs immediately when you pull the torch trigger. Before changing the cartridge, one of the following steps is necessary. Whenever possible, complete the first step.

 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.

WARNING

64 810470 Operator Manual Powermax65/85/105 SYNC

Lock the torch

SmartSYNC torches include a switch that lets you lock the torch. This torch-lock switch prevents the torch from firing accidentally, even when the plasma power supply is ON.

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

Tor ch LOCK position:

 The yellow label with the “X” shows that the

torch is not prepared to fire.

 Point the torch away from yourself and

others, and pull the trigger to make sure that it does not fire.



Operate the Plasma System

When the torch is locked, the Fault LED comes on, and the Torch Cap Sensor icon and 0-50-1 fault code show on the status screen.

 You CAN install the cartridge.

Tor ch “ready to fire” position:

 The green label with the “ ” shows that

the torch is prepared to fire.

 Do NOT change the cartridge.

Powermax65/85/105 SYNC Operator Manual 810470 65

Operate the Plasma System

Tighten 1/4 turn to install.

Install the cartridge

Cartridges are not preinstalled on new torches.

1. Make sure that the power switch on the plasma power supply stays OFF (O).

2. Make sure that the torch-lock switch on the torch is set to the yellow lock (X) position.

3. If this is a new torch, remove the vinyl cap from the torch.

4. Install the correct Hypertherm cartridge for your cutting or gouging application.

 Cutting and piercing with a

hand torch: Refer to Select

the correct cutting cartridge

on page 95.

 Gouging with a hand torch:

Refer to Select the correct

gouging cartridge on

page 111.

 Cutting, piercing, and

gouging with a machine torch: Refer to the

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

66 810470 Operator Manual Powermax65/85/105 SYNC

Step 4 – Set the power switch to ON (I)

Set the power switch to ON (I). The switch is on the rear panel of the plasma power supply.

 If the torch-lock switch is set

to the green “ready to fire” ( ) position when you

set the power switch to ON, the hand torch puts out a puff of air. Refer to Warning

puffs of air (hand torches) on

page 68.

 If the torch-lock switch is set

to the yellow lock (X) position when you set the power switch to ON, the 0-50-0 or 0-50-1 fault code and Torch Cap Sensor icon show on the status screen. Refer to Fault code and LED behavior on page 69.

Operate the Plasma System

Powermax65/85/105 SYNC Operator Manual 810470 67

Operate the Plasma System

Step 5 – Unlock the SmartSYNC torch

1. Move the torch-lock switch to the green “ready to fire” ( ) position.

2. Hand torch: Pull the torch trigger 1 time to get the warning puffs of air.

Machine torch: Send a START / STOP command from the CNC to fire a plasma arc. There are no warning puffs of air.

3. Hand torch: When the warning puffs of air stop, the torch is prepared to fire a plasma arc.

If you see a fault code and fault icon on the status screen, remove the fault condition before you continue. Refer to Fault codes on page 132.

Warning puffs of air (hand torches)

The following happens on SmartSYNC hand torches the first time that you try to fire the torch after moving the torch-lock switch to the yellow lock (X) position and then back to the green “ready to

fire” ( ) position:

The plasma arc does not fire.

The torch quickly puts out multiple puffs of air. You can feel a light tap in the torch handle with each puff of air.

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.

68 810470 Operator Manual Powermax65/85/105 SYNC

Fault code and LED behavior

2 3

Yel lo w Ye llo w

Green

312

On the plasma power supply:

Operate the Plasma System

When you set the torch-lock switch to the yellow lock (X) position while the plasma power supply stays ON, the Fault light-emitting diode (LED) comes on and the 0-50-1 fault code and Torch Cap Sensor icon show.

After you install the cartridge and set the torch-lock switch to the green “ready to fire” ( ) position, the Fault LED goes off and the fault code changes to 0-50-2.

Hand torch: After the torch puts out the warning puffs of air, the 0-50-2 fault code goes off. Machine torch: The 0-50-2 fault code shows for approximately 1 second and then goes off.

When you start the plasma power supply while the torch-lock switch is in



the yellow lock (X) position, the system shows the 0-50-0 fault code instead of 0-50-1. Move the torch-lock switch to the green “ready to fire” ( ) position to continue.

On the SmartSYNC hand torch:

When you set the torch-lock switch to the yellow lock (X) position while the plasma power supply stays ON, the LED on the hand torch changes from green to yellow.

When you install the Hypertherm cartridge and set the torch-lock switch to the green “ready to fire” ( ) position, the LED on the hand torch stays yellow.

After the torch puts out the warning puffs of air, the LED changes from yellow to green.

Powermax65/85/105 SYNC Operator Manual 810470 69

Operate the Plasma System

Step 6 – Adjust the output current (A) and operating mode if necessary

1. Make sure that the output current (A) is correct for your application.

 The plasma power supply automatically sets the output current related to the type of

Hypertherm cartridge that you install. For example, when you install a 65 A Hypertherm cartridge, the plasma power supply sets the output current to 65 A.

 Turn the adjustment knob as necessary to set the output current in

increments of 1 A. You can also use the hand torch to set the output current. Refer to page 71.

 Move the torch-lock switch to the green “ready to fire” ( ) position

before you adjust the output current.

When you adjust the current, a scale identifies the lowest and highest possible amperage setting related to the plasma power supply and Hypertherm cartridge.

2. Make sure that the operating mode is correct for your application.

 The plasma power supply automatically sets the operating mode related to the type of

Hypertherm cartridge that you install.

 When you install a Hypertherm cutting cartridge, the plasma power supply goes to

Cut mode. Gouge mode is not available.

 When you install a Hypertherm gouging cartridge, the plasma power supply goes to

Gouge mode. Cut mode and Expanded Metal mode are not available.

 You can adjust the operating mode manually if necessary. Refer to page 75. Move the

torch-lock switch to the green “ready to fire” ( ) position before you set the operating mode.

 The plasma power supply also automatically sets the gas pressure for optimum cutting

related to the operating mode, the torch type, the Hypertherm cartridge type, and the length of the torch lead.

70 810470 Operator Manual Powermax65/85/105 SYNC

Step 7 – Use the SmartSYNC torch

Use the hand torch

Use the methods in the following sections to cut and gouge correctly:

 Cut with the Hand Torch on page 93  Gouge with the Hand Torch on page 111

Adjust the amperage from the hand torch

The plasma power supply automatically sets the output current (A) related to the type of Hypertherm cartridge that you install. For example, when you install a 65 A Hypertherm cartridge, the plasma power supply sets the output current to 65 A.

If necessary, you can adjust the output current (A) from the SmartSYNC hand torch.

Operate the Plasma System

Push the button on the amperage

-adjustment control to move the current setting from one preset amperage to another.

The amperage for each setting changes related to the Hypertherm cartridge and plasma power supply that you are using. Refer to Amperage settings by plasma

power supply and cartridge on page 72.

Powermax65/85/105 SYNC Operator Manual 810470 71

Operate the Plasma System

Amperage settings by plasma power supply and cartridge

Powermax65 SYNC

Cartridge type

45 A 65 A

35 A 60 A

25 A 55 A

45 A

Powermax85 SYNC

Powermax105 SYNC

20 A

35 A

25 A

20 A

Cartridge type

45 A 65 A 85 A

35 A 55 A 75 A

30 A 50 A 65 A

45 A 55 A

35 A 45 A

25 A

35 A

25 A

Cartridge type

45 A 65 A 85 A 105 A

35A55A75A95A

50 A 65 A 85 A

45 A 55 A 65 A

72 810470 Operator Manual Powermax65/85/105 SYNC

30 A

35 A 45 A 55 A

35 A 45 A

30 A

30 A 30 A

Use the machine torch

Green = torch is

prepared to cut

Yel lo w = torch is locked, or there is a fault condition

LED OFF = system is

in Cut mode

LED ON = system is in

Gouge mode

Red = the cartridge is at end-of-life, or an internal system component is possibly faulty

Use the methods in the Powermax65/85/105 SYNC Mechanized Cutting Guide (810480) to cut and gouge correctly.

What occurs during and after cutting

Temperature control

Postflow – After you complete a cut and release

the torch trigger, air continues to flow from the torch to decrease the temperature of the cartridge. This is referred to as postflow.

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.

Operate the Plasma System

Hand torch LED behavior

Powermax65/85/105 SYNC Operator Manual 810470 73

Operate the Plasma System

Adjust the gas pressure manually

In automatic gas pressure mode, the plasma power supply automatically sets the gas pressure for optimum cutting related to the operating mode, the torch type, the Hypertherm cartridge type, and the length of the torch lead. But if it is necessary to adjust the gas pressure for a specific application, you can use manual gas pressure mode to do so.

Manual gas pressure mode must be used only by experienced operators.



1. Move the torch-lock switch to the green “ready to fire” ( ) position.

2. Push and hold until the green LED next to the button comes on to go into manual gas

pressure mode (approximately 2 seconds).

3. If necessary, push until the selection cursor points to the gas pressure setting.

4. Turn the adjustment knob to adjust the gas pressure to the necessary level. The arrow next to the pressure bar moves up and down as you adjust the pressure.

In many conditions, you can increase and decrease the gas pressure a maximum of 0.7 bar (10 psi). The acceptable range can change if the cartridge you are using has a smaller limit. If the bottom of the vertical bar is shaded, as shown to the right, the system does not let you decrease the gas pressure below the top of the shaded area.

74 810470 Operator Manual Powermax65/85/105 SYNC

Go back to automatic gas pressure mode

To go back to automatic gas pressure mode, push . The LED next to the button goes off. The system also goes back to automatic gas pressure mode when you install a different type of

cartridge.

 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, but the amperage setting stays the same.

 When you change from automatic gas pressure mode to manual gas pressure mode,

the plasma power supply uses the last manual gas pressure that you set, and the amperage setting stays the same.

 When you do a quick restart or a cold restart of the plasma power supply in manual

gas pressure mode, the plasma power supply keeps the last manual gas pressure and

amperage that you set unless you install a different type of cartridge.

Adjust the operating mode manually

Operate the Plasma System

The plasma power supply automatically sets the operating mode related to the type of Hypertherm cartridge that you install.

 When you install a Hypertherm cutting cartridge or FineCut

cartridge, the plasma power supply goes to Cut mode.

 Push the button to move from Cut mode to Expanded Metal

mode.

 Move the torch-lock switch to the green “ready to fire” ( )

position before you set the operating mode.

 Gouge mode is not available.

 When you install a Hypertherm gouging cartridge, the plasma

power supply goes to Gouge mode.

 Cut mode and Expanded Metal mode are not available.

Powermax65/85/105 SYNC Operator Manual 810470 75

Operate the Plasma System

Cut 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. A pilot arc occurs when the torch is fired but the plasma arc is not in contact with the workpiece.

Do these steps to cut expanded metal:

1. Install a Hypertherm cutting cartridge or FineCut cartridge.

2. Move the torch-lock switch to the green “ready to fire” ( )

position.

3. Push the button to move from Cut mode to Expanded Metal mode.

Go back to automatic setting of the operating mode

 When you manually set the operating mode, the plasma power supply keeps that setting

until you install a different type of Hypertherm cartridge or you install a different torch.

 Do not set the operating mode when the torch-lock switch is in the yellow lock (X)

position. When you unlock the torch, the plasma power supply automatically sets the operating mode to match the type of cartridge installed.

 If you manually set the operating mode and then replace the Hypertherm cartridge with a

new cartridge of the same type, the plasma power supply keeps the operating mode that you set.

 The plasma power supply also keeps your setting if you do a quick restart or a cold

restart.

A type of Hypertherm cartridge refers to the amperage of the cartridge



and to its application, such as gouging, standard drag-cutting, FineCut, or mechanized. Each type of Hypertherm cartridge has a different part number.

76 810470 Operator Manual Powermax65/85/105 SYNC

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. For example, you can compare data between Hypertherm cartridges if one cartridge had significantly better life than another cartridge, or if you want to calculate the average cartridge life over a period of time.

You can also use the Hypertherm cartridge reader accessory to monitor Hypertherm cartridge use. Refer to the Powermax65/85/105 SYNC

Dashboard User Guide (811460).

To see this information, go to the Cartridge Data screen (CARTRIDGE DATA 1):

1. Push and hold for 2 seconds to go to the main menu screen.

2. Turn the adjustment knob to go to . Push to select it.

Operate the Plasma System

Hypertherm Cartridge for Powermax SYNC Reader and

3. Turn the adjustment knob to go to , and push to select it. The Cartridge Data screen (CARTRIDGE DATA 1) shows.

4. When you are done, push the button to go back to the status screen.

The following fields show the use data for the installed Hypertherm cartridge:

STA – This field shows the total number of pilot arc starts that the Hypertherm cartridge has done in

its life.

XFR – This field shows the total number of arc transfers that the Hypertherm cartridge has done in

its life.

Powermax65/85/105 SYNC Operator Manual 810470 77

Operate the Plasma System

PT – This field shows the cumulative pilot arc time that the Hypertherm cartridge has had in its life,

in hours (HH), minutes (MM), and seconds (SS): HH:MM:SS.

XT – This field shows the cumulative arc transfer time that the Hypertherm cartridge has had in its

life, in hours (HH), minutes (MM), and seconds (SS): HH:MM:SS.

You can see this same data for the life of the plasma power supply. Refer to Power Supply Data

screen on page 162.

Show cartridge data on the status screen

You can show the cartridge data for pilot arc starts (STA) and arc transfer time (XT) on the status screen. When you set the STA/XT field to on, these values stay on the status screen until you set the STA/XT field to off.

1. Push and hold for 2 seconds to go to the main menu screen.

2. Turn the adjustment knob to go to . Push to select it.

3. Turn the adjustment knob to go to , and push to select it. The LCD Display screen

(LCD DISPLAY) shows.

4. Turn the adjustment knob to go to the STA/XT field, and push to select it.

78 810470 Operator Manual Powermax65/85/105 SYNC

5. Turn the adjustment knob to set the STA/XT field to on: .

6. Push to apply the setting.

7. Push to go back to the status screen.

The STA and XT fields now show on the screen.

Operate the Plasma System

Powermax65/85/105 SYNC Operator Manual 810470 79

Operate the Plasma System

LED is red

LED flashes yellow

When to replace the cartridge (fault code 0-32-n)

The system has a cartridge end-of-life detection feature that tells you when to install a new Hypertherm cartridge. This feature helps to prevent damage to the torch. You can choose to replace the cartridge before it gets to this condition if the cut quality is no longer satisfactory. Refer to Get

the most out of your cartridges on page 106.

When it is necessary to replace a cartridge, replace the full cartridge with a new one. Do not try to disassemble the cartridge. No maintenance is necessary on the cartridge except possibly to

remove molten metal from the tip of the cartridge.

The 0-32-0 and 0-32-1 fault codes identify the cartridge end-of-life condition, as follows:

 The 0-32-0 fault code shows when the system first senses that the Hypertherm cartridge is

at end-of-life. The LED on the hand torch also changes to red. To remove the fault code, install a new cartridge.

 If you restart the system and try to use the same cartridge, the 0-32-1 fault code shows

to remind you that the cartridge is at end-of-life. The LED on the hand torch also flashes yellow. Hypertherm strongly recommends that you install a new cartridge.

 If you continue to try to cut with a cartridge that is in an end-of-life condition, the 0-32-0

fault code shows again and stops the torch from firing.

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Conditions when cartridge end-of-life detection is disabled

The plasma power supply temporarily disables the Hypertherm cartridge end-of-life detection feature when one of the following conditions occurs:

 You install a FineCut hand cutting cartridge.  You set the output current below 40 A for any type of Hypertherm cartridge.

Prevent overheating

The duty cycle ratings help you to know how to operate a Powermax system without overheating it.

Duty cycle – Percentage of time during a 10-minute interval that a plasma arc can stay on without

causing the plasma power supply to overheat. For a complete list of duty cycle specifications for all of the plasma power supply

configurations, refer to the following sections:

 Powermax65 SYNC: Refer to Powermax65 SYNC on page 22.

Operate the Plasma System

 Powermax85 SYNC: Refer to Powermax85 SYNC on page 24.  Powermax105 SYNC: Refer to Powermax105 SYNC on page 26.

Table 14 – Duty cycle example for a Powermax65 SYNC

Output current Duty cycle*

Powermax65 SYNC

65 A 50% 46 A 100%

* Assumes ambient operating temperature of 40°C (104°F).

If you cut for more than the recommended duty cycle and the plasma power supply overheats, the following occurs:

 The plasma arc stops.

 The temperature fault icon comes on.

 The cooling fan inside the plasma power supply continues to operate.

When the plasma power supply overheats, do the following:

 Leave the plasma power supply on to let the fan cool the plasma power supply.  Wait for the temperature fault icon to go off before you start to cut again.

Powermax65/85/105 SYNC Operator Manual 810470 81

Operate the Plasma System

Decrease arc stretch

Stretching the plasma arc for long periods decreases the duty cycle. Whenever possible, drag the torch on the workpiece. Refer to Start

a cut from the edge of the workpiece on

page 98.

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).

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Adjust brightness and contrast

Do the following to adjust the brightness and contrast of the liquid-crystal display (LCD) screen:

1. Push and hold for 2 seconds to go to the main menu screen.

2. Turn the adjustment knob to go to . Push to select it.

3. Turn the adjustment knob to go to , and push to select it. The LCD Display screen

(LCD DISPLAY) shows.

Operate the Plasma System

4. Turn the adjustment knob to adjust the value in the field to increase or decrease the

brightness of the LCD screen.

Push to enter the value.

 0 = Darkest setting  9 = Brightest setting

5. Adjust the value in the field to increase or decrease the contrast of the LCD screen.

 0 = Lowest contrast  9 = Highest contrast

When you are done, push the button to go back to the status screen.

Powermax65/85/105 SYNC Operator Manual 810470 83

Operate the Plasma System

Controls and indicators on the plasma power supply

Cutting controls

Status screen – By default, this screen shows system status information. It also

shows fault codes and fault icons when faults occur. In different modes, this screen changes to show different kinds of

information about the plasma power supply, SmartSYNC torch, and Hypertherm cartridge.

Adjustment knob – Turn this knob to adjust the output current in increments of

1A. You can also use this knob to increase or decrease the gas pressure. Refer

to Adjust the gas pressure manually on page 74.

Fault LED (yellow) – When this LED is on, it shows that there is a fault condition

with the plasma power supply. This LED also comes on when the torch is set to the yellow lock (X)

position. Refer to page 65.

Automatic / manual gas pressure setting mode selector – Push and hold

this button until the green LED comes on to go into manual gas pressure

mode (approximately 2 seconds). Push the button again to go back to automatic gas pressure mode. Refer to page 75.

Manual gas pressure mode must be used only by



experienced operators.

In some conditions, you can push this button to immediately go from the screen that you are on to the status screen.

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Operate the Plasma System

Amperage / gas selector – Push this button in manual gas pressure mode to

select amperage or gas pressure for manual adjustments. The selection cursor identifies whether amperage or gas pressure is

selected. You can also push and hold this button for 2 seconds to go to the main

menu screen. Refer to page 88.

Operating mode button – The plasma power supply automatically sets the

mode to Cut mode or Gouge mode related to the type of Hypertherm cartridge that you install. With a Hypertherm cutting cartridge installed, you can push this button to change from Cut mode to Expanded Metal mode. Refer to page 75 for more information.

When you install a Hypertherm gouging cartridge, Cut mode and Expanded Metal mode are not available. When you install a Hypertherm cutting cartridge, Gouge mode is not available.

Expanded Metal mode. Use this mode with a Hypertherm cutting cartridge to cut expanded metal with a continuous pilot arc. Refer to page 76.

Cut mode. Use this mode with a Hypertherm cutting cartridge for most cutting and piercing applications.

Gouge mode. Use this mode with a Hypertherm gouging cartridge for gouging applications.

You can also use this button to go into gas test mode. Refer to page 151.

Power ON LED (green) – When this LED is on, it shows that the power switch is

set to ON (I) and the plasma power supply is prepared to cut.

If the LED flashes, this identifies a fault condition. Refer to Fault codes on page 132.

Powermax65/85/105 SYNC Operator Manual 810470 85

Operate the Plasma System

Status screen

By default the status screen shows system status information.

Torch started – This icon shows that the torch has received a start signal and has

started a pilot arc.

Torch is transferring – This icon shows that the plasma arc transferred to the

workpiece and the torch is cutting or gouging.

System process – This icon shows the maximum output current (A) of the

Hypertherm cartridge. If there are no cartridge communications with the plasma power supply, this icon

does not show on the status screen.

Current setting (amperage) – This is the current at which the plasma power supply

will cut or gouge, in amperage. Use either the adjustment knob on the plasma power supply or the

amperage-adjustment control on the hand torch to change the output current. Installing a Hypertherm cartridge of a different amperage also changes the current setting.

Non-default configuration – This icon shows that at least one default system setting

has been changed.

Remote control – This icon shows that a CNC or other controller is controlling the

plasma power supply. The front panel controls are disabled during remote mode operation. But fault codes and fault icons still show as they would otherwise, and you can go to the menu screens to see information about the plasma power supply, torch, and cartridge.

Cartridge data – These fields show the total number of pilot arc starts (STA) and the

cumulative plasma arc transfer time (XT) for the life of the Hypertherm cartridge that is installed on the torch. These fields do not show by default. Refer to

page 78.

86 810470 Operator Manual Powermax65/85/105 SYNC

Gas pressure indicators

For instructions on how to manually change the gas pressure, refer to page 74.

Gas pressure bar – This icon shows a visual indicator of the gas pressure when you

are in manual gas pressure mode. The midpoint of the vertical bar identifies the automatic pressure setting that is

set by the plasma power supply. The arrow shows the manual pressure setting, as follows:

Operate the Plasma System

 When you increase (+) the gas pressure from the set value, the arrow goes

above the midpoint.

 When you decrease (-) the gas pressure from the set value, the arrow goes

below the midpoint.

Gas pressure setting – The gas pressure shows in bar and psi when you are in

manual gas pressure mode.

Selection cursor – This icon shows whether amperage or gas pressure is selected

when you are in manual gas pressure mode.

Fault codes and fault icons

When a fault occurs with the plasma power supply or the torch, a fault code and related fault icon show on the status screen. For information on what each fault code means and how to

remove it, refer to Fault codes on page 132.

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Operate the Plasma System

Main menu screen

Use the main menu screen to go to the 4 submenu screens. Use the submenu screens to see information about the plasma power supply, torch, and Hypertherm cartridge, and to change system settings.

1. To go to the main menu screen, push and hold for 2 seconds.

2. Turn the adjustment knob to go to an icon on the screen.

3. Push to select the icon.

Cartridge and plasma power supply data – Select this icon to go to use data and

other information about the Hypertherm cartridge and the plasma power supply.

Refer to page 89.

System information – Select this icon to go to service-related information about

printed circuit boards (PCBs) in the plasma power supply and in the SmartSYNC torch. Refer to page 90.

Service – Select this icon to go to service-related information about fault codes, radio

frequency (RF) settings and logs, and cut counter transfers. Refer to page 91.

Settings – Select this icon to go to system settings that you can change, such as the

brightness and contrast of the LCD screen. Refer to page 92.

Back – Select this icon to go back to the screen you were on before.

Tip: Push the button to immediately go back to the status screen.

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Operate the Plasma System

Cartridge and Power Supply Data submenu

To go to the Cartridge and Power Supply Data submenu, select on the main menu screen.

Cartridge data – Select this icon to see data about the Hypertherm cartridge that is

installed on the torch. Refer to Monitor cartridge data on page 77.

Plasma power supply data – Select this icon to see data about plasma power supply

use and performance. Refer to Power Supply Data screen on page 162.

Cartridge history – Select this icon to see cumulative cartridge start data for the life

of the plasma power supply. Refer to Cartridge History screen on page 164.

Back – Select this icon to go back to the main menu screen.

Tip: Push the button to immediately go back to the status screen.

Powermax65/85/105 SYNC Operator Manual 810470 89

Operate the Plasma System

System Information submenu

To go to the System Information submenu, select on the main menu screen.

LCD/control PCB information – Select this icon to see service-related information

about the firmware on the plasma power supply’s LCD/control PCB.

DSP and power PCB information – Select this icon to see service-related

information about the plasma power supply’s power PCB and the firmware on the DSP PCB.

Torc h in fo r ma tio n – Select this icon to see service-related information about the

SmartSYNC torch that is connected to the plasma power supply. Refer to Torc h

PCB Information screen on page 167.

Back – Select this icon to go back to the main menu screen.

Tip: Push the button to immediately go back to the status screen.

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Operate the Plasma System

Service Information submenu

To go to the Service Information submenu, select on the main menu screen.

Power supply fault log – Select this icon to see the 10 most recent fault codes that

have occurred on the plasma power supply. Refer to See recent fault codes

(Power Supply Log screen) on page 150.

The plasma power supply does not show operational fault codes (0-nn-n) on this screen.

Radio frequency information – Select this icon to see service-related information

about radio frequency (RF) settings and logs. This information is for qualified service technicians.

Cut counters transfer – Select this icon to do a transfer of cut counter data before

installing a new DSP PCB. This feature is for qualified service technicians.

Back – Select this icon to go back to the main menu screen.

Tip: Push the button to immediately go back to the status screen.

Powermax65/85/105 SYNC Operator Manual 810470 91

Operate the Plasma System

System Settings submenu

To go to the System Settings submenu, select on the main menu screen.

Brightness and contrast – Select this icon to adjust the brightness and contrast of

the LCD screen or to show cartridge data on the status screen. Refer to Adjust

brightness and contrast on page 83 or Show cartridge data on the status screen on page 78.

CNC interface settings – Select this icon to see the node address given to this

Powermax plasma power supply (if applicable). Refer to CNC Interface Settings

screen on page 170.

System configuration settings – Select this icon to set system features to on or off,

such as the low gas pressure detection feature. Refer to Adjust system settings

on the Feature Configuration screen on page 153.

Back – Select this icon to go back to the main menu screen.

Tip: Push the button to immediately go back to the status screen.

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Cut with the Hand Torch

This section gives an overview of hand torch parts, dimensions, cartridges, cutting guidelines, and basic cutting methods.

 For gouging information, refer to Gouge with the Hand Torch on page 111.  To correct problems with cut quality, refer to Common problems on page 123.

Powermax65/85/105 SYNC Operator Manual 810470 93

Cut with the Hand Torch

About the hand torch

SmartSYNC hand torches come in 75° and 15° models.

 The 75° hand torch is a general purpose torch

designed for the widest range of applications.

 The 15° hand torch is designed to point heat

away from the operator during heavy gouging. It also makes it easier to cut overhead or in areas that are not easy to reach.

SmartSYNC hand torch features include the following:

 A control on the torch that lets you adjust the output current (A) from the torch (refer to

Adjust the amperage from the hand torch on page 71)

 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, including cartridge

end-of-life detection (refer to Cartridge Data screen on page 160 and Power Supply Data

screen on page 162)

 A torch-lock switch that prevents the torch from firing accidentally, even when the plasma

power supply is ON (refer to Step 5 – Unlock the SmartSYNC torch on page 68)

 The FastConnect quick-disconnect system that lets you easily remove the torch to move the

system or to change from one torch to another

For information about the thicknesses you can cut and pierce with a SmartSYNC hand torch, refer to Cutting specifications on page 33.

94 810470 Operator Manual Powermax65/85/105 SYNC

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

Drag-cutting (yellow)

Cut with the Hand Torch

Use these cartridges to drag the torch on the workpiece (drag-cut) for the widest range of cutting applications.

FineCut (yellow)

FlushCut (black)

 For a full list of the cutting and gouging cartridges available, refer to the

hand

Use these cartridges to get a narrower kerf on thin mild steel and stainless steel up to 3 mm (10 gauge).

Use these cartridges to remove lugs, bolts, pad eyes, and other attachments without piercing or damaging the workpiece below.

Powermax65/85/105 SYNC Parts Guide (810490).

 If your preference is to keep a standoff while cutting, you can use the gray mechanized

cutting cartridges on your SmartSYNC hand torch.

 For information on gouging processes and cartridges, refer to Gouge with the Hand Torch

on page 111.

 Plasma power supplies are shipped with a starter set of Hypertherm cartridges.

For help installing the cartridge, refer to Step 3 – Install the cartridge on



page 64.

Powermax65/85/105 SYNC Operator Manual 810470 95

Cut with the Hand Torch

Prepare to fire the torch

INSTANT-ON TORCHES – PLASMA ARC CAN CAUSE INJURY, BURNS

Ignition of the plasma arc occurs immediately when you pull the torch trigger. Before changing the cartridge, one of the following steps is necessary. Whenever possible, complete the first step.

 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.

WARNING

INSTANT-ON TORCHES – STAY CLEAR OF PLASMA ARC

The plasma arc will cut quickly through gloves and skin.

 Put on correct and approved protective equipment.  Keep hands, clothing, and objects away from the torch tip.  Do not hold the workpiece. Keep your hands clear of the cutting path.  Never point the torch toward yourself or others.

WARNING

RISK OF BURNS AND ELECTRIC SHOCK – USE INSULATED GLOVES

Always put on insulated gloves when changing the cartridges. The cartridges get very hot during cutting and can cause severe burns.

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.

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Cut with the Hand Torch

To prevent accidental firing, the hand torch has a torch-lock switch and a safety trigger. To fire the torch, do the following:

1. Install the correct cartridge. Refer to Step 3 – Install the cartridge on page 64. When you install a Hypertherm cutting cartridge, the system goes to

Cut mode.

 To change the mode from Cut mode to Expanded Metal mode,

push the button.

When you install a cutting cartridge, Gouge mode is not available.



2. Make sure that the torch-lock switch is in the green “ready to fire” ( ) position.

The first time that you pull the



torch trigger after you set the torch to the “ready to fire” position, multiple puffs of air quickly come from the torch. This is a warning that the torch is active and will fire an arc the next time that you pull the trigger. Refer to Warning puffs of air

(hand torches) on page 68.

3. Flip the trigger’s safety cover forward (toward the torch head) and pull the red torch trigger.

After you complete a cut and



release the torch trigger, air continues to flow from the torch to decrease the temperature of the cartridge. This is referred to as postflow.

Always let postflow complete before you remove a cartridge.

Powermax65/85/105 SYNC Operator Manual 810470 97

Cut with the Hand Torch

Start a cut from the edge of the workpiece

Slag produced during piercing can cause damage to the tip of the cartridge. Start the cut from the edge of the workpiece, when possible, to decrease this damage and to optimize cartridge life.

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.

98 810470 Operator Manual Powermax65/85/105 SYNC

Cut with the Hand Torch

3. Drag the torch lightly across the workpiece to continue with the cut. Keep a smooth, stable pace.

Powermax65/85/105 SYNC Operator Manual 810470 99

Cut with the Hand Torch

30°

Pierce a workpiece

SPARKS AND HOT METAL CAN INJURE EYES AND BURN SKIN

When firing the torch at an angle, sparks and hot metal will spray out from the torch tip. Point the torch away from yourself and others. Always put on correct protective equipment including gloves and eye protection.

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 plasma power supply. (Refer to

Recommended pierce capacity on page 33.)

 Straight pierce – Use a straight pierce to cut a workpiece that is thinner than 8 mm

(5/16 inch). If a straight pierce does not pierce the workpiece, try a rolling pierce.

 Rolling pierce – Use a rolling pierce to cut a workpiece that is 8 mm (5/16 inch) or thicker,

or if a straight pierce does not pierce the workpiece.

WARNING

1. Attach the work clamp to the workpiece.

2. Straight pierce: Hold the torch perpendicular (90°) to the workpiece.

Rolling pierce: Hold the torch at an approximate 30° angle to the workpiece with the torch tip touching the workpiece before firing the torch.

100 810470 Operator Manual Powermax65/85/105 SYNC

Hypertherm Manual Family Operator Manual (OM)

Specifications and Main Features

Frequently Asked Questions

User Manual

Contents

Electromagnetic Compatibility (EMC)

Warranty

Where to Find Information

Install and Set Up the Plasma Power Supply

Make sure that you have all the system components

What to do if components are missing or damaged

System configurations

Hypertherm plasma power supply ratings

Powermax65 SYNC

Powermax85 SYNC

Powermax105 SYNC

Find system specifications on the data plate

Find the part number for your system

Critical raw materials

Symbols and marks

IEC symbols

Acoustical noise levels

Radio frequency identification (RFID) specifications

Cutting specifications

Recommended cut capacity – hand cutting

Recommended pierce capacity

Maximum cut speeds (mild steel)

Gouge capacity

Set up the plasma power supply

Plasma power supply dimensions and weights

Powermax65 SYNC and Powermax85 SYNC

Powermax105 SYNC

Work lead weights

Connect to electrical power

Install a line-disconnect switch

Requirements for grounding

Rated output (cutting power) of the plasma power supply

Voltage configurations

Powermax65 SYNC

Powermax85 SYNC

Powermax105 SYNC

Prepare the power cord and plug

Install the power plug

Install the power cord (if necessary)

Install a 1-phase power cord (CSA systems only) (if necessary)

Use an extension cord (if necessary)

Powermax65 SYNC systems

Powermax85 SYNC systems

Powermax105 SYNC systems

Use a generator (if necessary)

Powermax65 SYNC and Powermax85 SYNC systems

Powermax105 SYNC systems

Connect the gas supply

Gas supply source

High-pressure gas cylinders

Inlet gas pressure requirements (while gas is flowing)

Maximum inlet pressure

Optimum inlet pressure

Minimum inlet pressure

Cutting

Maximum Control gouging

Maximum Removal gouging

Recommended gas inlet flow rates

Add additional gas filtration (if necessary)

Operate the Plasma System

Make sure that the plasma power supply is connected to gas and power

Step 1 – Connect the torch lead

Step 2 – Connect the work lead and work clamp

Work lead

Work clamp

Step 3 – Install the cartridge

Lock the torch

Install the cartridge

Step 4 – Set the power switch to ON (I)

Step 5 – Unlock the SmartSYNC torch

Warning puffs of air (hand torches)

Fault code and LED behavior

Step 6 – Adjust the output current (A) and operating mode if necessary

Step 7 – Use the SmartSYNC torch

Use the hand torch