Hypertherm Cartridge for Powermax SYNC
Reader and Dashboard User Guide
™
811460 – REVISION 0
ENGLISH
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Hypertherm Cartridge for Powermax SYNC
Reader and Dashboard User Guide
811460
ENGLISH
Original instructions
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.
Contents
Introduction............................................................................................................................................................. 7
Before you begin....................................................................................................................................... 7
Cartridge Reader app basics................................................................................................................. 8
Get data from cartridges..................................................................................................................................... 8
Scan a cartridge........................................................................................................................................ 8
Scan multiple cartridges........................................................................................................................ 10
Use labels to put records in categories............................................................................................. 11
Change a label for an existing record..................................................................................... 12
Select a label before you begin a scan.................................................................................. 12
Delete a label ............................................................................................................................... 13
View cartridge data saved in the app............................................................................................................. 14
About the cartridge data ....................................................................................................................... 14
Filter records ............................................................................................................................................ 17
Clear the filters............................................................................................................................. 17
View graphs of cartridge data.............................................................................................................. 18
Export data................................................................................................................................................ 18
Delete all records.................................................................................................................................... 19
Analyze cartridge data with the Cartridge Dashboard ............................................................................... 20
Import data from the app into the dashboard (CSV Data Input sheet)...................................... 20
View and filter imported cartridge data (Summary Report with Filters sheet) .......................... 23
Use the Cartridge Summary Report ................................................................................................... 24
Percentage of pilot arc starts that transferred...................................................................... 25
Cartridge usage data ................................................................................................................. 27
Top 5 fault codes......................................................................................................................... 28
Get the most out of your cartridges ............................................................................................................... 29
Get help ................................................................................................................................................................ 30
Troubleshoot a fault code...................................................................................................................... 30
See answers to common questions ................................................................................................... 31
Change the language used in the app............................................................................................... 31
Contents
Hypertherm Cartridge for Powermax SYNC Reader and Dashboard User Guide 811460 5
Contents
6 811460 Reader and Dashboard User Guide Hypertherm Cartridge for Powermax SYNC
Introduction
1
2
3
This guide gives you instructions for how to use the Hypertherm Cartridge Reader, Cartridge
Reader app, and Cartridge Dashboard.
Before you begin
Make sure that you have the Cartridge Reader, Cartridge Reader app, and Cartridge Dashboard.
Make sure that you know the location of the near-field communication (NFC)
antenna on your smartphone. Also make sure that the NFC antenna is enabled in
your smartphone settings. Refer to the operator manual for your smartphone.
1 Cartridge Reader The Cartridge Reader gives you access to the data stored on
a cartridge.
2 Cartridge Reader app The Cartridge Reader app lets you copy and save data from
a cartridge into the app. In the app, you can view, graph, and
export the data.
3 Cartridge Dashboard The Cartridge Dashboard is an Excel spreadsheet that lets
you filter and graph cartridge data from the app.
Order the Cartridge Reader kit (528083) from Hypertherm and read the instructions that
come with the kit.
Download and install the Hypertherm Cartridge Reader app from your app store.
Download the Cartridge Dashboard. Go to
https://www.hypertherm.com/hypertherm/accessories/cartridge-reader. Under Accessory
information, expand Resources. Download the Excel Data Analysis Tool for Hypertherm
Cartridge.
Hypertherm Cartridge for Powermax SYNC User Guide 811460 7
Cartridge Reader app basics
Home screen
1
2
3
4
1 Tap to view the main menu.
2 Tap to begin scanning a cartridge.
3 Tap to go to the home screen.
4 Tap to view scanned cartridge data saved in the app.
1
Get data from cartridges
Cartridges used with Powermax65/85/105 SYNC plasma power supplies
and SmartSYNC torches save data. Cartridges used on older systems
and torches with a cartridge adapter do not save data.
Scan a cartridge
When you scan a cartridge, the app saves the cartridge data as a record.
1. Put the Cartridge Reader fully into the Hypertherm
cartridge.
2. Hold the Cartridge Reader and cartridge together in
one hand.
3. On the home screen, tap Tap t o Scan .
If you scan the same cartridge more than one time, the app only saves the
most recent record.
4. Put the NFC antenna of your smartphone directly on
the Hypertherm H on the Cartridge Reader.
8 811460 User Guide Hypertherm Cartridge for Powermax SYNC
5. Do one of the following:
2
2
3
4
1
2
3
4
2
Android
iPhone
a. (Android phone) The app scans the cartridge and shows a notification. Tap Done .
b. (iPhone) Tap Start Scan . The app scans the cartridge and shows a notification. On the
Ready to Scan screen, tap Cancel . Then tap Done .
Hypertherm Cartridge for Powermax SYNC User Guide 811460 9
Scan multiple cartridges
1
2
2
123
Android iPhone
3
3
1. Put the silicon band that came with the Cartridge
Reader into the slots on the edges of the Cartridge
Reader.
2. Put the band around your smartphone so that the
Hypertherm H on the Cartridge Reader is on the
NFC antenna of your smartphone.
3. Put the cartridges that you want to scan in a row on a flat surface.
4. On the home screen, tap Tap t o Scan .
5. Do one of the following:
a. (Android phone) One at a time, put the cartridges into the Cartridge Reader. The app scans
each cartridge and shows a notification.
b. (iPhone) Tap Start Scan. One at a time, put the cartridges into the Cartridge Reader. The
app scans each cartridge and shows a notification. When you are done scanning cartridges,
tap Cancel on the Ready to Scan screen.
6. Ta p Done.
7. The app saves the data for each cartridge as a record.
Cartridges used with Powermax65/85/105 SYNC plasma power supplies
and torches save data. Cartridges used on older systems and torches
with a cartridge adapter do not save data.
10 811460 User Guide Hypertherm Cartridge for Powermax SYNC
Use labels to put records in categories
Labels let you put records into categories that are meaningful to you, such as operators, shifts,
cutting stations, and systems. You can then filter and sort the records by these categories. For
example, you may want to compare the records of a new operator with the records of an
experienced operator. Or you may want to compare the performance of cartridges used for different
jobs.
By default, records are identified by the following:
Unique identification (ID) number of the cartridge
Cartridge part number and description
The label Default and the time of the scan
You can change the Default label for existing records. You can also select a label before you begin a
scan and the app will automatically save the label with every record that you scan. Once you select
a label, that label stays the default label until you change it.
Labels are only saved in the app. They are not written to the cartridge.
Hypertherm Cartridge for Powermax SYNC User Guide 811460 11
Change a label for an existing record
1. On the home screen, tap Records.
2. Tap the label that you want to change.
3. On the Label List screen, do one of the following:
To use an existing label, tap the label.
To create a new label, type the new label in the box and then tap Add. Then tap Close.
The label that you select stays the default label until you change it.
Select a label before you begin a scan
1. On the home screen, tap Tap to Sc a n.
2. Tap Label or tap the add-labels icon ( ).
3. On the Label List screen, do one of the following:
To use an existing label, tap the label.
To create a new label, type the new label in the box and then tap Add. Then tap Close.
You can add all the new labels that you need at once on the Label List
screen.
12 811460 User Guide Hypertherm Cartridge for Powermax SYNC
Delete a label
When you delete a label, the app removes the label from the Label List screen. The app does not
remove the label from existing records that use that label.
1. On the home screen, tap Tap t o Scan .
2. Ta p Label.
3. On the Label List screen, do one of the following:
To delete 1 label, tap the delete icon ( ).
To delete all of the labels at once, tap Delete All.
4. Ta p Close.
Hypertherm Cartridge for Powermax SYNC User Guide 811460 13
View cartridge data saved in the app
2
3
4
1
Cartridge ID
1 Unique ID number of the cartridge
2 Cartridge part number and description
3 Date and time of the scan
4 Label selected for this scan
1
When you scan a cartridge, the app saves the cartridge data as
a record for the date and time of the scan.
If you scan the same cartridge more than one time, the
app only saves the most recent record.
1. On the home screen, tap Records.
2. Tap the record you want to view. The record details screen
appears.
About the cartridge data
Cartridge data gives you insight into cartridge usage and performance trends. Cartridge data also
helps you identify system, setup, operator, and cutting environment issues.
The record details screen shows the cartridge information that is measured and tracked.
14 811460 User Guide Hypertherm Cartridge for Powermax SYNC
3
4
Cartridge Use Data
1 Total number of pilot arc starts (number of times the
torch was fired)
2 Total number of arc transfers (number of times the
arc transferred to the workpiece)
3 Percentage of pilot arc starts that transferred to the
workpiece
4 Cumulative time in hours, minutes, and seconds that
there was a pilot arc
5 Cumulative time in hours, minutes, and seconds that
the arc was in contact with the workpiece
6 Combined total of pilot arc time and arc transfer time
7 Whether the cartridge has had an 0-32-0 or 0-32-1
fault, both of which identify end of life
2
1
5
6
7
Cartridge Fault Record
Shows the 4 most recent faults that occurred while
the cartridge was installed.
Fault Log 1 is the newest. If a fault did not occur, the
log shows 0-00-0.
For more information about fault codes, refer to
Troubleshoot a fault code on page 30.
Hypertherm Cartridge for Powermax SYNC User Guide 811460 15
Last Use Settings
3
4
2
1
5
Shows information about the most recent system and
settings used while the cartridge was installed.
1 Plasma power supply type
2 Torch type and lead length
3 Output current (A) setting
4 Gas pressure (PSI) setting
5 Operating mode (cut, expanded metal, or gouge)
Cartridge Information
Shows basic cartridge information from the factory.
• Part number and revision
• Manufacture date and test
• RFID tag part number, revision, and ID
16 811460 User Guide Hypertherm Cartridge for Powermax SYNC
Filter records
1. On the records screen, tap the actions menu (⋮) and then tap Filter.
2. Select the values for which you want to view records, and then tap Apply.
Clear the filters
When records are filtered, the records screen shows the
number of filtered records.
1. On the records screen, tap the actions menu (
then tap Filter.
2. Ta p Reset.
⋮) and
Hypertherm Cartridge for Powermax SYNC User Guide 811460 17
View graphs of cartridge data
Graphs let you view the combined data for all of the records
shown on the records screen.
If you filter the records on the records screen, only
the data for the filtered records is included in the
graphs.
1. On the records screen, tap the actions menu (⋮) and
then tap Graph.
2. The following graphs are available. Select the graph you
want to view.
Starts Counter
Tran sfer C ounter
Tran sfer Time
Number of Cartridges by Type
Average Transfer Performance
Top 10 Fault Codes
3. To go back to the records screen, tap the back arrow.
Export data
You can export the cartridge data for all of the records shown on the records screen. The app
exports the data as a comma-separated values (*.csv) file that can be opened in any spreadsheet
tool for data analysis, including the Hypertherm Cartridge Dashboard.
If you filter the records on the records screen, only the data for the filtered
records is included in the export.
1. On the records screen, tap the actions menu (⋮) and then tap Export.
18 811460 User Guide Hypertherm Cartridge for Powermax SYNC
2. Select an app on your phone to use to share the *.csv file. In the example, an email app was
used.
Delete all records
This option deletes all of the records currently saved in the app. You
cannot delete individual records or a set of filtered records. To exclude
unwanted records from the records screen, graphs, and exports, use
labels and filters.
1. On the records screen, tap the actions menu (⋮).
2. Ta p Delete All.
Hypertherm Cartridge for Powermax SYNC User Guide 811460 19
Analyze cartridge data with the Cartridge Dashboard
Import data into the
dashboard
Review and interpret
cartridge data
Do advanced analysis
directly in the pivot table
The Hypertherm Cartridge Dashboard is a spreadsheet tool you use to import, view and filter, and
analyze cartridge data.
The Cartridge Dashboard tool has 3 spreadsheets. Do not modify the spreadsheets except as
instructed.
Import data from the app into the dashboard (CSV Data Input sheet)
The Cartridge Dashboard uses a *.csv file you export from the app. Refer to Export data on page 18.
20 811460 User Guide Hypertherm Cartridge for Powermax SYNC
1. Open the Cartridge Dashboard tool.
2. Click the CSV Data Input sheet.
3. Delete any existing data that you do not want. Delete only the data. Do not delete the rows or
Do not
delete
the column headers.
a. Start in the upper-left cell in the first row of data that you want to delete.
b. Click and drag down and across all of the cells in the rows that you want to delete.
c. Scroll to the right to make sure that you delete the data for all of the columns.
4. Open the *.csv file of cartridge data that you exported from the app.
5. Copy all of the data in the *.csv file. Copy only the data. Do not copy the rows or the column
headers.
a. Start in the upper-left cell in the first row of data.
b. Click and drag down and across all of the cells in all of the rows.
c. Scroll to the right to make sure that you copy the data for all of the columns.
Hypertherm Cartridge for Powermax SYNC User Guide 811460 21
6. On the CSV Data Input sheet of the Cartridge Dashboard tool, click in cell A2 and then paste
the data you copied from the *.csv file.
Once you paste the data, the Cartridge Dashboard updates with the new
data. It is normal for this to take some time. Do not stop the update by
closing the Cartridge Dashboard tool.
22 811460 User Guide Hypertherm Cartridge for Powermax SYNC
View and filter imported cartridge data (Summary Report with Filters sheet)
After the Cartridge Dashboard updates with the data you pasted in from the *.csv file, the Cartridge
Summary Report spreadsheet is ready to use.
You can view the Cartridge Summary Report as is or you can filter the data. You can also change the
language used in the report.
1. In the Cartridge Dashboard tool, click the Summary Report with Filters sheet.
2. To change the language used in the Cartridge Summary Report, do the following:
a. In Choose Language, click the down arrow.
b. Click the language that you want.
3. To filter the data in the Cartridge Summary Report, do the following:
a. Click the cell to the right of the filter that you want to use.
b. Click the down arrow and then click the value that you want.
The report automatically updates as you make your selections.
Hypertherm Cartridge for Powermax SYNC User Guide 811460 23
Use the Cartridge Summary Report
Percentage of pilot arc starts that
transferred to the workpiece
Cartridge usage data
Top 5 fault codes
The Cartridge Summary Report can help you identify trends in the life of your cartridges and
opportunities to improve cartridge life.
How often it is necessary to change the cartridge relates to multiple variables. For example, you
should expect a difference in cartridge life between hand-cutting and mechanized cutting. This is
because operator technique is an important variable for hand-cutting. For mechanized cutting, more
variables can be kept consistent. No two cartridges will have the same number of pilot arc starts,
arc transfers, or overall arc time.
For more information about how to improve cartridge life, refer to Get the most out of your
cartridges on page 29.
The Cartridge Summary Report has 3 sections.
24 811460 User Guide Hypertherm Cartridge for Powermax SYNC
Percentage of pilot arc starts that transferred
1
2
1
Number of pilot arc
starts
Average transfers per cartridge – This chart shows the percentage of pilot arc starts that
transferred to the workpiece (blue) and the percentage of pilot arc starts that did not transfer
(red).
Hypertherm Cartridge for Powermax SYNC User Guide 811460 25
In this chart, you want to see much more blue than red. Blue shows that when operators pull
the trigger on the torch, they transfer the arc to the workpiece and cut. Red shows that
operators are needlessly firing the torch into the air, which shortens cartridge life.
For well-trained and experienced operators using hand-cutting cartridges, you should expect
an average rate of transfers of more than 85%. An average rate of transfers that is less than
85% indicates an opportunity to improve cartridge life through operator training.
For mechanized cartridges, you should expect an average rate of transfers of more than 90%.
Averages less than 90% indicate a problem with the mechanized system.
Effect on pilot life – This chart shows the effect that pilot arc time has on cartridge life.
2
Total a rc ti me
in hours
Percentage of arc time that was a pilot arc
1
2
1
2
Each dot on the chart represents a cartridge. The position of the dot shows the relationship
between a cartridge’s total arc time (vertical axis) and the percentage of that arc time that
there was a pilot arc (horizontal axis).
The lower the percentage of arc time spent as a pilot arc, the higher the total arc time you will
get from a cartridge. In this example, cartridge had a life of more than 3 arc hours because
there was a pilot arc for less than 5% of its arc time. In contrast, cartridge only had a life of
1 hour because there was a pilot arc for more than 20% of its arc time.
For well-trained and experienced operators using hand-cutting cartridges, you should expect
1 to 2 hours of total arc time with pilot arc percentages of less than 15%. Lower total arc
times with pilot arc percentages of more than 15% indicate an opportunity to improve
cartridge life through operator training.
26 811460 User Guide Hypertherm Cartridge for Powermax SYNC
Cartridge usage data
1
2
3
4
5
1 Total cartridges scanned This shows the total number of cartridges for which data was imported into
the Cartridge Dashboard tool, and the number of cartridges for which data
is currently shown in the Cartridge Summary Report.
2 Cartridge Type This shows the combined total number of each type of cartridge for which
data is currently shown in the Cartridge Summary Report.
3 Average number of transfers
(cuts) per cartridge
This shows the combined average number of pilot arc starts that
transferred to the workpiece for the selected cartridges, and the combined
percentage of arc transfers.
4 Percentage of starts
transferred
This shows the range of percentages of pilot arc starts that transferred to
the workpiece for the selected cartridges, and the combined average
percentage of arc transfers.
5 Range of transfer time
(cutting time) per cartridge
This shows the range of times in hours, minutes, and seconds that the arc
was in contact with the workpiece for the selected cartridges, and the
combined average arc transfer time.
This section shows combined totals for the selected cartridges.
Hypertherm Cartridge for Powermax SYNC User Guide 811460 27
Top 5 fault codes
1
2
3
5
4
This section lists the five operational (0-nn-n) fault codes that occurred most frequently for the
selected cartridges.
The following information shows for each fault code:
Fault code
Total number of occurrences of the fault code
Fault code description
Troubleshooting information
Fault code troubleshooting information is also available in the app. Refer
to Troubleshoot a fault code on page 30.
28 811460 User Guide Hypertherm Cartridge for Powermax SYNC
Get the most out of your cartridges
How often it is necessary to change the cartridge on your hand torch relates to the following:
Gas supply quality
It is extremely important to keep the gas supply line clean and dry. Oil, water, vapor, and
other contamination in the gas supply can degrade cut quality and cartridge life.
Cutting technique (hand-cutting)
Fire the torch only when necessary. Do not fire the torch when you are not cutting.
Frequent pilot arcs cause the nozzle in the cartridge to wear more quickly.
Start cuts from the edge of the workpiece whenever possible. This helps to extend the
life of the cartridge.
When cutting, only stretch the arc when it is necessary. Drag the torch on the workpiece
whenever possible.
When gouging, keep distance between the torch tip and the molten metal that builds up
during the gouge.
When piercing, use the correct method for the thickness of the workpiece that you are
cutting. In many conditions, a rolling pierce method is an efficient way to pierce the
workpiece while you decrease the cartridge wear that naturally occurs during piercing.
Cutting parameters (mechanized cutting)
Make sure that the arc current, arc voltage, cut speed, cut height, and other cut settings
are correct.
Use the correct torch height and pierce delay time for piercing.
Thickness of the workpiece
In general, the thicker the workpiece being cut, the more quickly the cartridges become
worn. For best results, 80% of the workpieces that you cut should be equal to or less
than the thickness specified for this system and cartridge.
For best results, do not cut material that is thicker than what is specified for this system
and cartridge.
Expanded metal cutting and pilot arc time
Expanded metal has a slotted or mesh pattern. Cutting expanded metal wears out
cartridges more quickly because it requires a continuous pilot arc. A pilot arc occurs
when the torch is fired but the plasma arc is not in contact with the workpiece.
Make sure that the operating mode is not set to Expanded Metal mode if you are not
cutting expanded metal.
Hypertherm Cartridge for Powermax SYNC User Guide 811460 29
Get help
Troubleshoot a fault code
The app includes troubleshooting information for the operational (0-nn-n) fault codes that may
appear on the status screen of the plasma power supply.
1. Tap the main menu (
2. Tap the fault code for which you want to view troubleshooting information.
3. To go back to the home screen, tap the back arrow. Then tap the main menu (
☰) and tap Fault Codes.
☰) and tap Home.
30 811460 User Guide Hypertherm Cartridge for Powermax SYNC
See answers to common questions
1. Tap the main menu (☰) and then tap Questions and Answers.
2. Tap the question for which you want to view the answer.
3. To go back to the home screen, tap the main menu (
☰) and then tap Home.
Change the language used in the app
1. Tap the main menu (☰) and then tap Language.
2. Tap the language you want to use and then tap Apply.
Hypertherm Cartridge for Powermax SYNC User Guide 811460 31
32 811460 User Guide Hypertherm Cartridge for Powermax SYNC
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