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Serial Communication Programmer Reference Guide

Powermax65/85/105 SYNC

Reference Guide

810400 Revision 2 March 2022

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Contents

Getting started....................................................................................................................................................... 7

Hardware requirements ........................................................................................................................... 7

Powermax65/85/105 SYNC hardware documents.............................................................. 8

Modbus specifications............................................................................................................................. 8

Transmission mode and format .................................................................................................. 8

Modbus request and response message frame format........................................................ 9

Error response message frame format................................................................................... 10

Example request and response message.............................................................................. 10

How to calculate a checksum (LRC)...................................................................................... 12

CNC settings on the Powermax65/85/105 SYNC ........................................................................ 12

Powermax65/85/105 SYNC Modbus addressing system........................................................................ 15

Backward compatible with 0x2xxx series.......................................................................................... 15

List of Powermax65/85/105 SYNC addresses ............................................................................... 16

Programming recommendations...................................................................................................................... 19

Examples of requests and responses ............................................................................................................ 20

Identify the plasma power supply type (SYNC or older system) ................................................. 20

Example request and response................................................................................................ 20

Read the ID of the SYNC torch, torch lead, and plasma power supply..................................... 21

0x3000 (torch and plasma power supply identification).................................................... 21

Example request and response................................................................................................ 22

Read the part number of the installed cartridge .............................................................................. 23

0x3038, 0x3039, 0x303A (cartridge part number, bytes 0 – 5)..................................... 23

Example request and response................................................................................................ 25

Powermax65/85/105 SYNC Reference Guide 810400 3

Serial Communication Programmer Reference Guide

Read the plasma power supply settings that are permitted for the installed cartridge .......... 26

0x3001 (permitted operating mode setting)......................................................................... 26

0x3002, 0x3003 (permitted minimum and maximum output current (A) settings)...... 26

0x3004, 0x3005 (permitted minimum and maximum gas pressure settings)............... 26

Example request and response................................................................................................ 27

Write operating settings and put the plasma power supply into remote control mode.......... 28

0x3080 (operating mode setting) ........................................................................................... 28

0x3081 (output current (A) setting)........................................................................................ 28

0x3082 (gas pressure setting) ................................................................................................ 29

Example request and response................................................................................................ 29

Remote control mode indicator on the plasma power supply .......................................... 30

Do a check for an active fault............................................................................................................... 30

0x301A (active fault code)........................................................................................................ 30

Example request and response................................................................................................ 31

Fault code list............................................................................................................................... 32

Start and stop a gas test....................................................................................................................... 36

0x3180 (coil: gas test)............................................................................................................... 36

Example request and response................................................................................................ 37

Stop fault code 0-50-0.......................................................................................................................... 38

0x308E, 0x308F (stop fault code 0-50-0 with a quick restart)....................................... 38

Example request and response................................................................................................ 39

Exit remote control mode ...................................................................................................................... 40

Example request and response................................................................................................ 40

Get data from the plasma power supply ....................................................................................................... 41

Read the plasma power supply settings............................................................................................ 41

0x3010 (operating mode).......................................................................................................... 41

0x3011 (output current (A) setting)........................................................................................ 41

0x3012 (gas pressure setting)................................................................................................. 42

Example request and response................................................................................................ 42

Read the actual output of the plasma power supply ...................................................................... 43

0x3018 (actual output current)................................................................................................ 43

0x3019 (actual gas pressure).................................................................................................. 43

Example request and response................................................................................................ 43

Read the total cut counts for this plasma power supply................................................................ 44

0x3028 (total number of torch starts – bytes 1 and 0)...................................................... 44

0x3029 (total number of starts – bytes 3 and 2) ................................................................ 45

0x302A (cumulative pilot arc time – bytes 1 and 0)........................................................... 45

0x302B (cumulative pilot arc time – bytes 3 and 2)........................................................... 45

4 810400 Reference Guide Powermax65/85/105 SYNC

Serial Communication Programmer Reference Guide

0x302C (total number of arc transfers – bytes 1 and 0)................................................... 45

0x302D (total number of arc transfers – bytes 3 and 2)................................................... 46

0x302E (cumulative arc transfer time – bytes 1 and 0)..................................................... 46

0x302F (cumulative arc transfer time – bytes 3 and 2) ..................................................... 46

Example request and response................................................................................................ 47

Read the 16-character UID number for the installed cartridge ................................................... 48

0x3030 – 0x3037 (cartridge UID, bytes 0 – 15)................................................................ 48

Example request and response................................................................................................ 49

Read the total cut counts for the installed cartridge....................................................................... 50

0x3040 (total number of starts)............................................................................................... 50

0x3041 (cumulative pilot arc time).......................................................................................... 50

0x3042 (total number of arc transfers).................................................................................. 50

0x3043 (cumulative arc transfer time) ................................................................................... 51

Example request and response................................................................................................ 51

Read the 4 most recent faults for the installed cartridge............................................................... 52

0x3044 (fault log 0).................................................................................................................... 52

0x3045 (fault log 1).................................................................................................................... 53

0x3046 (fault log 2).................................................................................................................... 53

0x3047 (fault log 3).................................................................................................................... 53

Example request and response................................................................................................ 54

Read the name of the installed cartridge........................................................................................... 55

0x3048 – 0x304D (cartridge name, bytes 0 – 11) ............................................................ 55

Example request and response................................................................................................ 56

Read the Start and Motion signal status of the plasma power supply....................................... 57

0x3100 (coil: Start switch signal status) ............................................................................... 57

0x3101 (coil: Motion switch signal status)............................................................................ 57

Example request and response................................................................................................ 58

Flowchart Examples ................................................................................................................ 61

Powermax65/85/105 SYNC Reference Guide 810400 5

Serial Communication Programmer Reference Guide

6 810400 Reference Guide Powermax65/85/105 SYNC

Getting started

CNC / THC

Machine interface cable

RS-485 serial interface cable

The Powermax65/85/105 SYNC plasma power supply supports serial communication with an external control using the Modbus serial communication protocol.

This guide is for the programmer who will use Modbus protocols and messages for communication between the Powermax65/85/105 SYNC and an external control such as a CNC or torch height control (THC). It lists the supported Modbus function codes and the Powermax65/85/105 SYNC register and coil addresses with which those function codes can be used. It also describes how to construct the messages for the Powermax65/85/105 SYNC.

Serial Communication Programmer Reference Guide

For more information about the Modbus protocol, refer to modbus.org

Hardware requirements

Using a Powermax65/85/105 SYNC plasma power supply in a mechanized system requires all of the following hardware.

SmartSYNC machine torch with torch lead and Hypertherm cartridges.

 RS-485 serial interface connector, board, and cables.

This hardware provides access to cut mode, amperage, gas pressure, and more.

 Machine interface receptacle, voltage divider board,

and cables. This hardware provides access to the divided arc voltage, plasma start/stop, and arc transfer signals.

If this hardware was not included with your system, you must order and install the hardware. Refer to the Powermax65/85/105 SYNC Parts Guide (810490).

Powermax65/85/105 SYNC Reference Guide 810400 7

Serial Communication Programmer Reference Guide

Powermax65/85/105 SYNC hardware documents

Refer to the following documents for more information about the required hardware for serial communications.

How-to Information Document

Order hardware, kits, and cables Powermax65/85/105 SYNC Parts Guide (810490)

Attach a machine torch to a cutting table

Install an RS-485 serial interface connector and board

Install a machine interface receptacle and voltage divider board

Connect external serial interface and machine interface cables

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

RS-485 Serial Interface Connector with PCB Field Service Bulletin (806710)

Machine Interface Receptacle with Voltage Divider PCB Field Service Bulletin (806980)

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, or with the hardware kits. Technical documentation is also available at www.hypertherm.com/docs

Modbus specifications

Transmission mode and format

Mode ASCII (American Standard Code for Information Interchange)

Addressing Controller: CNC

Connected device: Powermax65/85/105 SYNC

Coding system Hexadecimal, ASCII characters 0 - 9, A - F

Baud rate 19200

Bits per byte Start bit: 1

Data bits: 8

• Includes 1 bit for even parity

• Most significant byte (MSB) sent first

Stop bit: 1*

Parity Even**

Error-check field Longitudinal Redundancy Check (LRC)

* The stop bit setting on the plasma power supply and the external control must be the same. By default the

Powermax65/85/105 SYNC plasma power supply is set to 1 stop bit. Refer to CNC settings on the Powermax65/85/105 SYNC on page 12.

** The parity setting on the plasma power supply and the external control must be the same. By default the

Powermax65/85/105 SYNC plasma power supply is set to Even parity. Refer to CNC settings on the Powermax65/85/105 SYNC on page 12.

8 810400 Reference Guide Powermax65/85/105 SYNC

Modbus request and response message frame format

Start Node Address Function Data LRC End

Serial Communication Programmer Reference Guide

1 character

2 characters 2 characters 0 up to 2x252 characters 2 characters 2 characters

Each segment is explained as follows.

Segment Description

Start All messages must start with a colon (:). This character identifies that a new message

follows.

Node Address In a request message: These characters identify the unique address (node address) of

the plasma power supply to which the request message is being sent. In a response message: These characters identify its node address to confirm that the

correct plasma power supply responded.

Function In a request message: The function code tells the plasma power supply what to do. If

needed, the Data characters provide additional information about how to do the function. In a response message: The function code confirms the function that was done by the

plasma power supply. In an error response message: The Function segment of the message is different. Refer

to page 10.

Data In a request message: These characters can be included to provide additional

information about how to do the function. This can include items like discrete and register addresses, the quantity of items to be handled, and the count of actual data bytes in the field.

In a response message: These characters represent the result of the function done by the plasma power supply.

In an error response message: The Data segment of the message is different. Refer to page 10.

LRC These characters are used to perform a Longitudinal Redundancy Check (LRC), a method

for performing a checksum on the message.

In a request message: The LRC value is calculated by the CNC. When the plasma power supply receives the request message, it also calculates an LRC for the request message. If the LRCs are the same, the plasma power supply accepts the request message.

For more information on how to calculate an LRC, refer to page 12.

In a response message: The LRC value is calculated by the plasma power supply for the data in its response message. The CNC performs a checksum before accepting the response message.

<CR><LF> These characters identify the end of the message.

Powermax65/85/105 SYNC Reference Guide 810400 9

Serial Communication Programmer Reference Guide

:01043044000483<CR><LF>

Start Node Address Function Data LRC End

Error response message frame format

The plasma power supply sends an error response message to the CNC when it detects an error in the request data and when an error occurs during processing of the request.

The format of the error response message is similar to the request and response message format, with the following differences.

Segment Description

Function In an error response message: The MSB of the function code is set to 1. This makes

the function code value 80 hexadecimals higher than the value would be for a normal response. This identifies to the CNC that this is an error response message.

For example, if the request message contained the Read Register function code of 04, the error response message would contain 84 in the Function segment of the message.

Data In an error response message: The Data segment of the message contains an

exception code that identifies the reason for the error. For example, if the function code in the request message is invalid for the plasma power

supply, the Data segment of the error response message contains the 01 exception code (Illegal Function).

Example request and response message

The following is a request for the 4 most recent faults for the installed cartridge:

Segment Value Description

Start : Start of message

Node Address 01 Plasma power supply node address

Function 04 Read Registers

Data 3044 First register address (0x3044)

0004 Quantity of registers to read (0x0004 = 4):

• 0x3044 (fault log 0)

• 0x3045 (fault log 1)

• 0x3046 (fault log 2)

• 0x3047 (fault log 3)

LRC 83 Checksum

End <CR><LF> End of message

10 810400 Reference Guide Powermax65/85/105 SYNC

Serial Communication Programmer Reference Guide

:010408007900790000000001<CR><LF>

Start Node Address Function Data LRC End

The following is the response from the plasma power supply:

Segment Value Description

Start : Start of message

Node Address 01 Plasma power supply node address (confirmed)

Function 04 Read Registers (confirmed)

Data 08 Quantity of bytes in the Data segment (0x08 = 8)

0079 Value in address 0x3044 (newest fault): 0x0079 = 0121 = fault

code 0-12-1 (output gas pressure is low)

0079 Value in address 0x3045: 0x0079 = 0121 = fault code 0-12-1

(output gas pressure is low)

0000 Value in address 0x3046: 0x0000 = 0000 = 0-00-0 (no fault code)

0000 Value in address 0x3047 (oldest fault): 0x0000 = 0000 = 0-00-0

(no fault code)

LRC 01 Checksum

End <CR><LF> End of message

For more examples, refer to Examples of requests and responses on page 20.

Powermax65/85/105 SYNC Reference Guide 810400 11

Serial Communication Programmer Reference Guide

How to calculate a checksum (LRC)

Modbus ASCII requires a longitudinal redundancy check (LRC, also called a checksum) on each message.

For example, in the following request message, the LRC is 83.

:01043044000483<CR><LF>

Start Node Address Function Data LRC End

: 01 04 3044 0004 83 <CR><LF>

1. Add the hexadecimal values of the message, excluding the Start (:) and End characters

<CR><LF>) and the LRC itself (83):

(

For example: 0x01 + 0x04 + 0x30 + 0x44 + 0x00 + 0x04 = 0x7D

2. Do one of the following:

a. If the sum is less than or equal to FF, subtract the entire value from FF.

b. If the sum is more than FF, subtract the last two digits from FF.

In this example, 0x7D is less than FF, so you subtract the entire value from FF:

0xFF - 0x7D = 0x82

3. Add 1. For example: 0x82 + 0x01 = 0x83. The LRC is 83.

CNC settings on the Powermax65/85/105 SYNC

Use the CNC Interface Settings screen (CNC INTERFACE) to set parameters for serial communication.

1. Select on the main menu screen.

2. Select to go to the CNC INTERFACE screen.

3. Turn the adjustment knob to go to the field you want to change.

4. Push to select the field.

5. Turn the adjustment knob to change the value in the field.

12 810400 Reference Guide Powermax65/85/105 SYNC

6. Push to select the new value.

Baud rate

(cannot be changed)

Data bits

(cannot be changed)

Parity

(can be changed)

Stop bits (can be changed)

Serial Communication Programmer Reference Guide

Powermax65/85/105 SYNC Reference Guide 810400 13

Serial Communication Programmer Reference Guide

– Set the parity-check configuration and stop-bit configuration for this Powermax. Make

sure that the values in this field are the same as the values at the CNC.

Select one of the following values for parity checking:

E Even (default)

O Odd

N No parity checking

Select one of the following values for stop bit:

1 1 stop bit (default)

2 2 stop bits

– This is the Modbus node address for this Powermax. The default value is zero (0).

 For cutting systems with 1 Powermax plasma power supply: Keep the default value

of zero (0).

A value of zero (0) lets the CNC set the node address for the Powermax automatically. The node address is set by the first valid Modbus request message that the Powermax receives from the CNC after the Powermax power switch is set to the ON (I) position. This field continues to show a value of zero (0) during Modbus communication to indicate that the node address is being controlled by the CNC.

 For cutting systems with 2 or more Powermax plasma power supplies: Select a

unique number from 1 to 255 for each Powermax.

 After you set the node address for this Powermax, do a cold restart.

 Make sure that the CNC uses this node address when it communicates with each

Powermax.

14 810400 Reference Guide Powermax65/85/105 SYNC

Serial Communication Programmer Reference Guide

Powermax65/85/105 SYNC Modbus addressing system

Powermax65/85/105 SYNC provides more plasma power supply data than what is available for older Powermax plasma power supplies, as well as access to cartridge-usage data. A CNC can also request a gas test and a quick restart on a Powermax65/85/105 SYNC.

The Powermax65/85/105 SYNC register addresses are consecutively numbered in a 0x3xxx series of registers so that a single request can read or write multiple related registers at one time.

For the most efficient communication between a CNC and Powermax65/85/105 SYNC, do the following:

 Use only the 0x3xxx register addresses with Powermax65/85/105 SYNC.

 When possible, send a single request for multiple registers of data at one time.

Backward compatible with 0x2xxx series

Powermax65/85/105 SYNC supports the 0x2xxx series of Modbus addresses that was used for older Powermax plasma power supplies, as shown in Tabl e 1 . But Hypertherm strongly recommends that you use the 0x3xxx series with the Powermax65/85/105 SYNC.

Older Powermax plasma power supplies include Powermax65/85/105/125 and Powermax45 XP.

Table 1 – Powermax65/85/105 SYNC support for old addressing system

Old address Description Modbus functions (hex)

0x204C Actual gas pressure 04 (Read Register)

0x2093 Operating mode setting 06 (Write Single Register)

0x2094 Output current (A) setting 06 (Write Single Register)

0x2096 Gas pressure setting 06 (Write Single Register)

0x2098 Active fault code 04 (Read Register)

0x2099 Minimum output current (A) setting 04 (Read Register)

0x209A Maximum output current (A) setting 04 (Read Register)

0x209C Minimum gas pressure setting 04 (Read Register)

0x209D Maximum gas pressure setting 04 (Read Register)

0x209E, 0x209F Cumulative arc time in seconds 04 (Read Register)

0x0808, 0x0809 Torch lead length 01 (Read Coils)

0x0810 Start switch signal status 01 (Read Coils)

0x0811 Motion switch signal status 01 (Read Coils)

0x0832 Gas test status 05 (Write Single Coil)

Powermax65/85/105 SYNC Reference Guide 810400 15

Serial Communication Programmer Reference Guide

List of Powermax65/85/105 SYNC addresses

SYNC Address

Request: Read the ID of the SYNC torch, torch lead, and plasma power supply

0x3000 Torch and plasma power supply identification

Request: Read the permitted plasma power supply settings

0x3001 Permitted operating mode setting

0x3002 Permitted minimum output current (A) setting Amperes 04 (Read Registers) 0x2099

0x3003 Permitted maximum output current (A) setting Amperes 04 (Read Registers) 0x209A

0x3004 Permitted minimum gas pressure setting psi

0x3005 Permitted maximum gas pressure setting psi 04 (Read Registers) 0x209D

Request: Read the plasma power supply settings

0x3010 Operating mode setting

Description Unit

N/A 04 (Read Registers) N/A High byte: torch ID Low byte: SYNC ID

N/A 04 (Read Registers) N/A High byte: mode high Low byte: mode low

N/A 04 (Read Registers) N/A High byte: 0x00 Low byte: mode

Recommended Modbus Function (hex)

04 (Read Registers) 0x209C

Old Address

0x3011 Output current (A) setting Amperes 04 (Read Registers) N/A

0x3012 Gas pressure setting psi 04 (Read Registers) N/A

Request: Read the actual output of the plasma power supply

0x3018 Actual output current (A) Amperes 04 (Read Registers) N/A

0x3019 Actual gas pressure output at valve psi 04 (Read Registers) 0x204C

0x301A Active fault code N/A 04 (Read Registers) 0x2098

Request: Read the total cut counts for this plasma power supply

0x3028 Total number of starts (bytes 1 and 0) Number 04 (Read Registers) N/A

0x3029 Total number of starts (bytes 3 and 2) 04 (Read Registers) N/A

0x302A Cumulative pilot arc time (bytes 1 and 0) Seconds 04 (Read Registers) 0x209E

0x302B Cumulative pilot arc time (bytes 3 and 2) 04 (Read Registers) 0x209F

0x302C Total number of arc transfers (bytes 1 and 0) Number 04 (Read Registers) N/A

0x302D Total number of arc transfers (bytes 3 and 2) 04 (Read Registers) N/A

0x302E Cumulative arc transfer time (bytes 1 and 0) Seconds 04 (Read Registers) N/A

0x302F Cumulative arc transfer time (bytes 3 and 2) 04 (Read Registers) N/A

16 810400 Reference Guide Powermax65/85/105 SYNC

Serial Communication Programmer Reference Guide

SYNC Address

Description Unit

Recommended Modbus Function (hex)

Old Address

Request: Read the 16-character unique identification (UID) number for the installed cartridge

0x3030 UID (bytes 0 and 1) N/A 04 (Read Registers) N/A

0x3031 UID (bytes 2 and 3) N/A 04 (Read Registers) N/A

0x3032 UID (bytes 4 and 5) N/A 04 (Read Registers) N/A

0x3033 UID (bytes 6 and 7) N/A 04 (Read Registers) N/A

0x3034 UID (bytes 8 and 9) N/A 04 (Read Registers) N/A

0x3035 UID (bytes 10 and 11) N/A 04 (Read Registers) N/A

0x3036 UID (bytes 12 and 13) N/A 04 (Read Registers) N/A

0x3037 UID (bytes 14 and 15) N/A 04 (Read Registers) N/A

Request: Read the part number of the installed cartridge

0x3038 Part number (bytes 0 and 1) N/A 04 (Read Registers) N/A

0x3039 Part number (bytes 2 and 3) N/A 04 (Read Registers) N/A

0x303A Part number (bytes 4 and 5) N/A 04 (Read Registers) N/A

0x303B Part number revision level N/A 04 (Read Registers) N/A

Request: Read the amperage for which the installed cartridge is rated

0x303C Nominal current Amperes 04 (Read Registers) N/A

Request: Read the total cut counts for the installed cartridge

0x3040 Total number of starts Number 04 (Read Registers) N/A

0x3041 Cumulative pilot arc time Seconds 04 (Read Registers) N/A

0x3042 Total number of arc transfers Number 04 (Read Registers) N/A

0x3043 Cumulative arc transfer time 2 seconds

04 (Read Registers) N/A

per count

Request: Read the 4 most recent faults for the installed cartridge

0x3044 Fault log 0 (newest fault) N/A 04 (Read Registers) N/A

0x3045 Fault log 1 N/A 04 (Read Registers) N/A

0x3046 Fault log 2 N/A 04 (Read Registers) N/A

0x3047 Fault log 3 N/A 04 (Read Registers) N/A

Request: Read the 12-character name of the installed cartridge

0x3048 Name (bytes 0 and 1) N/A 04 (Read Registers) N/A

0x3049 Name (bytes 2 and 3) N/A 04 (Read Registers) N/A

0x304A Name (bytes 4 and 5) N/A 04 (Read Registers) N/A

0x304B Name (bytes 6 and 7) N/A 04 (Read Registers) N/A

0x304C Name (bytes 8 and 9) N/A 04 (Read Registers) N/A

0x304D Name (bytes 10 and 11) N/A 04 (Read Registers) N/A

Powermax65/85/105 SYNC Reference Guide 810400 17

Serial Communication Programmer Reference Guide

SYNC Address

Description Unit

Recommended Modbus Function (hex)

Old Address

Request: Write operating settings and put the plasma power supply into remote control mode

0x3080 Operating mode setting N/A 10 (Write Multiple Registers) 0x2093

0x3081 Output current (A) setting Amperes 10 (Write Multiple Registers) 0x2094

0x3082 Gas pressure setting psi 10 (Write Multiple Registers) 0x2096

Request: Stop fault code 0-50-0

0x308E Special quick restart command

N/A 10 (Write Multiple Registers) N/A (Write a value of 0x0404 to this address.)

0x308F Special quick restart approval

N/A 10 (Write Multiple Registers) N/A (Write a value of 0x0618 to this address.)

Request: Read the Start and Motion signal status of the plasma power supply

0x3100 (coil)

0x3101 (coil)

Start switch signal status (ON = 1, OFF = 0)

Motion switch signal status (ON = 1, OFF = 0)

N/A 01 (Read Coil) 0x0810

N/A 01 (Read Coil) 0x0811

Request: Start and stop a gas test

0x3180 (coil)

Gas test status (Write a value of 0xFF00 to this coil to start a

N/A 05 (Write Single Coil) 0x0832

gas test.) (Write a value of 0x0000 to this coil to stop a

gas test.)

18 810400 Reference Guide Powermax65/85/105 SYNC

Programming recommendations

 For the best results, use the programming examples that start on page 20 and the

flowcharts in Flowchart Examples on page 61. These recommendations give you faster and more reliable communication.

 Let the Powermax65/85/105 SYNC select the operating settings. Hypertherm

recommends that you let the Powermax65/85/105 SYNC set the operating mode, output current (A), and gas pressure automatically for the installed cartridge.

 Program the CNC to either automatically identify, or prompt the operator to identify,

the plasma power supply type (SYNC or older plasma power supply). Then use the appropriate register addresses (0x3xxx or 0x2xxx). This lets you reuse the programming on all of your CNCs and cutting tables.

 Use Modbus function code 04 (Read Input Registers) for Holding Registers and Input

Registers. It is not necessary to use Modbus function code 03 (Read Holding Registers) for holding registers. Hypertherm supports this usage to simplify Modbus programming.

 Send a single request for multiple registers at one time, when possible, for faster and

more reliable communication.

Serial Communication Programmer Reference Guide

 Do a check for faults every 1 second. This is equivalent to doing a check that the plasma

power supply is prepared for operation.

 Do all the recommended steps for all fault codes that occur, including notifications

that do not stop the cutting process. Troubleshooting all faults helps you to get optimal cut quality and consumable life.

 Program the CNC to log every active fault, including the date and time, to aid in

troubleshooting.

 Program a response time-out of 60 ms – 100 ms, to give sufficient time for

communication to occur.

 Program a delay of 50 ms between Start signals, to give sufficient time for the relay

circuits to complete switching.

 Do not stop gas postflow before it fully completes. Gas postflow is necessary to

decrease the temperature of the cartridge.

Powermax65/85/105 SYNC Reference Guide 810400 19

Serial Communication Programmer Reference Guide

Examples of requests and responses

Identify the plasma power supply type (SYNC or older system)

To identify the type of plasma power supply, and therefore the addressing system and features that are available, the CNC must use the following Modbus function code:

 43/14 (2B/0E) (Read Device Identification)

Convert the hexadecimal values in the response message to ASCII characters.

Table 2 – Device identifications

Device Identification Plasma Power Supply Type Addressing System

303831323838 (hex)

081288 (ASCII)

303831323233 (hex)

081223 (ASCII)

303831323531 (hex)

081251 (ASCII)

303831333335 (hex)

081335 (ASCII)

Powermax65/85/105 Old 0x2xxx addresses

Powermax65/85/105 SYNC New 0x3xxx addresses

Example request and response

Request from CNC:

:012B0E0401C1<CR><LF>

Value Description

: Start of message

01 Plasma power supply node address

2B0E Read Device Identification

Powermax45 XP Old 0x2xxx addresses

Powermax125 Old 0x2xxx addresses

04 Get 1 specific identification object

01 Starting address

C1 LRC

<CR><LF> End

20 810400 Reference Guide Powermax65/85/105 SYNC

Serial Communication Programmer Reference Guide

Response from plasma power supply:

:012B0E0481000101010630383133333504<CR><LF>

Value Description

: Start of message

01 Plasma power supply node address (confirmed)

2B0E Read Device Identification (confirmed)

04810001010106 For more information on this segment, refer to Section 6.21 43/14 (0x2B/0x0E)

Read Device Identification in the Modbus Application Protocol Specification at

modbus.org

303831333335 303831333335 (hex) = 081335 (ASCII) = Powermax65/85/105 SYNC

04 LRC

<CR><LF> End

Read the ID of the SYNC torch, torch lead, and plasma power supply

To identify the SYNC torch, torch lead, and plasma power supply, the CNC reads the value in the following register:

 0x3000 (torch and plasma power supply identification)

0x3000 (torch and plasma power supply identification)

Description: Reads the binary value of the installed torch type and lead length, and the binary

value of the plasma power supply type.

• High byte: the high byte identifies the torch type and lead length. Refer to Tab l e 3.

• Low byte: the low byte identifies the plasma power supply. Refer to Tabl e 4.

For example, a response that contains a value of 0508 identifies the following: High byte = 05 = 0x05 (machine torch with 35-foot – 50-foot lead) Low byte = 08 = 0x08 (Powermax105 SYNC CSA 200 V – 600 V)

Encoding or scaling: N/A

Unit: N/A

Function (hex): 04 (Read Registers)

Powermax65/85/105 SYNC Reference Guide 810400 21

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Table 3 – Torch type and lead length

High Byte

(Torch Type ID)

0x00 Hand torch with 7.6 m (25-foot) lead

0x01 Hand torch with 15 m (50-foot) lead

0x02 Hand torch with 23 m (75-foot) lead

0x04 Machine torch with 4.6 m – 7.6 m (15-foot – 25-foot) lead

0x05 Machine torch with 10.7 m – 15 m (35-foot – 50-foot) lead

0x06 Machine torch with 23 m (75-foot) lead

Low Byte (Type ID)

0x00 Powermax65 SYNC 200 V – 600 V CSA

0x01 Powermax65 SYNC 380 V CCC / 400 V CE

Torc h Typ e

Table 4 – Plasma power supply type

Plasma Power Supply Type

0x02 Powermax85 SYNC 200 V – 600 V CSA

0x03 Powermax85 SYNC 380 V CCC / 400 V CE

0x08 Powermax105 SYNC 200 V – 600 V CSA

0x09 Powermax105SYNC 230V–400V CE

0x0A Powermax105SYNC 380VCCC/400V CE

Example request and response

Request from CNC:

:010430000001CA<CR><LF>

Value Description

: Start of message

01 Plasma power supply node address

04 Read Registers

3000 First register address (0x3000)

0001 Quantity of registers to read (0x0001 = 1):

• 0x3000 (torch and plasma power supply identification)

CA LRC

<CR><LF> End

22 810400 Reference Guide Powermax65/85/105 SYNC

Response from plasma power supply:

:0104020508EC<CR><LF>

Value Description

: Start of message

01 Plasma power supply node address (confirmed)

04 Read Registers (confirmed)

02 Quantity of bytes in the Data segment (0x02 = 2)

0508 High byte = 05 = 0x05 = machine torch with 35-foot – 50-foot lead

Low byte = 08 = 0x08 = Powermax105 SYNC 200 V – 600 V CSA

EC LRC

<CR><LF> End

Read the part number of the installed cartridge

To read the part number of the installed cartridge, the CNC reads the values in the following registers:

Serial Communication Programmer Reference Guide

 0x3038 (part number, bytes 0 and 1)

 0x3039 (part number, bytes 2 and 3)

 0x303A (part number, bytes 4 and 5)

0x3038, 0x3039, 0x303A (cartridge part number, bytes 0 – 5)

Description: Identifies the type of machine torch cartridge that is installed by using the

cartridge part number. Convert the hexadecimal values in the response message to ASCII characters.

Refer to Tab l e 5.

Encoding or scaling: N/A

Unit: N/A

Function (hex): 04 (Read Registers)

Powermax65/85/105 SYNC Reference Guide 810400 23

Serial Communication Programmer Reference Guide

Table 5 – Machine torch cartridge type

Part Number Cartridge Type

343238393336 (hex)

428936 (ASCII)

343238393334 (hex)

428934 (ASCII)

343238393330 (hex)

428930 (ASCII)

343238393235 (hex)

428925 (ASCII)

343238393236 (hex)

428926 (ASCII)

343238393339 (hex)

428939 (ASCII)

343238393333 (hex)

428933 (ASCII)

343238393239 (hex)

428929 (ASCII)

343238393338 (hex)

428938 (ASCII)

Cut: 105 A cartridge

Cut: 85 A cartridge

Cut: 65 A cartridge

Cut: 45 A cartridge

FineCut: 45 A cartridge

Max Control gouge: 105 A cartridge

Max Control gouge: 65 A / 85 A cartridge

Max Control gouge: 45 A cartridge

Max Removal gouge: 105 A cartridge

343238393332 (hex)

428932 (ASCII)

000000000000 (hex)

000000 (ASCII)

Max Removal gouge: 65 A / 85 A cartridge

Cartridge communication failure or radio frequency error

24 810400 Reference Guide Powermax65/85/105 SYNC

Example request and response

Request from CNC:

:01043038000390<CR><LF>

Value Description

: Start of message

01 Plasma power supply node address

04 Read Registers

3038 First register address

0003 Quantity of registers to read (0x0003 = 3):

• 0x3038 (part number, bytes 0 and 1)

• 0x3039 (part number, bytes 2 and 3)

• 0x303A (part number, bytes 4 and 5)

90 LRC

<CR><LF> End

Serial Communication Programmer Reference Guide

Response from plasma power supply:

:010406343238393336B5<CR><LF>

Value Description

: Start of message

01 Plasma power supply node address (confirmed)

04 Read Registers (confirmed)

06 Quantity of bytes in the Data segment (0x06 =6)

343238393336 343238393336 (hex) = 428936 (ASCII) = 105 A cut cartridge

B5 LRC

<CR><LF> End

Powermax65/85/105 SYNC Reference Guide 810400 25

Serial Communication Programmer Reference Guide

Read the plasma power supply settings that are permitted for the installed cartridge

To read the plasma power supply settings that are permitted for the installed cartridge, the CNC reads the values in the following registers:

 0x3001 (permitted operating mode setting)

 0x3002 (permitted minimum output current (A) setting)

 0x3003 (permitted maximum output current (A) setting)

 0x3004 (permitted minimum gas pressure setting)

 0x3005 (permitted maximum gas pressure setting)

0x3001 (permitted operating mode setting)

Description: Reads the operating mode settings that are permitted for the installed cartridge.

Valid values are as follows:

•0x01 (cut)

• 0x02 (expanded metal)

• 0x03 (gouge)

Encoding or scaling: 16-bit, fixed-point binary with 1-bit sign at MSB and 0-bit decimal at LSB

Unit: N/A

Function (hex): 04 (Read Registers)

0x3002, 0x3003 (permitted minimum and maximum output current (A) settings)

Description: Read the hexadecimal values for the minimum and maximum output current (A)

settings that are permitted for the installed cartridge. Convert the hexadecimal value to decimal, and then divide that decimal value by 64

to get the output current (A).

Encoding or scaling: 16-bit, fixed-point binary with 1-bit sign at MSB and 6-bit decimal at LSB

Unit: Amperes

Function (hex): 04 (Read Registers)

0x3004, 0x3005 (permitted minimum and maximum gas pressure settings)

Description: Reads the hexadecimal values for the minimum and maximum gas pressure (psi)

settings for the installed cartridge, torch, and plasma power supply. Convert the hexadecimal value to decimal, and then divide that decimal value by

128 to get the gas pressure (psi).

Encoding or scaling: 16-bit, fixed-point binary with 1-bit sign at MSB and 7-bit decimal at LSB

Unit: N/A

Function (hex): 04 (Read Registers)

26 810400 Reference Guide Powermax65/85/105 SYNC

Example request and response

Request from CNC:

:010430010005C5<CR><LF>

Value Description

: Start of message

01 Plasma power supply node address

04 Read Registers

3001 First register address

0005 Quantity of registers to read (0x0005 =5):

• 0x3001 (permitted operating mode setting)

• 0x3002 (permitted minimum output current (A) setting)

• 0x3003 (permitted maximum output current (A) setting)

• 0x3004 (permitted minimum gas pressure setting)

• 0x3005 (permitted maximum gas pressure setting)

C5 LRC

Serial Communication Programmer Reference Guide

<CR><LF> End

Response from plasma power supply:

:01040A020107800B401D002700D8<CR><LF>

Value Description

: Start of message

01 Plasma power supply node address (confirmed)

04 Read Registers (confirmed)

0A Quantity of bytes in the Data segment (0x0A = 10)

0201 02 = 0x02 = expanded metal

01 = 0x01 = cut

0780

0B40

1D00

2700

D8 LRC

<CR><LF> End

0x0780 = 1920/64 = 30 A 0x0B40 = 2880/64 = 45 A

0x1D00 = 7424/128 = 58 psi 0x2700 = 9984/128 = 78 psi

Powermax65/85/105 SYNC Reference Guide 810400 27

Serial Communication Programmer Reference Guide

Write operating settings and put the plasma power supply into remote control mode

This write request is not necessary if you let the



Powermax65/85/105 SYNC automatically set the operating settings.

Hypertherm strongly recommends that you let the Powermax65/85/105 SYNC set the operating settings. Refer to Programming recommendations on page 19.

To override automatic settings and put the Powermax65/85/105 SYNC into remote control mode, the CNC must write values to the following registers:

 0x3080 (operating mode setting)

 0x3081 (output current (A) setting)

 0x3082 (gas pressure setting)

To avoid 0-11-n faults, make sure to write to all 3 registers in 1 request.



0x3080 (operating mode setting)

Description: Sets the operating mode. The following values are permitted:

• 0x0001 (cut)

• 0x0002 (expanded metal)

• 0x0003 (gouge)

Encoding or scaling: 16-bit, fixed-point binary with 1-bit sign at MSB and 0-bit decimal at LSB

Unit: N/A

Functions (hex): 10 (Write Multiple Registers) (recommended)

Also supported: 06 (Write Single Register)

0x3081 (output current (A) setting)

Description: Sets the output current (A).

To specify the output current (A) that you want: Multiply the output current (A) that

you want by 64, and convert the product to its hexadecimal value. For example, to set the output current (A) to 65 A: 65 x 64 = 4160 = 0x1040

Encoding or scaling: 16-bit, fixed-point binary with 1-bit sign at MSB and 6 bit decimal at LSB

Unit: Amperes

Function (hex): 10 (Write Multiple Registers) (recommended)

Also supported: 06 Write Single Register

28 810400 Reference Guide Powermax65/85/105 SYNC

Serial Communication Programmer Reference Guide

0x3082 (gas pressure setting)

Description: Sets the gas pressure in psi.

To have the plasma power supply set the gas pressure automatically: Write a

value of zero (0x0000) to address 0x3082. The plasma power supply will automatically set the gas pressure for optimum cutting related to the operating mode, the torch type, the cartridge type, and the length of the torch lead.

To specify the gas pressure (psi) that you want: Multiply the gas pressure (psi) that you want by 128, and convert the product to its hexadecimal value.

For example, to set the gas pressure to 45 psi: 45 X 128 = 5760 = 0x1680

Encoding or scaling: 16-bit, fixed-point binary with 1-bit sign at MSB and 7-bit decimal at LSB

Unit: psi

Function (hex): 10 (Write Multiple Registers) (recommended)

Also supported: 06 (Write Single Register)

Example request and response

In this example, you want to put the Powermax65/85/105 SYNC into remote control mode and cut at 63 A, with gas pressure set automatically by the plasma power supply.

Request from CNC:

:0110308000030600010FC0000066<CR><LF>

Value Description

: Start of message

01 Plasma power supply node address

10 Write Multiple Registers

3080 First register address (0x3080)

0003 Quantity of registers to write (0x0003 = 3):

• 0x3080 (operating mode)

• 0x3081 (output current (A))

• 0x3082 (gas pressure)

06 Quantity of bytes in the Data segment (0x06 = 6)

0001 Value to write to address 0x3080: 0x0001 = Cut mode

0FC0 Value to write to address 0x3081: 63 A X 64 = 4032 = 0x0FC0

0000 Value to write to address 0x3082 (0x0000 = automatic)

66 LRC

<CR><LF> End

Powermax65/85/105 SYNC Reference Guide 810400 29

Serial Communication Programmer Reference Guide

Response from plasma power supply:

:0110308000033C<CR><LF>

Value Description

: Start of message

01 Plasma power supply node address (confirmed)

10 Write Multiple Registers (confirmed)

3080 First register address (confirmed)

0003 Quantity of registers to write (confirmed)

3C LRC

<CR><LF> End

Refer also to Exit remote control mode on page 40.

Remote control mode indicator on the plasma power supply

When the Powermax65/85/105 SYNC enters remote control mode, an indicator shows on the LCD display.

The front panel controls are disabled when the Powermax65/85/105 SYNC is in remote control mode. Fault codes and fault icons still show, and you can still go to the menu screens to see information about the plasma power supply, torch, and cartridge.

Refer also to Exit remote control mode on page 40.

Do a check for an active fault

Active faults must be resolved before cutting can start. To do a check for an active fault, the CNC reads the value in the following register:

 0x301A (active fault code)

If there is no active fault, the CNC can start cutting.

0x301A (active fault code)

Description: Reads the hexadecimal value of the fault code for a fault that is currently active on

the plasma power supply. If there is no active fault, this reads a value of 0x0000 (0-00-0).

Refer to Fault code list on page 32 for the complete list of possible fault codes.

Encoding or scaling: 10-bit effective unsigned binary number from the LSB of a 16-bit binary number

Unit: N/A

Function (hex): 04 (Read Registers)

30 810400 Reference Guide Powermax65/85/105 SYNC

Example request and response

Request from CNC:

:0104301A0001B0<CR><LF>

Value Description

: Start of message

01 Plasma power supply node address

04 Read Registers

301A First register address (0x301A)

0001 Quantity of registers to read (0x0001 = 1):

• 0x301A (active fault code)

B0 LRC

<CR><LF> End

Response from plasma power supply:

Serial Communication Programmer Reference Guide

:01040201F404<CR><LF>

Value Description

: Start of message

01 Plasma power supply node address (confirmed)

04 Read Registers (confirmed)

02 Quantity of bytes in the Data segment (2)

01F4 0x01F4 = 500 (fault code 0-50-0)

The cartridge is off the torch. Or, the cartridge was removed with the torch-disable switch set to the green “ready to fire” ( ) position.

04 LRC

<CR><LF> End

Powermax65/85/105 SYNC Reference Guide 810400 31

Serial Communication Programmer Reference Guide

Fault code list

Tab le 6 lists all of the possible Powermax65/85/105 SYNC fault codes and brief descriptions. For more information about how to identify and troubleshoot each fault condition, refer to the Powermax65/85/105 SYNC Troubleshooting Guide (810430).

Table 6 – Fault codes and descriptions

Fault Code

(hex)

Operational faults

0000 0 There is no active fault. No

006E 110 (Fault code 0-11-0)

006F 111 (Fault code 0-11-1)

0070 112 (Fault code 0-11-2)

0079 121 (Fault code 0-12-1)

007A 122 (Fault code 0-12-2)

Fault Code

(decimal)

Steps Required to

Description

No, but recommended

The operating mode is incorrect or not permitted for the installed cartridge.

No, but recommended

The output current (A) is incorrect or not permitted for the installed cartridge.

No, but recommended

The gas pressure is incorrect or not permitted. The permitted gas pressure relates to the selected process and operating mode, and to the installed torch, torch lead, and cartridge.

No, but recommended

The gas pressure output is low.

No, but recommended

The gas pressure output is high.

Remove?

007B 123 (Fault code 0-12-3)

The gas pressure output is not stable.

0082 130 (Fault code 0-13-0)

The alternating current (AC) input power is not stable.

008C 140 (Fault code 0-14-0)

There is a problem with the cartridge installation. The cartridge cannot send data to the plasma power supply.

008D 141 (Fault code 0-14-1)

The cartridge is not recognized.

00C7 199 (Fault code 0-19-9)

The input power stopped. Or, power PCB hardware protection occurred for components in the plasma power supply.

00C8 200 (Fault code 0-20-0)

The gas pressure is lower than the minimum pressure for the selected process, operating mode, torch, lead length, and cartridge type.

No, but recommended

Ye s

No, but recommended

Ye s

No, but recommended

32 810400 Reference Guide Powermax65/85/105 SYNC

Serial Communication Programmer Reference Guide

Fault Code

(hex)

Fault Code

(decimal)

00D2 210 (Fault code 0-21-0)

The gas flow stopped during cutting (an excessive change to arc voltage occurred).

00DC 220 (Fault code 0-22-0)

There is no gas supply input.

012C 300 (Fault code 0-30-0)

There is a torch stuck open (TSO) condition.

012D 301 (Fault code 0-30-1)

There is a torch stuck closed (TSC) condition.

0140 320 (Fault code 0-32-0)

The system sensed that the cartridge in use is at end-of-life.

0141 321 (Fault code 0-32-1)

A cartridge is installed that had the 0-32-0 fault before and is at end-of-life.

0190 400 (Fault code 0-40-0)

The boost power-factor correction insulated-gate bipolar-transistor (PFC IGBT) is too cold.

This is applicable to CSA and CE/CCC 230 V – 400 V models only.

Description

Steps Required to

Remove?

Ye s

No, but recommended

Ye s

0191 401 (Fault code 0-40-1)

The boost PFC IGBT is too hot. This is applicable to CSA and CE/CCC 230 V –

400 V models only.

0192 402 (Fault code 0-40-2)

The inverter IGBT is too cold.

0193 403 (Fault code 0-40-3)

The inverter IGBT is too hot.

01F4 500 (Fault code 0-50-0)

The cartridge is off, the torch was disconnected when you set the plasma power supply to ON (I), or the torch was in the yellow lock (X) position during a restart.

01F5 501 (Fault code 0-50-1)

The torch-lock switch is set to the yellow lock (X) position.

01F6 502 (Fault code 0-50-2)

The torch-lock switch is set to the green “ready to fire” ( ) position, but the torch is not prepared to fire.

01F7 503 (Fault code 0-50-3)

This code shows momentarily while the system reads data from the cartridge.

Ye s

Powermax65/85/105 SYNC Reference Guide 810400 33

Serial Communication Programmer Reference Guide

Fault Code

(hex)

Fault Code

(decimal)

01FE 510 (Fault code 0-51-0)

The plasma power supply was receiving a signal to start cutting at the same time that the power switch was set to ON (I). This is sometimes referred to as a “stuck start.”

0208 520 (Fault code 0-52-0)

The torch is not connected.

0258 600 (Fault code 0-60-0)

An AC input voltage phase loss occurred.

0259 601 (Fault code 0-60-1)

The AC input voltage is too low.

025A 602 (Fault code 0-60-2)

The AC input voltage is too high.

0262 610 (Fault code 0-61-0)

The AC input is not stable.

03D4 980 (Fault code 0-98-0)

An internal communication failure occurred between the LCD/control PCB and the DSP PCB.

Description

Steps Required to

Remove?

Ye s

No, but recommended

03D5 981 (Fault code 0-98-1)

A radio frequency (RF) communication failure occurred between the cartridge and the torch.

03D6 982 (Fault code 0-98-2)

A communication failure occurred between the torch and the plasma power supply.

Internal component faults

03E8 1000 (Fault code 1-00-0)

A digital-signal processor (DSP) PCB fault occurred.

04B0 1200 (Fault code 1-20-0)

An input/output (I/O) fault occurred.

0514 1300 (Fault code 1-30-0)

A flash memory fault occurred.

07D0 2000 (Fault code 2-00-0)

The analog-to-digital converter (ADC) value is out of range.

07DA 2010 (Fault code 2-01-0)

The auxiliary switch is disconnected.

0834 2100 (Fault code 2-10-0)

The inverter IGBT temperature sensor is open.

No, but recommended

Ye s

0835 2101 (Fault code 2-10-1)

Ye s

The inverter IGBT temperature sensor short-circuited.

34 810400 Reference Guide Powermax65/85/105 SYNC

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Fault Code

(hex)

Fault Code

(decimal)

083E 2110 (Fault code 2-11-0)

The pressure sensor is open.

083F 2111 (Fault code 2-11-1)

The pressure sensor short-circuited.

0898 2200 (Fault code 2-20-0)

The DSP PCB does not recognize the torch.

0BB8 3000 (Fault code 3-00-0)

The DC bus voltage (VBUS) is out of range.

0C1C 3100 (Fault code 3-10-0)

The fan speed is less than the minimum speed.

0C1D 3101 (Fault code 3-10-1)

A fan fault occurred.

0C26 3110 (Fault code 3-11-0)

The PFC IGBT temperature sensor is open.

0C27 3111 (Fault code 3-11-1)

The PFC IGBT temperature sensor short-circuited.

Description

Steps Required to

Remove?

Ye s

0C28 3112 (Fault code 3-11-2)

There is a PFC IGBT temperature sensor circuit fault.

0C80 3200 (Fault code 3-20-0)

The fill valve is not connected.

0C81 3201 (Fault code 3-20-1)

The dump valve is not connected.

0C82 3202 (Fault code 3-20-2)

The plasma power supply does not recognize the solenoid valve electronic regulator.

0C83 3203 (Fault code 3-20-3)

The solenoid valve electronic regulator is not receiving power.

0D52 3410 (Fault code 3-41-0)

A driver integrated circuit (IC) fault occurred.

0D5C 3420 (Fault code 3-42-0)

The 5 VDC or 24 VDC supply is out of range.

0D5D 3421 (Fault code 3-42-1)

The 18 VDC supply is out of range.

0D66 3430 (Fault code 3-43-0)

The inverter capacitors are not balanced.

Ye s

0D71 3441 (Fault code 3-44-1)

Ye s

The PFC IGBT current is too high.

Powermax65/85/105 SYNC Reference Guide 810400 35

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Fault Code

(hex)

0DB7 3511 (Fault code 3-51-1)

0DC0 3520 (Fault code 3-52-0)

0E10 3600 (Fault code 3-60-0)

0E74 3700 (Fault code 3-70-0)

Fault Code

(decimal)

An inverter IGBT saturation fault occurred. The inverter current is too high.

A short-circuit caused high-current distortion in the inverter IGBT. This is sometimes referred to as a shoot-through.

The DSP PCB does not recognize the power PCB.

There is an internal serial communications fault between the DSP PCB and power PCB.

Start and stop a gas test

To start and stop a gas test, the CNC must write a value to the following coil:

 0x3180 (coil: gas test)

Description

Steps Required to

Remove?

Ye s

0x3180 (coil: gas test)

Description: Write a value for ON or OFF to this coil to start or stop a gas test.

• Write 0xFF00 (ON) to start a gas test.

• Write 0x0000 (OFF) to stop a gas test.

Encoding or scaling: N/A

Unit: N/A

Function (hex): 05 (Write Single Coil)

36 810400 Reference Guide Powermax65/85/105 SYNC

Example request and response

Request from CNC to start a gas test:

:01053180FF004A<CR><LF>

Value Description

: Start of message

01 Plasma power supply node address

05 Write Single Coil

3180 Coil address (0x3180)

FF00 Value to write to coil address 0x3180 (0xFF00 = ON)

4A LRC

<CR><LF> End

Response from plasma power supply:

:01053180FF004A<CR><LF>

Serial Communication Programmer Reference Guide

Value Description

: Start of message

01 Plasma power supply node address (confirmed)

05 Write Single Coil (confirmed)

3180 Coil address (0x3180) (confirmed)

FF00 Value to write to coil address 0x3180 (0xFF00 = ON) (confirmed)

4A LRC

<CR><LF> End

Request from CNC to stop a gas test:

:01053180000049<CR><LF>

Value Description

: Start of message

01 Plasma power supply node address

05 Write Single Coil

3180 Coil address (0x3180)

0000 Value to write to coil address 0x3180 (0x0000 = OFF)

49 LRC

<CR><LF> End

Powermax65/85/105 SYNC Reference Guide 810400 37

Serial Communication Programmer Reference Guide

Response from plasma power supply:

:01053180000049<CR><LF>

Value Description

: Start of message

01 Plasma power supply node address (confirmed)

05 Write Single Coil (confirmed)

3180 Coil address (0x3180) (confirmed)

0000 Value to write to coil address 0x3180 (0x0000 = OFF) (confirmed)

49 LRC

<CR><LF> End

Stop fault code 0-50-0

Before you change a cartridge, you must set the torch-disable switch to the yellow lock (X) position. Otherwise you get fault code 0-50-0 (the cartridge is off the torch). To stop fault code 0-50-0 after you install the new cartridge, The CNC must write values to the following registers:

 0x308E (command to stop fault code 0-50-0 with a special quick restart)

 0x308F (special quick restart approval)

To give sufficient time for the plasma power supply to complete the



restart, wait 2 seconds before you send a new read or write request.

This special quick restart only stops fault code 0-50-0. You cannot stop



other fault codes with this special quick restart.

0x308E, 0x308F (stop fault code 0-50-0 with a quick restart)

Description: Write a value of 0x0404 to address 0x308E and a value of 0x0618 to address

0x308F to do a special quick restart that stops fault code 0-50-0.

Encoding or scaling: N/A

Unit: N/A

Function (hex): 10 (Write Multiple Registers)

38 810400 Reference Guide Powermax65/85/105 SYNC

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Example request and response

Request from CNC:

:0110308E0002040404061805<CR><LF>

Value Description

: Start of message

01 Plasma power supply node address

10 Write Multiple Registers

308E First register address (0x308E)

0002 Quantity of registers to write (0x002 = 2):

• 0x308E (special quick restart command)

• 0x308F (special quick restart approval)

04 Quantity of bytes in the Data segment (0x04 = 4)

0404 Value to write to address 0x308E (0x0404 = special quick restart)

0618 Value to write to address 0x308F (0x0618 = approval)

05 LRC

<CR><LF> End

Response from plasma power supply:

:0110308E00022F<CR><LF>

Value Description

: Start of message

01 Plasma power supply node address (confirmed)

10 Write Multiple Registers (confirmed)

308E Register address (confirmed)

0002 Quantity of registers to write (confirmed)

2F LRC

<CR><LF> End

Powermax65/85/105 SYNC Reference Guide 810400 39

Serial Communication Programmer Reference Guide

Exit remote control mode

To exit remote control mode, the CNC must write a value of zero (0x0000) to the following registers (the same registers used to enter remote control mode):

 0x3080 (operating mode setting)

 0x3081 (output current (A) setting)

 0x3082 (gas pressure setting)

Example request and response

Request from CNC:

:0110308000030600000000000036<CR><LF>

Value Description

: Start of message

01 Plasma power supply node address

10 Write Multiple Registers

3080 First register address (0x3080)

0003 Quantity of registers to write (0x0003 = 3):

• 0x3080 (operating mode)

• 0x3081 (output current)

• 0x3082 (gas pressure)

06 Quantity of bytes in the Data segment (0x06 = 6)

0000 Value to write to address 0x3080 (0x0000)

0000 Value to write to address 0x3081 (0x0000)

0000 Value to write to address 0x3082 (0x0000)

36 LRC

<CR><LF> End

Response from plasma power supply:

:0110308000033C<CR><LF>

Value Description

: Start of message

01 Plasma power supply node address (confirmed)

10 Write Multiple Registers (confirmed)

3080 First register address (confirmed)

0003 Quantity of registers to write (confirmed)

3C LRC

<CR><LF> End

40 810400 Reference Guide Powermax65/85/105 SYNC

When the Powermax65/85/105 SYNC exits remote control mode, the remote mode indicator no longer shows on the LCD display. Refer to page 30.

You can also stop remote control mode by setting the power switch on the



Powermax65/85/105 SYNC to the OFF (O) position and waiting approximately 1 minute.

Get data from the plasma power supply

Read the plasma power supply settings

To read the plasma power supply settings, the CNC reads the values in the following registers:

 0x3010 (operating mode setting)

 0x3011 (output current (A) setting)

 0x3012 (gas pressure setting)

0x3010 (operating mode)

Serial Communication Programmer Reference Guide

Description: Reads the operating mode setting. Valid values are as follows:

• 0x0001 (cut)

• 0x0002 (expanded metal)

• 0x0003 (gouge)

Encoding or scaling: 16-bit, fixed-point binary with 1-bit sign at MSB and 0-bit decimal at LSB

Unit: N/A

Function (hex): 04 (Read Registers)

0x3011 (output current (A) setting)

Description: Reads the hexadecimal value for the output current (A) setting.

Convert the hexadecimal value to decimal, and then divide that decimal value by 64 to get the output current (A).

Encoding or scaling: 16-bit, fixed-point binary with 1-bit sign at MSB and 6 bit decimal at LSB

Unit: Amperes

Function (hex): 04 (Read Registers)

Powermax65/85/105 SYNC Reference Guide 810400 41

Serial Communication Programmer Reference Guide

0x3012 (gas pressure setting)

Description: Reads the hexadecimal value for the gas pressure setting in psi.

Convert the hexadecimal value to decimal, and then divide that decimal value by 128 to get the gas pressure (psi).

Encoding or scaling: 16-bit, fixed-point binary with 1-bit sign at MSB and 7-bit decimal at LSB

Unit: psi

Function (hex): 04 (Read Registers)

Example request and response

Request from CNC:

:010430100003B8<CR><LF>

Value Description

: Start of message

01 Plasma power supply node address

04 Read Registers

3010 First register address (0x3010)

0003 Quantity of registers to read (0x0003 = 3):

• 0x3010 (operating mode setting)

• 0x3011 (output current (A) setting)

• 0x3012 (gas pressure setting)

B8 LRC

<CR><LF> End

Response from plasma power supply:

:01040600011A40260074<CR><LF>

Value Description

: Start of message

01 Plasma power supply node address (confirmed)

04 Read Registers (confirmed)

06 Quantity of bytes in the Data segment (0x06 = 6)

00 01 00 = 0x00 = high byte

01 = 0x01 = cut

1A40 0x1A40 = 6720/64 = 105 A

2600 0x2600 = 9728/128 = 76 psi

74 LRC

<CR><LF> End

42 810400 Reference Guide Powermax65/85/105 SYNC

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Read the actual output of the plasma power supply

To read the actual output of the plasma power supply, the CNC reads the values in the following registers:

 0x3018 (actual output current)

 0x3019 (actual gas pressure)

0x3018 (actual output current)

Description: Reads the hexadecimal value for the actual output current (A).

Convert the hexadecimal value to decimal, and then divide that decimal value by 64 to get the output current (A).

Encoding or scaling: 16-bit, fixed-point binary with 1-bit sign at MSB and 6 bit decimal at LSB

Unit: Amperes

Function (hex): 04 (Read Registers)

0x3019 (actual gas pressure)

Description: Reads the hexadecimal value for the actual gas pressure in psi.

Convert the hexadecimal value to decimal, and then divide that decimal value by 128 to get the gas pressure (psi).

Encoding or scaling: 16-bit, fixed-point binary with 1-bit sign at MSB and 7-bit decimal at LSB

Unit: psi

Function (hex): 04 (Read Registers)

Example request and response

Request from CNC:

:010430180002B1<CR><LF>

Value Description

: Start of message

01 Plasma power supply node address

04 Read Registers

3018 First register address (0x3018)

0002 Quantity of registers to read (0x0002 = 2):

• 0x3018 (actual output current)

• 0x3019 (actual gas pressure)

B1 LRC

<CR><LF> End

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Serial Communication Programmer Reference Guide

Response from plasma power supply:

:010404104023DDA7<CR><LF>

Value Description

: Start of message

01 Plasma power supply node address (confirmed)

04 Read Registers (confirmed)

04 Quantity of bytes in the Data segment (0x04 = 4)

1040 0x1040 = 4160/64 = 65 A

23DD 0x23DD = 9181/128 = 72 psi

A7 LRC

<CR><LF> End

Read the total cut counts for this plasma power supply

To read the total cut counts for this plasma power supply, the CNC reads the values in the following registers:

 0x3028 (total number of torch starts – bytes 1 and 0)

 0x3029 (total number of torch starts – bytes 3 and 2)

 0x302A (cumulative pilot arc time – bytes 1 and 0)

 0x302B (cumulative pilot arc time – bytes 3 and 2)

 0x302C (total number of arc transfers – bytes 1 and 0)

 0x302D (total number of arc transfers – bytes 3 and 2)

 0x302E (cumulative arc transfer time – bytes 1 and 0)

 0x302F (cumulative arc transfer time – bytes 3 and 2)

0x3028 (total number of torch starts – bytes 1 and 0)

Description: Reads the hexadecimal value of the low word (bytes 1 and 0) for the total number

of torch starts that the plasma power supply has done in its life. Refer to 0x3029 (total number of starts – bytes 3 and 2).

Encoding or scaling: 32-bit unsigned binary number

Unit: Number

Function (hex): 04 (Read Registers)

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Serial Communication Programmer Reference Guide

0x3029 (total number of starts – bytes 3 and 2)

Description: Reads the hexadecimal value of the high word (bytes 3 and 2) for the total number

of torch starts that the plasma power supply has done in its life. You will need to interchange the hexadecimal values for 0x3028 and 0x3029, and

then convert the result to decimal.

Encoding or scaling: 32-bit unsigned binary number

Unit: Number

Function (hex): 04 (Read Registers)

0x302A (cumulative pilot arc time – bytes 1 and 0)

Description: Reads the hexadecimal value of the low word (bytes 1 and 0) for the cumulative

pilot arc time in seconds that the plasma power supply has had in its life. Refer to 0x302B (cumulative pilot arc time – bytes 3 and 2).

Encoding or scaling: 32-bit unsigned binary number

Unit: Seconds

Function (hex): 04 (Read Registers)

0x302B (cumulative pilot arc time – bytes 3 and 2)

Description: Reads the hexadecimal value of the high word (bytes 3 and 2) for the cumulative

pilot arc time in seconds that the plasma power supply has had in its life. You will need to interchange the hexadecimal values for 0x302A and 0x302B, and

then convert the result to decimal.

Encoding or scaling: 32-bit unsigned binary number

Unit: Seconds

Function (hex): 04 (Read Registers)

0x302C (total number of arc transfers – bytes 1 and 0)

Description: Reads the hexadecimal value of the low word (bytes 1 and 0) for the total number

of arc transfers that the plasma power supply has done in its life. Refer to 0x302D (total number of arc transfers – bytes 3 and 2).

Encoding or scaling: 32-bit unsigned binary number

Unit: Number

Function (hex): 04 (Read Registers)

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0x302D (total number of arc transfers – bytes 3 and 2)

Description: Reads the hexadecimal value of the high word (bytes 3 and 2) for the total number

of arc transfers that the plasma power supply has done in its life. You will need to interchange the hexadecimal values for 0x302C and 0x302D, and

then convert the result to decimal.

Encoding or scaling: 32-bit unsigned binary number

Unit: Number

Function (hex): 04 (Read Registers)

0x302E (cumulative arc transfer time – bytes 1 and 0)

Description: Reads the hexadecimal value of the low word (bytes 1 and 0) for the cumulative arc

transfer time in seconds that the plasma power supply has had in its life. Refer to 0x302F (cumulative arc transfer time – bytes 3 and 2).

Encoding or scaling: 32-bit unsigned binary number

Unit: Seconds

Function (hex): 04 (Read Registers)

0x302F (cumulative arc transfer time – bytes 3 and 2)

Description: Reads the hexadecimal value of the high word (bytes 3 and 2) for the cumulative

arc transfer time in seconds that the plasma power supply has had in its life. You will need to interchange the hexadecimal values for 0x302E and 0x302F, and

then convert the result to decimal.

Encoding or scaling: 32-bit unsigned binary number

Unit: Seconds

Function (hex): 04 (Read Registers)

46 810400 Reference Guide Powermax65/85/105 SYNC

Example request and response

Request from CNC:

:0104302800089B<CR><LF>

Value Description

: Start of message

01 Plasma power supply node address

04 Read Registers

3028 First register address (0x3028)

0008 Quantity of registers to read (0x0008 = 8):

• 0x3028 (total number of torch starts – bytes 1 and 0)

• 0x3029 (total number of torch starts – bytes 3 and 2)

• 0x302A (cumulative pilot arc time – bytes 1 and 0)

• 0x302B (cumulative pilot arc time – bytes 3 and 2)

• 0x302C (total number of arc transfers – bytes 1 and 0)

• 0x302D (total number of arc transfers – bytes 3 and 2)

• 0x302E (cumulative arc transfer time – bytes 1 and 0)

• 0x302F (cumulative arc transfer time – bytes 3 and 2)

Serial Communication Programmer Reference Guide

9B LRC

<CR><LF> End

Response from plasma power supply:

:010410D1B6000010EB0000D0750000D5AE00069B<CR><LF>

Value Description

: Start of message

01 Plasma power supply node address (confirmed)

04 Read Registers (confirmed)

10 Quantity of bytes in the Data segment (0x10 = 16)

D1B6 0000 D1B6 0000 = 0x0000D1B6 = 53,686 starts

10EB 0000 10EB 0000 = 0x000010EB = 4,331 seconds of pilot arc (72 minutes)

D075 0000 D075 0000 = 0x0000D075 = 53,365 arc transfers

D5AE 0006 D5AE 0006 = 0x0006D5AE = 447,918 seconds of arc transfer (124 hours)

9B LRC

<CR><LF> End

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Read the 16-character UID number for the installed cartridge

To read the unique identification (UID) number for the installed cartridge, the CNC reads the values in the following registers:

 0x3030 (UID, bytes 0 and 1)

 0x3031 (UID, bytes 2 and 3)

 0x3032 (UID, bytes 4 and 5)

 0x3033 (UID, bytes 6 and 7)

 0x3034 (UID, bytes 8 and 9)

 0x3035 (UID, bytes 10 and 11)

 0x3036 (UID, bytes 12 and 13)

 0x3037 (UID, bytes 14 and 15)

0x3030 – 0x3037 (cartridge UID, bytes 0 – 15)

Description: Reads the hexadecimal value for the 16-character ASCII UID for the installed

cartridge. Convert the hexadecimal values to ASCII. A hexadecimal value of 00000000000000000000000000000000 indicates a

cartridge communication failure or radio frequency error.

Encoding or scaling: N/A

Unit: N/A

Function (hex): 04 (Read Registers)

48 810400 Reference Guide Powermax65/85/105 SYNC

Example request and response

Request from CNC:

:01043030000893<CR><LF>

Value Description

: Start of message

01 Plasma power supply node address

04 Read Registers

3030 First register address (0x3030)

0008 Quantity of registers to read (0x0008 = 8):

• 0x3030 (UID, bytes 0 and 1)

• 0x3031 (UID, bytes 2 and 3)

• 0x3032 (UID, bytes 4 and 5)

• 0x3033 (UID, bytes 6 and 7)

• 0x3034 (UID, bytes 8 and 9)

• 0x3035 (UID, bytes 10 and 11)

• 0x3036 (UID, bytes 12 and 13)

• 0x3037 (UID, bytes 14 and 15)

Serial Communication Programmer Reference Guide

93 LRC

<CR><LF> End

Response from plasma power supply:

:0104104530303430314430303336464232354471<CR><LF>

Value Description

: Start of message

01 Plasma power supply node address (confirmed)

04 Read Registers (confirmed)

10 Quantity of bytes in the Data segment

(0x10 = 16)

45303034303144303033364642323544 = E00401D0036FB25D (ASCII)

71 LRC

<CR><LF> End

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Serial Communication Programmer Reference Guide

Read the total cut counts for the installed cartridge

To read the total cut counts for the installed cartridge, the CNC reads the values in the following registers:

 0x3040 (total number of starts)

 0x3041 (cumulative pilot arc time)

 0x3042 (total number of arc transfers)

 0x3043 (cumulative arc transfer time)

0x3040 (total number of starts)

Description: Reads the hexadecimal value for the total number of pilot arc starts that the

cartridge has done in its life. Convert the hexadecimal value to decimal.

Encoding or scaling: 16-bit unsigned binary number

Unit: N/A

Function (hex): 04 (Read Registers)

0x3041 (cumulative pilot arc time)

Description: Reads the hexadecimal value for the cumulative pilot arc time in seconds that the

cartridge has had in its life. Convert the hexadecimal value to decimal.

Encoding or scaling: 16-bit unsigned binary number

Unit: N/A

Function (hex): 04 (Read Registers)

0x3042 (total number of arc transfers)

Description: Reads the hexadecimal value for the total number of arc transfers that the cartridge

has done in its life. Convert the hexadecimal value to decimal.

Encoding or scaling: 16-bit unsigned binary number

Unit: N/A

Function (hex): 04 (Read Registers)

50 810400 Reference Guide Powermax65/85/105 SYNC

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0x3043 (cumulative arc transfer time)

Description: Reads the hexadecimal value for the cumulative arc transfer time in seconds that

the cartridge has had in its life. Each count equals 2 seconds. Convert the hexadecimal value to decimal, and multiply by 2.

Encoding or scaling: 16-bit unsigned binary number

Unit: N/A

Function (hex): 04 (Read Registers)

Example request and response

Request from CNC:

:01043040000487<CR><LF>

Value Description

: Start of message

01 Plasma power supply node address

04 Read Registers

3040 First register address (0x3040)

0004 Quantity of registers to read (0x0004 = 4):

• 0x3040 (total number of starts)

• 0x3041 (cumulative pilot arc time)

• 0x3042 (total number of arc transfers)

• 0x3043 (cumulative arc transfer time)

87 LRC

<CR><LF> End

Powermax65/85/105 SYNC Reference Guide 810400 51

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Response from plasma power supply:

:01040800D6000900D3098FA9<CR><LF>

Value Description

: Start of message

01 Plasma power supply node address (confirmed)

04 Read Registers (confirmed)

08 Quantity of bytes in the Data segment (0x08 = 8)

00D6 0x00D6 = 214 starts

0009 0x0009 = 9 seconds of pilot arc

00D3 0x00D3 = 211 arc transfers

098F 0x098F = 2,447 X 2 = 4,894 seconds of arc transfer (82 minutes)

A9 LRC

<CR><LF> End

Read the 4 most recent faults for the installed cartridge

To read the 4 most recent faults for the installed cartridge, the CNC reads the values in the following registers:

 0x3044 (fault log 0 – newest fault)

 0x3045 (fault log 1)

 0x3046 (fault log 2)

 0x3047 (fault log 3 – oldest fault)

0x3044 (fault log 0)

Description: Reads the hexadecimal value of the fault code for the most recent fault for the

installed cartridge. If there is no fault, this reads a value of 0x0000 (0-00-0). Convert the hexadecimal value to decimal. Refer to Fault code list on page 32 for the complete list of possible fault codes.

Encoding or scaling: 10-bit effective unsigned binary number from the LSB of a 16-bit binary number

Unit: N/A

Function (hex): 04 (Read Registers)

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0x3045 (fault log 1)

Description: Reads the hexadecimal value of the fault code for the second most-recent fault for

the installed cartridge. If there is no fault, this reads a value of 0x0000 (0-00-0). Convert the hexadecimal value to decimal. Refer to Fault code list on page 32 for the complete list of possible fault codes.

Encoding or scaling: 10-bit effective unsigned binary number from the LSB of a 16-bit binary number

Unit: N/A

Function (hex): 04 (Read Registers)

0x3046 (fault log 2)

Description: Reads the hexadecimal value of the fault code for the third most-recent fault for the

Encoding or scaling: 10-bit effective unsigned binary number from the LSB of a 16-bit binary number

Unit: N/A

Function (hex): 04 (Read Registers)

0x3047 (fault log 3)

Description: Reads the hexadecimal value of the fault code for the fourth most-recent fault for

Encoding or scaling: 10-bit effective unsigned binary number from the LSB of a 16-bit binary number

Unit: N/A

Function (hex): 04 (Read Registers)

Powermax65/85/105 SYNC Reference Guide 810400 53

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Example request and response

Request from CNC:

:01043044000483<CR><LF>

Value Description

: Start of message

01 Plasma power supply node address

04 Read Registers

3044 First register address (0x3044)

0004 Quantity of registers to read (0x0004 = 4):

• 0x3044 (fault log 0)

• 0x3045 (fault log 1)

• 0x3046 (fault log 2)

• 0x3047 (fault log 3)

83 LRC

<CR><LF> End

Response from plasma power supply:

:010408007900790000000001<CR><LF>

Value Description

: Start of message

01 Plasma power supply node address (confirmed)

04 Read Registers (confirmed)

08 Quantity of bytes in the Data segment (0x08 = 8)

0079 0x0079 = 0121 = fault code 0-12-1 (output gas pressure is low) (newest fault)

0079 0x0079 = 0121 = fault code 0-12-1 (output gas pressure is low)

0000 0x0000 = 0000 = 0-00-0 (no fault code)

0000 0x0000 = 0000 = 0-00-0 (no fault code) (oldest fault)

01 LRC

<CR><LF> End

54 810400 Reference Guide Powermax65/85/105 SYNC

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Read the name of the installed cartridge

To read the name of the installed cartridge, the CNC reads the values in the following registers:

 0x3048 (name, bytes 0 and 1)

 0x3049 (name, bytes 2 and 3)

 0x304A (name, bytes 4 and 5)

 0x304B (name, bytes 6 and 7)

 0x304C (name, bytes 8 and 9)

 0x304D (name, bytes 10 and 11)

0x3048 – 0x304D (cartridge name, bytes 0 – 11)

Description: Reads the hexadecimal values for the 12 bytes of the name of the installed

cartridge. Convert the hexadecimal values to ASCII text. Refer to Tab l e 7.

Encoding or scaling: N/A

Unit: N/A

Function (hex): 04 (Read Registers)

Table 7 – Cartridge names

Hex value ASCII Text Cartridge Name

43204D454348000000000000 C MECH Standard Mechanized Cutting

43204D464E43000000000000 C MFNC FineCut Mechanized Cutting

4720434E544C000000000000 G CNTL Maximum Control Gouging

4720524D564C000000000000 G RMVL Maximum Removal Gouging

432048414E44000000000000 C HAND Drag Hand Cutting

432048464E43000000000000 C HFNC FineCut Hand Cutting

4320464C5553480000000000 C FLUSH FlushCut Cutting

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Example request and response

Request from CNC:

:0104304800067D<CR><LF>

Value Description

: Start of message

01 Plasma power supply node address

04 Read Registers

3048 First register address

0006 Quantity of registers to read (0x0006 = 6):

• 0x3048 (name, bytes 0 and 1)

• 0x3049 (name, bytes 2 and 3)

• 0x304A (name, bytes 4 and 5)

• 0x304B (name, bytes 6 and 7)

• 0x304C (name, bytes 8 and 9)

• 0x304D (name, bytes 10 and 11)

7D LRC

<CR><LF> End

Response from plasma power supply:

:01040C43204D4543480000000000006F<CR><LF>

Value Description

: Start of message

01 Plasma power supply node address (confirmed)

04 Read Registers (confirmed)

0C Quantity of bytes in the Data segment (0x0C =12)

43204D454348000000000000 = C MECH (ASCII) = Standard Mechanized Cutting

6F LRC

<CR><LF> End

56 810400 Reference Guide Powermax65/85/105 SYNC

Serial Communication Programmer Reference Guide

Read the Start and Motion signal status of the plasma power supply

To read the status of the plasma power supply, the CNC reads the following coils:

 0x3100 (coil: Start switch signal status)

 0x3101 (coil: Motion switch signal status)

0x3100 (coil: Start switch signal status)

Description: Reads the hexadecimal value of the Start switch signal status coil.

Convert the hexadecimal value to binary, as follows:

• 0x00 = 0 (binary) = OFF (Start input is OFF)

• 0x01 = 1 (binary) = ON (Start input is ON) When the Start input is OFF, the plasma power supply is idle. When the Start input is ON, there is a pilot arc or the arc has transferred.

Encoding or scaling: N/A

Unit: N/A

Function (hex): 01 (Read Coil)

0x3101 (coil: Motion switch signal status)

Description: Reads the hexadecimal value of the Motion switch signal status coil.

Convert the hexadecimal value to binary, as follows:

• 0x00 = 0 (binary) = OFF (Motion output is OFF)

• 0x01 = 1 (binary) = ON (Motion output is ON) When the Motion output is OFF, there is no motion. When the Motion output is ON, there is motion.

Encoding or scaling: N/A

Unit: N/A

Function (hex): 01 (Read Coil)

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Example request and response

Request from CNC to read 1 coil:

:010131000001CC<CR><LF>

Value Description

: Start of message

01 Plasma power supply node address

01 Read Coil

3100 Coil address (0x3100)

0001 Quantity of coils to read (0x0001 = 1):

• 0x3100 (Start switch signal status)

CC LRC

<CR><LF> End

Response from plasma power supply for a read of 1 coil:

:01010100FD<CR><LF>

Value Description

: Start of message

01 Plasma power supply node address (confirmed)

01 Read Coil (confirmed)

01 Quantity of bytes in the Data segment (0x01 = 1)

00 0x00 = 0 (binary) = OFF (Start input is OFF)

FD LRC

<CR><LF> End

Request from CNC to read both coils at one time:

:010131000002CB<CR><LF>

Value Description

: Start of message

01 Plasma power supply node address

01 Read Coil

3100 Coil address (0x3100)

0002 Quantity of coils to read (0x0002 = 2):

• 0x3100 (Start switch signal status)

• 0x3101 (Motion switch signal status)

CB LRC

<CR><LF> End

58 810400 Reference Guide Powermax65/85/105 SYNC

Serial Communication Programmer Reference Guide

Response from plasma power supply:

:01010103FA<CR><LF>

Value Description

: Start of message

01 Plasma power supply node address (confirmed)

01 Read Coil (confirmed)

01 Quantity of bytes in the Data segment (0x01 = 1)

03 0x03 = 11 (binary) =

• 1 (binary) = ON (Start input is ON)

• 1 (binary) = ON (Motion input is ON)

FA LRC

<CR><LF> End

Powermax65/85/105 SYNC Reference Guide 810400 59

Serial Communication Programmer Reference Guide

60 810400 Reference Guide Powermax65/85/105 SYNC

Flowchart Examples

This section contains examples of how you can program your CNC using the information in this guide. Examples for Powermax65/85/105 SYNC and older plasma power supplies are included. Older Powermax plasma power supplies include Powermax65/85/105/125 and Powermax45 XP.

Example Page

Figure 1 – Operator selects the plasma power supply type (SYNC / older) page 62

Figure 2 – CNC automatically selects the plasma power supply type (SYNC / older) page 63

Figure 3 – CNC requests plasma power supply and torch lead information page 64

Figure 4 – Exit remote control mode page 64

Figure 5 – CNC reads and sets permitted cut mode, amperage, and gas pressure page 65

Figure 6 – CNC requests SYNC plasma power supply and cartridge data page 66

Figure 7 – CNC starts and stops a gas test page 67

Figure 8 – Serial communications during SYNC quick restart and cold restart (fault 0-19-9) page 68

Figure 9 – Continue cutting after SYNC restart, cartridge change, or cartridge fault page 69

Figure 10 – Stop SYNC cap-off fault 0-50-0 page 70

Figure 11 – Continuously check for SYNC faults / plasma power supply readiness page 71

Figure 12 – SYNC faults that stop with the next Start signal page 72

Figure 13 – SYNC cartridge end-of-life faults (0-32-0, 0-32-1) page 73

Figure 14 – SYNC faults that require action to continue to cut page 74

Figure 15 – Request data from older Powermax plasma power supplies page 75

Figure 16 – Operator or CNC does gas test to check air supply capacity page 76

Figure 17 – Behavior when SYNC tries to read the cartridge after cartridge installation page 77

Figure 18 – (Mech/mini) Cartridge cannot send data to the power supply (fault 0-14-0) page 78

Figure 19 – (Hand torch) Cartridge cannot send data to the power supply (fault 0-14-0) page 79

Powermax65/85/105 SYNC Reference Guide 810400 61

62 810400 Reference Guide Powermax65/85/105 SYNC

COMMUNICATE USING

POWERMAX SYNC

0x3xxx ADDRESSING.

IF VALID

RESPONSE

IF NO

RESPONSE

POWERMAX IS NOT

POWERED ON.

CHECK FOR

FAULT.

0x0301A

EXIT

ENTER

IF VALID

RESPONSE

IF NO

RESPONSE

POWERMAX IS NOT

POWERED ON.

EXIT

CHECK FOR

FAULT.

0x0298

COMMUNICATE USING

OLDER 0x2xxx

ADDRESSING.

OLDER

SYNC

ON THE CNC GUI SETUP SCREEN, USER

MANUALLY SELECTS THE POWERMAX

FAMILY AND MODEL CONNECTED.

CNC USES

APPROPRIATE

ADDRESSING.

EXAMPLE REQUEST

:0104301A0001B0

EXAMPLE REQUEST

:01042098000142

EXIT

Figure 1 – Operator selects the plasma power supply type (SYNC / older)

Serial Communication Programmer Reference Guide

EXAMPLE REQUEST :012B0E0401C1

01 = MODBUS ID 2B = ENCAPSULATED INTERFACE TRANSPORT 0E = READ DEVICE ID 04 = REQUEST ONE SPECIFIC ID OBJECT 01 = STARTING ADDRESS C1 = LRC

IF NO

RESPONSE

POWERMAX IS NOT

POWERED ON.

POWER SUPPLY CONNECTED?

READ DEVICE ID 0x2B0E0401C1

ENTER

IF VALID

RESPONSE

COMMUNICATE USING

POWERMAX 0x2xxx ADDRESSING

READ CURRENT SET MAX TO

DETERMINE MAX POWERMAX AMPS.

READ REGISTER 0x209A

COMMUNICATE USING

POWERMAX SYNC

0x3xxx ADDRESSING

WHICH ID WAS

DETECTED?

EXIT

RESPONSE TO DEVICE ID (SEE EXAMPLE 1 BELOW):

"081288" = POWERMAX45 XP

"081223" = POWERMAX65/85/105

"081251" = POWERMAX125

RESPONSE TO DEVICE ID (SEE EXAMPLE 2 BELOW): "081335" = POWERMAX65/85/105 SYNC

EXAMPLE 1 OLDER POWERMAX RESPONSE

:012B0E04810001010106 303831323233

=ASCII "081223" = POWERMAX65/85/105

EXAMPLE 2 SYNC RESPONSE

:012B0E04810001010106 303831333335

=ASCII "081335" = POWERMAX65/85/105 SYNC

EXAMPLE REQUEST: :010430000001CA EXAMPLE RESPONSE: :010402 0508

05 = MACHINE TORCH 50 FOOT 08 = POWERMAX105 SYNC 200 V –

600 V CSA

OLDER

SYNC

READ SYNC LEAD LENGTH AND

POWER SUPPLY ID.

READ REGISTER 0x3000

Figure 2 – CNC automatically selects the plasma power supply type (SYNC / older)

Powermax65/85/105 SYNC Reference Guide 810400 63

Serial Communication Programmer Reference Guide

READ TORCH LENGTH INDEX.

COIL READ 0x0808-0x0809

REQUEST POWERMAX LEAD LENGTH

AND MAX CURRENT CAPABILITY

EXIT

READ CURRENT SET MAX.

READ REGISTER 0x209A

ENTER

OLDER

REQUEST SYNC POWER SUPPLY ID, TORCH TYPE, LEAD LENGTH

EXIT

ENTER

SYNC

EXIT

ENTER

SET CUT MODE TO ZERO.

SET CURRENT TO ZERO. REGISTER WRITE 0x2094

SET PRESSURE TO ZERO.

SET CUT MODE, CURRENT, AND

PRESSURE TO ZERO.

Figure 3 – CNC requests plasma power supply and torch lead information

Figure 4 – Exit remote control mode

OLDERSYNC

64 810400 Reference Guide Powermax65/85/105 SYNC

Powermax65/85/105 SYNC Reference Guide 810400 65

SET

PARAMETERS

BY ?

SYNC AUTOMATICALLY SETS

MODE, CURRENT, AND PRESSURE

TO CARTRIDGE NOMINAL

CNC CUSTOM CUT MODE, CURRENT, PRESSURE

WRITE MODE , CURRENT,

AND PRESSURE

TO ENTER REMOTE CONTROL MODE

DETERMINE NEXT CUT MODE,

AMPS AND PRESSURE

BY CUT CHART, OPERATOR

INPUT, OR G-CODE

VERIFY NEXT AGAINST

CARTRIDGE CAPABILITY

CHECK FOR

FAULT.

0x0298

ALLOW

CYCLE START

RESOLVE

FAULT

WRITE CUT MODE.

WRITE SET CURRENT.

WRITE SET PRESSURE.

READ CARTRIDGE CUT MODE AND

MIN/MAX CURRENT AND

PRESSURE.

DETERMINE NEXT CUT MODE, AMPS

AND PRESSURE BY CUT CHART,

OPERATOR INPUT, OR G-CODE

VERIFY NEXT AGAINST MIN/MAX CAPABILITY

TO ENTER REMOTE

CONTROL MODE

READ CURRENT SET LOW AND HIGH.

READ PRESSURE SET LOW AND HIGH.

CHECK FOR

FAULT.

0x0301A

ALLOW

CYCLE START

MINOR OR

MAJOR ?

BEST PRACTICE / AUTOMATIC

ENTERENTER

READ CARTRIDGE PN.

POWER SUPPLY OR MAJOR FAULT

MINOR FAULT, OPERATION ALLOWED

FAULT DETECTED

NO FAULTS

0-00-0

POWER SUPPLY

OR MAJOR FAULT FAULT DETECTED

NO FAULTS

0-00-0

FIX THE PROBLEM

MINOR FAULT,

OPERATION ALLOWED

Figure 5 – CNC reads and sets permitted cut mode, amperage, and gas pressure

SYNC

OLDER

Serial Communication Programmer Reference Guide

READ LATEST FAULT.

READ CARTRIDGE

NOMINAL AMPS.

READ INSTANTANEOUS

SYSTEM PRESSURE.

REQUEST

DATA

READ POWER SUPPLY CUMULATIVE

COUNTS: STARTS, PILOT TIME, TRANSFERS, TRANSFER TIME.

READ TORCH TYPE/LENGTH ID,

CARTRIDGE MIN/MAX AMPS AND

PRESSURE.

READ CARTRIDGE CUMULATIVE

STARTS, PILOT TIME,

TRANSFERS, TRANSFER TIME.

READ CARTRIDGE FAULT LOG OF

UP TO 4 FAULTS.

READ POWER SUPPLY ACTIVE

SETTINGS: MODE, CURRENT,

PRESSURE.

ENTER

EXIT

SYNC

READ CARTRIDGE NAME.

CNC LOGS FAULTS FOR FUTURE

MAINTENANCE, TROUBLESHOOTING,

SHOP AIR CAPACITY OR OPERATOR

TRENDS, ETC.

Figure 6 – CNC requests SYNC plasma power supply and cartridge data

66 810400 Reference Guide Powermax65/85/105 SYNC

Serial Communication Programmer Reference Guide

TO TURN GAS ON

COIL WRITE 0xFF00 TO 0x3180

TO TURN GAS OFF

COIL WRITE 0x0000 TO 0x3180

READ ACTUAL PRESSURE.

SET PRESSURE.

OPTIONAL

EXIT

ENTER

TO TURN GAS ON

COIL WRITE 0xFF00 TO 0x0832

TO TURN GAS OFF

COIL WRITE 0x0000 TO 0x0832

READ ACTUAL PRESSURE.

SET PRESSURE.

ENTER

OPTIONAL

EXIT

DISPLAY ACTUAL

PRESSURE TO USER

DISPLAY ACTUAL

PRESSURE TO USER

Figure 7 – CNC starts and stops a gas test

SYNC

OLDER

Powermax65/85/105 SYNC Reference Guide 810400 67

Serial Communication Programmer Reference Guide

FAULT RESPONSE 0-19-9

(USER HAS SWITCHED OFF POWER,

OR PCB FAULT)

USER SWITCHES THE

POWER SUPPLY OFF

HAVE 60 SECONDS

ELAPSED?

YES

LCD GOES BLANK, SERIAL

COMMUNICATIONS CONTINUE

POWERMAX MODBUS

RESPONSES STOP

EXIT

ENTER

HAS THE USER SWITCHED

POWER SUPPLY BACK ON, AND

COMMUNICATIONS RESUMED?

YES

COMMUNICATIONS

RESUME

Figure 8 – Serial communications during SYNC quick restart and cold restart (fault 0-19-9)

68 810400 Reference Guide Powermax65/85/105 SYNC

Powermax65/85/105 SYNC Reference Guide 810400 69

PRIOR SETTINGS ARE RETAINED,

NO NEED TO RE-SEND.

READ CARTRIDGE PART NUMBER. REGISTER READ 0x3038-0x303A

SAME PART NUMBER AS

CARTRIDGE?

CHECK FOR

FAULT.

0x0301A

ALLOW

CYCLE

START

MINOR OR

MAJOR?

YES

PARAMETERS ARE AUTOMATICALLY SET

BASED ON THE NEW CARTRIDGE INSTALLED.

SYNC SETS NOMINAL MODE, CURRENT,

PRESSURE.

ENTER

SET POINTS

WRITE MODE, CURRENT, PRESSURE.

SET POINTS

POWER SUPPLY USES PRIOR PARAMETERS (CARTRIDGE NOMINAL OR CNC SET).

USE CNC CUSTOM

PARAMETERS

SYNC SETS

PARAMETERS

CNC SETS NEW

CUSTOM PARAMETERS

NO FAULTS

0-00-0

POWER SUPPLY OR MAJOR FAULT

MINOR FAULT, OPERATION ALLOWED

FAULT DETECTED

ENTER REMOTE CONTROL MODE BY

WRITING MODE, CURRENT, PRESSURE.

SYNC

FIX THE PROBLEM

Figure 9 – Continue cutting after SYNC restart, cartridge change, or cartridge fault

Serial Communication Programmer Reference Guide

CNC DISPLAYS A

CONFIRMATION DIALOGUE.

0-50-0

FAULT

SPECIAL QUICK RESTART. REGISTER WRITE

COMMAND CODE 0x0404 TO 0x308E

AND APPROVAL CODE 0x0618 TO 0x308F.

USER PRESSES A SOFT KEY TO

RESTART THE POWERMAX.

EXIT

CNC DISPLAYS 0-50-0 CAP OFF

FAULT MESSAGE. INSTRUCTS

USER TO INSTALL A CARTRIDGE.

USER PRESSES A SOFT

KEY TO CONFIRM.

CHECK FOR

FAULT.

0x0301A

WAIT 2 SECONDS FOR

POWER SUPPLY TO RESTART.

OPTIONAL USER

CONFIRMATION

SYNC

SPECIAL QUICK RESTART REQUEST EXAMPLE :0110308E000204 04040618

01 = POWERMAX ID 10 = WRITE MULTIPLE REGISTERS 308E = STARTING ADDRESS 0002 = QUANTITY OF REGISTERS 04 = BYTE COUNT 0404 = QUICK RESTART COMMAND CODE 0618 = QUICK RESTART APPROVAL CODE 05 = LRC

EXAMPLE RESPONSE :0110308E00022F :01 = POWERMAX ID 10 = MULTIPLE REGISTERS 308E = STARTING ADDRESS 0002 = 2 REGISTERS 2F = LRC

NOTES: 1: THE MINI MACHINE TORCH DOES NOT HAVE A LOCK/UNLOCK SWITCH. REMOVING THE CARTRIDGE WITH OUT POWERING OFF THE POWER SUPPLY WILL CAUSE A 0-50-0 FAULT, WHICH PREVENTS A PLASMA START.

2. ONCE A CARTRIDGE IS INSTALLED, 0-50-0 CAN BE STOPPED FROM THE CNC USING THE ABOVE QUICK RESTART COMMAND, OR MANUALLY BY CYCLING THE POWER SUPPLY ON/OFF SWITCH.

3. MAKE SURE THAT THE TORCH IS CONNECTED TO THE PLASMA POWER SUPPLY.

Figure 10 – Stop SYNC cap-off fault 0-50-0

70 810400 Reference Guide Powermax65/85/105 SYNC

Serial Communication Programmer Reference Guide

ENTER

CHECK FOR

FAULT.

0X0301A

MINOR OR

MAJOR?

IF CARTRIDGE-RELATED, REFER TO

CARTRIDGE-CHANGE EXAMPLES

POWER SUPPLY OR MAJOR FAULT

MINOR FAULT,

OPERATION ALLOWED

FAULT DETECTED

NO FAULTS

0-00-0

1-SECOND INTERVAL

FIX THE PROBLEM

Figure 11 – Continuously check for SYNC faults / plasma power supply readiness

SYNC

Powermax65/85/105 SYNC Reference Guide 810400 71

72 810400 Reference Guide Powermax65/85/105 SYNC

ENTER

0-30-0 TSO OR 0-30-1 TSC

ELECTRODE-TO-NOZZLE

CONTINUITY FAULT.

PLASMA START IS

ALLOWED.

ARC CONTINUES. BUT

CARTRIDGE LIFE AND CUT

QUALITY MAY BE COMPROMISED.

0-12-1 OUTPUT GAS

PRESSURE LOW.

0-20-0 INLET AIR

PRESSURE IS TOO

LOW TO OPERATE.

PLASMA START NOT

ALLOWED UNTIL

PRESSURE IS RESTORED.

0-22-0

NO GAS INPUT.

IF FAULT REPEATS OFTEN, REPLACE THE CARTRIDGE.

DO A GAS TEST TO MAKE

SURE PRESSURE IS WITHIN

THE RANGE SPECIFIED.

FAULT CLEARS AUTOMATICALLY AT NEXT START.

Figure 12 – SYNC faults that stop with the next Start signal

Serial Communication Programmer Reference Guide

SYNC

Serial Communication Programmer Reference Guide

ENTER

AT END OF LIFE.

SUGGEST REPLACING THE CARTRIDGE IMMEDIATELY.

0-32-1 CARTRIDGE

INSTALLED WAS

PREVIOUSLY AT END

OF LIFE.

PLASMA START ALLOWED BUT NOT RECOMMENDED.

CUT QUALITY MAY BE

COMPROMISED.

ACTIVE CUT STOPS.

CYCLE THE TORCH LOCK

SWITCH OR CYCLE POWER

TO THE POWER SUPPLY.

PLASMA START NOT ALLOWED.

SUGGEST REPLACING THE CARTRIDGE IMMEDIATELY.

CHANGE TO A

DIFFERENT

CARTRIDGE

USER

ACTION

EXIT

SAME

CARTRIDGE

CYCLE THE TORCH LOCK

SWITCH OR CYCLE POWER

TO THE POWER SUPPLY.

0-32-0 CARTRIDGE IS

Figure 13 – SYNC cartridge end-of-life faults (0-32-0, 0-32-1)

SYNC

Powermax65/85/105 SYNC Reference Guide 810400 73

74 810400 Reference Guide Powermax65/85/105 SYNC

0-11-1 REMOTE AMPERAGE

REQUESTED IS TOO HIGH OR LOW

FOR THE INSTALLED CARTRIDGE

(INVALID CNC REQUEST)

START ALLOWED, BUT NOT

RECOMMENDED UNTIL A VALID AMPERAGE IS SET

FAULT CLEARS WHEN

AMPERAGE IS SET WITHIN

CARTRIDGE MIN/MAX

POWERMAX SETS TO

CARTRIDGE MAX (IF TOO HIGH)

OR MIN (IF TOO LOW)

0-50-0 CARTRIDGE IS OFF FAULT

(CARTRIDGE REMOVED WITHOUT

LOCKING THE TORCH)

USER INSTALLS CARTRIDGE

AND MAKES SURE THE TORCH

IS UNLOCKED

USER INSTALLS A CARTRIDGE

AND UNLOCKS THE TORCH

TYPICAL CARTRIDGE CHANGE,

0-50-1 TORCH IS LOCKED

CNC-INITIATED QUICK RESTART

(SEE QUICK RESTART EXAMPLE)

USER DOES QUICK RESTART

USING THE MAIN POWER

SWITCH

QUICK

RESTART

ENTER

BY CNC

COMMAND

BY MAIN POWER

SWITCH

FAULT CLEARS AUTOMATICALLY

0-11-2 REMOTE PRESSURE

REQUESTED IS TOO HIGH OR LOW

FOR THE INSTALLED CARTRIDGE

(INVALID CNC REQUEST)

START ALLOWED, BUT NOT

RECOMMENDED UNTIL A

VALID PRESSURE IS SET

FAULT CLEARS WHEN PRESSURE

IS SET WITHIN CARTRIDGE

MIN/MAX

0-14-1 CARTRIDGE NOT

RECOGNIZED

START ALLOWED, BUT NOT

RECOMMENDED SINCE PARAMETERS

MAY NOT BE CORRECT

FAULT CLEARS WHEN CARTRIDGE

COMMUNICATION IS WORKING

SYNC

CNC GUIDES THE USER CNC GUIDES THE USER

POWERMAX SETS TO

CARTRIDGE MAX (IF TOO HIGH)

OR MIN (IF TOO LOW)

0-98-1 CARTRIDGE

0-98-2 TORCH

COMMUNICATION FAILURE

POWERMAX DEFAULTS TO 45A, CUT MODE, CUT PRESSURE

CNC GUIDES THE USER TO

CORRECT THE PROBLEM OR

MUST SET THE MODE AND

AMPS MANUALLY

Figure 14 – SYNC faults that require action to continue to cut

Serial Communication Programmer Reference Guide

READ LATEST FAULT.

READ INSTANTANEOUS

SYSTEM PRESSURE.

REQUEST

DATA

READ ARC TIME.

0x209E AND 0x209F

READ

TORCH LENGTH INDEX.

COIL READ 0x0808 AND

0x0809

EXIT

ENTER

OLDER

CNC LOGS FAULTS FOR FUTURE

MAINTENANCE, TROUBLESHOOTING,

SHOP AIR CAPACITY, OR OPERATOR

TRENDS, ETC.

Figure 15 – Request data from older Powermax plasma power supplies

Powermax65/85/105 SYNC Reference Guide 810400 75

76 810400 Reference Guide Powermax65/85/105 SYNC

NOTES:

1. TEST WITH THE LARGEST AMPERAGE CARTRIDGE USED AT THE SITE.

2. TEST AT VARIOUS TIMES OF THE DAY WHEN OTHER EQUIPMENT IS TAXING THE COMPRESSOR.

3. TEST IMMEDIATELY AFTER A LONG PERIOD OF CUTTING TO ENSURE THE COMPRESSOR IS KEEPING UP.

ACCESS THE LCD POWER SUPPLY

DATA MENU. LOCATE THE

PRESSURE FIELD "P: 72 / --"

TURN OFF GAS TEST

READ ACTUAL PRESSURE "P:72 / 71

DONE

BEGIN

WAIT 2 SECONDS FOR

PRESSURE TO STABILIZE

YES

PRESS AND HOLD THE MODE BUTTON FOR 2 SECONDS TO

INITIATE GAS TEST

INCREASE INCOMING AIR PRESSURE, USE

A LARGER DIAMETER AIR SUPPLY HOSE,

CHECK FOR FLOW RESTRICTIONS,

COMPRESSOR IS TOO SMALL, ETC.

"P: 72 / 71"

SET POINT ACTUAL NOW

SYNC OR OLDER (OPERATOR DOES GAS TEST)

IS ACTUAL PRESSURE WITHIN 1

OR 2 PSI OF SET POINT

TURN ON GAS TEST

TURN OFF GAS TEST

READ ACTUAL PRESSURE

EXIT

ENTER

DISPLAY ACTUAL

PRESSURE TO USER

WAIT 2 SECONDS FOR

PRESSURE TO STABILIZE

IS ACTUAL PRESSURE WITHIN 1

OR 2 PSI OF SET POINT

YES

GUIDE THE USER TO INCREASE

INCOMING AIR PRESSURE, USE A

LARGER DIAMETER AIR SUPPLY HOSE,

CHECK FOR FLOW RESTRICTIONS,

COMPRESSOR IS TOO SMALL, ETC.

NO FAULTS

FAULT

RESOLVE FAULT

CHECK FOR

FAULT.

0x0301A

EXAMPLE REQUEST :01053180 FF00

EXAMPLE REQUEST :01053180 0000

SYNC (CNC AUTOMATES GAS TEST)

READ POWER SUPPLY

ACTIVE PRESSURE SET POINT

EXAMPLE REQUEST :010430120001B8

Figure 16 – Operator or CNC does gas test to check air supply capacity

Serial Communication Programmer Reference Guide

Powermax65/85/105 SYNC Reference Guide 810400 77

ENTER

FAULT 0-50-3 CARTRIDGE READ IN PROGRESS.

NORMALLY TAKES LESS THAN 1 SECOND, BUT CAN TAKE

UP TO 6 SECONDS IF RFID HAS DIFFICULTY READING.

YES

FAULT CODE

CLEARS

(FAULT 0-00-0)

QUICK RESTART USING THE

MAIN POWER SWITCH OR

CNC COMMAND

COLD POWER ON

CARTRIDGE

READ OK

EXIT

CUT

ALLOWED

CUT ALLOWED

BUT NOT

RECOMMENDED

OTHER FAULT

CODES

FAULT CODE 0-32-1

CARTRIDGE EOL

MOVE THE LOCK SWITCH

TO THE UNLOCKED

POSITION

SEE 0-14-0 FAULT FLOWCHARTS

FOR HAND OR MECHANIZED,

TORCHES

2ND TRIGGER PULL, CUT

ALLOWED

1ST TRIGGER PULL, WARNING

PUFFS OF AIR, NO ARC

EXIT

FAULT CODE 0-50-2

HAND TORCH

ONLY

EXIT

FAULT CODE

CLEARS

(FAULT 0-00-0)

MINI/ROBOTIC TORCH

AFTER A QUICK RESTART

FAULT CODE

0-14-1 OR 0-98-1 OR 0-98-2

0-50-0 FAULT CODE

EXIT

MINI/ROBOTIC TORCH.

USER FORGETS TO POWER

OFF THE POWER SUPPLY

BEFORE CHANGING THE

CARTRIDGE

QUICK RESTART BY

USER OR CNC REQUIRED

USER INSTALLS A

NEW CARTRIDGE

FAULT CODE 0-14-0

CARTRIDGE CANNOT SEND

DATA TO THE POWER SUPPLY

NOTE: FOR MECHANIZED AND MINI TORCH INSTALLATIONS, SOME FAULT

SCENARIOS PREVENT 0-50-3 FROM DISPLAYING DURING THE CARTRIDGE READ.

SYNC

Figure 17 – Behavior when SYNC tries to read the cartridge after cartridge installation

Serial Communication Programmer Reference Guide

78 810400 Reference Guide Powermax65/85/105 SYNC

CUT NOT ALLOWED UNTIL USER OR

CNC INTERVENTION

USER

ACTION

INSTALL A DIFFERENT

CARTRIDGE

ADJUST MODE AND AMPS

FROM THE SYNC

FRONT PANEL

POWERMAX DEFAULTS TO 45A,

CUT MODE, SYSTEM PRESSURE

FAULT CODE REMAINS

OR 0-14-1 OR 0-98-1 OR 0-98-2

CUT IS ALLOWED

CHANGES A

SETTING

MINI/ROBOTIC TORCH

QUICK RESTART USING THE

MAIN POWER SWITCH OR

CNC COMMAND.

SEE NOTE BELOW.

IF IN REMOTE MODE,

SET MODE AND AMPS

FROM THE CNC

USING SERIAL COMMANDS

EXIT

ENTER

MINI/ROBOTIC TORCH

0-14-1 OR 0-98-1 OR 0-98-2

MOVE THE TORCH LOCK

TO THE UNLOCKED

POSITION (DOWN)

MOVE THE TORCH LOCK

TO THE LOCKED THEN

UNLOCKED POSITION

OTHER ACTIONS TO RETRY

READING THE CARTRIDGE

NOTE: MINI/ROBOTIC TORCHES DO NOT HAVE A LOCK SWITCH. DO A QUICK RESTART OF THE POWER SUPPLY AFTER CHANGING A CARTRIDGE.

FAULT CODE 0-14-0

CARTRIDGE CANNOT SEND

DATA TO THE POWER SUPPLY

Figure 18 – (Mech/mini) Cartridge cannot send data to the power supply (fault 0-14-0)

Serial Communication Programmer Reference Guide

SYNC - MECH/MINI (CLEAR THE FAULT OR SET PARAMETERS MANUALLY)

Powermax65/85/105 SYNC Reference Guide 810400 79

CUT NOT ALLOWED UNTIL USER

ACTION

USER

ACTION

POWERMAX DEFAULTS TO 45A,

CUT MODE, SYSTEM PRESSURE

CHANGE A

SETTING

ADDITIONAL TRIGGER PULLS

NO PUFFS, NO ARC.

CUTTING IS STILL NOT ALLOWED

0-14-0 REMAINS

1ST TRIGGER PULL, WARNING

PUFFS OF AIR, NO ARC

PULL

QUICK RESTART USING

THE MAIN POWER

SWITCH

INSTALL A DIFFERENT

CARTRIDGE

EXIT

ENTER

OTHER FAULT CODES REMAIN

0-14-1 OR 0-98-1 OR 0-98-2

CUT IS ALLOWED

EXIT

OTHER ACTIONS TO RETRY

READING THE CARTRIDGE

MOVE THE TORCH LOCK

TO THE UNLOCKED

POSITION

MOVE THE TORCH LOCK

TO THE LOCKED THEN

UNLOCKED POSITION

SET MODE AND AMPS

FROM THE SYNC

FRONT PANEL

FAULT CODE 0-14-0

CARTRIDGE CANNOT SEND

DATA TO THE POWER SUPPLY

SYNC - HAND TORCH (CLEAR THE FAULT OR SET PARAMETERS MANUALLY)

TRIGGER

Figure 19 – (Hand torch) Cartridge cannot send data to the power supply (fault 0-14-0)

Serial Communication Programmer Reference Guide

80 810400 Reference Guide Powermax65/85/105 SYNC

Hypertherm Manual Family Operator Manual (OM)

Specifications and Main Features

Frequently Asked Questions

User Manual

Getting started

Hardware requirements

Powermax65/85/105 SYNC hardware documents

Modbus specifications

Transmission mode and format

Modbus request and response message frame format

Error response message frame format

Example request and response message

How to calculate a checksum (LRC)

CNC settings on the Powermax65/85/105 SYNC

Powermax65/85/105 SYNC Modbus addressing system

Backward compatible with 0x2xxx series

List of Powermax65/85/105 SYNC addresses

Programming recommendations

Examples of requests and responses

Identify the plasma power supply type (SYNC or older system)

Example request and response

Read the ID of the SYNC torch, torch lead, and plasma power supply

0x3000 (torch and plasma power supply identification)

Example request and response

Read the part number of the installed cartridge

0x3038, 0x3039, 0x303A (cartridge part number, bytes 0 – 5)

Example request and response

Read the plasma power supply settings that are permitted for the installed cartridge

0x3001 (permitted operating mode setting)

0x3002, 0x3003 (permitted minimum and maximum output current (A) settings)

0x3004, 0x3005 (permitted minimum and maximum gas pressure settings)

Example request and response

Write operating settings and put the plasma power supply into remote control mode

0x3080 (operating mode setting)

0x3081 (output current (A) setting)

0x3082 (gas pressure setting)

Example request and response

Remote control mode indicator on the plasma power supply

Do a check for an active fault

0x301A (active fault code)

Example request and response

Fault code list

Start and stop a gas test

0x3180 (coil: gas test)

Example request and response

Stop fault code 0-50-0

0x308E, 0x308F (stop fault code 0-50-0 with a quick restart)

Example request and response

Exit remote control mode

Example request and response

Get data from the plasma power supply

Read the plasma power supply settings

0x3010 (operating mode)

0x3011 (output current (A) setting)

0x3012 (gas pressure setting)

Example request and response

Read the actual output of the plasma power supply

0x3018 (actual output current)

0x3019 (actual gas pressure)

Example request and response

Read the total cut counts for this plasma power supply

0x3028 (total number of torch starts – bytes 1 and 0)

0x3029 (total number of starts – bytes 3 and 2)

0x302A (cumulative pilot arc time – bytes 1 and 0)

0x302B (cumulative pilot arc time – bytes 3 and 2)

0x302C (total number of arc transfers – bytes 1 and 0)

0x302D (total number of arc transfers – bytes 3 and 2)

0x302E (cumulative arc transfer time – bytes 1 and 0)

0x302F (cumulative arc transfer time – bytes 3 and 2)

Example request and response

Read the 16-character UID number for the installed cartridge

0x3030 – 0x3037 (cartridge UID, bytes 0 – 15)

Example request and response

Read the total cut counts for the installed cartridge

0x3040 (total number of starts)

0x3041 (cumulative pilot arc time)

0x3042 (total number of arc transfers)

0x3043 (cumulative arc transfer time)

Example request and response

Read the 4 most recent faults for the installed cartridge