Hypertherm Powermax65 SYNC Operator Manual (OM)

SmartSYNC™ Robotic Torches

Operator Manual

811450 – REVISION 0

ENGLISH

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

Environmental stewardship is one of Hypertherm’s core values, and it is critical to our success and our customers’ success. We
are striving to reduce the environmental impact of everything we do. For more information:www.hypertherm.com/environment.

© 2022 Hypertherm, Inc.

SmartSYNC™ Robotic Torches

Operator Manual

811450

REVISION 0

ENGLISH

Original instructions

November 2022

Hypertherm, Inc.

Hanover, NH 03755 USA

www.hypertherm.com

Hypertherm, Inc.

21 Great Hollow Road, P.O. Box 5010
Hanover, NH 03755 USA
603-643-3441 Tel (Main Office)
603-643-5352 Fax (All Departments)
[e-mail] (Main Office)

800-643-9878 Tel (Technical Service)

[e-mail] (Technical Service)

800-737-2978 Tel (Customer Service)

[e-mail] (Customer Service)

Hypertherm México, S.A. de C.V.

52 55 5681 8109 Tel
52 55 5681 7978 Tel
[e-mail] (Technical Service)

Hypertherm Plasmatechnik GmbH

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

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

[e-mail] (Technical Service)

Hypertherm (Singapore) Pte Ltd.

Solaris @ Kallang 164
164 Kallang Way #03-13
Singapore 349248, Republic of Singapore
65 6841 2489 Tel
65 6841 2490 Fax
[e-mail] (Marketing)
[e-mail] (Technical Service)

Hypertherm Japan Ltd.

Level 9, Edobori Center Building
2-1-1 Edobori, Nishi-ku
Osaka 550-0002 Japan
81 6 6225 1183 Tel
81 6 6225 1184 Fax
[e-mail] (Main Office)
[e-mail] (Technical Service)

Hypertherm Europe B.V.

Laan van Kopenhagen 100
3317 DM Dordrecht
Nederland
31 165 596907 Tel
31 165 596901 Fax
31 165 596908 Tel (Marketing)

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

[e-mail] (Technical Service)

Hypertherm (Shanghai) Trading Co., Ltd.

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

86-21-80231128 Tel (Technical Service)

[e-mail] (Technical Service)

South America & Central America: Hypertherm Brasil Ltda.

Rua Bras Cubas, 231 – Jardim Maia
Guarulhos, SP – Brasil
CEP 07115-030
55 11 2409 2636 Tel
[e-mail] (Technical Service)

Hypertherm Korea Branch

#3904. APEC-ro 17. Heaundae-gu. Busan.
Korea 48060
82 (0)51 747 0358 Tel
82 (0)51 701 0358 Fax
[e-mail] (Marketing)
[e-mail] (Technical Service)

Hypertherm Pty Limited

GPO Box 4836
Sydney NSW 2001, Australia
61 7 3103 1695 Tel
61 7 3219 9010 Fax
[e-mail] (Main Office)
[e-mail] (Technical Service)

Hypertherm (India) Thermal Cutting Pvt. Ltd

A-18 / B-1 Extension,
Mohan Co-Operative Industrial Estate,
Mathura Road, New Delhi 110044, India
91-11-40521201/ 2/ 3 Tel
91-11 40521204 Fax
[e-mail] (Main Office)
[e-mail] (Technical Service)

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

www.hypertherm.com/hci.

ENGLISH

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

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

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

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

BG (БЪЛГAPCКИ/BULGARIAN)

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

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

CS (ČESKY/CZECH)

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

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

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

DA (DANSK/DANISH)

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

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

DE (DEUTSCH/GERMAN)

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

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

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

www.hypertherm.com/docs zur Verfügung.

ES (ESPAÑOL/SPANISH)

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

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

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

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

ET (EESTI/ESTONIAN)

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

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

FI (SUOMI/FINNISH)

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

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

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

FR (FRANÇAIS/FRENCH)

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

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

GR (ΕΛΛΗΝΙΚΆ/GREEK)

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

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

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

www.hypertherm.com/docs.

HU (MAGYAR/HUNGARIAN)

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

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

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

ID (BAHASA INDONESIA/INDONESIAN)

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

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

IT (ITALIANO/ITALIAN)

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

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

JA (日本語/JAPANESE)

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

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

KO (뼑뼑霢꽩 KOREAN)

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

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

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

NE (NEDERLANDS/DUTCH)

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

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

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

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

NO (NORSK/NORWEGIAN)

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

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

PL (POLSKI/POLISH)

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

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

www.hypertherm.com/docs.

PT (PORTUGUÊS/PORTUGUESE)

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

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

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

RO (ROMÂNĂ/ROMANIAN)

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

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

www.hypertherm.com/docs.

RU (PУССКИЙ/RUSSIAN)

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

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

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

SK (S LOVENČINA/S LOVAK)

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

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

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

www.hypertherm.com/docs.

SL (S LOVENŠČINA/ SLOVENIAN)

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

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

SR (SRPSKI/SERBIAN)

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

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

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

SV (SVENSKA/SWEDISH)

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

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

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

THࡗࡩࡠࡩࡷࡎ࡙THAI

࠻ࢀࡩࡳࡌ࡮ࡤࡐ࠸ᕍࡤࡐ࠸ࡩ࡚ࡶࡁᕎ࠾ࡩࡐࡤ࡯ࡒ࠸࡚ࡊᕑ࠹ࡤ࠾+\SHUWKHUPࡎࡨࡼ࠾ࡢࡘࡋࡵࡒ࡚ࡋࡤᕍࡩࡐ࠻ࢀࡩࡴࡐࡧࡐࢀࡩࡋᕎࡩࡐ࠻࡞ࡩࡘ
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Contents

Electromagnetic Compatibility (EMC).................................................................................... 9

Warranty..................................................................................................................................... 11

1 Where to Find More Information ........................................................................................... 13

2 Specifications............................................................................................................................ 15

About the robotic torch...................................................................................................................................... 15

Robotic torch components, dimensions, weights ....................................................................................... 16

Components............................................................................................................................................. 16

Dimensions ............................................................................................................................................... 16

180° robotic torch....................................................................................................................... 16

90° robotic torch ......................................................................................................................... 17

45° robotic torch ......................................................................................................................... 17

Weights ..................................................................................................................................................... 17

3 Mount the Robotic Torch......................................................................................................... 19

Minimum bend radius......................................................................................................................................... 20

Mount with a Hypertherm robotic torch clamp (228806) ......................................................................... 20

Connect the torch lead...................................................................................................................................... 23

SmartSYNC Robotic Torches Operator Manual 811450 7

Contents

4 Operate the Robotic Torch...................................................................................................... 25

Use the robotic teach tool................................................................................................................................. 26

Cutting processes .............................................................................................................................................. 27

Select the cartridge ................................................................................................................................ 27

Cutting guidelines................................................................................................................................... 28

Piercing guidelines.................................................................................................................................. 29

Gouging processes............................................................................................................................................ 30

Change the gouge contour................................................................................................................... 31

5 Troubleshooting and Maintenance Tasks............................................................................ 35

Cutting system problems .................................................................................................................................. 36

Cut quality problems .......................................................................................................................................... 38

Cut angle (bevel)..................................................................................................................................... 38

Dross.......................................................................................................................................................... 39

Gouging problems.............................................................................................................................................. 40

Routine maintenance.......................................................................................................................................... 41

Every use................................................................................................................................................... 42

Every 3 months ........................................................................................................................................ 43

Cartridge maintenance ...................................................................................................................................... 44

8 811450 Operator Manual SmartSYNC Robotic Torches

Electromagnetic Compatibility (EMC)

Introduction

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

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

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

Installation and use

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

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

Methods of reducing emissions

Mains supply

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

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

Maintenance of cutting equipment

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

Cutting cables

Assessment of area

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

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

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

b. Radio and television transmitters and receivers.

c. Computer and other control equipment.

d. Safety critical equipment, for example guarding of industrial

equipment.

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

pacemakers and hearing aids.

f. Equipment used for calibration or measurement.

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

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

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

out.

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

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

Equipotential bonding

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

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

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

Safety and compliance 9

Electromagnetic Compatibility (EMC)

Earthing of the workpiece

Where the workpiece is not bonded to earth for electrical safety, nor
connected to earth because of its size and position, for example, ship’s
hull or building steel work, a connection bonding the workpiece to earth
may reduce emissions in some, but not all instances. Care should be
taken to prevent the earthing of the workpiece increasing the risk of injury
to users, or damage to other electrical equipment. Where necessary, the
connection of the workpiece to earth should be made by a direct
connection to the workpiece, but in some countries where direct
connection is not permitted, the bonding should be achieved by suitable
capacitances selected according to national regulations.

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

Screening and shielding

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

10 Safety and compliance

Warranty

Attention

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

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

General

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

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

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

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

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

Patent indemnity

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

Limitation of liability

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

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

National and local codes

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

Safety and compliance 11

Warranty

Liability cap

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

Insurance

At all times you will have and maintain insurance in such quantities and
types, and with coverage sufficient and appropriate to defend and to hold
Hypertherm harmless in the event of any cause of action arising from the
use of the products.

Transfer of rights

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

Waterjet product warranty coverage

Product Parts coverage

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

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

PowerDredge
abrasive removal
system

EcoSift abrasive
recycling system

Abrasive metering
devices

On/off valve air
actuators

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

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

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

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

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

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

filter and compliance with Hypertherm’s
water quality requirements

12 Safety and compliance

Where to Find More Information

This operator manual gives information to help you do the following:

 Mount the SmartSYNC™ robotic torch

 Operate the SmartSYNC robotic torch

 Troubleshooting common issues and maintain the torch

For related information, refer to the following documents:

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

 Powermax65/85/105 SYNC Cut Charts Guide (810500MU)

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

 Safety and Compliance Manual (80669C)

For replacement part numbers for robotic torches, torch accessories, and cartridges, refer to the
Powermax65/85/105 SYNC Parts Guide (810490).

You can find these documents on the USB memory stick that came with your plasma power supply.
Technical documentation is also available at www.hypertherm.com/docs.

Technical documentation is current as of the date of its release.



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

SmartSYNC Robotic Torches Operator Manual 811450 13

Where to Find More Information

1

14 811450 Operator Manual SmartSYNC Robotic Torches

About the robotic torch

SmartSYNC robotic torch features
include the following:

 Automatic setting of operating

mode, amperage, and gas pressure related to the Hypertherm cartridge that you install, the
torch type, and the torch lead length.

 Communication of Hypertherm cartridge usage information to the plasma power supply,

including cartridge end-of-life detection. Refer to the Powermax65/85/105 SYNC Operator
Manual (810470) for more information.

Specifications

 The FastConnect™ quick-disconnect system to easily remove the torch for transport or to

change from one torch to another.

For information about the thicknesses that you can cut and pierce with a SmartSYNC robotic torch,
refer to the Cutting processes on page 27.

SmartSYNC Robotic Torches Operator Manual 811450 15

Specifications

2

1

2

6

5

3

4

7

1 Hypertherm cartridge

2 Shell
3 Increment markings

4 Anti-rotational slot

5 Strain relief for torch lead

6 Torch l e ad
7 Positioning holes (3)

32 mm (1.25 inch)

35 mm ± 0.3 mm

(1.37 inch ± 0.01 inch)

235 mm (9.25 inch)

180mm (7.08inch)

Robotic torch components, dimensions, weights

Components

A SmartSYNC 180° robotic torch is shown.



Dimensions

180° robotic torch

16 811450 Operator Manual SmartSYNC Robotic Torches

2

90° robotic torch

35 mm ± 0.3 mm

(1.37 inch ± 0.01 inch)

186mm (7.33inch)

139 mm (5.47 inch)

10 0 m m

(3.93 inch)

32 mm

(1.25 inch)

32 mm (1.25 inch)

35 mm ± 0.3 mm

(1.37 inch ± 0.01 inch)

214 mm (8.43 inch)

139 mm (5.47 inch)

76 mm

(2.98 inch)

45° robotic torch

Specifications

Weights

180° robotic torch with torch lead

Torch Weight*

180° robotic torch with 4.6 m (15 foot) lead 2.1 kg (5 lb)

180° robotic torch with 7.6 m (25 foot) lead 3.1 kg (7 lb)

180° robotic torch with 15 m (50 foot) lead 5.7 kg (13 lb)

* Without a Hypertherm cartridge installed.

SmartSYNC Robotic Torches Operator Manual 811450 17

Specifications

2

90° robotic torch with torch lead

Torch Weight*

90° robotic torch with 7.6 m (25 foot) lead 3.5 kg (8 lb)

90° robotic torch with 15 m (50 foot) lead 6.5 kg (14 lb)

90° robotic torch with 23 m (75 foot) lead 9.6 kg (21 lb)

* Without a Hypertherm cartridge installed.

45° robotic torch with torch lead

Torch Weight*

45° robotic torch with 7.6 m (25 foot) lead 3.5 kg (8 lb)

45° robotic torch with 15 m (50 foot) lead 6.5 kg (14 lb)

45° robotic torch with 23 m (75 foot) lead 9.6 kg (21 lb)

* Without a Hypertherm cartridge installed.

18 811450 Operator Manual SmartSYNC Robotic Torches

Mount the Robotic Torch

The robotic torch must be mounted correctly to the robot’s arm to make sure that there is correct
torch-to-work distance throughout each cut.

A robotic torch clamp with mating positioning dowels and anti-rotational tabs is available from
Hypertherm. Refer to Mount with a Hypertherm robotic torch clamp (228806) on page 20.

If you use an alternate torch clamp, comply with the manufacturer’s instructions on how to mount the
torch in the clamp.

NOTICE

SENSITIVE ELECTRONICS AND OTHER COMPONENTS INSIDE THE TORCH. PERMANENT
DAMAGE CAN OCCUR.

Do not disassemble the torch or the quick-disconnect shell to put the torch in the robotic cutting

system.

For information about how to configure the Powermax power supply for remote operation, refer to
the Powermax65/85/105 SYNC Mechanized Cutting Guide (810480).

SmartSYNC Robotic Torches Operator Manual 811450 19

Mount the Robotic Torch

3

76 mm

(3.0 in.)

1

2

7. 6 2 m m

(0.30 inch)

19.05 mm

(0.75 inch)

2

1

1

1 4.5 mm (0.18 inch) unthreaded holes

2 M4 x 0.7 threaded holes

Minimum bend radius

NOTICE

MINIMUM BEND RADIUS. KINKING AND OTHER DAMAGE CAN OCCUR.

Do not bend the torch lead too far.

Do not bend the torch lead around a radius that is less
than the minimum bend radius of 76 mm (3.0 inches).

Mount with a Hypertherm robotic torch clamp (228806)

1. Mount the torch clamp to the robot arm using mounting holes or .

20 811450 Operator Manual SmartSYNC Robotic Torches

3

2. Disconnect the front half of the clamp by removing the 4 screws .

1

2

1

2

5

2

6

3

4

1

1

2

3

4

5

6

Mount the Robotic Torch

3. Align the torch with the rear half of the
clamp using either the increment
markings or the positioning
holes .

If you are using the increment



markings, remove the
positioning dowel . Push

4. Make sure that the anti-rotational

the dowel through the clamp.

tabs on each half of the torch
clamp are aligned with the slot in
the torch.

SmartSYNC Robotic Torches Operator Manual 811450 21

Mount the Robotic Torch

3

123

2

3

1

24

1 3

5. Attach the front half of the clamp to the rear half of the clamp with the 4 screws .

6. Tighten the 4 screws to 1.7 N∙m (15 lbf∙in) in the order shown.

NOTICE

Do not tighten the screws too much. If you tighten the screws too much, you can cause damage to the
internal components of the torch.

22 811450 Operator Manual SmartSYNC Robotic Torches

3

Connect the torch lead

Red button

 Always set the power

switch on the plasma
power supply to OFF (O)
before you connect or
disconnect a torch.

 To connect a hand torch

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

 To disconnect the torch,

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

Mount the Robotic Torch

SmartSYNC Robotic Torches Operator Manual 811450 23

Mount the Robotic Torch

3

24 811450 Operator Manual SmartSYNC Robotic Torches

Operate the Robotic Torch

This section gives information to help you do the following:

 Use the robotic teach tool

 Select the correct Hypertherm cutting or gouging cartridge

 Pierce and cut metal

 Optimize cut quality

 Gouge metal

To troubleshoot cutting system problems, refer to Troubleshooting and Maintenance Tasks on
page 35.

SmartSYNC Robotic Torches Operator Manual 811450 25

Operate the Robotic Torch

4

1

1

58 mm (2.30 inch)

32 mm
(1.25 inch)

Use the robotic teach tool

A robotic torch teach tool (429054) is available from Hypertherm to help with programming the
robot before cutting.

Run your program with the torch teach tool installed on the torch to visually make sure that the torch
will not touch the workpiece while cutting.

Contact with the workpiece while cutting can cause damage to the cartridge and the cut surface.
The torch teach tool has a spring-loaded tip so that you can simulate different cartridge lengths and
stand-off distances.To install the torch teach tool do the following steps:

1. Set the power switch on the plasma power supply to OFF (O).

2. Remove the cartridge from the torch.

3. Install the torch teach tool on the torch.

26 811450 Operator Manual SmartSYNC Robotic Torches

4

Cutting processes

Select the cartridge

Hypertherm offers the following types of cutting cartridges for robotic torches:

Operate the Robotic Torch

Cartridge Type Purpose

Standard cut
(gray)

FineCut
(gray)

FlushCut
(black)

Ohmic ring

®

TM

Use these standard cartridges for
the widest range of cutting
applications.

Use these cartridges to get a
narrower kerf on thin mild steel and
stainless steel up to 3 mm
(10 gauge).

Use these cartridges to cut as
close to the base as possible
without piercing or causing
damage to the workpiece.

Use this cartridge accessory with
torch height controls (THCs) that
have support for ohmic contact to
find the surface of the workpiece
before each cut.

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

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

 For information on gouging processes and cartridges, refer to Gouging processes on

page 30.

 For help installing the cartridge, refer to Powermax65/85/105 SYNC Operator Manual

(810470).

 Select the cartridge with the amperage that is best for the thickness of the material that you

want to cut.

Make sure that the cartridge that you select is an amperage supported by



the plasma power supply. For example, if you have a Powermax85 SYNC,
select an 85 A, 65 A, or 45 A cartridge, not a 105 A cartridge.

SmartSYNC Robotic Torches Operator Manual 811450 27

Operate the Robotic Torch

4

Select the best cartridge for the material you that you want to cut.

Metric material thickness (mm)

0.5 1 2 3 5 8 10 12 15 20 25 30

FineCut

45 A

65 A

85 A

105 A

English material thickness (in.)

0.02 0.06 1/8 1/4 3/8 1/2 5/8 3/4 1 1-1/4 1-1/2

FineCut

45 A

65 A

85 A

105 A

Cutting guidelines

 Always start with the recommended settings from the cut charts. Refer to the

Powermax65/85/105 SYNC Cut Charts Guide (810500MU).

 Do not let the torch touch the workpiece during cutting system operation. Contact with the

workpiece can cause damage to the cartridge and to the surface of the workpiece.

 Do all cutting system maintenance tasks as scheduled. Refer to Troubleshooting and

Maintenance Tasks on page 35.

 Do not fire the torch unnecessarily. It decreases cartridge life.



Optimal cut quality

Near to optimal cut quality

Decreased cut quality or speed

Starting at the edge of the workpiece is permitted if the arc makes contact
with the workpiece when started.

 Prevent lead-outs that move away from the workpiece and stretch the plasma arc.

28 811450 Operator Manual SmartSYNC Robotic Torches

4

 Do the following to prevent the loss of a transferred plasma arc:

 Complete every cut with the plasma arc still attached to the workpiece.

 Decrease the cutting speed when the end of the cut is near.

Piercing guidelines

Piercing goes through the full thickness of the workpiece. Piercing is also typically the first action
involved in cutting a part.



You can keep unwanted results to a minimum, increase the number of pierces, and get maximum
cartridge life when you use the pierce and cut height settings that Hypertherm recommends in the
cut charts. Refer to the Powermax65/85/105 SYNC Cut Charts Guide (810500MU) and the
following:

 Pierce delay: Pierce delay is the length of time that the torch stays at the specified pierce

height before the torch starts to move for cutting. The pierce delay must be long enough that
the arc can pierce the material before the torch moves, but not so long that the pierce hole
enlarges and causes the arc to “wander” or extinguish before the torch starts to move.

Operate the Robotic Torch

Starting at the edge of the workpiece is permitted if the arc makes contact
with the workpiece when started.

Pierce delay times given in the cut charts use average delay times throughout the life of the
cartridges. If necessary, as the cartridge wears, increase the pierce delay time.

 Pierce height: Pierce height is the distance between the torch and the workpiece that is

necessary to initially pierce the workpiece before beginning to cut. For the
Powermax65/85/105 SYNC, the pierce height is generally between 150% and 400% of the
cut height. Refer to the Powermax65/85/105 SYNC Cut Charts Guide (810500MU) for
specific values.

 Pierce maximum thickness: When piercing materials close to the maximum thickness for a

specific process, think about the following important factors:

 Use a lead-in distance approximately equal to the thickness of the material being

pierced. For example, a 20 mm (3/4 inch) lead-in is necessary for 20 mm (3/4 inch)
material.

 To prevent damage to the cartridge from the collection of molten material caused by the

pierce, do not let the torch descend to cut height until it is away from the puddle of
molten material.

SmartSYNC Robotic Torches Operator Manual 811450 29

Operate the Robotic Torch

4

Gouging processes

Hypertherm offers the following gouging cartridges:

Cartridge Type Purpose

Maximum Control
gouging

(green)

Maximum Removal
gouging

(green)

Use these cartridges for more
precise metal removal, shallow
gouge contours, and light metal
washing.

Use these cartridges for
aggressive metal removal, deep
gouge contours, and extreme
metal washing.

30 811450 Operator Manual SmartSYNC Robotic Torches

4

Change the gouge contour

Standoff / arc stretch

Angle of the torch

Turn of the torch

Torch center line

Speed

Output current (A)

The width and the depth of the gouge contour are a result of the following factors. Adjust these

factors in combination to get the gouge that you want.

Operate the Robotic Torch

SmartSYNC Robotic Torches Operator Manual 811450 31

Operate the Robotic Torch

4

1

2

1

2

1

2

1

2

1

2

1

2

1

1

1

 Output current (A) of the plasma power supply – Decrease the amperage on the front

panel to make the gouge narrower and shallower . Increase the amperage to make the
gouge wider and deeper .

 Arc stretch is related to the output current (A) of the plasma power supply. The higher

the amperage, the longer that you can stretch the arc. Hypertherm recommends that you
keep amperage and arc stretch consistent.

 The lowest and highest possible amperage setting relates to the plasma power supply

and the Hypertherm cartridge you are using.

 Angle of the torch to the workpiece – Put the torch in a more upright position to make the

gouge narrower and deeper . Tilt down the torch so that it is closer to the workpiece to
make the gouge wider and more shallow .

 Turn of the torch – Turn the torch relative to the torch center line to make the gouge flatter

and steeper on one side .

32 811450 Operator Manual SmartSYNC Robotic Torches

Operate the Robotic Torch

4

1

2

1

2

1

2

1

2

1

2

2

1

 Torch-to-work standoff / arc stretch – Move the torch away from the workpiece to make

the gouge wider, shallower, and smoother on the bottom . Move the torch closer to the
workpiece to make the gouge narrower and deeper .

 Arc stretch is related to the output current (A) of the plasma power supply. The higher

the amperage, the longer that you can stretch the arc. Hypertherm recommends that you
keep amperage and arc stretch consistent.

 Keep at least a small distance between the torch tip and the molten metal to increase

cartridge life and prevent damage to the torch.

 Speed of the torch – Increase the speed of the torch movement to make the gouge

narrower and more shallow . Decrease the speed of the torch movement to make the
gouge wider and deeper .

SmartSYNC Robotic Torches Operator Manual 811450 33

Operate the Robotic Torch

4

34 811450 Operator Manual SmartSYNC Robotic Torches

Troubleshooting and Maintenance Tasks

This section is a supplement to the troubleshooting information in the



Powermax65/85/105 SYNC Operator Manual (810470). When you
troubleshoot a robotic cutting problem, use both resources.

NOTICE

SENSITIVE ELECTRONICS AND OTHER COMPONENTS INSIDE THE TORCH. PERMANENT
DAMAGE CAN OCCUR.

Do not disassemble the torch or the quick-disconnect shell to put the torch in the robotic cutting

system.

When a troubleshooting problem occurs, go through the troubleshooting information in this chapter
first.

If you cannot find a solution to the problem by complying with the recommendations in this chapter,
or if further aid is necessary, do the following:

1. Get the serial number for your system from the data plate that is on the rear panel.

2. Speak to your Hypertherm distributor or authorized repair facility.

3. Speak to the nearest Hypertherm office shown in the front of this manual.

Refer to the Powermax65/85/105 SYNC Parts Guide (810490) for



information on common replacement parts.

SmartSYNC Robotic Torches Operator Manual 811450 35

Troubleshooting and Maintenance Tasks

5

Cutting system problems

Problem Solutions

The plasma arc sputters or
hisses, or you lose the
plasma arc.

The plasma arc does not
transfer to the workpiece.

The torch does not
completely pierce the
workpiece, and there is
excessive sparking on the
top of the workpiece.

• Make sure that the cartridge is installed correctly.

• Examine the cartridge. Replace it if it is worn or damaged. A higher rate of 0-30-0
faults is typical as a cartridge gets near end-of-life. Refer to the
Powermax65/85/105 SYNC Operator Manual (810470).

• Examine the gas filtration system for signs of moisture. Refer to the
Powermax65/85/105 SYNC Operator Manual (810470).

• Clean the workpiece surface of any material that can prevent a good
metal-to-metal connection.

• Make sure that the work lead is correctly connected to the plasma power supply.

• Make sure that the work lead is making good contact with the cutting table or
workpiece, and is not damaged. Repair or replace it if necessary. Refer to the
Powermax65/85/105 SYNC Parts Guide (810490).

• Make sure that the cutting table is correctly grounded and is making good contact
with the workpiece.

• Decrease the cut height. Refer to the Powermax65/85/105 Cut Charts Guide
(810500MU).

• Examine the cartridge. Replace it if it is worn or damaged. A higher rate of 0-30-0
faults is typical as a cartridge gets near end-of-life. Refer to the
Powermax65/85/105 SYNC Operator Manual (810470).

• Decrease your cut speed.

• Restart the plasma power supply. Does it correctly recognize the type
of cartridge installed? Does it correctly set the amperage and
operating mode to align with the cartridge? If it does not, look at the
LCD screen. Do you see the icon at right on the LCD screen? If yes,
there is possibly a plasma power supply configuration setting that you
must change. If no, there is possibly a problem with the cartridge, torch, or plasma
power supply. Refer to the Powermax65/85/105 SYNC Operator Manual
(810470).

• Increase the output current (A) on the plasma power supply.

• If the output current (A) cannot be increased, do a check to see if the thickness of
the workpiece is more than the maximum capacity for this plasma power supply.
Refer to the cutting specifications in the Powermax65/85/105 SYNC Operator
Manual (810470).

• Clean the workpiece surface of any material that can prevent a good
metal-to-metal connection.

• Examine the torch lead. Make it straight if it is twisted or kinked. Replace it if it is
damaged.

• Examine the gas pressure and the gas supply hose.

• Adjust the gas flow rate. Refer to the gas supply specifications in the
Powermax65/85/105 SYNC Operator Manual (810470).

• Make sure that the cut chart parameters or the program code values are correct.
Refer to the Powermax65/85/105 SYNC Cut Charts Guide (810500MU).

36 811450 Operator Manual SmartSYNC Robotic Torches

5

Problem Solutions

Troubleshooting and Maintenance Tasks

Cartridge life is shorter
than expected.

• Do a check of the gas pressure and the gas supply hose. Refer to the
Powermax65/85/105 SYNC Operator Manual (810470).

• Do not start or stop cuts off of the surface of the workpiece. Starting at the edge of
the workpiece is permitted if the arc makes contact with the workpiece when
started.

• Examine the torch lead. Make it straight if it is twisted or kinked. Replace it if it is
damaged.

• Make sure that the output current, arc voltage, cut speed, and other cut settings
are correct. Refer to the Powermax65/85/105 SYNC Cut Charts Guide
(810500MU).

• Use the correct torch height for piercing. Refer to the Powermax65/85/105 SYNC
Cut Charts Guide (810500MU) for the initial pierce height.

• Make sure that the pierce delay time is correct. Refer to the Powermax65/85/105
SYNC Cut Charts Guide (810500MU).

• Examine the gas filtration system for signs of contaminants that. Refer to the
Powermax65/85/105 SYNC Operator Manual (810470).

• Examine the cut data on the Cartridge Data screen and the Power Supply Data
screen. Refer to the Powermax65/85/105 SYNC Operator Manual (810470). Also
refer to Cartridge maintenance on page 44.

• A faulty pilot arc IGBT can decrease cartridge life. Contact your Hypertherm
distributor or authorized repair facility, or contact the nearest Hypertherm office
shown in the front of this manual.

SmartSYNC Robotic Torches Operator Manual 811450 37

Troubleshooting and Maintenance Tasks

5

1

2

3

123

Cut quality problems

The following are problems that you can have when the appearance of a cut is not satisfactory:

 Cut angle (bevel) – The degree of angularity of the cut edge.

 Dross – The molten material that becomes solid on the top or bottom of the workpiece.

Each is explained in the following sections.

Cut angle (bevel)

Cut angle (bevel) Causes Solution

Negative bevel

More material is removed
from the bottom of the cut
than from the top.

No bevel (square cut) This is good cut quality.

Positive bevel

More material is removed
from the top of the cut than
from the bottom.

Irregular bevel

Positive and negative bevel
on the same workpiece.

• The cutting speed is too slow.

• The torch is too low.

• The amperage is too high.

• The cartridge is worn.

• The cutting speed is too fast.

• The torch is too high.

• The amperage is too low.

• The cartridge is severely worn.

• The torch is not aligned
perpendicular to the workpiece.

• Cut surface is concave on one
side and convex on the other side.

• Increase the cutting speed in small
increments (125 mm/min or
5 in/min or less).

• Lift the torch in small increments (2
mm or 1/16 in.).

• Decrease the amperage in 10 A
increments.

• Install a new cartridge.

• Decrease the cutting speed in
small increments (125 mm/min or
5 in/min or less).

• Lower the torch in small
increments (2 mm or 1/16 in.).

• Increase the amperage in 10 A
increments.

• Install a new cartridge.

The squarest cut angle is always on the right side with respect to the



forward motion of the torch. The left side always has some degree of
bevel. A bevel angle of more than 5 degrees shows a possible problem.

38 811450 Operator Manual SmartSYNC Robotic Torches

5

Dross

Troubleshooting and Maintenance Tasks

Dross (slag) is molten metal that is the result of the cut process and that hardens on the bottom of
the part. There is always some amount of dross when cutting with plasma. To keep the amount and
type of dross to a minimum, adjust your system correctly for your application.

Problem Causes Solution

Too much dross (splatter) on the
top of the plate.

Low-speed dross that collects on
the bottom of the cut and is heavy
and bubbly.

• The cartridge is worn.

• The cutting speed is too fast.

• The torch is too high. Or, if you
are using a torch height
control, arc voltage is too high.

• The cutting speed is too slow.

• The torch is too low. Or, if you
are using a torch height
control, arc voltage is too low.

• The amperage is too high.

• Install a new cartridge.

• Decrease the cutting speed in
small increments
(125 mm/min or 5 in/min or
less).

• Lower the torch in small
increments (2 mm or 1/16 in.).
Or, if you are using a torch
height control, decrease the
arc voltage in small increments
(5 volts or less).

• Increase the cutting speed in
small increments
(125 mm/min or 5 in/min or
less).

• Lift the torch in small
increments (2 mm or 1/16 in.).
Or, if you are using a torch
height control, increase the
arc voltage in small increments
(5 volts or less).

• Decrease the amperage in
10 A increments.

High-speed dross near the cut that
is a thin, linear bead of solid metal.
It is welded to the bottom of the
cut and is difficult to remove.

• The cartridge is worn.

• The cutting speed is too fast.

• The torch is too high. Or, if you
are using a torch height
control, arc voltage is too high.

• The amperage is too low.

• Install a new cartridge.

• Decrease the cutting speed in
small increments
(125 mm/min or 5 in/min or
less).

• Lower the torch in small
increments (2 mm or 1/16 in.).
Or, if you are using a torch
height control, decrease the
arc voltage in small increments
(5 volts or less).

• Increase the amperage in 10 A
increments.

SmartSYNC Robotic Torches Operator Manual 811450 39

Troubleshooting and Maintenance Tasks

5

Gouging problems

When gouging, always make sure of the following:

 A Hypertherm gouging cartridge is installed.

 The Hypertherm cartridge is not worn or damaged.

 The operating mode is set to Gouge mode.

 When you install a Hypertherm gouging cartridge, the plasma power supply

automatically sets the operating mode to Gouge mode. There is a condition in which the
operating mode does not automatically set to Gouge mode even if a Hypertherm
gouging cartridge is used.

Problem Solution

The arc goes out during
gouging.

The torch tip hits the
molten metal (slag).

The gouge has too much
depth.

The gouge does not have
enough depth.

The gouge has too much
width.

The gouge does not have
enough width.

• Decrease the arc stretch (standoff).

• Put the torch in a more upright position.

• Increase the arc stretch (standoff).

• Keep the torch tip pointed in the direction of the gouge that you want to make.

• Tilt the torch down so that it is closer to the workpiece.

• Increase the arc stretch (standoff).

• Increase the gouging speed.

• Decrease the output current (A).

• Put the torch in a more upright position.

• Decrease the arc stretch (standoff).

• Decrease the gouging speed.

• Increase the output current (A).

• Put the torch in a more upright position.

• Decrease the arc stretch (standoff).

• Increase the gouging speed.

• Decrease the output current (A).

• Tilt the torch down so that it is closer to the workpiece.

• Increase the arc stretch (standoff).

• Decrease the gouging speed.

• Increase output current (A).

40 811450 Operator Manual SmartSYNC Robotic Torches

5

Routine maintenance

Troubleshooting and Maintenance Tasks

WARNING

ELECTRIC SHOCK CAN KILL

Disconnect electric power before doing installation or maintenance. You can
get a serious electric shock if electric power is not disconnected. Electric
shock can seriously injure or kill you.

All work that requires removal of the plasma power supply outer cover or
panels must be done by a qualified technician.

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

WARNING

RISK OF BURNS AND ELECTRIC SHOCK – USE INSULATED GLOVES

Always put on insulated gloves when changing the cartridges. The cartridges
get very hot during cutting and can cause severe burns.

Touching the cartridges can also cause electric shock if the plasma power
supply is ON and the torch-lock switch is not in the yellow lock (X) position.

SmartSYNC Robotic Torches Operator Manual 811450 41

Troubleshooting and Maintenance Tasks

5

1

3

2

Every use

Plasma power supply Torch

Examine the indicator LEDs and correct any fault conditions.
Refer the Powermax65/85/105 SYNC Operator Manual
(810470).

To prevent overheating, do the following:

• Examine the work lead connector to make sure that it is
fully connected to the plasma power supply and is not
loose. Make sure that you turn the connector clockwise
approximately 1/4 turn until the connector is fully engaged
and locked in position.

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

Examine the cartridge for correct installation and
for wear. Refer to Cartridge maintenance on
page 44.

42 811450 Operator Manual SmartSYNC Robotic Torches

5

Every 3 months

132

4

Plasma power supply Torch

Troubleshooting and Maintenance Tasks

Examine the power cord and plug. Replace them if they
are damaged. Refer to the Powermax65/85/105 SYNC
Parts Guide (810490).

Examine the labels. Replace any damaged labels. Refer
to the Powermax65/85/105 SYNC Parts Guide
(810490).

Examine the torch for cracks and exposed wires.
Have a qualified service technician replace any

damaged parts. Contact your distributor or authorized
repair facility.

Examine the torch lead. Have a qualified service
technician replace it if it is damaged. Contact your
distributor or authorized repair facility.

SmartSYNC Robotic Torches Operator Manual 811450 43

Troubleshooting and Maintenance Tasks

5

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4

1

2

3

4

Cartridge maintenance

To help keep a cartridge operating correctly, do the following:

 Carefully remove molten metal that might collect

on the cartridge. Do not push the unwanted
material inside the nozzle or shield .

 Carefully remove molten metal that causes a

blockage of the holes in the shield that are
necessary for airflow. Do not push the

unwanted material inside the nozzle or
shield.

 Examine the O-ring on the torch body. If the

O-ring is cracked or worn, replace it. If the
O-ring is dry, or if it is not easy to install the
cartridge, apply a thin layer of silicone lubricant
on the O-ring and the threads. Make sure that the O-ring is shiny, but do not apply too much
lubricant.

44 811450 Operator Manual SmartSYNC Robotic Torches