Hypertherm powermax65 User manual
Powermax65/85/105 SYNC™
Mechanized Cutting Guide
810480 – REVISION 2
ENGLISH
Powermax, SYNC, SmartSYNC, FastConnect, Duramax, EDGE Pro, 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.
© 2021 Hypertherm, Inc.
Hypertherm Europe B.V.
Vaartveld 9, 4704 SE
Roosendaal, Nederland
31 165 596907 Tel
31 165 596901 Fax
31 165 596908 Tel (Marketing)
31 (0) 165 596900 Tel (Technical Service)
00 800 4973 7843 Tel (Technical Service)
(Technical Service Email)
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)
(Technical Service Email)
South America & Central America: Hypertherm Brasil Ltda.
Rua Bras Cubas, 231 – Jardim Maia
Guarulhos, SP – Brasil
CEP 07115-030
55 11 2409 2636 Tel
Hypertherm Korea Branch
#3904. APEC-ro 17. Heaundae-gu. Busan.
Korea 48060
82 (0)51 747 0358 Tel
82 (0)51 701 0358 Fax
TechSupportAP[email protected]
(Technical Service Email)
Hypertherm Pty Limited
GPO Box 4836
Sydney NSW 2001, Australia
61 (0) 437 606 995 Tel
61 7 3219 9010 Fax
TechSupportAP[email protected]
(Technical Service Email)
Hypertherm (India) Thermal Cutting Pvt. Ltd
A-18 / B-1 Extension,
Mohan Co-Operative Industrial Estate,
Mathura Road, New Delhi 110044, India
91-11-40521201/ 2/ 3 Tel
91-11 40521204 Fax
HTIndia.info@hypertherm.com (Main Office Email)
TechSupportAP[email protected]
(Technical Service Email)
Hypertherm, Inc.
Etna Road, P.O. Box 5010
Hanover, NH 03755 USA
603-643-3441 Tel (Main Office)
603-643-5352 Fax (All Departments)
800-643-9878 Tel (Technical Service)
800-737-2978 Tel (Customer Service)
866-643-7711 Tel (Return Materials Authorization)
877-371-2876 Fax (Return Materials Authorization)
Hypertherm México, S.A. de C.V.
Avenida Toluca No. 444, Anexo 1,
Colonia Olivar de los Padres
Delegación Álvaro Obregón
México, D.F. C.P. 01780
52 55 5681 8109 Tel
52 55 5683 2127 Fax
Soporte.Tecnico@hypertherm.com (Technical Service Email)
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)
Hypertherm (Singapore) Pte Ltd.
82 Genting Lane
Media Centre
Annexe Block #A01-01
Singapore 349567, Republic of Singapore
65 6841 2489 Tel
65 6841 2490 Fax
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
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 Hochfrequenz-Warnung (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 dumanuel de votre produit, duManuel 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
awww.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 (한국어/KOREAN)
경고! Hypertherm 장비를 사용하기 전에 제품 설명서와 안전 및 규정 준수
설명서(80669C), 워터젯 안전 및 규정 준수 설명서(80943C) 그리고 무선
주파수 경고 설명서(80945C)에 나와 있는 안전 지침을 읽으십시오.
전자 형식과 인쇄된 형식으로 설명서 사본이 제품과 함께 제공될 수
있습니다. 전자 사본도 Hypertherm 웹사이트에서 보실 수 있으며
설명서 사본은 www.hypertherm.com/docs 에서 여러 언어로 제공됩니다.
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 wformie
elektronicznej idrukowanej. Kopie elektroniczne znajdują się również wnaszej
witrynie internetowej. Wiele podręczników jest dostępnych wróżnych 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,
вРуководстве по безопасности и соответствию (80669С),
вРуководстве 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 (SLOVENČINA/SLOVAK)
VÝSTRAHA! Pred použitím akéhokoľvek zariadenia od spoločnosti Hypertherm
si prečítajte bezpečnostné pokyny v návode na obsluhu vášho zariadenia
avManuáli o bezpečnosti a súlade s normami (80669C), Manuáli
o bezpečnosti a súlade snormami pre systém rezania vodou (80943C)
avManuáli sinformáciami orádiofrekvencii (80945C).
Návod na obsluhu sa dodáva spolu sproduktom velektronickej atlačenej
podobe. Jeho elektronický formát je dostupný aj na našej webovej stránke.
Mnohé znávodov na obsluhu sú dostupné vo viacjazyčnej mutácii na stránke
www.hypertherm.com/docs.
SL (SLOVENŠČINA/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 (ภาษาไทย/THAI)
คําเตือน! กอนการใชงานอุปกรณของ Hypertherm ทั้งหมด โปรดอานคําแนะนําดาน
ความปลอดภัยในคูมือการใชสินคา คูมือดานความปลอดภัยและการปฏิบัติ
ตาม (80669C), คูมือดานความปลอดภัยและการปฏิบัติตามสําหรับการใชหัวตัดระบบ
วอเตอรเจ็ต (80943C) และ คูมือคําเตือนเกี่ยวกับความถี่วิทยุ (80945C)
การไมปฏิบัติตามคําแนะนําดานความปลอดภัยอาจสงผลใหเกิดการบาดเจ็บหรือเกิด
ความเสียหายตออุปกรณ
สําเนาคูมือทั้งในรูปแบบอิเล็กทรอนิกสและแบบสิ่งพิมพจะถูกแนบมาพรอมกับ
ผลิตภัณฑ สําเนาคูมือในรูปแบบอิเล็กทรอนิกสของผลิตภัณฑและสําเนาคูมือตาง
ๆ ในหลากหลายภาษานั้นยังมีใหบริการบนเว็บไซต www.hypertherm.com/docs
ของเราอีกดวย
TR (TÜRKÇE/TURKISH)
UYARI! Bir Hypertherm ekipmanını çalıştırmadan önce, ürününüzün kullanım
kılavuzunda, Güvenlik ve Uyumluluk Kılavuzu’nda (80669C), Su Jeti Güvenlik
ve Uyumluluk Kılavuzu’nda (80943C) ve Radyo Frekansı Uyarısı Kılavuzu’nda
(80945C) yer alan güvenlik talimatlarını okuyun.
Kılavuzların kopyaları, elektronik ve basılı formatta ürünle birlikte verilebilir.
Elektronik kopyalar web sitemizde de yer alır. Kılavuzların birçoğu
www.hypertherm.com/docs adresinde birçok dilde mevcuttur.
VI (TIẾNG VIỆT/VIETNAMESE)
CẢNH BÁO! Trước khi vận hành bất kỳ thiết bị Hypertherm nào, hãy
đọc các hướng dẫn an toàn trong hướng dẫn sử dụng sản phẩm của bạn,
Sổ tay An toàn và Tuân thủ
(80669C),
Sổ tay An toàn và Tuân thủ Tia nước
(80943C), và
Hướng dẫn Cảnh báo Tần số Vô tuyến
(80945C). Không tuân
thủ các hướng dẫn an toàn có thể dẫn đến thương tích cá nhân hoặc hư
hỏng thiết bị.
Bản sao của sổ tay có thể đi kèm với sản phẩm ở định dạng điện tử và in.
Bản điện tử cũng có trên trang web của chúng tôi. Nhiều sổ tay có sẵn bằng
nhiều ngôn ngữ tại www.hypertherm.com/docs.
ZH-CN (简 体中文/CHINESE SIMPLIFIED)
警告！ 在操作任何海宝设备之前，请阅读产品手册、《安全和法规遵守手
册》 (80669C)、《水射流安全和法规遵守手册》 (80943C) 以及
《射频警告手册》 (80945C) 中的安全操作说明。
随产品提供的手册可提供电子版和印刷版两种格式。电子版本同时也在我们
的网站上提供。很多手册有多种语言版本，详见 www.hypertherm.com/docs.
ZH-TW (繁 體中文/CHINESE TRADITIONAL)
警告！在操作任何Hypertherm設備前，請先閱讀您產品手冊內的安全指
示，包括 《安全和法規遵從手冊》(80669C)、《水刀安全和法規遵從手冊》
（80943C），以及 《無線電頻率警示訊號手冊》（80945C）。
電子版和印刷版手冊複本可能隨產品附上。您也可以前往我們的網站下載電
子版手冊。我們的網站上還以多種語言形式提供多種手冊，請造訪
www.hypertherm.com/docs。
Powermax65/85/105 SYNC Mechanized Cutting Guide 810480 9
Contents
1 Before You Begin....................................................................................................................... 13
2 Set Up the Machine Torch....................................................................................................... 15
About the machine torch ................................................................................................................................... 15
Machine torch components, dimensions, weights ...................................................................................... 16
Components............................................................................................................................................. 16
Full-length machine torch .......................................................................................................... 16
Mini machine torch...................................................................................................................... 17
Dimensions ............................................................................................................................................... 17
Full-length machine torch .......................................................................................................... 17
Mini machine torch...................................................................................................................... 18
Weights ..................................................................................................................................................... 18
Attach the torch to your equipment ................................................................................................................ 19
Minimum bend radius for torch lead ................................................................................................... 19
Remove the gear rack (optional).......................................................................................................... 20
Align the torch.......................................................................................................................................... 20
3 Configure Controls for Mechanized Cutting ....................................................................... 21
Connect a remote-start pendant (optional) .................................................................................................. 24
Connect a machine interface cable (optional) ............................................................................................. 25
Machine interface cables that use the internal voltage divider PCB .......................................... 26
Cable signals................................................................................................................................ 27
Contents
10 810480 Mechanized Cutting Guide Powermax65/85/105 SYNC
Machine interface cables that use an external voltage divider ..................................................... 27
Cable signals................................................................................................................................ 28
Access raw arc voltage (optional)........................................................................................... 29
Machine interface cables for tables with a 21.1:1 voltage ratio .................................................. 30
Cable signals................................................................................................................................ 31
Install the machine interface cable...................................................................................................... 31
Machine interface receptacle sockets.................................................................................... 32
Machine interface signals.......................................................................................................... 33
Set the 5-position voltage divider PCB................................................................................. 34
Connect an RS-485 serial interface cable (optional) ................................................................................ 35
Install the RS-485 serial interface cable ........................................................................................... 36
RS-485 serial interface signals for connecting to a CNC ................................................ 38
RS-485 serial interface signals for troubleshooting........................................................... 39
Set the parameters on the CNC Interface Settings screen.......................................................... 40
Remote mode indicator ......................................................................................................................... 41
More information about serial communication setup...................................................................... 42
4 Cut with the Machine Torch.................................................................................................... 43
Select the cartridge............................................................................................................................................ 44
Use a FlushCut specialty cartridge..................................................................................................... 46
Get the most out of your cartridges................................................................................................................ 47
Signs that a cartridge is near end-of-life ........................................................................................... 48
Show cartridge data on the status screen........................................................................................ 49
Prepare to fire the torch..................................................................................................................................... 51
Remote mode indicator ......................................................................................................................... 53
Understand and optimize cut quality .............................................................................................................. 53
What is good cut quality? ..................................................................................................................... 53
What is a cut chart? ............................................................................................................................... 54
Cutting and piercing guidelines........................................................................................................... 54
Cutting guidelines....................................................................................................................... 54
Piercing guidelines...................................................................................................................... 55
Understand torch height control for plasma cutting ................................................................................... 56
Torch height during the cut cycle ........................................................................................................ 57
Ohmic contact for initial height sensing ................................................................................ 57
Learn more................................................................................................................................................ 58
Cut stainless steel with F5................................................................................................................................ 59
Contents
Powermax65/85/105 SYNC Mechanized Cutting Guide 810480 11
5 Gouge with the Machine Torch.............................................................................................. 61
Gouging processes............................................................................................................................................ 61
Change the gouge contour............................................................................................................................... 62
6 Common Mechanized System Problems.............................................................................. 65
Cutting system problems .................................................................................................................................. 66
Cut quality problems .......................................................................................................................................... 67
Cut angle (bevel)..................................................................................................................................... 68
Find the cause of a cut-angle problem .................................................................................. 69
Dross.......................................................................................................................................................... 70
Gouging problems.............................................................................................................................................. 71
EMI grounding and shielding best practices................................................................................................ 72
Types of grounding and shielding........................................................................................................ 72
Grounding and shielding best practices ........................................................................................... 72
Example grounding diagram................................................................................................................. 75
Contents
12 810480 Mechanized Cutting Guide Powermax65/85/105 SYNC
Powermax65/85/105 SYNC Mechanized Cutting Guide 810480 13
Before You Begin
This guide gives information to help you do the following:
Set up a SmartSYNC™ machine torch
Configure a mechanized system
Cut and gouge with a SmartSYNC machine torch
Optimize cut quality
Understand torch height control
Troubleshoot common mechanized cutting issues
Understand EMI grounding and shielding best practices
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 Parts Guide (810490)
Safety and Compliance Manual (80669C)
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.
Before You Begin
1
14 810480 Mechanized Cutting Guide Powermax65/85/105 SYNC
Powermax65/85/105 SYNC Mechanized Cutting Guide 810480 15
Set Up the Machine Torch
This section gives information on the following:
SmartSYNC machine torch components and dimensions
Setup information for installing the SmartSYNC torch on X-Y tables, track burners, pipe
bevelers, or other mechanized equipment
Powermax65/85/105 SYNC plasma power supplies are shipped with a starter set of Hypertherm
cartridges. For a full list of the cutting and gouging cartridges available, refer to the
Powermax65/85/105 SYNC Parts Guide (810490).
About the machine torch
SmartSYNC machine torch features
include the following:
Automatic setting of operating
mode, amperage, and gas pressure based on 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)
A torch-lock switch that prevents the torch from firing accidentally, even when the plasma
power supply is ON
The FastConnect™ quick-disconnect system to easily remove the torch for transport or to
switch from one torch to another
For information about the thicknesses that you can cut and pierce with a SmartSYNC machine
torch, refer to the Powermax65/85/105 SYNC Operator Manual (810470).
Set Up the Machine Torch
2
16 810480 Mechanized Cutting Guide Powermax65/85/105 SYNC
Machine torch components, dimensions, weights
You cannot change a full-length machine torch into a mini machine torch,
or change a mini machine torch into a full-length machine torch.
Components
Full-length machine torch
12
3
4
5
6
1Torch lead
2Strain relief for torch lead
3Torch-lock switch
4Hypertherm cartridge
5Shell
632-pitch removable gear rack
Set Up the Machine Torch
2
Powermax65/85/105 SYNC Mechanized Cutting Guide 810480 17
Mini machine torch
Dimensions
Full-length machine torch
3
124
1Torch lead
2Strain relief for torch lead
3Shell
4Hypertherm cartridge
32 mm (1.25 inch)
368mm(14.5inch)
212 mm (8.3 inch)
312 mm (12.3 inch)
35 mm* (1.37 inch*)
* Measuring to the top of the torch-lock switch adds 6 mm (0.23 inch) to
the width of the torch shell.
41 mm* (1.6 inch*)
Set Up the Machine Torch
2
18 810480 Mechanized Cutting Guide Powermax65/85/105 SYNC
Mini machine torch
Weights
Full-length machine torch with torch lead
Mini machine torch with torch lead
32 mm (1.25 inch)35 mm (1.37 inch)
235mm(9.25inch)
180 mm (7.08 inch)
Torch Weight*
Machine torch with 4.6 m (15 foot) lead 2.2 kg (5 lb)
Machine torch with 7.6 m (25 foot) lead 3.2 kg (7 lb)
Machine torch with 10.7 m (35 foot) lead 4.2 kg (9 lb)
Machine torch with 15 m (50 foot) lead 5.8 kg (13 lb)
Machine torch with 23 m (75 foot) lead 8.3 kg (18 lb)
* Without a Hypertherm cartridge installed.
Torch We ight*
Mini machine torch with 4.6 m (15 foot) lead 2.1 kg (5 lb)
Mini machine torch with 7.6 m (25 foot) lead 3.1 kg (7 lb)
Mini machine torch with 10.7 m (35 foot) lead 4.1 kg (9 lb)
Mini machine torch with 15 m (50 foot) lead 5.7 kg (13 lb)
Mini machine torch with 23 m (75 foot) lead 8.2 kg (18 lb)
* Without a Hypertherm cartridge installed.
Set Up the Machine Torch
2
Powermax65/85/105 SYNC Mechanized Cutting Guide 810480 19
Attach the torch to your equipment
You can put the machine torch on a wide variety of X-Y tables, track burners, pipe bevelers, and
other equipment. To install the torch, refer to the instructions of the equipment manufacturer.
If your mechanized cutting system includes a track, do not disassemble the torch or the
quick-disconnect shell. Do the following:
1. Put a clamp on the torch or on the lead near the torch to hold the torch in position.
2. Open the track fully.
3. Put the torch lead in the track.
4. Close the track.
5. Install the torch.
Minimum bend radius for torch lead
Do not bend the torch lead around a radius that is less
than the minimum bend radius of 76 mm (3.0 inches).
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 mechanized
cutting system track.
NOTICE
MINIMUM BEND RADIUS. KINKING AND OTHER DAMAGE CAN OCCUR.
Do not bend the torch lead too far.
76 mm
(3.0 in.)
Set Up the Machine Torch
2
20 810480 Mechanized Cutting Guide Powermax65/85/105 SYNC
Remove the gear rack (optional)
The gear rack can be attached to either side of the full-length machine torch. If you must remove the
gear rack, remove the 2 screws that attach the rack to the torch shell.
When you install the gear rack, tighten the screws by hand. To avoid
damage to the screws, do not tighten too much.
Align the torch
Install the machine torch perpendicular
to the workpiece to get a vertical cut.
Use a square or digital level to align the
torch at a 90° angle to the workpiece.
Position the mounting bracket lower
on the torch to keep vibration at the tip
of the torch to a minimum.
Do not tighten the mounting bracket
too much. Too much force from the
mounting bracket can cause damage to
the printed circuit board (PCB) inside
the torch. Too much force can also warp
or cause other damage to the torch
shell.
1
90°
90°
1
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