Hypertherm Powermax45 SYNC

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Hypertherm, Inc.

Hanover, NH 03755 USA

www.hypertherm.com

Powermax45 SYNC

Operator Manual

811470

REVISION 2

ENGLISH

Original instructions

June 2024

Main Page

Table of Contents7
Electromagnetic Compatibility (EMC)11
Warranty13
Where to Find Information15
Install and Set up the Plasma Power Supply17
Make Sure that You Have All the System Components18
What to Do if Components Are Missing or Damaged19
Hypertherm Plasma Power Supply Ratings19
Find System Specifications on the Data Plate21
Find the Part Number for Your System22
Critical Raw Materials22
Symbols and Marks23
International Electrotechnical Commission (IEC) Symbols24
Acoustical Noise Levels25
Radio Frequency Identification (RFID) Specifications25
Cutting Specifications25
Recommended Cut Capacity25
Pierce Capacity25
Maximum Cut Speeds (Mild Steel)26
Put the Plasma Power Supply into the Correct Position27
Plasma Power Supply Dimensions and Weight29
Work Lead Weights29
Connect to Electrical Power30
Requirements for Grounding31
Rated Output (Cutting Power) of the Plasma Power Supply31
Voltage Configurations31
CSA/CE/CCC 200 V - 240 V (1-Phase)32
CSA 208 V (1-Phase)32
CCC 220 V (1-Phase)32
CE 230 V (1-Phase)32
CCC 380 V (3-Phase)33
CE 400 V (3-Phase)33
CSA 480 V (3-Phase)33
Decrease Output Current and Arc Stretch for Lower Rated Electrical Service34
Prepare the Power Cord and Plug35
CSA Systems35
CE/CCC Systems35
Extension Cord Recommendations36
Use a Generator (if Necessary)36
Adapter for 4-Wire 1-Phase Connections (CSA 1-Phase Models Only)37
Connect the Gas Supply37
Gas Supply Source39
High-Pressure Gas Cylinders40
Maximum Inlet Pressure41
Minimum Inlet Pressure and Gas Flow Rate41
Add more Gas Filtration41
Operate the Plasma System45
Step 1 - Make Sure that the Plasma Power Supply Is Connected to Power and Gas45
Step 2 - Connect the Torch Lead46
Step 3 - Connect the Work Lead and Work Clamp47
Work Lead47
Work Clamp48
Step 4 - Install the Cartridge48
Lock the Torch49
Install the Cartridge50
Cut Expanded Metal50
Step 5 - Set the Power Switch to on (I)51
Step 6 - Unlock the Smartsync Torch52
Warning Puffs of Air52
Change a Cartridge53
LED Behavior During a Cartridge Change53
Step 7 - Use the Smartsync Torch54
Use the Hand Torch54
What Occurs During and after Cutting54
Temperature Control54
Controls and Indicators on the Plasma Power Supply55
Cutting and Gouging Controls55
Indicator Leds56
Controls and Indicators on the Hand Torch57
Adjust the Operating Settings Manually57
Adjust the Output Current Manually58
Adjust the Output Current from the Hand Torch58
Adjust the Gas Pressure Manually59
Go Back to Automatic Settings Mode60
Monitor Cartridge Data61
Monitor Data for Individual Cartridges61
Prevent Overheating61
Decrease Arc Stretch62
Cut and Mark with the Hand Torch63
About the Hand Torch64
Select the Correct Cutting Cartridge65
Prepare to Fire the Torch66
Start a Cut from the Edge of the Workpiece68
Pierce a Workpiece70
Guidelines for Hand Torch Cutting72
Mark with the Hand Torch72
Marking Process Guidelines72
Get the most out of Your Cartridges73
Signs that a Cartridge Is Near End-Of-Life74
Hand Torch Components, Dimensions, and Weights75
Components75
Dimensions76
75° Torch76
Weights76
Gouge with the Hand Torch77
Prepare to Fire the Torch78
Start a Gouge at an Angle to the Workpiece80
Guidelines for Hand Torch Gouging82
Change the Output Current (A) of the Plasma Power Supply82
Change the Angle of the Torch to the Workpiece82
Change the Turn of the Torch83
Change the Torch-To-Work Standoff / Arc Stretch83
Change the Speed of the Torch84
Troubleshoot Common Problems85
Start Here: Troubleshooting Checklist86
Common Problems and Solutions89
Cold Restarts and Quick Restarts90
Do a Cold Restart90
Do a Quick Restart90
Examine the Gas Pressure91
Examine the Gas Quality92
Common Cutting and Gouging Problems93
Cutting Problems93
Gouging Problems94
Fault Icons and Fault Codes96
Fault Icons96
Fault Codes97
Remove Fault Code Conditions98
Operational Faults98
Internal Component Faults (1-Nn-N, 2-Nn-N, 3-Nn-N)109
Do a Gas Test109
Enter Gas Test Mode109
While Gas Test Mode Is Active110
Exit Gas Test Mode111
Troubleshoot Torch Stuck Open (TSO) Fault Codes that Occur During Postflow112
Troubleshoot Power-Related Problems with Generators112
Complete Regular Maintenance Tasks113
Examine the Plasma Power Supply and Torch113
Each Use115
With each Cartridge Change or each Week (Whichever Is more Frequent)116
At 3 Month Intervals117
Cartridge Maintenance118
Examine the Air Filter Bowl and Filter Element119
Drain Water from the Bowl (if Necessary)119
Remove the Air Filter Bowl and Filter Element119
Examine the Air Filter Bowl and O-Ring120
Examine the Filter Element121
Replace the Air Filter Bowl, O-Ring, and Filter Element121
Install the Air Filter Bowl and Filter Element122

Hypertherm Powermax45 SYNC - Page 3

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