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Install and Set Up the Plasma Power Supply
Connect the gas supply
Gas supply source
Hypertherm® recommends that air compressors supply air that complies with the requirements of ISO Standard 8573-1:2010 Class 1.4.2.

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Install and Set Up the Plasma Power Supply
- The Powermax45 SYNC system
  The Powermax45 SYNC® is a portable 45 A plasma cutting system that you can use for many handheld and mechanized cutting and gouging applications. The automatic gas and automatic voltage features make it easy to set up and use the system even if you have limited plasma cutting experience.
- Make sure that you have all the components
  It is important to make sure that you have all the components that come with your Powermax SYNC®.
- Hypertherm plasma power supply ratings
- Cutting specifications
- Correct position for the plasma power supply
  Make sure that the plasma power supply is in a safe position and location before you operate the cutting system.
- Connection requirements for electrical power
  Use the Hypertherm® input current ratings to determine conductor sizes for power connection and installation instructions.
- Power cord and plug requirements
- Connect the gas supply
  - Gas supply source
    Hypertherm® recommends that air compressors supply air that complies with the requirements of ISO Standard 8573-1:2010 Class 1.4.2.
    - High-pressure gas cylinders
    - Maximum inlet pressure
    - Minimum inlet pressure and gas flow rate
      Make sure that your worksite complies with the minimum gas flow rate and inlet gas pressure requirements for the cutting, gouging, and marking processes.
  - Add more gas filtration
    Add additional, external filtration if necessary to keep a clean, dry gas line.
Operate the Plasma System
Cut and Mark with the Hand Torch
Gouge with the Hand Torch
Troubleshoot Common Problems
Complete Regular Maintenance Tasks

Gas supply source

Hypertherm® recommends that air compressors supply air that complies with the requirements of ISO Standard 8573-1:2010 Class 1.4.2.

Any air compressors that supply air to the cutting system must have filtration to remove oil.

Table 1. Recommended requirements from ISO Standard 8573-1:2010 Class 1.4.2
Maximum particle count in 1.0 m³:	20,000 at 0.1 microns – 0.5 microns 400 at 0.5 microns – 1.0 microns 10 at 1.0 microns – 5.0 microns
Maximum water vapor pressure dewpoint:	3°C (37°F) ¹
Maximum oil concentration:	0.1 mg/m³ (for aerosol, liquid, and vapor)
¹ Speak to your air compressor manufacturer if you operate the cutting system in temperatures colder than 3°C (37°F) or if you are unsure that the air compressor can comply with the International Organization for Standardization (ISO) standard for air quality.

Notice

DIRTY, OILY AIR CAN CAUSE DAMAGE TO THE AIR FILTER BOWL

Some air compressors use synthetic lubricants that contain esters. Esters can cause damage to the polycarbonates in the air filter bowl.

Add more gas filtration if necessary.

Use shop-compressed gas or cylinder-compressed gas.
Use a high-pressure regulator on either type of gas supply. The regulator must be able to supply gas to the air inlet on the plasma power supply at the specified flow rate and specified pressure.
Use only clean, moisture-free gas.
Oil, water, vapor, and other contaminants in the gas supply can cause damage to internal components over time.
Poor gas supply quality causes:
- Decreased cut quality and cut speeds
- Decreased cut thickness capability
- Decreased consumable life

Note:

To correct these problems, use an optional air filtration system. Refer to Add more gas filtration.