Powermax SYNC: Collecting valuable data

By Hypertherm
Posted on 11/16/2022 in SPARK the blog, Plasma cutting

Hypertherm’s Powermax SYNC® contains a lot of advanced features to make plasma cutting easier and more efficient. One of those features is the data collection feature. As you use your system, it keeps track of things like the number of starts and transfers and pilot arc time. The system also keeps track of recent fault codes and tells you which torch type and amperage or power supply you used last, along with the operating mode, current, and gas pressure setting. This information can help you compare cartridge life and spot trends or habits that shorten the life of your cartridge.

Though some of this information shows up on your system display, to get the most out of this feature, you’ll want to get a cartridge reader and download an app.

The reader (part no. 528083) is a small disk that goes on the back of your smartphone. You can either temporarily attach it to your phone using a silicone band that comes with it or simply hold it in place with your hand. Once you have the reader and app, you’re ready to read your data. It’s easy to do.

  1. Grab the cartridge and hold it against the reader on the back of your phone.

  2. Open the app and press the red bar that says Tap to Scan.

  3. Tap Done once you the app tells you it is done scanning.

The app will save the data for each scanned cartridge using the cartridge ID number. It will also let you add labels to the record for each cartridge. For example, you can create labels for cartridges used by a specific operator or workstation or cartridges used with a specific system or shift.

Here’s what that looks like. You’ll see the cartridge ID at the top, followed by the cartridge part number and amperage. Line 3 will list the date and time you last scanned the cartridge and Line 4 is where you can add your label. For this example, the label field has been changed to Operator 2 to track everything this specific operator does.


Underneath the record information at the top of the screen, you’ll see several categories of data. Just tap on each category to drill down further. For example, if you click the arrow next to Cartridge Use Data, you’ll see a screen that looks something like this.


  • Lines 1, 2, and 3 tell you how many times the torch was fired, the number of times the arc transferred to the workpiece, and the transfer success rate, which is 100% in this example since all 3 pilot arc starts (Line 1) transferred successfully (Line 2).

  • Line 4 tells you how long you had a pilot arc and Line 5 how long the arc was in contact with the workpiece. Line 6 provides the total of Lines 4 and 5.

  • The final data point in this section is the end-of-life fault. You either see a No as in this example, or you’ll see one of two end of life fault codes, 0-32-0 or 0-32-1.

    • 0-32-0 appears as soon as the system senses that the cartridge is at the end of its life

    • 0-32-1 appears if you restart the system and try to reuse a used-up cartridge

Though we are not going to go into as much detail for the other data categories right now, this hopefully give you a better idea of how the data is presented.

Once you’ve collected your data, it’s time to do something with it. The app lets you filter the data in different ways. You can filter by cartridge type, system type, torch type, or label type. You can also filter to see which cartridges reached end of life and which have never been used. You can even enter in a range of transfer minutes if, for example, you want to see which cartridges have been used more than once but fewer than 60 minutes. The app can also present the data in a graph format if you’d like.

Although the app does a great job presenting data, there may come a time when you need something more powerful like a spreadsheet to better analyze all of the data that you’ve collected. To do so, you can easily export data from the app to a spreadsheet like Excel or the Hypertherm Cartridge Dashboard. Again, we’re not going to go into a lot of detail here, but just want you know it is possible to export the data you collect if you want to.

Hypertherm has created a user guide that contains detailed information about the cartridge reader, app, and analysis tools. That guide is available for download on our website.


Download user guide



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