Powermax125 Service Manual 808070 145
8 – Troubleshooting and System Tests
When pressing
the torch trigger
or start switch,
gas flows from the
torch, but the
torch does not fire
or fires for only a
short duration.
Worn or damaged
consumables.
•Overused or
improperly installed
consumables.
• Replace consumables.
• Oil, moisture, or
contaminants in the
gas supply line.
• Replace the gas filter element.
• Add appropriate filtration and purge
the lines with nitrogen to flush out oil
and moisture.
Damaged torch or lead
assembly.
• Electrode is not
moving properly in
the torch, or the
torch lead is
damaged.
•Perform Test 6 – Torch stuck
open/torch stuck closed on
page 158.
Insufficient or excessive gas
flow.
• Gas pressure is too
high or too low, or
the gas supply is
leaking or restricted.
• Verify that the inlet pressure is 5.9 to
9.3 bar (85 to 135 psi).
• Repair air leaks or restrictions.
• Manually adjust the gas pressure on
the power supply.
Poor air quality. • Gas filter element is
dirty.
• Oil, moisture, or
contaminants in the
gas supply line.
• Replace the gas filter element.
• Add appropriate filtration and purge
the lines with nitrogen to flush out oil
and moisture.
Insufficient input power. Undersized electrical
supply installation.
• Breaker or fuse.
•Supply wire.
• Extension cord.
• Verify that the external electrical
power is installed according to
Specifications on page 19.
Faulty inverter IGBT module
or power board.
• Faulty inverter IGBT
module or power
board.
• Use an IGBT tester to check the
inverter IGBT module.
Capacitor voltage imbalance
on the power board.
• Faulty resistors on
the power board or
faulty bulk
capacitor(s).
•Perform Test 1 – Voltage input on
page 150, Test 2 – DC power bus on
page 152, or Test 3 – Output diodes
on page 154.
• If the voltage across the capacitors is
not balanced, replace the power
board.
Problem Meaning Causes Solution
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