Troubleshoot Common Problems
Powermax45 SYNC Operator Manual 811470 93
Common cutting and gouging problems
Cutting problems
Problem Solution
Pulling the torch trigger
does not fire an arc.
Instead, the torch puts out
short puffs of air, and the
plasma power supply
sounds like it is releasing
pressure.
• The first time that you pull the torch trigger after you set the torch-lock
switch to the “ready to fire” ( ) position, multiple puffs of air quickly come
from the torch. With each puff of air, the plasma power supply makes a
pressure-release sound. This is a warning that occurs when you lock and
then unlock the torch. This does not identify a fault condition. The
purpose of the warning is to tell you that the torch is unlocked and will fire a
plasma arc the next time that you pull the trigger. Refer to page 52.
The plasma arc sputters or
hisses, or you lose the
plasma arc.
• Make sure that the Hypertherm cartridge is installed correctly.
• Examine the Hypertherm cartridge. Replace it if it is worn or damaged.
Refer to Signs that a cartridge is near end-of-life on page 74 and Cartridge
maintenance on page 118.
• Examine the gas filtration system for signs of moisture. Refer to page 121.
Cartridge life is shorter
than expected.
• Examine the gas pressure and the gas supply hose.
• Examine the gas filtration system for signs of moisture.
• Refer to Get the most out of your cartridges on page 73.
The plasma arc does not
transfer to the workpiece.
• Clean the area where the work clamp touches the workpiece. Remove any
rust, paint, or other material. Make sure that there is good metal-to-metal
contact.
• Examine the work clamp for damage. Repair or replace it if necessary.
• Move the torch closer to the workpiece and fire the torch again. Refer to
Cut and Mark with the Hand Torch on page 63.
• Examine the work lead for signs of damage. Replace it if necessary. Refer
to the Powermax45/65/85/105 SYNC Parts Guide (810490).
The plasma arc goes out
but ignites when you pull
the torch trigger again.
• Decrease the length of the arc stretch. Whenever possible, drag the torch
on the workpiece. Refer to page 68.
• Examine the Hypertherm cartridge. Replace it if it is worn or damaged.
Refer to Signs that a cartridge is near end-of-life on page 74 and Cartridge
maintenance on page 118.
• Make sure that the incoming gas supply hose has an internal diameter of
9.5 mm (3/8 inch) or greater.
• Examine the gas filtration system for contamination that is possibly
interfering with plasma power supply performance. Refer to page 119.
• If you manually adjusted the gas pressure before this problem occurred, set
the gas pressure back to the default setting. Refer to page 60.
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