Troubleshooting Guide
148 809240 Operator Manual Powermax45 XP
Torch Cap fault LED
The Torch Cap LED illuminates while the system is
powered ON.
• Make sure the torch lead is securely plugged into the plasma power supply. See page 48.
• Make sure the torch-disable switch on the torch is set to the green “ready to fire” ( ) position.
• Turn OFF (O) the power supply. Make sure that the consumables are installed correctly. See page 46.
Turn O N (I) the power supply.
If the consumables are not installed, or if they are not installed correctly,
the Torch Cap LED illuminates even if the torch-disable switch is set to
the green “ready to fire” ( ) position.
• Make sure the consumables are not too loose or too tight. Never tighten the consumables more than
finger-tight. It is normal for some gas to escape between the torch shell and the retaining cap during
use. This is part of the torch design.
• When you use the torch-disable switch to lock and then unlock the torch without turning OFF the
plasma power supply, the Torch Cap LED illuminates until you fire the torch 1 time to start the warning
puffs of air. See page 45.
• If the torch will not fire an arc, test the torch-disable switch to see if it is working properly. See
page 152. Replace the switch if it is broken.
• If the consumables are in good condition and appear to be installed correctly, the torch may be
damaged. Contact your distributor or authorized repair facility.
The Torch Cap LED blinks slowly (TSO) or
rapidly (TSC) while the system is powered ON.
• If the consumables became loose or were removed while the plasma power supply was ON and the
torch-disable switch remained ON, turn OFF (O) the power supply, correct the problem, and then turn
ON (I) the power supply to clear the fault.
• A slow blink rate (less than 1 blink per second) indicates a “torch stuck open” (TSO) condition.
Check the consumables, including the swirl ring. Make sure they are not worn or damaged. See
page 154. If you are in gouge/marking mode, make sure you are not using the Maximum Control
gouging consumables with the output current set below 26 A. Either increase the output current above
25 A or install the Precision gouging consumables. See Gouging processes on page 71. Next, check
the gas line. See Check the gas pressure on page 140 and Check the gas quality on page 141.
• A rapid blink rate (multiple blinks per second) indicates a “torch stuck closed” (TSC) condition.
Check the consumables, including the swirl ring. Make sure they are not worn or damaged.
See page 154. Next, check the gas line. See Check the gas pressure on page 140 and Check the gas
quality on page 141.
• If the fault persists, change all of the consumables, including the swirl ring. If the consumables are in
good condition and appear to be installed correctly, the torch may be damaged. Contact your
distributor or authorized repair facility.
ARC WELDING SUPPLIES - 07 847 7870
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