Do System Tests to Identify Defective Components
Powermax65/85/105 SYNC Troubleshooting Guide 810430 101
4. Measure the resistance again between the pilot arc IGBT and J28 (or J29). Is the resistance still
less than 100 ohms ()?
If yes, use an IGBT tester to do a check for a short-circuited pilot arc IGBT. Replace the
pilot arc IGBT if it is short-circuited.
If no, continue with the next step.
5. Put a new cartridge on the torch.
6. Measure the resistance again between the pilot arc IGBT and J28 (or J29). Is the resistance
now less than 100 ohms ()?
If yes, the original cartridge is bad.
If no, continue with the next step.
Do a check of the pilot arc IGBT
1. Make sure that the plasma power supply is still OFF and is disconnected from power.
2. Install a jumper wire from the pilot arc IGBT to the work lead connector on the power PCB,
as follows. Refer to Figure 22.
Use a wire that is 8 AWG at a minimum.
Connect to the work lead at J26 on Powermax65/85 SYNC CSA models.
Connect to the work lead at J27 on Powermax65/85 SYNC CE/CCC models and all
Powermax105 SYNC models.
3. Connect the power cord to the power source, and set the power switch on the plasma power
supply to ON (I).
4. Try to fire the torch. If the torch fires a plasma arc, replace the pilot arc IGBT.
Figure 22 – Jumper wire from pilot arc IGBT to work lead
Powermax65/85 SYNC Powermax105 SYNC
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