Prepare to Troubleshoot Internal Components
Powermax65/85/105 SYNC Troubleshooting Guide 810430 19
Examine the work lead and work clamp
Is the work lead connected correctly to the plasma power supply? Make sure that you turn the
connector clockwise approximately 1/4 turn until the connector is fully engaged in the lock position.
If you are using a water table, are the work clamp and work lead above the water line? It is very
important to prevent the work lead from getting wet.
Hypertherm recommends that you do the following:
• Connect the work lead to the outside frame of the water table.
• Put the plasma power supply higher than the work clamp and the water table.
These steps decrease the likelihood that water will get into the plasma power supply through the
work lead.
Examine the work lead. Are any wires exposed or frayed? Is the lead twisted or kinked?
Are the work lead and work clamp correctly rated for the plasma power supply? For example, do not
use a 65 A work lead with a Powermax85 SYNC plasma power supply. The amperage is identified
near the rubber boot of the work lead connector.
Is the work clamp connected to the workpiece that you are cutting? For mechanized cutting, is the
clamp connected to the cutting table?
Does the work clamp have good metal-to-metal contact? If not, remove any rust, paint, or other
debris to give a clean surface for a better connection.
Examine the torch and torch lead
Is the torch lead connected correctly to the plasma power supply? The torch lead connector makes a
click when it is fully connected.
Examine the torch lead. Are any wires exposed or frayed? Is the lead twisted or kinked?
Examine the torch handle or shell. Are any wires exposed? Are any wires pinched at the seam where
the 2 halves of the shell come together? Are there any other signs of damage to the shell?
SmartSYNC hand torches: Is the status LED on the torch solid yellow or red? Is the status LED
flashing yellow?
All hand torches: Are there any signs of damage to the torch trigger? Are the trigger and safety latch
operating correctly?
Is the torch-lock switch operating correctly? The mini machine torch does not have a torch-lock
switch.
Examine the Hypertherm cartridge
Is the Hypertherm cartridge worn or damaged? A higher rate of 0-30-0 faults is typical as a cartridge
gets near end-of-life.
Is the Hypertherm cartridge installed correctly?
Did you select the correct Hypertherm cartridge for the job that you are doing?
Is the operating mode correct for the Hypertherm cartridge that you are using? Use a cutting
cartridge in Cut mode and Expanded Metal mode. Use a gouging cartridge in Gouge mode.
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