Prepare to Troubleshoot Internal Components
Powermax65/85/105 SYNC Troubleshooting Guide 810430 23
Examine the gas pressure
Inlet gas supply: Incorrect gas pressure can cause errors that prevent cutting or problems
with cut quality. Refer to the Powermax65/85/105 SYNC Operator Manual (810470) for
information on the inlet gas supply requirements. For optimum system performance, make
sure that the inlet gas pressure stays between 7.6 bar – 8.3 bar (110 psi – 120 psi) while
gas is flowing. Never use more than the maximum gas pressure of 9.3 bar (135 psi).
Gas hose: An incoming gas supply hose with too small a diameter can cause problems with
cut quality and cut performance. For gas hoses that are less than 15 m (50 feet), use an
internal diameter of 10 mm (3/8 inch) or greater. For gas hoses that are 15 m – 30 m
(50 feet – 100 feet), use an internal diameter of 13 mm (1/2 inch) or greater.
Pressure setting: The plasma power supply adjusts gas pressure automatically, but you can
adjust the gas pressure manually if necessary.
If you manually adjust the gas pressure and then start to see problems with cut quality or cut
performance, set the gas pressure back to the default setting.
Gas test: You can do a gas test to see if the plasma power supply’s actual output gas
pressure is lower than the set pressure by more than an acceptable quantity. The set
pressure is the gas pressure that the system sets to align with the type of cartridge and
torch installed.
Pressure gauge: Install an inline pressure gauge at the gas inlet on the back of the plasma
power supply, after all external filtration. Use this gauge to monitor the gas pressure during
cutting and when the system is idle. The gas pressure should be stable. For optimum system
performance, make sure that the inlet gas pressure stays between 7.6 bar – 8.3 bar
(110 psi – 120 psi) while gas is flowing.
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