Hypertherm Powermax65 SYNC Troubleshooting Guide

Troubleshooting for Common Problems
4
Powermax65/85/105 SYNC Troubleshooting Guide 810430 67
Gas flows when
you fire the torch,
but there is no
plasma arc, or you
lose the arc
quickly.
The cartridge is worn
or has damage.
• The cartridge is not
installed correctly.
• The cartridge is at
end-of-life.
• Make sure that the cartridge is not
too loose or too tight.
• Install a new cartridge.
There is damage to
the cartridge or to
the torch lead.
• The electrode in the
cartridge is not moving
correctly.
• There is damage to the
torch lead.
•Do Test 6 – Torch stuck open (TSO)
or torch stuck closed (TSC) on
page 98.
The gas flow is too
high or is not
sufficient.
• The gas pressure is too
high or too low.
• The gas supply line has
leaks or blockages.
• Make sure that the inlet gas pressure
stays between 7.6 bar – 8.3 bar
(110 psi – 120 psi) while gas is
flowing.
• Make sure that the gas supply is not
more than 9.3 bar (135 psi).
• Repair gas leaks and blockages.
• Adjust the gas pressure on the
plasma power supply manually.
The gas quality is
unsatisfactory.
• The filter element in the
air filter is dirty.
• Oil, moisture, or other
contaminants are in the
gas supply line.
• Replace the air filter element.
•Add additional, external filtration that
is applicable for the work
environment. Refer to the
Powermax65/85/105 SYNC
Operator Manual (810470).
• Flush the gas supply line with
nitrogen to remove oil and moisture.
The input power is
not sufficient.
The electrical supply
installation for one or more of
the following is not sufficient:
• Circuit breaker or fuse
• Supply wire
• Extension cord
• Refer to the installation
specifications in the
Powermax65/85/105 SYNC
Operator Manual (810470).
An internal power
component is
defective.
• The inverter IGBT
module is defective.
•The power PCB is
defective.
• Use an IGBT tester to do a test of
the inverter IGBT module.
There is a capacitor
voltage imbalance on
the power PCB.
• Resistors on the power
PCB are defective.
• The bulk capacitors are
defective.
Do the following tests. If the voltage
across the bulk capacitors is not
balanced, replace the power PCB.
•Do Test 1 – Voltage input on
page 78.
•Do Test 2 – DC power bus on
page 83.
•Do Test 3 – Output diodes on
page 90
Problem Meaning Causes Solutions

Hypertherm Powermax65 SYNC Specifications

General

Brand	Hypertherm
Model	Powermax65 SYNC
Category	Welding System
Language	English