Troubleshooting for Common Problems
Powermax65/85/105 SYNC Troubleshooting Guide 810430 69
The plasma arc
makes sputtering
and hissing
sounds.
There is a problem
with the air filter
element, or it is
necessary to clean
the input gas supply.
• The filter element in the
air filter is dirty.
• Replace the air filter element.
• There is moisture in the
gas supply line.
• Examine the gas supply line for signs
of moisture. Clean or replace
external filtration components as
necessary.
• Flush the gas supply line with
nitrogen to remove oil and moisture.
• If necessary, add additional, external
filtration that is applicable for the
work environment. Refer to the
Powermax65/85/105 SYNC
Operator Manual (810470).
The system is not
cutting at full
cutting power,
and the plasma
arc does not time
out after
5seconds.
The system is not
connected to ground
sufficiently.
•The work lead
connection is not
satisfactory.
• If possible, move the work clamp
closer to the area of the workpiece
you are cutting.
• Clean the area where the work
clamp comes into contact with the
workpiece or cutting table. Remove
any rust, paint, or other residue.
Make sure that there is good
metal-to-metal contact.
• The work lead has
damage.
Measure the resistance across the work
lead. If the resistance is greater than
3 ohms (), repair or replace the work
lead. Identify the work lead connection
on the power PCB as follows:
• Powermax65/85 SYNC models: J26
• All other models: J27
• The pilot arc IGBT is
defective.
•Do Test 13 – Pilot arc IGBT on
page 125.
•The DSP PCB is
defective.
• Replace the DSP FSB.
The output from the
plasma power supply
is too low.
• The output current (A) is
set too low.
• Use the adjustment knob to increase
the output current (A) as necessary.
Problem Meaning Causes Solutions
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