Troubleshoot Common Problems
Powermax65/85/105 SYNC Operator Manual 810470 11 9
Examine the power source
Can the power source supply sufficient power to the plasma power supply for the applications that
you are doing?
If you are using a generator, make sure that it has sufficient power to let you do a full plasma arc
stretch. Refer to Use a generator (if necessary) on page 51 and Troubleshoot power-related
problems with generators on page 145.
Are the circuit breakers or fuses sufficient for your plasma power supply and for the applications that
you are doing? Refer to page 41. The recommended fuse / breaker sizes let the input current
increase quickly when you stretch the plasma arc.
Did the circuit breaker open (trip)?
Make sure that the mechanized cutting system is grounded and set up correctly (if applicable)
Is the mechanized cutting system correctly grounded or bonded? For information on grounding best
practices, refer to the Powermax65/85/105 SYNC Mechanized Cutting Guide (810480).
Does the routing of all cables keep electromagnetic interference (EMI), also called noise, to a
minimum? For information on best practices to decrease noise, refer to the
Powermax65/85/105 SYNC Mechanized Cutting Guide (810480).
For example, keep the torch lead and work lead together by using cable ties or intertwining them like
a twisted pair. Also keep the routing of the torch lead and work lead separate from the shielded
cables and from all other components of the mechanized cutting system.
Does other industrial equipment share the same ground as the plasma power supply? This can cause
noise problems.
For example, do you have an inverter-type welder with a work lead that is connected to the same
cutting table (or workpiece) as the plasma power supply? Disconnect the welder from power, and
remove its work lead from the cutting table.
Is excess cable wound into coils? This can cause noise problems. Instead, put the excess cable
down flat or in a figure-8 shape.
If you are using torch height control (THC), is an ohmic contact ring (428895) installed on the
Hypertherm cartridge? Is the ohmic contact ring connected correctly to the THC?
Examine the plasma power supply
Is the plasma power supply in an upright position on a flat, level surface?
Does the plasma power supply have sufficient ventilation (approximately 0.25 m or 10 inch of
clearance on all sides)?
Are the louvers in the plasma power supply cover blocked?
Is the power switch on the rear panel of the plasma power supply operating correctly?
Is there any visible damage to the plasma power supply?
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