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Hypertherm SYNC Powermax 85 User Manual

Hypertherm SYNC Powermax 85
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Troubleshoot Common Problems
6
Powermax65/85/105 SYNC Operator Manual 810470 121
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.
Refer to page 65.
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 the work lead will get wet and that water will get into the
plasma power supply through the work lead, which can cause severe damage to the plasma power
supply.
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 that causes interference.
Examine the torch and torch lead
Is the torch lead connected correctly to the plasma power supply? Refer to page 64. 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? Refer to page 130.
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? Refer to page 168. 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. Refer to Signs that a cartridge is near end-of-life on page 108.
Is the Hypertherm cartridge installed correctly? Refer to page 66.
Did you select the correct Hypertherm cartridge for the job that you are doing? Refer to page 96 and
page 111.
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. Refer to
page 77.

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Hypertherm SYNC Powermax 85 Specifications

General IconGeneral
BrandHypertherm
ModelSYNC Powermax 85
CategoryWelding System
LanguageEnglish

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