Start here: troubleshooting checklist

When a problem occurs, go through the troubleshooting checklist first. It is necessary to complete these steps before doing other troubleshooting procedures.

As you do this checklist, record any problems or questions. If you cannot find a solution to the problem by complying with the specified recommendations, or if more aid is necessary, do these steps:
  1. Get the serial number for your system from the data plate that is on the bottom of the plasma power supply.
  2. Speak to your Hypertherm® distributor or authorized repair facility.
  3. Speak to the nearest Hypertherm office.
Note:

Refer to the Powermax45/65/85/105 SYNC Parts Guide (810490) for information on frequently used replacement parts.

Make sure that any changes to the plasma power supply or power cord are done by a licensed electrician.

  • 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 Generator considerations.

    • Are the circuit breakers or fuses sufficient for your plasma power supply and for the applications that you are doing?

      Refer to Voltage configurations.

    • Did the circuit breaker open (trip)?
  • 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 inches of clearance on all sides)?
    • Are the louvers in the plasma power supply cover blocked?
    • Is the power switch on the front panel of the plasma power supply operating correctly?
    • Is there any visible damage to the plasma power supply?
  • Examine the front panel controls.
    • Is the fault Light Emitting Diode (LED) on?
      The image shows the symbol for the fault Light Emitting Diode.
    • Is the AC LED flashing?
      The image shows the symbol for the AC Light Emitting Diode.
    • Does the front panel show a fault code or fault icon?

      Refer to Fault icons and fault codes.

  • Examine the power cord.
    • Is the power cord plugged in, or is it connected correctly to a line-disconnect switch or other power source?
    • Is there any visible damage to the power cord?
    • Are there wires that are frayed or have other damage?
    • Are the power cord wires in the power plug or line-disconnect box short-circuited?
    • Is the power plug correct for the power cord?

      For example, do not install a 1-phase power plug on a 3-phase power cord. Refer to Power cord and plug requirements.

    • Is the power cord ground wire connected to ground in the plasma power supply and in the power plug or line-disconnect box?
    • Are the remaining power cord wires connected correctly in the plasma power supply and in the power plug or line-disconnect box?

      Refer to Power cord and plug requirements.

    • Are the power cord wires fully tightened inside the plasma power supply and in the power plug or line-disconnect box?
  • 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 Step 3 – Connect the work lead and work clamp.

    • Is the work lead twisted or kinked?
    • Are there wires in the work lead that are frayed or have other damage?
    • Is the work clamp connected to the workpiece that you are cutting?
    • Does the work clamp have good metal-to-metal contact?

      If necessary, remove any rust, paint, or other debris to give a clean surface for a better connection.

  • Examine the torch and torch lead.
    • Is the torch lead connected correctly to the plasma power supply?

      Refer to Step 2 – Connect the torch lead. The torch lead connector makes a click when it is fully connected.

    • Is the torch lead twisted or kinked?
    • Are there wires in the torch lead that are frayed or have other damage?
    • Are there signs of damage to the torch handle or shell, or to the wires in the torch handle?
    • Is the status LED on the torch solid yellow or red, or is it flashing yellow?

      Refer to Controls and indicators on the hand torch.

    • Are the torch trigger and safety latch operating correctly, and are there signs of damage to the torch trigger?
    • Is the torch-lock switch operating correctly?

      Refer to Step 6 – Unlock the SmartSYNC torch.

  • Examine the Hypertherm cartridge.
  • Examine the gas supply.
    • Is the gas supply hose connected correctly to the fitting on the rear panel of the plasma power supply?
    • Is the gas supply hose connected correctly to the air compressor, gas cylinder, or other gas source?
    • Are there signs of leaks at the fittings and connection points in the gas supply line?
    • Is the gas supply hose twisted or kinked, or does it have other signs of damage?
    • Is something causing the pressure to decrease too much while cutting?

      For example, is the gas supply hose too long? Are there other devices that use gas from the same source?

    • Is sufficient gas pressure getting to the plasma power supply?

      Refer to Minimum inlet pressure and gas flow rate.

    • Are you able to keep gas pressure constant while you are cutting?

      Refer to Troubleshooting for gas pressure problems.

  • Examine the gas quality.
    • Are there signs of contamination in the gas supply line, such as from oil, water, or dirt?

      It is extremely important to keep a clean, dry gas line. Refer to Keep a clean gas line.

    • Is your air filtration system sufficient to prevent moisture, oil, and other contaminants from getting into the plasma power supply’s gas line?
    • Is there contamination on the filter element in the plasma power supply’s built-in air filter?

      To replace the filter element, refer to Examine the filter element.