Troubleshooting for low gas pressure faults

When the Gas Pressure fault Light Emitting Diode (LED) and the System Fault LED both illuminate while the system is ON, the gas pressure is less than the minimum pressure for the selected process, operating mode, torch, lead length, and Hypertherm® cartridge type.

Fault codes and fault LEDs

Fault code Fault LEDs Torch LED Description Stops the system from operating?
None The image shows the Gas Pressure fault Light Emitting Diode.

ON

The image shows the System Fault Light Emitting Diode.

ON

 The image shows the torch Light Emitting Diode illuminated yellow.

Flashes yellow

 The gas pressure is too low. No

Corrective action – gas supply checks

  1. Examine all the input gas supply connections, and make sure that there are no leaks or loose connections.
  2. Make sure that the internal diameter of the incoming gas supply hose is ≥ 9.5 mm (3/8 inch).
  3. Make sure that the gas inlet fitting at the rear of the plasma power supply is connected correctly and is fully tightened.
    • CSA models: Tighten the 1/4 NPT fitting to 11.3 N m (100 lbf in).
    • CE/CCC models: Tighten the G-1/4 BSPP adapter to 10.2 N m (90 lbf in).
  4. Manually adjust the gas pressure on the plasma power supply, and do a quick restart.
  5. Examine the air filter at the rear of the plasma power supply:
    1. Replace the air filter element if it is contaminated.
    2. Clean the air filter bowl, or replace it if it has damage.
  6. Start a gas test, and let the gas flow for 3 – 5 minutes to find if the gas pressure remains stable.

    Refer to Do a gas test.

  7. If the actual pressure is different from the set pressure by more than 0.2 bar (3 psi) during the gas test, continue with the next procedure.

Corrective action – more external checks

  1. Set the power switch to OFF (O), and disconnect the power cord from the power source.
  2. Examine the Hypertherm cartridge for wear and damage, and replace it if necessary.
  3. Make sure that the torch lead is not kinked or twisted, and replace it if necessary.
  4. Make sure that the torch lead has a good connection to the plasma power supply.
  5. Examine the torch lead connector and the quick-disconnect receptacle for possible damage to the pins or wires, and replace them if necessary.
  6. Optional:: If other devices use the same gas supply, make sure that those devices do not prevent sufficient gas pressure to the plasma power supply.
  7. Optional:: Clean or repair external filters, if necessary.
  8. Optional:: If the plasma power supply is connected to an air compressor, make sure that the compressor is the correct size for this system.
  9. To find if electrical interference is preventing the solenoid valve from operating correctly, move the plasma power supply to another location.
  10. If you cannot find or correct the problem, a qualified service technician must repair the system.