This service manual includes service parts and procedures for the Powermax45 SYNC® plasma power supply.

This list of resources will help direct you to troubleshooting steps.

Examine these components to do a proper external inspection of the system.

Look inside of the plasma power supply for signs of possible damage.

Make sure that the plasma power supply is grounded correctly before doing troubleshooting procedures.

Unsatisfactory cut quality can have many causes. These can be related to the cartridge, the work lead connection, the gas supply, or an incorrect output current, cut speed, operating mode, or extension cord.

The power switch is set to ON (I), but the Power ON Light Emitting Diode (LED) is off. The voltage to the control circuits is not sufficient, or a power component has a short circuit.

The Power ON Light Emitting Diode (LED) is on. No fault LED or fault code shows on the front panel, but no gas flows when you fire the torch. The start signal is not getting to the control Printed Circuit Board (PCB).

The plasma arc does not transfer to the workpiece. The continuity between the work lead and the workpiece is unsatisfactory.

Gas flows from the torch when you set the power switch to ON (I), but you did not fire the torch. The incoming gas pressure is too high, or the system is not adjusting the gas pressure correctly.

Gas flows when you fire the torch, but there is no plasma arc, or you lose the arc quickly. The Hypertherm® cartridge or torch lead are worn or have damage, there is a problem with the gas flow or gas quality, or the input power is not sufficient.

There is a problem with the Hypertherm® cartridge, the cut height, the air filter element, or the input gas pressure.

There is a problem with the air filter element, or it is necessary to clean the input gas supply. There can also be a problem with the Hypertherm® cartridge.

The system is not connected to ground sufficiently. The output from the plasma power supply is too low.

Voltage to the control circuits is not sufficient, or a power component has a short circuit.

The plasma power supply will override manual gas mode under some conditions.

The 200 V – 240 V CSA/CE/CCC 1-phase plasma power supplies have over voltage protection on the power switch that is supplied by a mechanical trip coil. If voltage from the incoming circuit is more than the maximum voltage, the trip coil sets the power switch to OFF (O).

The Powermax45 SYNC® power supply shows faults using a combination of fault icons and fault code numbers. Some faults are shown by the icons only, others are shown by the icons and a fault code number.

An operational fault code can be for a notification or for a condition that stops the cutting process. Hypertherm® recommends that you do the steps for all faults that occur. Troubleshooting all faults helps you to get optimal cut quality and consumable life.

Fault codes in the 1-nn-n, 2-nn-n, and 3-nn-n formats identify possible damage to components inside the plasma power supply.

Use the part numbers and kit numbers in this section to order replacement parts and accessories for your plasma power supply and torches.

Hypertherm® recommends that service centers keep the following spare parts on hand for repairs because these parts are critical or are usually subjected to heavy and repeated wear. You may need to revise or expand this list for your customers, based on the conditions and work environments in your region.

For label kits, decals for side panels, and consumable labels, refer to the Powermax45/65/85/105 Parts Guide (810490).

You can see different safety and EMC symbols and marks on your system. Each image identifies a specific regional certification.

You can see different IEC symbols on the system. Each image has a specific meaning in the context of operating a plasma cutting system.

It is extremely important to keep a clean gas line in the plasma power supply.

Use the Powermax45 SYNC® setup menu to change system settings.