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Prepare to troubleshoot internal components
Troubleshooting for common problems
- Troubleshooting for common problems
- The cut quality is unsatisfactory, or the cut does not sever the workpiece
  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 ON, but the power LED is off
  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 LED is on, but no gas flows when you fire the torch
  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 arc does not transfer to the workpiece
  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
  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
  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.
- The plasma arc goes out while you are cutting, or the torch will intermittently not fire
- The plasma arc stopped while cutting, but starts when you fire the torch again
  There is a problem with the Hypertherm® cartridge, the cut height, the air filter element, or the input gas pressure.
- The plasma arc makes sputtering and hissing sounds
  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 cutting at full cutting power, and the plasma arc does not time out after 5 seconds
  The system is not connected to ground sufficiently. The output from the plasma power supply is too low.
- Nothing shows on the 2-digit display, the power switch is set to ON (I), and the Power ON LED is on
  Voltage to the control circuits is not sufficient, or a power component has a short circuit.
- The system changes the gas pressure after you set it manually
  The plasma power supply will override manual gas mode under some conditions.
- The system changes the output current (A) or the operating mode after you set them
- The plasma power supply stops (1-phase models)
  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).
Troubleshooting for fault codes
Service parts
Service procedures for the cover, panels, and connectors
Service procedures for the gas supply
Service procedures for the PCBs and related components
Change system settings
How the plasma power supply operates
System diagrams

Nothing shows on the 2-digit display, the power switch is set to ON (I), and the Power ON LED is on

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

There is a problem with the voltage or the power source

Voltage to the plasma power supply is incorrect.
Voltage to the plasma power supply is missing
There is a blown fuse

Make sure that the power cord is connected correctly to the power outlet or line-disconnect switch box
Make sure that the power is on at the main power panel or at the line-disconnect switch box.
Make sure that the circuit breaker did not open (trip).
Make sure that the line voltage is not too low (more than 15% below the rated voltage).

Refer to the electrical specifications in the Powermax45 SYNC Operator Manual (811470).
Examine the fuses in the line-disconnect switch box, and replace bad fuses as necessary.

The fan has a short circuit

Set the power switch to OFF (O), and disconnect the power cord from the power source.
Remove the plasma power supply handle and cover.
Remove the component barrier.
Disconnect the J7 fan connector from the power Printed Circuit Board (PCB).
Set the plasma power supply to ON (I).

Does the 2-digit display come on? OptionDescription

If yes...	Replace the fan.
If no...	Do Troubleshooting for fan faults (3-10-n).