Troubleshooting for when the Hypertherm cartridge or torch is not ready to cut

The Torch Cap fault Light Emitting Diode (LED) illuminates when the torch or Hypertherm® cartridge is not ready to cut or is not able to cut.

Fault codes and fault LEDs

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

ON

 The image shows the torch Light Emitting Diode illuminated yellow.

Yellow

 The Hypertherm cartridge was off, the torch was disconnected, or the torch was in the yellow lock (X) position during a restart. Yes

Corrective action for the Hypertherm cartridge and torch

  1. Move the torch-lock switch to the green "ready to fire" position.

    This fault can show when you do a restart while the torch-lock switch is in the yellow lock (X) position.

  2. Remove the Hypertherm cartridge, and reinstall it correctly.
  3. Reconnect the torch to the plasma power supply, and do a quick restart.
  4. Optional:: Machine torch: Lock and unlock the torch, or do a quick restart.

    This fault can be caused by removing the Hypertherm cartridge without first setting the torch-lock switch to the yellow lock position or setting the power switch to OFF (O).

  5. Optional:: Mini machine torch: Do a quick restart.

    This fault can be caused by removing the Hypertherm cartridge without first setting the power switch to OFF (O).

  6. If possible, do a test with a different torch that is known to work correctly.
  7. Push down the plunger in the torch head and then release.
    The image shows the plunger in the torch head.
  8. Does the plunger move freely and go back to its start position? OptionDescription
    If yes... Continue with the next procedure.
    If no... Replace the torch body.

Corrective action for the torch cap sensor in the torch and torch lead

  1. Disconnect the torch from the plasma power supply.
  2. Make sure that a Hypertherm cartridge is correctly installed on the torch and is not too loose or too tight.
  3. Make sure that the torch is set to the green "ready to fire" position.
    The image shows the torch in the green ready-to-fire position.
  4. Measure the resistance between pin 5 and pin 7 in the torch connector.
    The image shows the pin layout on the torch connector.
  5. Is the resistance very low? OptionDescription
    If yes... Continue with the next step.
    If no... The cap-sensor switch in the torch is open. Continue with step 9.
  6. Set the torch to the yellow lock (X) position.
    The image shows the torch in the yellow lock position.
  7. Measure the resistance between pin 5 and pin 7 in the torch connector again.
  8. Is the resistance open? OptionDescription
    If yes... Continue with Corrective action for the torch cap sensor in the plasma power supply.
    If no... The cap-sensor switch circuit is closed. Continue with the next step.
  9. Do a check for continuity on the torch wires:
    1. Remove the left side of the torch shell.
    2. Do a check for continuity between the blue wire and pin 5 (BLU) in the torch connector.
    3. Do a check for continuity between the orange wire and pin 7 (ORG) in the torch connector.
  10. Do both torch wires have continuity? OptionDescription
    If yes... Replace the cap-sensor switch.
    If no... Replace the torch lead.

Corrective action for the torch cap sensor in the plasma power supply

  1. Set the power switch to OFF (O), and disconnect the power cord from the power source.
  2. Remove the plasma power supply handle and cover.
  3. Remove the component barrier.
  4. Do a check for continuity on the torch receptacle.
  5. Does each torch receptacle wire have continuity? OptionDescription
    If yes... Continue with the next step.
    If no... Replace the torch receptacle.
  6. Reconnect the torch to the plasma power supply.
  7. Make sure that the Hypertherm cartridge is installed correctly on the torch.
  8. Make sure that the torch is set to the green "ready to fire" position.
  9. Measure the resistance between pin 1 and pin 2 at J19 on the power Printed Circuit Board (PCB).
    The image shows the J19 pins on the power Printed Circuit Board.
  10. Is the resistance very low, approximately 1 ohm (Ω) or less? OptionDescription
    If yes... If you cannot find or correct the problem, a qualified service technician must repair the system. Speak to your distributor or authorized repair facility.
    If no... The cap-sensor switch circuit is open. Replace the power PCB.