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Troubleshooting for common problems
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.

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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

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.

There is a problem with the Hypertherm cartridge, torch, or torch lead

Make sure that the Hypertherm cartridge is not too loose or too tight.
Examine the Hypertherm cartridge for wear or damage.
Replace it if it is worn or has damage.
Do Troubleshooting for TSO and TSC faults to identify if the problem is with the Hypertherm cartridge, the torch, or the torch lead.

A higher rate of TSO and TSC faults is typical as a Hypertherm cartridge gets near end-of-life.

The gas flow is too high or too low

For optimum system performance, make sure that the inlet gas pressure stays between 7.6 bar – 8.3 bar (110 psi – 120 psi) while gas is flowing.
Never use more than the maximum gas pressure of 9.3 bar (135 psi).
Examine the gas supply line, and repair gas leaks and blockages as necessary.
Adjust the gas pressure on the plasma power supply manually.

The gas quality is unsatisfactory

The filter element in the air filter is dirty.
Oil, moisture, or other contaminants are in the gas supply line.

Replace the air filter element.
Add additional, external filtration that is applicable for the work environment.

Refer to the Powermax45 SYNC Operator Manual (811470).
Flush the gas supply line with nitrogen to remove oil and moisture.

The input power is not sufficient

The electrical supply installation for one or more of the following is not sufficient:

Circuit breaker or fuse
Supply wire
Extension cord

Refer to the installation specifications in the Powermax45 SYNC Operator Manual (811470).

There is a voltage imbalance on the capacitors

The bulk capacitors on the power Printed Circuit Board (PCB) are defective.

Do Troubleshooting for input voltage faults.
If the voltage across the bulk capacitors is not balanced, replace the power PCB.