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Diagnostics and Troubleshooting
- Safety considerations for troubleshooting
  Before you start troubleshooting for a problem, make sure to read, understand, and comply with all of the safety instructions.
- Initial inspection steps
  Some conditions do not give a diagnostic code. For example, there are no diagnostic codes (and the cutting system does not work) if electric power is removed from the cutting system.
- Diagnostic code conventions
  It is important to know these abbreviations and categories when you see diagnostic codes on the Computer Numerical Control (CNC) or XPR® web interface.
- Diagnostic codes
  Use this table to identify a diagnostic code and where to find more troubleshooting information about it.
- General troubleshooting procedures
  - Causes of decreased consumable life
    These are some causes of decreased consumable life that can occur frequently.
  - Cutting faults that can occur frequently
    Hypertherm® recommends these steps when you have one of these cutting problems.
  - Do a gas leak test
    Do an automated gas leak test on the Computer Numerical Control (CNC) screen or XPR® web interface if you suspect a cutting system gas leak.
  - Coolant flow measurements
    There are two methods to measure coolant flow. You can use the Computer Numerical Control (CNC) or XPR® web interface, or you can do a container test.
  - Do a test for continuity between the nozzle and workpiece
    This test helps to find faulty connections or damage in the pilot-arc circuit. This test will do a check of the pilot-arc cable in the torch lead but not of the conductivity of the nozzle.
  - Measure resistance from thermistors
    Use this procedure to measure the resistance of each thermistor wire.
  - Do an ohmic-contact test
    Use this test to examine the resistance from the torch tip to the ohmic relay in the plasma cutting system. This test helps to find ohmic contact issues.
- Troubleshooting procedures for diagnostic codes
- PCB information
Parts List
Wiring Diagrams

Causes of decreased consumable life

These are some causes of decreased consumable life that can occur frequently.

Cuts are started or stopped off the surface of the workpiece.

To extend consumable life, start and stop all cuts on the surface of the workpiece.

The cut settings are not correct.

One or more of the following settings is not correct:

Arc current
Arc voltage
Travel speed
Motion delay
Gas flow rates
Initial torch height

Use the correct settings for the type and thickness of the metal that you are cutting. Refer to the cut charts in the XPR Cut Charts Instruction Manual (809830).

The cutting material is magnetic.

When possible, do not cut metal that is magnetic or that can easily become magnetic. For example, do not cut armor plate that has a high nickel content.