25
Section 4
Trouble Shooting
TROUBLE:
CAUSE/SOLUTION
Machine will not turn on. No fan, no display.
Check cords and wiring in the receptacle. Check circuit
breaker. Check plug condition.
Air Flows but arc does not start withing 2-3 seconds. Check consumables for wear and tightness. Check fuse.
Check Air Pressure. Sticky or slow spring/piston on torch
blow back mechanism. Release trigger and try again.
Air Flows but arc does not start or spark when nozzle
is rubbed on the metal.
Fuse blown. IGBT issue. PCB issue.
OK to cut light is not on. Will not start arc.
Increase air Pressure. Make sure air is connected.
Pilot arc will not light.
Fuse blown.
Pilot arc will not transfer and amps read approxi-
mately 25-27 amps while switch is held. (Arc barely
cuts or only “scratches” the surface of the metal or
cut is extremely slow on thin materials.
Check work clamp connection. Make sure rust is removed
from work clamp contact area. Faulty Clamp. Arc continuity
is not being sensed. If these steps do not correct the issue,
contact Everlast.
Arc Sputters.
Inadequate air flow or air pressure. Improperly sized nozzle.
Decrease size as amps are lowered. Increase air pressure to
73 psi while air is flowing through torch. Loose consumables.
Check tightness.
Consumables are dirty, smutty looking upon inspec-
tion. Premature wear on consumables. Shortened
consumable life.
Moisture, oil contamination of consumable. Wrong consum-
ables. Poor quality aftermarket consumables.
Premature wear on consumables. Short consuma-
ble life. Uneven wear of consumables, melting of
cup.
Moisture, oil contamination of consumable. Excessive pilot
arc time. Improper cutting technique. Wrong piercing tech-
nique.
Arc will not start. Air will not flow. Machine runs.
Torch cup is loose, safety contact pins dirty or not making
contact with cup face. Torch switch wire is loose. Problem
with Central connector. Torch is not properly connected.
Over current/Duty cycle LED illuminates. Machine
runs, but no output.
Duty cycle exceeded or Over current. Allow machine to cool.
Reset main power switch after full cool down period. Make
sure fan is not blocked. Check wiring.
Unstable Arc at lower amps.
Consumable orifice size is too large. Reduce orifice size.
Arc tries to start but irregular, dancing arc and/or arc
melts through side of nozzle.
Missing swirl ring, or worn electrode or both. Check and re-
place. Make sure swirl ring is not cracked.
Arc will try to start if touched to the metal, but no air
flow while switch is pressed.
Stuck or dirty solenoid valve. Contact Everlast.
Air flows continuously.
Place switch into “normal” or “cut” mode. Turn down post
flow time. Solenoid is stuck. Contact Everlast.
Excessively Beveled Cut.
Worn consumables, too high of stand-off height.
Cup and/or nozzle is melting or cracking.
Improper cutting technique/excessive piercing.
Power input circuit breaker trips repeatedly.
Improperly sized circuit. Internal issue. Contact Everlast.
Arc “Blows Out” when ready to cut.
Too high of air pressure. Reduce to 72 psi.
Summary of Contents for PowerPlasma 60S
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