Hypertherm Powermax105, Troubleshooting Manual, Page: 24 / 180

Prepare to Troubleshoot Internal Components
2
24 810430 Troubleshooting Guide Powermax65/85/105 SYNC
Examine the gas quality
It is extremely important to keep a clean, dry gas line to prevent oil, water, dirt, and other
contaminants from causing damage to internal components. A clean gas line also helps you to get
optimal cut quality and consumable life.
Dirty, oily air is the root cause of many common problems that occur in Powermax plasma power
supplies. In some conditions it can void the warranty on the plasma power supply and torch. Refer
to the gas quality recommendations in the
Powermax65/85/105 SYNC Operator Manual (810470).
The plasma power supply’s built-in air filter can remove particulates as small as 5 microns. It can
also remove some moisture from the gas supply. But if you work in an environment that is extremely
warm and humid, or if work site conditions let oil, vapor, or other contaminants into the gas line,
install an external filtration system that cleans the gas supply before it gets into the plasma power
supply.
To keep a clean gas line:
1. Examine the air filter element in the plasma power supply’s built-in air
filter. Replace it if it is contaminated. Refer to the
Powermax65/85/105 SYNC Operator Manual (810470).
2. Clean the air filter bowl. Remove oil, dirt, and other contaminants.

A yellow residue on the filter bowl shows that oil is getting into
the gas supply line.
3. Examine the O-ring at the top of the air filter bowl. Replace it if it has cracks or other damage.
4. If you use an external air filtration system, clean or replace any parts in it that are possibly
contaminated.
NOTICE
DIRTY, OILY AIR CAN CAUSE DAMAGE TO THE AIR FILTER BOWL
Synthetic lubricants containing esters that are used in some air compressors can cause damage to the
polycarbonates in the air filter bowl. Add additional gas filtration if necessary.