Hypertherm Powermax105, Troubleshooting Manual, Page: 69 / 180

Troubleshooting for Common Problems
4
Powermax65/85/105 SYNC Troubleshooting Guide 810430 69
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. • The filter element in the
air filter is dirty.
• Replace the air filter element.
• There is moisture in the
gas supply line.
• Examine the gas supply line for signs
of moisture. Clean or replace
external filtration components as
necessary.
• Flush the gas supply line with
nitrogen to remove oil and moisture.
• If necessary, add additional, external
filtration that is applicable for the
work environment. Refer to the
Powermax65/85/105 SYNC
Operator Manual
(810470).
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 work lead
connection is not
satisfactory.
• If possible, move the work clamp
closer to the area of the workpiece
you are cutting.
• Clean the area where the work
clamp comes into contact with the
workpiece or cutting table. Remove
any rust, paint, or other residue.
Make sure that there is good
metal-to-metal contact.
• The work lead has
damage.
Measure the resistance across the work
lead. If the resistance is greater than
3 ohms (Ω), repair or replace the work
lead. Identify the work lead connection
on the power PCB as follows:
• Powermax65/85 SYNC models: J26
• All other models: J27
• The pilot arc IGBT is
defective.
• Do Test 13 – Pilot arc IGBT on
page 125.
• The DSP PCB is
defective.
• Replace the DSP FSB.
The output from the
plasma power supply
is too low. • The output current (A) is
set too low.
• Use the adjustment knob to increase
the output current (A) as necessary.
Problem Meaning Causes Solutions