Hypertherm Powermax45 Service Manual - Manual (Page 90)

TroubleshooTing and sysTem TesTs
5-14
powermax
45 Service Manual
Problem This may mean Cause Solution
When pulling the torch’s
trigger, gas flows from
the torch, but the torch
does not fire or fires only
for a short period of time,
or the pilot arc starts but
extinguishes before the
normal 5-second time-out
period.
The consumables, torch,
or torch lead are not
functioning correctly, the
gas pressure may be too
low or too high, the air
quality may be poor, or
there is a voltage imbalance
on the power board.
• The consumables may be
worn or damaged.
• The torch or torch lead
may be damaged.
• The gas pressure is too
high or too low or the gas
supply is restricted.
• The gas filter element is
dirty.
• The power board is faulty.
• Inspect the consumables,
torch, and lead. Replace
any damaged parts.
• Verify that the gas supply
is providing at least
4.5 bar (65 psi) and
does not exceed 9.3 bar
(135 psi).
• Repair any restrictions in
the supply line.
• Replace the gas filter
element if dirty.
• Perform Test 3 – VBUS
and voltage balance on
page 5-20 to test the
voltage balance on the
power board.
Arc goes out while
cutting or intermittently
will not fire.
The arc lost contact with
the workpiece.
• The work lead or work
lead connection may be
faulty.
• The material being cut
may require the use of
continuous pilot arc mode.
• If you are cutting
expanded metal, grate,
or any metal with holes,
set the mode switch to
continuous pilot arc mode.
• Check for loose
connections at the work
clamp and at the power
supply.
• Reposition the work lead
on the workpiece.
• Clean the cutting surface
to ensure a better
connection with the work
lead.
The cut quality is poor
or the cut does not sever
the metal.
The consumables are worn,
there is a poor work lead
connection, the output from
the power supply is too
low, or the power board is
producing low current.
• The consumables need to
be replaced.
• The work lead may be
damaged or not properly
connected to the work
piece.
• The amps adjustment
knob may be set too low.
• The power board may be
faulty.
• Inspect the consumables
and replace if necessary.
• Inspect the work lead for
damage. Reposition it and
clean the work surface to
ensure good contact.
• Check the amps
adjustment knob setting. If
your input circuit is 200 V,
34 A; 240 V, 28 A; 400 V,
10 A; or 480 V, 8.5 A, turn
the knob to the highest
setting.