Common problems

Hypertherm Powermax Training

I pulled the trigger but…

Loosen the retaining cap and try again.

Check the consumable part numbers
and the order against the sticker on the
top of the machine.
Try another torch if possible.

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 Electrode and nozzle must separate
Plunger Plunger
spring

Swirl ring
Gas flow

Electrode

Nozzle

Parts at rest Parts with gas flowing

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 In order to start an arc

Pilot arc
current path

Separation arc
Parts at rest Parts with gas flowing

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 In order to make a pilot arc

Separation arc

Separation arc Pilot arc Pilot arc

current path current path

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It loses the arc…

Watch for either the Power or Pressure

interlock LED to flash on.
Try another torch if possible.

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Arc stretch may cause line sag
Start Transfer Arc stretch

Arc voltage

Line voltage

Interlock
minimum
voltage

Time

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There’s an error light on

Consult the Operation section of the

Operator Manual and correct the
condition.
If ONLY the red lightning bolt is on,
inspect the plunger pad for pitting.

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 PMX45 power up interlocks
General fault
Cap sense
Power
Temperature

Gas pressure

Powermax45 front panel

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Operation section of the manual

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 PMX1250 power up interlocks
Power

General fault Incoming voltage

Cap sense Temperature

Gas pressure

Operator manual 5-4

Service manual 3-3

Powermax1250 front panel

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Operation section of the manual

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I’m using lots of consumables

What kind of life are you getting?

Expect 1-2 hours of arc time.
Using a drag tip? Keep your torch on
the material.
Eliminate any moisture in the
incoming air supply.

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Keep the torch on the plate
Electrode Nozzle

Shield

Hottest

Hotter

Hot
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It doesn’t cut like it used to

How has it changed? (Expect some

minor angularity and dross.)
Replace the consumables. Try the
nozzle and electrode first, and then the
swirl ring.
Eliminate any moisture in the incoming
air supply.

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