new problem with powermax 45

[redpower1971]

Machine will cut fine for two or three cuts then wont fire. Yellow lightning bolt light comes on for about a minute then goes off....try again and still won't fire light comes back on and so on... If I put a new electrode and nozzle in it usually will work again.......for 3 to 8 cuts...then the same starts over. I can even put a used set in the torch and it will work for a few cuts and quit again. The other night I was try to finish a project and kept switching the same three sets of tips back and forth. Very frustrating. Any ideas will be greatly appreciated! Brian

[jimcolt]

Have you contacted Hypertherm tech service? They are very good at helping to diagnose issues like this and the call is free. Here is the contact info:
Technical Service
technical.service@hypertherm.com
800-643-9878 Tel - Toll Free in USA
and Canada

A couple of other things:

1. The yellow lightning bolt light indicates a general fault. Are any of the other LEDs illuminated when the problem occurs?
2. Ensure that the correct mix of consumables are installed in the torch....and that they are in good condition. You can refer to the manual in the cut chart section to determin the consumables are correct.
3. Worn out nozzles and electrode will cause misfiring conditions....there is a section in the manual to help determine the wear...and when they should be replaced.
4. Do you have mosture in your air? This can cause extremely rapid consumable wear and misfiring.
. Make sure you are not overtightening the retaining cap.....too tight and the consumables will get distorted...which will cause misfiring as well.
6. Are you setting the air pressure setting on the front panel bar graph LED's with the air flowing? This is accomplished by turning the amp knob fully counterclockwise. While this air is flowing you should also check inlet air pressure at the rear of the Powermax45.....if the hose is too small, too long, or has fittings that are restrictive, or the air pressure is dropping for any means...then this could cause the problem. Inlet air pressure must be between 85 and 140 psi while air is flowing at the torch.
7. Make sure the oring on the front of the torch is in place, and in good condition. Replace if necessary.

Hope this helps a bit with troubleshooting. If you can send me a good digital picture of the consumables after they misfire...it will help me diagnose the problem as well.

Best regards, Jim Colt Hypertherm

[scooter383]

Tuesday my plasma cutter wouldnt cut , hypertherm 900 and two florescent light were
flickering, well to make a long store short everyone in the area had the a/c on and the line
voltage was down to 99 volts. About 9pm it worked fine

[ccawgc]

you had a brown out and the line voltage was to low to run the powermax 900.
99 volts on a 115 volt circuit can equal 198 volts on the 230 volt circuit. way to low for proper operation. That's even the bottom end for the new powermax 45 machines.