Hypertherm Powermax 600 problems
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  1. #1
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    Hypertherm Powermax 600 problems

    Has anyone had a problem getting their 600 to fire. Mine is about two years old, has only about 4-6 hours use. Never had a problem with before. But now it won't even start cutting. Changed the consumables (tips, electrode) and all green lights but won't start cutting
    Good judgement comes from experience.
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  2. #2
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    Re: Hypertherm Powermax 600 problems

    Did you check that your ground clamp is secure on clean metal? And that your air is hooked up?
    Co-Own CNC shop:Miller :1251 plasma cutter, MaxStar 700 TIG/Stick, & XMT 456 Multiprocess Welder.& 2 Hypertherm HPR260's Plasma Cutter

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  3. #3
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    Re: Hypertherm Powermax 600 problems

    Two things to check first remove the torch nozzle and tip push the electrode to see if it goes in and out free if the plunger is stuck it won't fire if thats ok then unplug the torch and check for any corrosion if there is any clean it and if you have some dielectric greese put it on the terminals then plug it in and out a few times then try to cut.
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  4. #4
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    Re: Hypertherm Powermax 600 problems

    Specter, my torch in the past has always started regardless wether or not it was touching the metal to cut. I could just hold it up in the air and pulling the trigger would start the arc, it wouldn't stay on for more than a couple of seconds though, then shut off.
    Good judgement comes from experience.
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  5. #5
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    Re: Hypertherm Powermax 600 problems

    Mechanic, I tried taking the connection to the machine from the torch, looked at it's fine. I took the handle apart to see if anything had come loose, and no problem their either. One thing I didn't mention is that in the past (one time). The internal pressure regulator started leaking air. I knew because you could hear air leaking from inside the unit. I opened the casing and found that there is hose that comes off the bottom of the bowl of the air regulator. It has a built in filter that is replacable, and a type of spring loaded relief valve at the bottom of the bowl. I took it apart and blew it out and it quit leaking. Well that happened again (the leaking from the air reg.). And I was doing some cuttin yesterday with it and it was cutting fine, even though it was leaking air. So tonight I did the ssame thing to the regulator and it fixed the air leakage. But no arc
    Good judgement comes from experience.
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  6. #6
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    Re: Hypertherm Powermax 600 problems

    Hypertherm, and probably most other plasma cutters, are finicky about correct consumable installation. Go through the torch one more time and check by parts numbers as well as using the photo illustration on top of the case. I've been 'sure' I had everything in perfect order on mine a time or two before noticing I had some mismatched consumable somewhere in the assembly. Also, if you haven't done it already, unplug/disconnect the plasma cutter from your electrical supply for a good 5 minutes and try for a re-boot.
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  7. #7
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    Re: Hypertherm Powermax 600 problems

    Did you check the electrode plunger? it sounds like you have water or rust in the air valve or torch. when you pull the trigger does the air come on?
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  8. #8
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    Re: Hypertherm Powermax 600 problems

    I checked all the consumable part numbers made sure the plunger depresses easily. And still no arc oh and unplugged it for fifteen minutes. Air comes on when the amp dial isvturned down bit I believe that is normal. I have a large air drier on the unit. I would think it is something simple due to thelittle use it has seen.
    Good judgement comes from experience.
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  9. #9
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    Re: Hypertherm Powermax 600 problems

    When you pull the trigger does the air come out of the torch tip/
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  10. #10
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    Re: Hypertherm Powermax 600 problems

    When I pull the trigger nothing happens
    Good judgement comes from experience.
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  11. #11
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    Re: Hypertherm Powermax 600 problems

    Then when you had the cover off you must have unpluged or pulled out a wire from the air valve or the air valve is pluged and not letting air through. Take the cover off and check the wires to the air valves and check the filter to make sure air is getting through it. If you cant find anything PM me with your phone number and the best time to call you tomorrow evening.
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  12. #12
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    Re: Hypertherm Powermax 600 problems

    All good advice so far.

    It sounds like it may just be a simple wiring or broken wire issue.....you said the air flows when you turn the Amperage control fully counterclockwise (when you do this adjust the air flow regulator to about 65-70 psi)......but when you pull the trigger...nothing happens. This means the air solenoid and air flow circuitry is apparently working, but you are getting no signal from the torch trigger switch.

    I would suggest tracing the switch wires from the torch trigger to the connections back in the power supply. Could be a loose connection, broken wire, etc.

    Sounds like mechanic 416 is willing to help troubleshoot, or you can call Hypertherm tech service...they are free, and they are very good at helping find issues such as this. Here is their contact info:

    Technical Service
    technical.service@hypertherm.com
    800-643-9878 Tel - Toll Free in USA
    and Canada

    Good luck, and keep us posted.

    Jim Colt Hypertherm

  13. #13
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    Re: Hypertherm Powermax 600 problems

    jtrapper maybe Jim is right you better call Hypertherm tech service...they are "free", and they are very good at helping find issues such as this

    Sorry I even tryed to help good luck and hope you get it fixed soon. George
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  14. #14
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    Re: Hypertherm Powermax 600 problems

    Quote Originally Posted by mechanic416 View Post
    jtrapper maybe Jim is right you better call Hypertherm tech service...they are "free", and they are very good at helping find issues such as this

    Sorry I even tryed to help good luck and hope you get it fixed soon. George
    What is it with your attitude towards Jim?
    You sound like you have a little sand in your v@gina.
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  15. #15
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    Re: Hypertherm Powermax 600 problems

    I cannot figure him out....he has some kind of an issue! I thought it was great that he was willing to help out the OP with his problem....I just offered advice on how to get to tech service and he acts pissed about it!

    Jim

  16. #16
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    Re: Hypertherm Powermax 600 problems

    Thank you everybody for your help. My day job is now interfering with my ability to trouble shoot my problem. When I get it resolved I will post what the problem was. Thanks again, I think collectively you all have it narrowed down to the wiring betweeen the torch and machine.
    Good judgement comes from experience.
    Experience comes from bad judgement.

  17. #17
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    Re: Hypertherm Powermax 600 problems

    I was planning on my next post to follow after a call to Hypertherm to their technical dept.. but I didn't have to call them. Somehow it works, I really hate when things happen like that. Even though I was glad to see it works now. I'm not even going to speculate now. Trust me if I have anymore problems I'll be sure to follow up with you all. Thanks again everyone for all your advice.
    Good judgement comes from experience.
    Experience comes from bad judgement.

  18. #18
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    Re: Hypertherm Powermax 600 problems

    So is it still working?
    I've got mine apart again trying to figure it out. Worked ok for a bit , then started to poop out. My issue is the arc either won't start or it will but will only gouge the metal( 1/8" flat) or won't start or gouge for a bit but it I pump the trigger or tap the tip it sometimes kick's over.
    And yes Jim, it's still the same problem as before. I'm being stubborn and just don't want to part with over $500 clams for the RT60!!!!! Especially since I don't know for sure if it's the torch!
    200amp Air Liquide MIG, Hypertherm Plasma, Harris torches, Optrel helmet, Makita angle grinders, Pre-China Delta chop saw and belt sander, Miller leathers, shop made jigs etc, North- welders backpack.

  19. #19
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    Re: Hypertherm Powermax 600 problems

    Sounds like a torch issue to me. The torch is not very complicated....you can download the service manual ( www.hypertherm.com click on download library, choose powermax600, choose manuals, then service manual) and it will show an exploded view of the torch assembly. You can repair or replace components as needed in the torch head if you don't want to buy a whole new torch. It will be worth more to you if it works!

    Also....tech service at Hypertherm is very helpful...and free.
    Technical Service
    technical.service@hypertherm.com
    800-643-9878 Tel - Toll Free in USA
    and Canada

    Jim Colt


    Quote Originally Posted by bert the welder View Post
    So is it still working?
    I've got mine apart again trying to figure it out. Worked ok for a bit , then started to poop out. My issue is the arc either won't start or it will but will only gouge the metal( 1/8" flat) or won't start or gouge for a bit but it I pump the trigger or tap the tip it sometimes kick's over.
    And yes Jim, it's still the same problem as before. I'm being stubborn and just don't want to part with over $500 clams for the RT60!!!!! Especially since I don't know for sure if it's the torch!

  20. #20
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    Re: Hypertherm Powermax 600 problems

    Quote Originally Posted by LarryO View Post
    What is it with your attitude towards Jim?
    You sound like you have a little sand in your v@gina.
    I like that one Larry, may have to borrow it......
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  21. #21
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    Re: Hypertherm Powermax 600 problems

    Thanks Jim! Hadn't seen that section on the website before. I'll print it off and get a friend to go over everything with a circuit tester and see if we come up with the issue.
    Thanks again!!!!!
    B

    Quote Originally Posted by jimcolt View Post
    Sounds like a torch issue to me. The torch is not very complicated....you can download the service manual ( www.hypertherm.com click on download library, choose powermax600, choose manuals, then service manual) and it will show an exploded view of the torch assembly. You can repair or replace components as needed in the torch head if you don't want to buy a whole new torch. It will be worth more to you if it works!

    Also....tech service at Hypertherm is very helpful...and free.
    Technical Service
    technical.service@hypertherm.com
    800-643-9878 Tel - Toll Free in USA
    and Canada

    Jim Colt
    200amp Air Liquide MIG, Hypertherm Plasma, Harris torches, Optrel helmet, Makita angle grinders, Pre-China Delta chop saw and belt sander, Miller leathers, shop made jigs etc, North- welders backpack.

  22. #22
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    Re: Hypertherm Powermax 600 problems

    Often problems in the torch are pretty simple......although if internal parts are badly arced or burned...it may not be easily repairable. Still...it is usually cheaper to repair that buy a whole new one!
    The new RT60 torch is a much nicer torch...better cuts, longer consumable life.

    Jim

  23. #23
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    Re: Hypertherm Powermax 600 problems

    Try taking some pictures of the last set of consumables, Up inside the torch head.
    Care fully remove the handle and take a picture of the switch and back side of the head.
    Post the picture here.

  24. #24
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    Re: Hypertherm Powermax 600 problems

    Quote Originally Posted by ccawgc View Post
    Try taking some pictures of the last set of consumables, Up inside the torch head.
    Care fully remove the handle and take a picture of the switch and back side of the head.
    Post the picture here.
    Good thinkin'!
    200amp Air Liquide MIG, Hypertherm Plasma, Harris torches, Optrel helmet, Makita angle grinders, Pre-China Delta chop saw and belt sander, Miller leathers, shop made jigs etc, North- welders backpack.

  25. #25
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    Re: Hypertherm Powermax 600 problems

    Another thought, if the torch fires but will not cut. First check the ground, If that's good unscrew the cap 1/8 to 1/4 turn. Seen this a bunch of times. according to hypertherm it has something to do with the distance from the electrode to the nozzle. With all the older torches you always tighten the cap until it stops then back it off 1/8 to 1/4 turn. The brand new model torch has a hard stop that fixes this issue.

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