I'm getting a "Gas pressure" fault on my plasma cutter (Hypertherm
Powermax 380). The PC monitors the gas (air in my case) pressure &
inhibits power to the torch if it falls below 40 psi.

I've:
- checked the pressure on the supply line - it never drops below 80 psi
- changed the filter on the PC

The PC has a built-in air regulator & gauge. It's set to 60 psi, as it
it is supposed to be. The pressure doesn't drop when the torch trigger
is pulled & gas flows.

If I set the PC's regulator to 80 psi it works. Sometimes. The owners
manual says to check the torch lead for pinched hose or obstructions.
This suggests that there is a pressure sensor in the torch & upping the
regulator satisfies it. But the parts diagram doesn't show one.

Any ideas? Before I start tearing it apart, which I'd really rather not do.

Thanks,
Bob

PS - I went to the Hypertherm web site to order a Service Manual. $9,
thats reasonable. Plus $13 shipping! That's not only unreasonable,
it's offensive. Still, it's just $22 total.

Anybody know how good the Hypertherm service manuals are?

Bob

"Bob Engelhardt" wrote in message
...
PS - I went to the Hypertherm web site to order a Service Manual. $9,
thats reasonable. Plus $13 shipping! That's not only unreasonable, it's
offensive. Still, it's just $22 total.

Anybody know how good the Hypertherm service manuals are?

Bob

I don't know about the manual but the phone techs are pretty sharp and will
walk you through diagnosing the problem.
Steve

"Bob Engelhardt" wrote: (clip) Any ideas? Before I start tearing it
apart, which I'd really rather not do.
^^^^^^^^^^^^^^^^^^^^^
This may be too obvious to mention, but are you sure the tip is free of
obstructions? (Warning: the first time I took mine apart, I didn't know
what to expect, and I lost the electrode.)

BTW, in case you are new to this, the electrode and the tip are
consumables--it's a good idea to keep spares on hand.

Up North wrote:

"Bob Engelhardt" wrote in message
...
PS - I went to the Hypertherm web site to order a Service Manual. $9,
thats reasonable. Plus $13 shipping! That's not only unreasonable, it's
offensive. Still, it's just $22 total.

Anybody know how good the Hypertherm service manuals are?

Bob

I don't know about the manual but the phone techs are pretty sharp and will
walk you through diagnosing the problem.
Steve

Last time I looked they had the manuals available for download in PDF
format.

Bob Engelhardt wrote:

I'm getting a "Gas pressure" fault on my plasma cutter (Hypertherm
Powermax 380). The PC monitors the gas (air in my case) pressure &
inhibits power to the torch if it falls below 40 psi.

I've:
- checked the pressure on the supply line - it never drops below 80 psi
- changed the filter on the PC

The PC has a built-in air regulator & gauge. It's set to 60 psi, as it
it is supposed to be. The pressure doesn't drop when the torch trigger
is pulled & gas flows.

If I set the PC's regulator to 80 psi it works. Sometimes. The owners
manual says to check the torch lead for pinched hose or obstructions.
This suggests that there is a pressure sensor in the torch & upping the
regulator satisfies it. But the parts diagram doesn't show one.

Any ideas? Before I start tearing it apart, which I'd really rather not do.

Thanks,
Bob

There is no pressure sensor in the torch. The regulator, solenoid valve
and pressure sensor are all in the main unit.

On Wed, 26 Nov 2008 11:26:07 -0600, "Pete C."
wrote:


Up North wrote:

"Bob Engelhardt" wrote in message
...
PS - I went to the Hypertherm web site to order a Service Manual. $9,
thats reasonable. Plus $13 shipping! That's not only unreasonable, it's
offensive. Still, it's just $22 total.

Anybody know how good the Hypertherm service manuals are?

Bob

I don't know about the manual but the phone techs are pretty sharp and will
walk you through diagnosing the problem.
Steve

Last time I looked they had the manuals available for download in PDF
format.

Try this link (2.4mb):

https://www.hypertherm.com/library/f...)/803990r0.pdf

This manual is suppose to be for common problems (707kb):

https://www.hypertherm.com/library/f...oblemsRev2.pdf

or go to this page and start entering your data:

https://www.hypertherm.com/Xnet/libr...entLibrary.jsp

The operator, product info and some service training manuals
are available too.

--
Leon Fisk
Grand Rapids MI/Zone 5b
Remove no.spam for email

Up North wrote:
I don't know about the manual but the phone techs are pretty sharp and will
walk you through diagnosing the problem.

Thanks! I probably wouldn't even have tried calling. I.e., I didn't
think of that! Duh.

Bob

Pete C. wrote:
Last time I looked they had the manuals available for download in PDF
format.

I didn't see that, so I went back & looked. The manuals were for sale
at hypermax.org (weird) but no downloads. I went to hypertherm.com &
after some digging around, found the Service Manual to download. Thank you!

Bob

Leon Fisk wrote:

Try this link (2.4mb):

https://www.hypertherm.com/library/f...)/803990r0.pdf

That's the one I found. Couldn't download the pdf, so I got the zip.

This manual is suppose to be for common problems (707kb):

https://www.hypertherm.com/library/f...oblemsRev2.pdf


Good, I didn't see that one.

Thank you,
Bob

On Wed, 26 Nov 2008 11:28:59 -0500, Bob Engelhardt
wrote:

I'm getting a "Gas pressure" fault on my plasma cutter (Hypertherm
Powermax 380). The PC monitors the gas (air in my case) pressure &
inhibits power to the torch if it falls below 40 psi.

I've:
- checked the pressure on the supply line - it never drops below 80 psi
- changed the filter on the PC

The PC has a built-in air regulator & gauge. It's set to 60 psi, as it
it is supposed to be. The pressure doesn't drop when the torch trigger
is pulled & gas flows.

If I set the PC's regulator to 80 psi it works. Sometimes. The owners
manual says to check the torch lead for pinched hose or obstructions.
This suggests that there is a pressure sensor in the torch & upping the
regulator satisfies it. But the parts diagram doesn't show one.

Any ideas? Before I start tearing it apart, which I'd really rather not do.

Thanks,
Bob


There WILL be a safety pressure sensor somewhere i n there. Should be
pretty easy to find. Simply follow the air line in..and look for the
thingy with the wires on it.

Gunner


"They couldn't hit an elephant at this dist..."
Maj. Gen. John Sedgewick, killed by a sniper in 1864 at the battle of Spotsylvania

Leo Lichtman wrote:
This may be too obvious to mention, but are you sure the tip is free of
obstructions? ...

I didn't think that would cause my symptoms, but ... So I replaced
both the tip & electrode, just for something to try. No effect, but
thanks anyhow.

Bob

Pete C. wrote:
There is no pressure sensor in the torch. The regulator, solenoid valve
and pressure sensor are all in the main unit.

Thanks. Maybe the pressure sensor senses over pressure as well. That
would explain why my manual said the check the torch lead for kinks
and/or obstructions. I.e., a lead blockage would result in higher
pressure at the sensor.

Bob

Bob Engelhardt wrote:

Pete C. wrote:
There is no pressure sensor in the torch. The regulator, solenoid valve
and pressure sensor are all in the main unit.

Thanks. Maybe the pressure sensor senses over pressure as well. That
would explain why my manual said the check the torch lead for kinks
and/or obstructions. I.e., a lead blockage would result in higher
pressure at the sensor.

Bob

Possibly. I know on my Powermax 1000, it is a real pressure sensor, not
just a pressure switch.

Boy, do I feel stupid! It was just a matter of correct adjustment of
its regulator!!

Bob Engelhardt wrote:
...
The PC has a built-in air regulator & gauge. It's set to 60 psi, as it
it is supposed to be. The pressure doesn't drop when the torch trigger
is pulled & gas flows. ...

That's not true - it does drop & it's supposed to be adjusted while the
air is flowing. There's even a special setting to allow it to flow
without energizing the torch. 'Cause I didn't RTFM, I adjusted it
static, then it was too low with gas flowing.

My apologies for wasting the time of those who replied,
Bob

Bob -

I have a 600 and it is nice.

If you are new to these, then I suspect the issue is Static pressure
vs. dynamic pressure.

They need 40 at maximum air flow. e.g. can your tank supply 40 when the
torch is cooling ? Often the issue is the flow rate.

Set pressure when the torch is turned to cooling mode. Normally below
zero on the current control.

So many people set pressure in a non-flow condition and it dies when
used - being starved to death.

Martin

Bob Engelhardt wrote:
I'm getting a "Gas pressure" fault on my plasma cutter (Hypertherm
Powermax 380). The PC monitors the gas (air in my case) pressure &
inhibits power to the torch if it falls below 40 psi.

I've:
- checked the pressure on the supply line - it never drops below 80 psi
- changed the filter on the PC

The PC has a built-in air regulator & gauge. It's set to 60 psi, as it
it is supposed to be. The pressure doesn't drop when the torch trigger
is pulled & gas flows.

If I set the PC's regulator to 80 psi it works. Sometimes. The owners
manual says to check the torch lead for pinched hose or obstructions.
This suggests that there is a pressure sensor in the torch & upping the
regulator satisfies it. But the parts diagram doesn't show one.

Any ideas? Before I start tearing it apart, which I'd really rather not
do.

Thanks,
Bob

The .com is the company that makes the plasma machine and parts.....

The .org is a company that is aligned (but not owned by) and sells items
for money. They have good prices. Manuals are thankfully on the other site.

Martin

Bob Engelhardt wrote:
Pete C. wrote:
Last time I looked they had the manuals available for download in PDF
format.

I didn't see that, so I went back & looked. The manuals were for sale
at hypermax.org (weird) but no downloads. I went to hypertherm.com &
after some digging around, found the Service Manual to download. Thank
you!

Bob

If you run a torch without filters - from a rusty internal tank -
you can clog up the hose and torch.

Be sure you have the dynamic (flowing) air pressure in the torch head
before going to far.

Martin

Bob Engelhardt wrote:
Pete C. wrote:
There is no pressure sensor in the torch. The regulator, solenoid valve
and pressure sensor are all in the main unit.

Thanks. Maybe the pressure sensor senses over pressure as well. That
would explain why my manual said the check the torch lead for kinks
and/or obstructions. I.e., a lead blockage would result in higher
pressure at the sensor.

Bob