No. | Problem Symptoms | Cause of the Problem | Troubleshooting Method |
1 | The power indicator light does not turn on after switching on the “Power Switch” of the plasma cutting machine main unit. | The “Power Indicator Light” is broken. | Replace |
2A fuse is broken. | Replace |
No input three-phase 380V voltage. | Repair |
Input power phase loss. | Use a multimeter to check the three-phase power supply. |
The power switch is broken. | Replace |
Control board or main unit is broken. | Repair |
2 | After connecting the input power, the fan of the plasma cutting machine does not rotate, but the power indicator light is on. | Phase loss in the three-phase input power. | Use a multimeter to check the three-phase power supply. |
The fan blade is jammed by a foreign object. | Remove foreign objects. |
The fan power plug is loose. | Replug it. |
The fan lead is broken. | Repair |
The fan is damaged. | Repair or replace. |
3 | After connecting the input power, the power indicator light is on and the fan is normal, but there is no airflow ejected after turning on the “Test Air” switch. | No input compressed air. | Inspect and repair the air source and supply pipeline. |
Air filter pressure reducing valve fails, the pressure gauge indicates 0, and the “insufficient air pressure” indicator light is on. | Adjust the pressure of the pressure reducing valve or replace the pressure reducing valve. |
The “Test Air” switch is broken. | Replace |
The electromagnetic valve in the main unit is broken. | Repair or replace. |
The gas supply pipeline is leaking or broken. | Maintenance |
4 | When the “Test Air” switch on the main panel is turned on, airflow is ejected, but the machine does not respond when the torch switch is pressed. | The plasma torch switch is broken or the connection line is broken. | Repair or replace. |
The “Cutting” switch on the plasma cutting machine panel is broken. | Repair or replace. |
The control board of the cutting machine main unit is broken. | Repair or replace. |
The host control transformer or related circuits and components are damaged. | Maintenance |
The cutting machine is in a protective state due to temperature or other reasons. | Wait for the temperature to normalize. |
The water circuit is not working properly, causing low water pressure protection. | Check the water circuit and water pressure valve. |
5 | When the plasma torch switch is pressed, there is airflow from the nozzle, but neither “High Gear” nor “Low Gear” can cut. | Phase loss in the input power. | Maintenance |
Air pressure is less than 0.45Mpa. | Adjust the pressure of the pressure reducing valve. |
The input air flow is too small. | Ensure 0.3m3/min. |
Poor contact between the cutting ground wire and the workpiece. | Re-clamp or replace. |
Electrode nozzle or other parts in the torch are damaged. | Replace with new parts. |
The cutting method is incorrect. | Place the nozzle and workpiece correctly. |
The cable of the plasma cutting machine’s torch is broken. | Replace or reconnect properly. |
The gap in the “spark discharger” in the main unit is too large or short-circuited. | Ensure a gap of about 0.5mm. |
Some components in the main unit are damaged, such as: pressure controller, etc. | Repair or replace. |
The control board in the main unit is damaged. | Repair or replace. |
The torch of the plasma cutting machine is damaged. | Replace |
6 | Contact cutting is possible, but non-contact cutting is not. No sparks are ejected from the nozzle during non-transferred arc testing. | The 15A fuse core is broken. | Replace |
The air pressure on the pressure reducing valve is too high. | Adjust the pressure. |
Some parts in the torch are damaged. | Replace |
The torch is damp, and the moisture content in the compressed air is too high. | Dry and add a water filter device. |
The arc ignition line is broken. | Replace |
The torch is damaged. | Replace |
7 | Only one gear can work in both high and low gears. | The thick cut selection switch is broken or the wire is broken. | Replace |
One of the AC contactors is damaged. | Replace |
The main rectifier is broken or the related wire is broken. | Repair or replace. |
8 | The plasma arc is unstable when the plasma cutting machine is working. | The air pressure is too low or too high. | Adjust |
The electrode or nozzle in the torch is burnt. | Replace |
The input AC voltage is too low. | Adjust the input voltage. |
Poor contact between the cutting ground wire and the workpiece. | Re-clamp or replace. |
The cutting movement speed is too slow. | Adjust the cutting speed. |
The spark discharger cannot automatically break the arc. | Discharge normally for 0.5s, then repair. |
Related components in the main unit are not working properly. | Maintenance |
9 | The cutting thickness does not reach the rated index. | Low input voltage. | Adjust the input voltage. |
The diameter of the input power line is too small, causing too much line loss. | Increase the input capacity. |
The pressure of the input compressed air is too low or too high. | Adjust the air pressure. |
The flow of compressed air is too small. | Ensure the flow of compressed air. |
The selected gear for cutting thickness is inappropriate. | Switch to high gear. |
The cutting speed is too fast. | Slow down the cutting speed. |
The material of the workpiece does not match. | Adjust the parameters. |
The nozzle hole has been burnt. | Replace the nozzle. |
The electrode is burnt. | Replace |
The nozzle model is incorrect. | Change to the correct model of nozzle. |
There is a gas leak in the air duct. | Repair or replace. |
10 | The cut is skewed. | The electrode nozzle has been damaged. | Replace |
The installation position of the electrode nozzle is not concentric. | Reinstall correctly. |
The cutting speed is too fast. | Slow down the cutting speed. |
The nozzle axis is not perpendicular to the workpiece surface. | Adjust to solve. |
11 | The cut is too wide, resulting in poor cutting quality. | The cutting speed is too slow. | Adjust the speed. |
The electrode nozzle is burnt. | Replace |
The cutting material and thickness do not match the selected switch gear. | Choose the correct gear. |
The nozzle model is incorrect. | Replace the nozzle with the correct model. |
12 | The torch of the plasma cutting machine is burnt out. | The metal pressure cap is not tightened. | Regularly inspect the connections of the plasma cutting machine’s torch section to ensure all parts work well together. |
The conductive connection of the torch is loose and leaking. | |
Poor insulation at the torch joint. | |
The ceramic protective sleeve on the torch is damaged and not replaced. | |
Too much moisture in the compressed air. | |
The torch is mistaken when the sectional cutting machine is cutting in parallel. | |
The electrode was not replaced in time after it was burnt. | |
The water circuit is not normal when the water-cooled torch is working, and the interface is leaking. | |
13 | The rectifier diode often burns out. | The reverse breakdown voltage of the newly replaced diode is too low. | Reverse voltage resistance ≥1600V. |
Some iron-shell capacitors on the protection capacitor board are damaged. | Replace |
The main rectifier transformer is damaged. | Repair or replace. |
The torch is damaged. | Replace |