Hypertherm powermax 45 Consumables light flashing.

[JWBIRONWORKS]

I am running a T45v handtorch with 220673 shield, 220719 ohmic cap, 220671 nozzle, 220670 swirl ring and 220669 electrode mounted on a plasma cam DHC2. The cutter was purchased in september 2012. I was cutting this morning and the torch finished a cut, picked up went to the next path,lowered and contacted the steel, raised like it always does then the torch didn't fire. the air came on but no arc. The yellow consumables/torch light was flashing on the front panel of the powermax.
I replaced the electrode and the nozzle and checked the rest. cleaned everything and put it back together. turned the power back on...no yellow light. Torch cut one path and then moved to the next and it faulted again. I checked everything again put it back together the light is still flashing.
Manual says the torch is either stuck open or closed. Anyone got any suggestions? As usual I am in the middle of a job and have 2 behind it so I really can't wait to send the torch off. I'm hoping I'm just missing something.
Oh and the shop is about 45 degrees this morning so that shouldn't be an issue I don't think.
Any help would be appreciated,

John

[JWBIRONWORKS]

Time to feel stupid I called the hypertherm tech line at 1-800-643-9878 and talked with them. they said that the plunger was probably stuck in the torch head. I went back out and checked it and the plunger was moving freely. As I put it back together I left the shield of and as I screwed the retaining cap back on the nozzle would move up and down a little until I tightened it. Then it wouldn't move at all. I backed it off just a little (not even an 1/8th of a turn) until the nozzle would move again and then installed the shield. Powered the unit back up and everything is fine.
Talked to tech support and turns out I've been tightening the cap to tight all along. I've been wrapping my whole hand around the retaining cap and tightening it pretty snug. The tech told me to just use my thumb and forefinger.
I am up and running again with just a little phone time and a little embarrassment,

John

[plain ol Bill]

John I had been tightening mine too tight also - I will back off a little. Thanks for the tip. Tips like this help make this site GREAT!

[jimcolt]

The newer Duramax torch (as used on the 65, 85 and 105 Powermax's, as well as for an upgrade torch on many older Hypertherm's) has solved the "cap overtighteneing" issue.....it no longer occurs!


Jim Colt