Application Guide

21
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Troubleshooting
During cutting operations, performance faults may arise which are not caused by equipment malfunctioning but
by other operational faults such as:
1. The cut speed is too fast.
2. The consumables are worn.
3. The metal being cut is too thick.
4. The GROUND CLAMP (4) is not properly attached to the workpiece.
5. The supplied air pressure and flow rate is inadequate.
6. Input power is insufficient (use of extension cords can cause this).
7. PLASMA TORCH (9) is not being dragged in contact with the workpiece.
The following table represents the most common problems associated with using the plasma cutting machine and an
explanation on how to resolve them.
If you are unable to fix the problem by following the basic troubleshooting guide or if you need further assistance
call Forney Customer Service at 1-800-521-6038 or email at [e-mail].
TROUBLE EXPERIENCED POSSIBLE REASONS RECOMMENDED SOLUTION
All LEDs OFF,
No output power,
Fan not operating.
No input power. Connect machine to proper input power source.
Verify that circuit breaker has not been tripped in your
main power panel. Reset if needed.
POWER SWITCH (2) is OFF. Ensure POWER SWITCH (rear) is in the ON position.
GREEN LED (5) FLASHING.
Input voltage outside of
proper range.
Ensure that your input power supply is within 10% of
120VAC.
GREEN LED ON,
YELLOW LED (7) ON,
RED LED (6) OFF,
No output power,
Fan operating properly.
Unit has reached its duty
cycle limit.
Allow unit to cool with internal fan running, once cool
reduce arc cutting time to below duty cycle rating of the
plasma cutting machine.
Insufficient air flow causing
machine to overheat before
reaching duty cycle.
Check for obstructions blocking air flow and ensure that
there are 12 inches of clearance between any obstacles
and the vents on all sides of the machine.
GREEN LED ON,
YELLOW LED FLASHING,
RED LED OFF,
No output power,
Fan operating properly.
Insufficient air supply
pressure or flow.
Connect a proper air supply with 60-100 PSI and 1.5
CFM minimum. Ensure that any inline moisture filters are
rated to handle these requirements.
GREEN LED ON,
YELLOW LED OFF,
RED LED FLASHING,
No air flow or pilot arc when
torch trigger pressed.
SHIELD CUP (E) not
properly installed or
consumables missing or
installed improperly.
Excessively worn
consumables.
Check PLASMA TORCH (9) consumables are properly
installed, electrode is tightened with wrench, and that
SHIELD CUP properly contacts the pins in the TORCH
BODY (A).
Replace electrode and cutting tip.
PLASMA TORCH (9) has pilot
arc but does not cut.
GROUND CLAMP (4) not
connected.
Properly connect the GROUND CLAMP to the workpiece.
Ensure it is on clean, bare metal (not rusty or painted).
AC input power too low. Ensure plasma cutting machine has proper input power
source.
If used, eliminate or reduce length of extension cord.
The arc does not transfer to
the workpiece.
Insufficient GROUND
CLAMP (4) contact with the
workpiece.
Clean the area where the GROUND CLAMP attaches to
the workpiece to ensure a good metal to metal connection.
Inspect the GROUND CLAMP and its lead for damage,
repair or replace as necessary.
PLASMA TORCH may
not be in contact with the
workpiece.
Be sure to physically drag the CUTTING TIP (D) on the
workpiece as you cut.