Torch Won’t Fire or Volts Acting Weird

Torch Won’t Fire

1. Press STOP in the software interface

2. Check for an orange light on the Hypertherm — if seen, power cycle the unit

3. Reconnect the USB cable to the RS485 hub and power cycle it

4. Try a different RS485 port (port 1, 2, or 3)

5. Check DTHC Online indicator on screen (lower right)

6. If still no fire, check the Sensor PWM red light

7. If red light is off: restart the software to refresh hub communication

8. If red light is on but no torch fire, inspect the PWM-to-Hypertherm cable — check green plug wiring

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Volts Too Low

1. Confirm nozzle matches amperage (e.g., 220941 for 45A standard, 220930 for 45A fine cut)

2. Confirm air pressure is between 100–130 PSI

3. Press the tip volt button under the Sensor PWM — it should read ~109–126V

4. Make sure jumper under Sensor PWM is set to 50:1 ratio

5. If all above fails, try replacing the Sensor PWM

6. Check CPC port voltage: jumper pins 3 & 4, measure DC volts on 5 & 6 → should read 2.1–3.4V when firing

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Volts Too High

1. Check for worn consumables

2. Replace yellow voltage cable

3. Unplug and inspect the green plug at the Sensor PWM

4. Press tip volt button and verify readings

5. If Sensor PWM is OK, test CPC port voltage as above

6. If still high, DTHC card may need replacement

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Volts Read Zero

1. Confirm default preset volts = 120 on startup

2. Make sure DTHC Online light is on

3. Swap RS485 blue cable to another port and power cycle hub

4. Check CPC cable connection and Sensor PWM tip volt test

5. If all fails, replace Sensor PWM

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Hypertherm Tech Support:

1-800-643-9878
(For CPC voltage or hardware failures)