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Powermax 45 stopped firing

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Mtw fdu
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Powermax 45 stopped firing

Postby Mtw fdu » Mon Mar 12, 2018 4:32 am

Jim

Just a quick question please about my cnc machine.

I have an issue with the torch not firing and was wondering if you may know what to do. My machine has been running flawlessly for months now and just all of a sudden it just won't fire. My question to you is: Is there a "common" issue that makes the plasma not fire? Is there a fuse in the back of the machine that may need replacing etc? I have a Hypertherm Powermax 45. Everything else is working fine. I have even replaced the USB cable from the computer to the controller but there is no difference.

I have attached a pic of the inside of the controller for you to look at. Towards the left side of the pic is (I think) is the relay which has a red light on. Is this supposed to be on is there a fault somewhere. Also there is a very tiny screw on the front of the relay which I can access from the out of the controller box. Would this be any issue at all?

I am supposed to come over to the USA On the 19th March and see my software people to look at more software for my machine but if my machine is too far gone, am I wasting my time coming over? I need to see what else (if anything) I can do before I decide to cancel my trip. I am hoping it may only be a small issue.

Thank you kindly.


Mtw fdu.

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motoguy
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Re: Urgent Question for Jim Colt Please.

Postby motoguy » Mon Mar 12, 2018 9:36 am

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Re: Urgent Question for Jim Colt Please.

Postby tcaudle » Mon Mar 12, 2018 12:00 pm

If this is a Machine torch on the 45 then you can test by shorting the pins 3 & 4 on the round CPC connector. It should fire the torch. If it does not then its inside the plasma unit. If the torch fires from the CPC pins then its NOT the torch and there is nothing Jim can do for you. If its a hand torch you cannot fire it from the CPC connector. Your interface has to short pin 3 and 4 using a relay (typically) . Since you have a mix of electronics you need to track back and see why its not firing from the I/O card. I don't think the Promo has a torch fire circuit.

Mtw fdu
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Re: Urgent Question for Jim Colt Please.

Postby Mtw fdu » Mon Mar 12, 2018 3:26 pm

Thanks guys for your replies.

tcaudle. I will short it out tonight and check that it is working. I do have a machine torch. All other connections seem to be connected properly. I have also tried to fire the machine by clicking on the "torch on" icon in Mach 3. It flashes but doesn't fire.

Cheers guys.

Mtw fdu.
Camcutcnc 2 x 2 plasma cutter with UC 100 Motion Controller
Powermax 45 with Machine Torch
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Re: Urgent Question for Jim Colt Please.

Postby jimcolt » Mon Mar 12, 2018 3:44 pm

Good advice from tcaudle. That will isolate if the issue is with the plasma cutter or the cnc control / machine output. Jim Colt Hypertherm

Mtw fdu
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Re: Urgent Question for Jim Colt Please.

Postby Mtw fdu » Mon Mar 12, 2018 5:31 pm

I have been in contact with Hypertherm and they have suggested a few things as well to see if it is the plasma unit at fault. Checking the control board inside the plasma unit if the shorting out test does not work.

Thank you for your reply Jim.

Mtw fdu.
Camcutcnc 2 x 2 plasma cutter with UC 100 Motion Controller
Powermax 45 with Machine Torch
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Mtw fdu
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Re: Urgent Question for Jim Colt Please.

Postby Mtw fdu » Mon Mar 12, 2018 9:24 pm

Ok did a short test and it fires. At least this narrows it down to the board.

Will now check again the board of loose wires/connections etc. If I need to replace the board it won't cost that much.

Thanks for your help guys. Will keep you posted.

Mtw fdu.
Camcutcnc 2 x 2 plasma cutter with UC 100 Motion Controller
Powermax 45 with Machine Torch
Bobcad V27 and Mach 3
Proma THC
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Mtw fdu
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Re: Powermax 45 stopped firing

Postby Mtw fdu » Tue Mar 27, 2018 3:43 pm

Just a heads up on my progress.

I am now following a process of elimination going through each wire to fix my problem. Found some wires loose and am getting new connections made. I will try them out when I reconnect them. Won't be able to get much done due to the easter holiday weekend coming up.


Mtw fdu.
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Powermax 45 with Machine Torch
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Mtw fdu
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Re: Powermax 45 stopped firing

Postby Mtw fdu » Sat Apr 07, 2018 10:16 pm

Have ordered new parts from the US and it is currently in transit to me.

Hoping to get it sometime this coming week and get my cutter back up and running.

Mtw fdu.
Camcutcnc 2 x 2 plasma cutter with UC 100 Motion Controller
Powermax 45 with Machine Torch
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Mtw fdu
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Re: Powermax 45 stopped firing

Postby Mtw fdu » Wed Apr 18, 2018 7:28 am

Good news guys...received my parts in the mail today and have connected them to my controller. I have had it firing the plasma through the controller. However I have had my computer switched off for a month now and I have lost some settings I had in Mach 3. I have got all the settings saved on another usb thumb drive and I will have to go through and check every one of them. Mainly the feeds and speeds on my x axis have changed. Will look at steps per mm etc.

Mtw fdu.
Camcutcnc 2 x 2 plasma cutter with UC 100 Motion Controller
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SeanP
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Re: Powermax 45 stopped firing

Postby SeanP » Wed Apr 18, 2018 8:17 am

You should have a folder in C/Mach3 called xmlbackups, you can use those files to replace your xml file in C/Mach3, you need to change the backup filename extension to .xml
That should get you back to before, I've had that happen on occasion, not sure why.
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Mtw fdu
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Re: Powermax 45 stopped firing

Postby Mtw fdu » Wed Apr 18, 2018 4:26 pm

Thanks SeanP. Will check that out for sure.

Mtw fdu.
Camcutcnc 2 x 2 plasma cutter with UC 100 Motion Controller
Powermax 45 with Machine Torch
Bobcad V27 and Mach 3
Proma THC
Now with Rotary Axis

Mtw fdu
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Re: Powermax 45 stopped firing

Postby Mtw fdu » Sat Apr 21, 2018 7:09 am

Another day...and another problem.

While I was trying to get my plasma going today found out the fan is not working all the time. I had the cover off the controller and am not sure if the fan needs to go continuously. If this was the issue I am unsure. Does the fan need to go continuously? Found 1 of the wires partly off but have not checked the screw that holds it in yet. I also haven't unscrewed the fan to check the model number.

While I also tried to get the plasma to fire today I can only hear a "click" when I press the torch on on the Mach 3 screen. Not sure if there is enough power to the unit. Am unsure where to go from here. Any thoughts?

Thanks in advance.

Mtw fdu.
Camcutcnc 2 x 2 plasma cutter with UC 100 Motion Controller
Powermax 45 with Machine Torch
Bobcad V27 and Mach 3
Proma THC
Now with Rotary Axis

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Re: Powermax 45 stopped firing

Postby jimcolt » Sat Apr 21, 2018 9:50 am

In the Hypertherm Powermax units the fan activates when needed. It will come on with use when internal components start to get warm. This feature is to minimize the amount of shop dust that gets pulled through the unit. Jim Colt Hypertherm

Mtw fdu
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Re: Powermax 45 stopped firing

Postby Mtw fdu » Sat Apr 21, 2018 6:23 pm

Thanks Jim. Is it the same for the controller fan?

Here is a pic of the fan wires connected to the controller. Not sure if I should put the 1 that is out a bit back in. The "thinner" black wire next to the pink wire.

If I click on the "torch on" in Mach 3 and leave it on for a bit the plasma will fire and then cut out. Is there something else that could be wrong?

Thanks.

Mtw fdu.

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Rodw
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Re: Powermax 45 stopped firing

Postby Rodw » Mon Apr 23, 2018 5:12 am

mtw fdu,

You could try these guys for Hypertherm support in Australia https://trucut.com.au/
They are a division of ART who sell Hypertherm CNC systems around the world https://www.advancedrobotic.com/
Also Global Welding Supplies http://www.globalweldingsupplies.com.au/ but they are not into CNC.

Sorry they are all in Queensland but if you go back through the right channels, Hypertherm fulfils from Singapore if its not in Australia so you might get stuff sorted a bit quicker. Maybe you can ship your machine off for a service.

Mtw fdu
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Re: Powermax 45 stopped firing

Postby Mtw fdu » Mon Apr 23, 2018 5:53 am

Rodw

Thanks for your reply. However I do know that the plasma machine (hypertherm) is working ok. It is the controller part that is not do its job properly.

I have been given another idea from someone here in my local area and it is possible it could be the relay. He has also suggested that it may be the terminals that may need some contact cleaner on them. I have explained the situation to him and after about 3/4 of an hour talking with him has offered some good ideas. I will do all of that before I go any further.

Mtw fdu.
Camcutcnc 2 x 2 plasma cutter with UC 100 Motion Controller
Powermax 45 with Machine Torch
Bobcad V27 and Mach 3
Proma THC
Now with Rotary Axis

Mtw fdu
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Re: Powermax 45 stopped firing

Postby Mtw fdu » Tue Apr 24, 2018 7:46 pm

Update...have sprayed the contact cleaner over the terminals and it has done some good. I have managed to get the fan to stay on continuously now but the relay still looks as though it may need to be replaced. I can only get the 2 module relay from the US and that will probably take a couple weeks to get to me. Will keep you guys updated as I go any report any other issues (hopefully no more) when they arise.

Thanks for all your replies and suggestions so far.

Mtw fdu.
Camcutcnc 2 x 2 plasma cutter with UC 100 Motion Controller
Powermax 45 with Machine Torch
Bobcad V27 and Mach 3
Proma THC
Now with Rotary Axis

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Re: Powermax 45 stopped firing

Postby sphurley » Tue Apr 24, 2018 11:10 pm

Open contact relays? Not around plasma dust you don't.
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Mtw fdu
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Re: Powermax 45 stopped firing

Postby Mtw fdu » Wed Apr 25, 2018 6:40 am

sphurley wrote:Open contact relays? Not around plasma dust you don't.


Please explain??? Unsure what you mean?

I was told by my local tech guy to blow out the controller first of any dust etc then spray the contact cleaner. After it has dried blow out again with clean compressed air. Wait before starting plasma of any flames from sparks etc. There were no fumes from the contact cleaner.

Thanks.

Mtw fdu.
Camcutcnc 2 x 2 plasma cutter with UC 100 Motion Controller
Powermax 45 with Machine Torch
Bobcad V27 and Mach 3
Proma THC
Now with Rotary Axis

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Re: Powermax 45 stopped firing

Postby sphurley » Wed Apr 25, 2018 8:45 am

I used all solid state relays, that way no dust gets in to cause the issues you are having. Can you physically see your contacts (open frame). Contacts oxidize over time, the current (amps) is part of what keeps them working. Low current draw across the contacts on a relay can show open even when closed due to the oxidation.
Steve
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Mtw fdu
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Re: Powermax 45 stopped firing

Postby Mtw fdu » Wed Apr 25, 2018 4:28 pm

sphurley wrote:I used all solid state relays, that way no dust gets in to cause the issues you are having. Can you physically see your contacts (open frame). Contacts oxidize over time, the current (amps) is part of what keeps them working. Low current draw across the contacts on a relay can show open even when closed due to the oxidation.



Thanks for the clarification. Everything I got was in the whole package of buying the table from the guy at Camcutcnc. I had no choice of what hardware he was using. I am still not sure if it is dust that is causing this issue. When my tech guy comes around and checks the board etc with a multimeter is when I will find out what is wrong. I will then make the decision of where to go from there.

Cheers again for your input.

Mtw fdu.
Camcutcnc 2 x 2 plasma cutter with UC 100 Motion Controller
Powermax 45 with Machine Torch
Bobcad V27 and Mach 3
Proma THC
Now with Rotary Axis

Rodw
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Re: Powermax 45 stopped firing

Postby Rodw » Wed Apr 25, 2018 4:55 pm

A good technician can probably replace the faulty relays with something more readily available and mount them externally. A said above low current draw can cause relay contact oxidisation and intermittent faults like you describe. I got caught with this on the ArcOK relay in my plasma cutter. Adding a pull down resistor increased the current draw and "burnt" through the oxidisation so now its happy days....

Mtw fdu
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Re: Powermax 45 stopped firing

Postby Mtw fdu » Wed Apr 25, 2018 5:01 pm

Rodw wrote:A good technician can probably replace the faulty relays with something more readily available and mount them externally. A said above low current draw can cause relay contact oxidisation and intermittent faults like you describe. I got caught with this on the ArcOK relay in my plasma cutter. Adding a pull down resistor increased the current draw and "burnt" through the oxidisation so now its happy days....


Thanks for the info Rodw. I will talk to my tech guy about that and see what he says.

Cheers.

Mtw fdu.
Camcutcnc 2 x 2 plasma cutter with UC 100 Motion Controller
Powermax 45 with Machine Torch
Bobcad V27 and Mach 3
Proma THC
Now with Rotary Axis

Mtw fdu
Posts: 194
Joined: Sat Dec 20, 2014 3:12 am
Location: Barossa Valley, South Australia

Re: Powermax 45 stopped firing

Postby Mtw fdu » Thu Apr 26, 2018 6:06 am

Rodw

Can you show me your setup please?

Cheers.

Mtw fdu.
Camcutcnc 2 x 2 plasma cutter with UC 100 Motion Controller
Powermax 45 with Machine Torch
Bobcad V27 and Mach 3
Proma THC
Now with Rotary Axis


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