No current control on a Hypertherm 45XP

[stepper]

Hi All
I am hoping you may be able to offer me some help regarding the current control on my 45XP.
Although I have had my cutter for about 2 years, it has only been in use for about 3 months and then for probably a total of 5-6 hours of cutting.
I am now attempting the marking feature and have purchased the correct consumables, however, when I switch to gouging mode I have no control over the amperage which is stuck on 45 amps, out of curiosity I tried altering the pressure to test the control and that does not work either.

I have no warning lights, the pressure supplied is okay and on 45 amp setting, the machine cuts fine, according to the manual, I switch mode to gouging, then adjust my amperage to the required (10-15 amps in my case), this is where it all goes wrong, any ideas please.
Regards
Andy

[adbuch]

That's a good question. I have the 45xp, but have not done any marking or gouging with it. Is the Gouge/Marking Mode LED illuminated when you switch to that mode? Are you able to adjust the current setting when in the regular cutting mode?
David

45xp marking.jpg (81.38 KiB) Viewed 613 times

[stepper]

Yes, the led indicator is showing it is activated and no, I cannot alter the current whether I am in cutting or gouging.

[adbuch]

It sounds like you may have a malfunction with your machine. I would recommend phoning Hypertherm technical support or taking it in to your local Hypertherm dealer for some diagnostics and/or repair. I have attached the 45xp service manual. You could look over the troubleshooting section to see if there is any information that pertains to your particular problem.
David

OM_809240_R4_Powermax45XP.pdf

(17.26 MiB) Downloaded 53 times

[stepper]

Thanks David
Unfortunately there is no authorised dealer in the UK, I have sent an email to their tech support and will hopefully get an answer tomorrow.
Andy

[adbuch]

I will take a look at my 45xp later this evening to see if I can get any more ideas about your problem.
David

[adbuch]

Since you are not able to adjust the air pressure either, I am guessing that the Adjustment Knob potentiometer (or whatever the mechanism is that the knob is turning) is either dirty, has a bad connection, or is defective. Or it is working correctly, but the circuit board that is is connected to is defective (or there could be a bad connection between the Adjustment Knob and the circuit board. If you are handy with trouble shooting electrical devices, then perhaps open up the machine (remove cover) and check it out.
David

45xp cutting controls.jpg (54.88 KiB) Viewed 596 times

[adbuch]

After studying the 45xp manual, my best guess is a faulty Display Board with adjustment knob - Kit #428679. Or at least this would probably be the least expensive place to start. This part is available for around $100 (plus shipping). It might also be the ribbon cable. The first thing I would try is to open up the machine and unplug and re-seat the ribbon cable (on both ends). It is possible that there is a bad connection here due to oxidation or contamination.
David

[stepper]

I appreciate your efforts David, thank you.
I will look at this and feed back to you my findings.
Andy

[stepper]

Hi David
It appears that my Hypertherm is sill under warranty and a new board is being sent to me, hopefully this will correct the problem.
Andy

[adbuch]

Andy, that's great news! Let us know when you receive your replacement parts. Did Hypertherm tech support confirm that the display board was the most likely problem?
David

[stepper]

Hi David
Tech support answered my email with just 3 words, “Change the board”.
Rather abrupt and not really helpful I am sure you will agree, no questions, no indication on the possible problem, no explanation on which board they are talking about, no instructions on the procedure.
Good job I know how to do it along with the help and support you have very kindly given me.
Andy

[adbuch]

I assume they are sending you the Display Board with adjustment knob - Kit #428679. They have probably seen this problem before. No matter, it would not be too difficult to change out any of the boards since the schematic diagram is in the manual.
David

[stepper]

Hi David
Board arrived and swopped out, the control is now working as it should.
Thank you for your help and support.
Andy

[adbuch]

Andy - that's great news! Happy to help.
David