PM45 power errors at idle

[creepy]

PM45 on Bulltear table, CandCNC DTHC, machine torch. Working table, been running for a few months.

I've had a couple of occurances this week of the PM45 making little internal scratchy/static noises while sitting idle after a program. Not long cycles, the fan hadn't even come on. It has gone into error and flashes the AC and FAULT LED. Sometimes it won't shut off right away with the power switch, the LED's flash, then it shuts off. Same with turning it on without rebooting Mach3, I get the AC and Fault LED's flashing.

When I went to turn on the PM45 after these errors, it won't, and I have to reboot Mach3 while the plamsa is off to get the PM45 to turn on again.

It cuts fine and isn't messing up my parts. But when it goes to idle, it flakes out.

i'm not sure if its the plasma or what? flakey power supply? getting a bad input from DTHC?

Before posting this, I made sure of new consumables, dry air, good grounds. The machine *should* be fine, all the easy stuff is correct.

[jimcolt]

The Powermax45 does not really talk to the DTHC or to Mach for that matter. The only interface connections are hard wired start (an output contact closure from your machine) and arc voltage (an analog DC voltage reading that the DTHC monitors...essentially the voltage from the electrode (negative ) and the plate (positive), and your DTHC also monitors arc transferred current (arc good signal).

Best thing to do is to disconnect the Powermax45 and see how it acts with the hand torch.....if it works normally....then the issues is likely elsewhere. If you continue to get weird sounds and errors...Then call Hypertherm tech service....it is free, and the crew in tech service are second to none in terms of helping with issues.

Technical Service
technical.service@hypertherm.com
800-643-9878 Tel - Toll Free in USA
and Canada

Let us know how this works out for future reference!

Jim Colt

[creepy]

Cut a bunch of 3/8" last night, no problems.

Still heard the little noise, but i'm beginning to suspect its a small internal air leak. I have a good supply, constant pressure, but I see the air gauge on the plasma fluctuating at idle. both up and down. (but no air LED fault)

I will have to remove the cover and check the internal filter and look for a leak. Some cheap dissicant broke down last week, but there are two filters between that drier and the plasma. maybe somehow some got thru and is contaminating something.

I suppose there is an air solenoid in there too, i'll call tech b4 picking at that.

BUT - having to reboot Mach3 to clear to start cutting doesn't make sense.

So i'll update what the problem was...it may not even be the plasma.

[unixadm]

Are you getting the alternating flashing lights when turing it on? I had that originally when the DHTC torch relay was on and I powered on my PM45. My issue was I used a standard serial cable in the ABS box where I mounted the CandCNC DHTC card, not realizing it was screwing up the pinouts. The PM45 would error when powered on, and I removed the problem cable from the mix and the issue went away. I'm wondering if you have some sort of control issue between Mach3 and the DHTC card. If you disconnect the serial cable to the DHTC, does the PM45 power on consistently? If so, the issue is with the DHTC.

[creepy]

I'm still picking at this, but have an update. I'm using the supplied serial cable......there are differences in them? the dthc was working before, this isn't a new machine setup, I've been cutting for months.

removed the cover and cleaned out the internal filter. There was dirt and moisture in it, but not enough to make it drain, just a trace. no internal air leaks, and the air solenoid exaust was not dirty or wet, luckily. I have upgraded my air system since the wet probably got in there.

The scratchy noises are coming from the board side of the machine, in the bottom corner below the ac power switch, behind the board. It sounds like electrical static. sharp for a second when its turned on, then lowers to 'idle'.

I can make that noise repeat 100%. When the machine was acting up, the static was louder. I checked every electrical connection, all are tight. The ac switch teminals wiggle in their housing, but I think its supplied like that, the screws are tight, the terminal strips are a little loose inside their plastic housing. But the noise comes from below that area.

After this- The pm45 sat with power on for 2 hours without flaking out. I'd fire the torch for a second in the air every now and then too.

I haven't cut anything since having the cover off, maybe later tonight.

[creepy]

Well I cut out a diff ring in 3/8" and the THC won't work. The plasma was fine and hasn't made noise since I cleaned the internal filter.

May be unrelated things going on. Still troubleshooting. Just want to update, I have hopes there is nothing actually wrong with the PM45 now.