Powermax 45 Issue

[binfordw]

I've been having some trouble with cuts lately, small sections of an otherwise quality cut not piercing all the way and causing parts to hang in sheet. I had decided it was likely a moisture problem, and purchased a new dessicant dryer to place inbetween the plasma unit and my current sub-micronic paper filter.

I did some small parts with the new filter inline, and still had similar issues. After more checking, I noticed the air pressure was varying up and down on the units display. I then removed the units regulator and cleaned it, and did some testing.

When purging, the pressure drops on the display with no change in the reg setting. When the purge is stopped, the display shoots back up to showing a "high" airpressure level. I'm pretty certain with the trouble Ive had in the past with oily/wet air, that something is gummed up- I've had problems with my air solenoid before and had to clean it.


Are there any parts beside the solenoid that can gum up and cause an issue like this? Anything else I should be looking into?

[binfordw]

I just tried swapping the regulator out with another one, didnt seem to change anything.

Also, from what I can tell, The parts I was cutting messed up in the same spot, right after the last pierce. Seems like the purging air had just shut off right as the torch finished zeroing for the last pierce and restarted, it pierced the sheet, and didnt fully cut for the first .375"-.500" of the cut before finishing normally.

Maybe something is gummy and sluggish to respond? Just not sure what else there is besides the reg and the solenoid valve.

[I Lean]

I'm no help, but I'll be watching since I have a PM45.

[binfordw]

After more messing, It appears the digital "air pressure" readout spikes into the high orange range when the cuts fail to pierce, then jumps back down into the green normal range.

The regulator seems to be fine. Getting pretty stumped here.

[binfordw]

Is there somewhere I can get a diagram for the regulator? I looked on the online service manual but it wasnt shown.

[jimcolt]

I'm guessing that the failure to pierce may be blowing materials back into the shield/nozzle, which will block the flow at the torch and will cause a rapid increase in pressure. My best suggestion is to call Hypertherm tech service, I can almost guarantee that (with close to 40,000 Powermax45's in the field) they have seen these exact symptoms in the past. They are free, they arefriendly, and they are very good at what they do in the Hypertherm tech service group!

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

Jim Colt Hypertherm

Originally Posted by binfordw After more messing, It appears the digital "air pressure" readout spikes into the high orange range when the cuts fail to pierce, then jumps back down into the green normal range. The regulator seems to be fine. Getting pretty stumped here.

[binfordw]

Ah that would explain the raise in gas pressure during the short sections of bad cuts. I was thinking of it the other way around.

I agree tech support is my best bet, I just hate being down all weekend while I wait.

Do I purchase replacement parts through hypertherm?

[jimcolt]

Blocking the front of the torch will increase pressure, decrease flow. Hypertherm cannot sell direct, the tech service guys can help you find the closest distributor if needed.

Jim

[binfordw]

Aha, after your post about blockage I check the torchhead, and found particles (teflon perhaps?) in the small hardline to the torchhead assembly. I cleaned and blew it all out and it seems to be working fine now.


Now my problem is the regulator I cant get reassembled correctly lol. The unit works fine with an aftermarket reg though, so its useable for now.

Jim is there anywhere I can get a schematic on the regulator? The diaphram on the topside isnt sealing from what I can tell. It constantly blows air past it- not just when it purges off extra pressure during adjustments.

[jimcolt]

We just buy the regulator...sometimes the tech service guys can get component breakdowns for items like that..it is worth asking them on Monday.

Did you take a look at the service manual....I'm not sure if it is in there or not.

Jim Colt