Intermittent Powermax30

admin

Was wondering if anyone else has had an intermittent run issue on a Powermax30 (flashing consumables led) or maybe Jim Colt may shed some light? This has been an problem for about a month now intermittently. I have purchased all my consumables from my local weld shop so it shouldn't be caused from Chinese knockoffs. I have verified on each leg of power that I have proper voltage as well as 120 lbs of air pressure supplied to machine.You go to light unit off and it gives a quick spark and the air starts through torch and shuts off immediately as the led on the front panel starts flashing. I got the service manual from online and proceeded the flow chart procedures . I tested all the switches in the handle as well as continuity through wiring. I also made sure the consumables were not hung up inside the handle assembly and all was good. While troubleshooting on the powerboard I got to a point where I didn't see a correct voltage on one of the pins so I buttoned the unit back up to take in to the lws as it's still under warranty. I get a call that the unit is ready for pick up and I talk to the repairman. He said he plugged it in and it worked fine which is the same thing it's been doing this last month. So I pay my $100 shop charge and go home.I used the machine all that weekend with no problems. This weekend I go to use it and the Led light back on again and no worky again. I tried all day yesterday and got it to light off 2 times out of at least 100. Have proper voltages and air as well as new consumables Im at the point of boiling over cause I need this thing to cut . Figured it was smarter to just walk away and cool off before this thing gets slung across the shop . Figured maybe someone on here may be able to shed some light as they too have ran into this intermittent issue. I know the repair guy cant fix something that's working in front of him and I hate wasting $100 bills !! Oh and thanks in advance !!!!Lincoln 216 powermig/spoolgunLincoln weldpak155Lincoln weldpak100Gianttech cut50HF 80amp inverterEverlast140stHypertherm Powermax30Miller Maxstar150STL
Reply:Why would you pay any money if the machine is still in Warranty? Should be zero cost to you..Esab/Lorch ET-220iEsab 160i caddyThermal LM-200 Lincoln feedersThermal Pee-Wee 85sThermal 60i- 3phase /RPC powered (Beast)Thermal Drag-gun 35CINE 1500 Klutch 140i
Reply:Unit wasn't bought from them originally and also they found no defect for Hypertherm to cover. Kinda funny but my full time job has the same type of practice's with these type situations so I guess it conditioned me to the concept.. Looking back on it does suck . I took video and pics and will call them in morning and may even drive it there and plug it in there and try to see if it still does it. If it does I want a refund. Chances are it will work (Murphy's Law) that's why I brought it to this forum to get other peoples insight on the situation. There's something going on with it intermittently but it's always not working when I need it the most.Lincoln 216 powermig/spoolgunLincoln weldpak155Lincoln weldpak100Gianttech cut50HF 80amp inverterEverlast140stHypertherm Powermax30Miller Maxstar150STL
Reply:I am pretty sure Hypertherm would like to know what service department is pulling a fast one.. If they are a authorized repair center, then I don't see them charging for trying to find a problem. If they are independent, and not a authorized repair center, then I could see paying the cash. (If they told you up front on the cost of looking at it)It's one reason you pay a premium price for quality gear..(Support)Esab/Lorch ET-220iEsab 160i caddyThermal LM-200 Lincoln feedersThermal Pee-Wee 85sThermal 60i- 3phase /RPC powered (Beast)Thermal Drag-gun 35CINE 1500 Klutch 140i
Reply:From your description it sounds like maybe the gun has gotten twisted and kinked the air line that runs through the length of the gun.  Take the case back off, where the black air line connects to the air solenoid there is an insulating sheath.  Take you fingers and feel all the way down to where it begins to exit the front and see if you can feel where it may be kinked.  Loosen up the plastic locking nut on the front where the gun comes out of the unit.  At that point on the gun, grab the cable and twist it one way and see if it will fire.  If not twist it the other way and try again.  Hope this helps.
Reply:I had a pin in the gun connection that came loose over time. Looked like a poor solder job on one pin.
Reply:The consumables indicator light usually indicates that the PIP (parts in place) switch in the torch is not satisfied. There are a few things that can cause it, however the best bet is to contact Tech service at Hypertherm on an intermittent issue like this. Tech service keeps a log of every call for every system, they can search your symptoms quickly and find the normal method that was successful for repair.Here is what I know about your symptoms (I am nowhere near as familiar with troubleshooting a Powermax30 as our techs):- Overtightened retaining cap can cause this. Cap needs to be just snug enough to hold consumables in place.-Worn swirl ring or retaining cap. These cause the overall stack up length to change, which is sensed by the PIP switch.-Mix and match of consumables from different suppliers. -Worn or out of adjustment PIP switch in the torch.I'm sure there are others. Tech service again....is the best bet!Jim Colt   Hypertherm
Reply:Realize this is a little late but figued it may help someone out. The issue I was having with my unit was an intermittent internal air restriction caused by me . As I was rolling the torch lead up I was rolling it up like how I roll my extension cords and not realizing I was twisting the lead as it was coiling in its loops. This was causing the thin black hose inside the lead to twist over on itself up by the strain relief and pinching off the air supply and setting off the light.I was able to suck the lead back into the machine enough to cut out the bad section of hose and hook everything back up and she has been working fine ever since. So word to the wise be gentle when rolling your lead up and I wouldn’t step on it either. The hose internally can only take so much abuse. Happy plasma cutting!!!Lincoln 216 powermig/spoolgunLincoln weldpak155Lincoln weldpak100Gianttech cut50HF 80amp inverterEverlast140stHypertherm Powermax30Miller Maxstar150STL