Overvoltage Error in Mach, Torch won't fire HT 1250

[Oldsarge]

I'm to the point that I'm trying to do my first cuts on the table, and ran into this problem... Last week I clicked on fire torch in Mach, and it lit off perfectly. Fast forward to today... I hooked up air to the 1250, and I heard a slight hiss of air inside the machine. I loaded a file and clicked on run, and got an over-voltage message in Mach. I pulled the consumables, and this is what I got:

Pitted!

Something ugly going on here! Also the air never turned on so I unplugged everything and pulled the cover. There's a tiny hole on the solenoid that I'm assuming controls the air, and air is coming out of the hole. I have a regulator before the machine, and never ran more that 110 psi to it, and the regulator inside the machine seems to be before the solenoid, so that would be 2 regulators in line before hitting it.

Any ideas? Jim? How bad did I mess things up? My shop is 5 minutes from the house, so it's hard to run over there to check things at the moment..... I'm working on getting internet in there which will make life a lot better!

Forgot to add: Hypertherm PM 1250 G3 with Duramax machine torch, fine cut consumables... Can't remember the cut settings, will check tomorrow, but think it was 45A. Sorry, still learning and hope I didn't hurt anything too badly. Also, when the spring is loose on the electrode after the over-voltage message I'm assuming that electrode is pretty much trashed?

Thanks for any input, much appreciated!

Oldsarge

[jimcolt]

The electrode is definitely trashed. If there is no air flowing...this is what I would expect for consumable damage. Put new parts in the torch....then turn your amperage knob all the way counterclockwise....that activates the air solenoid without firing the torch. Is the air flowing? If not...then some troubleshooting will have to be done to determine the issue...could be a plugged passage in the internal plumbing, could be a stuck or failed solenoid valve...could be a restriction in the torch or leads. Hypertherm tech service can help you troubleshoot it...they are pretty good over the phone with situations like this...


Jim Colt

[Oldsarge]

Thanks Jim! I pulled the solenoid out today and checked it out. It seems like it was sticking, because I could hear the click when I dialed down the air pressure. I put a single drop of light machine oil in each port, then blew it out with compressed air... I put it all together, and it did the trick! I let air blow through for several minutes, and then cycled it on & off and it works like new!

Now to chase down the other little gremlins!

Oldsarge

[jimcolt]

Sounds great...good fix. Occasionally one of my plasma's (the Powermax45) solenoids sticks.....but only when I try cutting in the winter (in NH) at 20 degrees F or less....I'm sure it just freezes! Once the heat in my shop rises it always works fine.

Best regards, Jim

Thanks Jim! I pulled the solenoid out today and checked it out. It seems like it was sticking, because I could hear the click when I dialed down the air pressure. I put a single drop of light machine oil in each port, then blew it out with compressed air... I put it all together, and it did the trick! I let air blow through for several minutes, and then cycled it on & off and it works like new!

Now to chase down the other little gremlins!

Oldsarge