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you might have a bad relay on your circuit board. They arc and spot weld themselves at times (nothing a sharp hit can't fix) Replace the relay with a higher quality one if you can.
Hypertherm is tight with their dcoumentation. they hide the old stuff quite well. and the hotlinks are just to the catalog to get you upgrade and buy more of their product.
Right off hand without documentation, I would still open it up and take a look at the inverter portion of the unit first. If it has been used a great deal, there is a good chance the capacitors of the inverter or the power supply section feeding it have failed. If it was used longer than the duty cycle suggested, this could easily happen which would also raise the question of the coondition of the inverter transformer and the main power transformer and would mean serious time with a test meter. With that said though It is likely not a huge a problem that is causing it to not work, it is likely just a handful of parts- it just takes a little time to find them.
The Roomba is noted to cut out operating correctly. Remove the housing and blow out dust from all circuist and any dirt and dust inside the entire unit. It should work correctly afterwards
On the main circuit board for the power supply, there is usually a thermal fuse installed, its a sealed unit and is not servicible, look for a black epoxied case,approx 3/8x3/4 long, with 2 leads coming out of it. Inside is a set of bi-metal contact points which serves as an over voltage/over current protection. These contacts deform/corode over time and it sounds like there not contacting properly. As soon as you try to load the machine, the current passing through this high resistance heats these contacts up, and shuts off power to the unit. I am not familiar with the guts of a hypertherm, but have extensive experiance repairing inverter based plasma cutting equipment, and i have encountered this before. I assume hypertherm must have some equivelent to this thermal switch inside the power supply.....Good luck..
Air pressure is probably falling off. This can be caused by several things. The compressor that is too small to keep up is usually no.1. the 1250 is a large unit amd requires a sizeable air source. A way to test would be to connect a compressed air bottle from a welders supply.
Open the cover (only after a day of not being plugged in).
Check the airline that comes in through the back of the case.
The air line has either fallen off or has a hole in it.
If you are a technician and don't mind working with thousands of volts of electricity that is inside the case, then and only then can you plug it in. Safety First. Rember the voltages inside this unit are lethal. It will not give you a second chance.
If you feel you are qualified, then plug it in and start it up, use it as normal, while at first watching from a 2 meter distance, you may immediately see and/or hear where the noise is comming from.
DO NOT under any circumstances put your hand or hands inside the box while it is live.
Try running a WOODEN stick (at least a foot long) along the length of the airline inside the case and around the valve as it enters the case. The sound should change in pitch when you find it.
If you think you have found it, DO NOT touch anything inside, until you have both DSCONNECTED THE UNIT from the power source and WAIT ONE DAY before putting hands inside the unit. Any storred or residual energy will have discharged by this time, making it safe to work on. Safety first. The voltages inside are lethal. This aplies to all Plasma Cutters. Good luck.
recently had same issue with friends. remove the filter and see the other thin filter there that goes to your motor compartment.. remove that and clean it. also check inside your tubes make sure not partially clogged.
Since these do employ high voltages, you might be hearing an arc-over due to the accumulation of household airborne contaminents or moisture gathering in a dust buildup.
I suggest you pull the plug for at least a few hours to allow stored voltages to dissipate, remove the back cover of the set and with a clean paintbrush and a vacuum held close to it, remove any visible dust deposits.
Button it up and see if the problem has lessened.
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