During operation, the periodic plasma cutting torch begins to run away from the drawing at high speed. Since we have two identical machines in our workshop, we transferred the Shape cutting control MicroEDGE to another machine and it did the same thing on another machine.
Initial data:

Plasma cutting machine table 6000x3000 мм.

TITLE: KMP-KP080402

Produced: 2008.06.10

Model: KPM-M-4X9-1-2-P1650

Power source: Hypertherm Powermax 105

Shape cutting control MicroEDGE

Model Number: H2P2-0X56-0000-02

Serial Number: 0608011550

Item number: H2P2-0X56-0000

Changed Boards:

1) 2 axis servo board BD interface PCBS-0154 Rev B

2) PCI-4 AXIS MCC 3 3V Motion control card Axis card MICROEDGE Hypertherm


To eliminate viruses and malfunction of the program, we reinstalled the system and checked the functionality of the Phoenix system on another Shape cutting control MicroEDGE of the working machine. Everything worked fine.

This convinced us that the problem was with the Shape-cutting control MicroEDGE. To determine the faulty board, we replaced the 2-axis servo board BD interface (PCBS-0154 Rev B) and PCI-4 AXIS MCC 3 3V Motion control card with Shape cutting control MicroEDGE. We also inserted a hardware key from the machine on which these boards were installed.

After installing the boards and turning on the machine, the system writes “Drive Disabled Active”.

When we returned back the boards that were on this device, it still displayed the message “Drive Disabled Active”. Pressing the “Drive disable” key in the Phoenix program does not produce any results.

We checked whether the “Emergency STOP” key was released, and the button was disabled, but the system again displayed the message “Drive Disabled Active”.

Could replacing the boards cause a software failure or damage to the boards?

We cleaned all contacts and connected all cables and wires correctly.

How should we proceed?

 

On a plasma M/C grounding and earth bonding is very important.

 

On a plasma M/C grounding and earth bonding is very important.

Yes, but M/C was grounded.

 

Yes, but M/C was grounded.

To a common earth GND point?
Equi-potential bonded (sect4) ?

 

To a common earth GND point?
Equi-potential bonded (sect4) ?

Sorry, I didn't understand your question. I don't know English well and therefore partially use a translator. Kindly explain in more detail.
Thank you in advance

 

If you have two different systems working together, are they connected to a common earth GND point?

 

If you have two different systems working together, are they connected to a common earth GND point?

Yes, of course, all components of the plasma cutting machine are connected to one grounding point. The machine worked for 15 years. The whole problem occurred after replacing the boards (please see the problem description). I am interested in the opinion of anyone who knows Hypertherm plasma cutting machines, What could have happened after replacing the boards with identical ones and returning the old boards back?

 

I am interested in the opinion of anyone who knows Hypertherm plasma cutting machines, What could have happened after replacing the boards with identical ones and returning the old boards back?

I have worked on Hypertherm Plasma, but never come across that issue.