- What I had read on another post is that a power surge or similar power related issue could cause the toolman.thm file to corrupt and that could lead to errors in daylight and related tool values. That caused me to connect some dots. In late December we dealt with an issue where the CPU on our machine failed to boot, I was able to troubleshoot early on that the PSU was not providing power, after ruling out the unit itself we determined it was not getting power and the issue was eventually found to be a dead battery in our UPS unit. My therory at this point is that the battery was probably very weak in October last year when this error appeared for the first time and may well have caused a toolman.htm corruption. In early March, I decided to delete the old toolman file and rebuild a brand new one from scratch. The process is not too difficult, there's probably a thread on here already dealing with it, i'm happy to walk thru the steps for anyone that may require it, but as I said not difficult to do. We have been running about a month now since this was done and i am prepared to say we have this problem dealt with. I hope this post keeps someone else from going through the damage, expense, and racing heartbeat this situation caused us!Sudden Daylight Adjustment Mid-operation
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Dave Marshall
- New Member
- Posts: 3
- Joined: Wed, Dec 03 2025, 6:28PM
- Company Name: Ergonomic Accessories Inc
- Country: CANADA
Sudden Daylight Adjustment Mid-operation
Hi all, i thought I would drop a post here in case anyone else ever comes across this frustrating and frankly scary error. Around about last October our C40 machine began a brand new sporadic error. Suddenly and completely without warning mid-operation the daylight value of Tool 3 would change by about .75" causing the roughing bit to plunge down thru our spacer board and down into the base spoilboard. Sometimes the machine would run perfectly normal for days and then at random, boom, we are tearing up MDF. On one occasion, we had run 7 sheets without any issues at all, on the 8th sheet a very expensive plunge error. I have scoured this board and really couldn't find anyone that had a similar error, I spoke with Thermwood tech support and they really hadn't heard of it either, lucky us - What I had read on another post is that a power surge or similar power related issue could cause the toolman.thm file to corrupt and that could lead to errors in daylight and related tool values. That caused me to connect some dots. In late December we dealt with an issue where the CPU on our machine failed to boot, I was able to troubleshoot early on that the PSU was not providing power, after ruling out the unit itself we determined it was not getting power and the issue was eventually found to be a dead battery in our UPS unit. My therory at this point is that the battery was probably very weak in October last year when this error appeared for the first time and may well have caused a toolman.htm corruption. In early March, I decided to delete the old toolman file and rebuild a brand new one from scratch. The process is not too difficult, there's probably a thread on here already dealing with it, i'm happy to walk thru the steps for anyone that may require it, but as I said not difficult to do. We have been running about a month now since this was done and i am prepared to say we have this problem dealt with. I hope this post keeps someone else from going through the damage, expense, and racing heartbeat this situation caused us!
- What I had read on another post is that a power surge or similar power related issue could cause the toolman.thm file to corrupt and that could lead to errors in daylight and related tool values. That caused me to connect some dots. In late December we dealt with an issue where the CPU on our machine failed to boot, I was able to troubleshoot early on that the PSU was not providing power, after ruling out the unit itself we determined it was not getting power and the issue was eventually found to be a dead battery in our UPS unit. My therory at this point is that the battery was probably very weak in October last year when this error appeared for the first time and may well have caused a toolman.htm corruption. In early March, I decided to delete the old toolman file and rebuild a brand new one from scratch. The process is not too difficult, there's probably a thread on here already dealing with it, i'm happy to walk thru the steps for anyone that may require it, but as I said not difficult to do. We have been running about a month now since this was done and i am prepared to say we have this problem dealt with. I hope this post keeps someone else from going through the damage, expense, and racing heartbeat this situation caused us!