Router Issues

I've had this problem since new. When you click OK to start a cut, most of the time I can hear a relay click, but the router doesn't turn on.

I have to click stop, then the software sometimes hangs, sometimes crashes entirely, sometimes tries to go through with cut anyway. Then have to re-align, re-zero... and repeat. Eventually the router comes on. Pain in the arse. A 1 minute cut can take half hour.

Is it normal to see sparking inside the router as it's spinning?

Thanks,
Nathan.

You either have a bad relay (most likely) or a bad router and yes it needs fixed.
I won't go into trouble shooting as I don't know your background and it involves line voltage.
I would call ShopBot and see how they want to approach this.

To your second question, yes it is perfectly normal for there to be sparks in the top of the router.

Turns out one of the spring contacts for the motor bush had unseated itself, re-seated and all is fine. Sparks and arcing noise gone too!

Glad you got it figured out. I will remember this as a possibility for these indications.