Hypertherm Powermax30 XP Service Manual - Manual (Page 54)

54 Powermax30 XP Service Manual 808150 Revision 1
4 – Operation
Common hand-cutting faults
For more information on faults, see Troubleshooting guide on page 63.
 The torch sputters and hisses, but does not produce an arc. The cause can be:
 Overtightened consumables
 The torch does not cut completely through the workpiece. The causes can be:
 Cut speed is too fast
 Worn consumables
 Metal being cut is too thick for the selected amperage
 Installation of the wrong consumables
 Poor electrical contact between the ground clamp and the workpiece
 Low gas pressure or low gas flow rate
 Cut quality is poor. The causes can be:
 Metal being cut is too thick for the selected amperage
 Installation of the wrong consumables
 Cut speed is too fast or too slow
 Worn or damaged consumables
 The arc sputters and consumables life is shorter than expected. The causes can be:
 Moisture in the gas supply
 Low gas pressure
 Incorrect installation of the consumables
 Installation of the wrong consumables
Minimizing dross
Dross is the molten metal that solidifies on the workpiece. Some amount of dross is always present when cutting with air
plasma. However, you can control the amount and type of dross by adjusting your system correctly for your application.
Low-speed dross forms when the torch’s cutting speed is too slow and the arc shoots ahead. It forms as a heavy, bubbly
deposit at the bottom of the cut and is usually easy to remove. Increase your speed to reduce this type of dross.
High-speed dross forms when the cutting speed is too fast and the arc lags behind. It forms as a thin, linear bead of solid
metal attached very close to the cut. It forms to the bottom of the cut and is often more difficult to remove. Decrease your
speed to reduce this type of dross.
 Dross is more likely to form on warm or hot metal than on cool metal. For example, the
first cut in a series of cuts is likely to produce the least dross. As the workpiece heats up,
more dross may form on subsequent cuts.
 Worn or damaged consumables may produce intermittent dross.