Hypertherm Powermax45 Service Manual - Manual (Page 75)

operation
powermax
45 Service Manual 4-15
Common machine-cutting faults
The torch pilot arc will initiate, but will not transfer. Causes can be:
• The work cables connection on the cutting table is not making good contact or the table is not properly grounded.
• The torch-to-work distance is too great.
The workpiece is not totally penetrated, and there is excessive sparking on the top of the workpiece. Causes can be:
• The work cable’s connection on the cutting table is not making good contact or the table is not properly grounded.
• The amperage is set too low. See the cut charts in the Torch Setup section for more information.
• The cut speed is too high. See the cut charts in the Torch Setup section for more information.
• The consumables are worn and need to be replaced.
• The metal being cut exceeds the maximum capacity. See T45v and T45m torch specifications in the Specifications
section.
Dross forms on the bottom of the cut. Causes can be:
• The cutting speed is not correct. See the cut charts in the Torch Setup section for more information.
• The amperage is set too low. See the cut charts in the Torch Setup section for more information.
• The consumables are worn and need to be changed.
The cut angle is not square. Causes can be:
• The direction of the torch travel is incorrect. The high-quality cut is always on the right with respect to the forward
motion of the torch.
• The distance between the torch and the workpiece is not correct.
• The cutting speed is not correct. See the cut charts in the Torch Setup section for more information.
• The consumables are worn and need to be replaced.
The consumable life is shortened. Causes can be:
• The arc current, arc voltage, travel speed, and other variables are not set as specified in the cut charts.
• Firing the arc in the air (beginning or ending the cut off of the plate surface). Starting at the edge is acceptable as
long as the arc makes contact with the workpiece when started.
• Starting a pierce with an incorrect torch height. For the Powermax45, the pierce height is generally 2.5 times the
torch cutting height. Refer to the cut charts for specifics.