Problems with Hypertherm command THC

[kjferg]

I use a Hypertherm Hyperformce HPR 260 with a Hypertherm command THC on a Vicon table. I've been have issues with the THC unit, it will have random freezes during cutting. I have to restart the THC to get it working again. Most of the time it will not throw any errors up when it freezes but some time it will give the error "Cycle Start ON at INIT". Also, during cutting the pendent on the THC will throw up plate contact even thou the cut height is set to the correct height. I have to raise the cut height to almost the same as the piece height in order to stop receiving the plate contact message, which produces a poor cut. I'm also having some problems with random stops during cuts. For no reason the plasma will stop in mid cut and the THC will raise the torch body. No errors are given when this happens.

[jimcolt]

When you see "plate contact" on the pendant with the Command THC...that means that the torch shield has contacted the plate.....which can happen in a variety of situations. The THC will rapidly retract to cut height and continue cutting (collision avoidance) when this occurs. If you would like....you can shut the ohmic contact function off.

The other issues sound to me like either an electrical noise issue....or a loose connection somewhere between the THC, the Vicon CNCcontroller, and the HPR plasma. I would advise working first with tech service at Vicon, and or tech service at Hypertherm for help solving this issue.

Here is the Hypertherm contact info:

Technical Service
technical.service@hypertherm.com
800-643-9878 Tel - Toll Free in USA
and Canada

Jim Colt

[kjferg]

Thanks for the reply Jim. Well for the plate contacting, it dose not just contact the plate once then go back up, it will drag across the plate and cause the torch body to jump up and down rapidly. My guess it's the wrong cut height for the particular plate, but it is set to the height in the book.
As for the freezing and the random stops, we have already been on the phone with both Vicon and Hypertherm and both claim it's the other problem.

[jimcolt]

The rapid up down motion is likely due to setup of the DIP switches on the Command control board. You need to set it up to the asychronous setting, and to the conventional plasma settng (even though you are using a HyDefinition plasma). The Command system is a very accurate, fast reacting THC system and on most cutting machines the above listed settings will minimize the "sewing machine motion". In your manual for the Command you will find a section that tells how to change the DIP switch settings.....or the Hypertherm tech service guys can help you. (tell them Jim Colt suggested it)

As far as the plasma shutting off, there can be a half dozen scenarios that can cause that. The first thing I would do is check the error codes (if any) on the plasma system. If there is an error code it may steer a technician in the right direction as to what is causing the issue. Error codes can be read on the manual gas console (your manual will tell how to read these), or through the cnc control if your system has an auto gas console. If no error codes, then I would try to run the system with the THC in manual mode to see if the shutdown continues or goes away. The tech service guys should be able to run you through some diagnostic checks that will determine the problem, instead of just pointing at other components on the machine.

Jim

[grogsroom]

Hi, i also am having exactly the same issues with my hypertherm phc , after thinking it was my software and trying many different settings including the ones in the book ,the torch lifts and bounces and goes up without showing any errors, i;m wondering if there is problems with these phc.s, if anybody knows anything about this i would really appreciate the help, thanks, greg

[jimcolt]

The PHC is an entirely different product as compared to the Command THC in the previous post. It does not share a single component with the 12 year old Command THC. The sysmptoms you are describing can be caused by a variety of issues that could be related to settings, cut parameters, or setup. Have you talked with Hypertherm tech service? They are experts that can work with your particular symptoms and will help you troubleshoot to determine the exact issue. It is thier goal to resolve any issues with any Hypertherm products.

If you have not contacted tech service....here is the info:

Technical Service
technical.service@hypertherm.com
800-643-9878 Tel - Toll Free in USA
and Canada

If you have contacted them and your issue is not resolved....contact me directly.

jim.colt@hypertherm.com

Best regards, Jim

[grogsroom]

ok, thanks jim ,

[grogsroom]

just wanted to say jim your right about the tech guys ,they are great and are willing to spend some time with you ,taking me right through a couple cuts , i learned more in 20 minutes with them then i did trying to figure out the manual

[kjferg]

Alright, from what I can tell, it seems that the torch during cutting is slowly moving down until it hits the metal causing the anti-crash feature to kick in and stops the cutting process. I don't really see a pattern to when it dose it, it just seem to do it randomly. It was doing it towards the end of the day yesterday day, and now it's doing it first thing in the morning. Would this be a issue with the Hypertherm THC command or the Vicon table/software I use? I have a Hypertherm hyperformance HPR260 machine

[jimcolt]

Here is something to look at /think about, especially since you state that the Command THC system seems to be creeping down closer to the plate.

The THC uses arc voltage feedback to monitor the torch to work distance. It actually measures the voltage drop between the electrode and the plate, compares it to the preset voltage that either you set with the Command pendant control, or, it may be set in your cnc if you have the programmable version. With each successive cut, the end of the electrode in the torch erodes, producing a hole or a pit in the end of the electrode. If the pit in the electrode is nearing the end of its life (which is around a .040" pit for standard Hypertherm electrodes and .080" for silver electrodes)....and you are still running the same arc voltage setting that you were when the electrode was new....then expect the THC to move the torch closer to the plate (.040" closer if the electrode has a .040" pit) as the electrode wears.It is normal for the operator to have to bump the THC voltage setting up 5 to 10 volts through the life of the electrode in order to maintain the correct torch to work distance. Rule of thumb, 5 volts increase will compensate for .020" wear on an electrode.

The newest Hypertherm THC system, called the Arc Glide THC, automatically compensates for electrode wear....so no setting changes are required as the electrode wears.

The above phenomenon occurs with every cnc plasma system with arc voltage based THC systems.

Jim Colt Hypertherm

[kjferg]

Well, that makes a lot of sense. I would never have thought about it thou. I have only been running this table for about 5 months now, so, I'm still learning.
I will try this out today and let ya know if it helps. I'm still having a few other problems that I can't figure out. Every so often, the machine will just stop cutting, it dose not look like the torch hit the plate at these times. When I go to check the pendent it has a error message "Cycle Start ON at INIT" on it. I press the OPR SCRN Key to clear it, and I usually have to restart the THC Command in order to get everything working again. In the book for the THC Command, it stats that the error means, Cycle start is active during THC power up or while exiting Maintenance Mode. The corrective action it give for it is "Verify CNC start up signal is inactive". How would I got about verifying that's it is inactive? Another problem is that the THC Command will freeze up. It will give no errors and I lose all function on the pendent and no commands sent from the computer will work. The curses on the pendent is self is frozen on the last spot it was at, and I am unable to move it up or down the menu or switch to different screen. I have to restart a few times to get it back to working order. We have called both Vicon and Hypertherm before on these problems, and each tell us it's the other business problem.

[jimcolt]

"Cycle Start on at init" error is indicating that the output of the Vicon CNC is in the plasma start position....the Command, for safety reasons, will not allow this start signal to get to the plasma as the torch would fire at the wrong part of the cut cycle. This can be caused by a few different types of errors....This would need to be troublshot with tech engineers from Vicon.

On the issue of the Command pendant freezing....The Hypertherm tech service engineers should work with Vicon engineers on theis one. It sounds like some sort of an electrical noise issue that is affecting the microprocessor board in the Command unit....probably can be resolved with grounding of components.

Jim