hypertherm 1250 with phc lift and flashcut post processor

[woodman08]

we're having a terrible time with the machine not being constant.
we have followed the book on settings we have done everything that we think is right to the documentation provided but our cuts are terrible and different things happen each time.
(torch lifts for no reason)(bad cuts )(jirky movement)We have tried various files,thinking the file were causing trouble.We are at wits end.So i called hypertherm and they recommended going to the manufacturer then it would come to them and possibly sending in the PHC to see if its off cal,we have no manufacturer as this sorry to say was a gorilla machine that never did work and now at the anniversary it still isn't.Hypertherm chucked and said thats gorilla as they are out of business .
There has to be some bad setting or something off spec(i suspect the phc conmtrol) and i am surprised that hypertherm would not make an exception because the manufacture is out of business and let us ship the phc in for an inspection.
i was surprised at the treatment and comments from them, its not a good business way of maintaining a good reputation for further sales
this was an expensive machine and its not running good to the point where most work pieces are ruined near the end of the cut.It will not cut something 4inx 4in,seems its too small to be accurate

[jimcolt]

Woodman08,

I'd be happy to work with you to try to sort out your issues. I can help you get your settings correct on the Powermax 1250 and the Sensor PHC (if that is what your height control is) as those products are produced by Hypertherm....and I know that they will perform as designed.

One thing that s difficult to do from a remote location...is to determine if the machine motion or the electrical interface is of issue. Jerky, inconsistent x and y motion will cause any arc voltage based height control to do starange things.....such as dragging on the plate or rising off the plate, as constant machine speed is necessary to make this type of height control work.

Here are a few suggestions to get started:

1. Lets start fresh with new consumables in the Hypertherm torch....make sure they are a good match for the material that you would like to cut.

2. Choose some material....perhaps some 1/4" mild steel plate, and then program a simple part such as a 4" x 4" rectangle.

3. I would choose the 40 Amp consumables (and look at the machine cutting chart in your Hypertherm manual) 120930 shield, 220061 retaining cap, 120932 nozzle, 120926 electrode, 120925 swirl ring.

4. Make sure the ohmic wire from the PHC is attached to your retaining cap.

5. Use a programmed cut speed of 48 inches per minute, set the pierce height to 1/8" to 3/16" (3 to 5 mm) , pierce delay time to 1 second, cut height to 1/16" (1.5mm), and amperage to 40 Amps, and set arc voltage to 149, these settings are all out of the Hypertherm manual, and I know they work....with possible exception of the arc voltage as that varies from installation to installation.

6. Do an IHS test (the instruction manual will tell you how to do this...this will confirm the pierce height is correct).

7. Do a first test cut and carefully observe the torch to work distance....it needs to be 1/16". If too high, lower the arc voltage setting on the PHC, if too low, raise the arc voltage setting until it is just right.

8. Once the height seems correct, do another sample cut. If the height control is rising off the plate or crashing into the plate....then lets put the height control in manual mode and do another cut with the torch at a fixed height of 1/16", to do this you will have to ensure that your plate is level....so that 1/16" is maintained all around the cut perimeter.


Things that can go wrong and cause an arc voltage height control to provide inaccurate height:

1. If the cnc on the cutting machine settings are incorrect. The cnc must provide a height freeze signal in all corners, in small (under about 1" diameter holes) that locks out the arc voltage control to eliminate diving in these areas, the diving is due to the z , y axiss slowing down for cornering. If you see the torch dive and drag in corners, on kerf crossing, and in small holes and fine features...then you will need to revisit the arc voltage interface settings in your software.

3. If you are cutting along and the torch rises off the plate.....if it rises and stops at a certain height but keeps cutting....then simply lower the voltage setting until it is at the right height. If it continues to rise randomly, then there could be an issue with the pHC internally.

4. As consumables wear, expect the torch height control to move the torch coser to the plate. It is normal with any plasma/thc to have to increase the arc voltage as the consumables wear...in order to maintain the proper torch to work distance.

5. If the torch dives and drags often...and simply increasing the arc voltage does not work, and you are sure the cnc is freezing the height in corners and during decelleration...then check your work ground to your cutting table, a loose connection can cause thc diving. On some plate, such as small pieces or thin materials and especially aluminum, it is a good practice to have a welding cable with one end attached to the grounding (work cable connection) and the other end with a 100 amp welding clamp that can attach directly to the material you are cutting.

Please try the above, or at least report back to me with more detail and I'll try to help you out. You have a great plasma and THC system, I do not know much about the rest of the machine! perhaps with a little step by step testing, and new consumables are a must, then we can isolate where the issues are coming from.

If there would be a calibration issue wioth the Sensor PHC....the above tests will help us out. On this type of system it is important to set the arc voltage to whatever setting gives you the physical height required in the Hypertherm cut charts. The voltages listed in the cut charts are recommended starting points....but vary from site to site as there are at least a dozen variables that affect the relationship between voltage and height with any arc voltage height control system. Regardless, if there is an issue with part of the Hypertherm system we certainly will stand behind it as we always do.

Best regards, Jim Colt Hypertherm

Originally Posted by woodman08 we're having a terrible time with the machine not being constant. we have followed the book on settings we have done everything that we think is right to the documentation provided but our cuts are terrible and different things happen each time. (torch lifts for no reason)(bad cuts )(jirky movement)We have tried various files,thinking the file were causing trouble.We are at wits end.So i called hypertherm and they recommended going to the manufacturer then it would come to them and possibly sending in the PHC to see if its off cal,we have no manufacturer as this sorry to say was a gorilla machine that never did work and now at the anniversary it still isn't.Hypertherm chucked and said thats gorilla as they are out of business . There has to be some bad setting or something off spec(i suspect the phc conmtrol) and i am surprised that hypertherm would not make an exception because the manufacture is out of business and let us ship the phc in for an inspection. i was surprised at the treatment and comments from them, its not a good business way of maintaining a good reputation for further sales this was an expensive machine and its not running good to the point where most work pieces are ruined near the end of the cut.It will not cut something 4inx 4in,seems its too small to be accurate

[woodman08]

Right now we are re-routing a power supply to the compressor,once thats finished ,we'll run all the tests you have shown.
Really appreciate what you are going to do with us

[woodman08]

Thanks for the tips the setting of 48 in/sec made a big difference,we're not 100% yet but close,the machine sounds better cuts better but some areas are not ,i have re-checked the files and it still persists
Attached are photos and videos

YouTube - teswt of cutting a square cnc square test sept28
YouTube - wolf profile cut cnc wolf cut sept 28
YouTube - horse profile cut cnc horse profile sept 28
YouTube - letter_p.wmv letter p sept 28
Initially we had torch alarm problems but tech support helped there.
This machine was set at 150 in/sec and the feedrate ramping was 12.50 now 48 and running very smooth
The machine config is also attached,in conclusion there is nothing wrong with the hypertherm ,its finiky but does its job
Any suggestions would be appreciated

alone in southwestern ontario