Powermax 1000 dross problem

[Eric - Plasma]

I've been fighting this one for quite some time but can't fix it. Hoping someone here could give be some tips.
Trying to cut 16ga steel with a Hypertherm Powermax 1000 with 40amp consumables and the machine set to 25 amps. Mach3 voltage for DTHC was set to 150volts (I did a few test cuts to ensure cut height was .0625" at 150V) Consumables were all new.
Seems no matter what I do the bottom side dross dues not change. It's always heavy and stuck to the metal.

Here are my test cuts where the I only change I made was feed rate. Bottom line is at F90. and each line above had 10ipm added to the speed.

top side:


Bottom Side:

You will notice the "divot" .5" from the start. Seems anytime the program turns on the DTHC (S20) the machine pauses for .2 of a second. Haven't figured out why yet?

If I switch to fine cut consumables I can get the dross to be much more manageable. Any Ideas?

[jimcolt]

Make sure you have the consumable in the torch as shown in the attached cut chart (from the Powermax1000 operators manual). Make sure the nozzle and the mechanized shield are in good condition (refer to the consumables inspection area in the manual).

Bottom dross is caused by:

- Cutting too slow. Start at the optimum speed listed in the cut chart (114 ipm)...then on subsequent tests (height control off, torch height set with feeler gauge at the book spec, which is 1/16" (.060")) increase the speed by 10 ipm until the dross goes away. When dross is gone do another cut and read your arc voltage digital read out....that is the arc voltage and speed to use.

- Cutting too high off the material (see above for determining the correct arc voltage to run, arc voltage controls the height....

-Cutting with too much power (25 amps on 16 gauge is good....if you were cutting the 16 ga at 60 amps...that would be too much!

Jim Colt Hypertherm

[Eric - Plasma]

Thank you for the reply Jim. Sorry for the slow reply I thought I had e-mail notification set up for this thread but seems I did not.
Consumables were new and loaded properly.
Cutting at 25 amps with 40 amp consumables.

Think the problem was water in the air. I do have a desiccant dryer by the plasma machine that changes color when saturated. I thought they still looked okay but had a major melt down of the electrode when cutting 3/16 plate that I attributed to water in the line. Changed the consumables and new desiccant and it cut fine. I'll give the 16ga another go.

Thanks for your time