Here's my setup:
- Hypertherm PowerMax 125
- Brand new 45A Shielded Consumables - GENUINE!!! (420168 shield, 420156 ohmic retaining cap, 420158 nozzle, 220997 swirl ring, 220971 electrode)
- Bulltear 5x10 CNC Table with CandCNC Servos
- CommandCNC Software
- Air via Atlas Copco GX11FF 15HP Rotary Screw Compressor with integrated dryer
- New o-ring with Hypertherm supplied silicone on the torch
- Cutting at book settings (0.064 KERF, 0.6s PD, 0.15 PH, 0.06 CH, 45A, 43IPM, 132V)
- The ground is connected directly to the part being cut
Here's my issue:
1. There seems to be extensive dross right at the start of each cut (1st and 2nd pic below)
2. Even though the cut looks great from the top, it doesn't seem to be cutting all the way through (see the 3 pic)
3. After examining the cuts with DTHC off, I get an average voltage of 123V. However, when I try to cut with DTHC ON and that voltage with sensitive set to slow, the torch either keeps plunging after 15-20 secs of normal cut or hitting/falling off from the dross caused at the start of other cuts.
4. Since the flat bar is sitting on 2x 2x2 square tubes so that I can eliminate additional noise cause by water, I am able to see the cut arc and it seems to be trailing the torch, not leading...I know it's supposed to be leading...what could cause that? There are not sparks above the material...they are all below the material and the torch does look and sound good when cutting. I say that because at this point, it is very easy for me to spot whenever the torch is cutting too higher as I get a lot of sparks above the material and next to no cut/all dross inside the cut path.
PLEASE HELP! - What can I do to fix my issue. I think I've tried to cover all of details about my settings here. It's very perplexing especially when all the consumables are genuine and brand new.
Image #1
Image #2
Image #3
Image #4 - Torch O-ring - that black stuff is grease
