Skipping holes and features

[Suspensionfab25]

First post here and need some help!

We are using a messer/ Hypertherm HPR260xd plasma table to cut mild steel ranging from 1/4-1" in thickness. When running parts with multiple holes or slot features, the torch will sometimes skip or produce an incomplete cut and still continues to cut. The skip is randomized on what feature and the cutting torch it affects, but predominantly seen on the slave torch. We could run multiple sheets with no issues then have the problem occur, and the machine keeps running with no alarm on the controller. So it creates a problem that is hard to track and identify unless baby sitting it. Any idea what can be causing this issue? It just started out of the blue about 3 months ago and been causing headaches since. Thanks!

Programming Sigmanest
Machine Hypertherm HPR260xd plasma
Hole sizes .25"-1.00"

[tcaudle]

Does it lose arc when that happens and continues to move? Does it refire and keep cutting?

Loss of arc on ANY plasma usually falls into one of three types:
1. bad or poor workclamp connection tot he material being cut. That can be in the forma of a loose or dirty workclamp connector or a poor connection to the material. In cutting material its typically not sufficient to just clip the work clamp to the table . If you want consistent cuts , connect directly to the metal being cut. Either clip or magnetic clamp.
2. Worn consumables .
3, Small holes in thicker material are a challenge and if the height is off you can lose arc. Typically small holes are cut differently and at lower federates than other cuts. On really small holes turning the THC off for that cut is the best solution.

If the problem is always small cuts and holes than its more likely to be the cut methods than a plasma failure.

[Suspensionfab25]

Thanks for the response and feedback! Its tricky because usually when the arc is lost the error code will be displayed on the corner of the hmi controller and the fault has to be cleared to resume cycle. But in this case, Its almost like the controller has feedback that the arc was started and never lost. Ive talked to messer and Hypertherm and they are leaning on noise in the comm cable, controller, or in the hypertherm power supply board. I will update as we continue to dig around.