Fine cut comsumables

[Welder Kenny]

Hey everyone, I need help, I have a homemade table 48" x 96" with a Hypertherm 65,( best plasma made) Plasma, ridge torch and a promo THC. When I put in the fine cut consumables, they may start of fine but then in the middle of the job bam it fires I can see a spark but no arc start. running height control at .060 thinking I need to lower it when using fine cut consumables plus I was cutting .125 Aluminum? any help would be greatly appreciated. Thanks and God bless. Kenny da welder.

[Joe Jones]

What amperage setting are you trying to force fine cut consumables to tolerte? Fine cuts on a Hyperterm 45 only cut at 30 amps.

Joe

[4130metalworks]

Do you have all the correct fine cut consumables in? I accidentally used the wrong shield which gave me all kinds of grief

[adbuch]

Hey everyone, I need help, I have a homemade table 48" x 96" with a Hypertherm 65,( best plasma made) Plasma, ridge torch and a promo THC. When I put in the fine cut consumables, they may start of fine but then in the middle of the job bam it fires I can see a spark but no arc start. running height control at .060 thinking I need to lower it when using fine cut consumables plus I was cutting .125 Aluminum? any help would be greatly appreciated. Thanks and God bless. Kenny da welder.

Per Jim Colt:

"The Finecut consumables work very well up through 1/8" aluminum, and some have reported use on 3/16". There just is not a cut chart in the manual that provides starting guidelines for aluminum.

I always suggest using the cut chart for steel....the height is the same, the pierce height is the same, and the speeds are close. Slower speed will square up the edge, higher speed will minimize dross. It is also a good idea to use mig welding anti spatter spray on the front of the torch, and to wipe the spatter off periodically as the aluminum tends to build up."

Another option is to use 45 amp unshielded consumables for your 1/8" aluminum. See the Hypertherm cut charts below for reference.
David

Aluminum 45 amp unshielded.jpg (76.87 KiB) Viewed 857 times

Aluminum 45 amp unshielded.jpg (76.87 KiB) Viewed 857 times

For reference - here are the mechanized cut chart for the FineCuts. Use the same cut charts for both shielded and unshielded.

FineCuts mild steel.jpg (71.33 KiB) Viewed 857 times

FineCuts mild steel.jpg (71.33 KiB) Viewed 857 times

[Welder Kenny]

I'm running a powermax 65 at 45 amps, when it pieces the plate it cuts great but as it moves to the next cut it fires off (sparks) but to polit arc and it doesn't cut that item then it moves over and sometimes BAM it will fire off polit arc starts and away we go. I'm running sheet cam with Mach 3 I just can't figure out why it sometime doesn't fire off. I'm going to check cut height and piece height tomorrow. I feel like I need to be closer to the sheet for the pierce cut.?? Thanks everyone I really apricate all your wisdom. (we are better together then alone) Kenny,

[weldguy]

Do you get an error code on the Powermax lcd screen when it fails to fire?

[adbuch]

One of the main problems with using the FineCuts for aluminum is that they are easily "clogged up" (aluminum dross/spatter stuck between nozzle and shield creating electrical contact between the shield and nozzle) which for a Plasmacam table would cause an error condition and cause the torch to not fire. Are you having this problem when you install brand new FineCut consumables, or only after you have been cutting with them for a while?

David

[Welder Kenny]

I get no error code on my lcd screen on the powermax, I was using consumables that were used but only cut 1 small job. I'll be out in shop today playing with this issue, who knows we may figure this out yet. Thanks again

[SegoMan DeSigns]

How are you attaching the work lead to the table and or material?

[tinspark]

All Hypertherm OEM consumables, correct?

[adbuch]

I get no error code on my lcd screen on the powermax, I was using consumables that were used but only cut 1 small job. I'll be out in shop today playing with this issue, who knows we may figure this out yet. Thanks again

Post some photos of you lightly used consumables so we can see what you have.
David

[adbuch]

How are you attaching the work lead to the table and or material?

I personally have my work lead on my Powermax 85 connected to the material, cutting grates, and table frame.
David

[Welder Kenny]

I think I found my problem, I calibrated my Z axis and its right on the money but after looking at my THC I'm using a limit switch and I'm thinking the sloop in the switch is my issue, I'm going to try and verify this today.

[weldguy]

Ah yes, the difference between what the computer screen says and the actual height when measured can be shockingly different and something that many never check. I am sure you are correct and hopefully that fixes your issue. Please let us know.

[acourtjester]

If you have an extra switch input you may look at a Ohmic sensor module to help out with surface positioning.

[SegoMan DeSigns]

How are you attaching the work lead to the table and or material?

I personally have my work lead on my Powermax 85 connected to the material, cutting grates, and table frame.
David

I agree with that plan, my common earth bond stud is attached to the bottom of the water pan and a welding cable with mag clamp is attached to the material. If the material is rusted or painted it gets a cleaning with the flap disc.

[Welder Kenny]

Well after 3 hours of verifying the Z calibration and double checking everything, I think in my case I need to have the powermax plasma on and ready to cut don't ask me way but with plasma off and I run a program it takes off to start cutting touches the plate goes to pierce height and it shows on Mach that it's at .150 but when I measure it's double that, I power up the plasma and BAM, it measures perfectly. I even changed the pierce height and cut height, and it followed the commands.? I would like an ohmic sensor but not sure I know enough to plug it in correctly. thanks everyone for the support.

[acourtjester]

Here is a post about the Ohmic sensor I use very cheap and works great. All you need is a extra input on the controller card for it to connect to. And a post processor to generate the G-code using the probe input, similar to a limit switch input but separate. What controller board and software are you using now??
viewtopic.php?p=241177&hilit=ohmic+sensor#p241177

[Welder Kenny]

Acourtjester, I'm not sure my buddy did all the electronics I was just the muscle. I'm running a proma 300 THC with Mach 3 software, I think I maybe able to lift the lid on our box and look inside to see what shakes. I really want to learn this stuff, but I'm limited. Don't want to mess things up it will cut now. I wonder if I order the stuff and try it out on the bench first.

[acourtjester]

When you want to configure it into Mach 3 here ae the pages where you place the info to have it work. You will need to have the input pin selected on the BOB board or controller board you use. If you can tell me the BOB or controller card you use I will see if I can show you where to wire it in.
When testing you will see the digitize box turn yellow when the contact is made. Here is a Post Processor that should work when you have it operational. You can unzip the file and import it into SheetCam as a new post processor so you can use it.

Mach3 plasma mod Floating HeadTHC with probe Home at end.zip

(1.5 KiB) Downloaded 3 times

Mach3 plasma mod Floating HeadTHC with probe Home at end.zip

(1.5 KiB) Downloaded 3 times

[SegoMan DeSigns]

Acourtjester, I really want to learn this stuff, but I'm limited. Don't want to mess things up it will cut now. I wonder if I order the stuff and try it out on the bench first.

Your in the right place with the right attitude.. Tom AKA Acourtjester and many others will be happy to help you out, You need to start a build notes / part no's book for your table as we Hoomans are a tad forgetful at times or the online connection may be broken..

[acourtjester]

Now is a great time to have you buddy sit down and explain things about the system. Start with the big picture (this is a sum of the parts type thing) showing you the signal paths from computer to torch, how the software functions work. I am sending you a private message wit some videos I made sometime back with basic info that may help you understand thing about your table electronics and Mach 3 software.