Trouble with my plasma cam table, warping material and z-axis

[Firehouse Fab]

I need help, I have a plasma cam 4x4 table with a hypotherm 65 plasma cutter. We are cutting 14 gauge steel and having a ridiculous problem with warping of the metal, which is causing the tip to dive and catch the metal. Metal. And drag it off of a lineup. We're cutting at 45 amps, our travel speed is 85 inches per minute, I'm still a novice at this, and having a lot of trouble trying to get this system to work right. We had issues with the Z-Axis motor, we've had connectivity issues with the cable going from the torch to the motherboard. I would really appreciate some advice

[TJS]

Double check your Hypertherm cut chart. Pretty sure you are too slow. I think it should be around 220 to 250 IPM on 14ga. I don't have my book at this computer so do not quote me on this.

[TJS]

Here is 14ga. Virtually no warp.
https://youtube.com/shorts/AjwioIMky48? ... nOr4YUWZZN

[Firehouse Fab]

The design we're cut ting is a a lot bigger, but I think we're also having a problem with the control on the z-axis. It keeps dropping as it cuts, or diving into the work. So I don't know if the actual problem is the speed or if it's that z-axis not staying accurate. At this point. I'm really disappointed in the performance on my table,. It's got very few hours on it and we've had to replace motors and cables already so I'm just trying to figure it out. I'll see if changing the cut speed will help at all. I think we tried that but it wasn't burning all the way through. What amperage was that cut at? If you don't mind me asking

[Joe Jones]

Where are you located?

I like to troubleshoot PlasmaCam tables in person whenever possible.

If the table is only a few hours old, you should NOT need to replace motors or anything else. The problem is in your settings.

14 gauge should have almost ZERO warping issues. Your cut speed is way too slow. You are putting too much heat into the metal. The diving issue is the torch "searching" for material in order to measure the height control. When you cut material away, and the torch does not MOVE to new material, it will dive to try to touch down to the material it believes to still be beneath it, but the torch only finds the gap it created, which is why the torch is diving into the material.

Do you USE the height control of the machine? Is the torch ohmic sensing wire that extends from the top of the carriage motor connected to the torch tip through a retailer that has the ohmic sensing metal tab?

Have you looked at DIAGNOSTICS in DesignEdge? Does the height control sensing circuit work correctly?

What is your pierce height? What is your cut height? Change your cut speed to 160 or so.

Do you check the two boxes at the bottom of the HEIGHT CONTROL SETTINGS tab so the software can calibrate the cut settings correctly?

auto zero height control check boxes.jpg

Do you have BASIC or ADVANCED height control activated in your DesignEdge software? What torch are you using? (hand torch or machine torch?)

Which consumables are you using? Post the numbers of the shield, the electrode, and the nozzle. Photos always help.

You are cutting at 45 amps, which is plenty for 14 gauge material. Even 40 or 42 is a better setting IF the 65 will go down that low.

Can you post the file HERE that you are trying to cut? Is it intricate? Do you have your settings set to reduce heat?

Is your HT65 work load cable (ground cable) attached to the grates, or directly to the material?

Tell me about your compressor. Tank size, static pressure (at rest) and also tell me what the air from the compressor tank must pass through in order to get TO the plasma cutter. Is it a crisp, clean connection, or does the air travel through a hundred feet of elbows, water filters, and 1/4" I.D. Chinese air hoses?

Do you HAVE some way of removing WATER from the air supply before it reaches your plasma machine? A plasma cutter is not a water jet!

I would love to drop in and help you in person, but I do not know where you are located.

Joe



.

[Rockchucker]

The design we're cut ting is a a lot bigger, but I think we're also having a problem with the control on the z-axis. It keeps dropping as it cuts, or diving into the work. So I don't know if the actual problem is the speed or if it's that z-axis not staying accurate. At this point. I'm really disappointed in the performance on my table,. It's got very few hours on it and we've had to replace motors and cables already so I'm just trying to figure it out. I'll see if changing the cut speed will help at all. I think we tried that but it wasn't burning all the way through. What amperage was that cut at? If you don't mind me asking

I had this problem with my machine when i first rigged it up . Make SURE your grounding is all PERFECT! I thought mine was pretty good but it turns out these things throw out a ton of electrical noise and interference. I had my cables, control wires and torch lead running thru a metal tray because it went across a walkway. This wreaked havoc on a biblical scale and took me quite a while to figure out. Got a non conductive cable guard, bonded my computer cabinet to the star ground on the table and make sure to keep my main ground rod(the one that goes 10' into the ground) nice and moist. problem went away. Might be unrelated to your problem but its a good place to start.
Good luck!

[adbuch]

we're also having a problem with the control on the z-axis. It keeps dropping as it cuts, or diving into the work.

z force.jpg

[adbuch]

auto calibrate.jpg

[adbuch]

I need help, I have a plasma cam 4x4 table with a hypotherm 65 plasma cutter. We are cutting 14 gauge steel and having a ridiculous problem with warping of the metal, which is causing the tip to dive and catch the metal. Metal. And drag it off of a lineup. We're cutting at 45 amps, our travel speed is 85 inches per minute, I'm still a novice at this, and having a lot of trouble trying to get this system to work right. We had issues with the Z-Axis motor, we've had connectivity issues with the cable going from the torch to the motherboard. I would really appreciate some advice

Cut speed for 14 ga. steel at 45 amps would be around 200 ipm. If you have a Hypertherm Powermax 65/85 manual - it contains the mechanized cutting charts which will show you the current setting, pierce height, cut height, cut speed, pierce delay, etc. for the material you are cutting. Also you will get better cuts with less heat buildup and warping if you use the FineCut consumables. Make sure your air pressure to the plasma cutter (as measured at the entrance to the cutter with air flowing thru the torch) is 100 psi.

David

[Firehouse Fab]

Thank you for the info. I'll check that out.

[adbuch]

Thank you for the info. I'll check that out.

Initialize your table, then calibrate your height control by checking the two boxes I show above. Enter the correct settings for pierce height, cut height, pierce delay, cut speed, kerf width, lead-in length, etc. Set you plasma cutter to 45 amps and install you FineCut consumables. Then draw a straight line about 12 inches long and do a text cut. Pause about half way along the cut and physically measure your cut height (distance between your shield/nozzle and the material surface. This distance should be close to 0.060". If you happen to have the Sync model, then your cut height would be around 0.150" (same as pierce height).

Also check your Machine Control tab Z=Axis Motion Force when moving and make sure it is set to 36.


Let us know how you make out.

David