Baileigh 1530 CNC Plasma Table THC Problem

[Moosejaw]

I recently purchased a Baileigh 1530 5x10 Plasma Table (5x10) . The seller stated that the torch would drift up resulting in arc loss.
The torch height controller is a Haypercnc PHC -2C unit.
couple questions:
1) Does anyone have the manual on this unit?
2) Would i be better to replace this?
3) Any manuals for this table would be appreciated, the OEM is not very helpful.

Moose.

[weldguy]

Hey Moose

Torch drifting up is common issue with many THC when they are set improperly, or not functioning correctly.

If it is drifting up you know it is seeing a lower voltage than expected and raising the torch to increase arc length which will increase the arc voltage and it will continue to do this until it reaches the arc voltage value you have it set to.

If the plasma cutter is off because your doing a dry run this can happen since there is no arc voltage and it is seeing low voltage.

If the 2 wires that feed the arc voltage to the controller are not hooked up correctly at the plasma cutter this can also happen.

It could just be that the THC unit is defective or burned out also but I would not assume that yet.

First things forst I would draw a simple straight line 24" long or so and get the plasma cutting cutting it perfectly with THC turned off.

One that is working properly I would turn theTHC on and set the arc voltage setpoint to where it should be for your plasma cutter at the amperage youa re cutting with on the material thickness you are cutting.

Do another straight line cut and if torch drifts up try setting the setpoint voltage lower and lower until the torch stops drifting and maintains a height.

If you are unable to achieve this after a few trys I would then get a multimeter and check to be sure you are getting arc voltage signal at your THC.

Let us know.

[Moosejaw]

Thank you so much for your input. Im waiting for a THC for my Plasma Cutter. My cut master 58 does not have the board that should be here this week.
I will advise once I try cutting with it.

[weldguy]

Sounds good. Did you ever find a manual for your Haypercnc PHC -2C unit? Curios to know if it requires a divided voltage or a raw voltage signal from the plasma cutter.

[Moosejaw]

Never found the manual, Hypertherm sent me a new version of the manual. And its funny you should ask about the divided voltage. I just installed my automation interface kit on my cut master 58 and in step 6 the instructioins say there are three options for divided arc voltage signal. there is a jumper for arc voltage /16.67, /30, 50/ that's were i stoped. Tried to call the Hyperthermia guys but it was 30 min before quitting time on a Friday, likely having a cold one at the local watering hole.
Not sure what i need. The table came with a cut master 120 professional and my next step was to take the cover of of that unit and see where the jumper is set.
Not real good at all this but I'm thinking the THC needs a certain divided voltage to give good readings for the THC.
Any help would be appreciated.
Moose

[acourtjester]

Many THC use a 50:1 divider input.

[05Duramax]

This may be the manual that you were looking for https://xnet.hypertherm.com/Xnet/librar ... =HYP104210

[Moosejaw]

That is what Hpertherm sent me, the one I have is different, I think the one I have is an older unit. Thanks for sending.

[tcaudle]

The THC input determines the divide raiot you select in the Plasma interface card. YOu are dealing with a Thermal Dynamics Plasma and a Hypertherm THC . That beign siad Hyperterms with theior built in voltage divider typically are set to 50:1 . They also support 20:1 and a coupl of other ratios but noting that is 16 or 30.

It easy to tell. Find the divided voyage pair out of the TD and use a DVM and fire the torch . Most of them run about 125- 140 volts open voltage or less. So the ratio is what you read divided into the 145 volts (nearest number) . If you can get to the raw voltage side then read that and you will have a better number to start from/ (CAREFULi its dangerous)

I think you will be save to set the TD to the 50:1 and and you should read around 3 volts with the torch fired in the air and then set the THC to that same ratio.

[Moosejaw]

Ok lots has happened, finally talk to the right guy and got the manual, Took the torch controller apart and found one of the pins in the RS232 9 pin connector totally burnt. The circuit board was also damaged.IMG_1167.HEIC
IMG_1166 2.HEIC
took to circuit board repair shop replaced connector, several resistors, chip and new trace on board.
Installed and ready for smoke test. For test run torch moves into position, air comes on torch touches material and just sit there and does not fire.
Cutmaster 58 gives me a code 85, so did the following:
Checked consumables all good but I replaced them just the same.
Checked for sl100 torch short, took out consumables and not continuity (no short)
Checked air pressure at 95 psi
Called Baileigh service guy said my table and torch controler requires arc voltage so I took off the jumper
put everthing back togetehr and still no firing.

Cutmaster gives error code 85 on first try then goes to 75 error code.

Very frustrated, about ready to drop $40,000 on a new machine and pull this out of the shop with the dozer and put in the scrap pile.

Any help would help to keep me out of the nut house.

Moose

[weldguy]

The common cause of error 85 I have found is the plunger on the starter cartridge is stuck to the nozzle. Remove your consumables and look at the spring loaded plunger on the bottom of the start cartridge. At the bottom of that plunger is a beveled edge which contact the beveled edge in the top of the nozzle. Put the nozzle and cartridge together in your hand and you will see how they fit together. What happens is the electrical arcing can pit the beveled edge on the plunger and cause it to stick to the nozzle causing a error 85. Get a scotchbrite pad or fine sand paper and smooth out that beveled edge, blow clean with compressed air, reinstall your consumables and there is a good chance that everything is back to normal. Alternatively just install new consumables.

Not sure what you mean about "Called Baileigh service guy said my table and torch controler requires arc voltage so I took off the jumper" What jumper are you referring to? Be careful because you feed RAW arc voltage to a THC the requires divided voltage you will fry things.

If it were me I would leave the THC out of things at this point and focus on getting the torch to fire and cut consistantly by following what I mention above. Then re-introduce the THC and begin working on it.