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Fine cut consumable issues

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Boneyard Welding & Fab
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Fine cut consumable issues

Postby Boneyard Welding & Fab » Thu May 17, 2018 11:45 pm

Okay, so I'm running a Hypertherm 85 cutter on a Plasmacam dhc2 4x4 table. I have advanced hight and machine control software. So here's the issue I'm having. Running standard 85 amp torch consumables everything works as it should. If I switch to 45 amp fine cut nozzle and ohmic shield the machine fails to sense the material and won't operate. Sensing wire is hooked up the same to a Hypertherm ohmic collar on both consumables. Settings are the same except amp adjustment on the cutter, and standard adjustment for material thickness.

So what am I doing wrong here?
Boneyard Welding and Fabrication
Guysville, Ohio

Plasmacam DHC2 4x4
Hypertherm 85
Everlast powermts 221STi
Hobart champion elite

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rdj357
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Re: Fine cut consumable issues

Postby rdj357 » Fri May 18, 2018 8:27 am

Make sure the tab on the ohmic retaining cap is making good connection to the FineCut ohmic shield. Sometimes the little tab doesn't make contact and needs a little adjustment.

You can open the machine diagnostics page and look for the sense indicator in the bank of info at the top right of the screen. It will be white and turn yellow upon contact. With that screen up and the plasma source turned off, take the work clamp of the Hypertherm and touch the shield to see if it turns yellow. If not, try touching the ohmic shield post, etc. until you find where it is sensing and where it stops.

Also, make sure when you change materials or consumables that you check both the auto zero boxes on the height control tab (z-shift and arc voltage shift). I have my overtravel for sense set at 1" but if you have a small number in the overtravel box you will get the error if it travels that length and does not touch the material.
Robert Johnson
----- PlasmaCam 5x10 Table -----
FourNinety Creations & Learn PC, LLC

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User avatar
Boneyard Welding & Fab
Posts: 19
Joined: Mon Dec 18, 2017 7:45 pm
Location: Guysville, Ohio
Contact:

Re: Fine cut consumable issues

Postby Boneyard Welding & Fab » Fri May 18, 2018 8:54 am

Thanks. I'll run the machine diagnostic test and see what it comes up with.

I tested continuity on the shield and sensing wire with a multi meter, but maybe the connections aren't good enough. I always run the z shift and arc volt shift on auto, and I leave over travel set to 1" by default.

Appreciate the help, I'll update this post after I run the machine tests.
Boneyard Welding and Fabrication
Guysville, Ohio

Plasmacam DHC2 4x4
Hypertherm 85
Everlast powermts 221STi
Hobart champion elite

User avatar
Boneyard Welding & Fab
Posts: 19
Joined: Mon Dec 18, 2017 7:45 pm
Location: Guysville, Ohio
Contact:

Re: Fine cut consumable issues

Postby Boneyard Welding & Fab » Sun Jun 10, 2018 9:45 pm

Finally found the issue. Somehow the sensing wire connection strap on one of my torch barrels had come loose. Noticed this when I tried a different set of consumables, that the machine would only sense the material with one barrel but not the other. Not often I get a defective Hypertherm part but I guess it does happen from time to time.
Boneyard Welding and Fabrication
Guysville, Ohio

Plasmacam DHC2 4x4
Hypertherm 85
Everlast powermts 221STi
Hobart champion elite

User avatar
rdj357
Elite Contributing Member
Elite Contributing Member
Posts: 517
Joined: Sun Mar 11, 2012 4:40 pm

Re: Fine cut consumable issues

Postby rdj357 » Mon Jun 11, 2018 6:39 am

Glad you found it! Yep, those can be annoying - most of the time it is a lack of contact from the tab to the shield which can be corrected with a little squeeze from some pliers.
Robert Johnson
----- PlasmaCam 5x10 Table -----
FourNinety Creations & Learn PC, LLC

Learn Plasmacam Website
Learn Plasmacam on Facebook
Learn Plasmacam on YouTube

User avatar
Boneyard Welding & Fab
Posts: 19
Joined: Mon Dec 18, 2017 7:45 pm
Location: Guysville, Ohio
Contact:

Re: Fine cut consumable issues

Postby Boneyard Welding & Fab » Fri Aug 03, 2018 1:47 pm

Yeah, took me a little while but I found the issue. Thanks for chiming in with your ideas.
Boneyard Welding and Fabrication
Guysville, Ohio

Plasmacam DHC2 4x4
Hypertherm 85
Everlast powermts 221STi
Hobart champion elite


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