Hypertherm Duramax, Service Manual

Page: 51 / 74

Duramax/Duramax Hyamp Robotic Torches Service Manual 807460 51
3 – Operation
Common machine-cutting faults
The torch’s pilot arc will initiate, but will not transfer.
 The work lead is not making good contact with the cutting table, or the cutting table is not making good contact with
the workpiece.
 The torch-to-work distance/cut height is too large.
The workpiece is not totally pierced, and there is excessive sparking on the top of the workpiece.
 The metal surface is not clean of rust or paint.
 The consumables are worn and need to be replaced. For optimized performance in a mechanized application, replace
the nozzle and the electrode together.
 The work lead is not making good contact with the cutting table, or the cutting table is not making good contact with
the workpiece.
 The current (amperage) is set too low. See the Torch Setup section in the system’s Operator Manual for more
information.
 The cut speed is too high. See the cut charts in the Torch Setup section of the system’s Operator Manual for more
information.
 The metal being cut exceeds the maximum capacity for the selected amperage. See the Specifications section in the
system’s Operator Manual for more information.
Excessive dross forms on the bottom of the cut.
 The gas setting is too high or too low.
 The consumables are worn and need to be replaced. For optimized performance in a mechanized application, replace
the nozzle and the electrode together.
 The cutting speed is not correct. See the cut charts in the Torch Setup section of the system’s Operator Manual for
more information.
 The current (amperage) is set too low. See the cut charts in the Torch Setup section of the system’s Operator Manual
for more information.
The cut angle is not square.
 The torch is not square to the workpiece.
 The gas setting is incorrect.
 The consumables are worn and need to be replaced. For optimized performance in a mechanized application, replace
the nozzle and the electrode together.
 The direction of the torch travel is incorrect. The high-quality cut is always on the right with respect to the forward
motion of the torch.
 The torch-to-work distance/cut height is too large or too small.
 The cutting speed is not correct. See the cut charts in the Torch Setup section of the system’s Operator Manual for
more information.
The consumable life is shortened.
 The gas setting is incorrect.
 The arc current, arc voltage, travel speed, and other variables are not set as recommended in the cut charts.