Powermax 65 consumables only last 30 minutes

[djreiswig]

I think it's because he's having the error. But they still look good to me also.

[WyoGreen]

After reading thru this thread and looking at the pictures, my gut feeling is it's a air problem. When you added the 2nd air compressor, you had some improvement. Both air compressors appear to be relatively low volume compressors. You have a good filtration system, so water and oil should not be a problem.

So the standard question is, are you measuring air pressure right at the back of the plasma cutter, using a "T" and and an air gauge right where the air goes into the cutter? Keep an eye on the pressure gauge while cutting, particularly when you get the error.

[weldguy]

I'm with WyoGreen, it's likely an air issue. All good equipment except the air compressor and if memory serves me right most if not all my 0-30 issues were air related. Yep, gauge on back of the plasma cutter, never let it drop below 90-100psi, if it does you need to beef up the air supply.

[robertspark]

Those consumables don't look too bad to me.

I would suggest that its an air volume + pressure issue.
I run 2x3HP compressors in parallel.

If you have a buddy with another compressor I'd borrow it and give it a go and see if that sorts your problems.

Compressors have duty cycle too.

they should not be running flat out for long periods of time.

it looks like one of these compressors to me
https://www.searshometownstores.com/pro ... -Free-Pump

^^^

[stinovation]

Weldguy,

Appreciate the info. I've 20 pairs of consumables that all loot just like that. Consumable run time is now 45 minutes cutting and then 0-30 code. After the 0-30 code sometimes I'll pull the consumables wipe them down and put them back in. I've done that several times. They will only run another 5 or less minutes then the 0-30 code. When I pull them out the second time they all similar to the pictures. The divit in the middle of the electrode is maybe .020" deep and everything looks clean. Swirl ring, o'rings all in good shape. I'm not overtightening the cap. Air is clean, there is 120 psi at the regulator at the plasma and never drops below 100 psi while cutting. I started to look at the consumable switch in the head but I din't get very far, because the dissamble didn't feel right. I'm in the middle of a job, so I can't risk breaking something this week. I'm hoping to look at the consumable switch next week. I'm at a little bit of a loss. I would love to wear out a set of consumables, but I"m not able to becaue of the 0-30 code. Any ideas?

Thanks

[weldguy]

Checking the consumable or PIP switch will be a waste of time, it's working or you would have other issues.

Are you running your plasma cutter in auto air pressure mode or manual mode where you set the air pressure yourself?

Always use auto air pressure mode and be sure your in continuous cut mode not stitch cut or gouge.

If you have all those bases covered, orings are good and not missing one, tried a new swirl ring and still get 0-30's I am stumped and there may be something wrong with your plasma cutter.

Not that it should make any difference but out of curiosity have you tried cutting without the shield on the end of the retaining cap?

[robertspark]

how is the air filter? (on the machine)?

[stinovation]

All,

Thanks for all of the input. I'm new to this even the message board. I'm now catching up with Page two of post.

With all the money I've spent to get this up and running I was really hoping I wouldn't need a new air compressor....

But looks like that's where we are headed. I need to do a little bit of shopping, but I will get it replaced and report back.

Thank so much for all of you help!!

[adbuch]

All,

Thanks for all of the input. I'm new to this even the message board. I'm now catching up with Page two of post.

With all the money I've spent to get this up and running I was really hoping I wouldn't need a new air compressor....

But looks like that's where we are headed. I need to do a little bit of shopping, but I will get it replaced and report back.

Thank so much for all of you help!!

[robertspark]

have you checked the inline filter within the hypertherm?

have you tapped in a second air compressor for stable air pressure?

[djreiswig]

If you are maintaining 100psi at the rear of the plasma,then I don't think you have an air supply issue.

[stinovation]

robertspark,

the hypertherm inline air filter is stark white inside and out.

Please refer to Feb 11th post for air compressor. I tapped in a second air compressor which did improve consumable run time from 30 min to 45 min. The air compressors basically run all the time when the machine is cutting. They catch up about every 10 minutes then rest for a couple minutes then start back running again...if that makes sense.

The two compressors i'm running are not 100% duty cycle. So I'm thinking that I"m probably going to wear them out and will need to get a better compressor not to far down the road anyway. I found a guy about with a used Ingersoll rand 80 gallon 15 scfm @90 psi. I'm hoping to pick it up and have it installed this weekend. This is the direction i'm headed. We'll see how it goes.

Thanks

[stinovation]

I just verified that the machine is running in "Auto Pressure". I also looked at the settings and noticed that preset for the material I'm cutting is set at "75 psi".

I'm wondering if this is pressure it to low? Maybe I should bump it up to 85 psi or 100 psi? Maybe this could help increase consumable life?

[weldguy]

I am not sure that the 75psi setting your looking at is even relevant. Note the * indictaing that "marked settings are only active in Full Automation (TAP) installs" Do you have the Serial interface port connected to anything? See attached image where I circled the port in questions. If you do I suppose it is possible your software settings shown in your image are overriding the "Auto Air Pressure" mode we spoke of earlier.

Serial.PNG (210.44 KiB) Viewed 988 times

[stinovation]

My unit only has the round connector on the far right (CPC) port. There is a connector plugged in and the wires run to the control box for the CNC table. I think this controls the air pressure automatically.

My thought is to bump this up to 85psi and see if that increases run time while I work on a larger air compressor.

[djreiswig]

In order to control the amps and air pressure remotely you need to have the serial port. The round connector doesn't have this function. It just fires the torch, gives arc okay and divided voltage. Nothing else. If you don't have the serial port then most likely your air pressure is set automatically. I think you could adjust it from the front panel buttons, but you would have to actually do it. Not something that would accidentally happen.

[weldguy]

djreiswig is right, if the serial connector is not being used you cannot remotely adjust the air pressure or amps from your software. This will not be your issue.

[stinovation]

Okay, looks like pressure setting is not the solution. I was just hoping there might be something else I was missing. I was able to pick up a used compressor this past weekend but will probably be next weekend before I can get it set. I'll report back.

IMG_8600.jpg (67.66 KiB) Viewed 967 times

[weldguy]

Right on, hope that helps you out. Let us know, very curious.

[SegoMan DeSigns]

You would think our Hypertherm rep would drop by and help solve a problem with an existing machine but he is to busy schlepping expensive consumables..

[plasmanewbie]

You would think our Hypertherm rep would drop by and help solve a problem with an existing machine but he is to busy schlepping expensive consumables..

[HypHyDef]

You would think our Hypertherm rep would drop by and help solve a problem with an existing machine but he is to busy schlepping expensive consumables..

Back on Feb, 11th I posted this:
It looks like you are in great hands here with all the skilled people here, you can also give Hypertherm tech service a call and discuss what's happening. you can get in touch a few different ways. fill out a form and they will give you a call back here: https://www.hypertherm.com/en-US/contac ... -questions
Or you can call them directly here: Technical service
(800) 643-9878

Stinovation, I'm sorry that you are still having issues with you system, Please give our technical support team a call so they an help you. You have had a lot of great help here so far but maybe the our team can help you narrow down the problem and find a solution.

[Blackslacks]

Check for this too

[stinovation]

It took an extra week set the new compressor and get back to cutting.

I have good news on a couple of things. The new compressor is much quieter, and the consumable are lasting longer, but i'm still struggling with the 0-30 code. I didn't mention it until now but the 0-50 code comes up also. I just haven't mentioned it because the 0-30 code is 5:1 over the 0-50 code.

First set of consumables after the compressor upgrade resulted in about 1 1/2 hour cut time. Which is much better than where we started, but I'm still frustrated with the codes. I spefically uppgraded the plasma with break away / collision detection so that I could hit run and walk a way. But these 0-30 codes shut it down every 30 minutes of cut time.

Attached is picture of the new air compressor along with first set of consumables. That set has about 1 1/2 hours of cut time. The dimple in the electrode is definitely deeper than any of the others. It coded 0-30 three times during that 1 1/2 of run time, then I pulled the consumables and put in a new set. I'm really at a loss now. Maybe something is wrong with the Hypertherm....

Please let me know what you think.

[djreiswig]

0-50 is the cap switch. I'm wondering if there is something loose in your torch. Do you run a hand or machine torch? The 0-50 error will occur if you remove the cap without turning the power off. Is that what you are seeing, or does it occur while cutting?
Are you certain that the lead is inserted all the way into the power supply? If the pins aren't seated it might also cause intermittent issues.
I would disassemble the torch and see if something looks loose or if you have a connection issue.