PowerMax 800 help!

admin

About 11 years ago a bought a Hypertherm Powermax 800 plasma cutter from an fab shop that went out of business and had an auction. Me and my buddy went and they had a Powermax 1000 and a Powermax 800. My buddy bought the 1000 and I got the 800. I had to change the electrical plug and at that time I checked the jumpers on the machine for correct voltage input (220 volt single phase). The lead for the gun was very stiff but useable. The machine powered up and seemed to be ok. I did some test cuts and it seemed to work. Has projects came up I used the plasma and after about a month I noticed that the thing really didn't cut all that well. For a 60 amp machine it seems to lack power. It cuts 1/4" alright, struggles with 3/8", and is not even useable on 1/2"? I would think a 60 amp plasma cutter would cut 1/2" slowly but be able to do it. Even when I cut 1/4" the cuts are not that clean. The machine also sometimes just loses arc in the middle of a cut. Let off on the trigger and start again and is fine.  It came with a Motor Guard M-26 file mounted on it and I was using it. I replaced the filter in it and it made no difference. I bypassed the Motor Guard filter and it made no difference. I hav a IR T30 5hp 2 stage compressor so I have plenty of air. I tried it in all 4 220 volt outlets in my shop and it works the same. Even measured the voltage at my outlets and they were good. I don't use the machine much because it doesn't work that good. Just recently I replaced the gun has a last ditch effort with the new Duramax H RT gun. It is just a touch better but still not what it should be. I cut 4 6" circles in 1/4" steel with a circle jig and it didn't do a very good job. The kerf of the cut is angled even know the torch is held perfectly straight in the jig. By the time I got the 4 circles cut and a few straight cuts to clean up the drop from the circle the tip and electrode were shot. So it is using consumables up very fast! This is very frustrating. My buddy that bought the 1000 has had great luck with his machine. I've even used it to cut some 1" steel and it had no problem. So I know there are some very knowledgeable people here that know these machines and I'm hoping someone can help me.
Reply:check the distance from gun tip to work piece.  also make sure you have a fantastic ground.  also check that all tip pieces are fully seated as supposed to be.lincoln 125spmonkey wards 250 ac/dcmiller 211 w/spool gunahp  200 sx tiglotos ltp5000dof course duramax diesel
Reply:Originally Posted by duramax-robcheck the distance from gun tip to work piece.  also make sure you have a fantastic ground.  also check that all tip pieces are fully seated as supposed to be.
Reply:On my 600 the pins that plug the torch into the machine had some faulty solder joints. I just pulled the plug apart and resoldered them all. Worked like a champ! I have also had the ground wire break inside the insulation behing the clamp. Can’t see the broken wire because the insulation is so thick. I just trimmed it back and crimped on a new eyelet.
Reply:Originally Posted by walkerOn my 600 the pins that plug the torch into the machine had some faulty solder joints. I just pulled the plug apart and resoldered them all. Worked like a champ! I have also had the ground wire break inside the insulation behing the clamp. Can’t see the broken wire because the insulation is so thick. I just trimmed it back and crimped on a new eyelet.
Reply:Those connection points could be bad on the machine side as well as the torch side. Has the brand new torch ever functioned properly?
Reply:Originally Posted by walkerThose connection points could be bad on the machine side as well as the torch side. Has the brand new torch ever functioned properly?
Reply:FWIW, the Hypertherm tech line is great for diagnosing issues on your machine, just give them a call if you don’t get it figured out quickly.
Reply:Check the pilot arc contactor, it is most likely stuck closed.The contactor is no longer sold by hypertherm but they are a standard 30amp DC contactor. you can find it at one of the online electronics stores.The 800 is only a 50 amp unit. the 900 was a 55 amp. the 1000 is the 60A.the 1250 is 80A and the 1650 is 100A. All no longer made and going obsolete.
Reply:Originally Posted by ccawgcCheck the pilot arc contactor, it is most likely stuck closed.The contactor is no longer sold by hypertherm but they are a standard 30amp DC contactor. you can find it at one of the online electronics stores.The 800 is only a 50 amp unit. the 900 was a 55 amp. the 1000 is the 60A.the 1250 is 80A and the 1650 is 100A. All no longer made and going obsolete.
Reply:Originally Posted by vpd66Thanks for the info. I will look into it!
Reply:I have dug into the machine and have done some tests and checks has per the manual I found online and everything seems to be working. I have to say the manual is pretty indepth and if something is not working it would be fairly obvious. When i was inside the machine I gave it a cleaning with compressed air and sprayed it down with electro contact cleaner. Since then I have only used it on 10ga steel and it worked fine, but that was never a problem before. With the high price of steel right now I really don't want to cut up too much thicker stuff just to try it out! LOL
Reply:Originally Posted by vpd66I have dug into the machine and have done some tests and checks has per the manual I found online and everything seems to be working. I have to say the manual is pretty indepth and if something is not working it would be fairly obvious. When i was inside the machine I gave it a cleaning with compressed air and sprayed it down with electro contact cleaner. Since then I have only used it on 10ga steel and it worked fine, but that was never a problem before. With the high price of steel right now I really don't want to cut up too much thicker stuff just to try it out! LOL