plasma cutting?

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Hypertherm PowerMax 1000. Mine isn't cutting square. If I hold the torch straight up and down the cut should be perpendicular to the workpiece surface. Mine isn't. It blows off at about a 10 degree angle from square. If I cut a circle it leans out on one side and leans in on the other. Is this just worn consumables? This happens to me a lot. Am I running too much power for the thickness of the cut? I have no detectable moisture in my shop air, as tested by blowing air through the torch onto a mirror which showed no fogging. Any insight would be most welcomed. I'm tired of scrapping pieces.metalmagpie
Reply:Sounds like worn consumables.   Same happens with my ESAB.  Are u sure your air supply is dry?   Spatter or contamination on the cutting tip will cause that too.Tiger Sales:  AHP Distributor    www.tigersalesco.comAHP200x; AHP 160ST; MM350P,  Spoolmatic 30A; Everlast PowerTig 185; Thermal Dynamics 60i plasma.  For Sale:  Cobra Mig 250 w/ Push-pull gun.  Lincoln Wirematic 250
Reply:Also check your torch height. If you are using shielded consumables the shield must be on the plate. It sets the proper cut height. If using extended or pipe tips, then keep the tip just off the plate. 1/16 to 1/8 inch. If you raise up the torch the plasma stream tappers to a point and will cull on an angle. If the torch is at the correct angle, a to high torch will bevel both sides of the cut.
Reply:Generally consumables and/or technique. I'd start with fresh consumables. I was cutting a 4" circle in some inch plate a while back... the cut side looked perfect and the bottom side was about 3" in diameter  ... turned out to be worn consumables (electrode was worn short). As for the technique... make sure your moving fast enough... too slow tends to taper. What thickness are you cutting?
Reply:OP here. Changing consumables fixed the problem. The problem happened across all thicknesses but the last thing I was having trouble with was 3/8" steel. Now cutting fine. I may have been moving too slow, 'cuz there was some slag buildup but the slag still fell right off when tapped with a slag hammer, so I don't think my speed was too wrong.
Reply:Glad u fixed it.   and to keep the welding vocabulary nazi's happy the term for slag from plasma cutting is "dross"Tiger Sales:  AHP Distributor    www.tigersalesco.comAHP200x; AHP 160ST; MM350P,  Spoolmatic 30A; Everlast PowerTig 185; Thermal Dynamics 60i plasma.  For Sale:  Cobra Mig 250 w/ Push-pull gun.  Lincoln Wirematic 250
Reply:Originally Posted by forhire. make sure your moving fast enough... too slow tends to taper. What thickness are you cutting?
Reply:In your operators manual for the Powermax1000 there is a section on inspecting the consumables for wear. Assuming you are cutting at a constant speed and constant height...and the torch is perpendicular to the plate.....the cut edge angularity will be pretty much consistent all the way around a part (with a Hypertherm shielded torch...such as the Powermax1000.)If the angularity varies by more than about 1.5 degrees as measured side to side...then likely either the nozzle or the shield orifices are damaged. Any nicks or oval shape will change the shape of the arc....which causes cut edge variation.Other things that cause varying angles:- inconsistent cut height. Ttorch height variations of as little as .005" will show a measurable angle change in the cut edge. This is why cnc plasma systems need a good height control.-Worn torch retaining cap...this alters the air flow concentricity to the shield or nozzle and will push the arc to one side...causing varying angles.-Restriction or leak in the air flow to the torch.-worn or damaged swirl ring.Jim Colt  Hypertherm Originally Posted by metalmagpieOP here. Changing consumables fixed the problem. The problem happened across all thicknesses but the last thing I was having trouble with was 3/8" steel. Now cutting fine. I may have been moving too slow, 'cuz there was some slag buildup but the slag still fell right off when tapped with a slag hammer, so I don't think my speed was too wrong.