problem with Hypertherm PowerMax 1000

admin

I have a Hypertherm PowerMax 1000 plasma cutter with the stock T-60 torch. My problem is that a very short time (maybe 24" of cut) after installing new consumables in the torch, the machine won't cut straight anymore - the arc goes "off axis". The other day I had to make two straight cuts across a piece of 1/2" plate 24" long. I put in a new electrode (120926) and nozzle (120931). I was using the drag shield (120929). I made the first cut, which went just fine. The cut edge was nice and square. I made the second cut doing nothing differently and the cut was beveled maybe 15 degrees from square.The actual torch head works but was abused some before I got the machine. The plastic is cracked. Could this be the reason?metalmagpie
Reply:Clean (oil and water free) air source?MM200 w/Spoolmatic 1Syncrowave 180SDBobcat 225G Plus - LP/NGMUTT Suitcase WirefeederWC-1S/Spoolmatic 1HF-251D-1PakMaster 100XL '68 Red Face Code #6633 projectStar Jet 21-110Save Second Base!
Reply:The air runs through a refrigerated air dryer and then a filter. I don't think that's the problem. I did see where Jim Colt once posted the following about a PowerMax 900 which should behave nearly identically to my PowerMax 1000:This is what will cause the type of taper (varying) with a plasma cutter:1. Damaged nozzle orifice. This is almost always caused by piercing too close tothe plate. The Powermax900 should be using shielded consumables (check youroperators manual for correct part numbers) and you should be piercing the 3/8"at about .15"....with and adequate pierce delay to allow full pierce befor anymachine movement...then you should be cutting at .06". If you did one pierce tooclose on a new nozzle...the nozzle is likely damaged and will cut with varyingangularity. Posting some focused, closeup pictures of your used nozzle willallow me to instantly determine if this is the case.2. A missing or worn o-ring on the torch body will cause varying angularity.3. A worn retaining cap will cause varying angularity4. a worn swirl ring will cause varying angularity5. Varying cut height will vay the angularity.6. a worn out or leaky torch body will cause varying angularity.Since my torch body was actually cracked, there is little question it was leaky. I have new torch body halves and am installing those now. Will also install a new swirl ring and will check any O-rings I see. My cuts started on edges (not pierciing cuts) and since I used a drag shield the cut height should not have varied and should not be an issue.Thanks for the reply, Duane!metalmagpie
Reply:Rebuilding the torch head worked! Looks like new, cuts like new too!metalmagpie