Cutting faults that can occur frequently

Hypertherm® recommends these steps when you have one of these cutting problems.

The pilot arc starts but does not transfer to the workpiece.

  • Make sure that the work cable is correctly connected to the cutting table and is fully tightened.
  • Lower the torch so that it is closer to the workpiece.
  • Make sure that the system is not in a fault condition.

    Refer to Diagnostic codes.

The plasma arc does not cut completely through the workpiece, and there is too much sparking on top of the workpiece.

  • Increase the arc current.

    Refer to the XPR Cut Charts Instruction Manual (809830).

  • Decrease the cut speed.

    Refer to the XPR Cut Charts Instruction Manual (809830).

  • Replace consumables that are worn or have damage.
  • Cut thinner material.

There is dross on the bottom of the cut.

  • Adjust the cutting speed to align with the type and thickness of the metal being cut.

    Refer to the XPR Cut Charts Instruction Manual (809830).

  • Increase the arc current.

    Refer to the XPR Cut Charts Instruction Manual (809830).

  • Replace consumables that are worn or have damage.

The angle of the cut is not square.

  • Make sure that the direction of the torch travel is correct.

    The high-quality side of the cut is on the right with regard to the forward motion of the torch.

  • Make sure that the following settings are correct:
    • Torch height
    • Cut speed
    • Arc current

    For the recommended settings for the type and thickness of the metal that you are cutting, refer to the XPR Cut Charts Instruction Manual (809830).

  • Make sure that the torch head is perpendicular to the workpiece.
  • Replace consumables that are worn or have damage.