I have two Hypertherm 1000 G-3 Plasma generators with M-60 machine torches operating on Dyna Torch CNC cutting tables.
On the one particular machine I am having problems with we have installed Dyna Torches DASH no touch system. I am using Hypertherm Fine cut consumables and always have.
These two machines cut 14 and 12 Ga Laser quality carbon steel only, zero rust near mirror finish.
Problem I am having with the one machine is that it experances a no fire situation about one in every 4 to 20 pierces. The CNC will issue a G-23 code to fire the plasma the torch will travel down and the plasma generator will vent it's system pressure like always just before firing, however the plasma will not fire and then after 5 seconds the CNC controler will issue a falure to fire after 5 seconds code and ask if you would like to retry? The plasma will always re-fire after pressing retry. I have tried increasing the falure set time out to 10 seconds with no change in operation.
We have noticed that when the no fire occurs the Plasma generator will display a power on green lamp and the red fault lamp (not flashing) for a few seconds and then the fault lamp will go off. In the service manual this indicates stuck or jamed consumables. We have replaced all the consumables as well as the swirl ring and sheld cap many times, we only install the sheld cap finger tight as per instructions, and have tried different tightness.
Problem still there. we pulled the main torch body out and checked it for jamming and plunger movement as well as internal power cable jaming all seemed just fine. Put unit back into service problem still occurs, order new main torch body from Hypertherm P.N 3099839 and install nothing has changed still has miss fireing. It's not a over heating consumable problem
as this will occur sometimes in the first 2 minutes of operation in the morning after being off all night. The other 1000 G-3 is preforming the same cuts on the same material all day with no problems as well as a older Hypertherm 900 with a machine torch. The only differance is that the DASH system takes a little longer to locate it's pierce point. all three are on the same compressed air system with a state of the art air drying system set at 80 p.s.i.g. The only differance between the two 1000s are the one with the starting problem has the Dyna Torch DASH system installed on it, we where trying it out before purchasing for the other two machines.
These machines operate at 40 amps, 80 volts ,135 IPM with the cycle times and amperage we cannot be getting near exceeding there duty cycles.The little 900 been preforming this job for over 6 years.
Any help in what direction we should be checking would be greatly appreciated.