The company I work for purchased a Hypertherm XPR460 from Machitech with a Diamond Single head Plasma CNC, table 5 x 10.
Was informed that the Nozzle and Electrode would last 1000 pierces. We are only getting 56 to 150 and then needing to change them out.
There is a drier attached to the shop air. There is no water or grease in the lines. All gas and air pressures are set correctly.
Does anyone have any clue as to what the issue is? Machitech cannot figure it out.
I would say its moisture in the air. Unless the air supplied to the plasma cutter is 99.9 to 100% moisture free it will eat consumables in short order.
You have moisture in the air and with that kind of accelerated wear, it’s a lot of moisture.
What kind of dryer do you have and has it been maintained?
A refrigerated dryer with the capacity to keep up with the demand from the plasma cutter is the best option.
8573-1:2010 Class 1.4.2.
Maximum water vapor pressure dew point: 3°C (37°F)
Maximum oil concentration: 0.1 mg/m3
(for aerosol, liquid, and vapor)
Amazingly this machine has the highest tolerance for water vapor I’ve seen on a machine yet.
That said super dry air is always the way to go.
I’m assuming this is a three phase machine.
I would triple check whether the incoming voltage is very close on each one of the legs.
The air is 100% dry. And the drier is a large compacity drier. It feeds the whole shop. And use to have an ESAB 2 head plasma and 4 head oxy. No issues with it. No oil no water in line. all pressures are to spec.
The air is 100% dry. And the drier is a large compacity drier. It feeds the whole shop. And use to have an ESAB 2 head plasma and 4 head oxy. No issues with it. No oil no water in line. all pressures are to spec.
The air is 100% dry. And the drier is a large compacity drier. It feeds the whole shop. And use to have an ESAB 2 head plasma and 4 head oxy. No issues with it. No oil no water in line. all pressures are to spec.
I’m sure the company you bought the plasma from will figure it out. It will probably require an on site inspection to confirm your 100% dry air.
I had a professor in college that liked to repeat everything 3 times as well… It always made me laugh… but I never forgot that “the determinant of a matrix it is a number… it is a number it is a number.” My friends skipped a couple days of class to go on a hunting trip and asked me to take notes for them. I wrote every paragraph of notes I took and repeated it 3 times. My friend was frantically copying my notes and got about halfway through the second page of notes before he turned to me and asked if I had repeated everything in the notes 3 times. 
Now I have The air is 100% dry. And the drier is a large compacity drier. It feeds the whole shop. And use to have an ESAB 2 head plasma and 4 head oxy. No issues with it. No oil no water in line. all pressures are to spec. permanently etched in my brain thanks to you. 
“Repetition is the mother of learning, the father of action, which makes it the architect of accomplishment.” — Zig Ziglar