Symptom: The plasma jet was spraying at about 20-30° off vertical, burning through nozzle tips very rapidly, within a couple pierces, and lots of slag.
After changing consumables several times to no avail (and ruining them in the process), I opened the torch, I found the whip side power wire screw on the power wire was completely loose. Basically falling off, and I could easily unthread it by hand. It must have never been torqued to spec at the factory and worked loose due to relaxation across thermal cycles.
The heat due to the loose connection partially melted the whip side air hose, presumably choking the ID. This likely caused a double whammy of poor conductivity and poor air flow, contributing to the destruction of my consumables.
Unfortunately while the RazorCut 45 has a 3-year warranty, the torch is only 90 days so I’m SOL.
I believe this to be a manufacturing defect, either a design issue or more likely: incorrect assembly, proper steps not followed.
