Torch cutting off at the same time - suggestions on where to start looking?

CrossFire ® XR
1

Here are some pertinent details i know everyone wants before I get into it:

  • Hypertherm 45XP - yes i have swapped consumables… many times and these almost brand new
  • System has been setup and working great for almost 20 months so not a brand new system issue
  • I do have the wiring setup with all the ferrites/things to control EMI, dont think that is the problem at all
  • This happens with or without THC on, it does pass the THC test just fine
  • I have read alot of the troubleshooting and cleaned the Z axis, etc
  • I have not looked into wiring as I assumed that hasnt really changed and NOTHING has been moved to disconnected
  • The arc is strong and has great ground when it turns off so it isnt a poor ground issue

OK so I will try to post some photos or sample g-code later when I am back at the machine but I have been fighting this issue where my torch cuts off during cuts and it used to be occasional. I actually thought I fixed it a couple weeks ago with some of the suggestions in the forum however now its like clockwork where it starts a cut with a pierce, cuts the lead and then gets about 1" (or set period of time ~2-3 seconds) and then shuts off. I used the THC troubleshooting flow chart on the forums and the torch was originally picking up and turning off or sometimes just straight turning off. Cleaning it and being careful with the switch contacts fixed the THC rise but still this cut off has me stumped.

I am thiking I need to look into wiring, etc as something now isnt happy. I have not run a THC test again since it became like clockwork but instead came home to the comptuer to as for some help.

Anyone have any recommendations?

2

The razorweld machines have a history of issues with the internal regulator. It sounds like your air flow is dropping and shutting off the torch.

I would start with opening the machine and bypassing that regulator.

3

He’s rockin a hypertherm.

Air supply upstream?

Any lights going on, on the hypertherm when it cuts out?

4

Thanks. I missed that. I saw the 45 and must have glossed over the Hypertherm.

5

Good questions - air supply is great from what I can tell, plenty of pressure and flow. I also have a decent drying system (harbor frieght dryer with some additional large dessicant pack setups). Not of this has been altered (other than replacing dessicant) since I set up the machine in early 2024. There have been some times that the consumables light has kicked on but I am almost certain there were no lights that persisted after it happened (my plasma is on a shelf I made under the machine so I don’t always look at it). I will go try several more times however I do know the current consumables have only made 20-30 pierces and cut small parts. I just replaced them the time prior. Good suggestion and post more info.

It may see crazy but it seems like an environmental factor (or me bumping the machine) might be part of the issue. Often if it starts to act up then it will do it a lot, if I can get it to make a complete cut it will work for hours/days with no issue.

Another data point I wanted to mention is that if I turn THC off it will lose the arc but complete the program normally and refire the torch at each pierce but shut off like I am describing to go out at the exact same spot in the cut (was making a bunch of the same part in an row).