If you’re facing the frustration of a misfiring plasma cutter, you know how disruptive it can be to your workflow. Maintaining efficiency and achieving clean cuts are top priorities for fabricators, and experiencing equipment misfires can get you behind schedule and interfere with the quality of your work.
If your plasma cutter is misfiring during use, it’s important to determine the underlying cause to avoid further disruptions. Let’s troubleshoot some of the reasons why your plasma cutter is misfiring to achieve smooth operation and a satisfactory cut every time.
Improper Air Pressure
Check the air pressure if your plasma cutter is misfiring. Air pressure that is set too low can prevent the equipment from being cut properly. When the air pressure is set too high, the plasma cutter can start to sputter. Always ensure that the air pressure is set to the correct level for your specific machine before attempting to cut. If necessary, refer back to the instruction manual for guidance.
Incorrect Gas Flow Settings
Wrong gas pressure can lead to cut-quality issues, misfiring, and possible deterioration of components. Gas pressure that’s too low can prevent the arc from achieving a clean cut due to a weak arc, and when the gas pressure is too high, the arc can be unstable. Before use, always check the gas pressure settings, ensuring that it never exceeds factory-recommended settings.
If the settings appear correct, inspect the hoses and wires for visible damage or loose connections. Clean the hoses and wires responsible for carrying gas to the torch, as there could be built-up dirt, dust, or moisture that is dissipating the energy.
Worn or Deteriorated Parts
Wear and tear of the torch head on the plasma cutting table can contribute to a wide range of problems, such as misfiring. Regularly inspect your equipment for visible signs of wear and replace parts as needed. One part that requires regular inspection is the nozzle. The nozzle can experience slag, especially if it’s not routinely cleaned.
Early deterioration of parts can occur for several reasons. A slow travel speed when cutting can lead to overheating of the torch consumables, causing the parts to wear out prematurely. Dragging the torch nozzle on the workpiece repeatedly can damage the shield cap and cause the nozzle to overheat, exposing it to slag and leading to premature wear.
To ensure that your cutting machine continues to operate efficiently for as long as possible, Hornet offers its Protection Plus Consumable Loyalty Program, developed exclusively for Hornet customers. Receive exclusive discounts on parts, service, maintenance, and consumables, as well as peace of mind that your machine is in good hands.
Improper Torch Height and Amperage
When verifying the settings on your plasma cutter, check that both the pierce height and cut height are at appropriate levels. When the height is too low, the torch can become splashed with molten metal as it may be too close to the plate. This prevents the arc from transferring, resulting in a misfire. If the torch is too high, just the tip of the arc will reach the plate, leading to a positive bevel and top-edge rounding. This is made easy with the Hypertherm Torch Height Control or THC, where height automatically adjusts between pierce and cut height.
Correct amperage is also critical to ensure a smooth operation. The amperage must be set based on the type of material being cut and its thickness. Check the owner’s manual to verify the correct amperage to prevent reduced cut quality and a possible shorter equipment lifespan.
Electrical or Power Issues
Misfiring of a plasma cutter can occur when the main power supply doesn’t provide the machine with adequate power. It’s important to confirm that the power supply is not fluctuating and that you are meeting the specified power requirements outlined in the owner’s manual. Sometimes this can be caused by “dirty power” or inconsistent power from a municiple power source. In addition, you’ll want to check the infrared temperature to determine if it’s too high which could mean the earth ground needs to be replaced.
Pay attention to whether the arc appears weak or inconsistent. If the machine is not arcing, it may be due to poor contact between the workpiece and ground wiring. A burnt-out touch nozzle and low air pressure can also cause these issues. Repair often means checking the wire that is attached to the ground clamp to ensure that it’s securely connected. Also, check that the torch nozzle is properly installed.
If you’re looking for other ways to maximize the performance of your machine and increase overall production, ask us about our retrofit services. Modernizing your plasma cutting machine with the latest innovations and technologies can increase cut quality and efficiency without having to replace the entire machine.
Damaged O-Ring
Misfiring and other problems can sometimes develop due to a damaged O-ring. When the O-ring is damaged, coolant and gas can combine in the consumable chamber of the torch, reducing cut quality and interfering with operation. Too much or too little O-ring lube can also be a problem source, as too much can attract dirt and dust particles, while too little can damage the O-ring.
A damaged O-ring can also cause misfiring as it can cause improper gas flow surrounding the electrode. This essentially disrupts the arc formation due to inconstant pressure or leaks, often due to a worn-out or incorrect size O-ring. If you suspect that the O-ring is the cause of the misfiring, inspect it for signs of damage, wear, or contamination. Replace it if damaged with a new one of the proper size and material.
Addition of a Circular Lead-Out
Adding a circular lead-out when cutting holes can cause the arc to snap off before the power supply has the chance to properly shut down. Over time, this can reduce the lifespan of the electrode. It’s important to properly manage the gas pressure at the start and end of the cut to prevent a shortened consumable life. The right programming of the machine can help eliminate lead-out at the end of your cuts.
Contact Your CNC Cutting Table Experts
If your plasma cutter is misfiring, it’s essential to troubleshoot the issue to prevent poor cut quality and ensure optimal performance. Common causes of this problem, such as inadequate air supply, improper settings, and worn consumables, can often be managed with regular maintenance and the timely replacement of parts.
At Hornet Cutting Systems, we proudly design and manufacture industry-leading CNC cutting machines in Valley Center, Kansas, distributing our American-made products worldwide. As a 100% American-owned company, we specialize in helping you find the perfect cutting table tailored to your unique project specifications. Our team of experts considers critical factors such as material type, dimensions, and thickness to recommend a cutting solution that minimizes issues like misfiring. Contact us today at 1-844-209-5552 to learn more about our CNC plasma tables or discover how you can save tens of thousands on a used cutting table.
