Hypertherm XPR300 Breaker Tripping

Struqtural

New User
Location
Wisconsin
Occupation
Fabricator/Maintenance
So, I have somewhat of a head scratcher here.

I have an XPR300 that is used for plasma cutting on a Voortman V807 robotic cutting arm.

The inrush contactor/main contactors are good, checked all the grounds, software, cut charts, etc, but couldn't find anything out of the ordinary with Voortmans technical assistance.

The breaker that keeps tripping the main 125amp breaker leading into the hypertherm unit. Square D 125amp EDB34125.

Input current should be 91A at 480V.

After doing some research, I did find that the breaker is outside of the requirements for hypertherm, but the part I cannot understand is why it worked for half a year just fine, and only trips on specific steel parts such as angles and tubes.

The inrush should be the same for everything I am assuming, so why on Earth would it only trip on these parts specifically?

Could it the cut angle? Some sort of minute resistance change with those?

I will end up replacing the breaker itself with something more suitable, but I just wanted to reach out and ask if anyone else ever had this issue or could have some sort of logical, end all explanation as to why I can run large beams just fine, but not small angles without the breaker tripping randomly during the process.

Or if anyone has had this problem, any breaker suggestions?
 
Can you check the fall-of-potential across the breaker? The voltage drop across the breaker should be very close to zero, just a few millivolts. A bad connection can cause the breaker to heat up and trip.
 
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