Difference between revisions of "CNC Plasma Cutter"

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=== Job Crashes ===
 
=== Job Crashes ===
 +
 +
==== SmoothStepper Buffer Under run ====
 +
 +
'''Your work piece is trash, start again, home position lost'''
 +
 +
# Click through error
 +
# Start your job again
 +
 +
Causes:
 +
 +
* Communication error between smooth stepper and PC
 +
 +
 +
==== Touch off failure ====
 +
 +
'''Your work piece is not trash yet, but might be if you don't follow these steps'''
 +
 +
One of the following:
 +
 +
* Touch off get stuck with torch touching the plate
 +
* Touch off fails to detect plate and rams into the plate
 +
* Error probe ignored in status bar - If this is the case clean the shield nozzle, dross has gotten inside, do not move work piece
 +
 +
 +
# Hit escape '''ONCE''', not e-stop, not reset, escape
 +
# Double click in the g-code window to display line numbers  eg: 20:N0100 G91....  rather than N0100 G91....
 +
# Look for the current line, it should be highlighted and be: G31 Z -100
 +
# Look up a few lines for the torch moving to safe height: G00 Z1.5
 +
# In the operator console click in the line number box
 +
# Type in the line number of the safe hight move and hit return
 +
# Highlighted line should change to that line
 +
# Hit "Set next line" button
 +
# Hit cycle start
 +
 +
Causes:
 +
 +
* Dross has built up inside shield
 +
* Work piece is flapping around like a flag in a breeze, put some weights on it
 +
* Dross/corrosion on the plate cause a none conductive area where the torch touched off
 +
* Torch cable has become too taught and caused the probe connection to come loose or the probe ring not to touch the torch shield
 +
 +
 +
==== Torch fails to ignite ====
 +
 +
'''Your work piece is not trash yet, but might be if you don't follow these steps'''
 +
 +
Mach3 shows job stuck on M3 command.
 +
 +
# Hit F5 to re-ignite the torch (possibly twice)
 +
# Job should continue once M3 detects arc transfer signal from the plasma cutter
 +
 +
Causes:
 +
 +
* Unknown at this time
 +
 +
==== Mach3 Crash ====
 +
 +
'''Your work piece is trash, start again'''
 +
 +
# Shutdown the control box
 +
# Close Mach3
 +
# Turn on control box
 +
# Start Mach3
 +
# Run your job again
 +
 +
Causes:
 +
 +
* Unknown at this time
  
 
== Todo List ==
 
== Todo List ==

Revision as of 22:37, 10 May 2017

This tool is currently broken, please contact the area host for more information.


CNC Plasma Cutter
File:"IMAGENAME.JPG" (case sensitive, this is whatever you named the image when you uploaded it)
Owner/Loaner PS:One
Serial Number SERIAL NUMBER
Make/Model MODEL NUMBER
Arrival Date 10/16
Usability no
Contact CNC Area Host
Where Hot metals
Authorization Needed yes
Hackable no
Estimated Value $6000
Host Area CNC


CNC Plasma Cutter Area: CNC https://wiki.pumpingstationone.org/wiki/CNC_Plasma_Cutter



Pease talk to Tom Judge before tackling any items on this list.


PPE

  • Number 5 shades when a job is running
  • Thick gloves when handling freshly cut parts
  • Hearing protection recommended
  • Respirator/mask while cutting

Procedures

Machine Startup

  1. Wipe down machine with clean dry clotha
  2. Log in to machine
  3. Turn on air
  4. Make sure e-stop is depressed
  5. Turn on control box
  6. Start Mach3
  7. Clear e-stop
  8. Raise Z
  9. Move torch to end of table
  10. Remove torch shield and inspect for dross build up
  11. Reinstall torch shield
  12. Turn on plasma cutter
  13. Check cutter status (Air/torch/etc)

Machine Shutdown

  1. Hit e-stop
  2. Exit Mach3
  3. Turn off plasma cutter
  4. Turn off air
  5. Turn off control box
  6. Clean torch shield
  7. Sweep under table
  8. Wipe down machine with clean dry cloth
  9. Wipe down computer
  10. Leave the area cleaner than you found it

Running A Job

Job Crashes

SmoothStepper Buffer Under run

Your work piece is trash, start again, home position lost

  1. Click through error
  2. Start your job again

Causes:

  • Communication error between smooth stepper and PC


Touch off failure

Your work piece is not trash yet, but might be if you don't follow these steps

One of the following:

  • Touch off get stuck with torch touching the plate
  • Touch off fails to detect plate and rams into the plate
  • Error probe ignored in status bar - If this is the case clean the shield nozzle, dross has gotten inside, do not move work piece


  1. Hit escape ONCE, not e-stop, not reset, escape
  2. Double click in the g-code window to display line numbers eg: 20:N0100 G91.... rather than N0100 G91....
  3. Look for the current line, it should be highlighted and be: G31 Z -100
  4. Look up a few lines for the torch moving to safe height: G00 Z1.5
  5. In the operator console click in the line number box
  6. Type in the line number of the safe hight move and hit return
  7. Highlighted line should change to that line
  8. Hit "Set next line" button
  9. Hit cycle start

Causes:

  • Dross has built up inside shield
  • Work piece is flapping around like a flag in a breeze, put some weights on it
  • Dross/corrosion on the plate cause a none conductive area where the torch touched off
  • Torch cable has become too taught and caused the probe connection to come loose or the probe ring not to touch the torch shield


Torch fails to ignite

Your work piece is not trash yet, but might be if you don't follow these steps

Mach3 shows job stuck on M3 command.

  1. Hit F5 to re-ignite the torch (possibly twice)
  2. Job should continue once M3 detects arc transfer signal from the plasma cutter

Causes:

  • Unknown at this time

Mach3 Crash

Your work piece is trash, start again

  1. Shutdown the control box
  2. Close Mach3
  3. Turn on control box
  4. Start Mach3
  5. Run your job again

Causes:

  • Unknown at this time

Todo List

  • Air lines
  • Order water table
  • Plumb water table
  • Plumb new air lines
  • Limit switch covers
  • Hard stops
  • Scribe setup
  • Ventilation
  • Documentation

Future Items

  • Tube attachment
  • scribe attachment


Torch Consumables

The torch is a T45m hypertherm machine torch.

Standard

  • Deflector P/N: 2206732
  • Retaining Cap - Ohmic P/N: 220719
  • Nozzle P/N: 220671
  • Electrode P/N: 220669
  • Swirl Ring P/N: 220670

Fine Cut

NOTE: These parts are for a t30 unshielded torch, they are compatiable with the T45m when it is run at a setting lower than 30A and cutting materials thinner than 3/16". Ohmic sensing will not work with these parts installed.

  • Deflector P/N: 2206732
  • Retaining Cap - Ohmic P/N: 220483
  • Nozzle P/N: 220480
  • Electrode P/N: 220479
  • Swirl Ring P/N: 220478


Consumables catalog page


Feeds and Speeds

T45m Shielded Consumables

Mild Steel

Recommended Maximum
Arc Current (a) Material Thickness Torch-to-work distance (in) Initial Piece hieght (in) Pierce time delay (s) Cut Speed (ipm) Arc Voltage (V) Cut Speed (ipm) Arc Voltage (V)
30 0.018" 26Ga 0.06" 0.15" 0.0 360 117 400 118
0.030" 22Ga 340 116 400 117
0.036" 20Ga 320 115 400 117
0.060" 18Ga 0.2 225 111 280 115
45 0.036" 20Ga 0.06" 0.15" 0.0 380 115 400 112
0.060" 16 Ga 350 116 400 115
0.075" 14Ga 0.1 280 117 360 115
0.105" 12Ga 0.3 190 117 240 115
0.135" 10Ga 0.4 140 117 175 115
0.188" 3/16" 0.5 85 118 110 115
0.250" 1/4" 0.6 60 120 75 116
0.375" 3/8" 0.9 32 122 40 116
0.500" 1/2" Edge Start Recommended 20 132 25 125
0.625" 5/8" 11 138 14 127
0.750" 3/4" 8 140 10 131
1.000" 1" 4 146 5 142


Stainless Steel

Recommended Maximum
Arc Current (a) Material Thickness Torch-to-work distance (in) Initial Piece hieght (in) Pierce time delay (s) Cut Speed (ipm) Arc Voltage (V) Cut Speed (ipm) Arc Voltage (V)
30 0.018" 26Ga 0.06" 0.15" 0.0 360 117 400 123
0.030" 22Ga 340 116 400 121
0.036" 20Ga 320 115 400 119
0.060" 18Ga 0.2 145 111 185 118
45 0.036" 20Ga 0.06" 0.15" 0.0 300 115 400 109
0.060" 16 Ga 320 116 400 125
0.075" 14Ga 0.1 280 117 360 115
0.105" 12Ga 0.3 160 117 200 116
0.135" 10Ga 0.4 120 117 155 118
0.188" 3/16" 0.5 70 118 85 118
0.250" 1/4" 0.6 44 120 55 120
0.375" 3/8" 0.8 30 122 32 121
0.500" 1/2" Edge Start Recommended 14 132 18 128
0.750" 3/4" 7 140 9 131

Aluminium

Recommended Maximum
Arc Current (a) Material Thickness Torch-to-work distance (in) Initial Piece hieght (in) Pierce time delay (s) Cut Speed (ipm) Arc Voltage (V) Cut Speed (ipm) Arc Voltage (V)
30 0.018" 26Ga 0.06" 0.15" 0.0 360 117 400 120
0.060" 16Ga 0.2 340 118 400 121
0.075" 14Ga 215 118 270 121
45 0.060" 16Ga 0.06" 0.15" 0.0 360 116 400 114
0.075" 14Ga 340 117 400 116
0.105" 12 Ga 280 120 360 119
0.135" 10Ga 0.1 220 122 280 120
0.188" 3/16" 0.2 100 123 130 120
0.250" 1/4" 0.3 80 123 100 120
0.375" 3/8" 0.5 33 130 42 125
0.500" 1/2" Edge Start Recommended 20 134 25 130
0.750" 3/4" 8 143 10 138

T30v Unshielded Fine cut Consumables

Mild Steel

Recommended Maximum
Arc Current (a) Material Thickness Torch-to-work distance (in) Initial Piece hieght (in) Pierce time delay (s) Cut Speed (ipm) Arc Voltage (V) Cut Speed (ipm) Arc Voltage (V)
30 0.018" 26Ga 0.02 0.1 0.0 350 105 400 98
0.030" 22Ga 320 102 400 103
0.036" 20Ga 280 101 350 100
0.060" 16Ga 0.2 175 97 220 100
0.075" 14Ga 0.4 120 98 150 97
0.105" 12Ga 80 96 100 96
0.135" 10Ga 50 100 65 101

Stainless Steel

Recommended Maximum
Arc Current (a) Material Thickness Torch-to-work distance (in) Initial Piece hieght (in) Pierce time delay (s) Cut Speed (ipm) Arc Voltage (V) Cut Speed (ipm) Arc Voltage (V)
30 0.018" 26Ga 0.02 0.1 0.0 350 103 400 102
0.030" 22Ga 320 198 400 100
0.036" 20Ga 300 97 380 98
0.060" 16Ga 0.2 150 99 190 98
0.075" 14Ga 0.4 110 101 135 97
0.105" 12Ga 60 101 75 98
0.135" 10Ga 45 102 55 97



Aluminium

Recommended Maximum
Arc Current (a) Material Thickness Torch-to-work distance (in) Initial Piece hieght (in) Pierce time delay (s) Cut Speed (ipm) Arc Voltage (V) Cut Speed (ipm) Arc Voltage (V)
30 0.036" 20Ga 0.02 0.1 0.0 320 107 400 105
0.060" 16Ga 240 104 300 103
0.075" 14Ga 190 104 1240 103
0.105" 12Ga 0.2 145 103 180 103
0.135" 10Ga 95 101 120 101

Wiring

Stepper Coils

  • A+ Black
  • A- Green
  • B+ Red
  • B- Blue

Smooth Stepper Pin Mapping

C25 Interface board pins

SmoothStepper Target Device
Port Pin Type Device Connection Wire color
1 1 Output X Stepper Driver Pul+ Green
1 2 Output X Stepper Driver Dir+ Red
1 3 Output X Stepper Driver Ena+
1 4 Output Y Stepper Driver Pul+ Green
1 5 Output Y Stepper Driver Dir+ Red
1 6 Output Y Stepper Driver Ena+
1 7 Output THC Step In Green
1 8 Output THC Dir In Red
1 9 Output Z Stepper Driver Ena+
1 10 Input Plasma Interface Connector Torch Lit Out
1 11 Input Z Limit Connector 2 Grey
1 12 Input Y Limit Connector 2 Grey
1 13 Input X Limit Connector 2 Grey
1 14 Output A Stepper Driver Pul+ Green
1 15 Input E-Stop Switch Switch contact NC Grey
1 16 Output A Stepper Driver Dir+ Red
1 17 Output A Stepper Driver Ena+
2 1 Output Torch Relay Coil +
2 2 Input Touch off probe connector Pin 2
2 3 Input
2 4 Input
2 5 Input
2 6 Input
2 7 Input
2 8 Input
2 9 Input
2 10 Input
2 11 Input
2 12 Intput
2 13 Input
2 14 Output THC Enable relay Coil +
2 15 Input
2 16 Output
2 17 Output

Configuration

Stepper Drivers

Steps per inch: 1358

Driving current:

  • SW1 ON
  • SW2 ON
  • SW3 OFF

Holding Current:

  • SW4 OFF

Steps:

  • SW5
  • SW6
  • SW7
  • SW8

Parts

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