CNC Plasma Cutter

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CNC Plasma Cutter
IMG 4045.JPG
Owner/Loaner PS:One
Serial Number N.A.
Make/Model N.A.
Arrival Date 10/16
Usability yes
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/CNC_Plasma_Cutter




Authorisation

Authorisation requirements:

  • You must have a project to compete on the tool during your authorisation
  • Your drawings must be reviewed by the authoriser before your scheduled session
  • Authorisations will take place with a maximum of 2 members
  • You must bring your own material with at least 1'x1' excess for machine tuning
  • You must be prepared for the machine to waste some material, its not perfect, be prepared for some waste

Unclear: who are the authorizers and how do you contact them?

CNC Plasma Cutter Authorisation has more details.

Drawing guidelines

  • No sharp corners, all corners should be filleted with at least a 1/16" radius
  • The thicker the part, the larger the smallest feature
    • Small holes 1/4" and under are not advisable
    • Holes under 3/4" on 3/8" plate are not advisable
    • Not all these sizes are learnt yet, this is why you need extra material
  • Acceptable drawing formats:
    • DXF
    • SWF
  • Acceptable drawing formats for review:
    • DXF
    • SWF
    • AI

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

Starting a job from a particular line of code (needs update)

  • Run from here
  • Select next line

Previewing a job (needs update)

  • Load file
  • Select the 'Run BLK' button in the interface or type Alt-N
  • Press the start job button - this will step through each line of code

(warning: includes torch homing and torch ignite so be careful)

  • You can step backwards though a job by pressing the 'reverse order' button.

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 happened:

  • 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

Do This:

  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

  • Documentation



Squareness todo:

  • Physical end stops - probably want to move the wiring out of the X axis tubes for this
  • Limit switches on A-axis (slaved to X, the rail against the wall)

This will allow both manual squareness and automatic machine homing. Mach 3 has a routine that will home the X axis with the slave, then adjust which ever one did not hit the home switch independently.


Water table todo:

  • Fix 2 pin hole leaks (one at each end of tank)
  • Fit bladder input line (so it doesn't collect crap in the tank)
  • Wash out old compressor tank
  • Trim the top of the side where the A axis hardware grazes the top of the tank.
  • Paint the outside of the tank
  • Treat the water with the green goo

Plumbing/wiring todo:

  • Extend air line to under table to create a manifold for table mounted air consumers
  • Run large conduit for 220 outlet for the plasma cutter
  • Run small conduit for data/estop between the table and the PC
  • Run black pipe for connecting the table to the bladder (old compressor tank)
  • Water line from north side of the shop, with input into the old compressor tank
  • Air lines to the compressor tank (one vent on from the compressor)
  • Run ethernet line to PC so its not on wifi any more
  • Z axis limit switches


Plate marker todo:

  • Design and cut new y-axis trolly or offset plate to carry torch and marker
  • Machine mount for engraver
  • Mount new trolly with air slide and Z axis
  • Plumbing and wiring
  • Pen mount as well as engraver?

35A Fine Cut todo:

  • Build floating Z axis using left over linear rail
  • How to multiplex the digitise input for touch off? Relays to switch digitise input from ohmic sensor to switch on head? (and disconnect the switch from the z limit array) (the switch should be in the z limit switch array by default incase the THC plunges the torch into the work piece)


Roundness/cut quality todo:

  • Y Axis pulsing - new connection spigot for drive year to fix eccentric rotation of gear
  • Remove and clean X axis gears, reinstall and use loctite on set screws (the keep backing off)
  • Make sure all bearings are right against the rails so there is no slop
  • Investigate backlash and configure mach3 is required - 0.0001 on X, Y and A
  • Get quote for installing ground rod next to the table and execute it
  • Look into THC issues (cut rippling) if still present after ground rod - possible Z axis flex in the mount to the Y carriage.
  • Why is the THC seeing ~80V for a good clean cut from the hypertherm? Is the internal voltage divider broken (is this why the machine was retrofitted with a dangerous high voltage tap?)? Or is this related to a bad ground at the table?
  • Motion pauses: (Seen on large 3'x2' complex cuts)
    • Why are there zero move G1's at the end of curves generated with G2's
    • Do we need to add a CV on G-Code in the preamble of the post processor - Does not appear to need this
    • Smooth stepper under-run errors - I have only seen this when jogging not cutting, mostly related to rapiding the Z, maybe reduce the micro stepping on the driver for the new threaded drive step count is huge per inch which could be hurting us
    • Axis and Core frequency tuning for the smooth stepper? - Dropped to 64k on X,Y,A
    • Look ahead tuning - increased to 150
    • Is CV plasma mode hurting us?
    • System problems, AV jamming things up? - low cpu load not an issue


Ohter things:

  • Cleaning/maintenance schedule
  • Shelves/lockers in the unused space under the table for project/tool/etc storage?
  • Materials storage ideas?
    • sheet goods
    • 20-24' bar/tube stock

Future Items

  • Tube attachment
  • scribe attachment


Torch Consumables

The torch is a T45m hypertherm machine torch.

Consumables Change Log
Date What By
6/10/17 electrode, nozzle Andrew Camardella

What does a worn electrode look like?

Torch tips components are consumables. If you are getting a wide kerf or the plasma torch isn't cutting through the materials anymore you may need to change the tip parts. To change the consumables disconnect the ground clip from the black retaining cap and unscrew the entire tip from the retaining cap.


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

THERE IS CURRENTLY NO POST PROCESSOR FOR RUNNING WITH THESE CONSUMABLES INSTALLED


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

THERE IS CURRENTLY NO POST PROCESSOR FOR RUNNING WITH THESE CONSUMABLES INSTALLED

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

maintenance

maintenance page


Authorization

Authorizers

  • Tom Judge - 45A and 30A fine cut consumables
  • Andrew Camaradella - 45A auto Z only
  • Ron Olsen - 45A auto Z only

List of Currently Authorized Users - 45A Auto Z

Qualified Member Trained By Date
Tom Judge Danger Committee
Andrew Caramdella Danger Committee

List of Currently Authorized Users - 30A Fine Cut

Qualified Member Trained By Date
Tom Judge Danger Committee
Casey Olson Tom Judge