CNC Plasma Cutter
Status
Working. Stay tuned for an announcement about authorizations.
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
Safety and Protective Equipment
- 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
- Wipe down machine with clean dry clotha
- Log in to machine
- Turn on air
- Make sure e-stop is depressed
- Turn on control box
- Start Mach3
- Clear e-stop
- Raise Z
- Move torch to end of table
- Remove torch shield and inspect for dross build up
- Reinstall torch shield
- Turn on plasma cutter
- Check cutter status (Air/torch/etc)
Machine Shutdown
- Hit e-stop
- Exit Mach3
- Turn off plasma cutter
- Turn off air
- Turn off control box
- Clean torch shield
- Sweep under table
- Wipe down machine with clean dry cloth
- Wipe down computer
- 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
- 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 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:
- 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
- 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,ALook 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
- Shield P/N: 220673
- 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
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 | ? | 117 | 400 | 118 |
0.030" 22Ga | ? | 116 | 400 | 117 | ||||
0.036" 20Ga | ? | 115 | 400 | 117 | ||||
0.060" 18Ga | 0.2 | ? | 111 | 280 | 115 | |||
45 | 0.036" 20Ga | 0.06" | 0.15" | 0.0 | 380 | 115 | 400 | 112 |
0.060" 16 Ga | 150 | 116 | 400 | 115 | ||||
0.075" 14Ga | 0.1 | 150 | 117 | 360 | 115 | |||
0.105" 12Ga | 0.3 | 130 | 117 | 240 | 115 | |||
0.135" 10Ga | 0.4 | 110 | 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 | 4 | 132 | 25 | 125 | |||
0.625" 5/8" | 3 | 138 | 14 | 127 | ||||
0.750" 3/4" | 2 | 140 | 10 | 131 | ||||
1.000" 1" | ? | 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 | ? | 117 | 400 | 123 |
0.030" 22Ga | ? | 116 | 400 | 121 | ||||
0.036" 20Ga | ? | 115 | 400 | 119 | ||||
0.060" 18Ga | 0.2 | ? | 111 | 185 | 118 | |||
45 | 0.036" 20Ga | 0.06" | 0.15" | 0.0 | ? | 115 | 400 | 109 |
0.060" 16 Ga | 138 | 116 | 400 | 125 | ||||
0.075" 14Ga | 0.1 | ? | 117 | 360 | 115 | |||
0.105" 12Ga | 0.3 | ? | 117 | 200 | 116 | |||
0.135" 10Ga | 0.4 | ? | 117 | 155 | 118 | |||
0.188" 3/16" | 0.5 | ? | 118 | 85 | 118 | |||
0.250" 1/4" | 0.6 | ? | 120 | 55 | 120 | |||
0.375" 3/8" | 0.8 | ? | 122 | 32 | 121 | |||
0.500" 1/2" | Edge Start Recommended | ? | ? | 18 | 128 | |||
0.750" 3/4" | ? | ? | 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
- Steppers:
- Wantai 57BYGH115-003
- Nema 23 stepper motor
- 425oz-in torque
- 3 Amp
- Drivers:
- Wantai DQ542MA
- Manual: File:DQ542MA English Manual.pdf
- SmoothStepper Ethernet
- C25 Break out board
maintenance
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 |