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Line 9: − + − + + − == Authorisation ==+ − Authorisation requirements:+ + + − + − + − + − * You must bring your own material with at least 1'x1' excess for machine tuning+ − − Unclear: who are the authorizers and how do you contact them?+ Line 42:
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Line 189: + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + − * Air lines+ − * Order water table − * Plumb water table − * Plumb new air lines − * Limit switch covers − * Hard stops − * Scribe setup − * Ventilation + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + Line 204:
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Line 335: − − − '''THERE IS CURRENTLY NO POST PROCESSOR FOR RUNNING WITH THESE CONSUMABLES INSTALLED''' − Line 254:
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Line 1,161: − * Tom Judge - 45A and 30A fine cut consumables − + Line 1,045:
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Line 1,220: + − |Danger Committee − | − + − + − + + + + + +
→Procedures: Added, Error: "Probe ignore, activated at call for probe"
|where = Hot metals
|where = Hot metals
|doesitwork = yes
|doesitwork = yes
|contact = CNC Area Host
|contact = hotmetals at pumpingstationone.org
|value = $6000
|value = $6000
|image = IMG_4045.JPG
|image = Cncplasma.jpg
}}
}}
== Status ==
Working.
== Authorization ==
Authorization requirements:
* You must have a project to compete on the tool during your authorisation
* This is not a commercial machine; it was hand-built at PS1 and as such there is no website to check, nor any manual to read. You must be willing to accept the fact that the machine can be quirky and you may have to do some troubleshooting when using it (hopefully not, but ¯\_(ツ)_/¯).
* Your drawings must be reviewed by the authoriser before your scheduled session
* You should be familiar with how plasma cutters work (at the very least, read this: https://en.wikipedia.org/wiki/Plasma_cutting). If you can swing it, please get authorized on the Miller handheld plasma machine beforehand; this is not a requirement, just a useful suggestion.
* Authorisations will take place with a maximum of 2 members
* Read all of this page about the machine: https://wiki.pumpingstationone.org/CNC_Plasma_Cutter
* Read and be willing to add your experience/knowledge of using the machine here: https://wiki.pumpingstationone.org/Talk:CNC_Plasma_Cutter
* You must be prepared for the machine to waste some material, its not perfect, be prepared for some waste
[[CNC Plasma Cutter Authorization]] has more details.
== Drawing guidelines ==
== Drawing guidelines ==
** AI
** AI
== PPE ==
== Safety and Protective Equipment ==
* Number 5 shades when a job is running
* Number 5 shades when a job is running
=== Machine Startup ===
=== Machine Startup ===
Fill water table if not filled already. Takes about 35 minutes to fill. Be sure to have the splash guard on it so when it's filled the air does not spray water everywhere.
# Wipe down machine with clean dry clotha
# Wipe down machine with clean dry clotha
# '''Leave the area cleaner than you found it'''
# '''Leave the area cleaner than you found it'''
=== Running A Job ===
=== Creating a Job ===
# Start SheetCam
# Import a Drawing from the File menu. Remember that the origin is at the bottom left on Sheetcam, and the origin on the machine is back left.
# Click on Operation => Plasma Cut
# Unfortunately most settings can be changed by other users between jobs. Some that seem to work:
** 130 ipm feed rate
** Tool: T11: Plasma 12 Gauge (or whatever gauge you're cutting)
** Note that Inside/Outside offset determines if you're trying to cut an inside edge or outside edge.
** You may need to select a layer.
# Click OK and the path should be generated and display.
# To create a TAP file go to the P icon at top left. That's post-processing.
# It should save as type G-code/.tap.
This is now a runnable job.
=== Running a Job ===
Look elsewhere for turning on the machine, filling the table, turning on the plasma cutter.
# Start Mach3 CNC
# You should be able to move the gantry using the arrow keys to get into position. You MUST start your job over metal - it does an auto z-axis zero/home.
# If "Reset" is flashing, click it to reset the connection.
# Test the job without the plasma on if you want.
# Turn on plasma cutter and close curtain.
# Click Cycle Start (green).
=== Starting a job from a particular line of code (needs update)===
=== Starting a job from a particular line of code (needs update)===
* Unknown at this time
* Unknown at this time
==== Error: "Probe ignore, activated at call for probe" ====
'''Tends to happen when attempting to reignite torch after first cut'''
Causes:
*THCv set to high, e.g. cutting 1/4" steel @45A recommended THCv is 115, lower to 114 or until the torch ignites successfully
== Sheet Cam ==
https://www.youtube.com/user/arclightdynamics/videos has good tutorials.
Sheet Cam settings always use the last setting. So double check it's what you want.
Origin is bottom left. Origin on the machine is back left. Brown box is the material size, but it doesn't need to be set.
It's a good idea to have a bounding box on your work so it's placed correctly.
Isolate paths by selecting them then put them in a new layer. This includes the previously mentioned bounding box.
Cuts can be inside edge, outside edge or on the line. A lead in is a good idea to help keep the cuts clean. Lead out has not been tested but may help.
The post-processor to use for this machine is named 'PS1 Plasma'. It's already included in the list of post-processors on the installed copy of SheetCam.
=== Manual Controls ===
* Arrow keys move X/Y
* Shift PageUp/PageDown moves the Z axis
Click the zero button to set home. (this is from memory, please correct -- Burton)
== Todo List ==
== Todo List ==
* Documentation
* 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:
* <s>Fix 2 pin hole leaks (one at each end of tank)</s>
* <s>Fit bladder input line (so it doesn't collect crap in the tank)</s>
* Wash out old compressor tank
* <s>Trim the top of the side where the A axis hardware grazes the top of the tank.</s>
* Paint the outside of the tank
* <s>Treat the water with the green goo</s>
Plumbing/wiring todo:
* Extend air line to under table to create a manifold for table mounted air consumers
* <s>Run large conduit for 220 outlet for the plasma cutter</s>
* 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
* <s>Air lines to the compressor tank (one vent on from the compressor)</s>
* <s>Run ethernet line to PC so its not on wifi any more</s> - ''WiFi for network access is fine''
* 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:
* <s>Y Axis pulsing - new connection spigot for drive year to fix eccentric rotation of gear</s>
* 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
* <s>Investigate backlash and configure mach3 is required</s> - 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
** <s>Do we need to add a CV on G-Code in the preamble of the post processor</s> - 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
** <s>Axis and Core frequency tuning for the smooth stepper?</s> - Dropped to 64k on X,Y,A
** <s>Look ahead tuning</s> - increased to 150
** Is CV plasma mode hurting us?
** <s>System problems, AV jamming things up?</s> - 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 ==
== Future Items ==
=== Standard ===
=== Standard ===
* Shield P/N: 220673
* Deflector P/N: 2206732
* Deflector P/N: 2206732
* Retaining Cap - Ohmic P/N: 220719
* Retaining Cap - Ohmic P/N: 220719
=== Fine Cut ===
=== 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.
'''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.
|rowspan="4"|0.15"
|rowspan="4"|0.15"
|rowspan="3"|0.0
|rowspan="3"|0.0
|360
|?
|117
|117
|400
|400
|-
|-
|0.030" 22Ga
|0.030" 22Ga
|340
|?
|116
|116
|400
|400
|-
|-
|0.036" 20Ga
|0.036" 20Ga
|320
|?
|115
|115
|400
|400
|0.060" 18Ga
|0.060" 18Ga
|0.2
|0.2
|225
|?
|111
|111
|280
|280
|-
|-
|0.060" 16 Ga
|0.060" 16 Ga
|350
|150
|116
|116
|400
|400
|0.075" 14Ga
|0.075" 14Ga
|0.1
|0.1
|280
|150
|117
|117
|360
|360
|0.105" 12Ga
|0.105" 12Ga
|0.3
|0.3
|190
|130
|117
|117
|240
|240
|0.135" 10Ga
|0.135" 10Ga
|0.4
|0.4
|140
|110
|117
|117
|175
|175
|0.500" 1/2"
|0.500" 1/2"
|colspan="2" rowspan="4"|Edge Start Recommended
|colspan="2" rowspan="4"|Edge Start Recommended
|20
|4
|132
|132
|25
|25
|-
|-
|0.625" 5/8"
|0.625" 5/8"
|11
|3
|138
|138
|14
|14
|-
|-
|0.750" 3/4"
|0.750" 3/4"
|8
|2
|140
|140
|10
|10
|-
|-
|1.000" 1"
|1.000" 1"
|4
|?
|146
|146
|5
|5
|-
|-
|}
|}
==== Stainless Steel ====
==== Stainless Steel ====
|rowspan="4"|0.15"
|rowspan="4"|0.15"
|rowspan="3"|0.0
|rowspan="3"|0.0
|360
|?
|117
|117
|400
|400
|-
|-
|0.030" 22Ga
|0.030" 22Ga
|340
|?
|116
|116
|400
|400
|-
|-
|0.036" 20Ga
|0.036" 20Ga
|320
|?
|115
|115
|400
|400
|0.060" 18Ga
|0.060" 18Ga
|0.2
|0.2
|145
|?
|111
|111
|185
|185
|rowspan="8"|0.15"
|rowspan="8"|0.15"
|rowspan="2"|0.0
|rowspan="2"|0.0
|300
|?
|115
|115
|400
|400
|-
|-
|0.060" 16 Ga
|0.060" 16 Ga
|320
|138
|116
|116
|400
|400
|0.075" 14Ga
|0.075" 14Ga
|0.1
|0.1
|280
|?
|117
|117
|360
|360
|0.105" 12Ga
|0.105" 12Ga
|0.3
|0.3
|160
|?
|117
|117
|200
|200
|0.135" 10Ga
|0.135" 10Ga
|0.4
|0.4
|120
|?
|117
|117
|155
|155
|0.188" 3/16"
|0.188" 3/16"
|0.5
|0.5
|70
|?
|118
|118
|85
|85
|0.250" 1/4"
|0.250" 1/4"
|0.6
|0.6
|44
|?
|120
|120
|55
|55
|0.375" 3/8"
|0.375" 3/8"
|0.8
|0.8
|30
|?
|122
|122
|32
|32
|0.500" 1/2"
|0.500" 1/2"
|colspan="2" rowspan="2"|Edge Start Recommended
|colspan="2" rowspan="2"|Edge Start Recommended
|14
|?
|132
|?
|18
|18
|128
|128
|-
|-
|0.750" 3/4"
|0.750" 3/4"
|7
|?
|140
|?
|9
|9
|131
|131
** Wantai DQ542MA
** Wantai DQ542MA
** Manual: [[File:DQ542MA_English_Manual.pdf]]
** Manual: [[File:DQ542MA_English_Manual.pdf]]
* SmoothStepper Ethernet
* Ethernet SmoothStepper
**https://warp9td.com/index.php/products
**https://warp9td.com/index.php/documentation/doc-ess
**https://warp9td.com/index.php/gettingstarted/setting-up-the-smoothstepper-and-mach#THC
* C25 Break out board
* C25 Break out board
** https://cnc4pc.com/motion-control/breakout-boards/c25-smooth-stepper-terminal-board.html
** https://cnc4pc.com/motion-control/breakout-boards/c25-smooth-stepper-terminal-board.html
** Manual: [[File:C25R3_1_USER_MANUAL.pdf]]
** Manual: [[File:C25R3_1_USER_MANUAL.pdf]]
*Torch height control
**Proma Compact THC
**http://proma-elektronika.com/download/PDF/thcsd_en.pdf
**http://proma-elektronika.com/index.php/en/products/thc-torch-height-control/compact-thc-sd
==maintenance ==
==maintenance ==
=== Authorizers ===
=== Authorizers ===
* Andrew Camaradella - 45A auto Z only
* Andrew Camaradella - 45A auto Z only
* Ron Olsen - 45A auto Z only
* Ron Olson - 45A auto Z only
=== List of Currently Authorized Users - 45A Auto Z ===
=== List of Currently Authorized Users - 45A Auto Z ===
! Date
! Date
|-
|-
|Tom Judge
|Andrew Caramdella
|Danger Committee
|Danger Committee
|
|
|-
|-
|Andrew Caramdella
| Jake Chaitkin
|Danger Committee
| Ron Olson
|
| 6/9/2018
|-
| Zack Sasnow
| Ron Olson
| 6/9/2018
|-
| Erik Wessing
| Ron Olson
| 6/9/2018
|-
|Ryan Pierce
|Ron Olson
|9/2/18
|-
|Glenn Powers
|Ron Olson
|10/21/18
|-
|Sam Paris
|Ron Olson
|10/21/18
|-
|Farsheed Hamidi-Toosi
|Ron Olson
|10/21/18
|-
|Oliver Sanchez
|Ron Olson
|01/29/19
|-
|Greg Bell
|Ron Olson
|03/23/19
|-
|-
|}
|}
! Date
! Date
|-
|-
|Casey Olson
|Tom Judge
|Tom Judge
|-
|-
|Casey Olson
| Jake Chaitkin
|Tom Judge
| Ron Olson
|
| 6/9/2018
|-
| Zack Sasnow
| Ron Olson
| 6/9/2018
|-}
|-
|-
|}
|}