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{{Template:EquipmentPage
{{Template:EquipmentPage
|owner = PS:One
|owner = PS:One
|certification = yes
|certification = yes
|hackable = no
|hackable = no
|model = MODEL NUMBER
|model = N.A.
|serial = SERIAL NUMBER
|serial = N.A.
|arrived = 10/16
|arrived = 10/16
|where = Hot metals
|where = Removed
|doesitwork = no
|doesitwork = yes
|contact = CNC Area Host
|contact = hotmetals at pumpingstationone.org
|value = $6000
|value = $6000
|image = "IMAGENAME.JPG" (case sensitive, this is whatever you named the image when you uploaded it)
|image = Cncplasma.jpg
}}
}}
= HOLD UP, THIS IS NOT THE TOOL YOU WANT! WE'VE REPLACED IT =
See [[Tormach 1300PL CNC Plasma Cutter]] for the new machine. Everything on this page is invalid and kept for historical purposes only.
= Machine =
== Status ==
As of 12/21, the table is essentially borked. Coolant splashed into the electronics box, shorting it out. There have been a number of issues with the table over the years and as of right now the thought is to scrap the existing machine and replace it with a new one.
=== Possible Options ===
https://stvcnc.com/product/sparx-cnc4x8-plasma-table/
https://www.langmuirsystems.com/xr
https://www.stylecnc.com/plasma-cutter/cnc-plasma-cutting-table.html
https://tormach.com/machines/plasma-tables.html#landing_packages (most expensive)
== Authorization ==
Authorization requirements:
* 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)_/¯).
* 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.
* 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
[[CNC Plasma Cutter Authorization]] 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 ===
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
# 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'''
=== 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 ===
*Double click on the code preview window to see the line number that mach3 assigns to the line. (mach3#:sheetcam# - example 11:N110)
*Be careful and be ready to hit the e-stop
*If you don't know the exact line to start from, find the line directly after a TCH off before the line the job stopped. If it errors on that line try moving to the next movement line. The job should do some air moves until the next probe.
*Type the number of the line in the area "Line:_____" right next to the red stop button.
*Type Enter. The gcode preview should jump to the line you typed in.
*Click the "Set next line" button.
*Click the green Cycle Start button.
=== The job stopped while probing (not z-crash or skipping steps) ===
*Record the g-code line where the machine stopped.
*Check to see if there are any errors. If there errors send a message to Slack about them.
*Be careful and be ready to hit the e-stop.
*Click "Reset" twice (the first time goes into estop mode and the second time comes out of it).
*Click "Cycle Start". The cnc should move to pierce height and then start cutting (generally running correctly again)
=== 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
==== 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
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:
* Un-reliable with the water table
* <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 ==
* Tube attachment
* scribe attachment
== Torch Consumables ==
== Torch Consumables ==
The torch is a T45m hypertherm machine torch.
The torch is a T45m hypertherm machine torch.
{| class="wikitable" border="1"
!colspan="3"|Consumables Change Log
|-
! Date
! What
! By
|-
|6/10/17
|electrode, nozzle
|Andrew Camardella
|-
|}
[http://www.thefabricator.com/article/plasmacutting/plasma-cutting-maintenance-are-you-throwing-money-away 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 ===
=== 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
[[:File:T45m.pdf|Consumables catalog page]]
[[:File:T45m.pdf|Consumables catalog page]]
== Feeds and Speeds ==
== Feeds and Speeds ==
|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
=== T30v Unshielded Fine cut Consumables ===
=== T30v Unshielded Fine cut Consumables ===
'''THERE IS CURRENTLY NO POST PROCESSOR FOR RUNNING WITH THESE CONSUMABLES INSTALLED'''
==== Mild Steel ====
==== Mild Steel ====
{| class="wikitable"
{| class="wikitable"
|THC
|THC
|Step In
|Step In
|Green
|-
|-
|1
|1
|THC
|THC
|Dir In
|Dir In
|Red
|-
|-
|1
|1
|Coil +
|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 ==
== Parts ==
* Steppers: 4 * 57BYGH115-003 Nema 23 stepper motor 425oz-in
* Steppers:
* Drivers: DQ542MA
** Wantai 57BYGH115-003
* SmoothStepper Ethernet
** Nema 23 stepper motor
* C25 Break out board (https://cnc4pc.com/motion-control/breakout-boards/c25-smooth-stepper-terminal-board.html)
** 425oz-in torque
** 3 Amp
* Drivers:
** Wantai DQ542MA
** Manual: [[File:DQ542MA_English_Manual.pdf]]
* 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
** https://cnc4pc.com/motion-control/breakout-boards/c25-smooth-stepper-terminal-board.html
** 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 ==
[[CNC_Plasma_Cutter_maintenance|maintenance page]]
== Authorization ==
=== Authorizers ===
* Andrew Camaradella - 45A auto Z only
* Ron Olson - 45A auto Z only
=== List of Currently Authorized Users - 45A Auto Z ===
{| class="wikitable" border="1"
! Qualified Member
! Trained By
! Date
|-
|Andrew Caramdella
|Danger Committee
|
|-
| Jake Chaitkin
| 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
|-
|}
=== List of Currently Authorized Users - 30A Fine Cut ===
{| class="wikitable" border="1"
! Qualified Member
! Trained By
! Date
|-
|Casey Olson
|Tom Judge
|-
| Jake Chaitkin
| Ron Olson
| 6/9/2018
|-
| Zack Sasnow
| Ron Olson
| 6/9/2018
|-}
|-
|}
[[Category:Removed Equipment]]
