Torch Height and Amperage

[markabowdish]

Hello,

I am having issues with my Torch height while cutting.

If I put a large sheet of steel in with differences in height from the shearing or having some waves from storage maybe +- .125 of an inch. the torch is scraping or running into the material. it does not change the z height as it cuts to compensate for the material variance. this has caused some crashes.

I have been getting around this by setting the torch cut height to .1 instead of .06 and it will still lightly scrape the steel in some spots

THC is enabled, set to set to auto, torch calibration has been done successfully. the torch touches off and starts just as it should.

I can post a report when I get back to my shop. But is there a setting I am missing? or am I incorrect on how the THC works?

Also with amperage with a hypertherm 45xp is it best to always have the machine set to max amp settings for each thickness of steel? does the controller compensate for this or does one have to always set the amperage on the plasma machine manually for the best cut on different materials?

Thanks for any knowledge or ideas, Im always learning.

[Joey]

A report will help to verify the THC is working correctly. Turn the Plot on in the Utility menu to help build more plots when cutting.

Make sure the correct profile set is loaded into the Profile manager. Just make sure the Hypertherm amperage setting is the same as the profile selected.

For the 45 XP the best cut quality is usually at the max amperage setting. I would only turn down the Amperage for thin materials so the feed rate will not have to be so fast.

[markabowdish]

Report attached

[Joey]

I don't see any Good THC plots.

All the Plots have High voltage cycling.

I would not fire the torch anymore.

Can you Post Pictures of the Cabinet and how the THC and Acorn kits are wired? More pictures the Better!

On the Bright side the Plots all look the same. So its probably something in the initial wiring.

Not like it started out good and then something bad happened.

[markabowdish]

Joey,

I did another THC bench test again just to double check the THC and it performed fine.

Can this be a grounding issue with the table and unit? Or a lack there of.

I have read the hypertherm bulletin on grounding. And have work to do.

[Joey]

Yes or the TX board connection to the Hypertherm is incorrect.

Most likely a ground loop in the Cabinet.

Pictures of all the connections would help.

[markabowdish]

I have double checked the CPC to the THC I am 99% sure it is correct. (1% unsure because its not working)

Attached is photos of the cabinet, Its a doozy,

after reviewing the schematics I see that I am missing a wire from the ground to the common on the main power supply that powers the acorn board.


For the THC 24v power supply, I am grabbing 110 from the wall connected to the Main power supply.

I have heard of ground loops, I have never dealt with them and not quite sure what I'm looking for. but I'm ready to learn something new today. Let me know what other pictures or Explanations of the cabinet you need.

[Joey]

To help fight ground loops

All Grounds in the cabinet should be connected at a single point.

All grounds will connect at the ground bus bar that is mounted/continuity to the sub panel that is also mounted and has continuity to the cabinet.

As for the Acorn power supply connecting the ground and COM is needed to prevent Interference on the Acorn.

Shielded cable for the Hypertherm CNC cable is also recommended and should terminate as close to the TX as possible.

Try to also keep any other wires from running cover or close to the THC boards and Acorn.

That should be a good start. Looking at the LIVE Plot in the PID Config menu should help give you an idea of any ground loop or interference in the Cabinet.

[ShawnM]

Looking at his cabinet photos the grounds are all over the place and many dont appear to be connected together. They must all come to a single bus bar that is earth grounded.

[markabowdish]

So I have cleaned up my grounds, added more grounds per hypertherm tech, Shielded wiring from THC to hypertherm IO cable, removed any wires running next to THC,


I have not driven a ground rod separate for the machine, ( im not against it Id like to just see the THC work before taking on that project). If the separate earth ground is necessary for the THC to just work at all ill do it, It is my understanding from the report that the THC has never worked. can this be because of no separate earth ground? Currently its grounded through the Wall outlet. I understand this is not ideal


I ran a simple square and circle program in dry run, Not firing the torch and the THC still did not work tip of the torch dragged on the steel in some spots. does the THC work in dry run? is there a way to test THC without firing the torch?

Attached is a snip of the PID live plot.

And a report is attached.