Creepy
C&CNC Digital Torch Height Control card install in Hypertherm PowerMax45.
re-did the strain relief on the high voltage lines. the first one i tried was a little shady.
[img]http://i5.photobucket.com/albums/y166/chopshop69/plasma%20table/DSC000052.jpg[/img]
[img]http://i5.photobucket.com/albums/y166/chopshop69/plasma%20table/DSC000062.jpg[/img]
perfect, you can't tug the wire.
[img]http://i5.photobucket.com/albums/y166/chopshop69/plasma%20table/DSC000072.jpg[/img]
This circuit board interfaces the plasma cutter. It takes the raw arc voltage and provides the signal to the controller so it can montor and change the arc gap in real time. The torch tip will raise and lower as it cuts to maintain the perfect arc gap
It also has torch on/off, and senses when plasma arc is ready to cut after the initial firing.
[img]http://i5.photobucket.com/albums/y166/chopshop69/plasma%20table/DSC00008.jpg[/img]
i need to mount the board near the plasma, but it won't fit inside. Hmm, what's cheap or free, in my house? tupperware? naw, too ugly.
Umm.....dang, what about all those model cars i got, inside one of them? lol Oh wait! That gives me an idea...a display case!
I store the model collection at my buddies place, I called him and asked him to go out and grab me a display case. Went and picked it up, looks like it will work.
I scabbed all the hardware off an old computer to mount it with.
[img]http://i5.photobucket.com/albums/y166/chopshop69/plasma%20table/DSC00018.jpg[/img]
Made up some wire ends for the PM45 rear pinout port. One of the maintenance guys at work helped me, he had the special $$$$ crimpers. Still using the 18AWG.
[img]http://i5.photobucket.com/albums/y166/chopshop69/plasma%20table/DSC000042.jpg[/img]
"heatshrank" the pinouts lol is that a word?
[img]http://i5.photobucket.com/albums/y166/chopshop69/plasma%20table/DSC000092.jpg[/img]
pinouts for "torch on/off" 3&4.
[img]http://i5.photobucket.com/albums/y166/chopshop69/plasma%20table/DSC00011.jpg[/img]
pinouts for "arc transfer", also called "ok to move" 12&14
[img]http://i5.photobucket.com/albums/y166/chopshop69/plasma%20table/DSC000122.jpg[/img]
arc voltage to the right, trigger at top, arc transfer left
[img]http://i5.photobucket.com/albums/y166/chopshop69/plasma%20table/DSC00023.jpg[/img]
[img]http://i5.photobucket.com/albums/y166/chopshop69/plasma%20table/DSC00024.jpg[/img]
frig, it fits on the top of the plasma perfectly. 8-) So cool!
I removed the plasma case again and mounted the display case to it. super happy with it.
[img]http://i5.photobucket.com/albums/y166/chopshop69/plasma%20table/DSC00021.jpg[/img]
There is a DB9 cable out the the controller too, I put that to the front as the grounds must be isolated between the plasma setup and the controller . Wires will be run away from each other, the plasma chassis grounds to the table, the controller/pc thru the AC lines only.
[img]http://i5.photobucket.com/albums/y166/chopshop69/plasma%20table/DSC00029.jpg[/img]
;D epoxied that little guy in there. looks like 42's and no lift ;) and a Creepy sticker to round off the install. Tested the card, LED on, it works, this is a BIG step towards making sparks by the weekend.
[img]http://i5.photobucket.com/albums/y166/chopshop69/plasma%20table/DSC00031.jpg[/img]
I always say "i hate wiring" , but I think i like it, i just don't like being upside down under a dash.
The torch fired manually....gotta gear something up to keep the wires safe, then i think I'll be cutting something over the weekend. :?
Creepy
first cut.
[img]http://i5.photobucket.com/albums/y166/chopshop69/plasma%20table/DSC00037.jpg[/img]
[img]http://i5.photobucket.com/albums/y166/chopshop69/plasma%20table/DSC00048.jpg[/img]
first 3 hours frigging around.
[img]http://i5.photobucket.com/albums/y166/chopshop69/plasma%20table/DSC00059.jpg[/img]
1/8"
[img]http://i5.photobucket.com/albums/y166/chopshop69/plasma%20table/DSC00045.jpg[/img]
[img]http://i5.photobucket.com/albums/y166/chopshop69/plasma%20table/DSC00051.jpg[/img]
1/16", 50imp, 27ish amps
[img]http://i5.photobucket.com/albums/y166/chopshop69/plasma%20table/DSC00054.jpg[/img]
[img]http://i5.photobucket.com/albums/y166/chopshop69/plasma%20table/DSC00056.jpg[/img]
gotta get the sheetcam liscence monday, had to edit out a bunch of Z axis stuff and run a set torch height to make these practice cuts. the scrap metal was warped, so I didn't try too hard to get a great finish. but its really good for first cuts. interpolation smoothness is very good.
jeepsr4ever
Looking like a great start! Keep posting cut pics and video if you can we love it!
beatnikcustoms
Creepy, Where did you get the mount for the machine tourch? I will need to get one for my table. Also what installer profile did you use for you Mach?
Thanks,
Chris
Creepy
made the aluminum torch clamp, bored out 1.375", drilled and tapped (2) 1/4"-20 holes for the clamp, (2) 1/4" holes thru to mount on the upside down stock bracket. I let the full tip sit below the bottom of the floating head. about 1/2" clearance to work when cutting.
the profile instructions posted here aren't quite right. I used the 3000 stuff. I'd have to go look at exactly what its called, but its NOT the mp1000 series stuff. The DTHC manual included from c&cnc support disc had the proper instructions.
I'm still trying to get the DTHC to read volts while cutting, the flyout menu's for jog doesn't work.
Creepy
checked the profile i'm running...its MP3000-DTHC-UBOB2.
and got an answer about the jog screen, its not configured for the plasma profiles, its not a bug. torchhead guy said to use the keyboard and get a game controller, the flyout screen isn't used much.
on another topic - getting a stainless water tray made, will be ready thru the week. going to make a new slat setup, and save the stockers for dry cutting aluminum if the need may arise. oer make a frame for a light cutting table out in the yard.
i gotta get some home switches for x/y too. I'm used to homes, would prefer to work from reference on a big sheet.
Creepy
oh yeah, I'm working away out there. trying to tune the cuts.
[img]http://i5.photobucket.com/albums/y166/chopshop69/plasma%20table/DSC00081.jpg[/img]
[img]http://i5.photobucket.com/albums/y166/chopshop69/plasma%20table/DSC00066.jpg[/img]
the dimensional accuracy is excellent, working on the finish.
drew up some test pieces, working on feeds, getting rid of dross, and as it turns out, some ridigity issues.
this started happening and quickly got worse. gross. something is moving/not rigid. looking at the toolholder.
[img]http://i5.photobucket.com/albums/y166/chopshop69/plasma%20table/DSC00075.jpg[/img]
hhmm, floating head on Z is shakey, needed to preload these two bottom bearings on the rail. the one on the left is adjustable on a cam to preload.
[img]http://i5.photobucket.com/albums/y166/chopshop69/plasma%20table/DSC00063.jpg[/img]
frigged with that a bit.
[img]http://i5.photobucket.com/albums/y166/chopshop69/plasma%20table/DSC00065.jpg[/img]
[img]http://i5.photobucket.com/albums/y166/chopshop69/plasma%20table/DSC00076.jpg[/img]
here it is rigid again, and I have turned on the corner decelleration feature, cutting at 400imp.
[img]http://i5.photobucket.com/albums/y166/chopshop69/plasma%20table/DSC00077.jpg[/img]
yep. :) that's 2x2x1" hole in 14G.
[img]http://i5.photobucket.com/albums/y166/chopshop69/plasma%20table/DSC00079.jpg[/img]
Easy fix.
OK, enough screwing around.
Here is a CJ motor mount plate in 9/16" hardplate. about 15 seconds to cut out. I drew it up in autocad first.
[img]http://i5.photobucket.com/albums/y166/chopshop69/plasma%20table/DSC00083.jpg[/img]
[img]http://i5.photobucket.com/albums/y166/chopshop69/plasma%20table/DSC00084.jpg[/img]
[img]http://i5.photobucket.com/albums/y166/chopshop69/plasma%20table/DSC00085.jpg[/img]
apparently thick stuff is easier. :o Its damn near perfect running recommended settings, and I don't even have the voltage monitoring tip height working yet.
Stainless water tray from local sheetmetal shop will be ready soon, looking forward to getting the water system working. The dust sucks ass, a mask i was wearing looks like i was hanging my head over the blast furnace at the steel plant. orange dust.
oddly, with the dust, the thick metal isn't 1/2 as bad as cutting the thin stuff.
Creepy
5/16" lead in/out tests
[img]http://i5.photobucket.com/albums/y166/chopshop69/plasma%20table/DSC000053.jpg[/img]
[img]http://i5.photobucket.com/albums/y166/chopshop69/plasma%20table/DSC000063.jpg[/img]
[URL=http://s5.photobucket.com/albums/y166/chopshop69/plasma%20table/?action=view¤t=MOV00001.flv][img]http://i5.photobucket.com/albums/y166/chopshop69/plasma%20table/th_MOV00001.jpg[/img][/URL]
[URL=http://s5.photobucket.com/albums/y166/chopshop69/plasma%20table/?action=view¤t=MOV00002.flv][img]http://i5.photobucket.com/albums/y166/chopshop69/plasma%20table/th_MOV00002.jpg[/img][/URL]
Creepy
here's my first paying job......its for a Suzuki 450LTR. chain guard for rear sprocket out of 1/4" hardplate.
[img]http://i5.photobucket.com/albums/y166/chopshop69/plasma%20table/DSC000073.jpg[/img]
[img]http://i5.photobucket.com/albums/y166/chopshop69/plasma%20table/DSC000093.jpg[/img]
[img]http://i5.photobucket.com/albums/y166/chopshop69/plasma%20table/DSC000112.jpg[/img]
[img]http://i5.photobucket.com/albums/y166/chopshop69/plasma%20table/DSC000103.jpg[/img]
[img]http://i5.photobucket.com/albums/y166/chopshop69/plasma%20table/DSC000083.jpg[/img]
some frigging around.
[img]http://i5.photobucket.com/albums/y166/chopshop69/plasma%20table/DSC000143.jpg[/img]
[img]http://i5.photobucket.com/albums/y166/chopshop69/plasma%20table/DSC000123.jpg[/img]
[img]http://i5.photobucket.com/albums/y166/chopshop69/plasma%20table/DSC000133.jpg[/img]
CJ V8 motor mounts.
[img]http://i5.photobucket.com/albums/y166/chopshop69/plasma%20table/DSC000153.jpg[/img]
Creepy
Working on brackets for the cable carriers. I'll post up the .dxf once I'm done. and the cable carrier #'s.
No water tray yet, the shop is taking forever, but its really cheap.
Here's a vid showing the motion without the plasma on ruining the focus. feed was at 10% just at the start so I could get over to the controller and camera.
[URL=http://s5.photobucket.com/albums/y166/chopshop69/plasma%20table/?action=view¤t=MOV00017.flv][img]http://i5.photobucket.com/albums/y166/chopshop69/plasma%20table/th_MOV00017.jpg[/img][/URL]
Hope you like GWAR! lol, i didn't realize how loud it was.
Creepy
Been making brackets for the cable carrier, the machine is reproducing. ;)
its the raw steel one
[img]http://i5.photobucket.com/albums/y166/chopshop69/plasma%20table/DSC00003.jpg[/img]
complicated to wiggle around the 2 motors and stuff. motors removed for fit up.
[img]http://i5.photobucket.com/albums/y166/chopshop69/plasma%20table/DSC00002.jpg[/img]
[img]http://i5.photobucket.com/albums/y166/chopshop69/plasma%20table/DSC00016-1.jpg[/img]
[img]http://i5.photobucket.com/albums/y166/chopshop69/plasma%20table/DSC00005.jpg[/img]
[img]http://i5.photobucket.com/albums/y166/chopshop69/plasma%20table/DSC00006-1.jpg[/img]
[img]http://i5.photobucket.com/albums/y166/chopshop69/plasma%20table/DSC00007.jpg[/img]
[img]http://i5.photobucket.com/albums/y166/chopshop69/plasma%20table/DSC00008-1.jpg[/img]
[img]http://i5.photobucket.com/albums/y166/chopshop69/plasma%20table/DSC00009.jpg[/img]
bending it up
[img]http://i5.photobucket.com/albums/y166/chopshop69/plasma%20table/DSC00010-1.jpg[/img]
[img]http://i5.photobucket.com/albums/y166/chopshop69/plasma%20table/DSC00011-1.jpg[/img]
[img]http://i5.photobucket.com/albums/y166/chopshop69/plasma%20table/DSC00012-1.jpg[/img]
[img]http://i5.photobucket.com/albums/y166/chopshop69/plasma%20table/DSC00013.jpg[/img]
you only have to run the carrier from the mid point of the travel, I bought a little extra to make the run right across.
It was $195CAD including $50 shipping, for 10' and two mount kits. not too bad, its high quality stuff, looks great and works really smooth.
[img]http://i5.photobucket.com/albums/y166/chopshop69/plasma%20table/DSC00015-1.jpg[/img]
[img]http://i5.photobucket.com/albums/y166/chopshop69/plasma%20table/DSC00014.jpg[/img]
wires all in
[img]http://i5.photobucket.com/albums/y166/chopshop69/plasma%20table/DSC00017.jpg[/img]
Now I will move to the other axis and run a cable carrier down the side.
jeepsr4ever
When we install a cable carrier we like to include the torch lead into it. You did an outstanding job on yours! :t: Dont be afraid to run your table by the book. Check the other posts in this area for book speeds.
Creepy
The torch lead in with the motor wires is said to cause interference/noise and affect smooth operation of the motor, so I left it out. I have no experience with it, just what i was reading on-line and in the c&cnc manuals pertaining to grounding.
there is room to jam it in there if I feel like it later, it would be so much cleaner looking...i don't like it out, going to have to make a boom.
Creepy
Still waiting for the water table, its really holding me up now.
I can't mount the electronics to the table until i get the tray, so I've been working towards having everything ready to drop in place when the stainless water tray is done. The plasma and drives are mounted on the rear, the power supply and pc goes on the right side under the stainless desk.
I finished the cable carriers tho, any wires you see out will be inside the skins.
[img]http://i5.photobucket.com/albums/y166/chopshop69/plasma%20table/DSC000054.jpg[/img]
[img]http://i5.photobucket.com/albums/y166/chopshop69/plasma%20table/DSC000023.jpg[/img]
good shot of the 'no wires' hanging from the ceiling. Everything is run in the cable carrier, which follows the movements of the table. The wires are all locked in there, can't move.
[img]http://i5.photobucket.com/albums/y166/chopshop69/plasma%20table/DSC000034.jpg[/img]
ripping up a 4x8 sheet to skin in the sides.
[img]http://i5.photobucket.com/albums/y166/chopshop69/plasma%20table/DSC000013.jpg[/img]
skin with mounts holes, clearance hole for a bracket, and a spot for a couple of electrical fittings to pass the wires thru clean.
[img]http://i5.photobucket.com/albums/y166/chopshop69/plasma%20table/DSC000064.jpg[/img]
detail of pass thru fitting.
[img]http://i5.photobucket.com/albums/y166/chopshop69/plasma%20table/DSC000074.jpg[/img]
So I'm 1/2 building the table still, and half making parts while waiting. busy!
Creepy
Skipping ahead here a bunch - here is the first cut over water in the stainless tray. i have a bunch more build pics to get posted of the in between.
I wound up putting the plasma torch line in the cable carriers after proving to myself it wouldn't mess up the THC or motors.
Man, was the system ever picky about grounding before the DTHC would work. I pounded a 4' rod thru the floor into dirt and ran some booster cables from the table to the rod and the DTCH just started working like majic. Don't ignore the grounding! gantry, Z head, table chassis, plasma case all ground thru the floor post.
as for the water table - Smoke is all but eliminated!!! The water is 2" deep, and 1/4" under the material. There is a 60G air pig laying underneath plumbed with a 1.5" drain to the table, and i'm going to put an air chuck and gate valve on it to raise/lower the level. which i don't anticipate having to do much. fawking rust......the tray, water and slats were beautiful on installation, so clean and clear. Overnite the slats rusted and the water is now brown for life. lol
Just a few small things left, but its sooooo close to done!!
vid ran out of memory b4 end of cut. ::)
[URL=http://s5.photobucket.com/albums/y166/chopshop69/plasma%20table/?action=view¤t=MOV00328.flv][img]http://i5.photobucket.com/albums/y166/chopshop69/plasma%20table/th_MOV00328.jpg[/img][/URL]
jeepsr4ever
We have a new water tray/slat system coming out for these tables with an adendum to the print. I cant seem to load your movie. Also what operating system are you using?
Creepy
movie is just on photobucket, it works for the guys on my forum. I'll check the privacy settings...its in the same folder as the previous vid tho, does that work for you?
Operating system is Windows XP. no issues, runs good with SheetCAM TNG and Mach3 open and the machine running. That's all I have on the computer, its dedicated to the table.
i'm gonna put AutoCAd on it and see if it is still ok, I've got a muddy path worn between the house pc and the shop to fix drawings with ye olde flash drive.
Mudrat
[quote=Creepy]
as for the water table - Smoke is all but eliminated!!!
Just a few small things left, but its sooooo close to done!![/quote]
What were you cutting?
sadisticiron
what size cable carriers did u get
Creepy
was cutting mild steel, 14G in the vid.
I have read up on cutting aluminum over water if that is what you are getting at. My water system does not circulate water into the holding tank, there is a gate valve holding the water up in the tray. any hydrogen gas produced should dissipate into the air as I cut. There is no-where for the gas to be trapped, the slats run to the ends of the tray, so there can't even be a bit of gas trapped under the material. BUT - That being said, I am going to be very very careful the first few times I do aluminum!
Cable carriers are about 1" square inside. Fits everything good on the gantry, but I didn't have room to run the plasma cable inside the carrier on the side of the machine where there are twice as many wires. I should have got something bigger for that side.
