Plasma¶

This issue has multiple causes.

Please refer to the Plasma Operations Checklist . If the issue cannot be resolved, please Contact Us for support.

Note: When reaching out for plasma related support, we recommend providing as much information as possible including G-code and THC / Mach4 log files.

Plasma Operation Checklist

Mach4 Plasma Logging and Diagnostics

This issue has multiple causes.

Refer to the Avid CNC Mach4 Plasma Users Guide for more information.

Mach4 Plasma Users Guide

Electrical noise from plasma torch lead triggered "phantom limit".

In Mach4, at the top menu bar, navigate to Configure -> Avid CNC Mach4 Configuration. In the Avid CNC Mach4 Configuration window, select the Advanced Options tab, then check the box marked Disable all limits .

This option disables the limit switch function. Homing will still work and soft limits will be enabled after the machine is successfully homed.

The torch handle safety lock switch is preventing the torch from firing.

Ensure the safety lock is turned off, if present.

Note: This switch is not present on all torches. Please refer to your plasma torch owner's manual for more information.

The torch does not have a sufficient supply of clean, dry air. Gas supply error light or code 0-12 displayed on the Hypertherm power supply.

Check regulator to ensure the proper air pressure is being supplied. Additionally, check the air drier, emptying or replacing as needed.

Note: Please refer to your plasma torch owner's manual for more information on error codes and airflow requirements.

Consumables may not be properly seated in the torch. Consumable error light or code 0-30 displayed on the Hypertherm power supply.

Remove torch head and reseat the electrode and nozzle.

Note: Torch often will not fire on the first command after consumables have been replaced. Please refer to your plasma torch owner's manual for more information on error codes.

If this is the first time the torch has been fired since powering up, or the consumables have just been replaced, this is normal behavior. These puffs of air serve as a warning that the torch is active and will fire on the next command.

Rewind the G-code and Cycle Start again.

Please refer to your Hypertherm torch user manual for more information.

The plasma torch consumables used do not match CAM settings.

Shielded (standard mechanized) and FineCut consumables require different cutting settings. Make sure to match the CAM plasma tool and actual consumables.

Material clamp has a poor connection to stock material.

Check the material clamp position, ensuring it is firmly clamped on a clean area of stock material.

Note: Do not connect the material clamp to water table wall or material support slats.

Touchoff method not set properly in SheetCam.

By default the touchoff method should be set to "0" for Ohmic touchoff in Options -> Machine -> Post Processor -> Set custom post options . To use the mechanical touchoff switch set the touchoff method to "1" .

SheetCam Software Setup

Ohmic sensor not working properly, mechanical switch triggers

Ensure that the Ohmic ring is making contacting with the consumable shield. Touch the grounding clamp to the consumable shield and check for the Ohmic Signal Active light in Mach4.

'Path Rules' and 'Code Snippets' are not set correctly in SheetCAM.

Check to make sure SheetCAM has the Path Rules and Code Snippets set correctly and enabled for the operation.

Using Cut Rules

Jumper in Ohmic protection box set incorrectly for the intended touchoff method.

By default the jumper should be set to "Ohmic" for Ohmic touchoff. Move the jumper to the "Float" position to use mechanical touchoff.

Touchoff Method Jumper

This issue has multiple causes.

For best torch height control performance, update Mach4 and SheetCam to the latest Avid CNC versions.

Adjust the THC Profile and Sensitivity settings to achieve the desired performance.

Mach4 Software Download

Mach4 THC Tuning Instructions

This issue has multiple causes.

For best torch height control performance, update Mach4 and SheetCam to the latest Avid CNC versions.

Attempt to restart the cut at the previous or next Restart Point by following the linked instructions.

Mach4 Software Download

Mach4 Restart Plasma Cut Instructions

The torch lost the arc during the cut due to a void or failing to track the material.

Resume the cut. Before resuming, ensure that the torch height above the material is approximately correct.

Mach4 Plasma Resume Cut Instructions

A feature like sharp corners or small holes is causing a brief tip voltage spike and resulting in a torch dive.

Implement a SheetCam Path/Cut rule to inhibit THC motion on those features.

SheetCam Cut Rules

Mach4 Torch Height Control

Mach4 version is <v2.3.0. Previous Mach4 revisions used C:\Mach4Hobby\TMC3in1.

Find the correct folder or update Mach4 to latest version.

Note: When upgrading Mach4, we recommend that the SheetCam post processor also be updated to ensure the best performance.

Avid CNC Post and Tools for SheetCam

Cycle Start was commanded before the TMC3in1 or Warprunner established communication with the ESS. This takes several seconds after clicking Enable on the Mach4 screen.

Check for active communications with the TMC3in1 or Warprunner circuit boards.

v2.4.0+: Check the Mach4 Plasma Monitors group for a green Active Hardware Comms indicator.

v2.1.0-v2.3.8: Check the Mach4 Diagnostics tab for a green Active Communications LED under TMC3in1 Status.

Mach4 Plasma Monitors

If communication cannot be established, please Contact Us for troubleshooting assistance.

Faulty TMC3in1/WarpRunner Board.

Ensure TMC3in1/WarpRunner board is connected to the ESS. It may be necessary to replace the TMC3in1/WarpRunner board.

Please Contact Us to continue troubleshooting this issue.

Ohmic ring does not have continuity at the spade connector. Without continuity, no signal will be returned during touchoff.

Ensure the spade connector is securely connected to the torch tip and the Ohmic ring has contact with the consumable shield.

Plasma Torch Setup - Ohmic Ring

Material clamp has a poor connection to stock material or Ohmic ground wire is not connected.

Check the material clamp position, ensuring it is firmly clamped on a clean area of stock material.

Note: Do not connect the material clamp to water table wall or material support slats.

Plasma Setup - Ground Wire

Ohmic sensor is not plugged into the correct controller port.

For Mach4 plug into Aux 2

For Mach3 plug into Aux 1