Got a new (to me) crossfire. Replaced the Gen1 box with a new (from LS) Gen2 box with THC, IHC and the Z axis. Plasma is New Everlast 82i with Machine Torch, taking raw voltage from the leads, using CNC port for torch on/Off, set to CNC control. THC test is successful with about 125-130v to the table slat at about 1". Test “straight” cuts from the Firecontrol works perfectly without THC/IHC. Just set it and hit run. https://youtube.com/shorts/OzPVP4Sr6Ks?feature=share
Install went well and Z moves and i think this is the problem, it doesnt always move in the direction of the button being pushed I.e. pageup doesnt always start the stepper in the correct direction, up, and same with page down. Sometimes it moves down, sometimes it’ll move up. Switching direction on the keys doesnt always change the direction. I’ll be hitting up, its moving down, ill stop hit down and its still moving down but ill stop and then hit down again down will be up, or maybe down. Follow? Zero consistency with z directional control.
Ive checked connections, both inside and out of the control box with everything seated and appears to be correct.
When trying to run a basic circle in a square program with IHC enabled, with the torch touching the work, the green IHC light is on, when not touching, its grayed. The program starts, moves the z in the up direction till it hits the physical stop and errors out. I’m setting Z to zero or close to it when the torch is about a 1/16th over the work.
Suggestions or ideas? The Z up/down has never functioned in the correct direction consistently.
The Z axis moving in the wrong direction indicates that the DB9 connector that plugs the Z axis motor into the control box is not making a good connection.
Pull the connector and look for burnt pins. If it looks ok, just plug it in and pull it out a few times to clean the connections. Then plug it back in and don’t tighten the screws.
The screws on some of those connectors are too long and push the connector out when tightened all the way. This leaves a gap and causes arcing between the pins.
You shouldn’t have to worry about where you set the Z axis zero. As long as the torch is high enough to have clearance on is way to the first cut, the IHS system will set the zero at the height of the metal surface.
This could be caused either by a defective Stepper Driver or one lead to the stepper motor intermittently connecting. I’ve seen both cases. In this case, you might want to try the ‘Swap’ motor lead technique. Swap Z & X DB9 connectors and see if the problem moves to the other axis (just slowly jog each axis to check movement).
If it does then the problem is electronic, but still could be either cause but definitely within the Crossfire enclosure.
If it doesn’t then you’ve isolated the problem to the external Z DB9 connector or motor. Use an Ohmmeter to try to find the problem.
Ill try that a bit later. Ive tried taking out and putting it back in as well as using the extention that was included. Ill do it again and inspect both sides (box and wire) and report back. Thank you!
Got it sorted. There was a loose wire on the terminal block inside the box that was causing the intermittent behavor. Before opening the box - i tested the stepper on the Y axis output and it was flawless so ruled out the motor, thankfully.
However then ran in to THC voltage problems that turned out to be the laptop power cord being installed causing the problem. Unplugged the laptop and problem solved so Ill address that later. Finally got the test cuts done and aside from needing to learn the plasma equivalent of speeds and feeds (speeds amps and pressure?) for cut quality. Overall Im excited and looking forward to actual projects after a handful of additional playing around!
Thanks to both of you who replied. TomS and Ds690.
