We recently acquired a Crossfire Pro with the Everlast 62i Plasma, equipped with the CNC Upgrade and IPT60 Machine Torch. The machine has been working flawlessly for us for about 2 weeks. I set the machine up to run 2 copies of our most intricate design, which we had cut previously with no issues. It cut the first set perfect and then moved to start the next set everything was good until I heard the torch start to make a woosh-woosh-woosh sound almost like a loose air hose spinning around. I looked at the cut and noticed it had started to make very jagged serrated cuts resembling a saw blade effect.
At that point I changed all consumables including the swirl ring at which time I noticed that the electrode was near stuck in the torch, I gently replaced it and picked up where it had left off, hoping that would fix it. I started it back up from where it left off and the problem persisted, it would start the cut fine and then start to cut jagged. I was frustrated so I left it for the night and returned the next day with some gathered knowledge from Google searches and a post I made on the Facebook Langmuir Crossfire Owners Group.
At this point I have verified that there is no slop in any of the 3 axis. Everything is cleaned and lubricated and the air is dry and clean. I used a tap to clean the treads for the electrode so it now screws cleanly and easily. We then installed all new consumables for a second time and attempted to salvage what we were working on the night before. Picking up where I had left off I started the program. It made a few cuts no problem, and then it started to act up again. I’ll be honest I was a little frustrated, so I kept restarting the program until the piece was finished. During that time it would start fine, make a few cuts and then act up. I placed my hand on the z axis as it was moving and felt that there was no up and down movement while this was occurring the movement felt free and smooth. As I was working through the last few cuts of the file the Z axis began to just rise into space until it eventually would blow out. I then created a simple medallion file and ran the file once with THC on and once with THC off with no change, jagged cuts on both.
At this point I believe the only thing I have not checked is the THC wiring. It looks to be wired Divided.
Any and all help is appreciated, Thank You all in advance.
I replied to you on FB about the first pic. that’s not divided voltage, it’s raw from the CNC port which shouldn’t be used due to it being filtered voltage then being filtered again thru the VIM box which will give inconsistent voltage readings.
for true raw voltage, you should go thru the inside of the cutter straight from the lugs.
Besides that, what it your air pressure into and out of the cutter? i’ve have cuts like that ( with a cut60) when my output pressure (from the cutter) was a little too low. i bumped it up about 10 psi and it seemed to have fixed the issue.
Send us some pics of your consumables that you replaced and the ones you replaced them with. Good clear pics of the nozzle ends and the top and side of the electrode.
When this happened to my PTM60 torch, it was plugged holes in the torch cap. The tiny holes in the cap get plugged and cause the plasma stream to flutter. I ran a thin piece of wire through the holes to clean them and the jagged edge went away.
The air holes in the retaining cup from blow back will only get pugged up when using unshielded consumables and should be check when you change consumables. Also the retaining cup is also a consumable.
This does not happen or very rarely when using shielded consumables.
Thank you all for the input. Unfortunately I didn’t have time to mess with it today as we still have to get work out the door, I’m sure you all know how that goes. I should have some time tomorrow to get into it. I will update more then.
I’m not sure I believe what just happened, but… So I come in today and take the torch completely apart I clean every hole I can find put it back together and run my medallion test cut. It was still cutting jagged. So I’m standing in front of my setup and looking at it thinking, What did I change, What is different from 4 days ago when it worked? And as this is going thru my mind my eyes settle on my nice new wireless mouse…
I disconnected the dongle from the USB and moved the mouse away from the machine and try again. I’ll be Dipped if it didn’t cut it perfectly! So just to be sure I loaded up a different file more cutting and it ran that fine as well.
So Yeah, It was RF/EMI From my mouse or at least as of now that appears to be the case.
Thank You all for the help and responses, the machine now works even better than it did when we first set it up. lol If anything changes I will update here.
I wish more people would do that mental exercise. From the other side of the screen, it is hard for us wee little voices to know what has happened in your shop. Thank you for bringing this example to us both for the problem and the solution. Kudos!
You will be given the honorary “Medal of Metal” that we give to great contributors such as yourself. We have a list of recipients so there are others ahead of you but as soon as donation$ start pouring in, I am sure ‘someone’ will volunteer to make the awards.
I only buy Logitech gear if I can swing it so it was a Logitech Wireless with a Dongle.
I have since had to also make the change from Raw Voltage into the CNC Port to Direct Raw Voltage from the front of the machine. The machine is now cutting very well.
I am having this same issue and have the same Everlast 62i with CNC torch. Tried all the suggestion in this post and still getting the same results.
Crossfire XL w/THC
Everlast 62i CNC
3 stage air dryer supplies from off site air on campus
@UCIMach After removing the mouse Most of the issue was gone but I still had some weirdness as the z axis was just floating off into space. I then made the switch from Raw Voltage to CNC Port on the Plasma to what I am calling Direct Raw Voltage from the Positive and Negative connections in the front of the plasma. The issue appears to now be corrected, but I thought that once before…
As I look at your settings I notice that your air pressure is low compared to ours which is at 80psi at rest and “around” 75psi when cutting. Hope you find the fix.
Where is the work clamp? It must be on the metal your cutting. Also crank up the air pressure to around 78 psi on the front of the machine. It shouldn’t drop more than 3~5 psi while cutting.
Post your post processor settings. Cut height. 062, pierce height .12, delay .7
Bigdaddy2166
Aug 2024
cut height test.tap (224 Bytes)
Load the file onto FireControl. It will move the torch to the cut height and stop. You can measure the distance from the tip to the sheet. Report back with the findings.
that we give to great contributors such as yourself. We have a list of recipients so there are others ahead of you but as soon as donation$ start pouring in, I am sure ‘someone’ will volunteer to make the awards. 
