Solving Crossfire Pro CUT60 EMI and Ground Loop issues once and for all

I have been chasing EMI and ground loop issues on my Crossfire Pro with Primeweld CUT60 for years. To be clear, I do not believe this is a Langmuir problem, the Primeweld CUT60 is known to be a noisy girl and was removed from their recommendations list. But that said, the Crossfire Pro electronics were not designed to have robust protection against such cutters that throw off a lot of noise.

What were my symptoms? The most common was simply disconnections to the electronics during a cut. But it gets worse, it has smoked laptop USB ports, cooked laptop speakers and touchscreen digitizer, released the magic smoke from resistors inside VIM modules, and caused problem after problem. THC signals were unreliable during live fire, and the voltage signal would stay floating high (very slowly lowering over time) even after the touch shut off. The problems were substantially worse when THC was used, regardless of whether I was using raw or divided. With THC wiring disconnected the issues were far less common, but not zero. Yes to all the usual troubleshooting, I removed PC power ground, yes there was absolutely no continuity between the controls chassis (i.e. USB ground) and the table, etc.

I have finally solved it once and for all using signal isolation modules for both the IHS and THC.

I now have zero issues.

I get an absolutely rock solid THC voltage signal, every time, every cut.

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Isolation IS the key! The original design breaks several engineering design guidelines and literally begs for failure.

I have an OG Crossfire and added my own THC, IHS, Z Axis, and replaced the enclosure with a plastic NEMA 4 enclosure. The THC is the THC3T-02 which has an isolation power supply and, more importantly, an isolation amplifier as you have added to yours. I’ve never had a noise problem with mine.

Good job fixing yours!

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You could sell this as a kit.

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That is amazing: Solid information. Great description of the problems you were having.

Thanks for sharing.

Agree with BrownFox! (Second time for me publicly admitting that)

Congratulations on making it through the 5 stages of admitting I’m awesome.

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I would love to, but to be honest I’m already drowning in my current workload!

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Totally get it. Kick ass job putting it all together and providing a parts list.

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Even just using some colored pencils to draw up up the wiring would be gold.

Here is the schematic, it is very straightforward to wire.

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