So I’m not exactly sure what’s going on here but I’ve noticed that lately my cuts seem to be getting progressively further and further away from the work until all it’s doing is producing slag on top of the work and then eventually just cutting out the torch.
Reset the THC control defaults and then watch the Firecontrol screen during the cut. Specifically look at the IHS light on the screen. If the IHS light turns green at any time after the cut has started, Firecontrol thinks that the torch is hitting the metal and raises the torch by .060". It will do that every time that IHS light comes on during a cut, until it gets too high and the torch goes out.
The IHS light comes on whenever the IHS switch opens, which is only supposed to happen when the torch contacts the workpiece. However, if the Z axis rails are dirty or the rollers don’t roll smoothly, the Z carriage can hang up and cause the switch to open.
The IHS light will also come on if the connection to the IHS switch is broken. That can be caused by a loose IHS wire connection. Several users have reported that the IHS wire was not properly connected to the switch on their Z axis assembly and that caused intermittent issues.
The IHS light in Firecontrol should only come on when you lift the Z carriage. The IHS light is on the bottom of the screen. It’s all grayed out on this image, but the arrow is pointing to the location of the IHS light.
It’s not surprising that the “active” light stays on all the time with the settings you have. .5v is not much tolerance, so that alone will have it active most of the time. Changing the smart voltage distances to .05 doesn’t give it enough time to establish a stable voltage to work with. You may still be reading the higher pilot arc voltage and the THC is lifting to try to maintain that voltage. The default setting allows the torch to move far enough for the voltage to become stable before letting the THC take over.
Consumables may have been bad. You could have had another issue then it cutting bad trashed them . May want to clean swirl ring and stuff make sure electrode moves freely. Video looked to me like pilot arc didn’t transfer . I was thinking plunge rate to slow why 8 asked about the codes.