Re: [Emc-users] Plasma Mistake

[Marius Liebenberg]

Jim
The filter actually goes on the plasma arc voltage. It is filtered and 
reduced and rectified. Then it does not matter what happens to the torch 
and the earth clamp.
One thing that most people do not realize is that the plasma arc is at 
negative potential to earth. So the earth clamp is really the positive 
terminal and the arc voltage is the negative terminal.

-- Original Message --
From: "Jim Craig" <jimcraig5...@windstream.net>
To: "Marius Liebenberg" <mar...@mastercut.co.za>; "Enhanced Machine 
Controller (EMC)" <emc-users@lists.sourceforge.net>
Sent: 2016-05-20 16:47:29
Subject: Re: [Emc-users] Plasma Mistake

>Marius,
>
>That may be some good advice there. As it turns out the only items that 
>were fried were items that were powered by the 5V wall wart power 
>supply. This may be coincidence but it may not be either.
>
>The stepper drives survived as they are powered by a switching power 
>supply which I assume already has the HF filter built in.
>
>The computer also survived but we may want to switch to a UPC instead 
>of a power switch for further protection.
>
>I would need to put the HF filter prior to the 5V power supply. I 
>actually happen to have one of them laying around from a previous 
>project. Would the wall wart be sufficient on the other side of the HF 
>filter or should we find another power supply for our 5V needs?
>
>Thanks,
>
>Jim
>
>
>
>On 5/20/2016 9:12 AM, Marius Liebenberg wrote:
>>This is the reason that I prefer a proper input filter network that
>>will make sure that things stay in tact even with the earth clamp not
>>connected. I have done that many times and never broke any 
>>electronics.
>>
>>The circuit has a HF filter (pie) and a divider as well as a 
>>rectifier.
>>Then you connect your stuff to this filter and the polarity is always
>>correct and can be referenced to the circuit ground.
>>
>>
>>-- Original Message --
>>From: "Jim Craig" <jimcraig5...@windstream.net>
>>To: "emc-users" <emc-users@lists.sourceforge.net>
>>Sent: 2016-05-19 15:13:32
>>Subject: [Emc-users] Plasma Mistake
>>
>>>So my goal is to let others learn from my mistakes. So in that way I
>>>tend to make a lot of them so everyone can benefit. Last night I was
>>>working with the plasma machine and made a big one!
>>>
>>>Don't ever forget to hook up the ground to the plasma cutter!
>>>
>>>When we hit the go button the program started. The torch found the
>>>material. The pilot arc started and BAM everything stopped. Realtime
>>>error in LinuxCNC. Cleared repowered the machine and nothing would
>>>still
>>>work. That is when I realized the ground clamp was not on the cutting
>>>table.
>>>
>>>It took out the two breakout boards and the mesa THCAD-10 board.
>>>Everything else seems to have survived. I replaced one of the 
>>>breakout
>>>boards to see what all was damaged. The parallel ports are still
>>>working
>>>and the stepper drives are still working so the damage was limited.
>>>
>>>So this serves as a warning to anyone that is using a plasma CNC
>>>machine.
>>>
>>>My next question is what can I do in LinuxCNC to get a message box 
>>>each
>>>time a program is being started to check the plasma ground. This will
>>>help to mitigate this problem in the future.
>>>
>>>If there is no way to do it in LinuxCNC then I will add a piece of 
>>>code
>>>to the post processor we use in Fusion360 to add the message and a
>>>program pause in the initial preamble of the file.
>>>
>>>John T., I ordered a replacement THCAD-10 this morning. I just want 
>>>to
>>>thank you for the simple privacy statement on your website. I think 
>>>you
>>>should change your terms to be "You pay me, I ship you stuff!"
>>>
>>>Thanks and be warned!
>>>
>>>Jim C.
>>>
>>>
>>>--
>>>Mobile security can be enabling, not merely restricting. Employees 
>>>who
>>>bring their own devices (BYOD) to work are irked by the imposition of
>>>MDM
>>>restrictions. Mobile Device Manager Plus allows you to control only 
>>>the
>>>apps on BYO-devices by containerizing them, leaving personal data
>>>untouched!
>>>https://ad.doubleclick.net/ddm/clk/304595813;131938128;j
>>>

Re: [Emc-users] Plasma Mistake

[Ralph Stirling]

You could use one of the disk drive power connectors
in your PC for 5v power.
-- Ralph

From: Jim Craig [jimcraig5...@windstream.net]
Sent: Friday, May 20, 2016 7:47 AM
To: Marius Liebenberg; Enhanced Machine Controller (EMC)
Subject: Re: [Emc-users] Plasma Mistake

Marius,

That may be some good advice there. As it turns out the only items that
were fried were items that were powered by the 5V wall wart power
supply. This may be coincidence but it may not be either.

The stepper drives survived as they are powered by a switching power
supply which I assume already has the HF filter built in.

The computer also survived but we may want to switch to a UPC instead of
a power switch for further protection.

I would need to put the HF filter prior to the 5V power supply. I
actually happen to have one of them laying around from a previous
project. Would the wall wart be sufficient on the other side of the HF
filter or should we find another power supply for our 5V needs?

Thanks,

Jim



On 5/20/2016 9:12 AM, Marius Liebenberg wrote:
>This is the reason that I prefer a proper input filter network that
> will make sure that things stay in tact even with the earth clamp not
> connected. I have done that many times and never broke any electronics.
>
> The circuit has a HF filter (pie) and a divider as well as a rectifier.
> Then you connect your stuff to this filter and the polarity is always
> correct and can be referenced to the circuit ground.
>
>
> -- Original Message --
> From: "Jim Craig" <jimcraig5...@windstream.net>
> To: "emc-users" <emc-users@lists.sourceforge.net>
> Sent: 2016-05-19 15:13:32
> Subject: [Emc-users] Plasma Mistake
>
>> So my goal is to let others learn from my mistakes. So in that way I
>> tend to make a lot of them so everyone can benefit. Last night I was
>> working with the plasma machine and made a big one!
>>
>> Don't ever forget to hook up the ground to the plasma cutter!
>>
>> When we hit the go button the program started. The torch found the
>> material. The pilot arc started and BAM everything stopped. Realtime
>> error in LinuxCNC. Cleared repowered the machine and nothing would
>> still
>> work. That is when I realized the ground clamp was not on the cutting
>> table.
>>
>> It took out the two breakout boards and the mesa THCAD-10 board.
>> Everything else seems to have survived. I replaced one of the breakout
>> boards to see what all was damaged. The parallel ports are still
>> working
>> and the stepper drives are still working so the damage was limited.
>>
>> So this serves as a warning to anyone that is using a plasma CNC
>> machine.
>>
>> My next question is what can I do in LinuxCNC to get a message box each
>> time a program is being started to check the plasma ground. This will
>> help to mitigate this problem in the future.
>>
>> If there is no way to do it in LinuxCNC then I will add a piece of code
>> to the post processor we use in Fusion360 to add the message and a
>> program pause in the initial preamble of the file.
>>
>> John T., I ordered a replacement THCAD-10 this morning. I just want to
>> thank you for the simple privacy statement on your website. I think you
>> should change your terms to be "You pay me, I ship you stuff!"
>>
>> Thanks and be warned!
>>
>> Jim C.
>>
>>
>> --
>> Mobile security can be enabling, not merely restricting. Employees who
>> bring their own devices (BYOD) to work are irked by the imposition of
>> MDM
>> restrictions. Mobile Device Manager Plus allows you to control only the
>> apps on BYO-devices by containerizing them, leaving personal data
>> untouched!
>> https://ad.doubleclick.net/ddm/clk/304595813;131938128;j
>> ___
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>> Emc-users@lists.sourceforge.net
>> https://lists.sourceforge.net/lists/listinfo/emc-users
> --
> Mobile security can be enabling, not merely restricting. Employees who
> bring their own devices (BYOD) to work are irked by the imposition of MDM
> restrictions. Mobile Device Manager Plus allows you to control only the
> apps on BYO-devices by containerizing them, leaving personal data untouched!
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>


---

Re: [Emc-users] Plasma Mistake

[Jim Craig]

Marius,

That may be some good advice there. As it turns out the only items that 
were fried were items that were powered by the 5V wall wart power 
supply. This may be coincidence but it may not be either.

The stepper drives survived as they are powered by a switching power 
supply which I assume already has the HF filter built in.

The computer also survived but we may want to switch to a UPC instead of 
a power switch for further protection.

I would need to put the HF filter prior to the 5V power supply. I 
actually happen to have one of them laying around from a previous 
project. Would the wall wart be sufficient on the other side of the HF 
filter or should we find another power supply for our 5V needs?

Thanks,

Jim



On 5/20/2016 9:12 AM, Marius Liebenberg wrote:
>This is the reason that I prefer a proper input filter network that
> will make sure that things stay in tact even with the earth clamp not
> connected. I have done that many times and never broke any electronics.
>
> The circuit has a HF filter (pie) and a divider as well as a rectifier.
> Then you connect your stuff to this filter and the polarity is always
> correct and can be referenced to the circuit ground.
>
>
> -- Original Message --
> From: "Jim Craig" <jimcraig5...@windstream.net>
> To: "emc-users" <emc-users@lists.sourceforge.net>
> Sent: 2016-05-19 15:13:32
> Subject: [Emc-users] Plasma Mistake
>
>> So my goal is to let others learn from my mistakes. So in that way I
>> tend to make a lot of them so everyone can benefit. Last night I was
>> working with the plasma machine and made a big one!
>>
>> Don't ever forget to hook up the ground to the plasma cutter!
>>
>> When we hit the go button the program started. The torch found the
>> material. The pilot arc started and BAM everything stopped. Realtime
>> error in LinuxCNC. Cleared repowered the machine and nothing would
>> still
>> work. That is when I realized the ground clamp was not on the cutting
>> table.
>>
>> It took out the two breakout boards and the mesa THCAD-10 board.
>> Everything else seems to have survived. I replaced one of the breakout
>> boards to see what all was damaged. The parallel ports are still
>> working
>> and the stepper drives are still working so the damage was limited.
>>
>> So this serves as a warning to anyone that is using a plasma CNC
>> machine.
>>
>> My next question is what can I do in LinuxCNC to get a message box each
>> time a program is being started to check the plasma ground. This will
>> help to mitigate this problem in the future.
>>
>> If there is no way to do it in LinuxCNC then I will add a piece of code
>> to the post processor we use in Fusion360 to add the message and a
>> program pause in the initial preamble of the file.
>>
>> John T., I ordered a replacement THCAD-10 this morning. I just want to
>> thank you for the simple privacy statement on your website. I think you
>> should change your terms to be "You pay me, I ship you stuff!"
>>
>> Thanks and be warned!
>>
>> Jim C.
>>
>>
>> --
>> Mobile security can be enabling, not merely restricting. Employees who
>> bring their own devices (BYOD) to work are irked by the imposition of
>> MDM
>> restrictions. Mobile Device Manager Plus allows you to control only the
>> apps on BYO-devices by containerizing them, leaving personal data
>> untouched!
>> https://ad.doubleclick.net/ddm/clk/304595813;131938128;j
>> ___
>> Emc-users mailing list
>> Emc-users@lists.sourceforge.net
>> https://lists.sourceforge.net/lists/listinfo/emc-users
> --
> Mobile security can be enabling, not merely restricting. Employees who
> bring their own devices (BYOD) to work are irked by the imposition of MDM
> restrictions. Mobile Device Manager Plus allows you to control only the
> apps on BYO-devices by containerizing them, leaving personal data untouched!
> https://ad.doubleclick.net/ddm/clk/304595813;131938128;j
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> https://lists.sourceforge.net/lists/listinfo/emc-users
>


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Re: [Emc-users] Plasma Mistake

[Marius Liebenberg]

  This is the reason that I prefer a proper input filter network that 
will make sure that things stay in tact even with the earth clamp not 
connected. I have done that many times and never broke any electronics.

The circuit has a HF filter (pie) and a divider as well as a rectifier. 
Then you connect your stuff to this filter and the polarity is always 
correct and can be referenced to the circuit ground.


-- Original Message --
From: "Jim Craig" <jimcraig5...@windstream.net>
To: "emc-users" <emc-users@lists.sourceforge.net>
Sent: 2016-05-19 15:13:32
Subject: [Emc-users] Plasma Mistake

>So my goal is to let others learn from my mistakes. So in that way I
>tend to make a lot of them so everyone can benefit. Last night I was
>working with the plasma machine and made a big one!
>
>Don't ever forget to hook up the ground to the plasma cutter!
>
>When we hit the go button the program started. The torch found the
>material. The pilot arc started and BAM everything stopped. Realtime
>error in LinuxCNC. Cleared repowered the machine and nothing would 
>still
>work. That is when I realized the ground clamp was not on the cutting
>table.
>
>It took out the two breakout boards and the mesa THCAD-10 board.
>Everything else seems to have survived. I replaced one of the breakout
>boards to see what all was damaged. The parallel ports are still 
>working
>and the stepper drives are still working so the damage was limited.
>
>So this serves as a warning to anyone that is using a plasma CNC 
>machine.
>
>My next question is what can I do in LinuxCNC to get a message box each
>time a program is being started to check the plasma ground. This will
>help to mitigate this problem in the future.
>
>If there is no way to do it in LinuxCNC then I will add a piece of code
>to the post processor we use in Fusion360 to add the message and a
>program pause in the initial preamble of the file.
>
>John T., I ordered a replacement THCAD-10 this morning. I just want to
>thank you for the simple privacy statement on your website. I think you
>should change your terms to be "You pay me, I ship you stuff!"
>
>Thanks and be warned!
>
>Jim C.
>
>
>--
>Mobile security can be enabling, not merely restricting. Employees who
>bring their own devices (BYOD) to work are irked by the imposition of 
>MDM
>restrictions. Mobile Device Manager Plus allows you to control only the
>apps on BYO-devices by containerizing them, leaving personal data 
>untouched!
>https://ad.doubleclick.net/ddm/clk/304595813;131938128;j
>___
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>Emc-users@lists.sourceforge.net
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Re: [Emc-users] Plasma Mistake

[Lester Caine]

On 20/05/16 14:03, Jim Craig wrote:
> Anyway, Thanks everyone for the advice. We will be reviewing the 
> grounding of the whole system and adding in some friendly reminders.

I have a similar problem with DivisionMasters used to run automated arc
welding setups. Nice big earth connection between work and electronics
and care that it's actually making contact rather than insulated by
anodising or rust.

-- 
Lester Caine - G8HFL
-
Contact - http://lsces.co.uk/wiki/?page=contact
L.S.Caine Electronic Services - http://lsces.co.uk
EnquirySolve - http://enquirysolve.com/
Model Engineers Digital Workshop - http://medw.co.uk
Rainbow Digital Media - http://rainbowdigitalmedia.co.uk

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Re: [Emc-users] Plasma Mistake

[andy pugh]

On 20 May 2016 at 09:03, Jim Craig  wrote:
> HA! I may do that too. Put one right over the plasma cutter power
> switch. That would be a good place.


I wonder if there is a way to wire a relay interlock?


-- 
atp
"A motorcycle is a bicycle with a pandemonium attachment and is
designed for the especial use of mechanical geniuses, daredevils and
lunatics."
— George Fitch, Atlanta Constitution Newspaper, 1916

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Re: [Emc-users] Plasma Mistake

[Jim Craig]

On 5/20/2016 1:28 AM, Gregg Eshelman wrote:
> It would be easier to put a large sign below the control computer's screen, 
> and signs on/around the table. CHECK GROUND CLAMP!
>
>   
HA! I may do that too. Put one right over the plasma cutter power 
switch. That would be a good place.

Anyway, Thanks everyone for the advice. We will be reviewing the 
grounding of the whole system and adding in some friendly reminders.

Thanks again.


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Re: [Emc-users] Plasma Mistake

[Gregg Eshelman]

It would be easier to put a large sign below the control computer's screen, and 
signs on/around the table. CHECK GROUND CLAMP!

 
  From: Jim Craig <jimcraig5...@windstream.net>
 To: Enhanced Machine Controller (EMC) <emc-users@lists.sourceforge.net> 
 Sent: Thursday, May 19, 2016 10:26 AM
 Subject: Re: [Emc-users] Plasma Mistake
   
I think in addition to the message box in the g-code file I will add a 
HAL message component that will trigger off a one shot component that is 
connected to the machine on state. This way each time the machine is 
turned on the pop up message will show up to remind the user to connect 
the ground. (just in case as I am a forgetful dummy).
   
 
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Re: [Emc-users] Plasma Mistake

[Gene Heskett]

On Thursday 19 May 2016 12:26:53 Jim Craig wrote:

> I think in addition to the message box in the g-code file I will add a
> HAL message component that will trigger off a one shot component that
> is connected to the machine on state. This way each time the machine
> is turned on the pop up message will show up to remind the user to
> connect the ground. (just in case as I am a forgetful dummy).
>
> On 5/19/2016 10:57 AM, Dave Cole wrote:
> > Also, you will find out that how you put the clamp on the table will
> > affect the plasma flame "direction".   The plasma flame will point
> > somewhat in the direction of the best ground.
> > If you clip it on one leg and the other legs and supports are not
> > well connected you will see the effects of the poor ground path in
> > your cuts.  The way you ground a plasma table is really important.
> >
> > Dave
>
> The ground is normally placed on the grid in the water table. This
> gets the ground as close to the part as possible and creating a
> distributed ground grid under the plate being cut. What is the
> suggested best method to ground the table to the plasma cutter to
> prevent the directional arcing?
>
> Thanks,
>
> Jim

This is a bit of a puzzle.  First, connecting to the support grid is 
guaranteed to be a poor ground, as that will have to spot weld itself at 
someplace where the work is laying on the grid.  With the oxide coatings 
present on 99% of the metal that goes under the torch, its going to be a 
hit & occasionally miss problem.

Connecting the end of the star to the grid is OK, but from the grid to 
workpiece, I think I'd go get 4 small c-clamps, weld or bolt a 9 or 10" 
ground cable to them, bolting the cable to a handy place on the grid so 
that you can pick the clamps up and put one at each corner of the 
workpiece.  Screwed to about 1/4 turn from broke, that should give you a 
good, very low ohms ground.

Cheers, Gene Heskett
-- 
"There are four boxes to be used in defense of liberty:
 soap, ballot, jury, and ammo. Please use in that order."
-Ed Howdershelt (Author)
Genes Web page 

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Re: [Emc-users] Plasma Mistake

[Jim Craig]

I think in addition to the message box in the g-code file I will add a 
HAL message component that will trigger off a one shot component that is 
connected to the machine on state. This way each time the machine is 
turned on the pop up message will show up to remind the user to connect 
the ground. (just in case as I am a forgetful dummy).

On 5/19/2016 10:57 AM, Dave Cole wrote:
> Also, you will find out that how you put the clamp on the table will
> affect the plasma flame "direction".   The plasma flame will point
> somewhat in the direction of the best ground.
> If you clip it on one leg and the other legs and supports are not well
> connected you will see the effects of the poor ground path in your
> cuts.  The way you ground a plasma table is really important.
>
> Dave
>
The ground is normally placed on the grid in the water table. This gets 
the ground as close to the part as possible and creating a distributed 
ground grid under the plate being cut. What is the suggested best method 
to ground the table to the plasma cutter to prevent the directional arcing?

Thanks,

Jim

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Re: [Emc-users] Plasma Mistake

[Dave Cole]

If you want to keep using the ground clamp as is I'd order two sets 
of parts from John...  :-)  You won't need them next week or two weeks 
from now..   Just as soon as the memory of this fades a bit.

Also, you will find out that how you put the clamp on the table will 
affect the plasma flame "direction".   The plasma flame will point 
somewhat in the direction of the best ground.
If you clip it on one leg and the other legs and supports are not well 
connected you will see the effects of the poor ground path in your 
cuts.  The way you ground a plasma table is really important.

Dave

On 5/19/2016 11:35 AM, Jon Elson wrote:
> On 05/19/2016 08:13 AM, Jim Craig wrote:
>> Don't ever forget to hook up the ground to the plasma cutter!
>>
>>
> One suggestion is to run an EXTRA ground cable from the
> plasma power supply to the machine table.  Not the base of
> the frame, but the actual table the work sits on, if that
> moves.  This would prevent most of the damage if you ever
> forget again (probably won't happen for a long while!)
>
> Jon
>
> --
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Re: [Emc-users] Plasma Mistake

[Jon Elson]

On 05/19/2016 08:13 AM, Jim Craig wrote:
>
> Don't ever forget to hook up the ground to the plasma cutter!
>
>
One suggestion is to run an EXTRA ground cable from the 
plasma power supply to the machine table.  Not the base of 
the frame, but the actual table the work sits on, if that 
moves.  This would prevent most of the damage if you ever 
forget again (probably won't happen for a long while!)

Jon

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Re: [Emc-users] Plasma Mistake

[andy pugh]

On 19 May 2016 at 10:16, Jim Craig  wrote:
> In this situation the plasma cutter unit is used on the CNC machine as
> well as as a manual hand cutter. So the clamp remains to be universal.

Put a permanent bolt-on lug in the _middle_ of the ground lead then.

-- 
atp
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designed for the especial use of mechanical geniuses, daredevils and
lunatics."
— George Fitch, Atlanta Constitution Newspaper, 1916

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Re: [Emc-users] Plasma Mistake

[Jim Craig]

John,

In this situation the plasma cutter unit is used on the CNC machine as 
well as as a manual hand cutter. So the clamp remains to be universal. 
It is trivial to switch between use on the CNC table or as a manual hand 
cutter, as long as you don't forget the ground clamp.

Jim


On 5/19/2016 9:02 AM, John Kasunich wrote:
> One question:  Why do you have a ground "clamp".
>
> A CNC plasma is a more-or-less permanent installation.  Put a lug on that
> ground cable and bolt it to the machine table/frame.
>
>


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Re: [Emc-users] Plasma Mistake --> Ground

[Nicklas Karlsson]

To get a working usually involve exploring there others.

If ground clamp of plasma cutter must be checked every time problems could be 
expected every now and then. It is possible to mitigate with proper procedures 
as is done for air safety and it work most of the time although it cost money. 
They got it to work with nitroglycerin once upon a time but dynamite is 
preferred. It will probably be hard to get procedure compliance then there are 
no real danger.


On Thu, 19 May 2016 08:13:32 -0500
Jim Craig  wrote:

> So my goal is to let others learn from my mistakes. So in that way I 
> tend to make a lot of them so everyone can benefit. Last night I was 
> working with the plasma machine and made a big one!
> 
> Don't ever forget to hook up the ground to the plasma cutter!
> 
> When we hit the go button the program started. The torch found the 
> material. The pilot arc started and BAM everything stopped. Realtime 
> error in LinuxCNC. Cleared repowered the machine and nothing would still 
> work. That is when I realized the ground clamp was not on the cutting 
> table.
> 
> It took out the two breakout boards and the mesa THCAD-10 board. 
> Everything else seems to have survived. I replaced one of the breakout 
> boards to see what all was damaged. The parallel ports are still working 
> and the stepper drives are still working so the damage was limited.
> 
> So this serves as a warning to anyone that is using a plasma CNC machine.
> 
> My next question is what can I do in LinuxCNC to get a message box each 
> time a program is being started to check the plasma ground. This will 
> help to mitigate this problem in the future.
> 
> If there is no way to do it in LinuxCNC then I will add a piece of code 
> to the post processor we use in Fusion360 to add the message and a 
> program pause in the initial preamble of the file.
> 
> John T., I ordered a replacement THCAD-10 this morning. I just want to 
> thank you for the simple privacy statement on your website. I think you 
> should change your terms to be "You pay me, I ship you stuff!"
> 
> Thanks and be warned!
> 
> Jim C.
> 
> 
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> restrictions. Mobile Device Manager Plus allows you to control only the
> apps on BYO-devices by containerizing them, leaving personal data untouched!
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Re: [Emc-users] Plasma Mistake

[John Kasunich]

On Thu, May 19, 2016, at 09:13 AM, Jim Craig wrote:
> So my goal is to let others learn from my mistakes. So in that way I 
> tend to make a lot of them so everyone can benefit. Last night I was 
> working with the plasma machine and made a big one!
> 
> Don't ever forget to hook up the ground to the plasma cutter!
> 
> When we hit the go button the program started. The torch found the 
> material. The pilot arc started and BAM everything stopped. Realtime 
> error in LinuxCNC. Cleared repowered the machine and nothing would still 
> work. That is when I realized the ground clamp was not on the cutting 
> table.

One question:  Why do you have a ground "clamp".

A CNC plasma is a more-or-less permanent installation.  Put a lug on that
ground cable and bolt it to the machine table/frame.


-- 
  John Kasunich
  jmkasun...@fastmail.fm

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Re: [Emc-users] Plasma Mistake

[Jim Craig]

Les,

Thanks for the info. We were rethinking the machine grounding last 
night. We will look into it further when we are putting it back together.

Thanks again,

Jim

On 5/19/2016 8:28 AM, Les Newell wrote:
> Hi Jim,
>
> There are a few precautions you can take so forgetting to clamp the
> ground doesn't destroy your electronics. First use a star ground. Weld a
> bolt to the frame of your machine and connect that to your supply mains
> earth. Now make sure the mains earth for your computer and plasma cutter
> also connect to the same point. You don't want any loops, just direct
> connections straight to this single point.
>
> Second make sure none of your electronics have any connection to the
> frame of the machine. Cable screens etc should be isolated from the
> frame. The only connection should be that star point earth.
>
> Les
>
> On 19/05/2016 14:13, Jim Craig wrote:
>> So my goal is to let others learn from my mistakes. So in that way I
>> tend to make a lot of them so everyone can benefit. Last night I was
>> working with the plasma machine and made a big one!
>>
>> Don't ever forget to hook up the ground to the plasma cutter!
>>
>> When we hit the go button the program started. The torch found the
>> material. The pilot arc started and BAM everything stopped. Realtime
>> error in LinuxCNC. Cleared repowered the machine and nothing would still
>> work. That is when I realized the ground clamp was not on the cutting
>> table.
>>
>> It took out the two breakout boards and the mesa THCAD-10 board.
>> Everything else seems to have survived. I replaced one of the breakout
>> boards to see what all was damaged. The parallel ports are still working
>> and the stepper drives are still working so the damage was limited.
>>
>> So this serves as a warning to anyone that is using a plasma CNC machine.
>>
>> My next question is what can I do in LinuxCNC to get a message box each
>> time a program is being started to check the plasma ground. This will
>> help to mitigate this problem in the future.
>>
>> If there is no way to do it in LinuxCNC then I will add a piece of code
>> to the post processor we use in Fusion360 to add the message and a
>> program pause in the initial preamble of the file.
>>
>> John T., I ordered a replacement THCAD-10 this morning. I just want to
>> thank you for the simple privacy statement on your website. I think you
>> should change your terms to be "You pay me, I ship you stuff!"
>>
>> Thanks and be warned!
>>
>> Jim C.
>>
>
> --
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> bring their own devices (BYOD) to work are irked by the imposition of MDM
> restrictions. Mobile Device Manager Plus allows you to control only the
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Re: [Emc-users] Plasma Mistake

[Les Newell]

Hi Jim,

There are a few precautions you can take so forgetting to clamp the 
ground doesn't destroy your electronics. First use a star ground. Weld a 
bolt to the frame of your machine and connect that to your supply mains 
earth. Now make sure the mains earth for your computer and plasma cutter 
also connect to the same point. You don't want any loops, just direct 
connections straight to this single point.

Second make sure none of your electronics have any connection to the 
frame of the machine. Cable screens etc should be isolated from the 
frame. The only connection should be that star point earth.

Les

On 19/05/2016 14:13, Jim Craig wrote:
> So my goal is to let others learn from my mistakes. So in that way I
> tend to make a lot of them so everyone can benefit. Last night I was
> working with the plasma machine and made a big one!
>
> Don't ever forget to hook up the ground to the plasma cutter!
>
> When we hit the go button the program started. The torch found the
> material. The pilot arc started and BAM everything stopped. Realtime
> error in LinuxCNC. Cleared repowered the machine and nothing would still
> work. That is when I realized the ground clamp was not on the cutting
> table.
>
> It took out the two breakout boards and the mesa THCAD-10 board.
> Everything else seems to have survived. I replaced one of the breakout
> boards to see what all was damaged. The parallel ports are still working
> and the stepper drives are still working so the damage was limited.
>
> So this serves as a warning to anyone that is using a plasma CNC machine.
>
> My next question is what can I do in LinuxCNC to get a message box each
> time a program is being started to check the plasma ground. This will
> help to mitigate this problem in the future.
>
> If there is no way to do it in LinuxCNC then I will add a piece of code
> to the post processor we use in Fusion360 to add the message and a
> program pause in the initial preamble of the file.
>
> John T., I ordered a replacement THCAD-10 this morning. I just want to
> thank you for the simple privacy statement on your website. I think you
> should change your terms to be "You pay me, I ship you stuff!"
>
> Thanks and be warned!
>
> Jim C.
>


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Re: [Emc-users] Plasma Mistake

[Jim Craig]

I think I will use the following:

(msg, HEY STUPID IDIOT, CHECK GROUND CLAMP!!!)
M0

Thanks John,

Jim

On 5/19/2016 8:35 AM, John Thornton wrote:
> Thanks, in your G code put:
>
> (msg, CHECK GROUND CLAMP)
> M0
>
> JT
>
>
> On 5/19/2016 8:13 AM, Jim Craig wrote:
>> So my goal is to let others learn from my mistakes. So in that way I
>> tend to make a lot of them so everyone can benefit. Last night I was
>> working with the plasma machine and made a big one!
>>
>> Don't ever forget to hook up the ground to the plasma cutter!
>>
>> When we hit the go button the program started. The torch found the
>> material. The pilot arc started and BAM everything stopped. Realtime
>> error in LinuxCNC. Cleared repowered the machine and nothing would still
>> work. That is when I realized the ground clamp was not on the cutting
>> table.
>>
>> It took out the two breakout boards and the mesa THCAD-10 board.
>> Everything else seems to have survived. I replaced one of the breakout
>> boards to see what all was damaged. The parallel ports are still working
>> and the stepper drives are still working so the damage was limited.
>>
>> So this serves as a warning to anyone that is using a plasma CNC machine.
>>
>> My next question is what can I do in LinuxCNC to get a message box each
>> time a program is being started to check the plasma ground. This will
>> help to mitigate this problem in the future.
>>
>> If there is no way to do it in LinuxCNC then I will add a piece of code
>> to the post processor we use in Fusion360 to add the message and a
>> program pause in the initial preamble of the file.
>>
>> John T., I ordered a replacement THCAD-10 this morning. I just want to
>> thank you for the simple privacy statement on your website. I think you
>> should change your terms to be "You pay me, I ship you stuff!"
>>
>> Thanks and be warned!
>>
>> Jim C.
>>
>>
>> --
>> Mobile security can be enabling, not merely restricting. Employees who
>> bring their own devices (BYOD) to work are irked by the imposition of MDM
>> restrictions. Mobile Device Manager Plus allows you to control only the
>> apps on BYO-devices by containerizing them, leaving personal data untouched!
>> https://ad.doubleclick.net/ddm/clk/304595813;131938128;j
>> ___
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>> Emc-users@lists.sourceforge.net
>> https://lists.sourceforge.net/lists/listinfo/emc-users
>
> --
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> restrictions. Mobile Device Manager Plus allows you to control only the
> apps on BYO-devices by containerizing them, leaving personal data untouched!
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Re: [Emc-users] Plasma Mistake

[John Thornton]

Thanks, in your G code put:

(msg, CHECK GROUND CLAMP)
M0

JT


On 5/19/2016 8:13 AM, Jim Craig wrote:
> So my goal is to let others learn from my mistakes. So in that way I
> tend to make a lot of them so everyone can benefit. Last night I was
> working with the plasma machine and made a big one!
>
> Don't ever forget to hook up the ground to the plasma cutter!
>
> When we hit the go button the program started. The torch found the
> material. The pilot arc started and BAM everything stopped. Realtime
> error in LinuxCNC. Cleared repowered the machine and nothing would still
> work. That is when I realized the ground clamp was not on the cutting
> table.
>
> It took out the two breakout boards and the mesa THCAD-10 board.
> Everything else seems to have survived. I replaced one of the breakout
> boards to see what all was damaged. The parallel ports are still working
> and the stepper drives are still working so the damage was limited.
>
> So this serves as a warning to anyone that is using a plasma CNC machine.
>
> My next question is what can I do in LinuxCNC to get a message box each
> time a program is being started to check the plasma ground. This will
> help to mitigate this problem in the future.
>
> If there is no way to do it in LinuxCNC then I will add a piece of code
> to the post processor we use in Fusion360 to add the message and a
> program pause in the initial preamble of the file.
>
> John T., I ordered a replacement THCAD-10 this morning. I just want to
> thank you for the simple privacy statement on your website. I think you
> should change your terms to be "You pay me, I ship you stuff!"
>
> Thanks and be warned!
>
> Jim C.
>
>
> --
> Mobile security can be enabling, not merely restricting. Employees who
> bring their own devices (BYOD) to work are irked by the imposition of MDM
> restrictions. Mobile Device Manager Plus allows you to control only the
> apps on BYO-devices by containerizing them, leaving personal data untouched!
> https://ad.doubleclick.net/ddm/clk/304595813;131938128;j
> ___
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[Emc-users] Plasma Mistake

[Jim Craig]

So my goal is to let others learn from my mistakes. So in that way I 
tend to make a lot of them so everyone can benefit. Last night I was 
working with the plasma machine and made a big one!

Don't ever forget to hook up the ground to the plasma cutter!

When we hit the go button the program started. The torch found the 
material. The pilot arc started and BAM everything stopped. Realtime 
error in LinuxCNC. Cleared repowered the machine and nothing would still 
work. That is when I realized the ground clamp was not on the cutting 
table.

It took out the two breakout boards and the mesa THCAD-10 board. 
Everything else seems to have survived. I replaced one of the breakout 
boards to see what all was damaged. The parallel ports are still working 
and the stepper drives are still working so the damage was limited.

So this serves as a warning to anyone that is using a plasma CNC machine.

My next question is what can I do in LinuxCNC to get a message box each 
time a program is being started to check the plasma ground. This will 
help to mitigate this problem in the future.

If there is no way to do it in LinuxCNC then I will add a piece of code 
to the post processor we use in Fusion360 to add the message and a 
program pause in the initial preamble of the file.

John T., I ordered a replacement THCAD-10 this morning. I just want to 
thank you for the simple privacy statement on your website. I think you 
should change your terms to be "You pay me, I ship you stuff!"

Thanks and be warned!

Jim C.


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