Plasma Mega V set up

[storm]

I own the Mega V Plasma/Router.
We have been creating projects with the router since April and the machine has been working great for those.

I still have not seen any information on the Plasma set up, other than a single page on how to switch the pin outs.   We have been waiting for some videos or instructions from MillRight to come out on how to set everything up for the Plasma.
Does anyone have their plasma set up and running?  If so I would love a videos, pictures, or basic instructions.

Any information would be very helpful. 

[bLouChip]

Ditto. I'm a few weeks behind you, mine is on order with delivery expected late Dec. I'm going to use PrimeWeld CUT60 with the stock IPT60 torch for starters; I'll go to the PTM60 machine torch if necessary. I hope to post some videos of setup and use. Like you I've been using MR for a little while now, since Feb 2019, CK model, router and laser. Looking forward to using the Mega V Plasma unit. While researching plasma tables and power units, I found what has been an excellent source of plasma power unit and torch knowledge, consumable parts, and service if needed - www.georgesplasmacuttershop.com/
I'll stay in touch here.

[jv]

I haven't seen anyone use the plasma version yet. I spoke to a few people that bought the machine and then planned on saving up for the plasma torch down the road. So you guys might have to be a little creative figuring some stuff out and passing it along

[storm]

Spending weeks searching the web for any information on the plasma set up I have figured out a few things. Most of what I have learned is from seeing how other brand machines are set up.
The torch holder supplied by Millright is much better than their prototype shown in their one demo video. So well done on that design. What I don't know is if the limit switch on the torch holder is intended to be plugged into the Z axis machine control , or if it plugged into the probe port.
The Probe port has me concerned as I have never been able to get the probe working correctly. It just moves down on the Z and causes an error upon contact. I have tried at least 3 different macro set ups in UGS, including one found here on the Millright boards. But everything just errors. I do not know if it is a control board issue.

The other big question I have is, what G-code sender works with a plasma. I know Mach-3 has a plasma function, but doesn't not work with the Millright machines. Bruce has a post in these boards where he lists 8 or 10 different g-code senders that work with the Millright Machines, but I do not see any specific Plasma operations in any of those.
UGS appears to have two Switches, Spindle M3 M4 M5 and Coolant M7 M8 M9. Does it make sense to manipulate these switches to turn the torch on and off? Or does anybody know of a G-code sender with a plasma function that works with Millright?

Lastly, we use Vcarve Pro. Again there is not a specific Plasma function built into any of the Vetric software. There is one video out there where a guy uses the Vetric software and he just programs the Vetric Post Processor with macros that fire the torch, but he uses Mach-3 g-code sender. I am going to try and use this with UGS, as I really do not want to invest heavy into another program. Sheetcam looks to be a relatively inexpensive program ($150) built specifically for plasma but I have not figured out if it writes G-code that works with Millright.

[storm]

Think I answered one of my questions about Vcarve. I will just need to know what pin it switches on the Millright Control when activated.


From Vetric support:
These sections are for supporting jet-based cutting tools such as lasers, plasmas and waterjets.

JET_TOOL_POWER
+---------------------------------------------------

+ Commands output when the cutter's power is set

+---------------------------------------------------

begin JET_TOOL_POWER

"Commands"

For an example of a JET_TOOL_POWER section, see the file: Grbl.pp

Commands that are output when the power setting associated with a laser 'tool' is issued.

JET_TOOL_ON
+---------------------------------------------------

+ Commands output when the cutter's power is turned ON

+---------------------------------------------------

begin JET_TOOL_ON

"Commands"

For an example of a JET_TOOL_ON section, see the file: Grbl.pp

Commands that are output when the jet tool is powered on. This is broadly equivalent to SPINDLE_ON, but is typically issued a the end of a plunge move when the jet cutter is already at the intended cutting height, instead of before the plunge move as required by a spindle based cutter.

JET_TOOL_OFF
+---------------------------------------------------

+ Commands output when the cutter's power is turned OFF

+---------------------------------------------------

begin JET_TOOL_OFF

"Commands"

For an example of a JET_TOOL_OFF section, see the file: Grbl.pp

Commands that are output when the jet tool is powered off.

[Bruce]

The probe function is used to zero the Z axis vertically when you change endmill bits. I don't know how it would be used on a plasma cutter.

[storm]

Hello Bruce,
I appreciate you chiming in, I think you are one of the most knowledgeable members on these boards.

The plasma torch holder supplied is magnetically attaches to the Z Axis somehow. ( I haven't figured that out yet. Think I need to build a steel plate that attaches to the router mount)
The torch holder has 4 wheels and some travel, allowing it to move up and down about an inch. It has its own limit switch attached to the
torch holder. I think the idea is to program into the post processor a Z axis down move until the torch contacts the surface of the metal (thus triggering the attached limit switch), then retracting the Z to the proper torch height to initiate the Torch ON.

That is why I think it may need to be connected to the probe port.


The sequence needing to be programmed into a post processor should be:

Move to starting X Y.
Probe down.
When Limit switch is triggered retract to "XXX" height. ( the excess up/down movement in the wheels of the torch holder + .100 above the material.
Torch on
Pause "XXX" to allow for plasma pierce. ( I believe this should be a .6 second pause)
run cutting G Code
Torch off.
Retract to safe Z.

Repeat.

[Bruce]

Since you are working with metal, that should work with the probe. What are you using for G-code sender?

I would recommend touching base with Derek or someone at [e-mail]
You might also try the facebook group MillRight CNC Mega V Group: www.facebook.com/groups/1006388983068312
There might be some plasma users there also.

[storm]

Our current set up for the router is, Rhino for most of our intricate design work, Vetric Vcarve Pro, for light design, and all of our post processing, UGS Platform to run the machine.

I am comfortable manipulating the Vcarve Post Processor.

I am less knowledgeable with UGS, and we are trying to figure that out.

Millright Supplied us with a torch "on" Function that should enable pin #14 on the breakout board:
M3 S12000
G1 F300

I believe M5 will Torch "off" at the end of the cutting sequence.

[Bruce]

OK so
M3 is the spindle or laser on command.
S12000 is the RPM speed setting, or laser intensity.
G1 F300 sets the feedrate to 300 for all subsequent moves.
M5 turns the spindle or laser off

That makes sense to add the plasma cutter to the spindle and laser list of devices that can be controlled.

[storm]

Working on programming and general set up.

On the breakout board, between ground and pin 14. It is a simple On Off switch controlled by M3 on and M5 off. Changing "S" spindle speed has no additional effect for a plasma set up.

Working on the torch mount. When you remove the router from the holder, the breakaway torch holder attaches magnetically against the Z plate and the torch will fit through the router holder. It is a nice set up for a quick switch out, except the magnets are too small and week. with very little pressure you can rock the mount side to side. I had to design a bracket that attaches to the base of the holder that holds the mount from rocking, again using magnets to allow for the breakaway action.
Another issue I found is the torch holder sits tight against the Z plate, not offset like the router is. When you "home" the machine the torch bracket collides with the Z motor bracket before it hits the Z homing switch. I came up with a spacer to add to the Z Homing switch while in torch mode to allow the machine to hit the switch before the collision.

I am awaiting a Proma SD THC to arrive before I continue the set up. You will need the Proma SD, not the Proma 150.

Next big issue for my set up will be my UGS Platform causing an "Probe Error" anytime the probe makes contact and stalling any further action until the contact is broken. I will need the probe feature working (or a good work around) for the torch Touch Off. I am begging anyone with a way to fix the probe error please let me know.

[bLouChip]

Storm -   I'm checking in to see if you have any additional tips for the Mega V Plasma setup/build ? 

I concur on the torch mount design, and likewise I'm considering some minor change to fix it.  Do you mind posting pics of your fix ?  I like the basic design from MR and I may just be looking to broaden the magnetic footprint to give more stability. 

Also, I'm planning to add a break-away pause switch to the torch holder that pauses movement and I hope shuts down the plasma jet (virtual M5), but does not kill power to CNC or plasma power source.  I'd like to be able to resume cutting from the collision point.  But I need some expert help here -  I see pin outs on the CNC controller board that are labeled: FDHD (feed hold?),  RSM (resume?), and DOOR (as in interlock?).  So is the combination FDHD and DOOR going to pause XYZ and drop SPEN (spindle enable aka plasma trigger) ?  Or do I just need one or the other input ? how are they different ? Is there another solution ?

I read this post thread for pause/resume clues, millrightcnc.proboards.com/thread/2492/carveking-stop-end-switch

so maybe something similar is the way to go, will require a latching relay with manual reset, DPDT, being added to the plasma trigger circuit so the torch doesn't refire when the break-away micro or reed switch is reset.  latching relay like this: www.audiowind.com/pdf/D-262to264.pdf

Lastly, I post here this related forum thread in case it bears fruit and others could use - I'm about 1 to 2 weeks away from completing my build, a few customizations, and then running my first plasma burn. In preparation for that burn, I have posted a feature request to the laser software forum LightBurn that I use on my CarveKing laser unit. I love the LightBurn, it's much improved over the past 2 years and it not only gens the gcode but also manages the send, so no need for UGS in this case.  (I still use UGS for sending my Fusion360 projects.) 

forum.lightburnsoftware.com/t/feature-request-per-cut-focus-touch-off-for-plasma-cutting-w-thc/32101

Comments welcome.  Thanks much.

Lou

[bLouChip]

After some internet searching, I found information on the behavior of Feed Hold and Door on the Arduino Uno running GRBL 1.1h and I'll pass along here for anyone interested. Since my MV build is not complete yet, I don't know the GRBL version on the MV controller, but I believe it'll be irrelevant to the condition I'm trying to solve based what I discovered. but first - The condition I'm trying to solve is: kill the plasma jet when activating FDHD (feed hold) by way of a break-away switch placed on the magnetic torch mount. This is not the probe/touch-off limit switch already mounted to the magnetic torch mount that MR provides. I'm adding another switch, a magnetic reed switch NC, so the magnet will hold the switch open until it's removed from proximity, aka the torch mount breaks-away due to collision.

What I discovered about Feed Hold and Door is that in order for either to add stopping the spindle to their behavior, one must do: 1) grbl 1.1h+ is pre-req version, 2) grbl source code config.h file must be edited to include some #define constants enabling the behavior, 3) grbl needs to be recompiled and flashed onto the Arduino controller, and 4) even then I find some users complaining about varied behavior and issues with UGS interacting negatively with the new behavior. So in the end, I can't count on that solution.

Therefore, I'm planning to implement the default Feed Hold pin behavior and kill the plasma jet using a latched relay in series with the plasma trigger relay in the MV controller box. The break-away reed switch circuit will pick the latched DPDT relay, one contact will close Feed Hold input while the other contact will drop the plasma trigger line. The latched relay will remain latched until a manual reset is performed with a signal from a momentary push button, the latched state holds even if power is lost and resumed. LightBurn sw has a "run from here" feature to allow resuming from the collision point once the collision issue is resolved. UGS Platform V2.0.7 has this feature also, in UGS see menu Machine->Run From...

It's all theory right now anyway, I'm a week or so away from trying it out, but I want to account for the wiring in the drag chains while I'm building and add/mod the parts without having to disassemble. I'll post here how it turns out.

Question for MR folks:  It appeared the Arduino board is getting it's power from the USB port (aka my computer), is that right ?  Just curious, and good to know if so.

[storm]

Hello,
Yes I will get a picture of the torch holder set up I came up with. It works well.
I will also do a bit of a write up on everything I needed to do to be able to cut metal. It was not a fun or cheap process.

More information this weekend

[usafpilot67]

Feb 5, 2021 1:19:49 GMT storm said:

Hello,
Yes I will get a picture of the torch holder set up I came up with. It works well.
I will also do a bit of a write up on everything I needed to do to be able to cut metal. It was not a fun or cheap process.

More information this weekend

This is what I am running into. The router is hitting the z motor... the torch holder is almost worthless. For the torch im thinking about 3D printing a piece to fit into the router holder to hold the torch. This will eliminate the limit switch but the torch will remain in position and produce an accurate cut. Can you please post a picture of what you have done?