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Boogie
Boogie

11 Feb 2025 13:52 - 11 Feb 2025 14:33

Replied by Boogie on topic Converting a THCAD-300 to a THCAD-10?

Converting a THCAD-300 to a THCAD-10?

Category: Plasma & Laser

And will go with two THCAD-2 as ohmic sensor looks like very good approach. For the moment i'll stick to the hand held Duramax torch i have.

rodw

11 Feb 2025 12:13

Replied by rodw on topic Converting a THCAD-300 to a THCAD-10?

Converting a THCAD-300 to a THCAD-10?

Category: Plasma & Laser

The thcad2 replaces both the thcad 10 and thcad 5. The manual will tell you how to configure it. Go for a 200 volt range and you will be sweet for the 45XP

Personally, I would buy the cpc interface. There is a trick you can do with a short piece of fine wire inserted into the torch connector to permit CNC firing of the machine torch Search for it.

Boogie
Boogie

11 Feb 2025 12:07

Replied by Boogie on topic Converting a THCAD-300 to a THCAD-10?

Converting a THCAD-300 to a THCAD-10?

Category: Plasma & Laser

Thank you rodw.

I don't have THCAD yet and i just saw on Mesa website only THCAD-2 is available:( The rest is out of stock - looks like i'll have to go with THCAD-2 anyway and deal with voltage dividing somehow. My Hypertherm 45 XP is not equipped with CPC apparently, the second source as well. Buying CPC now is not and option so i will need to look at THCAD-2 if i can add some resistors to extend the range.

rodw

11 Feb 2025 10:18

Replied by rodw on topic Converting a THCAD-300 to a THCAD-10?

Converting a THCAD-300 to a THCAD-10?

Category: Plasma & Laser

My graph in the plasma primer in the linuxcnc docs is the only real data I have seen about volts over distance.
linuxcnc.org/docs/stable/html/plasma/plasma-cnc-primer.html
It showed for the specific machine, it was 7.53 volts per mm with 99.4% confidence over 16000 readings. So a 2 volt range is a good target to get your 0.01" which is realistic
You voltage will be around 130-150 volts when cutting. I have run a 300 v full scale and also 170 to 200v an I never saw any difference. I would just use your thcad 300, seeing you have it, set it to 1/32 frequency and make some parts.

kn612
kn612

10 Feb 2025 22:54

Servo Driver Plasma Retrofit was created by kn612

Servo Driver Plasma Retrofit

Category: Plasmac

I am looking for some guidance on switching my plasma table from hypertherm controls with servo motors/drivers to linuxcnc. I have retrofitted my other plasma table that uses steppers to qtplasmac/mesa hardware, however the servo wiring is beyond me. The current hypertherm controls cuts fine, however the microedge has been spontaneously rebooting and unreliable.I have a thcad 5 and thcad 10 already on hand, after reading around, I believe a mesa 7i97t is what I need? Either way I am unsure of the wiring that needs done. I apologize for my incompetence and am willing to learn. I really like the qtplasmac interface over hypertherms softwareI attached pictures of the hardware. Would it be possible to leave the pcb that the servo drivers connect to on the back panel and replace the microedge controller with some mesa hardware and the needed power supplies and linux computer?

PCW

10 Feb 2025 19:08

Replied by PCW on topic THC with Beckhoff EL5101 and THCAD2 => encoder signal loss

THC with Beckhoff EL5101 and THCAD2 => encoder signal loss

Category: Plasmac

I would check the signal at the EL5101, it sounds like an electrical issue.

Is the EL5101 setup and wired for the THCADs differential signals?

(a THCAD cannot output a 0 frequency unless it has it's input polarity reversed or lacks proper 5V power)

Sandro
Sandro

10 Feb 2025 17:32 - 10 Feb 2025 17:33

Replied by Sandro on topic THC with Beckhoff EL5101 and THCAD2 => encoder signal loss

THC with Beckhoff EL5101 and THCAD2 => encoder signal loss

Category: Plasmac

Hello everybody,

Thank you all very much for your inputs and recommendations. I can test most of them next weekend and report back to you.

I've tested the THCAD2 with a divider ratio of 1/128 and 1/64 already, but I can't remember if I also checked with 1/32. Will definitely try again.

I will also check the cabling again and the stability of the 5V power supply.

I think the frequency does not go to absolute zero but to less than 1 Hz (guess). I will also have a closer look at the duration of these drops. The EL5101 seems to provide some values for underflow, overflow and also the possibility to filter the frequency.

Warning: Spoiler!

static const lcec_pindesc_t slave_pins = {
{ HAL_BIT, HAL_IO, offsetof(lcec_el5101_data_t, ena_latch_c), "%s.%s.%s.enc-index-c-enable" },
{ HAL_BIT, HAL_IO, offsetof(lcec_el5101_data_t, ena_latch_ext_pos), "%s.%s.%s.enc-index-ext-pos-enable" },
{ HAL_BIT, HAL_IO, offsetof(lcec_el5101_data_t, ena_latch_ext_neg), "%s.%s.%s.enc-index-ext-neg-enable" },
{ HAL_BIT, HAL_IN, offsetof(lcec_el5101_data_t, reset), "%s.%s.%s.enc-reset" },
{ HAL_BIT, HAL_OUT, offsetof(lcec_el5101_data_t, inext), "%s.%s.%s.enc-inext" },
{ HAL_BIT, HAL_OUT, offsetof(lcec_el5101_data_t, overflow), "%s.%s.%s.enc-overflow" },
{ HAL_BIT, HAL_OUT, offsetof(lcec_el5101_data_t, underflow), "%s.%s.%s.enc-underflow" },
{ HAL_BIT, HAL_OUT, offsetof(lcec_el5101_data_t, latch_c_valid), "%s.%s.%s.enc-latch-c-valid" },
{ HAL_BIT, HAL_OUT, offsetof(lcec_el5101_data_t, latch_ext_valid), "%s.%s.%s.enc-latch-ext-valid" },
{ HAL_BIT, HAL_IO, offsetof(lcec_el5101_data_t, set_raw_count), "%s.%s.%s.enc-set-raw-count" },
{ HAL_S32, HAL_IN, offsetof(lcec_el5101_data_t, set_raw_count_val), "%s.%s.%s.enc-set-raw-count-val" },
{ HAL_S32, HAL_OUT, offsetof(lcec_el5101_data_t, raw_count), "%s.%s.%s.enc-raw-count" },
{ HAL_S32, HAL_OUT, offsetof(lcec_el5101_data_t, count), "%s.%s.%s.enc-count" },
{ HAL_S32, HAL_OUT, offsetof(lcec_el5101_data_t, raw_latch), "%s.%s.%s.enc-raw-latch" },
{ HAL_U32, HAL_OUT, offsetof(lcec_el5101_data_t, raw_frequency), "%s.%s.%s.enc-raw-freq" },
{ HAL_U32, HAL_OUT, offsetof(lcec_el5101_data_t, raw_period), "%s.%s.%s.enc-raw-period" },
{ HAL_U32, HAL_OUT, offsetof(lcec_el5101_data_t, raw_window), "%s.%s.%s.enc-raw-window" },
{ HAL_FLOAT, HAL_OUT, offsetof(lcec_el5101_data_t, pos), "%s.%s.%s.enc-pos" },
{ HAL_FLOAT, HAL_OUT, offsetof(lcec_el5101_data_t, period), "%s.%s.%s.enc-period" },
{ HAL_FLOAT, HAL_OUT, offsetof(lcec_el5101_data_t, frequency), "%s.%s.%s.enc-frequency" },
{ HAL_FLOAT, HAL_IO, offsetof(lcec_el5101_data_t, pos_scale), "%s.%s.%s.enc-pos-scale" },
{ HAL_FLOAT, HAL_IO, offsetof(lcec_el5101_data_t, freq_scale), "%s.%s.%s.enc-freq-scale" },
{ HAL_FLOAT, HAL_IO, offsetof(lcec_el5101_data_t, freq_filter_gain), "%s.%s.%s.enc-freq-filter-gain" },
{ HAL_FLOAT, HAL_OUT, offsetof(lcec_el5101_data_t, freq_filtered), "%s.%s.%s.enc-freq-filtered" },
{ HAL_TYPE_UNSPECIFIED, HAL_DIR_UNSPECIFIED, -1, NULL }
};

I was also thinking of some moving average to filter the drops. But I don't know how I could implement this. Writing a custom HAL component?

rodw

09 Feb 2025 22:36

Replied by rodw on topic THC with Beckhoff EL5101 and THCAD2 => encoder signal loss

THC with Beckhoff EL5101 and THCAD2 => encoder signal loss

Category: Plasmac

Hakan wrote:
Maybe the EL5101 can say when it doesn't have a good reading, or something along those lines. Obviously check cabling.
It seems you get zero Hz as frequency, that's a unique signal, THCAD always give some hundred/thousand of Hz.
Maybe some hal trickery to hold the last good value while frequency is zero. An own component perhaps.

Yes, a real time component could monitor the voltage and add a delay before it drops the voltage sent to plasmac. The moving average would do something similar. Say it averaged 1000 readings ( 1 second), it would take 1 second before it fell all the way to zero.

From your halscope plot, please let me know how long it lasts for.

PCW

09 Feb 2025 22:32 - 09 Feb 2025 22:41

Replied by PCW on topic THC with Beckhoff EL5101 and THCAD2 => encoder signal loss

THC with Beckhoff EL5101 and THCAD2 => encoder signal loss

Category: Plasmac

I would try at the THCADs 1/32 divide ratio

(The 1/1 ratio has relatively short pulse widths = 0.5 usec
which might be too short for the EL5101)

Hakan
Hakan

09 Feb 2025 21:22

Replied by Hakan on topic THC with Beckhoff EL5101 and THCAD2 => encoder signal loss

THC with Beckhoff EL5101 and THCAD2 => encoder signal loss

Category: Plasmac

Maybe the EL5101 can say when it doesn't have a good reading, or something along those lines. Obviously check cabling.
It seems you get zero Hz as frequency, that's a unique signal, THCAD always give some hundred/thousand of Hz.
Maybe some hal trickery to hold the last good value while frequency is zero. An own component perhaps.

rodw

09 Feb 2025 20:42

Replied by rodw on topic THC with Beckhoff EL5101 and THCAD2 => encoder signal loss

THC with Beckhoff EL5101 and THCAD2 => encoder signal loss

Category: Plasmac

Hmm, can you advise how long it drops to zero for? I did a component once that does a moving average of the torch voltage. You might be able to use it to bridge the outage...

Also you could try just using a 0-10 volt Ethercat analog input instead of the encoder input and thcad..

tommylight

09 Feb 2025 20:32

Replied by tommylight on topic THC with Beckhoff EL5101 and THCAD2 => encoder signal loss

THC with Beckhoff EL5101 and THCAD2 => encoder signal loss

Category: Plasmac

1. check wiring, literally remove each wire and re-seat it properly on the THCAD side and BeckHoff side
2. use a DVM with memory min/max and measure the 5V supply for the THCAD, if it goes under 4.75V change the power supply or add a 100-220Ufarad capacitor at the THCAD terminals and test again
3. set the divider higher or lower depending on how you look at it, if it is 1/32 set it to 1/64 and plot again.

Sandro
Sandro

09 Feb 2025 18:31 - 10 Feb 2025 17:18

THC with Beckhoff EL5101 and THCAD2 => encoder signal loss was created by Sandro

THC with Beckhoff EL5101 and THCAD2 => encoder signal loss

Category: Plasmac

Hello everyone,

I am currently setting up my plasma cutter and encountering some initial issues that need resolution. One of these issues is the intermittent loss of my THC encoder signal, which occurs briefly at irregular intervals. Aside from this, the signal quality appears to be satisfactory in terms of noise. When the signal is lost for a few milliseconds, the torch attempts to compensate by raising itself before leveling again. I have attached a photograph (apologies for the quality) that illustrates the signal drop, followed by a voltage increase caused by the raised torch before it levels again.

I am utilizing a Beckhoff EL5101 incremental encoder interface in conjunction with a Mesa THCAD2. I have also tested with a THCAD300 I had available, and the issue persists. Additionally, I am employing hypersensing with a second THCAD2 and another Beckhoff EL5101, exhibiting the same behavior. Given that I previously used the THCAD300 with a 7i76e without issues, I suspect that the Beckhoff modules might be the cause.

Attached are three screenshots: one showing arc voltage at 0V, another displaying encoder frequency initially at 0V and then at 12V for testing purposes, and finally, the problematic screenshot showing encoder frequency during cutting. What options do I have to filter these signal drops effectively?

Thank you in advance for any advice or recommendations.

Boogie
Boogie

09 Feb 2025 12:41

Replied by Boogie on topic Converting a THCAD-300 to a THCAD-10?

Converting a THCAD-300 to a THCAD-10?

Category: Plasma & Laser

I was asking as I was wondering what is the practical resolution. Everyone talks about better resolution, but do we practically need this "better" resolution? From mesa website: "10 bits at a 1 KHz sample rate and 12 bits at a 250 Hz sample rate"
is 250 Hz update slow? is 10-bits @ 1 kHz not enough? Heard somewhere that 0.01" THC control accuracy today is pretty good and pairing it with other info that 1 V arc voltage change relates to ca 0.004" (varies but can be used as rule) gives 2.5V arc voltage change. 300 V range @ 10-bit gives 300mV resolution. If 250 Hz is enough then 12-bit gives 73 mV.

I know 0.1 nV is better, but do we need it?

It's just because i have two plasma sources: Powermax 45XP and CUT 70P from Stahlwerk. I'm not going to buy CPC kit for 45XP so THCAD-300 will be more universal. I don't know if my 45XP has any divider installed inside. I don't know if CUT 70P has divider as well. I'm away so have no access to machines to open them and check internals. But I have now option to buy THCAD cheaper (shipping to US instead of to europe to avoid unnecessary and significant costs).

beauxnez
beauxnez

08 Feb 2025 21:49

Replied by beauxnez on topic Remora - ethernet NVEM / EC300 / EC500 cnc board

Remora - ethernet NVEM / EC300 / EC500 cnc board

Category: Computers and Hardware

BrysonW wrote:
Hello, this is a reply to beauxnez post from few days ago."hello, is it possible to make an nvem card work with qtplasmac?" The answer is yes, another friend and myself are right at the end of a plasma machine build, were using a ec500 as the controller and it works fantastic with qtplasmac. I will say the THC is the only thing that we don't have working at the moment. On ours the plasma output is just on output 1, torch is either on or off. It goes from the board and turns a relay on and off which is the actual switch. For ours we have a Everlast 82i for the plasma cutter which has a 50:1 voltage divider, that gives us a 0 - 5v output for the torch voltage but from my understanding there aren't any analog inputs on these boards. A analog to digital converter may be a option. I'm not sure what the output of the mesa THCAD boards looks like, there may be a way to use one of those. I'm just getting started on trying to setup a arduino to take the analog voltage, work some magic on it, and send the info to linuxcnc that way using modbus. The downside I'm seeing to this approach is effectively I'm setting up a second controller to take just one analog input, and I'll have to put a switch inline on the ethernet cables. The upside is another controller and analog input, so now I can dream up more features to add to this machine (During our build process it started as a basic machine, we now have individual limit switches for every axis, probing, etc. , touchscreen interface, and so on..) I saw that you managed to make a card work under remora with qtplasmacmy card now works with the 3 axes under axisI would now like to pass it under qtplasmac, you can help me because I have an error message

I saw that you managed to make a card work under remora with qtplasmac
my card now works with the 3 axes under axis
I would now like to pass it under qtplasmac, I need help because I have an error message?

File Attachment:

File Name: NVEM.hal
File Size:4 KB

File Attachment:

File Name: NVEM.ini
File Size:3 KB

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