PS:1 Wiki Dev - User contributions [en]

CNC Plasma Cutter

2019-01-28T01:21:32Z

Daddybird: /* Running A Job */

{{Template:EquipmentPage
|owner = PS:One
|hostarea = CNC
|certification = yes
|hackable = no
|model = N.A.
|serial = N.A.
|arrived = 10/16
|where = Hot metals
|doesitwork = yes
|contact = CNC Area Host
|value = $6000
|image = IMG_4045.JPG
}}

== Status ==

Working. Stay tuned for an announcement about authorizations.

== Authorization ==

Authorization requirements:

* This is not a commercial machine; it was hand-built at PS1 and as such there is no website to check, nor any manual to read. You must be willing to accept the fact that the machine can be quirky and you may have to do some troubleshooting when using it (hopefully not, but ¯\_(ツ)_/¯).
* You should be familiar with how plasma cutters work (at the very least, read this: https://en.wikipedia.org/wiki/Plasma_cutting). If you can swing it, please get authorized on the Miller handheld plasma machine beforehand; this is not a requirement, just a useful suggestion.
* Read all of this page about the machine: https://wiki.pumpingstationone.org/CNC_Plasma_Cutter
* Read and be willing to add your experience/knowledge of using the machine here: https://wiki.pumpingstationone.org/Talk:CNC_Plasma_Cutter

[[CNC Plasma Cutter Authorization]] has more details.

== Drawing guidelines ==

* No sharp corners, all corners should be filleted with at least a 1/16" radius
* The thicker the part, the larger the smallest feature
** Small holes 1/4" and under are not advisable
** Holes under 3/4" on 3/8" plate are not advisable
** Not all these sizes are learnt yet, this is why you need extra material
* Acceptable drawing formats:
** DXF
** SWF
* Acceptable drawing formats for review:
** DXF
** SWF
** AI

== Safety and Protective Equipment ==

* Number 5 shades when a job is running
* Thick gloves when handling freshly cut parts
* Hearing protection recommended
* Respirator/mask while cutting

== Procedures ==

=== Machine Startup ===
Fill water table if not filled already. Takes about 35 minutes to fill. Be sure to have the splash guard on it so when it's filled the air does not spray water everywhere.

# Wipe down machine with clean dry clotha
# Log in to machine
# Turn on air
# Make sure e-stop is depressed
# Turn on control box
# Start Mach3
# Clear e-stop
# Raise Z
# Move torch to end of table
# Remove torch shield and inspect for dross build up
# Reinstall torch shield
# Turn on plasma cutter
# Check cutter status (Air/torch/etc)

=== Machine Shutdown ===

# Hit e-stop
# Exit Mach3
# Turn off plasma cutter
# Turn off air
# Turn off control box
# Clean torch shield
# Sweep under table
# Wipe down machine with clean dry cloth
# Wipe down computer
# '''Leave the area cleaner than you found it'''

=== Creating a Job ===

# Start SheetCam
# Import a Drawing from the File menu. Remember that the origin is at the bottom left on Sheetcam, and the origin on the machine is back left.
# Click on Operation => Plasma Cut
# Unfortunately most settings can be changed by other users between jobs. Some that seem to work:
** 130 ipm feed rate
** Tool: T11: Plasma 12 Gauge (or whatever gauge you're cutting)
** Note that Inside/Outside offset determines if you're trying to cut an inside edge or outside edge.
** You may need to select a layer.
# Click OK and the path should be generated and display.
# To create a TAP file go to the P icon at top left. That's post-processing.
# It should save as type G-code/.tap.

This is now a runnable job.

=== Running a Job ===
Look elsewhere for turning on the machine, filling the table, turning on the plasma cutter.

# Start Mach3 CNC
# You should be able to move the gantry using the arrow keys to get into position. You MUST start your job over metal - it does an auto z-axis zero/home.
# If "Reset" is flashing, click it to reset the connection.
# Test the job without the plasma on if you want.
# Turn on plasma cutter and close curtain.
# Click Cycle Start (green).

=== Starting a job from a particular line of code (needs update)===
*Run from here
*Select next line

=== Previewing a job (needs update) ===
*Load file
*Select the 'Run BLK' button in the interface or type Alt-N
*Press the start job button - this will step through each line of code
(warning: includes torch homing and torch ignite so be careful)
*You can step backwards though a job by pressing the 'reverse order' button.

=== Job Crashes ===

==== SmoothStepper Buffer Under run ====

'''Your work piece is trash, start again, home position lost'''

# Click through error
# Start your job again

Causes:

* Communication error between smooth stepper and PC

==== Touch off failure ====

'''Your work piece is not trash yet, but might be if you don't follow these steps'''

One of the following happened:

* Touch off get stuck with torch touching the plate
* Touch off fails to detect plate and rams into the plate
* Error probe ignored in status bar - If this is the case clean the shield nozzle, dross has gotten inside, do not move work piece

Do This:

# Hit escape '''ONCE''', not e-stop, not reset, escape
# Double click in the g-code window to display line numbers eg: 20:N0100 G91.... rather than N0100 G91....
# Look for the current line, it should be highlighted and be: G31 Z -100
# Look up a few lines for the torch moving to safe height: G00 Z1.5
# In the operator console click in the line number box
# Type in the line number of the safe hight move and hit return
# Highlighted line should change to that line
# Hit "Set next line" button
# Hit cycle start

Causes:

* Dross has built up inside shield
* Work piece is flapping around like a flag in a breeze, put some weights on it
* Dross/corrosion on the plate cause a none conductive area where the torch touched off
* Torch cable has become too taught and caused the probe connection to come loose or the probe ring not to touch the torch shield

==== Torch fails to ignite ====

'''Your work piece is not trash yet, but might be if you don't follow these steps'''

Mach3 shows job stuck on M3 command.

# Hit F5 to re-ignite the torch (possibly twice)
# Job should continue once M3 detects arc transfer signal from the plasma cutter

Causes:

* Unknown at this time

==== Mach3 Crash ====

'''Your work piece is trash, start again'''

# Shutdown the control box
# Close Mach3
# Turn on control box
# Start Mach3
# Run your job again

Causes:

* Unknown at this time

== Sheet Cam ==

https://www.youtube.com/user/arclightdynamics/videos has good tutorials.

Sheet Cam settings always use the last setting. So double check it's what you want.

Origin is bottom left. Origin on the machine is back left. Brown box is the material size, but it doesn't need to be set.

It's a good idea to have a bounding box on your work so it's placed correctly.

Isolate paths by selecting them then put them in a new layer. This includes the previously mentioned bounding box.

Cuts can be inside edge, outside edge or on the line. A lead in is a good idea to help keep the cuts clean. Lead out has not been tested but may help.

The post-processor to use for this machine is named 'PS1 Plasma'. It's already included in the list of post-processors on the installed copy of SheetCam.

=== Manual Controls ===
* Arrow keys move X/Y
* Shift PageUp/PageDown moves the Z axis

Click the zero button to set home. (this is from memory, please correct -- Burton)

== Todo List ==

* Documentation

Squareness todo:

* Physical end stops - probably want to move the wiring out of the X axis tubes for this
* Limit switches on A-axis (slaved to X, the rail against the wall)

This will allow both manual squareness and automatic machine homing. Mach 3 has a routine that will home the X axis with the slave, then adjust which ever one did not hit the home switch independently.

Water table todo:

* <s>Fix 2 pin hole leaks (one at each end of tank)</s>
* <s>Fit bladder input line (so it doesn't collect crap in the tank)</s>
* Wash out old compressor tank
* <s>Trim the top of the side where the A axis hardware grazes the top of the tank.</s>
* Paint the outside of the tank
* <s>Treat the water with the green goo</s>

Plumbing/wiring todo:

* Extend air line to under table to create a manifold for table mounted air consumers
* Run large conduit for 220 outlet for the plasma cutter
* Run small conduit for data/estop between the table and the PC
* Run black pipe for connecting the table to the bladder (old compressor tank)
* Water line from north side of the shop, with input into the old compressor tank
* Air lines to the compressor tank (one vent on from the compressor)
* Run ethernet line to PC so its not on wifi any more
* Z axis limit switches

Plate marker todo:

* Design and cut new y-axis trolly or offset plate to carry torch and marker
* Machine mount for engraver
* Mount new trolly with air slide and Z axis
* Plumbing and wiring
* Pen mount as well as engraver?

35A Fine Cut todo:

* Build floating Z axis using left over linear rail
* How to multiplex the digitise input for touch off? Relays to switch digitise input from ohmic sensor to switch on head? (and disconnect the switch from the z limit array) (the switch should be in the z limit switch array by default incase the THC plunges the torch into the work piece)

Roundness/cut quality todo:

* <s>Y Axis pulsing - new connection spigot for drive year to fix eccentric rotation of gear</s>
* Remove and clean X axis gears, reinstall and use loctite on set screws (the keep backing off)
* Make sure all bearings are right against the rails so there is no slop
* <s>Investigate backlash and configure mach3 is required</s> - 0.0001 on X, Y and A
* Get quote for installing ground rod next to the table and execute it
* Look into THC issues (cut rippling) if still present after ground rod - possible Z axis flex in the mount to the Y carriage.
* Why is the THC seeing ~80V for a good clean cut from the hypertherm? Is the internal voltage divider broken (is this why the machine was retrofitted with a dangerous high voltage tap?)? Or is this related to a bad ground at the table?
* Motion pauses: (Seen on large 3'x2' complex cuts)
** Why are there zero move G1's at the end of curves generated with G2's
** <s>Do we need to add a CV on G-Code in the preamble of the post processor</s> - Does not appear to need this
** Smooth stepper under-run errors - I have only seen this when jogging not cutting, mostly related to rapiding the Z, maybe reduce the micro stepping on the driver for the new threaded drive step count is huge per inch which could be hurting us
** <s>Axis and Core frequency tuning for the smooth stepper?</s> - Dropped to 64k on X,Y,A
** <s>Look ahead tuning</s> - increased to 150
** Is CV plasma mode hurting us?
** <s>System problems, AV jamming things up?</s> - low cpu load not an issue

Ohter things:

* Cleaning/maintenance schedule
* Shelves/lockers in the unused space under the table for project/tool/etc storage?
* Materials storage ideas?
** sheet goods
** 20-24' bar/tube stock

== Future Items ==

* Tube attachment
* scribe attachment

== Torch Consumables ==

The torch is a T45m hypertherm machine torch.

{| class="wikitable" border="1"
!colspan="3"|Consumables Change Log
|-
! Date
! What
! By
|-
|6/10/17
|electrode, nozzle
|Andrew Camardella
|-
|}

[http://www.thefabricator.com/article/plasmacutting/plasma-cutting-maintenance-are-you-throwing-money-away What does a worn electrode look like?]

Torch tips components are consumables. If you are getting a wide kerf or the plasma torch isn't cutting through the materials anymore you may need to change the tip parts. To change the consumables disconnect the ground clip from the black retaining cap and unscrew the entire tip from the retaining cap.

=== Standard ===
* Shield P/N: 220673
* Deflector P/N: 2206732
* Retaining Cap - Ohmic P/N: 220719
* Nozzle P/N: 220671
* Electrode P/N: 220669
* Swirl Ring P/N: 220670

=== Fine Cut ===

'''THERE IS CURRENTLY NO POST PROCESSOR FOR RUNNING WITH THESE CONSUMABLES INSTALLED'''

'''NOTE''': These parts are for a t30 unshielded torch, they are compatiable with the T45m when it is run at a setting lower than 30A and cutting materials thinner than 3/16". Ohmic sensing will not work with these parts installed.

* Deflector P/N: 2206732
* Retaining Cap - Ohmic P/N: 220483
* Nozzle P/N: 220480
* Electrode P/N: 220479
* Swirl Ring P/N: 220478

[[:File:T45m.pdf|Consumables catalog page]]

== Feeds and Speeds ==

=== T45m Shielded Consumables ===

==== Mild Steel ====

{| class="wikitable"
!colspan="5"|
!colspan="2"|Recommended
!colspan="2"|Maximum
|-
!Arc Current (a)
!Material Thickness
!Torch-to-work distance (in)
!Initial Piece hieght (in)
!Pierce time delay (s)
!Cut Speed (ipm)
!Arc Voltage (V)
!Cut Speed (ipm)
!Arc Voltage (V)
|-
|rowspan="4"|30
|0.018" 26Ga
|rowspan="4"|0.06"
|rowspan="4"|0.15"
|rowspan="3"|0.0
|?
|117
|400
|118
|-
|0.030" 22Ga
|?
|116
|400
|117
|-
|0.036" 20Ga
|?
|115
|400
|117
|-
|0.060" 18Ga
|0.2
|?
|111
|280
|115
|-
|rowspan="12"|45
|0.036" 20Ga
|rowspan="12"|0.06"
|rowspan="8"|0.15"
|rowspan="2"|0.0
|380
|115
|400
|112
|-
|0.060" 16 Ga
|150
|116
|400
|115
|-
|0.075" 14Ga
|0.1
|150
|117
|360
|115
|-
|0.105" 12Ga
|0.3
|130
|117
|240
|115
|-
|0.135" 10Ga
|0.4
|110
|117
|175
|115
|-
|0.188" 3/16"
|0.5
|85
|118
|110
|115
|-
|0.250" 1/4"
|0.6
|60
|120
|75
|116
|-
|0.375" 3/8"
|0.9
|32
|122
|40
|116
|-
|0.500" 1/2"
|colspan="2" rowspan="4"|Edge Start Recommended
|4
|132
|25
|125
|-
|0.625" 5/8"
|3
|138
|14
|127
|-
|0.750" 3/4"
|2
|140
|10
|131
|-
|1.000" 1"
|?
|146
|5
|142
|-
|}

==== Stainless Steel ====

{| class="wikitable"
!colspan="5"|
!colspan="2"|Recommended
!colspan="2"|Maximum
|-
!Arc Current (a)
!Material Thickness
!Torch-to-work distance (in)
!Initial Piece hieght (in)
!Pierce time delay (s)
!Cut Speed (ipm)
!Arc Voltage (V)
!Cut Speed (ipm)
!Arc Voltage (V)
|-
|rowspan="4"|30
|0.018" 26Ga
|rowspan="4"|0.06"
|rowspan="4"|0.15"
|rowspan="3"|0.0
|?
|117
|400
|123
|-
|0.030" 22Ga
|?
|116
|400
|121
|-
|0.036" 20Ga
|?
|115
|400
|119
|-
|0.060" 18Ga
|0.2
|?
|111
|185
|118
|-
|rowspan="12"|45
|0.036" 20Ga
|rowspan="12"|0.06"
|rowspan="8"|0.15"
|rowspan="2"|0.0
|?
|115
|400
|109
|-
|0.060" 16 Ga
|138
|116
|400
|125
|-
|0.075" 14Ga
|0.1
|?
|117
|360
|115
|-
|0.105" 12Ga
|0.3
|?
|117
|200
|116
|-
|0.135" 10Ga
|0.4
|?
|117
|155
|118
|-
|0.188" 3/16"
|0.5
|?
|118
|85
|118
|-
|0.250" 1/4"
|0.6
|?
|120
|55
|120
|-
|0.375" 3/8"
|0.8
|?
|122
|32
|121
|-
|0.500" 1/2"
|colspan="2" rowspan="2"|Edge Start Recommended
|?
|?
|18
|128
|-
|0.750" 3/4"
|?
|?
|9
|131
|-
|}

==== Aluminium ====

{| class="wikitable"
!colspan="5"|
!colspan="2"|Recommended
!colspan="2"|Maximum
|-
!Arc Current (a)
!Material Thickness
!Torch-to-work distance (in)
!Initial Piece hieght (in)
!Pierce time delay (s)
!Cut Speed (ipm)
!Arc Voltage (V)
!Cut Speed (ipm)
!Arc Voltage (V)
|-
|rowspan="3"|30
|0.018" 26Ga
|rowspan="3"|0.06"
|rowspan="3"|0.15"
|0.0
|360
|117
|400
|120
|-
|0.060" 16Ga
|rowspan="2"|0.2
|340
|118
|400
|121
|-
|0.075" 14Ga
|215
|118
|270
|121
|-
|rowspan="11"|45
|0.060" 16Ga
|rowspan="12"|0.06"
|rowspan="7"|0.15"
|rowspan="3"|0.0
|360
|116
|400
|114
|-
|0.075" 14Ga
|340
|117
|400
|116
|-
|0.105" 12 Ga
|280
|120
|360
|119
|-
|0.135" 10Ga
|0.1
|220
|122
|280
|120
|-
|0.188" 3/16"
|0.2
|100
|123
|130
|120
|-
|0.250" 1/4"
|0.3
|80
|123
|100
|120
|-
|0.375" 3/8"
|0.5
|33
|130
|42
|125
|-
|0.500" 1/2"
|colspan="2" rowspan="2"|Edge Start Recommended
|20
|134
|25
|130
|-
|0.750" 3/4"
|8
|143
|10
|138
|-
|}

=== T30v Unshielded Fine cut Consumables ===
'''THERE IS CURRENTLY NO POST PROCESSOR FOR RUNNING WITH THESE CONSUMABLES INSTALLED'''
==== Mild Steel ====
{| class="wikitable"
!colspan="5"|
!colspan="2"|Recommended
!colspan="2"|Maximum
|-
!Arc Current (a)
!Material Thickness
!Torch-to-work distance (in)
!Initial Piece hieght (in)
!Pierce time delay (s)
!Cut Speed (ipm)
!Arc Voltage (V)
!Cut Speed (ipm)
!Arc Voltage (V)
|-
|rowspan="7"|30
|0.018" 26Ga
|rowspan="7"|0.02
|rowspan="7"|0.1
|rowspan="3"|0.0
|350
|105
|400
|98
|-
|0.030" 22Ga
|320
|102
|400
|103
|-
|0.036" 20Ga
|280
|101
|350
|100
|-
|0.060" 16Ga
|0.2
|175
|97
|220
|100
|-
|0.075" 14Ga
|rowspan="3"|0.4
|120
|98
|150
|97
|-
|0.105" 12Ga
|80
|96
|100
|96
|-
|0.135" 10Ga
|50
|100
|65
|101
|-
|}

==== Stainless Steel ====
{| class="wikitable"
!colspan="5"|
!colspan="2"|Recommended
!colspan="2"|Maximum
|-
!Arc Current (a)
!Material Thickness
!Torch-to-work distance (in)
!Initial Piece hieght (in)
!Pierce time delay (s)
!Cut Speed (ipm)
!Arc Voltage (V)
!Cut Speed (ipm)
!Arc Voltage (V)
|-
|rowspan="7"|30
|0.018" 26Ga
|rowspan="7"|0.02
|rowspan="7"|0.1
|rowspan="3"|0.0
|350
|103
|400
|102
|-
|0.030" 22Ga
|320
|198
|400
|100
|-
|0.036" 20Ga
|300
|97
|380
|98
|-
|0.060" 16Ga
|0.2
|150
|99
|190
|98
|-
|0.075" 14Ga
|rowspan="3"|0.4
|110
|101
|135
|97
|-
|0.105" 12Ga
|60
|101
|75
|98
|-
|0.135" 10Ga
|45
|102
|55
|97
|-
|}

==== Aluminium ====
{| class="wikitable"
!colspan="5"|
!colspan="2"|Recommended
!colspan="2"|Maximum
|-
!Arc Current (a)
!Material Thickness
!Torch-to-work distance (in)
!Initial Piece hieght (in)
!Pierce time delay (s)
!Cut Speed (ipm)
!Arc Voltage (V)
!Cut Speed (ipm)
!Arc Voltage (V)
|-
|rowspan="5"|30
|0.036" 20Ga
|rowspan="5"|0.02
|rowspan="5"|0.1
|rowspan="3"|0.0
|320
|107
|400
|105
|-
|0.060" 16Ga
|240
|104
|300
|103
|-
|0.075" 14Ga
|190
|104
|1240
|103
|-
|0.105" 12Ga
|rowspan="2"|0.2
|145
|103
|180
|103
|-
|0.135" 10Ga
|95
|101
|120
|101
|-
|}

== Wiring ==

=== Stepper Coils ===

* A+ Black
* A- Green
* B+ Red
* B- Blue

=== Smooth Stepper Pin Mapping ===

==== C25 Interface board pins ====

{| class="wikitable"
!colspan="3"|SmoothStepper
!colspan="2"|Target Device
|-
!Port
!Pin
!Type
!Device
!Connection
!Wire color
|-
|1
|1
|Output
|X Stepper Driver
|Pul+
|Green
|-
|1
|2
|Output
|X Stepper Driver
|Dir+
|Red
|-
|1
|3
|Output
|X Stepper Driver
|Ena+
|-
|1
|4
|Output
|Y Stepper Driver
|Pul+
|Green
|-
|1
|5
|Output
|Y Stepper Driver
|Dir+
|Red
|-
|1
|6
|Output
|Y Stepper Driver
|Ena+
|-
|1
|7
|Output
|THC
|Step In
|Green
|-
|1
|8
|Output
|THC
|Dir In
|Red
|-
|1
|9
|Output
|Z Stepper Driver
|Ena+
|-
|1
|10
|Input
|Plasma Interface Connector
|Torch Lit Out
|-
|1
|11
|Input
|Z Limit Connector
|2
|Grey
|-
|1
|12
|Input
|Y Limit Connector
|2
|Grey
|-
|1
|13
|Input
|X Limit Connector
|2
|Grey
|-
|1
|14
|Output
|A Stepper Driver
|Pul+
|Green
|-
|1
|15
|Input
|E-Stop Switch
|Switch contact NC
|Grey
|-
|1
|16
|Output
|A Stepper Driver
|Dir+
|Red
|-
|1
|17
|Output
|A Stepper Driver
|Ena+
|-
|2
|1
|Output
|Torch Relay
|Coil +
|-
|2
|2
|Input
|Touch off probe connector
|Pin 2
|-
|2
|3
|Input
|-
|2
|4
|Input
|-
|2
|5
|Input
|-
|2
|6
|Input
|-
|2
|7
|Input
|-
|2
|8
|Input
|-
|2
|9
|Input
|-
|2
|10
|Input
|-
|2
|11
|Input
|-
|2
|12
|Intput
|-
|2
|13
|Input
|-
|2
|14
|Output
|THC Enable relay
|Coil +
|-
|2
|15
|Input
|-
|2
|16
|Output
|-
|2
|17
|Output
|}

== Configuration ==

=== Stepper Drivers ===
Steps per inch: 1358

Driving current:
* SW1 ON
* SW2 ON
* SW3 OFF

Holding Current:
* SW4 OFF

Steps:
* SW5
* SW6
* SW7
* SW8

== Parts ==

* Steppers:
** Wantai 57BYGH115-003
** Nema 23 stepper motor
** 425oz-in torque
** 3 Amp
* Drivers:
** Wantai DQ542MA
** Manual: [[File:DQ542MA_English_Manual.pdf]]
* SmoothStepper Ethernet
* C25 Break out board
** https://cnc4pc.com/motion-control/breakout-boards/c25-smooth-stepper-terminal-board.html
** Manual: [[File:C25R3_1_USER_MANUAL.pdf]]

==maintenance ==
[[CNC_Plasma_Cutter_maintenance|maintenance page]]

== Authorization ==

=== Authorizers ===

* Andrew Camaradella - 45A auto Z only
* Ron Olson - 45A auto Z only

=== List of Currently Authorized Users - 45A Auto Z ===

{| class="wikitable" border="1"
! Qualified Member
! Trained By
! Date
|-
|Andrew Caramdella
|Danger Committee
|
|-
| Jake Chaitkin
| Ron Olson
| 6/9/2018
|-
| Zack Sasnow
| Ron Olson
| 6/9/2018
|-
| Erik Wessing
| Ron Olson
| 6/9/2018
|-
|Ryan Pierce
|Ron Olson
|9/2/18
|-
|Glenn Powers
|Ron Olson
|10/21/18
|-
|Sam Paris
|Ron Olson
|10/21/18
|-
|Farsheed Hamidi-Toosi
|Ron Olson
|10/21/18
|-
|}

=== List of Currently Authorized Users - 30A Fine Cut ===

{| class="wikitable" border="1"
! Qualified Member
! Trained By
! Date
|-
|Casey Olson
|Tom Judge
|-
| Jake Chaitkin
| Ron Olson
| 6/9/2018
|-
| Zack Sasnow
| Ron Olson
| 6/9/2018
|-}
|-
|}

CNC Plasma Cutter

2019-01-28T01:21:22Z

Daddybird: /* Creating A Job */

{{Template:EquipmentPage
|owner = PS:One
|hostarea = CNC
|certification = yes
|hackable = no
|model = N.A.
|serial = N.A.
|arrived = 10/16
|where = Hot metals
|doesitwork = yes
|contact = CNC Area Host
|value = $6000
|image = IMG_4045.JPG
}}

== Status ==

Working. Stay tuned for an announcement about authorizations.

== Authorization ==

Authorization requirements:

* This is not a commercial machine; it was hand-built at PS1 and as such there is no website to check, nor any manual to read. You must be willing to accept the fact that the machine can be quirky and you may have to do some troubleshooting when using it (hopefully not, but ¯\_(ツ)_/¯).
* You should be familiar with how plasma cutters work (at the very least, read this: https://en.wikipedia.org/wiki/Plasma_cutting). If you can swing it, please get authorized on the Miller handheld plasma machine beforehand; this is not a requirement, just a useful suggestion.
* Read all of this page about the machine: https://wiki.pumpingstationone.org/CNC_Plasma_Cutter
* Read and be willing to add your experience/knowledge of using the machine here: https://wiki.pumpingstationone.org/Talk:CNC_Plasma_Cutter

[[CNC Plasma Cutter Authorization]] has more details.

== Drawing guidelines ==

* No sharp corners, all corners should be filleted with at least a 1/16" radius
* The thicker the part, the larger the smallest feature
** Small holes 1/4" and under are not advisable
** Holes under 3/4" on 3/8" plate are not advisable
** Not all these sizes are learnt yet, this is why you need extra material
* Acceptable drawing formats:
** DXF
** SWF
* Acceptable drawing formats for review:
** DXF
** SWF
** AI

== Safety and Protective Equipment ==

* Number 5 shades when a job is running
* Thick gloves when handling freshly cut parts
* Hearing protection recommended
* Respirator/mask while cutting

== Procedures ==

=== Machine Startup ===
Fill water table if not filled already. Takes about 35 minutes to fill. Be sure to have the splash guard on it so when it's filled the air does not spray water everywhere.

# Wipe down machine with clean dry clotha
# Log in to machine
# Turn on air
# Make sure e-stop is depressed
# Turn on control box
# Start Mach3
# Clear e-stop
# Raise Z
# Move torch to end of table
# Remove torch shield and inspect for dross build up
# Reinstall torch shield
# Turn on plasma cutter
# Check cutter status (Air/torch/etc)

=== Machine Shutdown ===

# Hit e-stop
# Exit Mach3
# Turn off plasma cutter
# Turn off air
# Turn off control box
# Clean torch shield
# Sweep under table
# Wipe down machine with clean dry cloth
# Wipe down computer
# '''Leave the area cleaner than you found it'''

=== Creating a Job ===

# Start SheetCam
# Import a Drawing from the File menu. Remember that the origin is at the bottom left on Sheetcam, and the origin on the machine is back left.
# Click on Operation => Plasma Cut
# Unfortunately most settings can be changed by other users between jobs. Some that seem to work:
** 130 ipm feed rate
** Tool: T11: Plasma 12 Gauge (or whatever gauge you're cutting)
** Note that Inside/Outside offset determines if you're trying to cut an inside edge or outside edge.
** You may need to select a layer.
# Click OK and the path should be generated and display.
# To create a TAP file go to the P icon at top left. That's post-processing.
# It should save as type G-code/.tap.

This is now a runnable job.

=== Running A Job ===
Look elsewhere for turning on the machine, filling the table, turning on the plasma cutter.

# Start Mach3 CNC
# You should be able to move the gantry using the arrow keys to get into position. You MUST start your job over metal - it does an auto z-axis zero/home.
# If "Reset" is flashing, click it to reset the connection.
# Test the job without the plasma on if you want.
# Turn on plasma cutter and close curtain.
# Click Cycle Start (green).

=== Starting a job from a particular line of code (needs update)===
*Run from here
*Select next line

=== Previewing a job (needs update) ===
*Load file
*Select the 'Run BLK' button in the interface or type Alt-N
*Press the start job button - this will step through each line of code
(warning: includes torch homing and torch ignite so be careful)
*You can step backwards though a job by pressing the 'reverse order' button.

=== Job Crashes ===

==== SmoothStepper Buffer Under run ====

'''Your work piece is trash, start again, home position lost'''

# Click through error
# Start your job again

Causes:

* Communication error between smooth stepper and PC

==== Touch off failure ====

'''Your work piece is not trash yet, but might be if you don't follow these steps'''

One of the following happened:

* Touch off get stuck with torch touching the plate
* Touch off fails to detect plate and rams into the plate
* Error probe ignored in status bar - If this is the case clean the shield nozzle, dross has gotten inside, do not move work piece

Do This:

# Hit escape '''ONCE''', not e-stop, not reset, escape
# Double click in the g-code window to display line numbers eg: 20:N0100 G91.... rather than N0100 G91....
# Look for the current line, it should be highlighted and be: G31 Z -100
# Look up a few lines for the torch moving to safe height: G00 Z1.5
# In the operator console click in the line number box
# Type in the line number of the safe hight move and hit return
# Highlighted line should change to that line
# Hit "Set next line" button
# Hit cycle start

Causes:

* Dross has built up inside shield
* Work piece is flapping around like a flag in a breeze, put some weights on it
* Dross/corrosion on the plate cause a none conductive area where the torch touched off
* Torch cable has become too taught and caused the probe connection to come loose or the probe ring not to touch the torch shield

==== Torch fails to ignite ====

'''Your work piece is not trash yet, but might be if you don't follow these steps'''

Mach3 shows job stuck on M3 command.

# Hit F5 to re-ignite the torch (possibly twice)
# Job should continue once M3 detects arc transfer signal from the plasma cutter

Causes:

* Unknown at this time

==== Mach3 Crash ====

'''Your work piece is trash, start again'''

# Shutdown the control box
# Close Mach3
# Turn on control box
# Start Mach3
# Run your job again

Causes:

* Unknown at this time

== Sheet Cam ==

https://www.youtube.com/user/arclightdynamics/videos has good tutorials.

Sheet Cam settings always use the last setting. So double check it's what you want.

Origin is bottom left. Origin on the machine is back left. Brown box is the material size, but it doesn't need to be set.

It's a good idea to have a bounding box on your work so it's placed correctly.

Isolate paths by selecting them then put them in a new layer. This includes the previously mentioned bounding box.

Cuts can be inside edge, outside edge or on the line. A lead in is a good idea to help keep the cuts clean. Lead out has not been tested but may help.

The post-processor to use for this machine is named 'PS1 Plasma'. It's already included in the list of post-processors on the installed copy of SheetCam.

=== Manual Controls ===
* Arrow keys move X/Y
* Shift PageUp/PageDown moves the Z axis

Click the zero button to set home. (this is from memory, please correct -- Burton)

== Todo List ==

* Documentation

Squareness todo:

* Physical end stops - probably want to move the wiring out of the X axis tubes for this
* Limit switches on A-axis (slaved to X, the rail against the wall)

This will allow both manual squareness and automatic machine homing. Mach 3 has a routine that will home the X axis with the slave, then adjust which ever one did not hit the home switch independently.

Water table todo:

* <s>Fix 2 pin hole leaks (one at each end of tank)</s>
* <s>Fit bladder input line (so it doesn't collect crap in the tank)</s>
* Wash out old compressor tank
* <s>Trim the top of the side where the A axis hardware grazes the top of the tank.</s>
* Paint the outside of the tank
* <s>Treat the water with the green goo</s>

Plumbing/wiring todo:

* Extend air line to under table to create a manifold for table mounted air consumers
* Run large conduit for 220 outlet for the plasma cutter
* Run small conduit for data/estop between the table and the PC
* Run black pipe for connecting the table to the bladder (old compressor tank)
* Water line from north side of the shop, with input into the old compressor tank
* Air lines to the compressor tank (one vent on from the compressor)
* Run ethernet line to PC so its not on wifi any more
* Z axis limit switches

Plate marker todo:

* Design and cut new y-axis trolly or offset plate to carry torch and marker
* Machine mount for engraver
* Mount new trolly with air slide and Z axis
* Plumbing and wiring
* Pen mount as well as engraver?

35A Fine Cut todo:

* Build floating Z axis using left over linear rail
* How to multiplex the digitise input for touch off? Relays to switch digitise input from ohmic sensor to switch on head? (and disconnect the switch from the z limit array) (the switch should be in the z limit switch array by default incase the THC plunges the torch into the work piece)

Roundness/cut quality todo:

* <s>Y Axis pulsing - new connection spigot for drive year to fix eccentric rotation of gear</s>
* Remove and clean X axis gears, reinstall and use loctite on set screws (the keep backing off)
* Make sure all bearings are right against the rails so there is no slop
* <s>Investigate backlash and configure mach3 is required</s> - 0.0001 on X, Y and A
* Get quote for installing ground rod next to the table and execute it
* Look into THC issues (cut rippling) if still present after ground rod - possible Z axis flex in the mount to the Y carriage.
* Why is the THC seeing ~80V for a good clean cut from the hypertherm? Is the internal voltage divider broken (is this why the machine was retrofitted with a dangerous high voltage tap?)? Or is this related to a bad ground at the table?
* Motion pauses: (Seen on large 3'x2' complex cuts)
** Why are there zero move G1's at the end of curves generated with G2's
** <s>Do we need to add a CV on G-Code in the preamble of the post processor</s> - Does not appear to need this
** Smooth stepper under-run errors - I have only seen this when jogging not cutting, mostly related to rapiding the Z, maybe reduce the micro stepping on the driver for the new threaded drive step count is huge per inch which could be hurting us
** <s>Axis and Core frequency tuning for the smooth stepper?</s> - Dropped to 64k on X,Y,A
** <s>Look ahead tuning</s> - increased to 150
** Is CV plasma mode hurting us?
** <s>System problems, AV jamming things up?</s> - low cpu load not an issue

Ohter things:

* Cleaning/maintenance schedule
* Shelves/lockers in the unused space under the table for project/tool/etc storage?
* Materials storage ideas?
** sheet goods
** 20-24' bar/tube stock

== Future Items ==

* Tube attachment
* scribe attachment

== Torch Consumables ==

The torch is a T45m hypertherm machine torch.

{| class="wikitable" border="1"
!colspan="3"|Consumables Change Log
|-
! Date
! What
! By
|-
|6/10/17
|electrode, nozzle
|Andrew Camardella
|-
|}

[http://www.thefabricator.com/article/plasmacutting/plasma-cutting-maintenance-are-you-throwing-money-away What does a worn electrode look like?]

Torch tips components are consumables. If you are getting a wide kerf or the plasma torch isn't cutting through the materials anymore you may need to change the tip parts. To change the consumables disconnect the ground clip from the black retaining cap and unscrew the entire tip from the retaining cap.

=== Standard ===
* Shield P/N: 220673
* Deflector P/N: 2206732
* Retaining Cap - Ohmic P/N: 220719
* Nozzle P/N: 220671
* Electrode P/N: 220669
* Swirl Ring P/N: 220670

=== Fine Cut ===

'''THERE IS CURRENTLY NO POST PROCESSOR FOR RUNNING WITH THESE CONSUMABLES INSTALLED'''

'''NOTE''': These parts are for a t30 unshielded torch, they are compatiable with the T45m when it is run at a setting lower than 30A and cutting materials thinner than 3/16". Ohmic sensing will not work with these parts installed.

* Deflector P/N: 2206732
* Retaining Cap - Ohmic P/N: 220483
* Nozzle P/N: 220480
* Electrode P/N: 220479
* Swirl Ring P/N: 220478

[[:File:T45m.pdf|Consumables catalog page]]

== Feeds and Speeds ==

=== T45m Shielded Consumables ===

==== Mild Steel ====

{| class="wikitable"
!colspan="5"|
!colspan="2"|Recommended
!colspan="2"|Maximum
|-
!Arc Current (a)
!Material Thickness
!Torch-to-work distance (in)
!Initial Piece hieght (in)
!Pierce time delay (s)
!Cut Speed (ipm)
!Arc Voltage (V)
!Cut Speed (ipm)
!Arc Voltage (V)
|-
|rowspan="4"|30
|0.018" 26Ga
|rowspan="4"|0.06"
|rowspan="4"|0.15"
|rowspan="3"|0.0
|?
|117
|400
|118
|-
|0.030" 22Ga
|?
|116
|400
|117
|-
|0.036" 20Ga
|?
|115
|400
|117
|-
|0.060" 18Ga
|0.2
|?
|111
|280
|115
|-
|rowspan="12"|45
|0.036" 20Ga
|rowspan="12"|0.06"
|rowspan="8"|0.15"
|rowspan="2"|0.0
|380
|115
|400
|112
|-
|0.060" 16 Ga
|150
|116
|400
|115
|-
|0.075" 14Ga
|0.1
|150
|117
|360
|115
|-
|0.105" 12Ga
|0.3
|130
|117
|240
|115
|-
|0.135" 10Ga
|0.4
|110
|117
|175
|115
|-
|0.188" 3/16"
|0.5
|85
|118
|110
|115
|-
|0.250" 1/4"
|0.6
|60
|120
|75
|116
|-
|0.375" 3/8"
|0.9
|32
|122
|40
|116
|-
|0.500" 1/2"
|colspan="2" rowspan="4"|Edge Start Recommended
|4
|132
|25
|125
|-
|0.625" 5/8"
|3
|138
|14
|127
|-
|0.750" 3/4"
|2
|140
|10
|131
|-
|1.000" 1"
|?
|146
|5
|142
|-
|}

==== Stainless Steel ====

{| class="wikitable"
!colspan="5"|
!colspan="2"|Recommended
!colspan="2"|Maximum
|-
!Arc Current (a)
!Material Thickness
!Torch-to-work distance (in)
!Initial Piece hieght (in)
!Pierce time delay (s)
!Cut Speed (ipm)
!Arc Voltage (V)
!Cut Speed (ipm)
!Arc Voltage (V)
|-
|rowspan="4"|30
|0.018" 26Ga
|rowspan="4"|0.06"
|rowspan="4"|0.15"
|rowspan="3"|0.0
|?
|117
|400
|123
|-
|0.030" 22Ga
|?
|116
|400
|121
|-
|0.036" 20Ga
|?
|115
|400
|119
|-
|0.060" 18Ga
|0.2
|?
|111
|185
|118
|-
|rowspan="12"|45
|0.036" 20Ga
|rowspan="12"|0.06"
|rowspan="8"|0.15"
|rowspan="2"|0.0
|?
|115
|400
|109
|-
|0.060" 16 Ga
|138
|116
|400
|125
|-
|0.075" 14Ga
|0.1
|?
|117
|360
|115
|-
|0.105" 12Ga
|0.3
|?
|117
|200
|116
|-
|0.135" 10Ga
|0.4
|?
|117
|155
|118
|-
|0.188" 3/16"
|0.5
|?
|118
|85
|118
|-
|0.250" 1/4"
|0.6
|?
|120
|55
|120
|-
|0.375" 3/8"
|0.8
|?
|122
|32
|121
|-
|0.500" 1/2"
|colspan="2" rowspan="2"|Edge Start Recommended
|?
|?
|18
|128
|-
|0.750" 3/4"
|?
|?
|9
|131
|-
|}

==== Aluminium ====

{| class="wikitable"
!colspan="5"|
!colspan="2"|Recommended
!colspan="2"|Maximum
|-
!Arc Current (a)
!Material Thickness
!Torch-to-work distance (in)
!Initial Piece hieght (in)
!Pierce time delay (s)
!Cut Speed (ipm)
!Arc Voltage (V)
!Cut Speed (ipm)
!Arc Voltage (V)
|-
|rowspan="3"|30
|0.018" 26Ga
|rowspan="3"|0.06"
|rowspan="3"|0.15"
|0.0
|360
|117
|400
|120
|-
|0.060" 16Ga
|rowspan="2"|0.2
|340
|118
|400
|121
|-
|0.075" 14Ga
|215
|118
|270
|121
|-
|rowspan="11"|45
|0.060" 16Ga
|rowspan="12"|0.06"
|rowspan="7"|0.15"
|rowspan="3"|0.0
|360
|116
|400
|114
|-
|0.075" 14Ga
|340
|117
|400
|116
|-
|0.105" 12 Ga
|280
|120
|360
|119
|-
|0.135" 10Ga
|0.1
|220
|122
|280
|120
|-
|0.188" 3/16"
|0.2
|100
|123
|130
|120
|-
|0.250" 1/4"
|0.3
|80
|123
|100
|120
|-
|0.375" 3/8"
|0.5
|33
|130
|42
|125
|-
|0.500" 1/2"
|colspan="2" rowspan="2"|Edge Start Recommended
|20
|134
|25
|130
|-
|0.750" 3/4"
|8
|143
|10
|138
|-
|}

=== T30v Unshielded Fine cut Consumables ===
'''THERE IS CURRENTLY NO POST PROCESSOR FOR RUNNING WITH THESE CONSUMABLES INSTALLED'''
==== Mild Steel ====
{| class="wikitable"
!colspan="5"|
!colspan="2"|Recommended
!colspan="2"|Maximum
|-
!Arc Current (a)
!Material Thickness
!Torch-to-work distance (in)
!Initial Piece hieght (in)
!Pierce time delay (s)
!Cut Speed (ipm)
!Arc Voltage (V)
!Cut Speed (ipm)
!Arc Voltage (V)
|-
|rowspan="7"|30
|0.018" 26Ga
|rowspan="7"|0.02
|rowspan="7"|0.1
|rowspan="3"|0.0
|350
|105
|400
|98
|-
|0.030" 22Ga
|320
|102
|400
|103
|-
|0.036" 20Ga
|280
|101
|350
|100
|-
|0.060" 16Ga
|0.2
|175
|97
|220
|100
|-
|0.075" 14Ga
|rowspan="3"|0.4
|120
|98
|150
|97
|-
|0.105" 12Ga
|80
|96
|100
|96
|-
|0.135" 10Ga
|50
|100
|65
|101
|-
|}

==== Stainless Steel ====
{| class="wikitable"
!colspan="5"|
!colspan="2"|Recommended
!colspan="2"|Maximum
|-
!Arc Current (a)
!Material Thickness
!Torch-to-work distance (in)
!Initial Piece hieght (in)
!Pierce time delay (s)
!Cut Speed (ipm)
!Arc Voltage (V)
!Cut Speed (ipm)
!Arc Voltage (V)
|-
|rowspan="7"|30
|0.018" 26Ga
|rowspan="7"|0.02
|rowspan="7"|0.1
|rowspan="3"|0.0
|350
|103
|400
|102
|-
|0.030" 22Ga
|320
|198
|400
|100
|-
|0.036" 20Ga
|300
|97
|380
|98
|-
|0.060" 16Ga
|0.2
|150
|99
|190
|98
|-
|0.075" 14Ga
|rowspan="3"|0.4
|110
|101
|135
|97
|-
|0.105" 12Ga
|60
|101
|75
|98
|-
|0.135" 10Ga
|45
|102
|55
|97
|-
|}

==== Aluminium ====
{| class="wikitable"
!colspan="5"|
!colspan="2"|Recommended
!colspan="2"|Maximum
|-
!Arc Current (a)
!Material Thickness
!Torch-to-work distance (in)
!Initial Piece hieght (in)
!Pierce time delay (s)
!Cut Speed (ipm)
!Arc Voltage (V)
!Cut Speed (ipm)
!Arc Voltage (V)
|-
|rowspan="5"|30
|0.036" 20Ga
|rowspan="5"|0.02
|rowspan="5"|0.1
|rowspan="3"|0.0
|320
|107
|400
|105
|-
|0.060" 16Ga
|240
|104
|300
|103
|-
|0.075" 14Ga
|190
|104
|1240
|103
|-
|0.105" 12Ga
|rowspan="2"|0.2
|145
|103
|180
|103
|-
|0.135" 10Ga
|95
|101
|120
|101
|-
|}

== Wiring ==

=== Stepper Coils ===

* A+ Black
* A- Green
* B+ Red
* B- Blue

=== Smooth Stepper Pin Mapping ===

==== C25 Interface board pins ====

{| class="wikitable"
!colspan="3"|SmoothStepper
!colspan="2"|Target Device
|-
!Port
!Pin
!Type
!Device
!Connection
!Wire color
|-
|1
|1
|Output
|X Stepper Driver
|Pul+
|Green
|-
|1
|2
|Output
|X Stepper Driver
|Dir+
|Red
|-
|1
|3
|Output
|X Stepper Driver
|Ena+
|-
|1
|4
|Output
|Y Stepper Driver
|Pul+
|Green
|-
|1
|5
|Output
|Y Stepper Driver
|Dir+
|Red
|-
|1
|6
|Output
|Y Stepper Driver
|Ena+
|-
|1
|7
|Output
|THC
|Step In
|Green
|-
|1
|8
|Output
|THC
|Dir In
|Red
|-
|1
|9
|Output
|Z Stepper Driver
|Ena+
|-
|1
|10
|Input
|Plasma Interface Connector
|Torch Lit Out
|-
|1
|11
|Input
|Z Limit Connector
|2
|Grey
|-
|1
|12
|Input
|Y Limit Connector
|2
|Grey
|-
|1
|13
|Input
|X Limit Connector
|2
|Grey
|-
|1
|14
|Output
|A Stepper Driver
|Pul+
|Green
|-
|1
|15
|Input
|E-Stop Switch
|Switch contact NC
|Grey
|-
|1
|16
|Output
|A Stepper Driver
|Dir+
|Red
|-
|1
|17
|Output
|A Stepper Driver
|Ena+
|-
|2
|1
|Output
|Torch Relay
|Coil +
|-
|2
|2
|Input
|Touch off probe connector
|Pin 2
|-
|2
|3
|Input
|-
|2
|4
|Input
|-
|2
|5
|Input
|-
|2
|6
|Input
|-
|2
|7
|Input
|-
|2
|8
|Input
|-
|2
|9
|Input
|-
|2
|10
|Input
|-
|2
|11
|Input
|-
|2
|12
|Intput
|-
|2
|13
|Input
|-
|2
|14
|Output
|THC Enable relay
|Coil +
|-
|2
|15
|Input
|-
|2
|16
|Output
|-
|2
|17
|Output
|}

== Configuration ==

=== Stepper Drivers ===
Steps per inch: 1358

Driving current:
* SW1 ON
* SW2 ON
* SW3 OFF

Holding Current:
* SW4 OFF

Steps:
* SW5
* SW6
* SW7
* SW8

== Parts ==

* Steppers:
** Wantai 57BYGH115-003
** Nema 23 stepper motor
** 425oz-in torque
** 3 Amp
* Drivers:
** Wantai DQ542MA
** Manual: [[File:DQ542MA_English_Manual.pdf]]
* SmoothStepper Ethernet
* C25 Break out board
** https://cnc4pc.com/motion-control/breakout-boards/c25-smooth-stepper-terminal-board.html
** Manual: [[File:C25R3_1_USER_MANUAL.pdf]]

==maintenance ==
[[CNC_Plasma_Cutter_maintenance|maintenance page]]

== Authorization ==

=== Authorizers ===

* Andrew Camaradella - 45A auto Z only
* Ron Olson - 45A auto Z only

=== List of Currently Authorized Users - 45A Auto Z ===

{| class="wikitable" border="1"
! Qualified Member
! Trained By
! Date
|-
|Andrew Caramdella
|Danger Committee
|
|-
| Jake Chaitkin
| Ron Olson
| 6/9/2018
|-
| Zack Sasnow
| Ron Olson
| 6/9/2018
|-
| Erik Wessing
| Ron Olson
| 6/9/2018
|-
|Ryan Pierce
|Ron Olson
|9/2/18
|-
|Glenn Powers
|Ron Olson
|10/21/18
|-
|Sam Paris
|Ron Olson
|10/21/18
|-
|Farsheed Hamidi-Toosi
|Ron Olson
|10/21/18
|-
|}

=== List of Currently Authorized Users - 30A Fine Cut ===

{| class="wikitable" border="1"
! Qualified Member
! Trained By
! Date
|-
|Casey Olson
|Tom Judge
|-
| Jake Chaitkin
| Ron Olson
| 6/9/2018
|-
| Zack Sasnow
| Ron Olson
| 6/9/2018
|-}
|-
|}

CNC Plasma Cutter

2019-01-28T00:26:45Z

Daddybird: /* Running A Job */

{{Template:EquipmentPage
|owner = PS:One
|hostarea = CNC
|certification = yes
|hackable = no
|model = N.A.
|serial = N.A.
|arrived = 10/16
|where = Hot metals
|doesitwork = yes
|contact = CNC Area Host
|value = $6000
|image = IMG_4045.JPG
}}

== Status ==

Working. Stay tuned for an announcement about authorizations.

== Authorization ==

Authorization requirements:

* This is not a commercial machine; it was hand-built at PS1 and as such there is no website to check, nor any manual to read. You must be willing to accept the fact that the machine can be quirky and you may have to do some troubleshooting when using it (hopefully not, but ¯\_(ツ)_/¯).
* You should be familiar with how plasma cutters work (at the very least, read this: https://en.wikipedia.org/wiki/Plasma_cutting). If you can swing it, please get authorized on the Miller handheld plasma machine beforehand; this is not a requirement, just a useful suggestion.
* Read all of this page about the machine: https://wiki.pumpingstationone.org/CNC_Plasma_Cutter
* Read and be willing to add your experience/knowledge of using the machine here: https://wiki.pumpingstationone.org/Talk:CNC_Plasma_Cutter

[[CNC Plasma Cutter Authorization]] has more details.

== Drawing guidelines ==

* No sharp corners, all corners should be filleted with at least a 1/16" radius
* The thicker the part, the larger the smallest feature
** Small holes 1/4" and under are not advisable
** Holes under 3/4" on 3/8" plate are not advisable
** Not all these sizes are learnt yet, this is why you need extra material
* Acceptable drawing formats:
** DXF
** SWF
* Acceptable drawing formats for review:
** DXF
** SWF
** AI

== Safety and Protective Equipment ==

* Number 5 shades when a job is running
* Thick gloves when handling freshly cut parts
* Hearing protection recommended
* Respirator/mask while cutting

== Procedures ==

=== Machine Startup ===
Fill water table if not filled already. Takes about 35 minutes to fill. Be sure to have the splash guard on it so when it's filled the air does not spray water everywhere.

# Wipe down machine with clean dry clotha
# Log in to machine
# Turn on air
# Make sure e-stop is depressed
# Turn on control box
# Start Mach3
# Clear e-stop
# Raise Z
# Move torch to end of table
# Remove torch shield and inspect for dross build up
# Reinstall torch shield
# Turn on plasma cutter
# Check cutter status (Air/torch/etc)

=== Machine Shutdown ===

# Hit e-stop
# Exit Mach3
# Turn off plasma cutter
# Turn off air
# Turn off control box
# Clean torch shield
# Sweep under table
# Wipe down machine with clean dry cloth
# Wipe down computer
# '''Leave the area cleaner than you found it'''

=== Creating A Job ===

# Start SheetCam
# Import a Drawing from the File menu. Remember that the origin is at the bottom left on Sheetcam, and the origin on the machine is back left.
# Click on Operation => Plasma Cut
# Unfortunately most settings can be changed by other users between jobs. Some that seem to work:
** 130 ipm feed rate
** Tool: T11: Plasma 12 Gauge (or whatever gauge you're cutting)
** Note that Inside/Outside offset determines if you're trying to cut an inside edge or outside edge.
** You may need to select a layer.
# Click OK and the path should be generated and display.
# To create a TAP file go to the P icon at top left. That's post-processing.
# It should save as type G-code/.tap.

This is now a runnable job.

=== Running A Job ===
Look elsewhere for turning on the machine, filling the table, turning on the plasma cutter.

# Start Mach3 CNC
# You should be able to move the gantry using the arrow keys to get into position. You MUST start your job over metal - it does an auto z-axis zero/home.
# If "Reset" is flashing, click it to reset the connection.
# Test the job without the plasma on if you want.
# Turn on plasma cutter and close curtain.
# Click Cycle Start (green).

=== Starting a job from a particular line of code (needs update)===
*Run from here
*Select next line

=== Previewing a job (needs update) ===
*Load file
*Select the 'Run BLK' button in the interface or type Alt-N
*Press the start job button - this will step through each line of code
(warning: includes torch homing and torch ignite so be careful)
*You can step backwards though a job by pressing the 'reverse order' button.

=== Job Crashes ===

==== SmoothStepper Buffer Under run ====

'''Your work piece is trash, start again, home position lost'''

# Click through error
# Start your job again

Causes:

* Communication error between smooth stepper and PC

==== Touch off failure ====

'''Your work piece is not trash yet, but might be if you don't follow these steps'''

One of the following happened:

* Touch off get stuck with torch touching the plate
* Touch off fails to detect plate and rams into the plate
* Error probe ignored in status bar - If this is the case clean the shield nozzle, dross has gotten inside, do not move work piece

Do This:

# Hit escape '''ONCE''', not e-stop, not reset, escape
# Double click in the g-code window to display line numbers eg: 20:N0100 G91.... rather than N0100 G91....
# Look for the current line, it should be highlighted and be: G31 Z -100
# Look up a few lines for the torch moving to safe height: G00 Z1.5
# In the operator console click in the line number box
# Type in the line number of the safe hight move and hit return
# Highlighted line should change to that line
# Hit "Set next line" button
# Hit cycle start

Causes:

* Dross has built up inside shield
* Work piece is flapping around like a flag in a breeze, put some weights on it
* Dross/corrosion on the plate cause a none conductive area where the torch touched off
* Torch cable has become too taught and caused the probe connection to come loose or the probe ring not to touch the torch shield

==== Torch fails to ignite ====

'''Your work piece is not trash yet, but might be if you don't follow these steps'''

Mach3 shows job stuck on M3 command.

# Hit F5 to re-ignite the torch (possibly twice)
# Job should continue once M3 detects arc transfer signal from the plasma cutter

Causes:

* Unknown at this time

==== Mach3 Crash ====

'''Your work piece is trash, start again'''

# Shutdown the control box
# Close Mach3
# Turn on control box
# Start Mach3
# Run your job again

Causes:

* Unknown at this time

== Sheet Cam ==

https://www.youtube.com/user/arclightdynamics/videos has good tutorials.

Sheet Cam settings always use the last setting. So double check it's what you want.

Origin is bottom left. Origin on the machine is back left. Brown box is the material size, but it doesn't need to be set.

It's a good idea to have a bounding box on your work so it's placed correctly.

Isolate paths by selecting them then put them in a new layer. This includes the previously mentioned bounding box.

Cuts can be inside edge, outside edge or on the line. A lead in is a good idea to help keep the cuts clean. Lead out has not been tested but may help.

The post-processor to use for this machine is named 'PS1 Plasma'. It's already included in the list of post-processors on the installed copy of SheetCam.

=== Manual Controls ===
* Arrow keys move X/Y
* Shift PageUp/PageDown moves the Z axis

Click the zero button to set home. (this is from memory, please correct -- Burton)

== Todo List ==

* Documentation

Squareness todo:

* Physical end stops - probably want to move the wiring out of the X axis tubes for this
* Limit switches on A-axis (slaved to X, the rail against the wall)

This will allow both manual squareness and automatic machine homing. Mach 3 has a routine that will home the X axis with the slave, then adjust which ever one did not hit the home switch independently.

Water table todo:

* <s>Fix 2 pin hole leaks (one at each end of tank)</s>
* <s>Fit bladder input line (so it doesn't collect crap in the tank)</s>
* Wash out old compressor tank
* <s>Trim the top of the side where the A axis hardware grazes the top of the tank.</s>
* Paint the outside of the tank
* <s>Treat the water with the green goo</s>

Plumbing/wiring todo:

* Extend air line to under table to create a manifold for table mounted air consumers
* Run large conduit for 220 outlet for the plasma cutter
* Run small conduit for data/estop between the table and the PC
* Run black pipe for connecting the table to the bladder (old compressor tank)
* Water line from north side of the shop, with input into the old compressor tank
* Air lines to the compressor tank (one vent on from the compressor)
* Run ethernet line to PC so its not on wifi any more
* Z axis limit switches

Plate marker todo:

* Design and cut new y-axis trolly or offset plate to carry torch and marker
* Machine mount for engraver
* Mount new trolly with air slide and Z axis
* Plumbing and wiring
* Pen mount as well as engraver?

35A Fine Cut todo:

* Build floating Z axis using left over linear rail
* How to multiplex the digitise input for touch off? Relays to switch digitise input from ohmic sensor to switch on head? (and disconnect the switch from the z limit array) (the switch should be in the z limit switch array by default incase the THC plunges the torch into the work piece)

Roundness/cut quality todo:

* <s>Y Axis pulsing - new connection spigot for drive year to fix eccentric rotation of gear</s>
* Remove and clean X axis gears, reinstall and use loctite on set screws (the keep backing off)
* Make sure all bearings are right against the rails so there is no slop
* <s>Investigate backlash and configure mach3 is required</s> - 0.0001 on X, Y and A
* Get quote for installing ground rod next to the table and execute it
* Look into THC issues (cut rippling) if still present after ground rod - possible Z axis flex in the mount to the Y carriage.
* Why is the THC seeing ~80V for a good clean cut from the hypertherm? Is the internal voltage divider broken (is this why the machine was retrofitted with a dangerous high voltage tap?)? Or is this related to a bad ground at the table?
* Motion pauses: (Seen on large 3'x2' complex cuts)
** Why are there zero move G1's at the end of curves generated with G2's
** <s>Do we need to add a CV on G-Code in the preamble of the post processor</s> - Does not appear to need this
** Smooth stepper under-run errors - I have only seen this when jogging not cutting, mostly related to rapiding the Z, maybe reduce the micro stepping on the driver for the new threaded drive step count is huge per inch which could be hurting us
** <s>Axis and Core frequency tuning for the smooth stepper?</s> - Dropped to 64k on X,Y,A
** <s>Look ahead tuning</s> - increased to 150
** Is CV plasma mode hurting us?
** <s>System problems, AV jamming things up?</s> - low cpu load not an issue

Ohter things:

* Cleaning/maintenance schedule
* Shelves/lockers in the unused space under the table for project/tool/etc storage?
* Materials storage ideas?
** sheet goods
** 20-24' bar/tube stock

== Future Items ==

* Tube attachment
* scribe attachment

== Torch Consumables ==

The torch is a T45m hypertherm machine torch.

{| class="wikitable" border="1"
!colspan="3"|Consumables Change Log
|-
! Date
! What
! By
|-
|6/10/17
|electrode, nozzle
|Andrew Camardella
|-
|}

[http://www.thefabricator.com/article/plasmacutting/plasma-cutting-maintenance-are-you-throwing-money-away What does a worn electrode look like?]

Torch tips components are consumables. If you are getting a wide kerf or the plasma torch isn't cutting through the materials anymore you may need to change the tip parts. To change the consumables disconnect the ground clip from the black retaining cap and unscrew the entire tip from the retaining cap.

=== Standard ===
* Shield P/N: 220673
* Deflector P/N: 2206732
* Retaining Cap - Ohmic P/N: 220719
* Nozzle P/N: 220671
* Electrode P/N: 220669
* Swirl Ring P/N: 220670

=== Fine Cut ===

'''THERE IS CURRENTLY NO POST PROCESSOR FOR RUNNING WITH THESE CONSUMABLES INSTALLED'''

'''NOTE''': These parts are for a t30 unshielded torch, they are compatiable with the T45m when it is run at a setting lower than 30A and cutting materials thinner than 3/16". Ohmic sensing will not work with these parts installed.

* Deflector P/N: 2206732
* Retaining Cap - Ohmic P/N: 220483
* Nozzle P/N: 220480
* Electrode P/N: 220479
* Swirl Ring P/N: 220478

[[:File:T45m.pdf|Consumables catalog page]]

== Feeds and Speeds ==

=== T45m Shielded Consumables ===

==== Mild Steel ====

{| class="wikitable"
!colspan="5"|
!colspan="2"|Recommended
!colspan="2"|Maximum
|-
!Arc Current (a)
!Material Thickness
!Torch-to-work distance (in)
!Initial Piece hieght (in)
!Pierce time delay (s)
!Cut Speed (ipm)
!Arc Voltage (V)
!Cut Speed (ipm)
!Arc Voltage (V)
|-
|rowspan="4"|30
|0.018" 26Ga
|rowspan="4"|0.06"
|rowspan="4"|0.15"
|rowspan="3"|0.0
|?
|117
|400
|118
|-
|0.030" 22Ga
|?
|116
|400
|117
|-
|0.036" 20Ga
|?
|115
|400
|117
|-
|0.060" 18Ga
|0.2
|?
|111
|280
|115
|-
|rowspan="12"|45
|0.036" 20Ga
|rowspan="12"|0.06"
|rowspan="8"|0.15"
|rowspan="2"|0.0
|380
|115
|400
|112
|-
|0.060" 16 Ga
|150
|116
|400
|115
|-
|0.075" 14Ga
|0.1
|150
|117
|360
|115
|-
|0.105" 12Ga
|0.3
|130
|117
|240
|115
|-
|0.135" 10Ga
|0.4
|110
|117
|175
|115
|-
|0.188" 3/16"
|0.5
|85
|118
|110
|115
|-
|0.250" 1/4"
|0.6
|60
|120
|75
|116
|-
|0.375" 3/8"
|0.9
|32
|122
|40
|116
|-
|0.500" 1/2"
|colspan="2" rowspan="4"|Edge Start Recommended
|4
|132
|25
|125
|-
|0.625" 5/8"
|3
|138
|14
|127
|-
|0.750" 3/4"
|2
|140
|10
|131
|-
|1.000" 1"
|?
|146
|5
|142
|-
|}

==== Stainless Steel ====

{| class="wikitable"
!colspan="5"|
!colspan="2"|Recommended
!colspan="2"|Maximum
|-
!Arc Current (a)
!Material Thickness
!Torch-to-work distance (in)
!Initial Piece hieght (in)
!Pierce time delay (s)
!Cut Speed (ipm)
!Arc Voltage (V)
!Cut Speed (ipm)
!Arc Voltage (V)
|-
|rowspan="4"|30
|0.018" 26Ga
|rowspan="4"|0.06"
|rowspan="4"|0.15"
|rowspan="3"|0.0
|?
|117
|400
|123
|-
|0.030" 22Ga
|?
|116
|400
|121
|-
|0.036" 20Ga
|?
|115
|400
|119
|-
|0.060" 18Ga
|0.2
|?
|111
|185
|118
|-
|rowspan="12"|45
|0.036" 20Ga
|rowspan="12"|0.06"
|rowspan="8"|0.15"
|rowspan="2"|0.0
|?
|115
|400
|109
|-
|0.060" 16 Ga
|138
|116
|400
|125
|-
|0.075" 14Ga
|0.1
|?
|117
|360
|115
|-
|0.105" 12Ga
|0.3
|?
|117
|200
|116
|-
|0.135" 10Ga
|0.4
|?
|117
|155
|118
|-
|0.188" 3/16"
|0.5
|?
|118
|85
|118
|-
|0.250" 1/4"
|0.6
|?
|120
|55
|120
|-
|0.375" 3/8"
|0.8
|?
|122
|32
|121
|-
|0.500" 1/2"
|colspan="2" rowspan="2"|Edge Start Recommended
|?
|?
|18
|128
|-
|0.750" 3/4"
|?
|?
|9
|131
|-
|}

==== Aluminium ====

{| class="wikitable"
!colspan="5"|
!colspan="2"|Recommended
!colspan="2"|Maximum
|-
!Arc Current (a)
!Material Thickness
!Torch-to-work distance (in)
!Initial Piece hieght (in)
!Pierce time delay (s)
!Cut Speed (ipm)
!Arc Voltage (V)
!Cut Speed (ipm)
!Arc Voltage (V)
|-
|rowspan="3"|30
|0.018" 26Ga
|rowspan="3"|0.06"
|rowspan="3"|0.15"
|0.0
|360
|117
|400
|120
|-
|0.060" 16Ga
|rowspan="2"|0.2
|340
|118
|400
|121
|-
|0.075" 14Ga
|215
|118
|270
|121
|-
|rowspan="11"|45
|0.060" 16Ga
|rowspan="12"|0.06"
|rowspan="7"|0.15"
|rowspan="3"|0.0
|360
|116
|400
|114
|-
|0.075" 14Ga
|340
|117
|400
|116
|-
|0.105" 12 Ga
|280
|120
|360
|119
|-
|0.135" 10Ga
|0.1
|220
|122
|280
|120
|-
|0.188" 3/16"
|0.2
|100
|123
|130
|120
|-
|0.250" 1/4"
|0.3
|80
|123
|100
|120
|-
|0.375" 3/8"
|0.5
|33
|130
|42
|125
|-
|0.500" 1/2"
|colspan="2" rowspan="2"|Edge Start Recommended
|20
|134
|25
|130
|-
|0.750" 3/4"
|8
|143
|10
|138
|-
|}

=== T30v Unshielded Fine cut Consumables ===
'''THERE IS CURRENTLY NO POST PROCESSOR FOR RUNNING WITH THESE CONSUMABLES INSTALLED'''
==== Mild Steel ====
{| class="wikitable"
!colspan="5"|
!colspan="2"|Recommended
!colspan="2"|Maximum
|-
!Arc Current (a)
!Material Thickness
!Torch-to-work distance (in)
!Initial Piece hieght (in)
!Pierce time delay (s)
!Cut Speed (ipm)
!Arc Voltage (V)
!Cut Speed (ipm)
!Arc Voltage (V)
|-
|rowspan="7"|30
|0.018" 26Ga
|rowspan="7"|0.02
|rowspan="7"|0.1
|rowspan="3"|0.0
|350
|105
|400
|98
|-
|0.030" 22Ga
|320
|102
|400
|103
|-
|0.036" 20Ga
|280
|101
|350
|100
|-
|0.060" 16Ga
|0.2
|175
|97
|220
|100
|-
|0.075" 14Ga
|rowspan="3"|0.4
|120
|98
|150
|97
|-
|0.105" 12Ga
|80
|96
|100
|96
|-
|0.135" 10Ga
|50
|100
|65
|101
|-
|}

==== Stainless Steel ====
{| class="wikitable"
!colspan="5"|
!colspan="2"|Recommended
!colspan="2"|Maximum
|-
!Arc Current (a)
!Material Thickness
!Torch-to-work distance (in)
!Initial Piece hieght (in)
!Pierce time delay (s)
!Cut Speed (ipm)
!Arc Voltage (V)
!Cut Speed (ipm)
!Arc Voltage (V)
|-
|rowspan="7"|30
|0.018" 26Ga
|rowspan="7"|0.02
|rowspan="7"|0.1
|rowspan="3"|0.0
|350
|103
|400
|102
|-
|0.030" 22Ga
|320
|198
|400
|100
|-
|0.036" 20Ga
|300
|97
|380
|98
|-
|0.060" 16Ga
|0.2
|150
|99
|190
|98
|-
|0.075" 14Ga
|rowspan="3"|0.4
|110
|101
|135
|97
|-
|0.105" 12Ga
|60
|101
|75
|98
|-
|0.135" 10Ga
|45
|102
|55
|97
|-
|}

==== Aluminium ====
{| class="wikitable"
!colspan="5"|
!colspan="2"|Recommended
!colspan="2"|Maximum
|-
!Arc Current (a)
!Material Thickness
!Torch-to-work distance (in)
!Initial Piece hieght (in)
!Pierce time delay (s)
!Cut Speed (ipm)
!Arc Voltage (V)
!Cut Speed (ipm)
!Arc Voltage (V)
|-
|rowspan="5"|30
|0.036" 20Ga
|rowspan="5"|0.02
|rowspan="5"|0.1
|rowspan="3"|0.0
|320
|107
|400
|105
|-
|0.060" 16Ga
|240
|104
|300
|103
|-
|0.075" 14Ga
|190
|104
|1240
|103
|-
|0.105" 12Ga
|rowspan="2"|0.2
|145
|103
|180
|103
|-
|0.135" 10Ga
|95
|101
|120
|101
|-
|}

== Wiring ==

=== Stepper Coils ===

* A+ Black
* A- Green
* B+ Red
* B- Blue

=== Smooth Stepper Pin Mapping ===

==== C25 Interface board pins ====

{| class="wikitable"
!colspan="3"|SmoothStepper
!colspan="2"|Target Device
|-
!Port
!Pin
!Type
!Device
!Connection
!Wire color
|-
|1
|1
|Output
|X Stepper Driver
|Pul+
|Green
|-
|1
|2
|Output
|X Stepper Driver
|Dir+
|Red
|-
|1
|3
|Output
|X Stepper Driver
|Ena+
|-
|1
|4
|Output
|Y Stepper Driver
|Pul+
|Green
|-
|1
|5
|Output
|Y Stepper Driver
|Dir+
|Red
|-
|1
|6
|Output
|Y Stepper Driver
|Ena+
|-
|1
|7
|Output
|THC
|Step In
|Green
|-
|1
|8
|Output
|THC
|Dir In
|Red
|-
|1
|9
|Output
|Z Stepper Driver
|Ena+
|-
|1
|10
|Input
|Plasma Interface Connector
|Torch Lit Out
|-
|1
|11
|Input
|Z Limit Connector
|2
|Grey
|-
|1
|12
|Input
|Y Limit Connector
|2
|Grey
|-
|1
|13
|Input
|X Limit Connector
|2
|Grey
|-
|1
|14
|Output
|A Stepper Driver
|Pul+
|Green
|-
|1
|15
|Input
|E-Stop Switch
|Switch contact NC
|Grey
|-
|1
|16
|Output
|A Stepper Driver
|Dir+
|Red
|-
|1
|17
|Output
|A Stepper Driver
|Ena+
|-
|2
|1
|Output
|Torch Relay
|Coil +
|-
|2
|2
|Input
|Touch off probe connector
|Pin 2
|-
|2
|3
|Input
|-
|2
|4
|Input
|-
|2
|5
|Input
|-
|2
|6
|Input
|-
|2
|7
|Input
|-
|2
|8
|Input
|-
|2
|9
|Input
|-
|2
|10
|Input
|-
|2
|11
|Input
|-
|2
|12
|Intput
|-
|2
|13
|Input
|-
|2
|14
|Output
|THC Enable relay
|Coil +
|-
|2
|15
|Input
|-
|2
|16
|Output
|-
|2
|17
|Output
|}

== Configuration ==

=== Stepper Drivers ===
Steps per inch: 1358

Driving current:
* SW1 ON
* SW2 ON
* SW3 OFF

Holding Current:
* SW4 OFF

Steps:
* SW5
* SW6
* SW7
* SW8

== Parts ==

* Steppers:
** Wantai 57BYGH115-003
** Nema 23 stepper motor
** 425oz-in torque
** 3 Amp
* Drivers:
** Wantai DQ542MA
** Manual: [[File:DQ542MA_English_Manual.pdf]]
* SmoothStepper Ethernet
* C25 Break out board
** https://cnc4pc.com/motion-control/breakout-boards/c25-smooth-stepper-terminal-board.html
** Manual: [[File:C25R3_1_USER_MANUAL.pdf]]

==maintenance ==
[[CNC_Plasma_Cutter_maintenance|maintenance page]]

== Authorization ==

=== Authorizers ===

* Andrew Camaradella - 45A auto Z only
* Ron Olson - 45A auto Z only

=== List of Currently Authorized Users - 45A Auto Z ===

{| class="wikitable" border="1"
! Qualified Member
! Trained By
! Date
|-
|Andrew Caramdella
|Danger Committee
|
|-
| Jake Chaitkin
| Ron Olson
| 6/9/2018
|-
| Zack Sasnow
| Ron Olson
| 6/9/2018
|-
| Erik Wessing
| Ron Olson
| 6/9/2018
|-
|Ryan Pierce
|Ron Olson
|9/2/18
|-
|Glenn Powers
|Ron Olson
|10/21/18
|-
|Sam Paris
|Ron Olson
|10/21/18
|-
|Farsheed Hamidi-Toosi
|Ron Olson
|10/21/18
|-
|}

=== List of Currently Authorized Users - 30A Fine Cut ===

{| class="wikitable" border="1"
! Qualified Member
! Trained By
! Date
|-
|Casey Olson
|Tom Judge
|-
| Jake Chaitkin
| Ron Olson
| 6/9/2018
|-
| Zack Sasnow
| Ron Olson
| 6/9/2018
|-}
|-
|}

BOSS LS-3655 150w Laser Engraver

2019-01-06T00:27:59Z

Daddybird: /* About */

{{ Template:EquipmentPage
| owner=PS:One
| model=BOSS LS-3655 150w
| serial=SERIAL NUMBER
| arrived= January 2017
| doesitwork=yes
| contact=[[CNC|CNC Area Host]]
| where=CNC Shop
| certification=yes
| hackable=no
| value=$17,000
| image = BossLaser2.jpg
| hostarea = CNC
}}

== About ==

The BOSS LS-3655 is an industrial CO2 laser engraver with a 35.4" x 55.1" bed, supporting over-sized material pass-thru on four sides and up to 7 inches of table depth. Originally shipped with 100W tube, but that has been replaced with 150W tube in May, 2017.

== Status ==
* (2018/12/07) Working, but not that well. Had to use 100% power and speed 5 to cut through relatively thin leather. Perhaps needs to be cleaned?
* (2018/12/01) NOT working. Needs a tube replacement, probably. It's going to be a while. It will not happen faster if you ask when it's going to be fixed. NOBODY KNOWS YET.
* (2018/02/26) Working. Z-Axis motor having some issues? 2-25-2018
* (2017/05/20) 150W Tube & Power Supply installed. Alignment & focusing pending.
* (2017/06/12) The laser has been aligned and focused. 2" Laser lens focal depth set to 5.1mm.

== Software ==

*The software that drives the Boss laser from the attached computer is called RDWorksV8, the version that is appropriate to use is 8.01.18
*That is not the most recent version of the software, but it is the most recent approved version for PS1. If you are having issues with RDWorks, verify that you are using the correct version of the software.
*If your old shortcut to RDWorks doesn't work, go to start/C:/Program Files/RDWorks and open the program by clicking the application in that folder. DO NOT MOVE THAT APP TO YOUR OWN DESKTOP. You can create a new shortcut to it, but please do not move it.

== Usage Policy ==

The laser cutter is easily one of the most used machines at PS1. Due to this demand we request the cooperation of all members to share the laser cutter and associated computer. First and foremost, the practice "being excellent" should be observed at all times; respect yourself, other members, and the equipment. This is a usage policy so that everyone can use the laser:

* Any user not actively test cutting or cutting will cede the computer and laser to the next person waiting in line, as soon as that waiting user notifies the current computer user. If you are still designing your file, please do so on another computer. Artastic (another PC upstairs) in the Crafts Area also has a copy of Adobe Illustrator.
* If someone is waiting in line to use the laser, no active test cut or cut series shall be longer than 1 hour. No jobs will be allowed to start that overrun the 1 hour time limit when a new user is waiting.
* In the case that your last cut is longer than the 1 hour time limit, and a waiting user presents themselves after the cut has started, the cut job shall be allowed to finish and the waiting user will be allowed to set up their file in their own user account, during the cutting period.
* Continuous cutting shall not exceed 3 consecutive hours without a half hour break for the laser to cool. If a new user arrives before or during the cooling period the current user shall cede the laser to the next user, and the next user will wait for the cooling period to finish and the cooling period shall not count towards the 1 hours limit should another user present themselves.
* Waiting users shall notify the current user verbally that they are waiting and where they will be waiting until it is their turn. If multiple users are waiting, the next waiting user must start their test cutting or cut job within 10 minutes of being notified of a laser opening. The current user will keep a record of who is waiting, where they will be, and notify subsequent users of the status of the queue. The current user will find the next waiting user and verbally inform them that the laser is available.

== Authorization ==

How to get authorized: contact the CNC Area Host or one of the Volunteer Authorizers.

===Authorizers ===
====Area Host====
* Joe Mertz

====Volunteer authorizers:====
*Jeff Zelnio
*

====Other Authorized authorizers:====
* Ray Doeksen

Since demand fluctuates, and there are a random group of new and old members that want to be authorized at any one time, it makes sense to find the others and figure out your group schedule/plan. There generally is NOT going to be a calendar-based or widely publicized meetup event; you will have to conctact and make arrangements with actual people, at least until the Canvas Learning Management System is implemented more fully. http://canvas.pumpingstationone.org

=== Preparing yourself to become authorized ===

You need a few things to optimize and expedite your experience:

* 1. Know what you're doing as best as you can - come pre-trained on your own time to make the authorization go smoother and faster.
* 2. Have a PS1 username set up before starting the authorization http://members.pumpingstationone.org (from 2018 onwards, you will create a username as part of the signup process or migration to the Wild Apricot-managed member management system. A username is not an email address.
* 3. Have some familiarity with the kinds of files you would bring to the Boss to cut.

To that end; you could download and become familiar a bit with RDWorks, the software you will use to drive the Boss. Links are on this page.
You can read a bit of the manual, which is also linked on this page, or watch some YouTube videos.

To set up a PS1 username (this is NOT the email address you use, it's a different thing, it's entirely special to PS1) go to http://members.pumpingstationone.org, and click "Activate" ... if you don't already have a PS1 username.

Bring files in from Adobe Illustrator in Illustrator format, with lines set to have SOME sort of stroke, I'd recommend 1 point stroke, and some simple color applied to the stroke for each "layer" you want to have in RDWorks. You will want to have one color/layer assigned for each type or strength of cut/engrave you'll be doing in that job. For instance, you might want a deep engraving, a shallow engraving, a cut that goes all the way through the material and maybe a cut that just barely touches the top surface (called a 'kiss cut) and that would mean you would need four distinct colors of stroke used in your file. You should investigate the usefullness of SVG, DXF and DWG files as well, but Illustrator files will give you the best first experiences.

Authorizations will be limited to small groups, e.g. 4 or less, due to nature of the equipment.

== Troubleshooting ==
* Grinding noise; TBD; was grinding, but grinding stopped once the head was moved away from the sensors and the machine restarted.
* There is a small yellow proximity sensor just behind and to the right of the "head" when it returns to home position.
* If the sensor gets pushed out of position, off at an angle, then the grinding will happen. If you return it to vertical, this will stop and it will return to home without complaining.
* RDWorks is already installed on the machine for everyone to use, but you might have to find it by clicking Start/C:/Program Files/RDWorks and add a shortcut to your own desktop, start menu, or taskbar.
* Don't move the RDWorks instance that you find ... you will disable other users' shortcuts that they've made on their desktop, start menu or taskbar. If you can't get the instance to work, get help from an admin; it's probably been moved somewhere awkward by another user.
* Software requests an admin password; you may be using the most current version of the RD Works software, but maybe you shouldn't.
* The current version has some bugs, evidently, so use the tip hidden below under "resources" to fix the problem for you.
* You should be using RDWorksV8, version 8.01.18
* If the language for RDWorks (the Boss control software) is showing garbage, [https://www.youtube.com/watch?v=gwhQ2xzV1xo&feature=youtu.be follow this video].

==Power-On & Safety Check==
# Check Wiki for status updates
# Check if material is safe to cut: refer to the wiki for a list of safe and unsafe materials for cutting
# Check Fire Extinguisher: Make sure it is close by and charged
# Release Emergency Stop: Rotate red button until it releases
# Turn Power Key: Display will load up
# Turn on Air Assist & Chiller: Flip the switch and ensure exhaust & chiller are on and functioning. Double check chiller temp with laser temp.
* RD Works
# Load Program & Check USB Connection Status
# Importing Files: Importing AI, DXF, SVG, & images
# Introducing User Interface: quick review of UI including Drawing, Grouping, Preview, Work Tab, Layers, Laser Work, & Head Position
# Detailed Overview of Work Tab: major cutting settings & parameters reside here
# Starting a Job
# Saving a File
* Boss Laser Operation
# LED Keypad Overview
# Adjusting the Z-Height: raise and lower bed
# Autofocus: Setting focal height for material
# Setting Origin
# Jogging the Laser Head in XY
# Adjusting High Pressure Air Regulator: Changing the compressed air flow
# Loading a File via USB Port
# Load & Unload honeycomb
# Cleaning Up & Clearing Catch Tray
* Individual Walkthrough: each member is required to perform the following:
# Start-Up the machine
# Turn on exhaust, air-assist, & chiller
# Place Material, autofocus, set origin
# Load RDworks, create 3 layers (Cut, Scan, Dot) & run laser job
# Shutdown machine & clear catch tray

== Settings ==
[https://wiki.pumpingstationone.org/Boss_Laser_Settings Laser Settings Page]

* Honeycomb vs. Aluminum Lamella : The honeycomb is used for engraving and pieces that benefit from precise leveling. Use the aluminum lamella (slats under honeycomb) for cutting through to reduce flashback and improve airflow (warning small pieces will fall through).

* 4" Lens Focus Depth 38.5mm (this is a just an approximate, FD calibration must be performed each time the lens is changed)
* 2" Lens Focus Depth 5.3mm (this is a just an approximate, FD calibration must be performed each time the lens is changed)

== Procedures ==
[https://wiki.pumpingstationone.org/BOSS_Usage Boss Usage]

[https://wiki.pumpingstationone.org/BOSS_Maintenance Boss Maintenance]

=== Powering On Machine ===
* Check Fire Extinguisher
* Release Emergency Stop button
* Turn power key
* Turn on air assist & water chiller Switch & ensure both are functioning
* Turn on exhaust switch and ensure it is functioning. (Gray Switch to the left of the machine)

=== Powering Off Machine ===
* Turn key to off position, leave key in the lock
* Push emergency stop button in
* Turn the chiller, blower and air assist off using the main switch (switch with identifying lasercut plate)
* Reset the area by cleaning up any stray cut materials. Clean and straighten the area around the laser.

== Material Safety & Information ==
WARNING: Because many plastics are dangerous to cut, it is important to know what kind you are planning to use. If you are unsure of your materials composition, don’t cut it with the laser. You can request a SDS from your material supplier for specific information on the plastic you have or are considering using.

=== NEVER CUT THESE MATERIALS ===
** Any material containing chlorine:
***PVC (Poly Vinyl Chloride)
***Vinyl
***Pleather
***Artificial leather
**Plastics:
*** Polycarbonate/Lexan – [Thick ( >1mm )]
*** ABS
*** HDPE/milk bottle plastic
** Foams:
*** PolyStyrene Foam
*** PolyPropylene Foam
** Other:
*** Epoxy
*** Fiberglass
*** Coated Carbon Fiber
***Any foodstuff ( such as meat, seaweed 'nori' sheets, bread, tortillas... )

=== Safe Materials for Cutting ===
** Plastics:
*** ABS (acrylonitrile butadiene styrene)
*** Acrylic (also known as Plexiglas, Lucite, PMMA)
*** Delrin (POM, acetal)
*** Kapton tape (Polyimide)
*** Mylar (polyester)
*** Nylon – melts badly
*** PETG (polyethylene terephthalate glycol)
*** Styrene
*** Two-tone acrylic – top color different than core material, usually for custom instrumentation panels, signs, and plaques.
** Foam:
*** Depron foam – often used for RC planes.
*** EPM
*** Gator foam – foam core gets burned and eaten away compared to the top and bottom hard shell.
** Other:
*** Cloths (leather, suede, felt, hemp, cotton)
*** Papers
*** Rubbers (only if they do not contain chlorine Teflon (PTFE, Polytetrafluoroethylene)
*** Woods (MDF, balsa, birch, poplar, red oak, cherry, holly, etc.)

==== Aligning Materials ====

** The table is not aligned with the laser's X-Y axis
** To align your material use the laser pointer by holding one axis constant while moving along the other axis to align corners of your material

== Laser Materials and the Woodshop Table-Saw Saw-stop ==

*Conductive materials such as aluminum and other metals, carbon fiber materials, mirrored acrylic, carbon-filled materials, etc. will typically cause the brake to activate.
*Carbon from lasered wood or lasered plywood is also conductive and will trigger the saw stop. do not use the table saw to cut your material. Once you have lasered a piece of wood,
**The band saw can be used instead for both mirrored acrylic and lasered wood. Use safety goggles when using the bandsaw in general, but especially when using it to cut acrylic. (NOTE: authorization is required for the table saw and the bandsaw, so attending a woodshop authorization might be a good idea).

== Resources ==

The proprietary LaserWORKS software can be downloaded from BOSS here - https://www.bosslaser.com/laser-software/ However, the current version (8.01.28) of the laser software seems to require admin rights every time it's used. So instead you may want to download the [https://appdb.winehq.org/objectManager.php?sClass=version&iId=35522 8.01.18 version of the software] until this is fixed.

Manuals for the BOSS laser and the LaserWORKS software are located here - https://www.bosslaser.com/download-manuals-guides/

[https://www.bosslaser.com/laser-test-files BOSS test files are available here]

[https://www.bosslaser.com/laser-settings Some laser settings from Boss]

[https://www.facebook.com/groups/900528680076062/ Excellent Facebook Group for RDWorks Tips and help]

[https://rdworkslab.com/index.php Forum for RDworks user group]

== Youtube Channels ==
Following are a couple good YouTube Channels with lots of information on the software and machine
* [https://wiki.pumpingstationone.org/index.php?title=Special:UserLogin&returnto=BOSS+LS-3655+150w+Laser+Engraver SarbarMultimedia]
* [https://www.youtube.com/channel/UCOuDR90TZ24qEFFIbVmDAMw Thunder Laser]

== Cleaning & Maintenance ==

* When changing the lens, make sure the convex/domed side of the lens is facing upwards (towards the ceiling)
* Focus Lens should be cleaned once a week with Acetone or Denatured Alcohol
* (How often should the air filter be changed?)

== List of Currently Authorized Users ==

{| class="wikitable" border="1"
! Qualified Member
! Trained By
! Date
|-
|Andrew Camardella
|Danger Committee
|
|-
|Matt Keith
|Danger Committee
|
|-
|Sky Nova
|Danger Committee
|
|-
|Jason Araujo
|Danger Committee
|
|-
|Ray Doeksen
|Danger Committee
|
|-
|Matt Meshulam
|Danger Committee
|
|-
|Ashish Jasani
|Danger Committee
|
|-
|Joe Juhnke
|Ashish Jasani
|
|-
|Casey Olson
|Ray Doeksen
|
|-
|Andrew Vaughan
|Burton Kent
|
|-
|[[User:mct|McTavish McArdle]]
|Burton Kent
|
|-
|Erik Wessing
|Ray Doeksen
|
|-
|Theo T
|Ray Doeksen
|
|-
|Molly Adamski
|Joe Juhnke
|
|-
|[[User:deadwisdom|Brantley Harris]]
|Ray Doeksen
|
|-
|Amir Badri
|Sky Nova
|
|-
|Aaron Carlock
|Jeff Z
|
|-
|Gabe Tavas
|Joe Juhnke
|
|-
|Sam Dreyer
|Jeff Z
|
|-
|Stephanie Pelzer
|Jeff Z
|
|-
|Nick Prorok
|Jeff Z
|3/02/2018
|-
|Alisha Ciardi
|Burton Kent
|03/2018
|-}
|-
|Bao Nguyen
|Zander Bueno
|05/04/2018
|-
|Chris Laurent
|Jeff Z
|07/06/2018
|-
|[[user:thingsspun|Jake Chaitkin]]
|Nick Prorok
|2018-07-09
|-
|[[user:aidanfowler12|Aidan Fowler]]
|Ray Doeksen
|2018-08-02
|-
|Farsheed Hamidi-Toosi
|Jeff Z
|2018-10-03
|-

[[Category:Laser Cutter]]
[[Category:Fabrication]]
[[Category:Certification Clarification Needed]]

3dSystems CubePro

2018-10-17T23:36:53Z

Daddybird: /* Maintenance */

{{Template:EquipmentPage
|owner = PS:One
|serial = TBD.
|certification = no
|hackable = no
|model = CubePro
|arrived = 2014
|image = Cube Pro.jpeg
|doesitwork = yes
|contact = [[CNC|CNC Area Host]]
|where = 3d Printer Row
|value = $4400
}}
== Status ==
* Functioning, but mostly out of filament. New filament is approx. $99/cartridge.
* (2017/06/12) CubePro Trio has been hacked so the counter does not update the EEPROM Chip on the proprietary cartridges. More work has to be done, but we should be able to print using 3rd party filament in the near future.

== Authorization ==

No authorization is required, but you may have to provide your own filament for this machine, which only uses proprietary filament, and costs about $99 per 600 gram spool. Methods to trick the machine into using standard filament, have been attempted (see below.)

== Getting Started ==

Use the computer to the right of the CubePro (the one called "Artastic" was used in the past, in 2017 there may be a different computer, or download and install the proprietary software yourself) to prepare your files using the Cube pro software, then export the file to a USB thumbdrive and plug it into the USB port on the left side of the printer itself. Select the file you prepared from the print menu using the touch screen on the front of the printer. Open-source slicer (gcode preparation) software that is used for the other 3D printers will not work with this machine.

[[File:Cube pro usb slot.jpeg|left|thumb|USB Port]][[File:Cube Pro touchscreen.jpeg|center|thumb|touchscreen]]

== Documentation ==

[http://cubify.com/en/CubePro/Activate CubePro 3D Printer activation page]

Calibration prints (specific to filament type):
[[File:Cubepro calibration files.zip]]

[http://cubify.s3.amazonaws.com/public/cubepro/cubepro_user_guide.pdf CubePro 3D Printer]

== Notes ==
Filament (ABS, PLA, Nylon some time after August of 2014) comes in [http://cubify.com/en/CubePro/Supplies DRMed canisters from CubePro] at approximately 500 grams for $99.

== Maintenance ==
Print bed leveled and fully calibrated on 2/12/15 by Will Garza
Instructions provided by Cubify:

CubePro Filament Flow Error

Check the cartridge - Is the filament releasing freely from the cartridge without binding up. If it is jammed, open the cartridge using the thumb tabs on the side of the unit and try to untangle the filament. If this is unsuccessful we will be happy to replace the cartridge to resolve the issue.

If the cartridge is not jammed, move forward with checking the print jet

Check the print jet - Go to the control jets function on the touch screen to test the print jet. Choose the corresponding print jet by selecting A, B, or C. Set the temperature to 260C. Once the actual temperature meets 260C, turn the RPM up to 4.0. This will start the gears which should make the machine start extruding material. Follow steps below depending on what happens.

Filament Flow Error - No material extruding - no clicking noise present - It is possible that the material is not properly loaded and the gears are not catching the filament. Please follow the link below for steps on reloading the filament.

https://teamplatform.com/l/c88cec3e

Filament Flow Error - No material extruding - clicking noise present - The clicking noise is consistent with a clogged print jet. Please follow the below instructions for removing the clog.

1. Go to the control jets function on the touch screen
2. Set the temperature to 290C.
3. Once the actual temperature meets 290C, turn the RPMs to 1.0
4. Run for several minutes (If the filament flow error comes up, continue to steps for manually removing clog)
5. Set the temperature back to 0C
6. Go to the change cartridge function and load the filament
7. Go back to the control jets function to test the print jet.

If the above steps do not resolve the issue, follow the link below for instructions on manually removing the clog.

https://www.dropbox.com/s/e40gfn7m1al9fti/CubeProJamTroubleshootingGuide.pdf?dl=0

If manually removing the clog does not resolve the issue a new print jet assembly will be needed.

No Filament Error Present - Material is extruding correctly - This confirms that the print jet is functioning correctly. The error message received during the print is related to settings. If the Z gap is to tight and the plate is not level, the material has nowhere to go and will throw a filament flow error. Please refer to the user guide for setting the Z gap and leveling the print Pad.

=== Troubleshooting ===
Refer to our [[3D Print Troubleshooting]] page.

[[Category:CNC]]

Jellybox

2018-10-17T23:36:31Z

Daddybird: /* Troubleshooting and Maintenance */

Needs an equipment label.

Needs some information! Needs a photo. Needs some categories added.

== Status ==

Functional

== Authorization ==

Has been made available without authorization required, at least that's the impression given and the de facto condition. Might be cleared up by the addition of an equipment label by anyone who knows.

== Description ==

Excellent self-leveling 1.75 mm 3D printer. Uses only SD cards for input, at the moment. There are very good profiles available for this printer in Cura, the default Jellybox profile works quite well.

== Usage notes ==

Sensitive to hygroscopic filament (water absorption), like all printers, but notably. Keep the filament dry, store it carefully. Works well with PLA filament. Works well with blue tape on the build plate.

== Troubleshooting and Maintenance ==

How to unclog the hot end (extruder/nozzle): https://forum.imade3d.com/t/howto-unclog-a-clogged-nozzle-hotend/499

Refer to our [[3D Print Troubleshooting]] page.

Lulzbot Taz3

2018-10-17T23:36:14Z

Daddybird: /* Other Resources */

{{Template:EquipmentPage
|owner = PS:One
|certification = yes
|hackable = no
|model = Aleph Objects Taz3
|serial = KT-PR0013-5509
|arrived = January 2014
|doesitwork = yes
|contact = [[CNC|CNC Area Host]]
|where = [[CNC]] 2nd Floor
|value = $2395
|image = Taz3.2.jpg
|hostarea = CNC
}}

== Status ==

4/29/2-17 - [[Taz 3 OctoPrint Server]] is hooked up. Future authorizations will cover the Octoprint server and its web interface operation.

== Past Status ==
Still no Octoprint as of 4/4/2017 :(

As of 1/29/2017, things for the Taz3 are ''looking pretty good.'' It is operating as expected and a nice new printed spool holder is being installed on the top. [[User:Skynaya|Skynaya]] ([[User talk:Skynaya|talk]]) 09:48, 29 January 2017 (CST)

As of 1/17/2017 there appears to be an issue with Repetier where the server has to be stopped after boot or the COM port will be blocked. It can be disabled by going to the start menu and finding "Stop Server" for Repetier, but you may need admin credentials to override it. I'm looking into disabling this behavior. However, we will be switching to Octoprint servers to operate the printers soon. [[User:Skynaya|Skynaya]] ([[User talk:Skynaya|talk]]) 14:06, 18 January 2017 (CST)

As of 12/28/2016 device was jammed due to improper movement. Currently being worked on. --[[User:Skynaya|Skynaya]] ([[User talk:Skynaya|talk]]) 16:41, 3 January 2017 (CST)

As of 12/20/2015 Someone has put a note saying "no work" on the print bed, no further information known.

As of 12/10/2015 Undergoing testing. Functional. New LCD installed, SD card reader should be working but has not been tested in use. Fiberglass flexible print bed add-on installed. Firmware updated for new Hexagon extruder heads, no longer compatible with Flexistruder, for now. Hexagon heads need to be set higher than old heads (temperatures will need to be higher.) Additional testing required to advise what temperatures are best. --[[User:Rdoeksen|Rdoeksen]] ([[User talk:Rdoeksen|talk]]) 16:17, 10 December 2015 (CST)

As of 11/13/2015 the main PLA/ABS extruder is not working, replacement extruders and parts are ordered or awaiting installation by CNC Area Host.

As of 9/28/2015 not clogged, working normally, DO NOT RUN PLA for longer than 1hr --[[User:Rtystgeeke|Rtystgeeke]] ([[User talk:Rtystgeeke|talk]]) 15:26, 28 September 2015 (CDT)

As of 7/20/2015 nozzle clogged with PLA, resistor wire is broken (needs replacement), bottom wood disk is broken (needs replacement) --Andrew Camardella 7/20/2015 5:35pm

As of 6/3/2015 nozzle unclogged, tested with ABS. --[[User:Rdoeksen|Rdoeksen]] ([[User talk:Rdoeksen|talk]]) 19:22, 3 June 2015 (CDT)

As of 6/1/2015 clogged with PLA through the length of the hot end and nozzle. Needs to be disassembled, burned out, nozzle cleaned. Probably needs replacement nozzle. Needs replacement parts for the hot end (wood discs, maybe aluminum disk) --[[User:Rdoeksen|Rdoeksen]] ([[User talk:Rdoeksen|talk]]) 18:53, 1 June 2015 (CDT)

As of 5/20/2015 not clogged, running normally.

Seems to be extruding fine as of 4/30/2015. [Extruder nozzle clogged. Needs unclogging or nozzle replacement. (As of 4/28/2015, clogged )]

== Authorization ==

Under construction. Ask CNC Area Host. No regularly scheduled authorizations. Authorization sessions can be arranged for 3 or more members as required. If you want to schedule an authorization session, find 2 or more other people (by asking on the Google Group) and email the CNC Area Host for referral to an authorizer.

== Operation ==

=== [[Taz 3 OctoPrint Server]] ===

The Taz 3 now uses OctoPrint as its host device. You can now send jobs to the printer via any computer in the space, even your personal device. It's a web service, load the URL in a web browser; you don't need to download or install anything.

The OctoPrint server for the Taz 3 can be reached at http://10.100.1.200/

* When connecting to the OctoPrint server, you may first need to select "Connect" under the left side Connection tab if the printer has been turned off.
** All settings to connect are retained and should not be modified. *Since someone CAN modify them, and then nobody else will be able to use it, why don't we put the proper settings here in the wiki so people can fix what's wrong?
* Once the printer is connected, you can begin warming it up with the Temperature tab.
** Enter a temperature in Celsius and click "Set"
* You can control the printer's movements and extrusion using the "Control" tab.

* To get started printing, upload an STL using the left side "Files" tab.
* Find the STL you uploaded and click the "Slice" button, it looks like a magic wand.
* From here, you can select what slicer engine you'd like to use and what settings you'd like to print with.
** Cura is the default slicing engine.
** Select one of the preset slicing profiles, and then manually set your preferred temperatures and speeds using the Basic and Advanced tabs.
* Now locate the newly generated GCO file (G-Code) in the left side Files tab. You can now click "Load and Print" to print your object.
* It is preferred if you delete your files from the OctoPrint server when you are done. You can download your GCO file for future printing if you would like to retain the specific sliced project.

This is only a high level overview of how to use OctoPrint. If you are already authorized but have not used OctoPrint, feel free to attend future authorization sessions. OctoPrint will accept g-code from the most popular slicers such as Cura, Slic3r, Repetier-Host, and Simplify3D.

== Troubleshooting ==

Under construction. Please add information to this section if you discover some useful tips and tricks.

*Usually is COM5
*If you can't connect on COM5, you may need to reboot the PC, because another user is still logged in after they connected on COM5. If a reboot doesn't resolve the "Connect" problem, then shut the PC down, unplug the unit's power cord, and restarting the machine. This has has fixed the problem as of 3/19/17 - first time I've had the COM5 problem for a while.
*Make sure baud rate is set to 115200
*Make sure protocol is set to Autodetect
*In Repetier Host, home the machine to get full motion on the axes
*In Simplify3D, if you are asking for login information just close the box with the X button and the program will launch.

== Mods ==
Factory standard settings, accessories and equipment. Alternate Flexistruder available at PS1 but not installed.

=== Windows Drivers ===
Windows users driving the printer tethered (over a USB cable) will need to [https://www.lulzbot.com/support/TAZ install drivers.]

=== Usable Print Area ===
298mm x 275mm x 250mm (11.7in x 10.8in x 9.8in)

=== Nozzle size ===
* 0.50 mm nozzle --[[User:Rdoeksen|Rdoeksen]] ([[User talk:Rdoeksen|talk]]) 16:20, 10 December 2015 (CST)(please verify?)

=== Host Software ===
Users of Linux, Windows, OSX will need to install the following software:
* [https://github.com/kliment/Printrun#getting-printrun Pronterface] - or [http://www.repetier.com/download/ Repeteir-Host] for manual operation of the printer as well as for starting print jobs
* [http://slic3r.org/download Slic3r] - for creating gcode (print jobs) from 3D models
* Additionally, Lulzbot provides a [http://devel.lulzbot.com/TAZ/2.1/software/2013Q4/slic3r/config/pt35mm-nozzle/medium_ABS_no-support_pt35nzl_pt2-layer-height_config.ini slic3r config file] for the Taz3
* Alternately, you can use [http://wiki.ultimaker.com/Cura Cura by Ultimaker]

== Suggested Settings ==

Both of these files have appropriate settings for the 'printer settings' and 'filament settings' tabs. To use them, go to File > Load Config in Slic3r and select the downloaded file. You must then go to each tab and hit the 'save' icon next to the settings selection dropdown box, or else Slic3r will forget the settings when you close it.

For settings in Simplify3D, you need to 'import FFF profile'. This can be found under File/Import FFF Profile, then browse your computer to find it.

==== ABS for Simplify3D ====

[[File:ABS Fast2.0(.3mm).zip]]

ABS profile for the Taz3 at %15 infill, supports enabled, .3mm layer height, extruder at 230C and bed at 90C, with appropriate cooling (none).

==== PLA for Simplify3D ====

[[File:PLA_Simplify3D.zip]]

PLA profile for the Taz3 at %15 infill, supports enabled, .3mm layer height, extruder at 190C and bed at 65C, with appropriate cooling (increasing speed with layer height).

==== Ninjaflex for Simplify3D ====

[[File:Ninjaflex_Simplify3D.zip]]

Ninjaflex profile for the Taz3 at %15 infill, supports enabled, .3mm layer height, extruder at 220C and bed nonheated.
*Ninjaflex can only be run with the flexistruder extruder type, which requires the firmware "Marlin 2014" or older.

==== ABS Print Settings Without Support - Fast ====

[[File: Taz3_print_settings_NO_SUPPORT.ini]]

This file is for the 'print settings' tab of Slic3r. This is a 'fast' profile, geared towards finishing prints relatively quickly. It still provides excellent surface quality. This profile does not include support, so for large overhangs you'll need the next configuration file.

==== ABS Print Settings With Support - Fast ====

[[File: Taz3_print_settings_SUPPORT.ini]]

This file is for 'print settings' tab of Slic3r. This is a 'fast' profile, geared towards finishing prints relatively quickly. It still provides excellent surface quality. This profile includes support, appropriate for large overhangs.

==== Sky's Config Bundle ====

[[File:Sky config bundle.zip]]

Here is a range of configuration settings for Slic3r in Repetier that I've found useful with a lot of trial and error. [[User:Skynaya|Skynaya]] ([[User talk:Skynaya|talk]]) 21:35, 13 April 2017 (CDT)

== Other Resources ==
[http://download.lulzbot.com/TAZ/3.0/documentation/2013Q4/LulzBot_TAZ_3.0-User_Manual-ebook.pdf The manual is available online]. A printed form of it can be found near the printer. The manual explains how to operate the printer.

[https://wiki.pumpingstationone.org/images/Basic_ABS_Settings_for_Taz_with_Repetier_Host_software.pdf This PDF] contains the screenshots for each tab and setting. When you first use Repetier on your windows login, you have to adjust some settings for first time use.

=== Filament ===

The extruders available accept 3 mm filament, and can print either ABS or PLA. There is an alternate extruder for use with Ninjaflex, called 'Flexistruder' but the Flexistruder is not supported with the current firmware installation.

[http://www.microcenter.com/category/4294898923/3D-Printing MicroCenter (online and in store)]

[http://www.monoprice.com/Search/Index?keyword=3d+printer+filament Monoprice]

=== Find Something to Print ===

[http://thingiverse.com Thingiverse] is a great place to find printable 3D models that other people have designed, and to publish your own.

=== Designing 3D Models ===

Page in progress to describe [https://wiki.pumpingstationone.org/3D_Modeling 3D modeling.]

=== Troubleshooting ===
Refer to our [[3D Print Troubleshooting]] page.

== List of Currently Certified Users ==
{| class="wikitable" border="1"
! qualified member
! trained by
! date
|-
|[[User:Dbever|Derek Bever]]
|Hours of shouting at 3D printers
|-
|Elizabeth Koprucki
|Derek Bever
|-
|Andrew Kos
|Elizabeth Koprucki
|-
|[[User:rdoeksen|Ray Doeksen]]
|Elizabeth Koprucki
|-
|[[User:Negativek|Everett Wilson]]
|Derek Bever
|-
|[[User:daveplays|David Earley]]
|Derek Bever
|-
|[[User:Lyn|Lyn Cole]]
|Derek Bever
|-
|[[User:nerobro|Greg Teiber]]
|Derek Bever
|-
|[[User:nick|Nick Castillo]]
|Derek Bever
|-
|[[User:tom4writer|Tom Forajter]]
|Elizabeth Koprucki
|-
|[[User:dditzler|David Ditzler]]
|Elizabeth Koprucki
|-
|[[User:davidfell|David Fell]]
|Elizabeth Koprucki
|-
|[[user:rob|Rob Riggs (Colorado Rob)]]
|Elizabeth
|-
|Mark Stevens
|Elizabeth Koprucki
|-
|[[User:ad9581|Arturo Duarte]]
|Elizabeth Koprucki
|-
|[[User:justin|Justin T. Conroy]]
|Derek Bever
|-
|[[User:jivnyahoo|James Porter]]
|Elizabeth Koprucki
|-
|[[User:ryankelly11|Ryan Kelly]]
|Elizabeth Koprucki
|-
|[[User:JanetD|Janet Dornhoff]]
|Elizabeth Koprucki
|-
|Genevieve Aphrodite
|Justin Conroy
|-
|Sloan Lavery
|Elizabeth Koprucki
|-
|[[User:spacekid|Adam Glick]]
|Ray Doeksen
|-
|[[User:funk|Tyler Natoli]]
|Elizabeth Koprucki
|-
|Chris Marchwick
|Elizabeth Koprucki
|-
|[[User:marty|Marty Dubin]]
|Elizabeth Koprucki
|-
|[[User:amishhammer|Tom Judge]]
|Justin Conroy
|-}
|-
|[[User:brian|Brian Dunn]]
|Derek Bever
|-|-
|[[User:lofgren|Tim Lofgren]]
|Derek Bever
|-
|[[User:lgaboarder|Jeff McBride]]
|Elizabeth Koprucki
|-
|Thomas Wright
|Justin Conroy
|-
|[[User:dsiegfried|David Siegfried]]
|Derek Bever
|-
|Donald Jacobson
|Elizabeth Koprucki
|-
|[[User:Sparr|Clarence Risher]]
|Elizabeth Koprucki
|-
|[[User:ironwill|Will Garza]]
|Elizabeth Koprucki
|-
|[[User:emertonom|Nick Halderman]]
|Elizabeth Koprucki
|-
|[[User:tactics|Michael Maloney]]
|Elizabeth Koprucki
|-
|[[User:tactics|Brennan Koziarz]]
|Elizabeth Koprucki
|-
|[[User:rogermoore|Roger Moore]]
|Elizabeth Koprucki
|-
|[[User:aaronmintz|Aaron Mintz]]
|Elizabeth Koprucki
|-
|[[User:mlm|Matt Makris]]
|Elizabeth Koprucki
|-
|Matt Meshulam
|Elizabeth Koprucki
|-
|Ron Olson
|Elizabeth Koprucki
|-
|[[User:daroldhiga|Darold Higa]]
|Ray Doeksen
|-
|Nora Sluzas
|Elizabeth Koprucki
|-
|Matt Triano
|Elizabeth Koprucki
|-
|Curtiss Cooke
|Elizabeth Koprucki
|-
|Andrew Sowa
|Elizabeth Koprucki
|-
|Eric Yu
|Elizabeth Koprucki
|-
|[[User:lucas|Lucas Goossen]]
|Elizabeth Koprucki
|-
|Jessica Wiedner
|Derek Bever
|-
|Scott Little
|Derek Bever
|-
|Kevin Pulver
|Ray Doeksen
|-
|Jenny Tong
|Ray Doeksen
|-
|Mike Mandrea
|Elizabeth Koprucki
|-
|John Farmer
|Elizabeth Koprucki
|-
|Andy Richardson
|Elizabeth Koprucki
|-
|Alex Trimm
|Elizabeth Koprucki
|-
|[[User:rickalm|Rick Alm]]
|Elizabeth Koprucki
|-
|Davis Mazariegos
|Elizabeth Koprucki
|-
|Knute Martell
|Elizabeth Koprucki
|-
|Hugh Sato
|Elizabeth Koprucki
|-
|Ryan Neuman
|Will Garza
|-
|[[User:Tina|Tina C]]
|Elizabeth Koprucki
|-
|Scott Drane
|Elizabeth Koprucki
|-
|Michael Patton
|[[User:rdoeksen|Ray Doeksen]]
|-
|Chris Leeson
|[[User:rdoeksen|Ray Doeksen]]
|-
|Matt Pollina
|[[User:rdoeksen|Ray Doeksen]]
|-
|Scott Anamizu
|[[User:rdoeksen|Ray Doeksen]]
|-
|[[user:kuroishi|Doorman Dave]]
|Elizabeth Koprucki
|-
|Simon Pyle
|[[User:rdoeksen|Ray Doeksen]]
|-
|Brad Jiminez
|[[User:rdoeksen|Ray Doeksen]]
|-
|Nate Scheidler
|[[User:rdoeksen|Ray Doeksen]]
|-
|Alan Insley
|[[User:rdoeksen|Ray Doeksen]]
|-
|Wessing
|[[User:rdoeksen|Ray Doeksen]]
|-
|[[User:w9lp|Casey Coley]]
|Andrew Camardella
|-
|Deanna Williams
|Brad Jimenez
|-
|Jim Hartmann
|Ray Doeksen --[[User:Rdoeksen|Rdoeksen]] ([[User talk:Rdoeksen|talk]]) 14:44, 20 September 2015 (CDT)
|-
|Hunter Koerner
|Ray Doeksen
|-
|Temnulen Erdenekhun
|Ray Doeksen
|-
|Greg Teiber
|Ray Doeksen
|-
|Bob Williams
|Ray Doeksen
|-
|Elizabeth Arundel
|Brad Jimenez
|-
|Alex Al-Hamdan
|Brad Jimenez
|-
|Nem Simeunovic
|Brad Jimenez
|-
|Dafe Hughes
|Brad Jimenez
|-
|Gary Silver
|Brad Jimenez
|-
|Daniel Maziarz
|Brad Jimenez
|-
|Greg Kudlacz
|Brad Jimenez
|-
|Adam Moffatt
|Brad Jimenez
|-
|Kevin Schwartzenberg
|Andrew Camardella
|-
|Michael Slingerland
|Andrew Camardella
|-
|Andrew Dalesandro
|Andrew Camardella
|-
|Erik Funkhouser
|Brad Jimenez
|-
|Elizabeth Carter
|Brad Jimenez
|-
|Idris Raja
|Brad Jimenez
|-
|Shelly Loke-Gayares
|Brad Jimenez
|-
|Craig Koszewski
|Brad Jimenez
|-
|Brandon Love
|Brad Jimenez
|-
|Todd Allen
|Andrew Camardella
[[Category:Fabrication]]
[[Category:CNC]]
|-
|Parker Rueve
|Brad Jimenez
|-
|Mike Czubak
|Brad Jimenez
|-
|Paula Brinkman Lowe
|Brad Jimenez
|-
|Xander Czubak
|Brad Jimenez
|-
|Angus Brinkman Lowe
|Brad Jimenez
|-
|Chris Smith
|Brad Jimenez
|-
|James Villalpando
|Brad Jimenez
|-
|Zachariah Reed
|Brad Jimenez
|-
|Calvin Moravec
|Brad Jimenez
|-
|Joshua Havenga
|Brad Jimenez
|-
|Sky Nova
|Andrew Camardella
|-
|Brian Carstensen
|Andrew Camardella
|-
|Aaron Carlock
|Andrew Camardella
|-
|Rob Dumas
|Andrew Camardella
|-
|Mike Kirda
|Sky Nova
|-
|Ashley Borg
|Sky Nova
|-
|Ed Breuer
|Sky Nova
|-
|Mark Haughey
|Sky Nova
|-
|[[User:stepcut|Jeremy Shaw]]
|Sky Nova
|-
|Paul McClay
|Sky Nova
|-
|Sam Chen
|Sky Nova
|-
|James Jacobs
|Sky Nova
|-
|Martina Josimovska
|Sky Nova
|-
|Brian Adamson
|Sky Nova
|-
|Ian Stubbs
|Sky Nova
|-
|Grant Wagner
|Ashish Jasani
|-
|Sam Dreyer
|Sky Nova
|-
|Anastasiia Holubova
|Sky Nova
|-
|Timothy A Rogers
|Sky Nova
|-
|Travis Bee
|Sky Nova
|-
|Zack Sasnow
|Sky Nova
|-
|[[user:wittnl|Nathan Witt]]
|Sky Nova
|-
|Marsalis Smith
|Sky Nova
|-
|Daniel Martinez Olivas
|Sky Nova
|-
|Chris Versteeg
|Sky Nova
|-
|[[User:lorxus|Paul Rapoport]]
| Sky Nova
|-
|Matt Maggio
|Andrew Carmardella
|-
|Nick Prorok
|Andrew Sowa
|6/09/18
|-
|}

LulzBot 3D Printer

2018-10-17T23:35:49Z

Daddybird: Created page with "=== Troubleshooting === Refer to our 3D Print Troubleshooting page."

=== Troubleshooting ===
Refer to our [[3D Print Troubleshooting]] page.

Prusa i3 MK2S .203 3D Printer

2018-10-17T23:34:41Z

Daddybird:

{{Template:EquipmentPage
|owner = PS:One
|hostarea = CNC
|certification = yes
|hackable = no
|model = Prusa i3 MK2S
|serial = SERIAL NUMBER
|arrived = 12/2017
|where = CNC Area, downstairs
|doesitwork = no
|contact = CNC Area Host
|value = $500
|image =
}}

== Status ==
12/10/2017 - Still Need to Configure Octoprint. Can print via SD Card.

== Operation ==

=== [[Prusa i3 OctoPrint Server]] ===

The Prusa i3 now uses OctoPrint as its host device. You can now send jobs to the printer via any computer in the space, even your personal device.

The OctoPrint server for the Prusa i3 can be reached at http://10.100.1.203/

ONE OF THEM THAT IS. There are two Prusa i3, it isn't clear which one is which from anywhere except right up on them when you can read the equipment label.

* When connecting to the OctoPrint server, you may first need to select "Connect" under the left side Connection tab if the printer has been turned off.
** All settings to connect are retained and should not be modified.
* Once the printer is connected, you can begin warming it up with the Temperature tab.
** Enter a temperature in Celsius and click "Set"
* You can control the printer's movements and extrusion using the "Control" tab.

* To get started printing, upload an STL using the left side "Files" tab.
* Find the STL you uploaded and click the "Slice" button, it looks like a magic wand.
* From here, you can select what slicer engine you'd like to use and what settings you'd like to print with.
** Cura is the default slicing engine.
** Select one of the preset slicing profiles, and then manually set your preferred temperatures and speeds using the Basic and Advanced tabs.
* Now locate the newly generated GCO file (G-Code) in the left side Files tab. You can now click "Load and Print" to print your object.
* It is preferred if you delete your files from the OctoPrint server when you are done. You can download your GCO file for future printing if you would like to retain the specific sliced project.

This is only a high level overview of how to use OctoPrint. If you are already authorized but have not used OctoPrint, feel free to attend future authorization sessions. OctoPrint will accept g-code from the most popular slicers such as Cura, Slic3r, Repetier-Host, and Simplify3D.

=== Troubleshooting ===
Refer to our [[3D Print Troubleshooting]] page.

Prusa i3 MK2S .202

2018-10-17T23:34:12Z

Daddybird: /* Operation */

{{Template:EquipmentPage
|owner = PS:One
|hostarea = CNC
|certification = yes
|hackable = no
|model = Prusa i3 MK2S
|serial = SERIAL NUMBER
|arrived = 12/2017
|where = CNC Area, downstairs
|doesitwork = yes
|contact = CNC Area Host
|value = $600
|image =
}}

== Description ==
A very nice for 2018 filament-based (FDM) 3D printer. Uses 1.75 mm filament. See https://shop.prusa3d.com/en/3d-printers/59-original-prusa-i3-mk2-kit.html for details. Capable of printing many different kinds of filament. Ships with 0.4 mm nozzles.

== Status ==

2/23/2018 - There are two of these mostly identical printers: one is connected to Octoprint, and has a broken SD card reader, but that Octoprint server is somewhat dorked up and would not slice for me, while the other Prusa i3 Mk2S is NOT connected to Octoprint, but has a working SD card reader. You can print, one or the other of them is working well enough that I'd say "it" is "working."

12/10/2017 - Still needs to be calibrated. Still Need to Configure Octoprint. Can print via SD Card.

== Operation ==

=== [[Prusa i3 OctoPrint Server]] ===

The Prusa i3 now uses OctoPrint as its host device. You can now send jobs to the printer via any computer in the space, even your personal device.

The OctoPrint server for the Prusa i3 can be reached at http://10.100.1.202/

ONE OF THEM THAT IS.

* When connecting to the OctoPrint server, you may first need to select "Connect" under the left side Connection tab if the printer has been turned off.
** All settings to connect are retained and should not be modified.
* Once the printer is connected, you can begin warming it up with the Temperature tab.
** Enter a temperature in Celsius and click "Set"
* You can control the printer's movements and extrusion using the "Control" tab.

* To get started printing, upload an STL using the left side "Files" tab.
* Find the STL you uploaded and click the "Slice" button, it looks like a magic wand.
* From here, you can select what slicer engine you'd like to use and what settings you'd like to print with.
** Cura is the default slicing engine.
** Select one of the preset slicing profiles, and then manually set your preferred temperatures and speeds using the Basic and Advanced tabs.
* Now locate the newly generated GCO file (G-Code) in the left side Files tab. You can now click "Load and Print" to print your object.
* It is preferred if you delete your files from the OctoPrint server when you are done. You can download your GCO file for future printing if you would like to retain the specific sliced project.

This is only a high level overview of how to use OctoPrint. If you are already authorized but have not used OctoPrint, feel free to attend future authorization sessions. OctoPrint will accept g-code from the most popular slicers such as Cura, Slic3r, Repetier-Host, and Simplify3D.

=== Troubleshooting ===
Refer to our [[3D Print Troubleshooting]] page.

3D Print Troubleshooting

2018-10-17T23:31:40Z

Daddybird:

[https://www.simplify3d.com/support/print-quality-troubleshooting/#gaps-between-infill-and-outline Common problems with identifying images.]

=== Moisture in Filament ===
Our filament mostly isn't stored in an airtight container. This means that the filament will absorb water over time. Hydrolysis is when a water molecule breaks a plastic polymer chain. The water can also vaporize and create air bubbles and voids. This affects print quality in every aspect:
# Loss of strength
# Poor finish
# Poor adhesion between layers
# Poor adhesion to the bed.
# Failed prints.

=== PLA ===

=== ABS ===
ABS has warping issues and needs to retain heat.

3D Print Troubleshooting

2018-10-17T15:47:37Z

Daddybird: Created page with "Placeholder, will flesh out later. === Moisture in Filament === === PLA === === ABS === ABS has warping issues and needs to retain heat."

Placeholder, will flesh out later.

=== Moisture in Filament ===

=== PLA ===

=== ABS ===
ABS has warping issues and needs to retain heat.

IT Infrastructure

2018-07-12T02:15:32Z

Daddybird: /* About */

== About ==

This page is intended to be a one stop shop for all IT systems in the space.

For questions, please pop on by the Slack #systemsgroup. For urgent inquiries, you may contact the CTO at cto [at] pumpingstationone.org.

[https://wiki.pumpingstationone.org/Software_Licenses Software Licenses are covered here.]

== IT systems ==

=== Internet ===

Our internet provider is Comcast. We currently have a 150Mbps/75Mbps package with an LTE failover link, 5 static IPs, and 1 line of voice service.

Our static IP block is -

* 96.90.87.40/
** 96.90.87.41 (Primary space IP)
** 96.90.87.42 (Unallocated)
** 96.90.87.43 (Unallocated)
** 96.90.87.44 (Unallocated)
** 96.90.87.45 (Unallocated)
* Gateway: 96.90.87.46

=== Internal Static IPs ===

* [[10.10.x.x]]
** VM Servers
*** 10.10.0.30 | [[DC1 VM (pumpingstationone.org Active Directory)]]
*** 10.10.0.36 | [[vCenter VM]]
*** 10.10.0.40 | [[Fileserver VM]]
*** 10.10.0.60 | [[selfservice VM]]
* [[10.100.x.x]]
** Networking Equipment
*** 10.100.0.1 | [[UniFi_Security_Gateway_Pro|Unifi Security Gateway 4P (USG)]]
*** 10.100.0.2 | [[UniFi_48_Port_Switch|Unifi 48 port Switch (48port)]]
*** 10.100.0.3 | [[UniFi_24_Port_Switch|Unifi 24 port Switch (24port)]]
*** 10.100.0.4 | [[UniFi_8_Port_POE_Switch|Unifi 8 port PoE Switch (8portPOE)]]
*** 10.100.0.9 | [[UniFi_Controller|Unifi Controller (UBNT)]]
*** 10.100.0.20 | [[General_Area_UniFi_AP|Unifi AP-AC-Pro (General Area AP)]]
*** 10.100.0.21 | [[CNC_UniFi_AP|Unifi AP-AC-Pro (CNC AP)]]
*** 10.100.0.22 | [[Upstairs_UniFi_AP|Unifi AP-AC-Pro (Upstairs AP)]]
*** 10.100.0.23 | [[Woodshop_UniFi_AP|Unifi AP-AC-Pro (Woodshop AP)]]
** VM Servers
*** 10.100.0.115 | [[Systems#Mailman|Mail VM]]
*** 10.100.0.119 | [[Systems#Request_Tracker|RT VM (Request Tracker)]]
*** 10.100.0.121 | [[The_Wiki|Wiki VM (MediaWiki)]]
*** 10.100.0.123 | [[Member_Management_System|ps1auth VM (Member Database)]]
*** 10.100.0.132 | [[Samba DC (ad.pumpingstationone.org Active Directory)]]
** Physical Servers
*** 10.100.1.14 | [[R720xd ESXi Host (hv1.pumpingstationone.org)]]

=== Infrastructure As Code ===
VSphere and VM/Server Configurations.

[https://github.com/pumpingstationone/infrastructure/ TerraForm/Ansible Scripts and Docs]

=== Active PS1 Domains/Sub ===

* *.pumpingstationone.org
** wwww.pumpingstationone.org (Main)
** wiki.pumpingstationone.org (Wiki)
** members.pumpingstationone.org
** selfservice.pumpingstationone.org
** discourse.pumpingstationone.org (discussion Board)
** rt.pumpingstationone.org (Help Desk)
** canvas.pumpingstationone.org (Training)
** space.pumpingstationone.org

[[File:PS1_DNS.png]]

=== Network Equipment ===

[[Ubiquiti Systems]]

=== Physical Servers ===

Dell PowerEdge 1950 (Count 2)

=== VM Environment ===

[[File:PS1_VM_Env.png]]

=== Cloud Environment ===

[[File:PS1_Cloud_Env.png]]

=== Network Layout ===

[[File:PS1_Net.png]]

Software Licenses

2018-07-12T02:13:55Z

Daddybird: Created page with "=== Adobe Creative Cloud === We have 2 licenses for Creative Cloud, but they seem to be used by 4 computers. They are regular licenses, not educational?"

=== Adobe Creative Cloud ===
We have 2 licenses for Creative Cloud, but they seem to be used by 4 computers. They are regular licenses, not educational?

BOSS Maintenance

2018-06-20T04:48:30Z

Daddybird: /* Cleaning Lens */

== Alignment ==
[https://www.youtube.com/watch?v=wY5D27TQwZI Aligning the laser lens]

== Cleaning Lens ==
You can only mess this up in three ways:
# Scratching the lens
# Leaving a fingerprint on the lens surface (hold by the edge).
# Not screwing things back in properly.

Avoid those three things and you're good, I promise. It's not hard, a 9 year old could do this.

To clean the lens:
# Unscrew the laser head/nozzle. It's pretty easy to figure out.
# The lens is held in place by an internal threaded "tube" (insert better word here) that can be removed by unscrewing with a key. It's almost like a standard slotted screw head, except hollow in the middle. The key is the exact width of the hole so it'll touch the sides of the slotted, threaded tube. (This sounds incomprehensible, but if you just look inside it's obvious how it works).
# Unscrew the lens onto a lint free cloth (microfiber towels).
# There's a silicone gasket too, don't lose that.
# Clean the lens with acetone.
# Put back in, curved side up. I forget which side the gasket goes on. Maybe there's two gaskets?
# Screw the threaded slotted tube back in.
# Screw back in the laser nozzle.

BOSS Maintenance

2018-06-20T04:43:26Z

Daddybird:

== Alignment ==
[https://www.youtube.com/watch?v=wY5D27TQwZI Aligning the laser lens]

== Cleaning Lens ==
# Unscrew the laser head/nozzle. It's pretty easy to figure out.
# The lens is held in place by an internal threaded "tube" (insert better word here) that can be removed by unscrewing with a key. It's almost like a standard slotted screw head, except hollow in the middle. The key is the exact width of the hole so it'll touch the sides of the slotted, threaded tube. (This sounds incomprehensible, but if you just look inside it's obvious how it works).
# Unscrew the lens onto a lint free cloth (microfiber towels).
# There's a silicone gasket too, don't lose that.
# Clean the lens with acetone.
# Put back in, curved side up. I forget which side the gasket goes on. Maybe there's two gaskets?
# Screw the threaded slotted tube back in.
# Screw back in the laser nozzle.

BOSS Maintenance

2018-06-20T04:35:11Z

Daddybird: Created page with " [https://www.youtube.com/watch?v=wY5D27TQwZI Aligning the laser lens]"

[https://www.youtube.com/watch?v=wY5D27TQwZI Aligning the laser lens]

BOSS LS-3655 150w Laser Engraver

2018-06-20T04:33:33Z

Daddybird: /* Procedures */

{{ Template:EquipmentPage
| owner=PS:One
| model=BOSS LS-3655 150w
| serial=SERIAL NUMBER
| arrived= January 2017
| doesitwork=yes
| contact=[[CNC|CNC Area Host]]
| where=CNC Shop
| certification=yes
| hackable=no
| value=$17,000
| image = BossLaser2.jpg
| hostarea = CNC
}}

== About ==

The BOSS LS-3655 is an industrial CO2 laser engraver with a 36" x 55" bed, supporting over-sized material pass-thru on four sides and up to 7 inches of table depth. Originally shipped with 100W tube, but that has been replaced with 150W tube in May, 2017.

== Status ==

* (2018/02/26) Working. Z-Axis motor having some issues? 2-25-2018
* (2017/05/20) 150W Tube & Power Supply installed. Alignment & focusing pending.
* (2017/06/12) The laser has been aligned and focused. 2" Laser lens focal depth set to 5.1mm.

== Usage Policy ==

The laser cutter is easily one of the most used machines at PS1. Due to this demand we request the cooperation of all members to share the laser cutter and associated computer. First and foremost, the practice "being excellent" should be observed at all times; respect yourself, other members, and the equipment. This is a usage policy so that everyone can use the laser:

* Any user not actively test cutting or cutting will cede the computer and laser to the next person waiting in line, as soon as that waiting user notifies the current computer user. If you are still designing your file, please do so on another computer. Artastic (another PC upstairs) in the Crafts Area also has a copy of Adobe Illustrator.
* If someone is waiting in line to use the laser, no active test cut or cut series shall be longer than 1 hour. No jobs will be allowed to start that overrun the 1 hour time limit when a new user is waiting.
* In the case that your last cut is longer than the 1 hour time limit, and a waiting user presents themselves after the cut has started, the cut job shall be allowed to finish and the waiting user will be allowed to set up their file in their own user account, during the cutting period.
* Continuous cutting shall not exceed 3 consecutive hours without a half hour break for the laser to cool. If a new user arrives before or during the cooling period the current user shall cede the laser to the next user, and the next user will wait for the cooling period to finish and the cooling period shall not count towards the 1 hours limit should another user present themselves.
* Waiting users shall notify the current user verbally that they are waiting and where they will be waiting until it is their turn. If multiple users are waiting, the next waiting user must start their test cutting or cut job within 10 minutes of being notified of a laser opening. The current user will keep a record of who is waiting, where they will be, and notify subsequent users of the status of the queue. The current user will find the next waiting user and verbally inform them that the laser is available.

== Authorizations ==

How to get authorized: contact the CNC Area Host or one of the Volunteer Authorizers. There's a sign posted in the CNC area that has names of people that are laser authorizers.

Since demand fluctuates, and there are a random group of new and old members that want to be authorized at any one time, it makes sense to find the others and figure out your group schedule/plan. There generally is NOT going to be a calendar-based or widely publicized meetup event; you will have to conctact and make arrangements with actual people, at least until the Canvas Learning Management System is implemented more fully. http://canvas.pumpingstationone.org

=== Preparing yourself to become authorized ===

You need a few things to optimize and expedite your experience:

* 1. Know what you're doing as best as you can - come pre-trained on your own time to make the authorization go smoother and faster.
* 2. Have a PS1 username set up before starting the authorization http://members.pumpingstationone.org
* 3. Have some familiarity with the kinds of files you would bring to the Boss to cut.

To that end; you could download and become familiar a bit with RDWorks, the software you will use to drive the Boss. Links are on this page.
You can read a bit of the manual, which is also linked on this page, or watch some YouTube videos.

To set up a PS1 username (this is NOT the email address you use, it's a different thing, it's entirely special to PS1) go to http://members.pumpingstationone.org, and click "Activate" ... if you don't already have a PS1 username.

You will want to bring files in from Adobe Illustrator in Illustrator format, with lines set to have SOME sort of stroke, I'd recommend 1 point stroke, and some simple color applied to the stroke for each "layer" you want to have in RDWorks. You will want to have one color/layer assigned for each type or strength of cut/engrave you'll be doing in that job. For instance, you might want a deep engraving, a shallow engraving, a cut that goes all the way through the material and maybe a cut that just barely touches the top surface (called a 'kiss cut) and that would mean you would need four distinct colors of stroke used in your file. You should investigate the usefullness of SVG, DXF and DWG files as well, but Illustrator files will give you the best first experiences.

Authorizations will be limited to small groups, e.g. 4 or less, due to nature of the equipment.

==Power-On & Safety Check==
# Check Wiki for status updates
# Check if material is safe to cut: refer to the wiki for a list of safe and unsafe materials for cutting
# Check Fire Extinguisher: Make sure it is close by and charged
# Release Emergency Stop: Rotate red button until it releases
# Turn Power Key: Display will load up
# Turn on Air Assist & Chiller: Flip the switch and ensure exhaust & chiller are on and functioning. Double check chiller temp with laser temp.
* RD Works
# Load Program & Check USB Connection Status
# Importing Files: Importing AI, DXF, SVG, & images
# Introducing User Interface: quick review of UI including Drawing, Grouping, Preview, Work Tab, Layers, Laser Work, & Head Position
# Detailed Overview of Work Tab: major cutting settings & parameters reside here
# Starting a Job
# Saving a File
* Boss Laser Operation
# LED Keypad Overview
# Adjusting the Z-Height: raise and lower bed
# Autofocus: Setting focal height for material
# Setting Origin
# Jogging the Laser Head in XY
# Adjusting High Pressure Air Regulator: Changing the compressed air flow
# Loading a File via USB Port
# Load & Unload honeycomb
# Cleaning Up & Clearing Catch Tray
* Individual Walkthrough: each member is required to perform the following:
# Start-Up the machine
# Turn on exhaust, air-assist, & chiller
# Place Material, autofocus, set origin
# Load RDworks, create 3 layers (Cut, Scan, Dot) & run laser job
# Shutdown machine & clear catch tray

== Settings ==
[https://wiki.pumpingstationone.org/Boss_Laser_Settings Laser Settings Page]

* Honeycomb vs. Aluminum Lamella : The honeycomb is used for engraving and pieces that benefit from precise leveling. Use the aluminum lamella (slats under honeycomb) for cutting through to reduce flashback and improve airflow (warning small pieces will fall through).

* 4" Lens Focus Depth 38.5mm (this is a just an approximate, FD calibration must be performed each time the lens is changed)
* 2" Lens Focus Depth 5.3mm (this is a just an approximate, FD calibration must be performed each time the lens is changed)

== Procedures ==
[https://wiki.pumpingstationone.org/BOSS_Usage Boss Usage]

[https://wiki.pumpingstationone.org/BOSS_Maintenance Boss Maintenance]

=== Powering On Machine ===
* Check Fire Extinguisher
* Release Emergency Stop button
* Turn power key
* Turn on air assist & water chiller Switch & ensure both are functioning

=== Powering Off Machine ===
* Turn key to off position, leave key in the lock
* Push emergency stop button in
* Turn the chiller, blower and air assist off using the main switch (switch with identifying lasercut plate)
* Reset the area by cleaning up any stray cut materials. Clean and straighten the area around the laser.

== Material Safety & Information ==
WARNING: Because many plastics are dangerous to cut, it is important to know what kind you are planning to use. If you are unsure of your materials composition, don’t cut it with the laser. You can request a SDS from your material supplier for specific information on the plastic you have or are considering using.

=== NEVER CUT THESE MATERIALS ===
** Any material containing chlorine:
***PVC (Poly Vinyl Chloride)
***Vinyl
***Pleather
***Artificial leather
**Plastics:
*** Polycarbonate/Lexan – [Thick ( >1mm )]
*** ABS
*** HDPE/milk bottle plastic
** Foams:
*** PolyStyrene Foam
*** PolyPropylene Foam
** Other:
*** Epoxy
*** Fiberglass
*** Coated Carbon Fiber
***Any foodstuff ( such as meat, seaweed 'nori' sheets, bread, tortillas... )

=== Safe Materials for Cutting ===
** Plastics:
*** ABS (acrylonitrile butadiene styrene)
*** Acrylic (also known as Plexiglas, Lucite, PMMA)
*** Delrin (POM, acetal)
*** Kapton tape (Polyimide)
*** Mylar (polyester)
*** Nylon – melts badly
*** PETG (polyethylene terephthalate glycol)
*** Styrene
*** Two-tone acrylic – top color different than core material, usually for custom instrumentation panels, signs, and plaques.
** Foam:
*** Depron foam – often used for RC planes.
*** EPM
*** Gator foam – foam core gets burned and eaten away compared to the top and bottom hard shell.
** Other:
*** Cloths (leather, suede, felt, hemp, cotton)
*** Papers
*** Rubbers (only if they do not contain chlorine Teflon (PTFE, Polytetrafluoroethylene)
*** Woods (MDF, balsa, birch, poplar, red oak, cherry, holly, etc.)

==== Aligning Materials ====

** The table is not aligned with the laser's X-Y axis
** To align your material use the laser pointer by holding one axis constant while moving along the other axis to align corners of your material

== Laser Materials and the Woodshop Table-Saw Saw-stop ==

*Conductive materials such as aluminum and other metals, carbon fiber materials, mirrored acrylic, carbon-filled materials, etc. will typically cause the brake to activate.
*Carbon from lasered wood or lasered plywood is also conductive and will trigger the saw stop. do not use the table saw to cut your material. Once you have lasered a piece of wood,
**The band saw can be used instead for both mirrored acrylic and lasered wood. Use safety goggles when using the bandsaw in general, but especially when using it to cut acrylic. (NOTE: authorization is required for the table saw and the bandsaw, so attending a woodshop authorization might be a good idea).

== Resources ==

The proprietary LaserWORKS software can be downloaded from BOSS here - https://www.bosslaser.com/laser-software/ However, the current version (8.01.28) of the laser software seems to require admin rights every time it's used. So instead you may want to download the [https://appdb.winehq.org/objectManager.php?sClass=version&iId=35522 8.01.18 version of the software] until this is fixed.

Manuals for the BOSS laser and the LaserWORKS software are located here - https://www.bosslaser.com/download-manuals-guides/

[https://www.bosslaser.com/laser-test-files BOSS test files are available here]

[https://www.bosslaser.com/laser-settings Some laser settings from Boss]

[https://www.facebook.com/groups/900528680076062/ Excellent Facebook Group for RDWorks Tips and help]

[https://rdworkslab.com/index.php Forum for RDworks user group]

If the language for RDWorks (the Boss control software) is showing garbage, [https://www.youtube.com/watch?v=gwhQ2xzV1xo&feature=youtu.be follow this video].

== Youtube Channels ==
Following are a couple good YouTube Channels with lots of information on the software and machine
* [https://wiki.pumpingstationone.org/index.php?title=Special:UserLogin&returnto=BOSS+LS-3655+150w+Laser+Engraver SarbarMultimedia]
* [https://www.youtube.com/channel/UCOuDR90TZ24qEFFIbVmDAMw Thunder Laser]

== Cleaning & Maintenance ==

* When changing the lens, make sure the convex/domed side of the lens is facing upwards (towards the ceiling)
* Focus Lens should be cleaned once a week with Acetone or Denatured Alcohol

== List of Currently Certified Users ==

{| class="wikitable" border="1"
! Qualified Member
! Trained By
! Date
|-
|Andrew Camardella
|Danger Committee
|
|-
|Matt Keith
|Danger Committee
|
|-
|Skylar Nova
|Danger Committee
|
|-
|Jason Araujo
|Danger Committee
|
|-
|Ray Doeksen
|Danger Committee
|
|-
|Matt Meshulam
|Danger Committee
|
|-
|Ashish Jasani
|Danger Committee
|
|-
|Joe Juhnke
|Ashish Jasani
|
|-
|Casey Olson
|Ray Doeksen
|
|-
|Andrew Vaughan
|Burton Kent
|
|-
|[[User:mct|McTavish McArdle]]
|Burton Kent
|
|-
|Erik Wessing
|Ray Doeksen
|
|-
|Theo T
|Ray Doeksen
|
|-
|Molly Adamski
|Joe Juhnke
|
|-
|[[User:deadwisdom|Brantley Harris]]
|Ray Doeksen
|
|-
|Amir Badri
|Sky Nova
|
|-
|Aaron Carlock
|Jeff Z
|
|-
|Gabe Tavas
|Joe Juhnke
|
|-
|Sam Dreyer
|Jeff Z
|
|-
|Stephanie Pelzer
|Jeff Z
|
|-
|Nick Prorok
|Jeff Z
|3/02/2018
|-
|Alisha Ciardi
|Burton Kent
|03/2018
|-}
|-
|Bao Nguyen
|Zander Bueno
|05/04/2018
|-

[[Category:Laser Cutter]]
[[Category:Fabrication]]
[[Category:Certification Clarification Needed]]

Universal Maintenance

2018-06-19T21:47:05Z

Daddybird: Created page with " ===What are typical preventive maintenance (PM) events?=== Each laser system consists of components that will wear naturally during normal operation. Inspection and the ev..."

===What are typical preventive maintenance (PM) events?===

Each laser system consists of components that will wear naturally during normal operation. Inspection and the eventual replacement of these components is important to preserve the high quality of laser material processing one comes to expect from a ULS laser system. Typical preventative maintenance includes replacing the timing belts, bearings, idler and drive gear for the X-axis motion system approximately once every 1 to 2 years. Every 2 to 3 years the belts, bearings, idlers and drive gears should be replaced on the Y-axis motion system. While this is a general guide to preventative maintenance, there are many factors that can increase or decrease the time between preventative maintenance events such as: quality of exhaust system, material processed, duration of operation and routine maintenance (cleaning) performed.

Page 103 of the Universal Manual suggests the following:

'''Every 8 hours of engraving'''

* Clean X-Axis and Y-Axis bearings
* Clean X-Axis and Y-Axis and bearing tracks
* Clean X-Axis belt
* Check beam window, #2 mirror, #3 mirror and focus lens for debris. Clean ONLY if dirty.

'''Every month'''

* Clean cooling fan filters
* Clean Z-Axis lead screws with white lithium grease
* Check for X-Axis and Y-Axis belt wear. Replace as necessary.
* Check and/or clean X-Axis and Y-Axis drive gears
* Check for X-Axis and Y-Axis bearing wear.

'''Every 6 months'''

* Clean exhaust plenum

That's a pretty comprehensive cleaning regimen that we could probably adapt
to our own needs. The Boss manual lists something similar on Page 45.

I'm not sure it's feasible to suggest a DAILY clean of the belts, bearings,
and optics, but if five or so folks who use it regularly were trained in
how to do it, that would probably make two to three times a week realistic.
We'd have to avoid diffusion of responsibility by creating a checklist/log
of some sort so we could all be aware of when it's due for a clean or when
you could get away with a quick cut. I would be more than happy to lend my
dope office manager skillz to piloting such a program.

Universal PLS6.150D 150W Laser Engraver

2018-06-19T21:44:26Z

Daddybird: /* Procedures */

{{ Template:EquipmentPage
| owner=PS:One
| model=PLS6.150D
| serial=SERIAL NUMBER
| arrived= August 2017
| doesitwork=yes
| contact=[[CNC|CNC Area Host]]
| where=CNC Shop
| certification=yes
| hackable=no
| value=$17,000
| image = tbd
| hostarea = CNC
}}

== About ==

The Universal Laser Systems PLS6.150D is a free-standing platform with a materials processing envelope of 32" x 18" x 9" or 5,184 in³ (813 x 457 x 229 mm or 84,950 cm³) that supports dual lasers. As a dual laser platform, the PLS6.150 can support up to two 10.6µ CO2 lasers with a power range of 10 watts to 150 watts. Additionally, it can support a single 9.3µ CO2 of 30, 50 or 75 watts. (if a 9.3u CO2 laser is installed, only one 10.6 CO2 of up to 75 watts may be installed at the same time.)

Ours has two 75w lasers totalling 150w of power.

The unit was donated from SAIC.

== Status ==

* (2017/05/20) Wiki page created
* (August 2017) Laser donated from SAIC - thank you, Anna Yu!
* (12/2/2017) Hooked up to Epilog air and exhaust connection. The air assist works but does leak using the quick connect fitting, the other fitting requires a 1/2" (I think) screw fitting which will create a better seal. The x-axis is off by ~3/8" , y is off too but didn't measure.
Current status: connected to exhaust and compressed air using the ones designed for the Epilog while the Epilog is out of service. Figuring out authorizations. If you want to be part of that, get in touch with CNC Area Host or folks on the Danger Committee.

== Authorizations ==
Authorization for the laser is not viral, meaning you must seek out a Volunteer Authorizer. Please post on the Google Group email list or contact cnc-auths@pumpingstationone.org; look for a recent thread about laser authorizations and post there.

Danger Committee folks from the other laser systems should consider themselves on the Danger Committee for this bad boy, too. Let's get this thing in regular rotation, stat!

== References and Manuals ==
* [[Media:Universal PLS6.150D quick start guide.pdf|Preflight checklist]]
* [[Media:Illustrator and Photoshop Setup and Basic Operation.pdf|Illustrator and Photoshop basic setup and operation]]
* [[Media:Universal PLS6.150D user guide.pdf|Universal Laser PLS6.150D User Manual]]
* [https://docs.google.com/spreadsheets/d/11G3HMFiu8aKGAu2Eg_p9LCSjKiajoUDsriVcqi_09hU/pub?output=html#| Materials Settings Reference]

== Procedures ==

=== Maintenance ===
[https://wiki.pumpingstationone.org/Universal_Maintenance Universal Maintenance]

=== Setting Up Your Computer===
* [https://drive.google.com/a/pumpingstationone.org/file/d/1GjEZzCSGFAl5Zumf7hG24kqdu1ZAlszw/view?usp=sharing Download the Adobe Illustrator CC Template to your profile]
TIPS:
* To make your life easier, get used to setting your vector cuts red and raster black.
* White is one of the colors in the template, but acts as a mask unless you tell it otherwise.
* Click "Apply" every time you do anything in the print settings, or it won't save.

=== Air assist===
* Turn on the air assist by flipping the switch dangling from the board behind the laser.
* Air assist is used for vector cutting to have nice traces and avoid your material to burn. However some people like to have it disabled for raster jobs.
* Turn air assist off when you've finished and you don't need it while doing your settings.

=== Water Trap ===
* Check the WATER TRAP adjacent to the regulator for accumulated water from time to time. Place a container (and maybe some paper towels) under the regulator and vent accumulated water from the bottom using the small petcock. If too much water accumulates in the regulator, it may flow through the air hose and into the machine, spraying onto the bed/material.

=== Powering On Machine ===
* Turn on the Power Switch and let the machine complete the entire boot up cycle, approximately 1-2 minutes.

=== Powering Off Machine ===
* Allow the Exhaust & Air Assist to run for approximately 10-15 after completing a job. (DO NOT CYCLE THE EXHAUST SYSTEM RAPIDLY).
* Turn off the Exhaust & Air Assist FIRST
* Power down the machine
* Clean up you materials, throw away scrap, make sure the focusing tool is replaced

== Laser Materials ==

https://wiki.pumpingstationone.org/Laser_Materials

== Banned Materials ==

{| class="wikitable"
|-
! MATERIAL
! BANNED REASON
|-
| PETG, PET
| Along with other emissions, is known to emit Benzene which is known to cause cancer.
|-
| Polystyrene
| Known to emit styrene fumes.
|-
| ABS
| Emits cyanide gas and tends to melt.
|-
| PVC
| Emits chlorine gas during a cut.
|-
| Bending Plywood
| Bends into the path of the laser carriage during operation.
|-
| Tropical Hardwoods
| A lot of tropical hardwoods have toxins in the wood.
|-
| Corian
| Creates a fine grit inside the laser bed and will grind down equipment.
|-
| Casting Wax
| Melts a lot.
|-
| Nylon
| Emits toxic fumes.
|-
| Vinyl
| Emits chlorine gas during a cut
|-
| Delrin
| Along with other emissions, is known to emit Benzene which is known to cause cancer.
|-
| Foamcore
| Foamcore is an expanded polystyrene and is known to emit styrene fumes when cut.
|}

== List of Currently Authorized Users ==

{| class="wikitable" border="1"
! Qualified Member
! Trained By
! Date
|-
|Ashish Jasani
|Ashish Jasani
|
|-
|Theo T
|Ashish Jasani
|
|-
|Revant Ohri
|Ashish Jasani
|12/19/2017
|-
|Sam Dreyer
|Ashish Jasani
|1/12/2018
|-
|[[User:frenchy|Jeremie Davis]]
|Joseph Juhnke
|1/27/2018
|-
|[[User:shoelessone|Kevin Mitchell]]
|Joseph Juhnke
|1/27/2018
|-
|[[User:mcclearin|Deanna Williams]]
|Joseph Juhnke
|1/27/2018
|-
|[[User:rex|Aaron Carlock]]
|Joe Mertz
|2/28/2018
|-
|Nick Prorok
|Joe Mertz
|2/28/2018
|-
|[[user:mct|McTavish Mcardle]]
|Joe Mertz
|2018-05-09
|-
|[[user:Lorxus|Paul Rapoport]]
|Joe Mertz
|2018-05-09
|-
|[[user:Brendanf|Brendan Fortune]]
|[[user:mcclearin|Deanna Williams]]
| 12-May-2018
|}

[[Category:Laser Cutter]]
[[Category:Fabrication]]
[[Category:Certification Clarification Needed]]

BOSS LS-3655 150w Laser Engraver

2018-06-12T01:32:38Z

Daddybird: /* Procedures */

{{ Template:EquipmentPage
| owner=PS:One
| model=BOSS LS-3655 150w
| serial=SERIAL NUMBER
| arrived= January 2017
| doesitwork=yes
| contact=[[CNC|CNC Area Host]]
| where=CNC Shop
| certification=yes
| hackable=no
| value=$17,000
| image = BossLaser2.jpg
| hostarea = CNC
}}

== About ==

The BOSS LS-3655 is an industrial CO2 laser engraver with a 36" x 55" bed, supporting over-sized material pass-thru on four sides and up to 7 inches of table depth. Originally shipped with 100W tube, but that has been replaced with 150W tube in May, 2017.

== Status ==

* (2018/02/26) Working. Z-Axis motor having some issues? 2-25-2018
* (2017/05/20) 150W Tube & Power Supply installed. Alignment & focusing pending.
* (2017/06/12) The laser has been aligned and focused. 2" Laser lens focal depth set to 5.1mm.

== Usage Policy ==

The laser cutter is easily one of the most used machines at PS1. Due to this demand we request the cooperation of all members to share the laser cutter and associated computer. First and foremost, the practice "being excellent" should be observed at all times; respect yourself, other members, and the equipment. This is a usage policy so that everyone can use the laser:

* Any user not actively test cutting or cutting will cede the computer and laser to the next person waiting in line, as soon as that waiting user notifies the current computer user. If you are still designing your file, please do so on another computer. Artastic (another PC upstairs) in the Crafts Area also has a copy of Adobe Illustrator.
* If someone is waiting in line to use the laser, no active test cut or cut series shall be longer than 1 hour. No jobs will be allowed to start that overrun the 1 hour time limit when a new user is waiting.
* In the case that your last cut is longer than the 1 hour time limit, and a waiting user presents themselves after the cut has started, the cut job shall be allowed to finish and the waiting user will be allowed to set up their file in their own user account, during the cutting period.
* Continuous cutting shall not exceed 3 consecutive hours without a half hour break for the laser to cool. If a new user arrives before or during the cooling period the current user shall cede the laser to the next user, and the next user will wait for the cooling period to finish and the cooling period shall not count towards the 1 hours limit should another user present themselves.
* Waiting users shall notify the current user verbally that they are waiting and where they will be waiting until it is their turn. If multiple users are waiting, the next waiting user must start their test cutting or cut job within 10 minutes of being notified of a laser opening. The current user will keep a record of who is waiting, where they will be, and notify subsequent users of the status of the queue. The current user will find the next waiting user and verbally inform them that the laser is available.

== Authorizations ==

How to get authorized: contact the CNC Area Host or one of the Volunteer Authorizers. There's a sign posted in the CNC area that has names of people that are laser authorizers.

Since demand fluctuates, and there are a random group of new and old members that want to be authorized at any one time, it makes sense to find the others and figure out your group schedule/plan. There generally is NOT going to be a calendar-based or widely publicized meetup event; you will have to conctact and make arrangements with actual people, at least until the Canvas Learning Management System is implemented more fully. http://canvas.pumpingstationone.org

=== Preparing yourself to become authorized ===

You need a few things to optimize and expedite your experience:

* 1. Know what you're doing as best as you can - come pre-trained on your own time to make the authorization go smoother and faster.
* 2. Have a PS1 username set up before starting the authorization http://members.pumpingstationone.org
* 3. Have some familiarity with the kinds of files you would bring to the Boss to cut.

To that end; you could download and become familiar a bit with RDWorks, the software you will use to drive the Boss. Links are on this page.
You can read a bit of the manual, which is also linked on this page, or watch some YouTube videos.

To set up a PS1 username (this is NOT the email address you use, it's a different thing, it's entirely special to PS1) go to http://members.pumpingstationone.org, and click "Activate" ... if you don't already have a PS1 username.

You will want to bring files in from Adobe Illustrator in Illustrator format, with lines set to have SOME sort of stroke, I'd recommend 1 point stroke, and some simple color applied to the stroke for each "layer" you want to have in RDWorks. You will want to have one color/layer assigned for each type or strength of cut/engrave you'll be doing in that job. For instance, you might want a deep engraving, a shallow engraving, a cut that goes all the way through the material and maybe a cut that just barely touches the top surface (called a 'kiss cut) and that would mean you would need four distinct colors of stroke used in your file. You should investigate the usefullness of SVG, DXF and DWG files as well, but Illustrator files will give you the best first experiences.

Authorizations will be limited to small groups, e.g. 4 or less, due to nature of the equipment.

==Power-On & Safety Check==
# Check Wiki for status updates
# Check if material is safe to cut: refer to the wiki for a list of safe and unsafe materials for cutting
# Check Fire Extinguisher: Make sure it is close by and charged
# Release Emergency Stop: Rotate red button until it releases
# Turn Power Key: Display will load up
# Turn on Air Assist & Chiller: Flip the switch and ensure exhaust & chiller are on and functioning. Double check chiller temp with laser temp.
* RD Works
# Load Program & Check USB Connection Status
# Importing Files: Importing AI, DXF, SVG, & images
# Introducing User Interface: quick review of UI including Drawing, Grouping, Preview, Work Tab, Layers, Laser Work, & Head Position
# Detailed Overview of Work Tab: major cutting settings & parameters reside here
# Starting a Job
# Saving a File
* Boss Laser Operation
# LED Keypad Overview
# Adjusting the Z-Height: raise and lower bed
# Autofocus: Setting focal height for material
# Setting Origin
# Jogging the Laser Head in XY
# Adjusting High Pressure Air Regulator: Changing the compressed air flow
# Loading a File via USB Port
# Load & Unload honeycomb
# Cleaning Up & Clearing Catch Tray
* Individual Walkthrough: each member is required to perform the following:
# Start-Up the machine
# Turn on exhaust, air-assist, & chiller
# Place Material, autofocus, set origin
# Load RDworks, create 3 layers (Cut, Scan, Dot) & run laser job
# Shutdown machine & clear catch tray

== Settings ==
[https://wiki.pumpingstationone.org/Boss_Laser_Settings Laser Settings Page]

* Honeycomb vs. Aluminum Lamella : The honeycomb is used for engraving and pieces that benefit from precise leveling. Use the aluminum lamella (slats under honeycomb) for cutting through to reduce flashback and improve airflow (warning small pieces will fall through).

* 4" Lens Focus Depth 38.5mm (this is a just an approximate, FD calibration must be performed each time the lens is changed)
* 2" Lens Focus Depth 5.3mm (this is a just an approximate, FD calibration must be performed each time the lens is changed)

== Procedures ==
(https://wiki.pumpingstationone.org/BOSS_Usage Boss Usage)

=== Powering On Machine ===
* Check Fire Extinguisher
* Release Emergency Stop button
* Turn power key
* Turn on air assist & water chiller Switch & ensure both are functioning

=== Powering Off Machine ===
* Turn key to off position, leave key in the lock
* Push emergency stop button in
* Turn the chiller, blower and air assist off using the main switch (switch with identifying lasercut plate)
* Reset the area by cleaning up any stray cut materials. Clean and straighten the area around the laser.

== Material Safety & Information ==
WARNING: Because many plastics are dangerous to cut, it is important to know what kind you are planning to use. If you are unsure of your materials composition, don’t cut it with the laser. You can request a SDS from your material supplier for specific information on the plastic you have or are considering using.

=== NEVER CUT THESE MATERIALS ===
** Any material containing chlorine:
***PVC (Poly Vinyl Chloride)
***Vinyl
***Pleather
***Artificial leather
**Plastics:
*** Polycarbonate/Lexan – [Thick ( >1mm )]
*** ABS
*** HDPE/milk bottle plastic
** Foams:
*** PolyStyrene Foam
*** PolyPropylene Foam
** Other:
*** Epoxy
*** Fiberglass
*** Coated Carbon Fiber
***Any foodstuff ( such as meat, seaweed 'nori' sheets, bread, tortillas... )

=== Safe Materials for Cutting ===
** Plastics:
*** ABS (acrylonitrile butadiene styrene)
*** Acrylic (also known as Plexiglas, Lucite, PMMA)
*** Delrin (POM, acetal)
*** Kapton tape (Polyimide)
*** Mylar (polyester)
*** Nylon – melts badly
*** PETG (polyethylene terephthalate glycol)
*** Styrene
*** Two-tone acrylic – top color different than core material, usually for custom instrumentation panels, signs, and plaques.
** Foam:
*** Depron foam – often used for RC planes.
*** EPM
*** Gator foam – foam core gets burned and eaten away compared to the top and bottom hard shell.
** Other:
*** Cloths (leather, suede, felt, hemp, cotton)
*** Papers
*** Rubbers (only if they do not contain chlorine Teflon (PTFE, Polytetrafluoroethylene)
*** Woods (MDF, balsa, birch, poplar, red oak, cherry, holly, etc.)

==== Aligning Materials ====

** The table is not aligned with the laser's X-Y axis
** To align your material use the laser pointer by holding one axis constant while moving along the other axis to align corners of your material

== Laser Materials and the Woodshop Table-Saw Saw-stop ==

*Conductive materials such as aluminum and other metals, carbon fiber materials, mirrored acrylic, carbon-filled materials, etc. will typically cause the brake to activate.
*Carbon from lasered wood or lasered plywood is also conductive and will trigger the saw stop. do not use the table saw to cut your material. Once you have lasered a piece of wood,
**The band saw can be used instead for both mirrored acrylic and lasered wood. Use safety goggles when using the bandsaw in general, but especially when using it to cut acrylic. (NOTE: authorization is required for the table saw and the bandsaw, so attending a woodshop authorization might be a good idea).

== Resources ==

The proprietary LaserWORKS software can be downloaded from BOSS here - https://www.bosslaser.com/laser-software/ However, the current version (8.01.28) of the laser software seems to require admin rights every time it's used. So instead you may want to download the [https://appdb.winehq.org/objectManager.php?sClass=version&iId=35522 8.01.18 version of the software] until this is fixed.

Manuals for the BOSS laser and the LaserWORKS software are located here - https://www.bosslaser.com/download-manuals-guides/

[https://www.bosslaser.com/laser-test-files BOSS test files are available here]

[https://www.bosslaser.com/laser-settings Some laser settings from Boss]

[https://www.facebook.com/groups/900528680076062/ Excellent Facebook Group for RDWorks Tips and help]

[https://rdworkslab.com/index.php Forum for RDworks user group]

If the language for RDWorks (the Boss control software) is showing garbage, [https://www.youtube.com/watch?v=gwhQ2xzV1xo&feature=youtu.be follow this video].

== Youtube Channels ==
Following are a couple good YouTube Channels with lots of information on the software and machine
* [https://wiki.pumpingstationone.org/index.php?title=Special:UserLogin&returnto=BOSS+LS-3655+150w+Laser+Engraver SarbarMultimedia]
* [https://www.youtube.com/channel/UCOuDR90TZ24qEFFIbVmDAMw Thunder Laser]

== Cleaning & Maintenance ==

* When changing the lens, make sure the convex/domed side of the lens is facing upwards (towards the ceiling)
* Focus Lens should be cleaned once a week with Acetone or Denatured Alcohol

== List of Currently Certified Users ==

{| class="wikitable" border="1"
! Qualified Member
! Trained By
! Date
|-
|Andrew Camardella
|Danger Committee
|
|-
|Matt Keith
|Danger Committee
|
|-
|Skylar Nova
|Danger Committee
|
|-
|Jason Araujo
|Danger Committee
|
|-
|Ray Doeksen
|Danger Committee
|
|-
|Matt Meshulam
|Danger Committee
|
|-
|Ashish Jasani
|Danger Committee
|
|-
|Joe Juhnke
|Ashish Jasani
|
|-
|Casey Olson
|Ray Doeksen
|
|-
|Andrew Vaughan
|Burton Kent
|
|-
|[[User:mct|McTavish McArdle]]
|Burton Kent
|
|-
|Erik Wessing
|Ray Doeksen
|
|-
|Theo T
|Ray Doeksen
|
|-
|Molly Adamski
|Joe Juhnke
|
|-
|[[User:deadwisdom|Brantley Harris]]
|Ray Doeksen
|
|-
|Amir Badri
|Sky Nova
|
|-
|Aaron Carlock
|Jeff Z
|
|-
|Gabe Tavas
|Joe Juhnke
|
|-
|Sam Dreyer
|Jeff Z
|
|-
|Stephanie Pelzer
|Jeff Z
|
|-
|Nick Prorok
|Jeff Z
|3/02/2018
|-
|Alisha Ciardi
|Burton Kent
|03/2018
|-}
|-
|Bao Nguyen
|Zander Bueno
|05/04/2018
|-

[[Category:Laser Cutter]]
[[Category:Fabrication]]
[[Category:Certification Clarification Needed]]

BOSS LS-3655 150w Laser Engraver

2018-06-12T01:32:29Z

Daddybird: /* Procedures */

{{ Template:EquipmentPage
| owner=PS:One
| model=BOSS LS-3655 150w
| serial=SERIAL NUMBER
| arrived= January 2017
| doesitwork=yes
| contact=[[CNC|CNC Area Host]]
| where=CNC Shop
| certification=yes
| hackable=no
| value=$17,000
| image = BossLaser2.jpg
| hostarea = CNC
}}

== About ==

The BOSS LS-3655 is an industrial CO2 laser engraver with a 36" x 55" bed, supporting over-sized material pass-thru on four sides and up to 7 inches of table depth. Originally shipped with 100W tube, but that has been replaced with 150W tube in May, 2017.

== Status ==

* (2018/02/26) Working. Z-Axis motor having some issues? 2-25-2018
* (2017/05/20) 150W Tube & Power Supply installed. Alignment & focusing pending.
* (2017/06/12) The laser has been aligned and focused. 2" Laser lens focal depth set to 5.1mm.

== Usage Policy ==

The laser cutter is easily one of the most used machines at PS1. Due to this demand we request the cooperation of all members to share the laser cutter and associated computer. First and foremost, the practice "being excellent" should be observed at all times; respect yourself, other members, and the equipment. This is a usage policy so that everyone can use the laser:

* Any user not actively test cutting or cutting will cede the computer and laser to the next person waiting in line, as soon as that waiting user notifies the current computer user. If you are still designing your file, please do so on another computer. Artastic (another PC upstairs) in the Crafts Area also has a copy of Adobe Illustrator.
* If someone is waiting in line to use the laser, no active test cut or cut series shall be longer than 1 hour. No jobs will be allowed to start that overrun the 1 hour time limit when a new user is waiting.
* In the case that your last cut is longer than the 1 hour time limit, and a waiting user presents themselves after the cut has started, the cut job shall be allowed to finish and the waiting user will be allowed to set up their file in their own user account, during the cutting period.
* Continuous cutting shall not exceed 3 consecutive hours without a half hour break for the laser to cool. If a new user arrives before or during the cooling period the current user shall cede the laser to the next user, and the next user will wait for the cooling period to finish and the cooling period shall not count towards the 1 hours limit should another user present themselves.
* Waiting users shall notify the current user verbally that they are waiting and where they will be waiting until it is their turn. If multiple users are waiting, the next waiting user must start their test cutting or cut job within 10 minutes of being notified of a laser opening. The current user will keep a record of who is waiting, where they will be, and notify subsequent users of the status of the queue. The current user will find the next waiting user and verbally inform them that the laser is available.

== Authorizations ==

How to get authorized: contact the CNC Area Host or one of the Volunteer Authorizers. There's a sign posted in the CNC area that has names of people that are laser authorizers.

Since demand fluctuates, and there are a random group of new and old members that want to be authorized at any one time, it makes sense to find the others and figure out your group schedule/plan. There generally is NOT going to be a calendar-based or widely publicized meetup event; you will have to conctact and make arrangements with actual people, at least until the Canvas Learning Management System is implemented more fully. http://canvas.pumpingstationone.org

=== Preparing yourself to become authorized ===

You need a few things to optimize and expedite your experience:

* 1. Know what you're doing as best as you can - come pre-trained on your own time to make the authorization go smoother and faster.
* 2. Have a PS1 username set up before starting the authorization http://members.pumpingstationone.org
* 3. Have some familiarity with the kinds of files you would bring to the Boss to cut.

To that end; you could download and become familiar a bit with RDWorks, the software you will use to drive the Boss. Links are on this page.
You can read a bit of the manual, which is also linked on this page, or watch some YouTube videos.

To set up a PS1 username (this is NOT the email address you use, it's a different thing, it's entirely special to PS1) go to http://members.pumpingstationone.org, and click "Activate" ... if you don't already have a PS1 username.

You will want to bring files in from Adobe Illustrator in Illustrator format, with lines set to have SOME sort of stroke, I'd recommend 1 point stroke, and some simple color applied to the stroke for each "layer" you want to have in RDWorks. You will want to have one color/layer assigned for each type or strength of cut/engrave you'll be doing in that job. For instance, you might want a deep engraving, a shallow engraving, a cut that goes all the way through the material and maybe a cut that just barely touches the top surface (called a 'kiss cut) and that would mean you would need four distinct colors of stroke used in your file. You should investigate the usefullness of SVG, DXF and DWG files as well, but Illustrator files will give you the best first experiences.

Authorizations will be limited to small groups, e.g. 4 or less, due to nature of the equipment.

==Power-On & Safety Check==
# Check Wiki for status updates
# Check if material is safe to cut: refer to the wiki for a list of safe and unsafe materials for cutting
# Check Fire Extinguisher: Make sure it is close by and charged
# Release Emergency Stop: Rotate red button until it releases
# Turn Power Key: Display will load up
# Turn on Air Assist & Chiller: Flip the switch and ensure exhaust & chiller are on and functioning. Double check chiller temp with laser temp.
* RD Works
# Load Program & Check USB Connection Status
# Importing Files: Importing AI, DXF, SVG, & images
# Introducing User Interface: quick review of UI including Drawing, Grouping, Preview, Work Tab, Layers, Laser Work, & Head Position
# Detailed Overview of Work Tab: major cutting settings & parameters reside here
# Starting a Job
# Saving a File
* Boss Laser Operation
# LED Keypad Overview
# Adjusting the Z-Height: raise and lower bed
# Autofocus: Setting focal height for material
# Setting Origin
# Jogging the Laser Head in XY
# Adjusting High Pressure Air Regulator: Changing the compressed air flow
# Loading a File via USB Port
# Load & Unload honeycomb
# Cleaning Up & Clearing Catch Tray
* Individual Walkthrough: each member is required to perform the following:
# Start-Up the machine
# Turn on exhaust, air-assist, & chiller
# Place Material, autofocus, set origin
# Load RDworks, create 3 layers (Cut, Scan, Dot) & run laser job
# Shutdown machine & clear catch tray

== Settings ==
[https://wiki.pumpingstationone.org/Boss_Laser_Settings Laser Settings Page]

* Honeycomb vs. Aluminum Lamella : The honeycomb is used for engraving and pieces that benefit from precise leveling. Use the aluminum lamella (slats under honeycomb) for cutting through to reduce flashback and improve airflow (warning small pieces will fall through).

* 4" Lens Focus Depth 38.5mm (this is a just an approximate, FD calibration must be performed each time the lens is changed)
* 2" Lens Focus Depth 5.3mm (this is a just an approximate, FD calibration must be performed each time the lens is changed)

== Procedures ==
(https://wiki.pumpingstationone.org/BOSS_Usage Boss Usage)

=== Powering On Machine ===
* Check Fire Extinguisher
* Release Emergency Stop button
* Turn power key
* Turn on air assist & water chiller Switch & ensure both are functioning

=== Powering Off Machine ===
* Turn key to off position, leave key in the lock
* Push emergency stop button in
* Turn the chiller, blower and air assist off using the main switch (switch with identifying lasercut plate)
* Reset the area by cleaning up any stray cut materials. Clean and straighten the area around the laser.

== Material Safety & Information ==
WARNING: Because many plastics are dangerous to cut, it is important to know what kind you are planning to use. If you are unsure of your materials composition, don’t cut it with the laser. You can request a SDS from your material supplier for specific information on the plastic you have or are considering using.

=== NEVER CUT THESE MATERIALS ===
** Any material containing chlorine:
***PVC (Poly Vinyl Chloride)
***Vinyl
***Pleather
***Artificial leather
**Plastics:
*** Polycarbonate/Lexan – [Thick ( >1mm )]
*** ABS
*** HDPE/milk bottle plastic
** Foams:
*** PolyStyrene Foam
*** PolyPropylene Foam
** Other:
*** Epoxy
*** Fiberglass
*** Coated Carbon Fiber
***Any foodstuff ( such as meat, seaweed 'nori' sheets, bread, tortillas... )

=== Safe Materials for Cutting ===
** Plastics:
*** ABS (acrylonitrile butadiene styrene)
*** Acrylic (also known as Plexiglas, Lucite, PMMA)
*** Delrin (POM, acetal)
*** Kapton tape (Polyimide)
*** Mylar (polyester)
*** Nylon – melts badly
*** PETG (polyethylene terephthalate glycol)
*** Styrene
*** Two-tone acrylic – top color different than core material, usually for custom instrumentation panels, signs, and plaques.
** Foam:
*** Depron foam – often used for RC planes.
*** EPM
*** Gator foam – foam core gets burned and eaten away compared to the top and bottom hard shell.
** Other:
*** Cloths (leather, suede, felt, hemp, cotton)
*** Papers
*** Rubbers (only if they do not contain chlorine Teflon (PTFE, Polytetrafluoroethylene)
*** Woods (MDF, balsa, birch, poplar, red oak, cherry, holly, etc.)

==== Aligning Materials ====

** The table is not aligned with the laser's X-Y axis
** To align your material use the laser pointer by holding one axis constant while moving along the other axis to align corners of your material

== Laser Materials and the Woodshop Table-Saw Saw-stop ==

*Conductive materials such as aluminum and other metals, carbon fiber materials, mirrored acrylic, carbon-filled materials, etc. will typically cause the brake to activate.
*Carbon from lasered wood or lasered plywood is also conductive and will trigger the saw stop. do not use the table saw to cut your material. Once you have lasered a piece of wood,
**The band saw can be used instead for both mirrored acrylic and lasered wood. Use safety goggles when using the bandsaw in general, but especially when using it to cut acrylic. (NOTE: authorization is required for the table saw and the bandsaw, so attending a woodshop authorization might be a good idea).

== Resources ==

The proprietary LaserWORKS software can be downloaded from BOSS here - https://www.bosslaser.com/laser-software/ However, the current version (8.01.28) of the laser software seems to require admin rights every time it's used. So instead you may want to download the [https://appdb.winehq.org/objectManager.php?sClass=version&iId=35522 8.01.18 version of the software] until this is fixed.

Manuals for the BOSS laser and the LaserWORKS software are located here - https://www.bosslaser.com/download-manuals-guides/

[https://www.bosslaser.com/laser-test-files BOSS test files are available here]

[https://www.bosslaser.com/laser-settings Some laser settings from Boss]

[https://www.facebook.com/groups/900528680076062/ Excellent Facebook Group for RDWorks Tips and help]

[https://rdworkslab.com/index.php Forum for RDworks user group]

If the language for RDWorks (the Boss control software) is showing garbage, [https://www.youtube.com/watch?v=gwhQ2xzV1xo&feature=youtu.be follow this video].

== Youtube Channels ==
Following are a couple good YouTube Channels with lots of information on the software and machine
* [https://wiki.pumpingstationone.org/index.php?title=Special:UserLogin&returnto=BOSS+LS-3655+150w+Laser+Engraver SarbarMultimedia]
* [https://www.youtube.com/channel/UCOuDR90TZ24qEFFIbVmDAMw Thunder Laser]

== Cleaning & Maintenance ==

* When changing the lens, make sure the convex/domed side of the lens is facing upwards (towards the ceiling)
* Focus Lens should be cleaned once a week with Acetone or Denatured Alcohol

== List of Currently Certified Users ==

{| class="wikitable" border="1"
! Qualified Member
! Trained By
! Date
|-
|Andrew Camardella
|Danger Committee
|
|-
|Matt Keith
|Danger Committee
|
|-
|Skylar Nova
|Danger Committee
|
|-
|Jason Araujo
|Danger Committee
|
|-
|Ray Doeksen
|Danger Committee
|
|-
|Matt Meshulam
|Danger Committee
|
|-
|Ashish Jasani
|Danger Committee
|
|-
|Joe Juhnke
|Ashish Jasani
|
|-
|Casey Olson
|Ray Doeksen
|
|-
|Andrew Vaughan
|Burton Kent
|
|-
|[[User:mct|McTavish McArdle]]
|Burton Kent
|
|-
|Erik Wessing
|Ray Doeksen
|
|-
|Theo T
|Ray Doeksen
|
|-
|Molly Adamski
|Joe Juhnke
|
|-
|[[User:deadwisdom|Brantley Harris]]
|Ray Doeksen
|
|-
|Amir Badri
|Sky Nova
|
|-
|Aaron Carlock
|Jeff Z
|
|-
|Gabe Tavas
|Joe Juhnke
|
|-
|Sam Dreyer
|Jeff Z
|
|-
|Stephanie Pelzer
|Jeff Z
|
|-
|Nick Prorok
|Jeff Z
|3/02/2018
|-
|Alisha Ciardi
|Burton Kent
|03/2018
|-}
|-
|Bao Nguyen
|Zander Bueno
|05/04/2018
|-

[[Category:Laser Cutter]]
[[Category:Fabrication]]
[[Category:Certification Clarification Needed]]

BOSS LS-3655 150w Laser Engraver

2018-06-12T01:31:46Z

Daddybird: /* Settings */

{{ Template:EquipmentPage
| owner=PS:One
| model=BOSS LS-3655 150w
| serial=SERIAL NUMBER
| arrived= January 2017
| doesitwork=yes
| contact=[[CNC|CNC Area Host]]
| where=CNC Shop
| certification=yes
| hackable=no
| value=$17,000
| image = BossLaser2.jpg
| hostarea = CNC
}}

== About ==

The BOSS LS-3655 is an industrial CO2 laser engraver with a 36" x 55" bed, supporting over-sized material pass-thru on four sides and up to 7 inches of table depth. Originally shipped with 100W tube, but that has been replaced with 150W tube in May, 2017.

== Status ==

* (2018/02/26) Working. Z-Axis motor having some issues? 2-25-2018
* (2017/05/20) 150W Tube & Power Supply installed. Alignment & focusing pending.
* (2017/06/12) The laser has been aligned and focused. 2" Laser lens focal depth set to 5.1mm.

== Usage Policy ==

The laser cutter is easily one of the most used machines at PS1. Due to this demand we request the cooperation of all members to share the laser cutter and associated computer. First and foremost, the practice "being excellent" should be observed at all times; respect yourself, other members, and the equipment. This is a usage policy so that everyone can use the laser:

* Any user not actively test cutting or cutting will cede the computer and laser to the next person waiting in line, as soon as that waiting user notifies the current computer user. If you are still designing your file, please do so on another computer. Artastic (another PC upstairs) in the Crafts Area also has a copy of Adobe Illustrator.
* If someone is waiting in line to use the laser, no active test cut or cut series shall be longer than 1 hour. No jobs will be allowed to start that overrun the 1 hour time limit when a new user is waiting.
* In the case that your last cut is longer than the 1 hour time limit, and a waiting user presents themselves after the cut has started, the cut job shall be allowed to finish and the waiting user will be allowed to set up their file in their own user account, during the cutting period.
* Continuous cutting shall not exceed 3 consecutive hours without a half hour break for the laser to cool. If a new user arrives before or during the cooling period the current user shall cede the laser to the next user, and the next user will wait for the cooling period to finish and the cooling period shall not count towards the 1 hours limit should another user present themselves.
* Waiting users shall notify the current user verbally that they are waiting and where they will be waiting until it is their turn. If multiple users are waiting, the next waiting user must start their test cutting or cut job within 10 minutes of being notified of a laser opening. The current user will keep a record of who is waiting, where they will be, and notify subsequent users of the status of the queue. The current user will find the next waiting user and verbally inform them that the laser is available.

== Authorizations ==

How to get authorized: contact the CNC Area Host or one of the Volunteer Authorizers. There's a sign posted in the CNC area that has names of people that are laser authorizers.

Since demand fluctuates, and there are a random group of new and old members that want to be authorized at any one time, it makes sense to find the others and figure out your group schedule/plan. There generally is NOT going to be a calendar-based or widely publicized meetup event; you will have to conctact and make arrangements with actual people, at least until the Canvas Learning Management System is implemented more fully. http://canvas.pumpingstationone.org

=== Preparing yourself to become authorized ===

You need a few things to optimize and expedite your experience:

* 1. Know what you're doing as best as you can - come pre-trained on your own time to make the authorization go smoother and faster.
* 2. Have a PS1 username set up before starting the authorization http://members.pumpingstationone.org
* 3. Have some familiarity with the kinds of files you would bring to the Boss to cut.

To that end; you could download and become familiar a bit with RDWorks, the software you will use to drive the Boss. Links are on this page.
You can read a bit of the manual, which is also linked on this page, or watch some YouTube videos.

To set up a PS1 username (this is NOT the email address you use, it's a different thing, it's entirely special to PS1) go to http://members.pumpingstationone.org, and click "Activate" ... if you don't already have a PS1 username.

You will want to bring files in from Adobe Illustrator in Illustrator format, with lines set to have SOME sort of stroke, I'd recommend 1 point stroke, and some simple color applied to the stroke for each "layer" you want to have in RDWorks. You will want to have one color/layer assigned for each type or strength of cut/engrave you'll be doing in that job. For instance, you might want a deep engraving, a shallow engraving, a cut that goes all the way through the material and maybe a cut that just barely touches the top surface (called a 'kiss cut) and that would mean you would need four distinct colors of stroke used in your file. You should investigate the usefullness of SVG, DXF and DWG files as well, but Illustrator files will give you the best first experiences.

Authorizations will be limited to small groups, e.g. 4 or less, due to nature of the equipment.

==Power-On & Safety Check==
# Check Wiki for status updates
# Check if material is safe to cut: refer to the wiki for a list of safe and unsafe materials for cutting
# Check Fire Extinguisher: Make sure it is close by and charged
# Release Emergency Stop: Rotate red button until it releases
# Turn Power Key: Display will load up
# Turn on Air Assist & Chiller: Flip the switch and ensure exhaust & chiller are on and functioning. Double check chiller temp with laser temp.
* RD Works
# Load Program & Check USB Connection Status
# Importing Files: Importing AI, DXF, SVG, & images
# Introducing User Interface: quick review of UI including Drawing, Grouping, Preview, Work Tab, Layers, Laser Work, & Head Position
# Detailed Overview of Work Tab: major cutting settings & parameters reside here
# Starting a Job
# Saving a File
* Boss Laser Operation
# LED Keypad Overview
# Adjusting the Z-Height: raise and lower bed
# Autofocus: Setting focal height for material
# Setting Origin
# Jogging the Laser Head in XY
# Adjusting High Pressure Air Regulator: Changing the compressed air flow
# Loading a File via USB Port
# Load & Unload honeycomb
# Cleaning Up & Clearing Catch Tray
* Individual Walkthrough: each member is required to perform the following:
# Start-Up the machine
# Turn on exhaust, air-assist, & chiller
# Place Material, autofocus, set origin
# Load RDworks, create 3 layers (Cut, Scan, Dot) & run laser job
# Shutdown machine & clear catch tray

== Settings ==
[https://wiki.pumpingstationone.org/Boss_Laser_Settings Laser Settings Page]

* Honeycomb vs. Aluminum Lamella : The honeycomb is used for engraving and pieces that benefit from precise leveling. Use the aluminum lamella (slats under honeycomb) for cutting through to reduce flashback and improve airflow (warning small pieces will fall through).

* 4" Lens Focus Depth 38.5mm (this is a just an approximate, FD calibration must be performed each time the lens is changed)
* 2" Lens Focus Depth 5.3mm (this is a just an approximate, FD calibration must be performed each time the lens is changed)

== Procedures ==

=== Powering On Machine ===
* Check Fire Extinguisher
* Release Emergency Stop button
* Turn power key
* Turn on air assist & water chiller Switch & ensure both are functioning

=== Powering Off Machine ===
* Turn key to off position, leave key in the lock
* Push emergency stop button in
* Turn the chiller, blower and air assist off using the main switch (switch with identifying lasercut plate)
* Reset the area by cleaning up any stray cut materials. Clean and straighten the area around the laser.

== Material Safety & Information ==
WARNING: Because many plastics are dangerous to cut, it is important to know what kind you are planning to use. If you are unsure of your materials composition, don’t cut it with the laser. You can request a SDS from your material supplier for specific information on the plastic you have or are considering using.

=== NEVER CUT THESE MATERIALS ===
** Any material containing chlorine:
***PVC (Poly Vinyl Chloride)
***Vinyl
***Pleather
***Artificial leather
**Plastics:
*** Polycarbonate/Lexan – [Thick ( >1mm )]
*** ABS
*** HDPE/milk bottle plastic
** Foams:
*** PolyStyrene Foam
*** PolyPropylene Foam
** Other:
*** Epoxy
*** Fiberglass
*** Coated Carbon Fiber
***Any foodstuff ( such as meat, seaweed 'nori' sheets, bread, tortillas... )

=== Safe Materials for Cutting ===
** Plastics:
*** ABS (acrylonitrile butadiene styrene)
*** Acrylic (also known as Plexiglas, Lucite, PMMA)
*** Delrin (POM, acetal)
*** Kapton tape (Polyimide)
*** Mylar (polyester)
*** Nylon – melts badly
*** PETG (polyethylene terephthalate glycol)
*** Styrene
*** Two-tone acrylic – top color different than core material, usually for custom instrumentation panels, signs, and plaques.
** Foam:
*** Depron foam – often used for RC planes.
*** EPM
*** Gator foam – foam core gets burned and eaten away compared to the top and bottom hard shell.
** Other:
*** Cloths (leather, suede, felt, hemp, cotton)
*** Papers
*** Rubbers (only if they do not contain chlorine Teflon (PTFE, Polytetrafluoroethylene)
*** Woods (MDF, balsa, birch, poplar, red oak, cherry, holly, etc.)

==== Aligning Materials ====

** The table is not aligned with the laser's X-Y axis
** To align your material use the laser pointer by holding one axis constant while moving along the other axis to align corners of your material

== Laser Materials and the Woodshop Table-Saw Saw-stop ==

*Conductive materials such as aluminum and other metals, carbon fiber materials, mirrored acrylic, carbon-filled materials, etc. will typically cause the brake to activate.
*Carbon from lasered wood or lasered plywood is also conductive and will trigger the saw stop. do not use the table saw to cut your material. Once you have lasered a piece of wood,
**The band saw can be used instead for both mirrored acrylic and lasered wood. Use safety goggles when using the bandsaw in general, but especially when using it to cut acrylic. (NOTE: authorization is required for the table saw and the bandsaw, so attending a woodshop authorization might be a good idea).

== Resources ==

The proprietary LaserWORKS software can be downloaded from BOSS here - https://www.bosslaser.com/laser-software/ However, the current version (8.01.28) of the laser software seems to require admin rights every time it's used. So instead you may want to download the [https://appdb.winehq.org/objectManager.php?sClass=version&iId=35522 8.01.18 version of the software] until this is fixed.

Manuals for the BOSS laser and the LaserWORKS software are located here - https://www.bosslaser.com/download-manuals-guides/

[https://www.bosslaser.com/laser-test-files BOSS test files are available here]

[https://www.bosslaser.com/laser-settings Some laser settings from Boss]

[https://www.facebook.com/groups/900528680076062/ Excellent Facebook Group for RDWorks Tips and help]

[https://rdworkslab.com/index.php Forum for RDworks user group]

If the language for RDWorks (the Boss control software) is showing garbage, [https://www.youtube.com/watch?v=gwhQ2xzV1xo&feature=youtu.be follow this video].

== Youtube Channels ==
Following are a couple good YouTube Channels with lots of information on the software and machine
* [https://wiki.pumpingstationone.org/index.php?title=Special:UserLogin&returnto=BOSS+LS-3655+150w+Laser+Engraver SarbarMultimedia]
* [https://www.youtube.com/channel/UCOuDR90TZ24qEFFIbVmDAMw Thunder Laser]

== Cleaning & Maintenance ==

* When changing the lens, make sure the convex/domed side of the lens is facing upwards (towards the ceiling)
* Focus Lens should be cleaned once a week with Acetone or Denatured Alcohol

== List of Currently Certified Users ==

{| class="wikitable" border="1"
! Qualified Member
! Trained By
! Date
|-
|Andrew Camardella
|Danger Committee
|
|-
|Matt Keith
|Danger Committee
|
|-
|Skylar Nova
|Danger Committee
|
|-
|Jason Araujo
|Danger Committee
|
|-
|Ray Doeksen
|Danger Committee
|
|-
|Matt Meshulam
|Danger Committee
|
|-
|Ashish Jasani
|Danger Committee
|
|-
|Joe Juhnke
|Ashish Jasani
|
|-
|Casey Olson
|Ray Doeksen
|
|-
|Andrew Vaughan
|Burton Kent
|
|-
|[[User:mct|McTavish McArdle]]
|Burton Kent
|
|-
|Erik Wessing
|Ray Doeksen
|
|-
|Theo T
|Ray Doeksen
|
|-
|Molly Adamski
|Joe Juhnke
|
|-
|[[User:deadwisdom|Brantley Harris]]
|Ray Doeksen
|
|-
|Amir Badri
|Sky Nova
|
|-
|Aaron Carlock
|Jeff Z
|
|-
|Gabe Tavas
|Joe Juhnke
|
|-
|Sam Dreyer
|Jeff Z
|
|-
|Stephanie Pelzer
|Jeff Z
|
|-
|Nick Prorok
|Jeff Z
|3/02/2018
|-
|Alisha Ciardi
|Burton Kent
|03/2018
|-}
|-
|Bao Nguyen
|Zander Bueno
|05/04/2018
|-

[[Category:Laser Cutter]]
[[Category:Fabrication]]
[[Category:Certification Clarification Needed]]

CNC Plasma Cutter

2018-06-10T16:55:54Z

Daddybird: /* Sheet Cam */

{{Template:EquipmentPage
|owner = PS:One
|hostarea = CNC
|certification = yes
|hackable = no
|model = N.A.
|serial = N.A.
|arrived = 10/16
|where = Hot metals
|doesitwork = yes
|contact = CNC Area Host
|value = $6000
|image = IMG_4045.JPG
}}

== Status ==

Working. Stay tuned for an announcement about authorizations.

== Authorisation ==

Authorisation requirements:

* This is not a commercial machine; it was hand-built at PS1 and as such there is no website to check, nor any manual to read. You must be willing to accept the fact that the machine can be quirky and you may have to do some troubleshooting when using it (hopefully not, but ¯\_(ツ)_/¯).
* You should be familiar with how plasma cutters work (at the very least, read this: https://en.wikipedia.org/wiki/Plasma_cutting). If you can swing it, please get authorized on the Miller handheld plasma machine beforehand; this is not a requirement, just a useful suggestion.
* Read all of this page about the machine: https://wiki.pumpingstationone.org/CNC_Plasma_Cutter
* Read and be willing to add your experience/knowledge of using the machine here: https://wiki.pumpingstationone.org/Talk:CNC_Plasma_Cutter

[[CNC Plasma Cutter Authorisation]] has more details.

== Drawing guidelines ==

* No sharp corners, all corners should be filleted with at least a 1/16" radius
* The thicker the part, the larger the smallest feature
** Small holes 1/4" and under are not advisable
** Holes under 3/4" on 3/8" plate are not advisable
** Not all these sizes are learnt yet, this is why you need extra material
* Acceptable drawing formats:
** DXF
** SWF
* Acceptable drawing formats for review:
** DXF
** SWF
** AI

== Safety and Protective Equipment ==

* Number 5 shades when a job is running
* Thick gloves when handling freshly cut parts
* Hearing protection recommended
* Respirator/mask while cutting

== Procedures ==

=== Machine Startup ===
Fill water table if not filled already. Takes about 35 minutes to fill. Be sure to have the splash guard on it so when it's filled the air does not spray water everywhere.

# Wipe down machine with clean dry clotha
# Log in to machine
# Turn on air
# Make sure e-stop is depressed
# Turn on control box
# Start Mach3
# Clear e-stop
# Raise Z
# Move torch to end of table
# Remove torch shield and inspect for dross build up
# Reinstall torch shield
# Turn on plasma cutter
# Check cutter status (Air/torch/etc)

=== Machine Shutdown ===

# Hit e-stop
# Exit Mach3
# Turn off plasma cutter
# Turn off air
# Turn off control box
# Clean torch shield
# Sweep under table
# Wipe down machine with clean dry cloth
# Wipe down computer
# '''Leave the area cleaner than you found it'''

=== Running A Job ===

=== Starting a job from a particular line of code (needs update)===
*Run from here
*Select next line

=== Previewing a job (needs update) ===
*Load file
*Select the 'Run BLK' button in the interface or type Alt-N
*Press the start job button - this will step through each line of code
(warning: includes torch homing and torch ignite so be careful)
*You can step backwards though a job by pressing the 'reverse order' button.

=== Job Crashes ===

==== SmoothStepper Buffer Under run ====

'''Your work piece is trash, start again, home position lost'''

# Click through error
# Start your job again

Causes:

* Communication error between smooth stepper and PC

==== Touch off failure ====

'''Your work piece is not trash yet, but might be if you don't follow these steps'''

One of the following happened:

* Touch off get stuck with torch touching the plate
* Touch off fails to detect plate and rams into the plate
* Error probe ignored in status bar - If this is the case clean the shield nozzle, dross has gotten inside, do not move work piece

Do This:

# Hit escape '''ONCE''', not e-stop, not reset, escape
# Double click in the g-code window to display line numbers eg: 20:N0100 G91.... rather than N0100 G91....
# Look for the current line, it should be highlighted and be: G31 Z -100
# Look up a few lines for the torch moving to safe height: G00 Z1.5
# In the operator console click in the line number box
# Type in the line number of the safe hight move and hit return
# Highlighted line should change to that line
# Hit "Set next line" button
# Hit cycle start

Causes:

* Dross has built up inside shield
* Work piece is flapping around like a flag in a breeze, put some weights on it
* Dross/corrosion on the plate cause a none conductive area where the torch touched off
* Torch cable has become too taught and caused the probe connection to come loose or the probe ring not to touch the torch shield

==== Torch fails to ignite ====

'''Your work piece is not trash yet, but might be if you don't follow these steps'''

Mach3 shows job stuck on M3 command.

# Hit F5 to re-ignite the torch (possibly twice)
# Job should continue once M3 detects arc transfer signal from the plasma cutter

Causes:

* Unknown at this time

==== Mach3 Crash ====

'''Your work piece is trash, start again'''

# Shutdown the control box
# Close Mach3
# Turn on control box
# Start Mach3
# Run your job again

Causes:

* Unknown at this time

== Sheet Cam ==

https://www.youtube.com/user/arclightdynamics/videos has good tutorials.

Sheet Cam settings always use the last setting. So double check it's what you want.

Origin is bottom left. Origin on the machine is back left. Brown box is the material size, but it doesn't need to be set.

It's a good idea to have a bounding box on your work so it's placed correctly.

Isolate paths by selecting them then put them in a new layer. This includes the previously mentioned bounding box.

Cuts can be inside edge, outside edge or on the line. A lead in is a good idea to help keep the cuts clean. Lead out has not been tested but may help.

=== Manual Controls ===
* Arrow keys move X/Y
* Shift PageUp/PageDown moves the Z axis

Click the zero button to set home. (this is from memory, please correct -- Burton)

== Todo List ==

* Documentation

Squareness todo:

* Physical end stops - probably want to move the wiring out of the X axis tubes for this
* Limit switches on A-axis (slaved to X, the rail against the wall)

This will allow both manual squareness and automatic machine homing. Mach 3 has a routine that will home the X axis with the slave, then adjust which ever one did not hit the home switch independently.

Water table todo:

* <s>Fix 2 pin hole leaks (one at each end of tank)</s>
* <s>Fit bladder input line (so it doesn't collect crap in the tank)</s>
* Wash out old compressor tank
* <s>Trim the top of the side where the A axis hardware grazes the top of the tank.</s>
* Paint the outside of the tank
* <s>Treat the water with the green goo</s>

Plumbing/wiring todo:

* Extend air line to under table to create a manifold for table mounted air consumers
* Run large conduit for 220 outlet for the plasma cutter
* Run small conduit for data/estop between the table and the PC
* Run black pipe for connecting the table to the bladder (old compressor tank)
* Water line from north side of the shop, with input into the old compressor tank
* Air lines to the compressor tank (one vent on from the compressor)
* Run ethernet line to PC so its not on wifi any more
* Z axis limit switches

Plate marker todo:

* Design and cut new y-axis trolly or offset plate to carry torch and marker
* Machine mount for engraver
* Mount new trolly with air slide and Z axis
* Plumbing and wiring
* Pen mount as well as engraver?

35A Fine Cut todo:

* Build floating Z axis using left over linear rail
* How to multiplex the digitise input for touch off? Relays to switch digitise input from ohmic sensor to switch on head? (and disconnect the switch from the z limit array) (the switch should be in the z limit switch array by default incase the THC plunges the torch into the work piece)

Roundness/cut quality todo:

* <s>Y Axis pulsing - new connection spigot for drive year to fix eccentric rotation of gear</s>
* Remove and clean X axis gears, reinstall and use loctite on set screws (the keep backing off)
* Make sure all bearings are right against the rails so there is no slop
* <s>Investigate backlash and configure mach3 is required</s> - 0.0001 on X, Y and A
* Get quote for installing ground rod next to the table and execute it
* Look into THC issues (cut rippling) if still present after ground rod - possible Z axis flex in the mount to the Y carriage.
* Why is the THC seeing ~80V for a good clean cut from the hypertherm? Is the internal voltage divider broken (is this why the machine was retrofitted with a dangerous high voltage tap?)? Or is this related to a bad ground at the table?
* Motion pauses: (Seen on large 3'x2' complex cuts)
** Why are there zero move G1's at the end of curves generated with G2's
** <s>Do we need to add a CV on G-Code in the preamble of the post processor</s> - Does not appear to need this
** Smooth stepper under-run errors - I have only seen this when jogging not cutting, mostly related to rapiding the Z, maybe reduce the micro stepping on the driver for the new threaded drive step count is huge per inch which could be hurting us
** <s>Axis and Core frequency tuning for the smooth stepper?</s> - Dropped to 64k on X,Y,A
** <s>Look ahead tuning</s> - increased to 150
** Is CV plasma mode hurting us?
** <s>System problems, AV jamming things up?</s> - low cpu load not an issue

Ohter things:

* Cleaning/maintenance schedule
* Shelves/lockers in the unused space under the table for project/tool/etc storage?
* Materials storage ideas?
** sheet goods
** 20-24' bar/tube stock

== Future Items ==

* Tube attachment
* scribe attachment

== Torch Consumables ==

The torch is a T45m hypertherm machine torch.

{| class="wikitable" border="1"
!colspan="3"|Consumables Change Log
|-
! Date
! What
! By
|-
|6/10/17
|electrode, nozzle
|Andrew Camardella
|-
|}

[http://www.thefabricator.com/article/plasmacutting/plasma-cutting-maintenance-are-you-throwing-money-away What does a worn electrode look like?]

Torch tips components are consumables. If you are getting a wide kerf or the plasma torch isn't cutting through the materials anymore you may need to change the tip parts. To change the consumables disconnect the ground clip from the black retaining cap and unscrew the entire tip from the retaining cap.

=== Standard ===
* Shield P/N: 220673
* Deflector P/N: 2206732
* Retaining Cap - Ohmic P/N: 220719
* Nozzle P/N: 220671
* Electrode P/N: 220669
* Swirl Ring P/N: 220670

=== Fine Cut ===

'''THERE IS CURRENTLY NO POST PROCESSOR FOR RUNNING WITH THESE CONSUMABLES INSTALLED'''

'''NOTE''': These parts are for a t30 unshielded torch, they are compatiable with the T45m when it is run at a setting lower than 30A and cutting materials thinner than 3/16". Ohmic sensing will not work with these parts installed.

* Deflector P/N: 2206732
* Retaining Cap - Ohmic P/N: 220483
* Nozzle P/N: 220480
* Electrode P/N: 220479
* Swirl Ring P/N: 220478

[[:File:T45m.pdf|Consumables catalog page]]

== Feeds and Speeds ==

=== T45m Shielded Consumables ===

==== Mild Steel ====

{| class="wikitable"
!colspan="5"|
!colspan="2"|Recommended
!colspan="2"|Maximum
|-
!Arc Current (a)
!Material Thickness
!Torch-to-work distance (in)
!Initial Piece hieght (in)
!Pierce time delay (s)
!Cut Speed (ipm)
!Arc Voltage (V)
!Cut Speed (ipm)
!Arc Voltage (V)
|-
|rowspan="4"|30
|0.018" 26Ga
|rowspan="4"|0.06"
|rowspan="4"|0.15"
|rowspan="3"|0.0
|?
|117
|400
|118
|-
|0.030" 22Ga
|?
|116
|400
|117
|-
|0.036" 20Ga
|?
|115
|400
|117
|-
|0.060" 18Ga
|0.2
|?
|111
|280
|115
|-
|rowspan="12"|45
|0.036" 20Ga
|rowspan="12"|0.06"
|rowspan="8"|0.15"
|rowspan="2"|0.0
|380
|115
|400
|112
|-
|0.060" 16 Ga
|150
|116
|400
|115
|-
|0.075" 14Ga
|0.1
|150
|117
|360
|115
|-
|0.105" 12Ga
|0.3
|130
|117
|240
|115
|-
|0.135" 10Ga
|0.4
|110
|117
|175
|115
|-
|0.188" 3/16"
|0.5
|85
|118
|110
|115
|-
|0.250" 1/4"
|0.6
|60
|120
|75
|116
|-
|0.375" 3/8"
|0.9
|32
|122
|40
|116
|-
|0.500" 1/2"
|colspan="2" rowspan="4"|Edge Start Recommended
|4
|132
|25
|125
|-
|0.625" 5/8"
|3
|138
|14
|127
|-
|0.750" 3/4"
|2
|140
|10
|131
|-
|1.000" 1"
|?
|146
|5
|142
|-
|}

==== Stainless Steel ====

{| class="wikitable"
!colspan="5"|
!colspan="2"|Recommended
!colspan="2"|Maximum
|-
!Arc Current (a)
!Material Thickness
!Torch-to-work distance (in)
!Initial Piece hieght (in)
!Pierce time delay (s)
!Cut Speed (ipm)
!Arc Voltage (V)
!Cut Speed (ipm)
!Arc Voltage (V)
|-
|rowspan="4"|30
|0.018" 26Ga
|rowspan="4"|0.06"
|rowspan="4"|0.15"
|rowspan="3"|0.0
|?
|117
|400
|123
|-
|0.030" 22Ga
|?
|116
|400
|121
|-
|0.036" 20Ga
|?
|115
|400
|119
|-
|0.060" 18Ga
|0.2
|?
|111
|185
|118
|-
|rowspan="12"|45
|0.036" 20Ga
|rowspan="12"|0.06"
|rowspan="8"|0.15"
|rowspan="2"|0.0
|?
|115
|400
|109
|-
|0.060" 16 Ga
|138
|116
|400
|125
|-
|0.075" 14Ga
|0.1
|?
|117
|360
|115
|-
|0.105" 12Ga
|0.3
|?
|117
|200
|116
|-
|0.135" 10Ga
|0.4
|?
|117
|155
|118
|-
|0.188" 3/16"
|0.5
|?
|118
|85
|118
|-
|0.250" 1/4"
|0.6
|?
|120
|55
|120
|-
|0.375" 3/8"
|0.8
|?
|122
|32
|121
|-
|0.500" 1/2"
|colspan="2" rowspan="2"|Edge Start Recommended
|?
|?
|18
|128
|-
|0.750" 3/4"
|?
|?
|9
|131
|-
|}

==== Aluminium ====

{| class="wikitable"
!colspan="5"|
!colspan="2"|Recommended
!colspan="2"|Maximum
|-
!Arc Current (a)
!Material Thickness
!Torch-to-work distance (in)
!Initial Piece hieght (in)
!Pierce time delay (s)
!Cut Speed (ipm)
!Arc Voltage (V)
!Cut Speed (ipm)
!Arc Voltage (V)
|-
|rowspan="3"|30
|0.018" 26Ga
|rowspan="3"|0.06"
|rowspan="3"|0.15"
|0.0
|360
|117
|400
|120
|-
|0.060" 16Ga
|rowspan="2"|0.2
|340
|118
|400
|121
|-
|0.075" 14Ga
|215
|118
|270
|121
|-
|rowspan="11"|45
|0.060" 16Ga
|rowspan="12"|0.06"
|rowspan="7"|0.15"
|rowspan="3"|0.0
|360
|116
|400
|114
|-
|0.075" 14Ga
|340
|117
|400
|116
|-
|0.105" 12 Ga
|280
|120
|360
|119
|-
|0.135" 10Ga
|0.1
|220
|122
|280
|120
|-
|0.188" 3/16"
|0.2
|100
|123
|130
|120
|-
|0.250" 1/4"
|0.3
|80
|123
|100
|120
|-
|0.375" 3/8"
|0.5
|33
|130
|42
|125
|-
|0.500" 1/2"
|colspan="2" rowspan="2"|Edge Start Recommended
|20
|134
|25
|130
|-
|0.750" 3/4"
|8
|143
|10
|138
|-
|}

=== T30v Unshielded Fine cut Consumables ===
'''THERE IS CURRENTLY NO POST PROCESSOR FOR RUNNING WITH THESE CONSUMABLES INSTALLED'''
==== Mild Steel ====
{| class="wikitable"
!colspan="5"|
!colspan="2"|Recommended
!colspan="2"|Maximum
|-
!Arc Current (a)
!Material Thickness
!Torch-to-work distance (in)
!Initial Piece hieght (in)
!Pierce time delay (s)
!Cut Speed (ipm)
!Arc Voltage (V)
!Cut Speed (ipm)
!Arc Voltage (V)
|-
|rowspan="7"|30
|0.018" 26Ga
|rowspan="7"|0.02
|rowspan="7"|0.1
|rowspan="3"|0.0
|350
|105
|400
|98
|-
|0.030" 22Ga
|320
|102
|400
|103
|-
|0.036" 20Ga
|280
|101
|350
|100
|-
|0.060" 16Ga
|0.2
|175
|97
|220
|100
|-
|0.075" 14Ga
|rowspan="3"|0.4
|120
|98
|150
|97
|-
|0.105" 12Ga
|80
|96
|100
|96
|-
|0.135" 10Ga
|50
|100
|65
|101
|-
|}

==== Stainless Steel ====
{| class="wikitable"
!colspan="5"|
!colspan="2"|Recommended
!colspan="2"|Maximum
|-
!Arc Current (a)
!Material Thickness
!Torch-to-work distance (in)
!Initial Piece hieght (in)
!Pierce time delay (s)
!Cut Speed (ipm)
!Arc Voltage (V)
!Cut Speed (ipm)
!Arc Voltage (V)
|-
|rowspan="7"|30
|0.018" 26Ga
|rowspan="7"|0.02
|rowspan="7"|0.1
|rowspan="3"|0.0
|350
|103
|400
|102
|-
|0.030" 22Ga
|320
|198
|400
|100
|-
|0.036" 20Ga
|300
|97
|380
|98
|-
|0.060" 16Ga
|0.2
|150
|99
|190
|98
|-
|0.075" 14Ga
|rowspan="3"|0.4
|110
|101
|135
|97
|-
|0.105" 12Ga
|60
|101
|75
|98
|-
|0.135" 10Ga
|45
|102
|55
|97
|-
|}

==== Aluminium ====
{| class="wikitable"
!colspan="5"|
!colspan="2"|Recommended
!colspan="2"|Maximum
|-
!Arc Current (a)
!Material Thickness
!Torch-to-work distance (in)
!Initial Piece hieght (in)
!Pierce time delay (s)
!Cut Speed (ipm)
!Arc Voltage (V)
!Cut Speed (ipm)
!Arc Voltage (V)
|-
|rowspan="5"|30
|0.036" 20Ga
|rowspan="5"|0.02
|rowspan="5"|0.1
|rowspan="3"|0.0
|320
|107
|400
|105
|-
|0.060" 16Ga
|240
|104
|300
|103
|-
|0.075" 14Ga
|190
|104
|1240
|103
|-
|0.105" 12Ga
|rowspan="2"|0.2
|145
|103
|180
|103
|-
|0.135" 10Ga
|95
|101
|120
|101
|-
|}

== Wiring ==

=== Stepper Coils ===

* A+ Black
* A- Green
* B+ Red
* B- Blue

=== Smooth Stepper Pin Mapping ===

==== C25 Interface board pins ====

{| class="wikitable"
!colspan="3"|SmoothStepper
!colspan="2"|Target Device
|-
!Port
!Pin
!Type
!Device
!Connection
!Wire color
|-
|1
|1
|Output
|X Stepper Driver
|Pul+
|Green
|-
|1
|2
|Output
|X Stepper Driver
|Dir+
|Red
|-
|1
|3
|Output
|X Stepper Driver
|Ena+
|-
|1
|4
|Output
|Y Stepper Driver
|Pul+
|Green
|-
|1
|5
|Output
|Y Stepper Driver
|Dir+
|Red
|-
|1
|6
|Output
|Y Stepper Driver
|Ena+
|-
|1
|7
|Output
|THC
|Step In
|Green
|-
|1
|8
|Output
|THC
|Dir In
|Red
|-
|1
|9
|Output
|Z Stepper Driver
|Ena+
|-
|1
|10
|Input
|Plasma Interface Connector
|Torch Lit Out
|-
|1
|11
|Input
|Z Limit Connector
|2
|Grey
|-
|1
|12
|Input
|Y Limit Connector
|2
|Grey
|-
|1
|13
|Input
|X Limit Connector
|2
|Grey
|-
|1
|14
|Output
|A Stepper Driver
|Pul+
|Green
|-
|1
|15
|Input
|E-Stop Switch
|Switch contact NC
|Grey
|-
|1
|16
|Output
|A Stepper Driver
|Dir+
|Red
|-
|1
|17
|Output
|A Stepper Driver
|Ena+
|-
|2
|1
|Output
|Torch Relay
|Coil +
|-
|2
|2
|Input
|Touch off probe connector
|Pin 2
|-
|2
|3
|Input
|-
|2
|4
|Input
|-
|2
|5
|Input
|-
|2
|6
|Input
|-
|2
|7
|Input
|-
|2
|8
|Input
|-
|2
|9
|Input
|-
|2
|10
|Input
|-
|2
|11
|Input
|-
|2
|12
|Intput
|-
|2
|13
|Input
|-
|2
|14
|Output
|THC Enable relay
|Coil +
|-
|2
|15
|Input
|-
|2
|16
|Output
|-
|2
|17
|Output
|}

== Configuration ==

=== Stepper Drivers ===
Steps per inch: 1358

Driving current:
* SW1 ON
* SW2 ON
* SW3 OFF

Holding Current:
* SW4 OFF

Steps:
* SW5
* SW6
* SW7
* SW8

== Parts ==

* Steppers:
** Wantai 57BYGH115-003
** Nema 23 stepper motor
** 425oz-in torque
** 3 Amp
* Drivers:
** Wantai DQ542MA
** Manual: [[File:DQ542MA_English_Manual.pdf]]
* SmoothStepper Ethernet
* C25 Break out board
** https://cnc4pc.com/motion-control/breakout-boards/c25-smooth-stepper-terminal-board.html
** Manual: [[File:C25R3_1_USER_MANUAL.pdf]]

==maintenance ==
[[CNC_Plasma_Cutter_maintenance|maintenance page]]

== Authorization ==

=== Authorizers ===

* Tom Judge - 45A and 30A fine cut consumables
* Andrew Camaradella - 45A auto Z only
* Ron Olson - 45A auto Z only

=== List of Currently Authorized Users - 45A Auto Z ===

{| class="wikitable" border="1"
! Qualified Member
! Trained By
! Date
|-
|Tom Judge
|Danger Committee
|
|-
|Andrew Caramdella
|Danger Committee
|
|-
| Jake Chaitkin
| Ron Olson
| 6/9/2018
|-}
|}

=== List of Currently Authorized Users - 30A Fine Cut ===

{| class="wikitable" border="1"
! Qualified Member
! Trained By
! Date
|-
|Tom Judge
|Danger Committee
|
|-
|Casey Olson
|Tom Judge
|-
| Jake Chaitkin
| Ron Olson
| 6/9/2018
|-}
|-
|}

CNC Plasma Cutter

2018-06-10T16:53:36Z

Daddybird: /* Machine Startup */

{{Template:EquipmentPage
|owner = PS:One
|hostarea = CNC
|certification = yes
|hackable = no
|model = N.A.
|serial = N.A.
|arrived = 10/16
|where = Hot metals
|doesitwork = yes
|contact = CNC Area Host
|value = $6000
|image = IMG_4045.JPG
}}

== Status ==

Working. Stay tuned for an announcement about authorizations.

== Authorisation ==

Authorisation requirements:

* This is not a commercial machine; it was hand-built at PS1 and as such there is no website to check, nor any manual to read. You must be willing to accept the fact that the machine can be quirky and you may have to do some troubleshooting when using it (hopefully not, but ¯\_(ツ)_/¯).
* You should be familiar with how plasma cutters work (at the very least, read this: https://en.wikipedia.org/wiki/Plasma_cutting). If you can swing it, please get authorized on the Miller handheld plasma machine beforehand; this is not a requirement, just a useful suggestion.
* Read all of this page about the machine: https://wiki.pumpingstationone.org/CNC_Plasma_Cutter
* Read and be willing to add your experience/knowledge of using the machine here: https://wiki.pumpingstationone.org/Talk:CNC_Plasma_Cutter

[[CNC Plasma Cutter Authorisation]] has more details.

== Drawing guidelines ==

* No sharp corners, all corners should be filleted with at least a 1/16" radius
* The thicker the part, the larger the smallest feature
** Small holes 1/4" and under are not advisable
** Holes under 3/4" on 3/8" plate are not advisable
** Not all these sizes are learnt yet, this is why you need extra material
* Acceptable drawing formats:
** DXF
** SWF
* Acceptable drawing formats for review:
** DXF
** SWF
** AI

== Safety and Protective Equipment ==

* Number 5 shades when a job is running
* Thick gloves when handling freshly cut parts
* Hearing protection recommended
* Respirator/mask while cutting

== Procedures ==

=== Machine Startup ===
Fill water table if not filled already. Takes about 35 minutes to fill. Be sure to have the splash guard on it so when it's filled the air does not spray water everywhere.

# Wipe down machine with clean dry clotha
# Log in to machine
# Turn on air
# Make sure e-stop is depressed
# Turn on control box
# Start Mach3
# Clear e-stop
# Raise Z
# Move torch to end of table
# Remove torch shield and inspect for dross build up
# Reinstall torch shield
# Turn on plasma cutter
# Check cutter status (Air/torch/etc)

=== Machine Shutdown ===

# Hit e-stop
# Exit Mach3
# Turn off plasma cutter
# Turn off air
# Turn off control box
# Clean torch shield
# Sweep under table
# Wipe down machine with clean dry cloth
# Wipe down computer
# '''Leave the area cleaner than you found it'''

=== Running A Job ===

=== Starting a job from a particular line of code (needs update)===
*Run from here
*Select next line

=== Previewing a job (needs update) ===
*Load file
*Select the 'Run BLK' button in the interface or type Alt-N
*Press the start job button - this will step through each line of code
(warning: includes torch homing and torch ignite so be careful)
*You can step backwards though a job by pressing the 'reverse order' button.

=== Job Crashes ===

==== SmoothStepper Buffer Under run ====

'''Your work piece is trash, start again, home position lost'''

# Click through error
# Start your job again

Causes:

* Communication error between smooth stepper and PC

==== Touch off failure ====

'''Your work piece is not trash yet, but might be if you don't follow these steps'''

One of the following happened:

* Touch off get stuck with torch touching the plate
* Touch off fails to detect plate and rams into the plate
* Error probe ignored in status bar - If this is the case clean the shield nozzle, dross has gotten inside, do not move work piece

Do This:

# Hit escape '''ONCE''', not e-stop, not reset, escape
# Double click in the g-code window to display line numbers eg: 20:N0100 G91.... rather than N0100 G91....
# Look for the current line, it should be highlighted and be: G31 Z -100
# Look up a few lines for the torch moving to safe height: G00 Z1.5
# In the operator console click in the line number box
# Type in the line number of the safe hight move and hit return
# Highlighted line should change to that line
# Hit "Set next line" button
# Hit cycle start

Causes:

* Dross has built up inside shield
* Work piece is flapping around like a flag in a breeze, put some weights on it
* Dross/corrosion on the plate cause a none conductive area where the torch touched off
* Torch cable has become too taught and caused the probe connection to come loose or the probe ring not to touch the torch shield

==== Torch fails to ignite ====

'''Your work piece is not trash yet, but might be if you don't follow these steps'''

Mach3 shows job stuck on M3 command.

# Hit F5 to re-ignite the torch (possibly twice)
# Job should continue once M3 detects arc transfer signal from the plasma cutter

Causes:

* Unknown at this time

==== Mach3 Crash ====

'''Your work piece is trash, start again'''

# Shutdown the control box
# Close Mach3
# Turn on control box
# Start Mach3
# Run your job again

Causes:

* Unknown at this time

== Sheet Cam ==
Sheet Cam settings always use the last setting. So double check it's what you want.

Origin is bottom left. Origin on the machine is back left. Brown box is the material size, but it doesn't need to be set.

It's a good idea to have a bounding box on your work so it's placed correctly.

Isolate paths by selecting them then put them in a new layer. This includes the previously mentioned bounding box.

Cuts can be inside edge, outside edge or on the line. A lead in is a good idea to help keep the cuts clean. Lead out has not been tested but may help.

=== Manual Controls ===
* Arrow keys move X/Y
* Shift PageUp/PageDown moves the Z axis

Click the zero button to set home. (this is from memory, please correct -- Burton)

== Todo List ==

* Documentation

Squareness todo:

* Physical end stops - probably want to move the wiring out of the X axis tubes for this
* Limit switches on A-axis (slaved to X, the rail against the wall)

This will allow both manual squareness and automatic machine homing. Mach 3 has a routine that will home the X axis with the slave, then adjust which ever one did not hit the home switch independently.

Water table todo:

* <s>Fix 2 pin hole leaks (one at each end of tank)</s>
* <s>Fit bladder input line (so it doesn't collect crap in the tank)</s>
* Wash out old compressor tank
* <s>Trim the top of the side where the A axis hardware grazes the top of the tank.</s>
* Paint the outside of the tank
* <s>Treat the water with the green goo</s>

Plumbing/wiring todo:

* Extend air line to under table to create a manifold for table mounted air consumers
* Run large conduit for 220 outlet for the plasma cutter
* Run small conduit for data/estop between the table and the PC
* Run black pipe for connecting the table to the bladder (old compressor tank)
* Water line from north side of the shop, with input into the old compressor tank
* Air lines to the compressor tank (one vent on from the compressor)
* Run ethernet line to PC so its not on wifi any more
* Z axis limit switches

Plate marker todo:

* Design and cut new y-axis trolly or offset plate to carry torch and marker
* Machine mount for engraver
* Mount new trolly with air slide and Z axis
* Plumbing and wiring
* Pen mount as well as engraver?

35A Fine Cut todo:

* Build floating Z axis using left over linear rail
* How to multiplex the digitise input for touch off? Relays to switch digitise input from ohmic sensor to switch on head? (and disconnect the switch from the z limit array) (the switch should be in the z limit switch array by default incase the THC plunges the torch into the work piece)

Roundness/cut quality todo:

* <s>Y Axis pulsing - new connection spigot for drive year to fix eccentric rotation of gear</s>
* Remove and clean X axis gears, reinstall and use loctite on set screws (the keep backing off)
* Make sure all bearings are right against the rails so there is no slop
* <s>Investigate backlash and configure mach3 is required</s> - 0.0001 on X, Y and A
* Get quote for installing ground rod next to the table and execute it
* Look into THC issues (cut rippling) if still present after ground rod - possible Z axis flex in the mount to the Y carriage.
* Why is the THC seeing ~80V for a good clean cut from the hypertherm? Is the internal voltage divider broken (is this why the machine was retrofitted with a dangerous high voltage tap?)? Or is this related to a bad ground at the table?
* Motion pauses: (Seen on large 3'x2' complex cuts)
** Why are there zero move G1's at the end of curves generated with G2's
** <s>Do we need to add a CV on G-Code in the preamble of the post processor</s> - Does not appear to need this
** Smooth stepper under-run errors - I have only seen this when jogging not cutting, mostly related to rapiding the Z, maybe reduce the micro stepping on the driver for the new threaded drive step count is huge per inch which could be hurting us
** <s>Axis and Core frequency tuning for the smooth stepper?</s> - Dropped to 64k on X,Y,A
** <s>Look ahead tuning</s> - increased to 150
** Is CV plasma mode hurting us?
** <s>System problems, AV jamming things up?</s> - low cpu load not an issue

Ohter things:

* Cleaning/maintenance schedule
* Shelves/lockers in the unused space under the table for project/tool/etc storage?
* Materials storage ideas?
** sheet goods
** 20-24' bar/tube stock

== Future Items ==

* Tube attachment
* scribe attachment

== Torch Consumables ==

The torch is a T45m hypertherm machine torch.

{| class="wikitable" border="1"
!colspan="3"|Consumables Change Log
|-
! Date
! What
! By
|-
|6/10/17
|electrode, nozzle
|Andrew Camardella
|-
|}

[http://www.thefabricator.com/article/plasmacutting/plasma-cutting-maintenance-are-you-throwing-money-away What does a worn electrode look like?]

Torch tips components are consumables. If you are getting a wide kerf or the plasma torch isn't cutting through the materials anymore you may need to change the tip parts. To change the consumables disconnect the ground clip from the black retaining cap and unscrew the entire tip from the retaining cap.

=== Standard ===
* Shield P/N: 220673
* Deflector P/N: 2206732
* Retaining Cap - Ohmic P/N: 220719
* Nozzle P/N: 220671
* Electrode P/N: 220669
* Swirl Ring P/N: 220670

=== Fine Cut ===

'''THERE IS CURRENTLY NO POST PROCESSOR FOR RUNNING WITH THESE CONSUMABLES INSTALLED'''

'''NOTE''': These parts are for a t30 unshielded torch, they are compatiable with the T45m when it is run at a setting lower than 30A and cutting materials thinner than 3/16". Ohmic sensing will not work with these parts installed.

* Deflector P/N: 2206732
* Retaining Cap - Ohmic P/N: 220483
* Nozzle P/N: 220480
* Electrode P/N: 220479
* Swirl Ring P/N: 220478

[[:File:T45m.pdf|Consumables catalog page]]

== Feeds and Speeds ==

=== T45m Shielded Consumables ===

==== Mild Steel ====

{| class="wikitable"
!colspan="5"|
!colspan="2"|Recommended
!colspan="2"|Maximum
|-
!Arc Current (a)
!Material Thickness
!Torch-to-work distance (in)
!Initial Piece hieght (in)
!Pierce time delay (s)
!Cut Speed (ipm)
!Arc Voltage (V)
!Cut Speed (ipm)
!Arc Voltage (V)
|-
|rowspan="4"|30
|0.018" 26Ga
|rowspan="4"|0.06"
|rowspan="4"|0.15"
|rowspan="3"|0.0
|?
|117
|400
|118
|-
|0.030" 22Ga
|?
|116
|400
|117
|-
|0.036" 20Ga
|?
|115
|400
|117
|-
|0.060" 18Ga
|0.2
|?
|111
|280
|115
|-
|rowspan="12"|45
|0.036" 20Ga
|rowspan="12"|0.06"
|rowspan="8"|0.15"
|rowspan="2"|0.0
|380
|115
|400
|112
|-
|0.060" 16 Ga
|150
|116
|400
|115
|-
|0.075" 14Ga
|0.1
|150
|117
|360
|115
|-
|0.105" 12Ga
|0.3
|130
|117
|240
|115
|-
|0.135" 10Ga
|0.4
|110
|117
|175
|115
|-
|0.188" 3/16"
|0.5
|85
|118
|110
|115
|-
|0.250" 1/4"
|0.6
|60
|120
|75
|116
|-
|0.375" 3/8"
|0.9
|32
|122
|40
|116
|-
|0.500" 1/2"
|colspan="2" rowspan="4"|Edge Start Recommended
|4
|132
|25
|125
|-
|0.625" 5/8"
|3
|138
|14
|127
|-
|0.750" 3/4"
|2
|140
|10
|131
|-
|1.000" 1"
|?
|146
|5
|142
|-
|}

==== Stainless Steel ====

{| class="wikitable"
!colspan="5"|
!colspan="2"|Recommended
!colspan="2"|Maximum
|-
!Arc Current (a)
!Material Thickness
!Torch-to-work distance (in)
!Initial Piece hieght (in)
!Pierce time delay (s)
!Cut Speed (ipm)
!Arc Voltage (V)
!Cut Speed (ipm)
!Arc Voltage (V)
|-
|rowspan="4"|30
|0.018" 26Ga
|rowspan="4"|0.06"
|rowspan="4"|0.15"
|rowspan="3"|0.0
|?
|117
|400
|123
|-
|0.030" 22Ga
|?
|116
|400
|121
|-
|0.036" 20Ga
|?
|115
|400
|119
|-
|0.060" 18Ga
|0.2
|?
|111
|185
|118
|-
|rowspan="12"|45
|0.036" 20Ga
|rowspan="12"|0.06"
|rowspan="8"|0.15"
|rowspan="2"|0.0
|?
|115
|400
|109
|-
|0.060" 16 Ga
|138
|116
|400
|125
|-
|0.075" 14Ga
|0.1
|?
|117
|360
|115
|-
|0.105" 12Ga
|0.3
|?
|117
|200
|116
|-
|0.135" 10Ga
|0.4
|?
|117
|155
|118
|-
|0.188" 3/16"
|0.5
|?
|118
|85
|118
|-
|0.250" 1/4"
|0.6
|?
|120
|55
|120
|-
|0.375" 3/8"
|0.8
|?
|122
|32
|121
|-
|0.500" 1/2"
|colspan="2" rowspan="2"|Edge Start Recommended
|?
|?
|18
|128
|-
|0.750" 3/4"
|?
|?
|9
|131
|-
|}

==== Aluminium ====

{| class="wikitable"
!colspan="5"|
!colspan="2"|Recommended
!colspan="2"|Maximum
|-
!Arc Current (a)
!Material Thickness
!Torch-to-work distance (in)
!Initial Piece hieght (in)
!Pierce time delay (s)
!Cut Speed (ipm)
!Arc Voltage (V)
!Cut Speed (ipm)
!Arc Voltage (V)
|-
|rowspan="3"|30
|0.018" 26Ga
|rowspan="3"|0.06"
|rowspan="3"|0.15"
|0.0
|360
|117
|400
|120
|-
|0.060" 16Ga
|rowspan="2"|0.2
|340
|118
|400
|121
|-
|0.075" 14Ga
|215
|118
|270
|121
|-
|rowspan="11"|45
|0.060" 16Ga
|rowspan="12"|0.06"
|rowspan="7"|0.15"
|rowspan="3"|0.0
|360
|116
|400
|114
|-
|0.075" 14Ga
|340
|117
|400
|116
|-
|0.105" 12 Ga
|280
|120
|360
|119
|-
|0.135" 10Ga
|0.1
|220
|122
|280
|120
|-
|0.188" 3/16"
|0.2
|100
|123
|130
|120
|-
|0.250" 1/4"
|0.3
|80
|123
|100
|120
|-
|0.375" 3/8"
|0.5
|33
|130
|42
|125
|-
|0.500" 1/2"
|colspan="2" rowspan="2"|Edge Start Recommended
|20
|134
|25
|130
|-
|0.750" 3/4"
|8
|143
|10
|138
|-
|}

=== T30v Unshielded Fine cut Consumables ===
'''THERE IS CURRENTLY NO POST PROCESSOR FOR RUNNING WITH THESE CONSUMABLES INSTALLED'''
==== Mild Steel ====
{| class="wikitable"
!colspan="5"|
!colspan="2"|Recommended
!colspan="2"|Maximum
|-
!Arc Current (a)
!Material Thickness
!Torch-to-work distance (in)
!Initial Piece hieght (in)
!Pierce time delay (s)
!Cut Speed (ipm)
!Arc Voltage (V)
!Cut Speed (ipm)
!Arc Voltage (V)
|-
|rowspan="7"|30
|0.018" 26Ga
|rowspan="7"|0.02
|rowspan="7"|0.1
|rowspan="3"|0.0
|350
|105
|400
|98
|-
|0.030" 22Ga
|320
|102
|400
|103
|-
|0.036" 20Ga
|280
|101
|350
|100
|-
|0.060" 16Ga
|0.2
|175
|97
|220
|100
|-
|0.075" 14Ga
|rowspan="3"|0.4
|120
|98
|150
|97
|-
|0.105" 12Ga
|80
|96
|100
|96
|-
|0.135" 10Ga
|50
|100
|65
|101
|-
|}

==== Stainless Steel ====
{| class="wikitable"
!colspan="5"|
!colspan="2"|Recommended
!colspan="2"|Maximum
|-
!Arc Current (a)
!Material Thickness
!Torch-to-work distance (in)
!Initial Piece hieght (in)
!Pierce time delay (s)
!Cut Speed (ipm)
!Arc Voltage (V)
!Cut Speed (ipm)
!Arc Voltage (V)
|-
|rowspan="7"|30
|0.018" 26Ga
|rowspan="7"|0.02
|rowspan="7"|0.1
|rowspan="3"|0.0
|350
|103
|400
|102
|-
|0.030" 22Ga
|320
|198
|400
|100
|-
|0.036" 20Ga
|300
|97
|380
|98
|-
|0.060" 16Ga
|0.2
|150
|99
|190
|98
|-
|0.075" 14Ga
|rowspan="3"|0.4
|110
|101
|135
|97
|-
|0.105" 12Ga
|60
|101
|75
|98
|-
|0.135" 10Ga
|45
|102
|55
|97
|-
|}

==== Aluminium ====
{| class="wikitable"
!colspan="5"|
!colspan="2"|Recommended
!colspan="2"|Maximum
|-
!Arc Current (a)
!Material Thickness
!Torch-to-work distance (in)
!Initial Piece hieght (in)
!Pierce time delay (s)
!Cut Speed (ipm)
!Arc Voltage (V)
!Cut Speed (ipm)
!Arc Voltage (V)
|-
|rowspan="5"|30
|0.036" 20Ga
|rowspan="5"|0.02
|rowspan="5"|0.1
|rowspan="3"|0.0
|320
|107
|400
|105
|-
|0.060" 16Ga
|240
|104
|300
|103
|-
|0.075" 14Ga
|190
|104
|1240
|103
|-
|0.105" 12Ga
|rowspan="2"|0.2
|145
|103
|180
|103
|-
|0.135" 10Ga
|95
|101
|120
|101
|-
|}

== Wiring ==

=== Stepper Coils ===

* A+ Black
* A- Green
* B+ Red
* B- Blue

=== Smooth Stepper Pin Mapping ===

==== C25 Interface board pins ====

{| class="wikitable"
!colspan="3"|SmoothStepper
!colspan="2"|Target Device
|-
!Port
!Pin
!Type
!Device
!Connection
!Wire color
|-
|1
|1
|Output
|X Stepper Driver
|Pul+
|Green
|-
|1
|2
|Output
|X Stepper Driver
|Dir+
|Red
|-
|1
|3
|Output
|X Stepper Driver
|Ena+
|-
|1
|4
|Output
|Y Stepper Driver
|Pul+
|Green
|-
|1
|5
|Output
|Y Stepper Driver
|Dir+
|Red
|-
|1
|6
|Output
|Y Stepper Driver
|Ena+
|-
|1
|7
|Output
|THC
|Step In
|Green
|-
|1
|8
|Output
|THC
|Dir In
|Red
|-
|1
|9
|Output
|Z Stepper Driver
|Ena+
|-
|1
|10
|Input
|Plasma Interface Connector
|Torch Lit Out
|-
|1
|11
|Input
|Z Limit Connector
|2
|Grey
|-
|1
|12
|Input
|Y Limit Connector
|2
|Grey
|-
|1
|13
|Input
|X Limit Connector
|2
|Grey
|-
|1
|14
|Output
|A Stepper Driver
|Pul+
|Green
|-
|1
|15
|Input
|E-Stop Switch
|Switch contact NC
|Grey
|-
|1
|16
|Output
|A Stepper Driver
|Dir+
|Red
|-
|1
|17
|Output
|A Stepper Driver
|Ena+
|-
|2
|1
|Output
|Torch Relay
|Coil +
|-
|2
|2
|Input
|Touch off probe connector
|Pin 2
|-
|2
|3
|Input
|-
|2
|4
|Input
|-
|2
|5
|Input
|-
|2
|6
|Input
|-
|2
|7
|Input
|-
|2
|8
|Input
|-
|2
|9
|Input
|-
|2
|10
|Input
|-
|2
|11
|Input
|-
|2
|12
|Intput
|-
|2
|13
|Input
|-
|2
|14
|Output
|THC Enable relay
|Coil +
|-
|2
|15
|Input
|-
|2
|16
|Output
|-
|2
|17
|Output
|}

== Configuration ==

=== Stepper Drivers ===
Steps per inch: 1358

Driving current:
* SW1 ON
* SW2 ON
* SW3 OFF

Holding Current:
* SW4 OFF

Steps:
* SW5
* SW6
* SW7
* SW8

== Parts ==

* Steppers:
** Wantai 57BYGH115-003
** Nema 23 stepper motor
** 425oz-in torque
** 3 Amp
* Drivers:
** Wantai DQ542MA
** Manual: [[File:DQ542MA_English_Manual.pdf]]
* SmoothStepper Ethernet
* C25 Break out board
** https://cnc4pc.com/motion-control/breakout-boards/c25-smooth-stepper-terminal-board.html
** Manual: [[File:C25R3_1_USER_MANUAL.pdf]]

==maintenance ==
[[CNC_Plasma_Cutter_maintenance|maintenance page]]

== Authorization ==

=== Authorizers ===

* Tom Judge - 45A and 30A fine cut consumables
* Andrew Camaradella - 45A auto Z only
* Ron Olson - 45A auto Z only

=== List of Currently Authorized Users - 45A Auto Z ===

{| class="wikitable" border="1"
! Qualified Member
! Trained By
! Date
|-
|Tom Judge
|Danger Committee
|
|-
|Andrew Caramdella
|Danger Committee
|
|-
| Jake Chaitkin
| Ron Olson
| 6/9/2018
|-}
|}

=== List of Currently Authorized Users - 30A Fine Cut ===

{| class="wikitable" border="1"
! Qualified Member
! Trained By
! Date
|-
|Tom Judge
|Danger Committee
|
|-
|Casey Olson
|Tom Judge
|-
| Jake Chaitkin
| Ron Olson
| 6/9/2018
|-}
|-
|}

CNC Plasma Cutter

2018-06-10T14:20:23Z

Daddybird:

{{Template:EquipmentPage
|owner = PS:One
|hostarea = CNC
|certification = yes
|hackable = no
|model = N.A.
|serial = N.A.
|arrived = 10/16
|where = Hot metals
|doesitwork = yes
|contact = CNC Area Host
|value = $6000
|image = IMG_4045.JPG
}}

== Status ==

Working. Stay tuned for an announcement about authorizations.

== Authorisation ==

Authorisation requirements:

* This is not a commercial machine; it was hand-built at PS1 and as such there is no website to check, nor any manual to read. You must be willing to accept the fact that the machine can be quirky and you may have to do some troubleshooting when using it (hopefully not, but ¯\_(ツ)_/¯).
* You should be familiar with how plasma cutters work (at the very least, read this: https://en.wikipedia.org/wiki/Plasma_cutting). If you can swing it, please get authorized on the Miller handheld plasma machine beforehand; this is not a requirement, just a useful suggestion.
* Read all of this page about the machine: https://wiki.pumpingstationone.org/CNC_Plasma_Cutter
* Read and be willing to add your experience/knowledge of using the machine here: https://wiki.pumpingstationone.org/Talk:CNC_Plasma_Cutter

[[CNC Plasma Cutter Authorisation]] has more details.

== Drawing guidelines ==

* No sharp corners, all corners should be filleted with at least a 1/16" radius
* The thicker the part, the larger the smallest feature
** Small holes 1/4" and under are not advisable
** Holes under 3/4" on 3/8" plate are not advisable
** Not all these sizes are learnt yet, this is why you need extra material
* Acceptable drawing formats:
** DXF
** SWF
* Acceptable drawing formats for review:
** DXF
** SWF
** AI

== Safety and Protective Equipment ==

* Number 5 shades when a job is running
* Thick gloves when handling freshly cut parts
* Hearing protection recommended
* Respirator/mask while cutting

== Procedures ==

=== Machine Startup ===

# Wipe down machine with clean dry clotha
# Log in to machine
# Turn on air
# Make sure e-stop is depressed
# Turn on control box
# Start Mach3
# Clear e-stop
# Raise Z
# Move torch to end of table
# Remove torch shield and inspect for dross build up
# Reinstall torch shield
# Turn on plasma cutter
# Check cutter status (Air/torch/etc)

=== Machine Shutdown ===

# Hit e-stop
# Exit Mach3
# Turn off plasma cutter
# Turn off air
# Turn off control box
# Clean torch shield
# Sweep under table
# Wipe down machine with clean dry cloth
# Wipe down computer
# '''Leave the area cleaner than you found it'''

=== Running A Job ===

=== Starting a job from a particular line of code (needs update)===
*Run from here
*Select next line

=== Previewing a job (needs update) ===
*Load file
*Select the 'Run BLK' button in the interface or type Alt-N
*Press the start job button - this will step through each line of code
(warning: includes torch homing and torch ignite so be careful)
*You can step backwards though a job by pressing the 'reverse order' button.

=== Job Crashes ===

==== SmoothStepper Buffer Under run ====

'''Your work piece is trash, start again, home position lost'''

# Click through error
# Start your job again

Causes:

* Communication error between smooth stepper and PC

==== Touch off failure ====

'''Your work piece is not trash yet, but might be if you don't follow these steps'''

One of the following happened:

* Touch off get stuck with torch touching the plate
* Touch off fails to detect plate and rams into the plate
* Error probe ignored in status bar - If this is the case clean the shield nozzle, dross has gotten inside, do not move work piece

Do This:

# Hit escape '''ONCE''', not e-stop, not reset, escape
# Double click in the g-code window to display line numbers eg: 20:N0100 G91.... rather than N0100 G91....
# Look for the current line, it should be highlighted and be: G31 Z -100
# Look up a few lines for the torch moving to safe height: G00 Z1.5
# In the operator console click in the line number box
# Type in the line number of the safe hight move and hit return
# Highlighted line should change to that line
# Hit "Set next line" button
# Hit cycle start

Causes:

* Dross has built up inside shield
* Work piece is flapping around like a flag in a breeze, put some weights on it
* Dross/corrosion on the plate cause a none conductive area where the torch touched off
* Torch cable has become too taught and caused the probe connection to come loose or the probe ring not to touch the torch shield

==== Torch fails to ignite ====

'''Your work piece is not trash yet, but might be if you don't follow these steps'''

Mach3 shows job stuck on M3 command.

# Hit F5 to re-ignite the torch (possibly twice)
# Job should continue once M3 detects arc transfer signal from the plasma cutter

Causes:

* Unknown at this time

==== Mach3 Crash ====

'''Your work piece is trash, start again'''

# Shutdown the control box
# Close Mach3
# Turn on control box
# Start Mach3
# Run your job again

Causes:

* Unknown at this time

== Sheet Cam ==
Sheet Cam settings always use the last setting. So double check it's what you want.

Origin is bottom left. Origin on the machine is back left. Brown box is the material size, but it doesn't need to be set.

It's a good idea to have a bounding box on your work so it's placed correctly.

Isolate paths by selecting them then put them in a new layer. This includes the previously mentioned bounding box.

Cuts can be inside edge, outside edge or on the line. A lead in is a good idea to help keep the cuts clean. Lead out has not been tested but may help.

=== Manual Controls ===
* Arrow keys move X/Y
* Shift PageUp/PageDown moves the Z axis

Click the zero button to set home. (this is from memory, please correct -- Burton)

== Todo List ==

* Documentation

Squareness todo:

* Physical end stops - probably want to move the wiring out of the X axis tubes for this
* Limit switches on A-axis (slaved to X, the rail against the wall)

This will allow both manual squareness and automatic machine homing. Mach 3 has a routine that will home the X axis with the slave, then adjust which ever one did not hit the home switch independently.

Water table todo:

* <s>Fix 2 pin hole leaks (one at each end of tank)</s>
* <s>Fit bladder input line (so it doesn't collect crap in the tank)</s>
* Wash out old compressor tank
* <s>Trim the top of the side where the A axis hardware grazes the top of the tank.</s>
* Paint the outside of the tank
* <s>Treat the water with the green goo</s>

Plumbing/wiring todo:

* Extend air line to under table to create a manifold for table mounted air consumers
* Run large conduit for 220 outlet for the plasma cutter
* Run small conduit for data/estop between the table and the PC
* Run black pipe for connecting the table to the bladder (old compressor tank)
* Water line from north side of the shop, with input into the old compressor tank
* Air lines to the compressor tank (one vent on from the compressor)
* Run ethernet line to PC so its not on wifi any more
* Z axis limit switches

Plate marker todo:

* Design and cut new y-axis trolly or offset plate to carry torch and marker
* Machine mount for engraver
* Mount new trolly with air slide and Z axis
* Plumbing and wiring
* Pen mount as well as engraver?

35A Fine Cut todo:

* Build floating Z axis using left over linear rail
* How to multiplex the digitise input for touch off? Relays to switch digitise input from ohmic sensor to switch on head? (and disconnect the switch from the z limit array) (the switch should be in the z limit switch array by default incase the THC plunges the torch into the work piece)

Roundness/cut quality todo:

* <s>Y Axis pulsing - new connection spigot for drive year to fix eccentric rotation of gear</s>
* Remove and clean X axis gears, reinstall and use loctite on set screws (the keep backing off)
* Make sure all bearings are right against the rails so there is no slop
* <s>Investigate backlash and configure mach3 is required</s> - 0.0001 on X, Y and A
* Get quote for installing ground rod next to the table and execute it
* Look into THC issues (cut rippling) if still present after ground rod - possible Z axis flex in the mount to the Y carriage.
* Why is the THC seeing ~80V for a good clean cut from the hypertherm? Is the internal voltage divider broken (is this why the machine was retrofitted with a dangerous high voltage tap?)? Or is this related to a bad ground at the table?
* Motion pauses: (Seen on large 3'x2' complex cuts)
** Why are there zero move G1's at the end of curves generated with G2's
** <s>Do we need to add a CV on G-Code in the preamble of the post processor</s> - Does not appear to need this
** Smooth stepper under-run errors - I have only seen this when jogging not cutting, mostly related to rapiding the Z, maybe reduce the micro stepping on the driver for the new threaded drive step count is huge per inch which could be hurting us
** <s>Axis and Core frequency tuning for the smooth stepper?</s> - Dropped to 64k on X,Y,A
** <s>Look ahead tuning</s> - increased to 150
** Is CV plasma mode hurting us?
** <s>System problems, AV jamming things up?</s> - low cpu load not an issue

Ohter things:

* Cleaning/maintenance schedule
* Shelves/lockers in the unused space under the table for project/tool/etc storage?
* Materials storage ideas?
** sheet goods
** 20-24' bar/tube stock

== Future Items ==

* Tube attachment
* scribe attachment

== Torch Consumables ==

The torch is a T45m hypertherm machine torch.

{| class="wikitable" border="1"
!colspan="3"|Consumables Change Log
|-
! Date
! What
! By
|-
|6/10/17
|electrode, nozzle
|Andrew Camardella
|-
|}

[http://www.thefabricator.com/article/plasmacutting/plasma-cutting-maintenance-are-you-throwing-money-away What does a worn electrode look like?]

Torch tips components are consumables. If you are getting a wide kerf or the plasma torch isn't cutting through the materials anymore you may need to change the tip parts. To change the consumables disconnect the ground clip from the black retaining cap and unscrew the entire tip from the retaining cap.

=== Standard ===
* Shield P/N: 220673
* Deflector P/N: 2206732
* Retaining Cap - Ohmic P/N: 220719
* Nozzle P/N: 220671
* Electrode P/N: 220669
* Swirl Ring P/N: 220670

=== Fine Cut ===

'''THERE IS CURRENTLY NO POST PROCESSOR FOR RUNNING WITH THESE CONSUMABLES INSTALLED'''

'''NOTE''': These parts are for a t30 unshielded torch, they are compatiable with the T45m when it is run at a setting lower than 30A and cutting materials thinner than 3/16". Ohmic sensing will not work with these parts installed.

* Deflector P/N: 2206732
* Retaining Cap - Ohmic P/N: 220483
* Nozzle P/N: 220480
* Electrode P/N: 220479
* Swirl Ring P/N: 220478

[[:File:T45m.pdf|Consumables catalog page]]

== Feeds and Speeds ==

=== T45m Shielded Consumables ===

==== Mild Steel ====

{| class="wikitable"
!colspan="5"|
!colspan="2"|Recommended
!colspan="2"|Maximum
|-
!Arc Current (a)
!Material Thickness
!Torch-to-work distance (in)
!Initial Piece hieght (in)
!Pierce time delay (s)
!Cut Speed (ipm)
!Arc Voltage (V)
!Cut Speed (ipm)
!Arc Voltage (V)
|-
|rowspan="4"|30
|0.018" 26Ga
|rowspan="4"|0.06"
|rowspan="4"|0.15"
|rowspan="3"|0.0
|?
|117
|400
|118
|-
|0.030" 22Ga
|?
|116
|400
|117
|-
|0.036" 20Ga
|?
|115
|400
|117
|-
|0.060" 18Ga
|0.2
|?
|111
|280
|115
|-
|rowspan="12"|45
|0.036" 20Ga
|rowspan="12"|0.06"
|rowspan="8"|0.15"
|rowspan="2"|0.0
|380
|115
|400
|112
|-
|0.060" 16 Ga
|150
|116
|400
|115
|-
|0.075" 14Ga
|0.1
|150
|117
|360
|115
|-
|0.105" 12Ga
|0.3
|130
|117
|240
|115
|-
|0.135" 10Ga
|0.4
|110
|117
|175
|115
|-
|0.188" 3/16"
|0.5
|85
|118
|110
|115
|-
|0.250" 1/4"
|0.6
|60
|120
|75
|116
|-
|0.375" 3/8"
|0.9
|32
|122
|40
|116
|-
|0.500" 1/2"
|colspan="2" rowspan="4"|Edge Start Recommended
|4
|132
|25
|125
|-
|0.625" 5/8"
|3
|138
|14
|127
|-
|0.750" 3/4"
|2
|140
|10
|131
|-
|1.000" 1"
|?
|146
|5
|142
|-
|}

==== Stainless Steel ====

{| class="wikitable"
!colspan="5"|
!colspan="2"|Recommended
!colspan="2"|Maximum
|-
!Arc Current (a)
!Material Thickness
!Torch-to-work distance (in)
!Initial Piece hieght (in)
!Pierce time delay (s)
!Cut Speed (ipm)
!Arc Voltage (V)
!Cut Speed (ipm)
!Arc Voltage (V)
|-
|rowspan="4"|30
|0.018" 26Ga
|rowspan="4"|0.06"
|rowspan="4"|0.15"
|rowspan="3"|0.0
|?
|117
|400
|123
|-
|0.030" 22Ga
|?
|116
|400
|121
|-
|0.036" 20Ga
|?
|115
|400
|119
|-
|0.060" 18Ga
|0.2
|?
|111
|185
|118
|-
|rowspan="12"|45
|0.036" 20Ga
|rowspan="12"|0.06"
|rowspan="8"|0.15"
|rowspan="2"|0.0
|?
|115
|400
|109
|-
|0.060" 16 Ga
|138
|116
|400
|125
|-
|0.075" 14Ga
|0.1
|?
|117
|360
|115
|-
|0.105" 12Ga
|0.3
|?
|117
|200
|116
|-
|0.135" 10Ga
|0.4
|?
|117
|155
|118
|-
|0.188" 3/16"
|0.5
|?
|118
|85
|118
|-
|0.250" 1/4"
|0.6
|?
|120
|55
|120
|-
|0.375" 3/8"
|0.8
|?
|122
|32
|121
|-
|0.500" 1/2"
|colspan="2" rowspan="2"|Edge Start Recommended
|?
|?
|18
|128
|-
|0.750" 3/4"
|?
|?
|9
|131
|-
|}

==== Aluminium ====

{| class="wikitable"
!colspan="5"|
!colspan="2"|Recommended
!colspan="2"|Maximum
|-
!Arc Current (a)
!Material Thickness
!Torch-to-work distance (in)
!Initial Piece hieght (in)
!Pierce time delay (s)
!Cut Speed (ipm)
!Arc Voltage (V)
!Cut Speed (ipm)
!Arc Voltage (V)
|-
|rowspan="3"|30
|0.018" 26Ga
|rowspan="3"|0.06"
|rowspan="3"|0.15"
|0.0
|360
|117
|400
|120
|-
|0.060" 16Ga
|rowspan="2"|0.2
|340
|118
|400
|121
|-
|0.075" 14Ga
|215
|118
|270
|121
|-
|rowspan="11"|45
|0.060" 16Ga
|rowspan="12"|0.06"
|rowspan="7"|0.15"
|rowspan="3"|0.0
|360
|116
|400
|114
|-
|0.075" 14Ga
|340
|117
|400
|116
|-
|0.105" 12 Ga
|280
|120
|360
|119
|-
|0.135" 10Ga
|0.1
|220
|122
|280
|120
|-
|0.188" 3/16"
|0.2
|100
|123
|130
|120
|-
|0.250" 1/4"
|0.3
|80
|123
|100
|120
|-
|0.375" 3/8"
|0.5
|33
|130
|42
|125
|-
|0.500" 1/2"
|colspan="2" rowspan="2"|Edge Start Recommended
|20
|134
|25
|130
|-
|0.750" 3/4"
|8
|143
|10
|138
|-
|}

=== T30v Unshielded Fine cut Consumables ===
'''THERE IS CURRENTLY NO POST PROCESSOR FOR RUNNING WITH THESE CONSUMABLES INSTALLED'''
==== Mild Steel ====
{| class="wikitable"
!colspan="5"|
!colspan="2"|Recommended
!colspan="2"|Maximum
|-
!Arc Current (a)
!Material Thickness
!Torch-to-work distance (in)
!Initial Piece hieght (in)
!Pierce time delay (s)
!Cut Speed (ipm)
!Arc Voltage (V)
!Cut Speed (ipm)
!Arc Voltage (V)
|-
|rowspan="7"|30
|0.018" 26Ga
|rowspan="7"|0.02
|rowspan="7"|0.1
|rowspan="3"|0.0
|350
|105
|400
|98
|-
|0.030" 22Ga
|320
|102
|400
|103
|-
|0.036" 20Ga
|280
|101
|350
|100
|-
|0.060" 16Ga
|0.2
|175
|97
|220
|100
|-
|0.075" 14Ga
|rowspan="3"|0.4
|120
|98
|150
|97
|-
|0.105" 12Ga
|80
|96
|100
|96
|-
|0.135" 10Ga
|50
|100
|65
|101
|-
|}

==== Stainless Steel ====
{| class="wikitable"
!colspan="5"|
!colspan="2"|Recommended
!colspan="2"|Maximum
|-
!Arc Current (a)
!Material Thickness
!Torch-to-work distance (in)
!Initial Piece hieght (in)
!Pierce time delay (s)
!Cut Speed (ipm)
!Arc Voltage (V)
!Cut Speed (ipm)
!Arc Voltage (V)
|-
|rowspan="7"|30
|0.018" 26Ga
|rowspan="7"|0.02
|rowspan="7"|0.1
|rowspan="3"|0.0
|350
|103
|400
|102
|-
|0.030" 22Ga
|320
|198
|400
|100
|-
|0.036" 20Ga
|300
|97
|380
|98
|-
|0.060" 16Ga
|0.2
|150
|99
|190
|98
|-
|0.075" 14Ga
|rowspan="3"|0.4
|110
|101
|135
|97
|-
|0.105" 12Ga
|60
|101
|75
|98
|-
|0.135" 10Ga
|45
|102
|55
|97
|-
|}

==== Aluminium ====
{| class="wikitable"
!colspan="5"|
!colspan="2"|Recommended
!colspan="2"|Maximum
|-
!Arc Current (a)
!Material Thickness
!Torch-to-work distance (in)
!Initial Piece hieght (in)
!Pierce time delay (s)
!Cut Speed (ipm)
!Arc Voltage (V)
!Cut Speed (ipm)
!Arc Voltage (V)
|-
|rowspan="5"|30
|0.036" 20Ga
|rowspan="5"|0.02
|rowspan="5"|0.1
|rowspan="3"|0.0
|320
|107
|400
|105
|-
|0.060" 16Ga
|240
|104
|300
|103
|-
|0.075" 14Ga
|190
|104
|1240
|103
|-
|0.105" 12Ga
|rowspan="2"|0.2
|145
|103
|180
|103
|-
|0.135" 10Ga
|95
|101
|120
|101
|-
|}

== Wiring ==

=== Stepper Coils ===

* A+ Black
* A- Green
* B+ Red
* B- Blue

=== Smooth Stepper Pin Mapping ===

==== C25 Interface board pins ====

{| class="wikitable"
!colspan="3"|SmoothStepper
!colspan="2"|Target Device
|-
!Port
!Pin
!Type
!Device
!Connection
!Wire color
|-
|1
|1
|Output
|X Stepper Driver
|Pul+
|Green
|-
|1
|2
|Output
|X Stepper Driver
|Dir+
|Red
|-
|1
|3
|Output
|X Stepper Driver
|Ena+
|-
|1
|4
|Output
|Y Stepper Driver
|Pul+
|Green
|-
|1
|5
|Output
|Y Stepper Driver
|Dir+
|Red
|-
|1
|6
|Output
|Y Stepper Driver
|Ena+
|-
|1
|7
|Output
|THC
|Step In
|Green
|-
|1
|8
|Output
|THC
|Dir In
|Red
|-
|1
|9
|Output
|Z Stepper Driver
|Ena+
|-
|1
|10
|Input
|Plasma Interface Connector
|Torch Lit Out
|-
|1
|11
|Input
|Z Limit Connector
|2
|Grey
|-
|1
|12
|Input
|Y Limit Connector
|2
|Grey
|-
|1
|13
|Input
|X Limit Connector
|2
|Grey
|-
|1
|14
|Output
|A Stepper Driver
|Pul+
|Green
|-
|1
|15
|Input
|E-Stop Switch
|Switch contact NC
|Grey
|-
|1
|16
|Output
|A Stepper Driver
|Dir+
|Red
|-
|1
|17
|Output
|A Stepper Driver
|Ena+
|-
|2
|1
|Output
|Torch Relay
|Coil +
|-
|2
|2
|Input
|Touch off probe connector
|Pin 2
|-
|2
|3
|Input
|-
|2
|4
|Input
|-
|2
|5
|Input
|-
|2
|6
|Input
|-
|2
|7
|Input
|-
|2
|8
|Input
|-
|2
|9
|Input
|-
|2
|10
|Input
|-
|2
|11
|Input
|-
|2
|12
|Intput
|-
|2
|13
|Input
|-
|2
|14
|Output
|THC Enable relay
|Coil +
|-
|2
|15
|Input
|-
|2
|16
|Output
|-
|2
|17
|Output
|}

== Configuration ==

=== Stepper Drivers ===
Steps per inch: 1358

Driving current:
* SW1 ON
* SW2 ON
* SW3 OFF

Holding Current:
* SW4 OFF

Steps:
* SW5
* SW6
* SW7
* SW8

== Parts ==

* Steppers:
** Wantai 57BYGH115-003
** Nema 23 stepper motor
** 425oz-in torque
** 3 Amp
* Drivers:
** Wantai DQ542MA
** Manual: [[File:DQ542MA_English_Manual.pdf]]
* SmoothStepper Ethernet
* C25 Break out board
** https://cnc4pc.com/motion-control/breakout-boards/c25-smooth-stepper-terminal-board.html
** Manual: [[File:C25R3_1_USER_MANUAL.pdf]]

==maintenance ==
[[CNC_Plasma_Cutter_maintenance|maintenance page]]

== Authorization ==

=== Authorizers ===

* Tom Judge - 45A and 30A fine cut consumables
* Andrew Camaradella - 45A auto Z only
* Ron Olson - 45A auto Z only

=== List of Currently Authorized Users - 45A Auto Z ===

{| class="wikitable" border="1"
! Qualified Member
! Trained By
! Date
|-
|Tom Judge
|Danger Committee
|
|-
|Andrew Caramdella
|Danger Committee
|
|-
| Jake Chaitkin
| Ron Olson
| 6/9/2018
|-}
|}

=== List of Currently Authorized Users - 30A Fine Cut ===

{| class="wikitable" border="1"
! Qualified Member
! Trained By
! Date
|-
|Tom Judge
|Danger Committee
|
|-
|Casey Olson
|Tom Judge
|-
| Jake Chaitkin
| Ron Olson
| 6/9/2018
|-}
|-
|}

Ryobi Pressure Washer 1600psi

2018-05-20T00:23:13Z

Daddybird:

{{Template:EquipmentPage
|owner = PS:One
|hostarea = General Area
|certification = Yes
|hackable = No
|model = MODEL NUMBER
|serial = SERIAL NUMBER
|arrived = DATE
|where = Boiler Room
|doesitwork = Yes
|contact = Andrew Camardella
|value = $150
|image = "IMAGENAME.JPG" (case sensitive, this is whatever you named the image when you uploaded it)
}}

Originally purchased to clean flaky paint, greasy items (old compressor tank for cnc plasma cutter water table), and also clean silkscreens.

Usage:
# Wet the hose gaskets on both ends. This will help you screw the hose into the pressure washer body and the pressure washer wand.
# Screw the hose into the body. Be sure the thread is lined up properly.
# Screw the hose into the wand - mind the screw thread.
# Put the wand end onto the wand's body. Be sure it is in correctly.
# Drag the hose from by the small metals sink outside.
# Bring the pressure washer outside as well.
# Check that the grit trap is in the hose connector, and screw in the hose.
# Make sure the pressure washer is OFF. (the 0 button should be down).
# Plug in the pressure washer, and turn on the hose.
# Check that there's water going to the pressure washer by pressing the button on the wand. Even without the power being on, water should come out. If not, you need to find out why, as this is the one thing most likely to damage it.
# Turn it on and wash.

Only use the proper soap!

Cleaning up:
# Turn it off.
# Turn off the water and unplug the washer.
# Depress the button to remove any extra pressure in the system.
# I like to detach the nozzle and pressure hose, then put it somewhere (small metals sink, possibly) to drip dry while cleaning up.
# Detach the garden hose, letting it drain away from the building.
# Coil the cord and put the pressure washer back in the box.
# Put the garden hose away. It should be under the sink where people won't trip.
# Put the hose and wand back in the box.
# Put the box where you found it (currently in the boiler room).

BOSS LS-3655 150w Laser Engraver

2018-05-20T00:10:27Z

Daddybird: /* Resources */

{{ Template:EquipmentPage
| owner=PS:One
| model=BOSS LS-3655 150w
| serial=SERIAL NUMBER
| arrived= January 2017
| doesitwork=yes
| contact=[[CNC|CNC Area Host]]
| where=CNC Shop
| certification=yes
| hackable=no
| value=$17,000
| image = BossLaser2.jpg
| hostarea = CNC
}}

== About ==

The BOSS LS-3655 is an industrial CO2 laser engraver with a 36" x 55" bed, supporting over-sized material pass-thru on four sides and up to 7 inches of table depth. Originally shipped with 100W tube, but that has been replaced with 150W tube in May, 2017.

== Status ==

* (2018/02/26) Working. Z-Axis motor having some issues? 2-25-2018
* (2017/05/20) 150W Tube & Power Supply installed. Alignment & focusing pending.
* (2017/06/12) The laser has been aligned and focused. 2" Laser lens focal depth set to 5.1mm.

== Usage Policy ==

The laser cutter is easily one of the most used machines at PS1. Due to this demand we request the cooperation of all members to share the laser cutter and associated computer. First and foremost, the practice "being excellent" should be observed at all times; respect yourself, other members, and the equipment. This is a usage policy so that everyone can use the laser:

* Any user not actively test cutting or cutting will cede the computer and laser to the next person waiting in line, as soon as that waiting user notifies the current computer user. If you are still designing your file, please do so on another computer. Artastic (another PC upstairs) in the Crafts Area also has a copy of Adobe Illustrator.
* If someone is waiting in line to use the laser, no active test cut or cut series shall be longer than 1 hour. No jobs will be allowed to start that overrun the 1 hour time limit when a new user is waiting.
* In the case that your last cut is longer than the 1 hour time limit, and a waiting user presents themselves after the cut has started, the cut job shall be allowed to finish and the waiting user will be allowed to set up their file in their own user account, during the cutting period.
* Continuous cutting shall not exceed 3 consecutive hours without a half hour break for the laser to cool. If a new user arrives before or during the cooling period the current user shall cede the laser to the next user, and the next user will wait for the cooling period to finish and the cooling period shall not count towards the 1 hours limit should another user present themselves.
* Waiting users shall notify the current user verbally that they are waiting and where they will be waiting until it is their turn. If multiple users are waiting, the next waiting user must start their test cutting or cut job within 10 minutes of being notified of a laser opening. The current user will keep a record of who is waiting, where they will be, and notify subsequent users of the status of the queue. The current user will find the next waiting user and verbally inform them that the laser is available.

== Authorizations ==

How to get authorized: contact the CNC Area Host or one of the Volunteer Authorizers. There's a sign posted in the CNC area that has names of people that are laser authorizers.

Since demand fluctuates, and there are a random group of new and old members that want to be authorized at any one time, it makes sense to find the others and figure out your group schedule/plan. There generally is NOT going to be a calendar-based or widely publicized meetup event; you will have to conctact and make arrangements with actual people, at least until the Canvas Learning Management System is implemented more fully. http://canvas.pumpingstationone.org

=== Preparing yourself to become authorized ===

You need a few things to optimize and expedite your experience:

* 1. Know what you're doing as best as you can - come pre-trained on your own time to make the authorization go smoother and faster.
* 2. Have a PS1 username set up before starting the authorization http://members.pumpingstationone.org
* 3. Have some familiarity with the kinds of files you would bring to the Boss to cut.

To that end; you could download and become familiar a bit with RDWorks, the software you will use to drive the Boss. Links are on this page.
You can read a bit of the manual, which is also linked on this page, or watch some YouTube videos.

To set up a PS1 username (this is NOT the email address you use, it's a different thing, it's entirely special to PS1) go to http://members.pumpingstationone.org, and click "Activate" ... if you don't already have a PS1 username.

You will want to bring files in from Adobe Illustrator in Illustrator format, with lines set to have SOME sort of stroke, I'd recommend 1 point stroke, and some simple color applied to the stroke for each "layer" you want to have in RDWorks. You will want to have one color/layer assigned for each type or strength of cut/engrave you'll be doing in that job. For instance, you might want a deep engraving, a shallow engraving, a cut that goes all the way through the material and maybe a cut that just barely touches the top surface (called a 'kiss cut) and that would mean you would need four distinct colors of stroke used in your file. You should investigate the usefullness of SVG, DXF and DWG files as well, but Illustrator files will give you the best first experiences.

Authorizations will be limited to small groups, e.g. 4 or less, due to nature of the equipment.

==Power-On & Safety Check==
# Check Wiki for status updates
# Check if material is safe to cut: refer to the wiki for a list of safe and unsafe materials for cutting
# Check Fire Extinguisher: Make sure it is close by and charged
# Release Emergency Stop: Rotate red button until it releases
# Turn Power Key: Display will load up
# Turn on Air Assist & Chiller: Flip the switch and ensure exhaust & chiller are on and functioning. Double check chiller temp with laser temp.
* RD Works
# Load Program & Check USB Connection Status
# Importing Files: Importing AI, DXF, SVG, & images
# Introducing User Interface: quick review of UI including Drawing, Grouping, Preview, Work Tab, Layers, Laser Work, & Head Position
# Detailed Overview of Work Tab: major cutting settings & parameters reside here
# Starting a Job
# Saving a File
* Boss Laser Operation
# LED Keypad Overview
# Adjusting the Z-Height: raise and lower bed
# Autofocus: Setting focal height for material
# Setting Origin
# Jogging the Laser Head in XY
# Adjusting High Pressure Air Regulator: Changing the compressed air flow
# Loading a File via USB Port
# Load & Unload honeycomb
# Cleaning Up & Clearing Catch Tray
* Individual Walkthrough: each member is required to perform the following:
# Start-Up the machine
# Turn on exhaust, air-assist, & chiller
# Place Material, autofocus, set origin
# Load RDworks, create 3 layers (Cut, Scan, Dot) & run laser job
# Shutdown machine & clear catch tray

== Settings ==
* Honeycomb vs. Aluminum Lamella : The honeycomb is used for engraving and pieces that benefit from precise leveling. Use the aluminum lamella (slats under honeycomb) for cutting through to reduce flashback and improve airflow (warning small pieces will fall through).

* 4" Lens Focus Depth 38.5mm (this is a just an approximate, FD calibration must be performed each time the lens is changed)
* 2" Lens Focus Depth 5.3mm (this is a just an approximate, FD calibration must be performed each time the lens is changed)

== Procedures ==

=== Powering On Machine ===
* Check Fire Extinguisher
* Release Emergency Stop button
* Turn power key
* Turn on air assist & water chiller Switch & ensure both are functioning

=== Powering Off Machine ===
* Turn key to off position, leave key in the lock
* Push emergency stop button in
* Turn the chiller, blower and air assist off using the main switch (switch with identifying lasercut plate)
* Reset the area by cleaning up any stray cut materials. Clean and straighten the area around the laser.

== Material Safety & Information ==
=== Safe Materials for Cutting ===
** Plastics:
*** ABS (acrylonitrile butadiene styrene)
*** Acrylic (also known as Plexiglas, Lucite, PMMA)
*** Delrin (POM, acetal)
*** High density polyethylene (HDPE) – melts badly
*** Kapton tape (Polyimide)
*** Mylar (polyester)
*** Nylon – melts badly
*** PETG (polyethylene terephthalate glycol)
*** Polyethylene (PE) – melts badly
*** Polypropylene (PP) – melts somewhat
*** Styrene
*** Two-tone acrylic – top color different than core material, usually for custom instrumentation panels, signs, and plaques.
** Foam:
*** Depron foam – often used for RC planes.
*** EPM
*** Gator foam – foam core gets burned and eaten away compared to the top and bottom hard shell.
** Other:
*** Cloths (leather, suede, felt, hemp, cotton)
*** Papers
*** Rubbers (only if they do not contain chlorine Teflon (PTFE, Polytetrafluoroethylene)
*** Woods (MDF, balsa, birch, poplar, red oak, cherry, holly, etc.)

=== MATERIALS NOT SAFE ===
** Polycarbonate (PC, Lexan) due to the fumes.
** Any material containing chlorine such as PVC & Vinyl

==== Aligning Materials ====
** The table is not aligned with the laser's X-Y axis
** To align your material use the laser pointer by holding one axis constant while moving along the other axis to align corners of your material

== Resources ==

The proprietary LaserWORKS software can be downloaded from BOSS here - https://www.bosslaser.com/laser-software/ However, the current version (8.01.28) of the laser software seems to require admin rights every time it's used. So instead you may want to download the [https://appdb.winehq.org/objectManager.php?sClass=version&iId=35522 8.01.18 version of the software] until this is fixed.

Manuals for the BOSS laser and the LaserWORKS software are located here - https://www.bosslaser.com/download-manuals-guides/

[https://www.bosslaser.com/laser-test-files BOSS test files are available here]

[https://www.bosslaser.com/laser-settings Some laser settings from Boss]

[https://www.facebook.com/groups/900528680076062/ Excellent Facebook Group for RDWorks Tips and help]

[https://rdworkslab.com/index.php Forum for RDworks user group]

If the language for RDWorks (the Boss control software) is showing garbage, [https://www.youtube.com/watch?v=gwhQ2xzV1xo&feature=youtu.be follow this video].

== Youtube Channels ==
Following are a couple good YouTube Channels with lots of information on the software and machine
* [https://wiki.pumpingstationone.org/index.php?title=Special:UserLogin&returnto=BOSS+LS-3655+150w+Laser+Engraver SarbarMultimedia]
* [https://www.youtube.com/channel/UCOuDR90TZ24qEFFIbVmDAMw Thunder Laser]

== Cleaning & Maintenance ==

* When changing the lens, make sure the convex/domed side of the lens is facing upwards (towards the ceiling)
* Focus Lens should be cleaned once a week with Acetone or Denatured Alcohol

== List of Currently Certified Users ==

{| class="wikitable" border="1"
! Qualified Member
! Trained By
! Date
|-
|Andrew Camardella
|Danger Committee
|
|-
|Matt Keith
|Danger Committee
|
|-
|Skylar Nova
|Danger Committee
|
|-
|Jason Araujo
|Danger Committee
|
|-
|Ray Doeksen
|Danger Committee
|
|-
|Matt Meshulam
|Danger Committee
|
|-
|Ashish Jasani
|Danger Committee
|
|-
|Joe Juhnke
|Ashish Jasani
|
|-
|Casey Olson
|Ray Doeksen
|
|-
|Andrew Vaughan
|Burton Kent
|
|-
|[[User:mct|McTavish McArdle]]
|Burton Kent
|
|-
|Erik Wessing
|Ray Doeksen
|
|-
|Theo T
|Ray Doeksen
|
|-
|Molly Adamski
|Joe Juhnke
|
|-
|[[User:deadwisdom|Brantley Harris]]
|Ray Doeksen
|
|-
|Amir Badri
|Sky Nova
|
|-
|Aaron Carlock
|Jeff Z
|
|-
|Gabe Tavas
|Joe Juhnke
|
|-
|Sam Dreyer
|Jeff Z
|
|-
|Stephanie Pelzer
|Jeff Z
|
|-
|Nick Prorok
|Jeff Z
|3/02/2018
|-
|Alisha Ciardi
|Burton Kent
|03/2018
|-}
|-
|Bao Nguyen
|Zander Bueno
|05/04/2018
|-

[[Category:Laser Cutter]]
[[Category:Fabrication]]
[[Category:Certification Clarification Needed]]

Vinyl Cutter

2018-05-14T23:37:56Z

Daddybird: /* Tips on how to use (After Certified) */

{{Template:EquipmentPage
|owner=PS:One
|model=Jaguar II |serial=
|arrived=2012
|doesitwork=yes
|contact=Donald Jacobson
|where=Upstairs
|certification=yes
|hackable=no
|value=$2300
|image= Vinylcutter.jpg
|hostarea = CNC
}}

== Status ==
2016-03-12: Cutter operational but some issues with the depth of cut which needs to be adjusted.

== Authorization ==

Viral. Any authorized user can train and authorize another. Record authorizations on this wiki page, below. At the moment there are no regularly scheduled authorization sessions. Contact/ask an authorized user or the area host.

== Tips on how to use (After Certified) ==

The user guide is here
[https://www.proworldinc.com/skin/frontend/cls/proworld/pdf/jagII.pdf]

See a [https://www.youtube.com/watch?v=HjMWrVCrecA&t=520s Useful Video]

Loading the Media.

* Raise the lever on the upper back right of the machine
* Slide in the media. It helps to have a rectangular piece so the machine can recognize the size. Center it over some of the grooved rollers so they are as close to the edges as possible.
* Slide the pinch rollers from behind over the grooved roller you chose.
* Lower roller with the lever.
* Read the display and push the arrow button for the type of media you are loading. For a single sheet (not a roll), for example you would press the right arrow (see screen shot below)

== Importing ==

The Software used is CoCut Standard 2015. We no longer use the software that came with the cutter.

The software does not import svgs, but does import Adobe Illustrator files. Open your SVG in Illustrator and resave it as an .ai file. Then import your file into CoCut Pro.

Notes:

* Make sure to check any files you download from the internet for hidden artifacts
* Make sure all your borders/strokes are set to 0px or you will get 3 cuts for the border (inner stroke, outer stroke and object edge)

== Cutting ==

When your graphic is ready to cut, click the File...Cut/Plot menus. This should bring up a couple of new windows. One is the Production Manager. This may show some older, incomplete jobs from failed attempts. Delete those old jobs.

The other window shows your setup. Note the orientation of your job. You may want to rotate it to fit the orientation of your vinyl in the plotter. Use the turned stick man button at the bottom to do this.

Make sure you set the size of your vinyl.

Note:

The output settings for speed and pressure do not work on our machine you must change these settings on the machine itself.

* Take the cutter offline (hit on/off line button)
* Hit the speed or pressure button
* Use arrow keys to change value
* Hit enter
* Put the cutter online by hitting the on/off line button a second time

=== Blades ===

There are 3 types of blade for the cutter:

* Black Cap - Fine detail cutting - http://www.signtechnologies.net/catalogue/341/8/cutters-and-plotters/P-gcc-jaguar-ii-cutting-plotter
* Green Cap - Sandblasted/reflective materials - http://www.signtechnologies.net/catalogue/84/8/cutters-and-plotters/blades/P-gcc-blade-green-cap-for-sandblastreflective-material
* Red Cap - Standard Vinyl - http://www.signtechnologies.net/catalogue/83/8/cutters-and-plotters/blades/P-gcc-blade-red-cap-for-standard-vinyl

These blades will be arriving shortly.

== Purchasing Materials ==

New Materials can be purchased locally through [http://www.raycosignsupply.com/vinyl-material Rayco] near Peterson and Pulaski, the plotter size is 24 inches. Generally you are on your own for materials; if you use the materials that are near the cutter, it is fair game, and it would be cool if you put some money in the nearby gray donation box or ask the area host how to contribute. Area hosts use donations to buy more materials and parts for machines. Suggested donation $1/square foot?
* Economy/Intermediary stock is for the majority of projects and has an expected life of 3 years
* High performance stock is intended for cars and boats and has an expected life of 7 years.

* Transfer tape: http://www.ebay.com/itm/6-APPLICATION-TRANSFER-Paper-TAPE-300-ft-roll-for-Vinyl-Cutter-PLOTTER-FRESH-/351496781486?hash=item51d6d73eae

== Recommended Certifiers ==

* Elizabeth Koprucki

== Certified Users ==

{| class="wikitable" border="1"
! Qualified Member
! Trained By
|-
|Donald Jacobson
|Donald Jacobson
|-
|-
|Bart dring
|Donald Jacobson
|-
|Ray Doeksen
|Elizabeth Koprucki
|-
|[[User:davidfell|David Fell]]
|Elizabeth Koprucki
|-
|[[User:dbever|Derek Bever]]
|Elizabeth Koprucki
|-
|[[User:RogerMoore|Roger Moore]]
|Elizabeth Koprucki
|-
|[[User:tom4writer|Tom Forajter]]
|Elizabeth Koprucki
|-
|[[User:ad9581|Arturo Duarte]]
|Elizabeth Koprucki
|-
|[[User:funk|Tyler Natoli]]
|Elizabeth Koprucki
|-
|Sloan Lavery
|Elizabeth Koprucki
|-
|Tyler Hsu
|Elizabeth Koprucki
|-
|Casey Olson
|Justin and Derek!
|-
|[[User:lgaboarder|Jeff McBride]]
|Elizabeth Koprucki
|-
|[[User:Sparr|Clarence Risher]]
|Elizabeth Koprucki
|-
|[[User:ironwill|Will Garza]]
|Elizabeth Koprucki
|-
|[[User:emertonom|Nick Halderman]]
|Elizabeth Koprucki
|-
|[[User:aaronmintz|Aaron Mintz]]
|Elizabeth Koprucki
|-
|Matt Makris
|Elizabeth Koprucki
|-
|Matt Meshulam
|Elizabeth Koprucki
|-
|Mark Cabael
|Elizabeth Koprucki
|-
|[[User:amishhammer|Tom Judge]]
|Elizabeth Koprucki
|-
|[[User:speedebikes|Todd Allen]]
|Elizabeth Koprucki
|-
|[[User:lucas|Lucas Goossen]]
|[[User:amishhammer|Tom Judge]]
|-
|Sonia Yaco
|Elizabeth Koprucki
|-
|Alex Trimm
|Elizabeth Koprucki
|-
|Davis Mazariegos
|Elizabeth Koprucki
|-
|Knute Martell
|Elizabeth Koprucki
|-
|Ryan Neuman
|Elizabeth Koprucki
|-
|Scott Drane
|Elizabeth Koprucki
|-
|James Huber
|Knute Martell
|-
|[[user:kuroishi|Doorman Dave]]
|Elizabeth Koprucki
|-
|Mike Mandrea
|Tom Judge
|-
|[[user:wessing|Erik Wessing]]
|[[user:justin|Justin Conroy]]
|-
|Michael Patton
|Andrew Camardella
|-
|Burton Kent
|Tom Judge
[[Category:Shop Equipment]]
|-
|Niko Hawley
|Tom Judge
|-
|Tom Boeman
|Tom Judge
|-
|Will Alt
|Tom Judge
|-
|[[user:slingerland|Michael Slingerland]]
|Andrew Camardella
|-
|[[User:bobsabayesian|Bob Loos]]
|Andrew Camardella
|-
|[[User:mct|McTavish McArdle]]
|Andrew Camardella
|-
|[[User:esp|Simon Pyle]]
|Andrew Camardella
|-
|Zachery Small
|Michael Patton

|-
|[[User:Leo|Leo]]
|Mohamed Dardiri
|-
|Amir Badri
|Leo Rodman

|-
|Jackson Ammenheuser
|Leo Rodman

|-
|[[skynaya|Skylar Nova]]
|Leo Rodman

|-
|[[Mari Belmares]]
|Andrew Camardella

|-
|[[user:headlight|James Villalpando]]
|Andrew Camardella

|-
|[[user:headlight|Jeremy Shaw]]
|Leo Rodman

|-
|Ashley Borg
|Justin Conroy

|-
|Molly Adamski
|Jeremy Shaw

Member Storage Registry

2018-04-25T03:27:52Z

Daddybird: /* Catwalk Shelf Registry */

Full Members are allowed storage space, and may claim an unoccupied, unclaimed member storage locker or member storage shelf. A locker or shelf could be empty but still be claimed/occupied. Label your shelf or locker adequately.

If you find something on this page that seems inaccurate, Please contact the affected member or the General Area Host. Please do not edit other members' entries.

'''You should use the same name here that you have listed on [https://members.pumpingstationone.org the members site] so that we can verify your membership status. This will help you avoid your storage space getting ticketed and you having to do something about it later.'''

== Catwalk Shelf Registry ==

The catwalk is where the majority of our [[Systems]] infrastructure is located. Additionally, member shelves are on the catwalk.

'''Please do not store items on the catwalk, except on member shelves. Loose items will be ticketed'''

On the catwalk, numbering starts with the upper left shelf and goes down, then across. The top row is ignored because the opening is too obstructed to be used.

{|Class="wikitable sortable" border="1" style="td { border: 1px solid #000000}"
|-
! Shelf No. !! Member Name
|-
| C1 || Ron Olson
|-
| C2 || Jennie P.
|-
| C3 || Mark
|-
| C4 || [[User:Wessing|Erik Wessing]]
|-
| C5 || Sam Paris
|-
| C6 || [[User:Adamstein|Adam Stein]]
|-
| C7 || Will McShane
|-
| C8 || Glenn Powers
|-
| C9 || Lyn Cole
|-
| C10 || Aushra Abouzeid
|-
| C11 || Ryan Pierce
|-
| C12 || Hilary Lee
|-
| C13 || Bo Driscoll (Michael Driscoll)
|-
| C14 || Jeff Kantarek
|-
| C15 || Ananda Stevens
|-
| C16 || Casey Olson
|-
| C17 || Shawn Blaszak
|-
| C18 || [[User:Frenchy|Frenchy]]
|-
| C19 || [[User:Bioguy|Bioguy]]
|-
| C20 || [[User:Jason|Jason Shanfield]]
|-
| C21 || Ed Bennett
|-
| C22 || Anna Yu
|-
| C23 || Rhonda Jackson (and "PAPER FOR MEMBERS")
|-
| C24 || [[User:t440music|Tommy TBones Cramer]]
|-
| C25 || Rob Riggs (Colorado Rob)
|-
| C26 || Skylar Nova
|-
| C27 || Bart Dring
|-
| C28 || Dan Locks
|-
| C29 || Burton Kent
|-
| C30 || [[user:amishhammer|Tom Judge]]
|-
| C31 || [[user:lynxkcg|John Farmer]]
|-
| C32 || [[User:Davidfell|David Fell]]
|-
| C33 || Elizabeth Koprucki
|-
| C34 || Jesse Seay
|-
| C35 || Ray Doeksen
|-
| C36 || [[user: jcmertz|Joe Mertz]]
|-
| C37 || Daniel Conrad
|-
| C38 || Peter Borah
|-
| C39 || Patrick Callahan
|-
| C40 || [[User:Hef|Hef]]
|-
| C41 || Kathryn Born
|-
| C42 || Kari Danek
|-
| C43 || Sevin Straus
|-
| C44 || Simon Pyle
|-
| C45 || Eric Stein
|-
| C46 || Bryanna Denney
|-
| C47 || Peter Antor
|-
| C48 || Michael Skilton
|-
| C49 || Matt Triano
|-
| C50 || Steve Farkas
|-
| C51 || [[user:knitmeapony|Laurie]]
|-
| C52 || Gerald
|-
| C53 || Sam Chen
|-
| C54 || [[user:Carlfk|Carl Karsten]]
|-
| C55 || Andrew Camardella
|-
| C56 || Mohamed Dardiri
|-
| C57 || Daniel Baltudis
|-
| C58 || [[User:Skm|Sheila Miguez]]
|-
| C59 || Brian Chojnowski
|-
| C60 || Brian Cuocci
|-
| C61 || Shae (Shawn Kurko)
|-
| C62 || Ron Bean
|-
| C63 || Zlatan Klebic
|-
| C64 || [[User:justin|Justin T. Conroy]]
|-
| C65 || Alejandro Drexler
|-
| C66 || Eddie Muela
|}

=== Top Catwalk Shelf ===
These shelves are difficult to impossible to reach, but adventurous people store things there anyway. Here's their status, lettered left to right:
{|Class="wikitable sortable" border="1" style="td { border: 1px solid #000000}"
|-
! Column !! Member Name
|-
| A || (unlabeled)
|-
| B || Ian Monroe
|-
| C || (unlabeled)
|-
| D || (unlabeled)
|-
| E || "Jeremy"
|-
| F || Tony Phelps and Tim Foley
|-
| G || (unlabeled)
|-
| H || (unlabeled)
|-
| I || Randy C (empty)
|-
| J || (unlabeled)
|-
| K || (unlabeled)
|}

== General Work Area Shelves ==
In the general area, numbering starts with the upper left shelf and goes down, then across.

{|Class="wikitable sortable" border="1" style="td { border: 1px solid #000000}"
|-
! Shelf No. !! Member Name
|-
| G1 || General Area Host Storage
|-
| G2 || Zack Sasnow
|-
| G3 ||
|-
| G4 || Ashley Borg
|-
| G5 || [[User:tucker|Tucker Tomlinson]]
|-
| G6 || Carlos Garcia
|-
| G7 || [[User:Mkeith|Matt Keith]]
|-
| G8 || [[User:andrewvaughan|Andrew Vaughan]]
|-
| G9 || Chris Iacullo
|-
| G10 || [[User:Ekaj|Jacob Snyder]]
|}

== Locker Registry ==

Again, numbering starts with the upper left locker and goes down, then across.

{|Class="wikitable sortable" border="1" style="td { border: 1px solid #000000}"
|-
! Locker No. !! Member Name or (apparent contents)
|-
| L1 || Eric Beauchamp
|-
| L2 || Joseph W Juhnke
|-
| L3 || Charles Barker
|-
| L4 || Dan Thomson
|-
| L5 || Jonathan Bisson
|-
| L6 || Abel Greenwald
|-
| L7 || Earl Wood
|-
| L8 || Saul Weiner
|-
| L9 || Elizabeth Arundel (Anne)
|-
| L10 || Zach Ferraro
|-
| L11 || Kushal Som
|-
| L12 || [[:Category:Metal Casting|Metal Casting]]
|-
| L13 || Erik Funkhouser
|-
| L14 || Andy Larkin
|-
| L15 || Tool Cage Re-supply
|-
| L16 || [[user:mct|McTavish McArdle]]
|-
| L17 || Jonny Panic
|-
| L18 || Jeff Paules
|-
| L19 || Glenn Trussell
|-
| L20 || Terri Pittman
|-
| L21 || Wayne Openlander
|-
| L22 || [unoccupied]
|-
| L23 || Cody Ryan
|-
| L24 || Heather Blankenship
|-
| L25 || Dubi Kaufman
|-
| L26 || Derek Bever
|-
| L27 || [unoccupied]
|-
| L28 || [unoccupied]
|-
| L29 || Mohamed
|-
| L30 || Nem Simeunovic
|-
| L31 || (Magazines)
|-
| L32 || Andy Muhic
|-
| L33 || [unoccupied]
|}

[[Category:Registry]]

CNC Plasma Cutter

2018-03-10T14:47:16Z

Daddybird: /* Authorisation */

{{Template:EquipmentPage
|owner = PS:One
|hostarea = CNC
|certification = yes
|hackable = no
|model = N.A.
|serial = N.A.
|arrived = 10/16
|where = Hot metals
|doesitwork = yes
|contact = CNC Area Host
|value = $6000
|image = IMG_4045.JPG
}}

== Authorisation ==

Authorisation requirements:

* You must have a project to compete on the tool during your authorisation
* Your drawings must be reviewed by the authoriser before your scheduled session
* Authorisations will take place with a maximum of 2 members
* You must bring your own material with at least 1'x1' excess for machine tuning
* You must be prepared for the machine to waste some material, its not perfect, be prepared for some waste

Unclear: who are the authorizers and how do you contact them?

[[CNC Plasma Cutter Authorisation]] has more details.

== Drawing guidelines ==

* No sharp corners, all corners should be filleted with at least a 1/16" radius
* The thicker the part, the larger the smallest feature
** Small holes 1/4" and under are not advisable
** Holes under 3/4" on 3/8" plate are not advisable
** Not all these sizes are learnt yet, this is why you need extra material
* Acceptable drawing formats:
** DXF
** SWF
* Acceptable drawing formats for review:
** DXF
** SWF
** AI

== PPE ==

* Number 5 shades when a job is running
* Thick gloves when handling freshly cut parts
* Hearing protection recommended
* Respirator/mask while cutting

== Procedures ==

=== Machine Startup ===

# Wipe down machine with clean dry clotha
# Log in to machine
# Turn on air
# Make sure e-stop is depressed
# Turn on control box
# Start Mach3
# Clear e-stop
# Raise Z
# Move torch to end of table
# Remove torch shield and inspect for dross build up
# Reinstall torch shield
# Turn on plasma cutter
# Check cutter status (Air/torch/etc)

=== Machine Shutdown ===

# Hit e-stop
# Exit Mach3
# Turn off plasma cutter
# Turn off air
# Turn off control box
# Clean torch shield
# Sweep under table
# Wipe down machine with clean dry cloth
# Wipe down computer
# '''Leave the area cleaner than you found it'''

=== Running A Job ===

=== Starting a job from a particular line of code (needs update)===
*Run from here
*Select next line

=== Previewing a job (needs update) ===
*Load file
*Select the 'Run BLK' button in the interface or type Alt-N
*Press the start job button - this will step through each line of code
(warning: includes torch homing and torch ignite so be careful)
*You can step backwards though a job by pressing the 'reverse order' button.

=== Job Crashes ===

==== SmoothStepper Buffer Under run ====

'''Your work piece is trash, start again, home position lost'''

# Click through error
# Start your job again

Causes:

* Communication error between smooth stepper and PC

==== Touch off failure ====

'''Your work piece is not trash yet, but might be if you don't follow these steps'''

One of the following happened:

* Touch off get stuck with torch touching the plate
* Touch off fails to detect plate and rams into the plate
* Error probe ignored in status bar - If this is the case clean the shield nozzle, dross has gotten inside, do not move work piece

Do This:

# Hit escape '''ONCE''', not e-stop, not reset, escape
# Double click in the g-code window to display line numbers eg: 20:N0100 G91.... rather than N0100 G91....
# Look for the current line, it should be highlighted and be: G31 Z -100
# Look up a few lines for the torch moving to safe height: G00 Z1.5
# In the operator console click in the line number box
# Type in the line number of the safe hight move and hit return
# Highlighted line should change to that line
# Hit "Set next line" button
# Hit cycle start

Causes:

* Dross has built up inside shield
* Work piece is flapping around like a flag in a breeze, put some weights on it
* Dross/corrosion on the plate cause a none conductive area where the torch touched off
* Torch cable has become too taught and caused the probe connection to come loose or the probe ring not to touch the torch shield

==== Torch fails to ignite ====

'''Your work piece is not trash yet, but might be if you don't follow these steps'''

Mach3 shows job stuck on M3 command.

# Hit F5 to re-ignite the torch (possibly twice)
# Job should continue once M3 detects arc transfer signal from the plasma cutter

Causes:

* Unknown at this time

==== Mach3 Crash ====

'''Your work piece is trash, start again'''

# Shutdown the control box
# Close Mach3
# Turn on control box
# Start Mach3
# Run your job again

Causes:

* Unknown at this time

== Todo List ==

* Documentation

Squareness todo:

* Physical end stops - probably want to move the wiring out of the X axis tubes for this
* Limit switches on A-axis (slaved to X, the rail against the wall)

This will allow both manual squareness and automatic machine homing. Mach 3 has a routine that will home the X axis with the slave, then adjust which ever one did not hit the home switch independently.

Water table todo:

* <s>Fix 2 pin hole leaks (one at each end of tank)</s>
* <s>Fit bladder input line (so it doesn't collect crap in the tank)</s>
* Wash out old compressor tank
* <s>Trim the top of the side where the A axis hardware grazes the top of the tank.</s>
* Paint the outside of the tank
* <s>Treat the water with the green goo</s>

Plumbing/wiring todo:

* Extend air line to under table to create a manifold for table mounted air consumers
* Run large conduit for 220 outlet for the plasma cutter
* Run small conduit for data/estop between the table and the PC
* Run black pipe for connecting the table to the bladder (old compressor tank)
* Water line from north side of the shop, with input into the old compressor tank
* Air lines to the compressor tank (one vent on from the compressor)
* Run ethernet line to PC so its not on wifi any more
* Z axis limit switches

Plate marker todo:

* Design and cut new y-axis trolly or offset plate to carry torch and marker
* Machine mount for engraver
* Mount new trolly with air slide and Z axis
* Plumbing and wiring
* Pen mount as well as engraver?

35A Fine Cut todo:

* Build floating Z axis using left over linear rail
* How to multiplex the digitise input for touch off? Relays to switch digitise input from ohmic sensor to switch on head? (and disconnect the switch from the z limit array) (the switch should be in the z limit switch array by default incase the THC plunges the torch into the work piece)

Roundness/cut quality todo:

* <s>Y Axis pulsing - new connection spigot for drive year to fix eccentric rotation of gear</s>
* Remove and clean X axis gears, reinstall and use loctite on set screws (the keep backing off)
* Make sure all bearings are right against the rails so there is no slop
* <s>Investigate backlash and configure mach3 is required</s> - 0.0001 on X, Y and A
* Get quote for installing ground rod next to the table and execute it
* Look into THC issues (cut rippling) if still present after ground rod - possible Z axis flex in the mount to the Y carriage.
* Why is the THC seeing ~80V for a good clean cut from the hypertherm? Is the internal voltage divider broken (is this why the machine was retrofitted with a dangerous high voltage tap?)? Or is this related to a bad ground at the table?
* Motion pauses: (Seen on large 3'x2' complex cuts)
** Why are there zero move G1's at the end of curves generated with G2's
** <s>Do we need to add a CV on G-Code in the preamble of the post processor</s> - Does not appear to need this
** Smooth stepper under-run errors - I have only seen this when jogging not cutting, mostly related to rapiding the Z, maybe reduce the micro stepping on the driver for the new threaded drive step count is huge per inch which could be hurting us
** <s>Axis and Core frequency tuning for the smooth stepper?</s> - Dropped to 64k on X,Y,A
** <s>Look ahead tuning</s> - increased to 150
** Is CV plasma mode hurting us?
** <s>System problems, AV jamming things up?</s> - low cpu load not an issue

Ohter things:

* Cleaning/maintenance schedule
* Shelves/lockers in the unused space under the table for project/tool/etc storage?
* Materials storage ideas?
** sheet goods
** 20-24' bar/tube stock

== Future Items ==

* Tube attachment
* scribe attachment

== Torch Consumables ==

The torch is a T45m hypertherm machine torch.

{| class="wikitable" border="1"
!colspan="3"|Consumables Change Log
|-
! Date
! What
! By
|-
|6/10/17
|electrode, nozzle
|Andrew Camardella
|-
|}

[http://www.thefabricator.com/article/plasmacutting/plasma-cutting-maintenance-are-you-throwing-money-away What does a worn electrode look like?]

Torch tips components are consumables. If you are getting a wide kerf or the plasma torch isn't cutting through the materials anymore you may need to change the tip parts. To change the consumables disconnect the ground clip from the black retaining cap and unscrew the entire tip from the retaining cap.

=== Standard ===

* Deflector P/N: 2206732
* Retaining Cap - Ohmic P/N: 220719
* Nozzle P/N: 220671
* Electrode P/N: 220669
* Swirl Ring P/N: 220670

=== Fine Cut ===

'''THERE IS CURRENTLY NO POST PROCESSOR FOR RUNNING WITH THESE CONSUMABLES INSTALLED'''

'''NOTE''': These parts are for a t30 unshielded torch, they are compatiable with the T45m when it is run at a setting lower than 30A and cutting materials thinner than 3/16". Ohmic sensing will not work with these parts installed.

* Deflector P/N: 2206732
* Retaining Cap - Ohmic P/N: 220483
* Nozzle P/N: 220480
* Electrode P/N: 220479
* Swirl Ring P/N: 220478

[[:File:T45m.pdf|Consumables catalog page]]

== Feeds and Speeds ==

=== T45m Shielded Consumables ===

==== Mild Steel ====

{| class="wikitable"
!colspan="5"|
!colspan="2"|Recommended
!colspan="2"|Maximum
|-
!Arc Current (a)
!Material Thickness
!Torch-to-work distance (in)
!Initial Piece hieght (in)
!Pierce time delay (s)
!Cut Speed (ipm)
!Arc Voltage (V)
!Cut Speed (ipm)
!Arc Voltage (V)
|-
|rowspan="4"|30
|0.018" 26Ga
|rowspan="4"|0.06"
|rowspan="4"|0.15"
|rowspan="3"|0.0
|360
|117
|400
|118
|-
|0.030" 22Ga
|340
|116
|400
|117
|-
|0.036" 20Ga
|320
|115
|400
|117
|-
|0.060" 18Ga
|0.2
|225
|111
|280
|115
|-
|rowspan="12"|45
|0.036" 20Ga
|rowspan="12"|0.06"
|rowspan="8"|0.15"
|rowspan="2"|0.0
|380
|115
|400
|112
|-
|0.060" 16 Ga
|350
|116
|400
|115
|-
|0.075" 14Ga
|0.1
|280
|117
|360
|115
|-
|0.105" 12Ga
|0.3
|190
|117
|240
|115
|-
|0.135" 10Ga
|0.4
|140
|117
|175
|115
|-
|0.188" 3/16"
|0.5
|85
|118
|110
|115
|-
|0.250" 1/4"
|0.6
|60
|120
|75
|116
|-
|0.375" 3/8"
|0.9
|32
|122
|40
|116
|-
|0.500" 1/2"
|colspan="2" rowspan="4"|Edge Start Recommended
|20
|132
|25
|125
|-
|0.625" 5/8"
|11
|138
|14
|127
|-
|0.750" 3/4"
|8
|140
|10
|131
|-
|1.000" 1"
|4
|146
|5
|142
|-
|}

==== Stainless Steel ====

{| class="wikitable"
!colspan="5"|
!colspan="2"|Recommended
!colspan="2"|Maximum
|-
!Arc Current (a)
!Material Thickness
!Torch-to-work distance (in)
!Initial Piece hieght (in)
!Pierce time delay (s)
!Cut Speed (ipm)
!Arc Voltage (V)
!Cut Speed (ipm)
!Arc Voltage (V)
|-
|rowspan="4"|30
|0.018" 26Ga
|rowspan="4"|0.06"
|rowspan="4"|0.15"
|rowspan="3"|0.0
|360
|117
|400
|123
|-
|0.030" 22Ga
|340
|116
|400
|121
|-
|0.036" 20Ga
|320
|115
|400
|119
|-
|0.060" 18Ga
|0.2
|145
|111
|185
|118
|-
|rowspan="12"|45
|0.036" 20Ga
|rowspan="12"|0.06"
|rowspan="8"|0.15"
|rowspan="2"|0.0
|300
|115
|400
|109
|-
|0.060" 16 Ga
|320
|116
|400
|125
|-
|0.075" 14Ga
|0.1
|280
|117
|360
|115
|-
|0.105" 12Ga
|0.3
|160
|117
|200
|116
|-
|0.135" 10Ga
|0.4
|120
|117
|155
|118
|-
|0.188" 3/16"
|0.5
|70
|118
|85
|118
|-
|0.250" 1/4"
|0.6
|44
|120
|55
|120
|-
|0.375" 3/8"
|0.8
|30
|122
|32
|121
|-
|0.500" 1/2"
|colspan="2" rowspan="2"|Edge Start Recommended
|14
|132
|18
|128
|-
|0.750" 3/4"
|7
|140
|9
|131
|-
|}

==== Aluminium ====

{| class="wikitable"
!colspan="5"|
!colspan="2"|Recommended
!colspan="2"|Maximum
|-
!Arc Current (a)
!Material Thickness
!Torch-to-work distance (in)
!Initial Piece hieght (in)
!Pierce time delay (s)
!Cut Speed (ipm)
!Arc Voltage (V)
!Cut Speed (ipm)
!Arc Voltage (V)
|-
|rowspan="3"|30
|0.018" 26Ga
|rowspan="3"|0.06"
|rowspan="3"|0.15"
|0.0
|360
|117
|400
|120
|-
|0.060" 16Ga
|rowspan="2"|0.2
|340
|118
|400
|121
|-
|0.075" 14Ga
|215
|118
|270
|121
|-
|rowspan="11"|45
|0.060" 16Ga
|rowspan="12"|0.06"
|rowspan="7"|0.15"
|rowspan="3"|0.0
|360
|116
|400
|114
|-
|0.075" 14Ga
|340
|117
|400
|116
|-
|0.105" 12 Ga
|280
|120
|360
|119
|-
|0.135" 10Ga
|0.1
|220
|122
|280
|120
|-
|0.188" 3/16"
|0.2
|100
|123
|130
|120
|-
|0.250" 1/4"
|0.3
|80
|123
|100
|120
|-
|0.375" 3/8"
|0.5
|33
|130
|42
|125
|-
|0.500" 1/2"
|colspan="2" rowspan="2"|Edge Start Recommended
|20
|134
|25
|130
|-
|0.750" 3/4"
|8
|143
|10
|138
|-
|}

=== T30v Unshielded Fine cut Consumables ===
'''THERE IS CURRENTLY NO POST PROCESSOR FOR RUNNING WITH THESE CONSUMABLES INSTALLED'''
==== Mild Steel ====
{| class="wikitable"
!colspan="5"|
!colspan="2"|Recommended
!colspan="2"|Maximum
|-
!Arc Current (a)
!Material Thickness
!Torch-to-work distance (in)
!Initial Piece hieght (in)
!Pierce time delay (s)
!Cut Speed (ipm)
!Arc Voltage (V)
!Cut Speed (ipm)
!Arc Voltage (V)
|-
|rowspan="7"|30
|0.018" 26Ga
|rowspan="7"|0.02
|rowspan="7"|0.1
|rowspan="3"|0.0
|350
|105
|400
|98
|-
|0.030" 22Ga
|320
|102
|400
|103
|-
|0.036" 20Ga
|280
|101
|350
|100
|-
|0.060" 16Ga
|0.2
|175
|97
|220
|100
|-
|0.075" 14Ga
|rowspan="3"|0.4
|120
|98
|150
|97
|-
|0.105" 12Ga
|80
|96
|100
|96
|-
|0.135" 10Ga
|50
|100
|65
|101
|-
|}

==== Stainless Steel ====
{| class="wikitable"
!colspan="5"|
!colspan="2"|Recommended
!colspan="2"|Maximum
|-
!Arc Current (a)
!Material Thickness
!Torch-to-work distance (in)
!Initial Piece hieght (in)
!Pierce time delay (s)
!Cut Speed (ipm)
!Arc Voltage (V)
!Cut Speed (ipm)
!Arc Voltage (V)
|-
|rowspan="7"|30
|0.018" 26Ga
|rowspan="7"|0.02
|rowspan="7"|0.1
|rowspan="3"|0.0
|350
|103
|400
|102
|-
|0.030" 22Ga
|320
|198
|400
|100
|-
|0.036" 20Ga
|300
|97
|380
|98
|-
|0.060" 16Ga
|0.2
|150
|99
|190
|98
|-
|0.075" 14Ga
|rowspan="3"|0.4
|110
|101
|135
|97
|-
|0.105" 12Ga
|60
|101
|75
|98
|-
|0.135" 10Ga
|45
|102
|55
|97
|-
|}

==== Aluminium ====
{| class="wikitable"
!colspan="5"|
!colspan="2"|Recommended
!colspan="2"|Maximum
|-
!Arc Current (a)
!Material Thickness
!Torch-to-work distance (in)
!Initial Piece hieght (in)
!Pierce time delay (s)
!Cut Speed (ipm)
!Arc Voltage (V)
!Cut Speed (ipm)
!Arc Voltage (V)
|-
|rowspan="5"|30
|0.036" 20Ga
|rowspan="5"|0.02
|rowspan="5"|0.1
|rowspan="3"|0.0
|320
|107
|400
|105
|-
|0.060" 16Ga
|240
|104
|300
|103
|-
|0.075" 14Ga
|190
|104
|1240
|103
|-
|0.105" 12Ga
|rowspan="2"|0.2
|145
|103
|180
|103
|-
|0.135" 10Ga
|95
|101
|120
|101
|-
|}

== Wiring ==

=== Stepper Coils ===

* A+ Black
* A- Green
* B+ Red
* B- Blue

=== Smooth Stepper Pin Mapping ===

==== C25 Interface board pins ====

{| class="wikitable"
!colspan="3"|SmoothStepper
!colspan="2"|Target Device
|-
!Port
!Pin
!Type
!Device
!Connection
!Wire color
|-
|1
|1
|Output
|X Stepper Driver
|Pul+
|Green
|-
|1
|2
|Output
|X Stepper Driver
|Dir+
|Red
|-
|1
|3
|Output
|X Stepper Driver
|Ena+
|-
|1
|4
|Output
|Y Stepper Driver
|Pul+
|Green
|-
|1
|5
|Output
|Y Stepper Driver
|Dir+
|Red
|-
|1
|6
|Output
|Y Stepper Driver
|Ena+
|-
|1
|7
|Output
|THC
|Step In
|Green
|-
|1
|8
|Output
|THC
|Dir In
|Red
|-
|1
|9
|Output
|Z Stepper Driver
|Ena+
|-
|1
|10
|Input
|Plasma Interface Connector
|Torch Lit Out
|-
|1
|11
|Input
|Z Limit Connector
|2
|Grey
|-
|1
|12
|Input
|Y Limit Connector
|2
|Grey
|-
|1
|13
|Input
|X Limit Connector
|2
|Grey
|-
|1
|14
|Output
|A Stepper Driver
|Pul+
|Green
|-
|1
|15
|Input
|E-Stop Switch
|Switch contact NC
|Grey
|-
|1
|16
|Output
|A Stepper Driver
|Dir+
|Red
|-
|1
|17
|Output
|A Stepper Driver
|Ena+
|-
|2
|1
|Output
|Torch Relay
|Coil +
|-
|2
|2
|Input
|Touch off probe connector
|Pin 2
|-
|2
|3
|Input
|-
|2
|4
|Input
|-
|2
|5
|Input
|-
|2
|6
|Input
|-
|2
|7
|Input
|-
|2
|8
|Input
|-
|2
|9
|Input
|-
|2
|10
|Input
|-
|2
|11
|Input
|-
|2
|12
|Intput
|-
|2
|13
|Input
|-
|2
|14
|Output
|THC Enable relay
|Coil +
|-
|2
|15
|Input
|-
|2
|16
|Output
|-
|2
|17
|Output
|}

== Configuration ==

=== Stepper Drivers ===
Steps per inch: 1358

Driving current:
* SW1 ON
* SW2 ON
* SW3 OFF

Holding Current:
* SW4 OFF

Steps:
* SW5
* SW6
* SW7
* SW8

== Parts ==

* Steppers:
** Wantai 57BYGH115-003
** Nema 23 stepper motor
** 425oz-in torque
** 3 Amp
* Drivers:
** Wantai DQ542MA
** Manual: [[File:DQ542MA_English_Manual.pdf]]
* SmoothStepper Ethernet
* C25 Break out board
** https://cnc4pc.com/motion-control/breakout-boards/c25-smooth-stepper-terminal-board.html
** Manual: [[File:C25R3_1_USER_MANUAL.pdf]]

==maintenance ==
[[CNC_Plasma_Cutter_maintenance|maintenance page]]

== Authorization ==

=== Authorizers ===

* Tom Judge - 45A and 30A fine cut consumables
* Andrew Camaradella - 45A auto Z only
* Ron Olsen - 45A auto Z only

=== List of Currently Authorized Users - 45A Auto Z ===

{| class="wikitable" border="1"
! Qualified Member
! Trained By
! Date
|-
|Tom Judge
|Danger Committee
|
|-
|Andrew Caramdella
|Danger Committee
|
|-
|}

=== List of Currently Authorized Users - 30A Fine Cut ===

{| class="wikitable" border="1"
! Qualified Member
! Trained By
! Date
|-
|Tom Judge
|Danger Committee
|
|-
|Casey Olson
|Tom Judge
|
|-
|}

CNC Plasma Cutter

2018-03-10T14:46:55Z

Daddybird: /* Authorisation */

{{Template:EquipmentPage
|owner = PS:One
|hostarea = CNC
|certification = yes
|hackable = no
|model = N.A.
|serial = N.A.
|arrived = 10/16
|where = Hot metals
|doesitwork = yes
|contact = CNC Area Host
|value = $6000
|image = IMG_4045.JPG
}}

== Authorisation ==

Authorisation requirements:

* You must have a project to compete on the tool during your authorisation
* Your drawings must be reviewed by the authoriser before your scheduled session
* Authorisations will take place with a maximum of 2 members
* You must bring your own material with at least 1'x1' excess for machine tuning
* You must be prepared for the machine to waste some material, its not perfect, be prepared for some waste

Unclear: who are the authorizers and how do you contact them?

[[CNC_Plasma_Cutter_Authorisation]] has more details.

== Drawing guidelines ==

* No sharp corners, all corners should be filleted with at least a 1/16" radius
* The thicker the part, the larger the smallest feature
** Small holes 1/4" and under are not advisable
** Holes under 3/4" on 3/8" plate are not advisable
** Not all these sizes are learnt yet, this is why you need extra material
* Acceptable drawing formats:
** DXF
** SWF
* Acceptable drawing formats for review:
** DXF
** SWF
** AI

== PPE ==

* Number 5 shades when a job is running
* Thick gloves when handling freshly cut parts
* Hearing protection recommended
* Respirator/mask while cutting

== Procedures ==

=== Machine Startup ===

# Wipe down machine with clean dry clotha
# Log in to machine
# Turn on air
# Make sure e-stop is depressed
# Turn on control box
# Start Mach3
# Clear e-stop
# Raise Z
# Move torch to end of table
# Remove torch shield and inspect for dross build up
# Reinstall torch shield
# Turn on plasma cutter
# Check cutter status (Air/torch/etc)

=== Machine Shutdown ===

# Hit e-stop
# Exit Mach3
# Turn off plasma cutter
# Turn off air
# Turn off control box
# Clean torch shield
# Sweep under table
# Wipe down machine with clean dry cloth
# Wipe down computer
# '''Leave the area cleaner than you found it'''

=== Running A Job ===

=== Starting a job from a particular line of code (needs update)===
*Run from here
*Select next line

=== Previewing a job (needs update) ===
*Load file
*Select the 'Run BLK' button in the interface or type Alt-N
*Press the start job button - this will step through each line of code
(warning: includes torch homing and torch ignite so be careful)
*You can step backwards though a job by pressing the 'reverse order' button.

=== Job Crashes ===

==== SmoothStepper Buffer Under run ====

'''Your work piece is trash, start again, home position lost'''

# Click through error
# Start your job again

Causes:

* Communication error between smooth stepper and PC

==== Touch off failure ====

'''Your work piece is not trash yet, but might be if you don't follow these steps'''

One of the following happened:

* Touch off get stuck with torch touching the plate
* Touch off fails to detect plate and rams into the plate
* Error probe ignored in status bar - If this is the case clean the shield nozzle, dross has gotten inside, do not move work piece

Do This:

# Hit escape '''ONCE''', not e-stop, not reset, escape
# Double click in the g-code window to display line numbers eg: 20:N0100 G91.... rather than N0100 G91....
# Look for the current line, it should be highlighted and be: G31 Z -100
# Look up a few lines for the torch moving to safe height: G00 Z1.5
# In the operator console click in the line number box
# Type in the line number of the safe hight move and hit return
# Highlighted line should change to that line
# Hit "Set next line" button
# Hit cycle start

Causes:

* Dross has built up inside shield
* Work piece is flapping around like a flag in a breeze, put some weights on it
* Dross/corrosion on the plate cause a none conductive area where the torch touched off
* Torch cable has become too taught and caused the probe connection to come loose or the probe ring not to touch the torch shield

==== Torch fails to ignite ====

'''Your work piece is not trash yet, but might be if you don't follow these steps'''

Mach3 shows job stuck on M3 command.

# Hit F5 to re-ignite the torch (possibly twice)
# Job should continue once M3 detects arc transfer signal from the plasma cutter

Causes:

* Unknown at this time

==== Mach3 Crash ====

'''Your work piece is trash, start again'''

# Shutdown the control box
# Close Mach3
# Turn on control box
# Start Mach3
# Run your job again

Causes:

* Unknown at this time

== Todo List ==

* Documentation

Squareness todo:

* Physical end stops - probably want to move the wiring out of the X axis tubes for this
* Limit switches on A-axis (slaved to X, the rail against the wall)

This will allow both manual squareness and automatic machine homing. Mach 3 has a routine that will home the X axis with the slave, then adjust which ever one did not hit the home switch independently.

Water table todo:

* <s>Fix 2 pin hole leaks (one at each end of tank)</s>
* <s>Fit bladder input line (so it doesn't collect crap in the tank)</s>
* Wash out old compressor tank
* <s>Trim the top of the side where the A axis hardware grazes the top of the tank.</s>
* Paint the outside of the tank
* <s>Treat the water with the green goo</s>

Plumbing/wiring todo:

* Extend air line to under table to create a manifold for table mounted air consumers
* Run large conduit for 220 outlet for the plasma cutter
* Run small conduit for data/estop between the table and the PC
* Run black pipe for connecting the table to the bladder (old compressor tank)
* Water line from north side of the shop, with input into the old compressor tank
* Air lines to the compressor tank (one vent on from the compressor)
* Run ethernet line to PC so its not on wifi any more
* Z axis limit switches

Plate marker todo:

* Design and cut new y-axis trolly or offset plate to carry torch and marker
* Machine mount for engraver
* Mount new trolly with air slide and Z axis
* Plumbing and wiring
* Pen mount as well as engraver?

35A Fine Cut todo:

* Build floating Z axis using left over linear rail
* How to multiplex the digitise input for touch off? Relays to switch digitise input from ohmic sensor to switch on head? (and disconnect the switch from the z limit array) (the switch should be in the z limit switch array by default incase the THC plunges the torch into the work piece)

Roundness/cut quality todo:

* <s>Y Axis pulsing - new connection spigot for drive year to fix eccentric rotation of gear</s>
* Remove and clean X axis gears, reinstall and use loctite on set screws (the keep backing off)
* Make sure all bearings are right against the rails so there is no slop
* <s>Investigate backlash and configure mach3 is required</s> - 0.0001 on X, Y and A
* Get quote for installing ground rod next to the table and execute it
* Look into THC issues (cut rippling) if still present after ground rod - possible Z axis flex in the mount to the Y carriage.
* Why is the THC seeing ~80V for a good clean cut from the hypertherm? Is the internal voltage divider broken (is this why the machine was retrofitted with a dangerous high voltage tap?)? Or is this related to a bad ground at the table?
* Motion pauses: (Seen on large 3'x2' complex cuts)
** Why are there zero move G1's at the end of curves generated with G2's
** <s>Do we need to add a CV on G-Code in the preamble of the post processor</s> - Does not appear to need this
** Smooth stepper under-run errors - I have only seen this when jogging not cutting, mostly related to rapiding the Z, maybe reduce the micro stepping on the driver for the new threaded drive step count is huge per inch which could be hurting us
** <s>Axis and Core frequency tuning for the smooth stepper?</s> - Dropped to 64k on X,Y,A
** <s>Look ahead tuning</s> - increased to 150
** Is CV plasma mode hurting us?
** <s>System problems, AV jamming things up?</s> - low cpu load not an issue

Ohter things:

* Cleaning/maintenance schedule
* Shelves/lockers in the unused space under the table for project/tool/etc storage?
* Materials storage ideas?
** sheet goods
** 20-24' bar/tube stock

== Future Items ==

* Tube attachment
* scribe attachment

== Torch Consumables ==

The torch is a T45m hypertherm machine torch.

{| class="wikitable" border="1"
!colspan="3"|Consumables Change Log
|-
! Date
! What
! By
|-
|6/10/17
|electrode, nozzle
|Andrew Camardella
|-
|}

[http://www.thefabricator.com/article/plasmacutting/plasma-cutting-maintenance-are-you-throwing-money-away What does a worn electrode look like?]

Torch tips components are consumables. If you are getting a wide kerf or the plasma torch isn't cutting through the materials anymore you may need to change the tip parts. To change the consumables disconnect the ground clip from the black retaining cap and unscrew the entire tip from the retaining cap.

=== Standard ===

* Deflector P/N: 2206732
* Retaining Cap - Ohmic P/N: 220719
* Nozzle P/N: 220671
* Electrode P/N: 220669
* Swirl Ring P/N: 220670

=== Fine Cut ===

'''THERE IS CURRENTLY NO POST PROCESSOR FOR RUNNING WITH THESE CONSUMABLES INSTALLED'''

'''NOTE''': These parts are for a t30 unshielded torch, they are compatiable with the T45m when it is run at a setting lower than 30A and cutting materials thinner than 3/16". Ohmic sensing will not work with these parts installed.

* Deflector P/N: 2206732
* Retaining Cap - Ohmic P/N: 220483
* Nozzle P/N: 220480
* Electrode P/N: 220479
* Swirl Ring P/N: 220478

[[:File:T45m.pdf|Consumables catalog page]]

== Feeds and Speeds ==

=== T45m Shielded Consumables ===

==== Mild Steel ====

{| class="wikitable"
!colspan="5"|
!colspan="2"|Recommended
!colspan="2"|Maximum
|-
!Arc Current (a)
!Material Thickness
!Torch-to-work distance (in)
!Initial Piece hieght (in)
!Pierce time delay (s)
!Cut Speed (ipm)
!Arc Voltage (V)
!Cut Speed (ipm)
!Arc Voltage (V)
|-
|rowspan="4"|30
|0.018" 26Ga
|rowspan="4"|0.06"
|rowspan="4"|0.15"
|rowspan="3"|0.0
|360
|117
|400
|118
|-
|0.030" 22Ga
|340
|116
|400
|117
|-
|0.036" 20Ga
|320
|115
|400
|117
|-
|0.060" 18Ga
|0.2
|225
|111
|280
|115
|-
|rowspan="12"|45
|0.036" 20Ga
|rowspan="12"|0.06"
|rowspan="8"|0.15"
|rowspan="2"|0.0
|380
|115
|400
|112
|-
|0.060" 16 Ga
|350
|116
|400
|115
|-
|0.075" 14Ga
|0.1
|280
|117
|360
|115
|-
|0.105" 12Ga
|0.3
|190
|117
|240
|115
|-
|0.135" 10Ga
|0.4
|140
|117
|175
|115
|-
|0.188" 3/16"
|0.5
|85
|118
|110
|115
|-
|0.250" 1/4"
|0.6
|60
|120
|75
|116
|-
|0.375" 3/8"
|0.9
|32
|122
|40
|116
|-
|0.500" 1/2"
|colspan="2" rowspan="4"|Edge Start Recommended
|20
|132
|25
|125
|-
|0.625" 5/8"
|11
|138
|14
|127
|-
|0.750" 3/4"
|8
|140
|10
|131
|-
|1.000" 1"
|4
|146
|5
|142
|-
|}

==== Stainless Steel ====

{| class="wikitable"
!colspan="5"|
!colspan="2"|Recommended
!colspan="2"|Maximum
|-
!Arc Current (a)
!Material Thickness
!Torch-to-work distance (in)
!Initial Piece hieght (in)
!Pierce time delay (s)
!Cut Speed (ipm)
!Arc Voltage (V)
!Cut Speed (ipm)
!Arc Voltage (V)
|-
|rowspan="4"|30
|0.018" 26Ga
|rowspan="4"|0.06"
|rowspan="4"|0.15"
|rowspan="3"|0.0
|360
|117
|400
|123
|-
|0.030" 22Ga
|340
|116
|400
|121
|-
|0.036" 20Ga
|320
|115
|400
|119
|-
|0.060" 18Ga
|0.2
|145
|111
|185
|118
|-
|rowspan="12"|45
|0.036" 20Ga
|rowspan="12"|0.06"
|rowspan="8"|0.15"
|rowspan="2"|0.0
|300
|115
|400
|109
|-
|0.060" 16 Ga
|320
|116
|400
|125
|-
|0.075" 14Ga
|0.1
|280
|117
|360
|115
|-
|0.105" 12Ga
|0.3
|160
|117
|200
|116
|-
|0.135" 10Ga
|0.4
|120
|117
|155
|118
|-
|0.188" 3/16"
|0.5
|70
|118
|85
|118
|-
|0.250" 1/4"
|0.6
|44
|120
|55
|120
|-
|0.375" 3/8"
|0.8
|30
|122
|32
|121
|-
|0.500" 1/2"
|colspan="2" rowspan="2"|Edge Start Recommended
|14
|132
|18
|128
|-
|0.750" 3/4"
|7
|140
|9
|131
|-
|}

==== Aluminium ====

{| class="wikitable"
!colspan="5"|
!colspan="2"|Recommended
!colspan="2"|Maximum
|-
!Arc Current (a)
!Material Thickness
!Torch-to-work distance (in)
!Initial Piece hieght (in)
!Pierce time delay (s)
!Cut Speed (ipm)
!Arc Voltage (V)
!Cut Speed (ipm)
!Arc Voltage (V)
|-
|rowspan="3"|30
|0.018" 26Ga
|rowspan="3"|0.06"
|rowspan="3"|0.15"
|0.0
|360
|117
|400
|120
|-
|0.060" 16Ga
|rowspan="2"|0.2
|340
|118
|400
|121
|-
|0.075" 14Ga
|215
|118
|270
|121
|-
|rowspan="11"|45
|0.060" 16Ga
|rowspan="12"|0.06"
|rowspan="7"|0.15"
|rowspan="3"|0.0
|360
|116
|400
|114
|-
|0.075" 14Ga
|340
|117
|400
|116
|-
|0.105" 12 Ga
|280
|120
|360
|119
|-
|0.135" 10Ga
|0.1
|220
|122
|280
|120
|-
|0.188" 3/16"
|0.2
|100
|123
|130
|120
|-
|0.250" 1/4"
|0.3
|80
|123
|100
|120
|-
|0.375" 3/8"
|0.5
|33
|130
|42
|125
|-
|0.500" 1/2"
|colspan="2" rowspan="2"|Edge Start Recommended
|20
|134
|25
|130
|-
|0.750" 3/4"
|8
|143
|10
|138
|-
|}

=== T30v Unshielded Fine cut Consumables ===
'''THERE IS CURRENTLY NO POST PROCESSOR FOR RUNNING WITH THESE CONSUMABLES INSTALLED'''
==== Mild Steel ====
{| class="wikitable"
!colspan="5"|
!colspan="2"|Recommended
!colspan="2"|Maximum
|-
!Arc Current (a)
!Material Thickness
!Torch-to-work distance (in)
!Initial Piece hieght (in)
!Pierce time delay (s)
!Cut Speed (ipm)
!Arc Voltage (V)
!Cut Speed (ipm)
!Arc Voltage (V)
|-
|rowspan="7"|30
|0.018" 26Ga
|rowspan="7"|0.02
|rowspan="7"|0.1
|rowspan="3"|0.0
|350
|105
|400
|98
|-
|0.030" 22Ga
|320
|102
|400
|103
|-
|0.036" 20Ga
|280
|101
|350
|100
|-
|0.060" 16Ga
|0.2
|175
|97
|220
|100
|-
|0.075" 14Ga
|rowspan="3"|0.4
|120
|98
|150
|97
|-
|0.105" 12Ga
|80
|96
|100
|96
|-
|0.135" 10Ga
|50
|100
|65
|101
|-
|}

==== Stainless Steel ====
{| class="wikitable"
!colspan="5"|
!colspan="2"|Recommended
!colspan="2"|Maximum
|-
!Arc Current (a)
!Material Thickness
!Torch-to-work distance (in)
!Initial Piece hieght (in)
!Pierce time delay (s)
!Cut Speed (ipm)
!Arc Voltage (V)
!Cut Speed (ipm)
!Arc Voltage (V)
|-
|rowspan="7"|30
|0.018" 26Ga
|rowspan="7"|0.02
|rowspan="7"|0.1
|rowspan="3"|0.0
|350
|103
|400
|102
|-
|0.030" 22Ga
|320
|198
|400
|100
|-
|0.036" 20Ga
|300
|97
|380
|98
|-
|0.060" 16Ga
|0.2
|150
|99
|190
|98
|-
|0.075" 14Ga
|rowspan="3"|0.4
|110
|101
|135
|97
|-
|0.105" 12Ga
|60
|101
|75
|98
|-
|0.135" 10Ga
|45
|102
|55
|97
|-
|}

==== Aluminium ====
{| class="wikitable"
!colspan="5"|
!colspan="2"|Recommended
!colspan="2"|Maximum
|-
!Arc Current (a)
!Material Thickness
!Torch-to-work distance (in)
!Initial Piece hieght (in)
!Pierce time delay (s)
!Cut Speed (ipm)
!Arc Voltage (V)
!Cut Speed (ipm)
!Arc Voltage (V)
|-
|rowspan="5"|30
|0.036" 20Ga
|rowspan="5"|0.02
|rowspan="5"|0.1
|rowspan="3"|0.0
|320
|107
|400
|105
|-
|0.060" 16Ga
|240
|104
|300
|103
|-
|0.075" 14Ga
|190
|104
|1240
|103
|-
|0.105" 12Ga
|rowspan="2"|0.2
|145
|103
|180
|103
|-
|0.135" 10Ga
|95
|101
|120
|101
|-
|}

== Wiring ==

=== Stepper Coils ===

* A+ Black
* A- Green
* B+ Red
* B- Blue

=== Smooth Stepper Pin Mapping ===

==== C25 Interface board pins ====

{| class="wikitable"
!colspan="3"|SmoothStepper
!colspan="2"|Target Device
|-
!Port
!Pin
!Type
!Device
!Connection
!Wire color
|-
|1
|1
|Output
|X Stepper Driver
|Pul+
|Green
|-
|1
|2
|Output
|X Stepper Driver
|Dir+
|Red
|-
|1
|3
|Output
|X Stepper Driver
|Ena+
|-
|1
|4
|Output
|Y Stepper Driver
|Pul+
|Green
|-
|1
|5
|Output
|Y Stepper Driver
|Dir+
|Red
|-
|1
|6
|Output
|Y Stepper Driver
|Ena+
|-
|1
|7
|Output
|THC
|Step In
|Green
|-
|1
|8
|Output
|THC
|Dir In
|Red
|-
|1
|9
|Output
|Z Stepper Driver
|Ena+
|-
|1
|10
|Input
|Plasma Interface Connector
|Torch Lit Out
|-
|1
|11
|Input
|Z Limit Connector
|2
|Grey
|-
|1
|12
|Input
|Y Limit Connector
|2
|Grey
|-
|1
|13
|Input
|X Limit Connector
|2
|Grey
|-
|1
|14
|Output
|A Stepper Driver
|Pul+
|Green
|-
|1
|15
|Input
|E-Stop Switch
|Switch contact NC
|Grey
|-
|1
|16
|Output
|A Stepper Driver
|Dir+
|Red
|-
|1
|17
|Output
|A Stepper Driver
|Ena+
|-
|2
|1
|Output
|Torch Relay
|Coil +
|-
|2
|2
|Input
|Touch off probe connector
|Pin 2
|-
|2
|3
|Input
|-
|2
|4
|Input
|-
|2
|5
|Input
|-
|2
|6
|Input
|-
|2
|7
|Input
|-
|2
|8
|Input
|-
|2
|9
|Input
|-
|2
|10
|Input
|-
|2
|11
|Input
|-
|2
|12
|Intput
|-
|2
|13
|Input
|-
|2
|14
|Output
|THC Enable relay
|Coil +
|-
|2
|15
|Input
|-
|2
|16
|Output
|-
|2
|17
|Output
|}

== Configuration ==

=== Stepper Drivers ===
Steps per inch: 1358

Driving current:
* SW1 ON
* SW2 ON
* SW3 OFF

Holding Current:
* SW4 OFF

Steps:
* SW5
* SW6
* SW7
* SW8

== Parts ==

* Steppers:
** Wantai 57BYGH115-003
** Nema 23 stepper motor
** 425oz-in torque
** 3 Amp
* Drivers:
** Wantai DQ542MA
** Manual: [[File:DQ542MA_English_Manual.pdf]]
* SmoothStepper Ethernet
* C25 Break out board
** https://cnc4pc.com/motion-control/breakout-boards/c25-smooth-stepper-terminal-board.html
** Manual: [[File:C25R3_1_USER_MANUAL.pdf]]

==maintenance ==
[[CNC_Plasma_Cutter_maintenance|maintenance page]]

== Authorization ==

=== Authorizers ===

* Tom Judge - 45A and 30A fine cut consumables
* Andrew Camaradella - 45A auto Z only
* Ron Olsen - 45A auto Z only

=== List of Currently Authorized Users - 45A Auto Z ===

{| class="wikitable" border="1"
! Qualified Member
! Trained By
! Date
|-
|Tom Judge
|Danger Committee
|
|-
|Andrew Caramdella
|Danger Committee
|
|-
|}

=== List of Currently Authorized Users - 30A Fine Cut ===

{| class="wikitable" border="1"
! Qualified Member
! Trained By
! Date
|-
|Tom Judge
|Danger Committee
|
|-
|Casey Olson
|Tom Judge
|
|-
|}

CNC Plasma Cutter Authorization

2018-03-10T14:46:08Z

Daddybird: Copied and spruced up from Ron Olson's post in the Google Group: https://groups.google.com/forum/#!topic/pumping-station-one/fNWLw_rRlbs

Authorization will take place in two parts, much like the Shopbot. Part 1 will be the software (explained in mind-numbing detail below), and Part 2 will be the actual care and feeding of the machine itself.

For folks who want to get authorized, here's some info:

* [[CNC Plasma Cutter|The wiki has a lot of good info about the machine]]. I recommend reading all of it: https://wiki.pumpingstationone.org/CNC_Plasma_Cutter
* We use SheetCam (https://www.sheetcam.com/index) for generating gcode. I recommend downloading the program; the demo version is limited to generating something like 100 lines of gcode, but that's the only restriction I've found. The company has a lot of good videos on youtube and knowing how to use this program is pretty critical.
* Note that you do not design your part in SheetCam, but import it as either a DXF or SVG file; I've done all my stuff in Illustrator and then exported it as DXF and imported into SheetCam with good results.
* Seriously, spend the time to get familiar with SheetCam.
* Mach3 is the program that actually runs the machine, and it has its own interface and quirks; on a good day you shouldn't have to do much more than import the SheetCam-generated file and run. On a bad day it's a good idea to know how to move around in this program as well to troubleshoot WTF is going on.
* You are responsible for bringing your own metal sheet, something like: https://www.homedepot.com/p/Everbilt-24-in-x-24-in-16-Gauge-Plain-Sheet-Metal-800657/204604786. If you're done with your sheet take the remains with you or throw it away (preferably out in the alley so the scrap metal guys can take it).
* Any material without parking tickets will be summarily thrown away with no warning; writing your name on the metal is not sufficient and will not be honored. Seriously, just find a parking ticket slip and tape it onto your piece if you really want to keep using it. Place your ticketed work in the project holding area and do not throw it under the machine.
* This is a homemade machine; there is no manual and there is no company website to go to. My only request, and I make this in the strongest, gentlest way, is to document what you do [https://wiki.pumpingstationone.org/index.php?title=Talk:CNC_Plasma_Cutter&action=edit&redlink=1 on the Talk page of the machine on the wiki], preferably with pics. This will help you remember what you did, and help others to know what can be done. We need a lot of knowledge for this machine and we need to know both successes and failures so that the rising tide will lift all boats.
* I recommend, but do not require, you get authorized on the Miller handheld plasma cutter too. Why? Because knowing how plasma cutting works and why it might stop working can help in troubleshooting the CNC machine; the only difference between the the handheld plasma cutter and the CNC one is that you are the computer.

Boss Laser Settings

2018-01-11T12:14:45Z

Daddybird: /* Known Settings */

The below is to help you figure out your settings for your cutting job on the [[BOSS LS-3655 150w Laser Engraver|Boss Laser]]. Please do not be creative with settings unless you know what you're doing, because you can easily set things on fire.

==Test Cuts==
There are several test cut pieces. These test various power/speed in a pie shape going from 10% to 100%. These are a good starting point.

==Known Settings==
Known, successfully used settings.

===Cutting===
{| class="wikitable"
|-
! Material
! Thickness
! Speed (mm/second)
! Power (%)
! Kerf
|-
| Acrylic
| 1/16"
| 50
| 50
|
|-
| Plywood
| 1/4"
| 25?
| 80
|
|-
| MDF Core Plywood (Owl Lumber)
| 0.177"
| 25
| 75
| 0.0184
|-
| ABS
| 1/8"
| 20
| 65
|
|-
| Balsa
| 1/16" medium density
| 150
| 10
|
|-
| Balsa
| 3/32" medium density
| 150
| 25
|
|-
| Balsa
| 1/8" medium density
| 150
| 30
|
|-
| Cermark Engraving Brass
|
| 30
| 70
|
|-
| Masonite
| 1/8"
| 15
| 50
| 0.5mm
|-
| MDF
| 1/4"
| 7.5
| 70
| 0.6mm
|}

===Engraving===
{| class="wikitable"
|-
! Material
! Depth
! Speed (mm/second)
! Power (%)
|-
| Masonite
| 0.4mm
| 100
| 10
|-
| Masonite
| 1mm
| 100
| 15
|-
| Masonite
| 1.3mm
| 100
| 20
|-
| Masonite
| 1.6mm
| 100
| 25
|-
| Speedycarve (rubber)
| ~1mm
| 50
| 10
|}

Boss Laser Settings

2018-01-11T12:13:32Z

Daddybird: /* Cutting */

The below is to help you figure out your settings for your cutting job on the [[BOSS LS-3655 150w Laser Engraver|Boss Laser]]. Please do not be creative with settings unless you know what you're doing, because you can easily set things on fire.

==Test Cuts==
There are several test cut pieces. These test various power/speed in a pie shape going from 10% to 100%. These are a good starting point.

==Known Settings==
Known, successfully used settings.

===Cutting===
{| class="wikitable"
|-
! Material
! Thickness
! Speed (mm/second)
! Power (%)
! Kerf
|-
| Acrylic
| 1/16"
| 50
| 50
|
|-
| Plywood
| 1/4"
| 25?
| 80
|
|-
| MDF Core Plywood (Owl Lumber)
| 0.117
| 25
| 75
| 0.0184
|-
| ABS
| 1/8"
| 20
| 65
|
|-
| Balsa
| 1/16" medium density
| 150
| 10
|
|-
| Balsa
| 3/32" medium density
| 150
| 25
|
|-
| Balsa
| 1/8" medium density
| 150
| 30
|
|-
| Cermark Engraving Brass
|
| 30
| 70
|
|-
| Masonite
| 1/8"
| 15
| 50
| 0.5mm
|-
| MDF
| 1/4"
| 7.5
| 70
| 0.6mm
|}

===Engraving===
{| class="wikitable"
|-
! Material
! Depth
! Speed (mm/second)
! Power (%)
|-
| Masonite
| 0.4mm
| 100
| 10
|-
| Masonite
| 1mm
| 100
| 15
|-
| Masonite
| 1.3mm
| 100
| 20
|-
| Masonite
| 1.6mm
| 100
| 25
|-
| Speedycarve (rubber)
| ~1mm
| 50
| 10
|}

Shopbot PRS CNC router

2017-12-24T06:41:04Z

Daddybird: /* Adds shopbot magnet template */

{{Template:EquipmentPage
|owner = PS:One
|serial = TBD.
|certification = yes
|hackable = no
|model = Shopbot PRS #10108 96-48
|arrived = 2014
|image = Shopbot.jpg
|doesitwork = yes
|contact = [[CNC|CNC Area Host]]
|where = TBD
|value = $16000
|hostarea = CNC
}}
= ShopBot PRS #10108 96-48 =

* [http://www.shopbottools.com/mProducts/prSstandard.htm OEM website and specs]
* Nominal Cutting Area 96"x 48"x 6" (2.44m x 1.22m x .15m)
* Total Movement Area 102" x 50" x 8" (2.59m x 1.27m x .20m)

The spindle uses ER25 collets. These eventually wear out, so check before using them. Collets are a durable expendable.

Some people buy their own collets. There are a number of suppliers of collets, nuts, and related accessories. [http://www.techniksusa.com/ Techniks] and [http://www.shars.com/ Shars] are both brands that have been recommended by experienced CNC users, although other brands may also be of equivalent price and quality:

* [http://www.shars.com/1-4-ultra-precision-5-micron-er25-collet Shars ER25 Collet Ultra Precision 5 Micron]
* [https://www.ebay.com/itm/TECHNIKS-1-4-SUPER-PRECISION-ER25-COLLET-0002-ACCURACY-CNC-CHUCK-MILL-/130701349603?hash=item1e6e6852e3 Techniks 1/4" Super Precision ER25 Collet .0002 Accuracy]
* [https://www.toolstoday.com/cnc-high-precision-spring-collets-for-er25-tool-holder.html?variantids=11644,0&keywords=CO-286 Amana CNC High Precision Spring Collets for ER25 Tool Holder]
* [https://www.amazon.com/HHIP-3900-5215-ER-25-Spring-Collet/dp/B01ABWS9IG/ HHIP 3900-5215 ER-25 Spring Collet, 1/4"]
* [https://www.amazon.com/Dorian-Tool-Alloy-Precision-Collet/dp/B00CB14HXW/ Dorian Tool ER25 Alloy Steel Ultra Precision Collet, 0.236" - 0.276" Hole Size]

=Status history=
August 2017: Dust collection system out of commission.

June 2017: There is an intermittent break in the wiring for the Z-axis Zero Plate. Check for continuity before using (the #1 input should light up on screen when you touch the contacts together). It usually works near the front of the table, but not halfway back. This will get fixed eventually, but it's a good idea to be in the habit of checking.

12/27/16 - Fixed Shopbot x-axis homing. The cable had been pulled on hard enough that some of the conductors broke inside the cable. It has been spliced, soldered, and heatshrinked back together.

= How to Get Authorized =

'''Authorization for this tool by authorized proctors only.''' This means you cannot get authorized by just anyone who is already authorized. You can only get authorized by a few people, the proctors listed below.

Authorization sessions are scheduled roughly monthly. Check the [https://www.meetup.com/Pumping-Station-One/events/ Meetup calendar] for upcoming authorizations. If no ShopBot sessions are currently scheduled, ask on the [https://groups.google.com/group/pumping-station-one/ Google Group].

Be aware that this authorization consists of two parts; the first session is a classroom session that will cover the software required and introduce you to the essential settings and chip-load calculation, and the second part, scheduled separately, is a hands-on class.

== Authorized Proctors ==
{| class="wikitable" border="1"
|-
|Elizabeth Koprucki
|Danger Committee
|-
|Bart Dring
|Danger Committee
|-
|Ryan Pierce
|Danger Committee
|-
|Nathan Ellis
|Danger Committee
|-
|Michael Skilton
|Danger Committee
|-
|Khoi Nguyen
|Michael Skilton
|-
|Andrew Camardella
|Elizabeth Koprucki
|-
|Matt Meshulam
|Andrew Camardella
|-
|}

== How to Become an Authorized Proctor ==
Get an ok from the area host. Successfully run an authorization supervised by an authorized proctor.
It's recommended that initial authorizations be limited to 2 or less.

= Documentation =

[[File:Shopbotassembly.pdf|Shopbotassembly.pdf]]

[[File:Squaringshopbot.pdf|Squaring the ShopBot]]

[[File:Programming_handbook.pdf|Programming Handbook]]

[[File:PRS Maintenance Schedule.pdf|Maintenance Schedule]]

[[File:ShopBot_USB_Connection_Troubleshoot.pdf]] - USB Troubleshooting Guide

[[File:ShopBot_Tech_Support_FAQ_2016_09_12.pdf]] - Tech Support FAQ

[[File:SBG00142 User Guide 2013 05 01.pdf|SBG00142 User Guide 2013 05 01.pdf]] - User Guide

[[File:B17P.763_Schematic.pdf]] - Omer Nail Gun Documentation

[http://www.shopbottools.com/ShopBotDocs/files/quick%20start%20guide%202013%2007%2023.pdf QuickStart]

X, Y, Z probe: https://pumpingstationone.org/2015/09/xyz-finder-for-the-shopbot/

[http://drshopbot.com/index.php?title=Main_Page "Dr Shopbot" wiki]

[http://drshopbot.com/index.php?title=MaintainingConnection "Maintaining Connections"]

[[File:Shopbotmagnets.ai.zip]] - Template for the dust skirt and magnet placement.

== Tutorials ==
[https://www.youtube.com/watch?v=xWCZfYHOYWw Part 1 of our Shopbot Authorization] - This is available as a refresher only. You still need to go to the class when it happens to get access to the hands-on Part 2.

[http://www.woodguide.org/files/2014/07/CNCrouter_bit_basics.pdf Router Bit Basics for CNC - VERY USEFUL]

[https://groups.google.com/forum/?fromgroups=#!searchin/pumping-station-one/shopbot Shopbot Threads on Member List]

[https://groups.google.com/forum/?fromgroups=#!searchin/pumping-station-one/shopbot Shopbot Forum]

[https://groups.google.com/d/msg/pumping-station-one/vUF3iKRQ9yc/_qNnLXzZ3QcJ Overview of Cut Load calcualtions for setting bit feed and speed rates]

= Software Tool Chain =
*Illustrator
*Inkscape
*Vectric Aspire
**Allows for 2D and 3D linework and toolpath creation
**Only available on the Shapeoko Computer
*Vectric V-Carve Makerspace Edition
** http://www.vectric.com/products/vcarve/trial.html
**Allows for 2D linework and toolpath creation
**Allows at home use of V-Carve - output only at PS1
**Our Makerspace Code is: E4793-F6472-BB9E5-9B114-3FEEB-73649-16F4F
*Autodesk Fusion 360
**The ShopBot computer does not have this and may not be fast enough to run it.
**You '''MUST''' use the custom post-processor below. Otherwise, you will bypass the safety check to make sure the spindle really is running!
**For local '''Windows''', to install this on your local computer:
***Unzip and install this in C:\Users\YourName\AppData\Roaming\Autodesk\Fusion 360 CAM\Posts
***Note that AppData is often a hidden folder!
***Inside Fusion 360, when you select Actions / Post Process, under Configuration Folder, hit Setup and select Use Personal Posts.
**For local '''Mac'''
*** Unzip and install in Macintosh HD> Users> USERNAME> Autodesk> Fusion 360 CAM> Posts
*** In Fusion 360, when you select Actions > Post Process, under Settings select Personal Posts for the Source
**For '''Cloud'''
*** Open Fusion 360 and navigate to Libraries > Assets in the Data Panel.
*** Double click the Assets > CAMPosts folder to enter it.
*** Use the Upload button to upload the desired post processor from your local machine to the Assets > CAMPosts folder. This will upload the post to the cloud and allow you to access it anywhere you may login to your Fusion 360 account through My Cloud Posts.
*** After enabling cloud libraries in Fusion 360, you will be able to access your cloud post processor library by setting the Configuration Folder (Windows) or Source (Mac) to My Cloud Posts. Both of these dialog boxes are shown below. You will then be able to select the Cloud post you uploaded in the Post Configuration field (Windows) or the Post Processor field (Mac).
====Chip Load Calculation====
*[http://www.pdsspindles.com/engineering-speeds Bit Parameter Overview by PDS Spindles]
*[http://www.monstertool.com/monster_tool_calculators.html Monster Tools Chip Load Calculator]
*[http://www.pdsspindles.com/admin/modules/page_editor/uploads/image/Chip%20load%20for%20common%20tool%20diameters%20(Inches).jpg Chip Load Chart by PDS Spindles]
*[https://groups.google.com/forum/#!searchin/pumping-station-one/makerspace$20edition/pumping-station-one/cTwfUHxESjU/7m_lI8UWCgAJ How to install Makerspace Version]

== User Tips & Troubleshooting Reports ==
[http://www.sgstool.com/PDF-speedfeeds/SGS-Speeds-Feeds-GP.pdf Some feed and speed recommendations for small bits]

Add your experiences with feeds and speeds or other tips here:
[[Shopbot_User_Tips]]

Add troubleshooting reports here:
[[Shopbot_Troubleshooting_Reports]]

=== Materials ===

* [[Shopbot_PRS_CNC_router/Aluminium|Aluminium]]
* [[Shopbot_PRS_CNC_router/Brass|Brass]]
* [[Shopbot_PRS_CNC_router/Wood|Wood]]

== Authorization Checklist ==

This is here as a checklist for proctors to follow when authorizing people. It can also help remind you of things after you are authorized. Just reading this does not authorizing you.

* How to get authorized
** Watch [http://www.meetup.com/Pumping-Station-One/ the meetup group] for a recurring class on the second Thursday and last Sunday of the month. Sometimes check [https://groups.google.com/forum/#!forum/pumping-station-one the forum] for announcements or ask on the forum if no announcements have been made for a few weeks.

* Authorization group size
** There is no cap to the software instruction preceding the machine usage portion of the class. If you come to this portion it is easier to get fully authorized at a later date.
** 3 machine users - each person will run a job (~1/2 hr each) and everyone will assist each other in completing a job profile and pocket cut. You must be present for the entire authorization

* Safety
** Safety Glasses
** Hearing Protection
** Dust Protection

* What can go wrong (and what to do)

* How does machine work
** Axes
** Motors
** Spindle

* Daily Maintenance
** Spindle bearing warm up.
*** The "C5" warm up routine should be run on the first job of the day. It runs the spindle at 3 speeds for 3 minutes each to warm up the bearings. (When it doubt, warm it up)

* Extended Maintenance
** See maintenance schedule file under documentation.
** Grease the racks
** Use Grease type: Manual states any type is safe there is some in the draw

* Machine Control
** Turn on sequence
*** Log into computer
*** Turn on Shopbot big red and yellow twist switch (see zeroing below)
*** Insert Key and turn to "engaged" position.
*** The VDF should light up, the spindle fan should be on.
*** Start "Shopbot 3" program.
*** Open Tools...Spindle RPM Control menu (to allow RPM control)
**** Make sure collet is tightened or no tool or nut is installed
**** Run the C5 warm up routine
** Jogging
*** Keypad
*** Arrow Keys + Page Up, Page Down (ctrl for fast jog)

* CAM Software
** Vectric V Carve
** Just the basics...separate class for advanced V Carve.
** Online videos

* Running your Job
** Zeroing X & Y
*** With machine off slow push gantry towards X0 until it hits hard stops (optional)
*** Turn on big red switch while still holding gantry.
*** Jog machine away from X0 Y0 so machine will find switches
*** Click X, Y zero button.
** Zeroing Z (top of work piece)
*** Jog over your work piece
*** Place Z zero plate on work piece under the bit
*** Place clip on bit
*** Test connection by touching plate to bit and watch for light #1 to light
*** Click the Z 0 button (it will touch off twice!!!)
*** If Z is critical, you may want to verify that your bit has been zeroed properly by using a "MZ,0" command over the surface you have zeroed the bit to. Repeat zeroing if not correct.

* Waste Board and clamping

* Collets, Bits, Feeds and Speeds
** Feeds and Speeds
*** Use a Cut Load Calculator to determine which feeds and speeds you should be using for your specific bits. An overview is avaialble at: [https://groups.google.com/d/msg/pumping-station-one/vUF3iKRQ9yc/_qNnLXzZ3QcJ]
** Collets
*** We currently have collets for 1/2, 1/4, 3/16 and 1/8" shank bits.
*** Try to keep them clean and store them away from dust between uses. Dust between the gaps will produce runout. The drawer mounted under the Shopbot is the right place to store these items.
*** If the collet nuts are not threading smoothly try cleaning the threads with a small brush, spindle threads as well.
** Bits
*** Use bits designed for the material you are cutting. Don't just steal a bits from the Bridgeport. They won't do a good job and will probably overheat.
*** For cutting out things, use the smallest appropriate bit. Using a 1/2" bit to cutout will just create a lot of mess.

* ShopBot should not be used for...
** Metals other than aluminum
** Cutting anything that requires coolant or lubricant (it will ruin the waste board)
** Ripping lumber (use the table saw)
** Thickness Planning (Use the planner if you can)
** Drilling holes with drill bits (a small end mill works better)

* How to leave the machine (be excellent)
** Machine
*** Home the machine to X0, Y0
*** Turn off both switches
*** Remove Key
*** Remove bit and collet.
*** Place both collet wrenches on top of electronics box
*** clean up work area
*** Smooth out waste board if you puckered it at all.
*** Check if the dust collector needs to be emptied

** Post a picture on our [[Blog]] please!

== Use checklist ==

PS1 is experimenting with the use of checklists to encourage the safe use and proper care of tools in the workspace. The latest version of the [[checklists]] for this tool is stored as a [https://docs.google.com/document/d/1L78Rr_T8vhV8XZLRReKIWYXAyOnS8CLfJmAxehVeThU/edit Google Doc] that can be edited by anyone. If you make changes, update the effective date at the bottom of the document. Print a new copy, and replace the old one.

Physical checklists are necessarily constrained in length. Following is a more extensive pre-flight checklist:

* Did you home the machine?
* Is the dust collect gate open?
* Are you sure you have the right X, Y orientation for your file and material?
* Did you set the proper X,Y zero for your work piece on the Shopbot.
* Is the correct bit installed and tight?
* Is the key in and turned on?
* Is the dust skirt set right so it does not get smashed.
* Is Z zero set to the work top?
* Are the touch plate and clip returned?
* Is the material properly secured?
* Open the Shopbot spindle control dialog (Tools > Spindle RPM Control)
* Safety glasses, hearing protection on.
* Start the job with the E-Stop ready to hit.
* Turn on dust collector ( I like to wait so I can hear that things sound right on the shopbot before turning on the collector)

== List of Currently Authorized Users ==
{| class="wikitable" border="1"
! Qualified Member
! Trained By
! Date
|-
|Elizabeth Koprucki
|Danger Committee
|
|-
|Bart Dring
|Danger Committee
|
|-
|Ryan Pierce
|Danger Committee
|
|-
|Nathan Ellis
|Danger Committee
|
|-
|Michael Skilton
|Danger Committee
|
|-
|Arturo Duarte
|Bart
|
|-
|Derek Bever
|Bart
|
|-
|Everett
|Bart
|
|-
|Vincent Colombo
|Bart
|
|-
|[[User:justin|Justin T. Conroy]]
|Bart
|
|-
|Hugh Sato
|Bart
|
|-
|Sergey Nekrasov
|Bart
|
|-
|Valerie Moore
|Bart
|
|-
|Patrick Schless
|Bart
|
|-
|Tom Forajter
|Bart
|
|-
|Todd Allen
|Michael Skilton
|
|-
|[[User:RogerMoore|Roger Moore]]
|Bart
|
|-
|Tim Saylor
|Bart
|
|-
|Hef
|Bart
|
|-
|Jeff McBride
|Bart
|
|-
| Maxwell ?
| Michael Skilton
|
|-
|Samuel Swope
|Michael Skilton
|
|-
| Khoi Nguyen
|Michael Skilton
|
|-
|Brian Chojnowski
|Michael Skilton
|
|-
|Josh Cooper
|Bart
|
|-
|Andrew Camardella
|Bart
|
|-
|Adam Glick
|Bart
|
|-
|Yehuda Braun
|Bart
|
|-
| Jeff Kantarek
| Michael Sklton
|
|-
| Justin Miles
|Michael Skilton
|
|-
|Will Garza
|Michael Skilton
|
|-
|Clarence Risher
|Michael Skilton
|
|-
|[[User:ericbeau|Eric Beauchamp]]
|Michael Skilton
|
|-
|[[User:Jason|Jason]]
|Michael Skilton
|
|-
|Eric Stein
|Bart
|
|-
|Colin Parsons
|Bart
|
|-
|David Ditzler
|Bart
|
|-
|Ray Doeksen
|Bart Dring
|
|-
|Ron Bean
|Khoi Nguyen & Michael Skilton
|
|-
| Thomas Wright
|Khoi Nguyen & Michael Skilton
|
|-
|David Morton
|Bart Dring
|
|-
|Ron Olson
|Bart Dring
|
|-
|Kyle Bieneman
|Bart Dring
|
|-
|[[User:amishhammer|Tom Judge]]
|Michael Skilton
|
|-
|Bryan Gleason
|Michael Skilton
|
|-
|Dave Schact
|Ryan Pierce
|
|-
|Chris Agocs
|Andrew Camardella
|
|-
|[[user:kuroishi | Doorman Dave ]]
|Andrew Camardella
|
|-
|Alec Weege
|Andrew Camardella
|
|-
|Sam Reicks
|Andrew Camardella
|
|-
|Touly Phiachantharath
|Andrew Camardella
|
|-
|Lucas Goossen
|Andrew Camardella
|
|-
|[[user:Tina|Tina C]]
|Andrew Camardella
|
|-
|Ryan Neuman
|Andrew Camardella
|
|-
|Dan Loeser
|Andrew Camardella
|
|-
|Ben Bogler
|Andrew Camardella
|
|-
|Erin Banwell
|Ryan Pierce
|
|-
|Brad Rios
|Ryan Pierce
|
|-
|Aaron Carlock
|Andrew Camardella
|
|-
|James Villalpando
|Andrew Camardella
|
|-
|Connor Jansen
|Andrew Camardella
|
|-
|Tait Leswing
|Bart
|
|-
|Raj Perera
|Khoi Nguyen
|
|-
|Keith Hultman
|Andrew Camardella
|
|-
|David Srebro
|Andrew Camardella
|
|-
|[[user:Wessing | Erik Wessing ]]
|Andrew Camardella
|
|-
|Leeswann Bolden
|Andrew Camardella
|
|-
|Josh Myers
|Andrew Camardella
|
|-
|Kurt Ziegel
|Andrew Camardella
|
|-
|Glenn Powers
|Andrew Camardella
|
|-
|[[User:mqudsi|Mahmoud Al-Qudsi]]
|Andrew Camardella
|
|-
|Casey Olson
|Khoi
|
|-
|Mike Jones
|Andrew Camardella
|
|-
|Aaron Feigen
|Andrew Camardella
|
|-
|Jim Baker
|Andrew Camardella
|
|-
|Eric Reusche
|Khoi Nguyen
|
|-
|Ralph Brendler
|Andrew Camardella
|
|-
|John McDonald
|Andrew Camardella
|
|-
|Alex Al-Hamdan
|Andrew Camardella
|
|-
|Eugene Liokumovich
|Andrew Camardella
|
|-
|Randal Cox
|Andrew Camardella
|
|-
|Simon Pyle
|Andrew Camardella
|
|-
|Jean Michel Crettaz
|Andrew Camardella
|
|-
|Brian Zable
|Andrew Camardella
|
|-
|Daylan Dufelmeier
|Andrew Camardella
|
|-
|Steve Kruse
|Matt Meshulam
|
|-
|Mike Mandrea
|Andrew Camardella
|
|-
|Jeff Zelnio
|Andrew Camardella
|
|-
|Aaron Stoddart
|Matt Meshulam
|
|-
|Koun Park
|Matt Meshulam
|
|-
|Dan Baltudis
|Matt Meshulam
|
|-
|Curtiss Cooke
|Matt Meshulam
|
|-
|Jeannine Chuchan
|Matt Meshulam
|
|-
|Brennan Koziarz
|Matt Meshulam
|
|-
|Brandon Love
|Matt Meshulam
|
|-
|Mike Vitale
|Matt Meshulam
|
|-
|Emma Purola
|Matt Meshulam
|
|-
|Chris Kohl
|Matt Meshulam
|
|-
|Daniel Sojka
|Matt Meshulam
|
|-
|Naguib Azab
|Matt Meshulam
|
|-
|Mark Zumwalt
|Matt Meshulam
|
|-
|Joseph Juhnke
|Andrew Camardella
|
|-
|Alex Berkowitz
|Andrew Camardella
|
|-
|Andy Muhic
|Matt Meshulam
|
|-
|Adam Stein
|Matt Meshulam
|
|-
|John Farmer
|Matt Meshulam
|
|-
|Joshua Havenga
|Matt Meshulam
|
|-
|[[user:mct|McTavish McArdle]]
|Matt Meshulam
|
|-
|Frank Bowles
|Matt Meshulam
|
|-
|Joe Iklov
|Matt Meshulam
|
|-
|Matthew Quigley
|Matt Meshulam
|
|-
|Derwin Umali
|Andrew Camardella
|
|-
|Doug Mahoney
|Matt Meshulam
|
|-
|Rob Robinson
|Matt Meshulam
|
|-
|Dan Sloboda
|Matt Meshulam
|
|-
|Jacob Collins
|Matt Meshulam
|
|-
|Donald Wells
|Matt Meshulam
|
|-
|[[user:jim|Jim Brink]]
|Matt Meshulam
|
|-
|[[user:mkeith|Matt Keith]]
|Matt Meshulam
|
|-
|[[user:vmorris|Victoria Morris]]
|Matt Meshulam
|
|-
|[[user:bobsabayesian|Bob Loos]]
|Matt Meshulam
|
|-
|[[user:muthpete|Peter Muth]]
|Matt Meshulam
|
|-
|[[user:guijemont|Guillaume Emont]]
|Matt Meshulam
|
|-
|[[user:erikthefunk|Erik Funkhouser]]
|Matt Meshulam
|
|-
|[[user:mrashes|Max Rashes]]
|Matt Meshulam
|
|-
|[[user:panchan99|Juan Ramos]]
|Matt Meshulam
|
|-
|[[user:Justjoe|Joe Dowling]]
|Matt Meshulam
|
|-
|[[user:smash|Ashley Matrisciano]]
|Matt Meshulam
|
|-
|Ryan Kapp
|Matt Meshulam
|
|-
|Idris Raja
|Matt Meshulam
|
|-
|[[user:Dannyblanchard|Danny Blanchard]]
|Matt Meshulam
|
|-
|Aaron Mintz
|Matt Meshulam
|
|-
|[[user:ianstubbs|Ian Stubbs]]
|Matt Meshulam
|
|-
|[[user:skynaya|Skylar Nova]]
|Matt Meshulam
|
|-
|Chris Ruhland
|Matt Meshulam
|
|-
|[[user:Jaypee|Jay Pee]]
|Matt Meshulam
|
|-
|[[user:Ryanmafi|Ryan Fiebing]]
|Matt Meshulam
|
|-
|[[user:sblaszak|Shawn Blaszak]]
|Matt Meshulam
|
|-
|[[user:tonyiacullo|Tony Iacullo]]
|Matt Meshulam
|
|-
|Mark Haughey
|Matt Meshulam
|
|-
|Chris Iacullo
|Matt Meshulam
|
|-
|Ian Monroe
|Matt Meshulam
|
|-
|Ashish Jasani
|Matt Meshulam
|
|-
|Kurt Gilman
|Matt Meshulam
|
|-
|Abel Greenwald
|Matt Meshulam
|
|-
|Vaidotas (Vai) Staugaitis
|Matt Meshulam
|
|-
|Leo Battikhi
|Matt Meshulam
|
|-
|Matt Schaid
|Matt Meshulam
|
|-
|Jamie Vollmer
|Matt Meshulam
|
|-
|Bhairavi Warke
|Matt Meshulam
|
|-
|Denis Kuznetsov
|Matt Meshulam
|
|-
|Brian Carstensen
|Matt Meshulam
|
|-
|Rob Dumas
|Matt Meshulam
|
|-
|Mark Weiser
|Matt Meshulam
|
|-
|Tom Burtonwood
|Matt Meshulam
|
|-
|Steve Madonna
|Matt Meshulam
|
|-
|Jason Araujo
|Matt Meshulam
|
|-
|Bruce Alan Mace
|Matt Meshulam
|
|-
|Molly Adamski
|Matt Meshulam
|
|-
|Jeremy Shaw
|Matt Meshulam
|
|-
|Sam Chen
|Matt Meshulam
|
|-
|John McBride
|Matt Meshulam
|
|-
|Adomas Tautkus
|Matt Meshulam
|
|-
|Tim Buckley
|Matt Meshulam
|
|-
|Martina Josimovska
|Matt Meshulam
|
|-
|James Jacobs
|Matt Meshulam
|
|-
|George Shaw
|Matt Meshulam
|
|-
|David Earl
|Matt Meshulam
|
|-
|[[User:pedrosk| Eduard Breuer]]
|Matt Meshulam
|
|-|-
|Matthew Kim
|Matt Meshulam
|
|-
|Corey Peoples
|Matt Meshulam
|
|-
|Paul Graham
|Matt Meshulam
|
|-
|Matt Grunstad
|Matt Meshulam
|
|-
|Rolf Scheidt
|Matt Meshulam
|
|-
|Arjun Sharma
|Matt Meshulam
|
|-
|Chris Laurent
|Matt Meshulam
|
|-
|[[User:dwlocks|Dan Locks]]
|Matt Meshulam
|
|-
|Zack Sasnow
|Matt Meshulam
|
|-
|Ben Stringer
|Matt Meshulam
|
|-
|[[User:Ekaj|Jacob Snyder]]
|Matt Meshulam
|8/24/17
|-
|James Beck
|Matt Meshulam
|9/13/17
|-
| Sam Gates
|Matt Meshulam
|10/01/17
|-
| Tommy TBones Cramer
|Matt Meshulam
|09/24/17
|-
| tee
|Matt Meshulam
|10/26/17
|-
|[[User:wittnl|Nathan Witt]]
|Matt Meshulam
|2017-12-09
|-
|[[User:GalaxyCascade|Steve Griegoliet]]
|Matt Meshulam
|12/09/17
|-
| Chinbayar Davaatseren
| Matt Meshulam
| 12/09/17
|}

If you have been authorized but cannot log in, request to be added to the "ShopBot Authorized" Samba group (send an email to info (at) pumpingstationone.org with your username and the name of the person who certified you) so that your login works. If you don't have a log-in on https://members.pumpingstationone.org/ you will have issues here - sign up on that site first if you haven't already.

= Maintenance =

== Maintenance Log ==
{| class="wikitable" border="1"
!Date
!Preformed by
!Service Type
!Notes
|-
|4/16/2017
|Ryan Pierce
|Created new AutoDesk Fusion 360 Post Processor. Modified Vectric Post Processors.
|Created new Fusion 360 Post Processor. It includes the changes listed below for the Vectric Post Processors. For Vectric, modified the Post Processors so that if the spindle does not spin up, it gives the user a Retry/Cancel dialog box instead of Abort/Retry/Ignore where Ignore is identical to Retry. Also, these Post Processors broke the Preview mode in the ShopBot software because the preview mode did the real spindle check and it failed because, of course, the spindle wasn't running. The new version will ignore the spindle check in preview mode.
|-
|11/8/2014
|Ryan Pierce
|Updated VCarve Post Processor
|Previously, installed new Post Processor to preset an Abort / Retry / Ignore dialog box when the spindle is started but doesn't spin up. Usual culprit is that a job is started when the the interlock is disabled, which results in the non-spinning bit crashing into the workpiece. Abort stops the job. Today, fixed Retry code. If you power on the VFD and the motor start is enabled, the VFD refuses to start. So I've re-programmed the Retry button to stop the VFD, wait 2 seconds, start the VFD, wait 2 more seconds, and check again to see if it is running. The Ignore button actually acts as Retry because we don't want someone clicking through this dialog box and damaging the machine. NOTE: The Aspire PC in the shop also has this Post Processor, but if you use Aspire, VCarve Pro, etc. on your personal computer, you will need the latest Post Processor to support this safety check.
|-
|11/8/2014
|Ryan Pierce
|Updated ShopBot software
|Did upgrade from 3.8.14 to 3.8.26. Installed latest firmware on ShopBot controller. (This was mandatory.) Two features of interest: Fixed occasional erractic behavior after repeated Stops and Resumes (and Nudges or Command Insertions). Reduced liklihood of Keypad lockup.
|-
|5/31/2015
|Ron Olson
|Created new VCarve Post Processors
|For drag/engraving bits, it's important that the spindle be turned '''off''' so as to not destroy the bit. Instead of manually modifying the sbp every time to remove the check that the spindle is turned on, I created a couple of new post processors (inches and mm, similar to Ryan's), that explicitly ''turn off'' the spindle. The user is given two opportunities to cancel the job if that is not what he/she wants.
|-
|}

== Outstanding Maintenance Issues ==

=== Lack of True E-Stop ===
As shipped, the ShopBot PRS does not support an Emergency Stop. This could be hacked, but it runs the risk of damaging the machine if engaged in a non-emergency situation. Suggested solution: Installing a 10A double pole 24V coil DIN mount relay, and powering the coil via the 24V supply through a normally closed E-Stop button. One pole will disconnect the 63V stepper motor current. One pole will break the control signal that enables the VFD and will cause the VFD to brake to a stop.

=== Automatic Dust Collection ===
The ShopBot has +5V TTL outputs that could be used to trigger automatic dust collection (when the spindle goes live) and/or a warning light (when the gantry is enabled to move.)

=== Limit Switch Issues ===
Every time you start the ShopBot, it resets itself so that the limit switches are disabled! You can turn them on (if memory serves) with the Values -> Input Switch Assignment menu item. Limit switches are really useful - but they need to be enabled. When they are, they will stop manual jogging when the limit is hit (although pressing the key again will let you continue moving the gantry) and they will also stop a running job (but give you the option of ignoring the limits.)

I found a couple more problems when testing all the limits. When I took the gantry to X maximum, the dust collector hose pulled off! I put it back on, but I'm not sure how stable this is. Also, when I originally set the Y maximum and minimum, I wanted as much spindle travel as possible. But it appears that if you're at the Y max and move in the X direction, you can hit the middle support with the dust collector boot. We've got several inches Y travel beyond the nominal 48", so we may want to look into reducing this to clear the supports.

== Resources ==
[[File:ShopBot PSOne Post Processors.zip]] - Post Processors for Vectric Aspire and VCarve Pro 8.0 which includes the change to check that the spindle actually started.

[[File:ShopBot_TC_PS1-NO-SPIN.zip]] - Post Processors for Vectric Aspire and VCarve Pro which include changes to explicitly *disable* spinning

[[File:ShopBot PSOne Fusion 360 Post Processor.zip]] - Post Processor for Autodesk Fusion 360 which includes the change to check that the spindle actually started.

[[Category:Fabrication]]
[[Category:CNC]]
[[Category:Future Things Bus Data Sources]]

File:Shopbotmagnets.ai.zip

2017-12-24T06:39:05Z

Daddybird: Design/holder for shopbot skirt.

Design/holder for shopbot skirt.

Get Help

2017-12-22T15:10:32Z

Daddybird: /* Email Lists */

== Email Lists ==

* Public E-mail: info@pumpingstationone.org:
** This sends an email to [[Systems#Request Tracker|RT]]
* [http://groups.google.com/group/pumping-station-one-public Pumping Station: One Google Group - public list] - For general hacker / maker content and announcements to, discussions with, or questions from, non-members.
* [http://groups.google.com/group/pumping-station-one Pumping Station: One Google Group (private)] - Members-only Google-based discussion group. Access restricted to members, available by web or by email.
* [http://groups.google.com/group/pumping-station-one-announce Pumping Station: One Announce (private)] - Members-only . Announcements only, no discussions. Unused, only two posts.
* [https://lists.pumpingstationone.org/listinfo/systems Systems List] computer system administrator stuff
* [https://groups.google.com/forum/#!forum/ps1-hosts Area Host list] Discussion of the tools and facilities of Pumping Station: One. Members-only Google-based discussion group. Access restricted to members, available by web or by email.
* [https://discourse.pumpingstationone.org/ Discourse] - combined forum/mail site (not currently functioning or supported)
* If you need to contact the board of directors privately you should email directors-only@pumpingstationone.org

== Social Networks ==
* Twitter:
** Official Account: [http://twitter.com/@pumpingstation1 @pumpingstation1]
** Mascot Carl: [http://twitter.com/@carrrl @carrrl]
** Hashtag [http://twitter.com/#search?q=%23psone312 #psone312]
* Facebook:
** Page: https://www.facebook.com/PumpingStationOne
** Group: http://www.facebook.com/group.php?gid=43740233740 (defunct, not actively managed by us anymore)
* Flickr: http://flickr.com/groups/pumpingstationone
* Vimeo: https://vimeo.com/psone/videos

== Links ==
* Website: [http://pumpingstationone.org/ http://pumpingstationone.org/]
* [[Blog]]: [http://pumpingstationone.org/ http://pumpingstationone.org/] Members are encouraged to post to our blog.
* [[Wiki]]: [http://wiki.pumpingstationone.org http://wiki.pumpingstationone.org/]
* GitHub: [https://github.com/pumpingstation1 https://github.com/pumpingstation1]
* Thingiverse: [https://www.thingiverse.com/groups/pumping-station-one https://www.thingiverse.com/groups/pumping-station-one]
* [[IRC]]: #pumpingstationone on irc.freenode.net or [http://pumpingstationone.org/chat/ chat in browser]
* [[Slack]]: https://pumpingstation1.slack.com
* Trello: https://trello.com/pumpingstationone
* Other Hackerspaces: http://hackerspaces.org/wiki/Hackerspaces
* Spaces We've Worked With:
** [http://www.tvbgone.com/cfe_tvbg_main.php Mitch Altman] of [https://www.noisebridge.net/wiki/Noisebridge Noisebridge ''San Francisco'']
** [http://www.i3detroit.com/ i3 Detroit]
** [http://www.c3kc.org/ CCCKC ''Kansas City'']

PS:One The History

2017-12-22T15:01:41Z

Daddybird: /* Short, Partial History of PS1 */

== Intro ==
This page is intended to document the History of Pumping Station: One. We are a very active and lively organization focused on the future.

== The Birth of PS:One ==
* CCCamp 2007
* Eric Michaud and Gang
* Mercury Cafe
* [[Origins]] of the name and the logo for Pumping Station: One
* The Birth of The Bylaws
** Nikki
* Shopping for a Space
** Elston
* Grand Opening at Elston

=== Short, Partial History of PS1 ===
([https://groups.google.com/forum/#!topic/pumping-station-one/A3GokBuiKYk Ed Bennett told this story on the mailing list] to illustrate how board members can give themselves fun, fancy titles.)

PS1 reinvents itself every two years*, and right now (end of 2017) we're a halfway through. When I (Ed Bennett) joined we had ~50 members, if I remember correctly. PS1 lived in one-room schoolhouse of about 2000 sq feet.

We were a social club with power tools and two missions.

PS1's first mission is the one in our charter and bylaws. The second mission was to have fun. There was a little happy hour every day from 4 to maybe 6pm when people dropped by after work to have a beer or two with their friends and sit in silence (mostly) and use their laptops for an hour or two. It was cheaper than the University Club and had free parking. The trash barrel in the "kitchen" corner would occasionally overflow with beer cans, and Jim invented the Power Wheels Racing Series. We had a bench mounted drill press, a craftsman bandsaw, a crackerbox welder, a grinder, a sander, and an assortment of hand power tools.

Everything started to change when Tim Saylor (president and Chief Cat-Herder) co-signed a loan to buy the Epilog. People started joining just to use the laser. When we moved into 3519, the place seemed cavernous and empty. We started getting more tools and more members. The same social group that started the place continued to make it their own for a couple more two-year cycles and gradually faded into the background. The trash cans stopped overflowing with beer cans, and directors pretty much quit giving themselves funny titles. We gradually started to run ourselves like a business staffed by volunteers who gave their spare time for free. The spirit of whimsy is still among us. I hope that never changes, but it's not surprising at all that a member who actually spends time around the space would ask why the directors sometimes give themselves funny names.**

* This is my (Ed Bennett's) telling of the story. Other peoples' views will naturally differ.

** State law is fine with this, but it's not encouraged. As long as there is a person designated to perform the duties of President, and another person to perform the duties of Treasurer, directors can call themselves whatever they want.

[[Administration History|'''Historical Boards''']]

'''Legal Council''': Nikki - ''Not technically on the Board''

Founding [[Members]]

== Projects Around the Time ==
* Rep Rap Group
* PS:One Bylaws
* Shopping for a Space
* Space Build Out

PS:One The History

2017-12-22T15:01:19Z

Daddybird: /* The Birth of PS:One */

== Intro ==
This page is intended to document the History of Pumping Station: One. We are a very active and lively organization focused on the future.

== The Birth of PS:One ==
* CCCamp 2007
* Eric Michaud and Gang
* Mercury Cafe
* [[Origins]] of the name and the logo for Pumping Station: One
* The Birth of The Bylaws
** Nikki
* Shopping for a Space
** Elston
* Grand Opening at Elston

=== Short, Partial History of PS1 ===
[https://groups.google.com/forum/#!topic/pumping-station-one/A3GokBuiKYk Ed Bennett told this story on the mailing list] to illustrate how board members can give themselves fun, fancy titles.
PS1 reinvents itself every two years*, and right now (end of 2017) we're a halfway through. When I (Ed Bennett) joined we had ~50 members, if I remember correctly. PS1 lived in one-room schoolhouse of about 2000 sq feet.

We were a social club with power tools and two missions.

PS1's first mission is the one in our charter and bylaws. The second mission was to have fun. There was a little happy hour every day from 4 to maybe 6pm when people dropped by after work to have a beer or two with their friends and sit in silence (mostly) and use their laptops for an hour or two. It was cheaper than the University Club and had free parking. The trash barrel in the "kitchen" corner would occasionally overflow with beer cans, and Jim invented the Power Wheels Racing Series. We had a bench mounted drill press, a craftsman bandsaw, a crackerbox welder, a grinder, a sander, and an assortment of hand power tools.

Everything started to change when Tim Saylor (president and Chief Cat-Herder) co-signed a loan to buy the Epilog. People started joining just to use the laser. When we moved into 3519, the place seemed cavernous and empty. We started getting more tools and more members. The same social group that started the place continued to make it their own for a couple more two-year cycles and gradually faded into the background. The trash cans stopped overflowing with beer cans, and directors pretty much quit giving themselves funny titles. We gradually started to run ourselves like a business staffed by volunteers who gave their spare time for free. The spirit of whimsy is still among us. I hope that never changes, but it's not surprising at all that a member who actually spends time around the space would ask why the directors sometimes give themselves funny names.**

* This is my (Ed Bennett's) telling of the story. Other peoples' views will naturally differ.

** State law is fine with this, but it's not encouraged. As long as there is a person designated to perform the duties of President, and another person to perform the duties of Treasurer, directors can call themselves whatever they want.

[[Administration History|'''Historical Boards''']]

'''Legal Council''': Nikki - ''Not technically on the Board''

Founding [[Members]]

== Projects Around the Time ==
* Rep Rap Group
* PS:One Bylaws
* Shopping for a Space
* Space Build Out

PS:One The History

2017-12-22T14:55:01Z

Daddybird: Ed Bennett's "oral" history of PS1.

== Intro ==
This page is intended to document the History of Pumping Station: One. We are a very active and lively organization focused on the future.

== The Birth of PS:One ==
* CCCamp 2007
* Eric Michaud and Gang
* Mercury Cafe
* [[Origins]] of the name and the logo for Pumping Station: One
* The Birth of The Bylaws
** Nikki
* Shopping for a Space
** Elston
* Grand Opening at Elston

PS1 reinvents itself every two years*, and right now (end of 2017) we're a halfway through. When I (Ed Bennett) joined we had ~50 members, if I remember correctly. PS1 lived in one-room schoolhouse of about 2000 sq feet.

We were a social club with power tools and two missions.

PS1's first mission is the one in our charter and bylaws. The second mission was to have fun. There was a little happy hour every day from 4 to maybe 6pm when people dropped by after work to have a beer or two with their friends and sit in silence (mostly) and use their laptops for an hour or two. It was cheaper than the University Club and had free parking. The trash barrel in the "kitchen" corner would occasionally overflow with beer cans, and Jim invented the Power Wheels Racing Series. We had a bench mounted drill press, a craftsman bandsaw, a crackerbox welder, a grinder, a sander, and an assortment of hand power tools.

Everything started to change when Tim Saylor (president and Chief Cat-Herder) co-signed a loan to buy the Epilog. People started joining just to use the laser. When we moved into 3519, the place seemed cavernous and empty. We started getting more tools and more members. The same social group that started the place continued to make it their own for a couple more two-year cycles and gradually faded into the background. The trash cans stopped overflowing with beer cans, and directors pretty much quit giving themselves funny titles. We gradually started to run ourselves like a business staffed by volunteers who gave their spare time for free. The spirit of whimsy is still among us. I hope that never changes, but it's not surprising at all that a member who actually spends time around the space would ask why the directors sometimes give themselves funny names.**

* This is my (Ed Bennett's) telling of the story. Other peoples' views will naturally differ.

** State law is fine with this, but it's not encouraged. As long as there is a person designated to perform the duties of President, and another person to perform the duties of Treasurer, directors can call themselves whatever they want.

[[Administration History|'''Historical Boards''']]

'''Legal Council''': Nikki - ''Not technically on the Board''

Founding [[Members]]

== Projects Around the Time ==
* Rep Rap Group
* PS:One Bylaws
* Shopping for a Space
* Space Build Out

Boss Laser Settings

2017-12-18T01:56:07Z

Daddybird: /* Cutting */

The below is to help you figure out your settings for your cutting job on the [[BOSS LS-3655 150w Laser Engraver|Boss Laser]]. Please do not be creative with settings unless you know what you're doing, because you can easily set things on fire.

==Test Cuts==
There are several test cut pieces. These test various power/speed in a pie shape going from 10% to 100%. These are a good starting point.

==Known Settings==
Known, successfully used settings.

===Cutting===
{| class="wikitable"
|-
! Material
! Thickness
! Speed (mm/second)
! Power (%)
! Kerf
|-
| Acrylic
| 1/16"
| 50
| 50
|
|-
| Plywood
| 1/4"
| 25?
| 80
|
|-
| ABS
| 1/8"
| 20
| 65
|
|-
| Balsa
| 1/16" medium density
| 150
| 10
|
|-
| Balsa
| 3/32" medium density
| 150
| 25
|
|-
| Balsa
| 1/8" medium density
| 150
| 30
|
|-
| Cermark Engraving Brass
|
| 30
| 70
|
|-
| Masonite
| 1/8"
| 15
| 50
| 0.5mm
|-
| MDF
| 1/4"
| 7.5
| 70
| 0.6mm
|}

===Engraving===
{| class="wikitable"
|-
! Material
! Depth
! Speed (mm/second)
! Power (%)
|-
| Masonite
| 0.4mm
| 100
| 10
|-
| Masonite
| 1mm
| 100
| 15
|-
| Masonite
| 1.3mm
| 100
| 20
|-
| Masonite
| 1.6mm
| 100
| 25
|}

BOSS LS-3655 150w Laser Engraver

2017-11-30T02:48:09Z

Daddybird: /* Resources */

Shopbot User Tips

2017-11-09T14:25:05Z

Daddybird:

== Post-Processors ==
When creating toolpaths for the PS1 Shopbot, there are now '''two distinct''' options:
* Shopbot TC_PS1(Inch) and Shopbot TC_PS1(mm)
** For general usage of the Shopbot (typically cutting)
* Shopbot TC_PS1-NO_SPIN(Inch) and Shopbot TC_PS1-NO_SPIN(mm)
** For dragging, engraving, and other tasks where the bit (may not actually ''be'' a bit) must '''not''' spin.
Be careful when creating a toolpath file that you select the right post-processor!

== Positioning your work ==
== Feeds and speeds==
====Spindle Speed====
The Shopbot does not appear to pick up spindle speed instructions unless you have first opened up the Spindle RPM Control menu (under Tools):

[[File:spindle-control-menu2.png]]

'''My speeds aren’t changing on my Spindle when I run the warm-up routine and during cut files. What is the problem?'''

*Note: On ShopBot desktops and MAX, the RPM must be manually adjusted.

The Spindle RPM Control window needs to be open in order for the spindle to change speed. If you see this window pop up during the warm-up routine or software start-up, do not close it. To open it manually, type TR in the ShopBot console (the blank box next to the ShopBot CNC logo). Click on RPM to open the fill-in sheet, and make sure that the correct VFD is selected. Start when SB3 start is set to 1, and the Hz scale is set to 60 for a V1000 spindle and to 100 for a 74X spindle.

The RPM Control window is not available on software versions earlier than 3.6.X.

Perhaps the fact that this can be done via console means that it could also be added to Gcode files by the post-processor? I'm not really sure. I did just notice this, though, a bit lower down in the FAQ:

'''I want the RPM Control Window to open every time I start ShopBot 3'''

This can be accomplished in one of two ways:

1) ...blah blah blah...

2) Navigate to C:\Program Files (x86)\ShopBot\Virtual Tools. Open this file with a text
editor like Notepad or SBEdit. Edit this one line of code:

VT = Spindle [&R]PM Control, Virtual Tools\Spindle Control\Spindle Control.exe, 0, 0

Change the last number, which is a zero, to one. It will now look like this:

VT = Spindle [&R]PM Control, Virtual Tools\Spindle Control\Spindle Control.exe, 0, 1

Save the file, close and reopen the SB3 software to see the changes take effect.

'''''This needs to be done only once for your Shopbot login.'''''

===Drilling===
Cutting Speed [CS] is based on Surface Feet per Minute [FPM or SFM].
RPM = (Cutting Speed(ft/min) x 12/1(in/fr))/Diameter of Cutter(in) x pi
RPM = (12CS)/(pixD)

<TABLE>
<table border="1">
<CAPTION ALIGN=TOP>Material and Cutting Feed</CAPTION>
<TR><TD>Material </TD><TD>Cutting Speed (FPM)</TD></TR>
<TR><TD>Low Carbon Steel </TD><TD ALIGN=CENTER>90 </TD></TR>
<TR><TD>Alloy Steel SAE 4140</TD><TD ALIGN=CENTER>50 </TD></TR>
<TR><TD>Cast Iron</TD><TD ALIGN=CENTER>70 </TD></TR>
<TR><TD>Aluminum </TD><TD ALIGN=CENTER>300</TD></TR>
</TABLE>

<TABLE>
<table border="1">
<CAPTION ALIGN=TOP>Drilling Feeds</CAPTION>
<TR><TD>Drill Dia.(in)</TD><TD>Feed per Revolution(in) </TD></TR>
<TR><TD>under 1/8 </TD><TD ALIGN=CENTER>.001 to .002</TD></TR>
<TR><TD>1/8 to 1/4 </TD><TD ALIGN=CENTER>.002 to .004</TD></TR>
<TR><TD>1/4 to 1/2 </TD><TD ALIGN=CENTER>.004 to .007</TD></TR>
<TR><TD>1/2 to 1 </TD><TD ALIGN=CENTER>.007 to .015</TD></TR>
<TR><TD>over 1 </TD><TD ALIGN=CENTER>.015 to .025</TD></TR>
</TABLE>

Example:
1/2 in drill, Low Carbon Steel

Dia = 0.50
Material LCS : 90

RPM = 12CS/pi*D = 12*90/.5pi = 2160/pi = 687.5<br>
Feed = .004-.007<br>
<TABLE>
<table border="1">

<TR><TD>Answer:</TD><TD>687.5 RPM </TD></TR>
<TR><TD> </TD><TD>.004-.007 in. per Rev</TD></TR>
</TABLE>

===REAMING===
Speed - 1/2 - 1/3 the speed for drilling
Feed - 2-3 times the feed for drilling

===MILLING===

====Recommended Feed and Speed Rates====
RPM = (12CS)/(pixD)

Feedrate = RPMxfxn<BR>
n = number of teeth<BR>
f = feed per tooth<BR>

<TABLE>
<table border="1">
<CAPTION ALIGN=TOP>Cutting Speed</CAPTION>
<TR><TD>Drill Dia.(in)</TD><TD>Feed per Revolution(in) </TD></TR>
<TR><TD>Material </TD><TD>High Speed Steel</TD><TD>Cemented Carbide</TD><TR>
<TR><TD>Aluminum </TD><TD>300-800 </TD><TD>1000-2000 </TD><TR>
<TR><TD>Brass </TD><TD>200-400 </TD><TD>500-800 </TD><TR>
<TR><TD>Bronze </TD><TD> 65-130 </TD><TD>200-400 </TD><TR>
<TR><TD>Cast Iron </TD><TD> 50-80 </TD><TD>250-350 </TD><TR>
<TR><TD>Low Carbon Steel </TD><TD> 60-100 </TD><TD>300-600 </TD><TR>
<TR><TD>Medium Carbon Steel</TD><TD> 50-80 </TD><TD>225-400 </TD><TR>
<TR><TD>High Carbon Steel </TD><TD> 40-70 </TD><TD>150-250 </TD><TR>
<TR><TD>Medium Alloy Steel </TD><TD>40-70 </TD><TD>150-350 </TD><TR>
<TR><TD>Stainless Steel </TD><TD> 30-80 </TD><TD>100-300 </TD><TR>

<TABLE>
<table border="1">
<CAPTION ALIGN=TOP>Feeds for End Mills (feed per tooth)</CAPTION>
<TR><TD>Cutter</TD><TD>Al. </TD><TD>Brass</TD><TD>Bronze</TD><TD>Cast </TD><TD>Low </TD><TD>Med </TD><TD>High </TD><TD>Stainless</TD><TR>
<TR><TD>Dia. </TD><TD>----</TD><TD>-----</TD><TD>------</TD><TD>Iron </TD><TD>Carbon</TD><TD>Carbon</TD><TD>Carbon</TD><TD>Steel </TD><TR>
<TR><TD>------</TD><TD>----</TD><TD>-----</TD><TD>------</TD><TD>-----</TD><TD>Steel </TD><TD>Steel </TD><TD>Steel </TD><TD>---------</TD><TR>
<TR><TD>1/8 </TD><TD>.002</TD><TD>.001 </TD><TD>.0005 </TD><TD>.0005</TD><TD>.0005 </TD><TD>.0005 </TD><TD>.0005 </TD><TD>.0005 </TD><TR>
<TR><TD>1/4 </TD><TD>.002</TD><TD>.002 </TD><TD>.001 </TD><TD>.001 </TD><TD>.001 </TD><TD>.001 </TD><TD>.0005 </TD><TD>.001 </TD><TR>
<TR><TD>3/8 </TD><TD>.003</TD><TD>.003 </TD><TD>.002 </TD><TD>.002 </TD><TD>.002 </TD><TD>.002 </TD><TD>.001 </TD><TD>.002 </TD><TR>
<TR><TD>1/2 </TD><TD>.005</TD><TD>.003 </TD><TD>.003 </TD><TD>.0025</TD><TD>.003 </TD><TD>.002 </TD><TD>.001 </TD><TD>.002 </TD><TR>
<TR><TD>3/4 </TD><TD>.006</TD><TD>.004 </TD><TD>.003 </TD><TD>.003 </TD><TD>.004 </TD><TD>.003 </TD><TD>.002 </TD><TD>.003 </TD><TR>
<TR><TD>1 </TD><TD>.007</TD><TD>.005 </TD><TD>.004 </TD><TD>.0035</TD><TD> .005 </TD><TD>.003 </TD><TD>.003 </TD><TD>.004 </TD><TR>
<TR><TD>1 1/2 </TD><TD>.008</TD><TD>.005 </TD><TD>.005 </TD><TD>.004 </TD><TD>.006 </TD><TD>.004 </TD><TD>.003 </TD><TD>.004 </TD><TR>
<TR><TD>2 </TD><TD>.009</TD><TD>.006 </TD><TD>.005 </TD><TD>.005 </TD><TD>.007 </TD><TD>.004 </TD><TD>.003 </TD><TD>.005 </TD><TR>

Example - 0.50 in HSS two flute end mill cutting aluminum<BR>

RPM = 12CS/piD = 12x300/.5pi = 2292 RPM<BR>
RPM = 12CS/piD = 12x800/.5pi = 6112 RPM<BR>

Feedrate = RPMxfxn = 2292x.005x2=23 IPM<BR>
Feedrate = RPMxfxn = 6112x.005x2=61 IPM<BR>

<TABLE>
<table border="1">
<CAPTION ALIGN=TOP>Answer:</CAPTION>
<TR><TD>RPM Range: </TD><TD>2292 - 6112 RPM</TD></TR>
<TR><TD>Feedrate Range:</TD><TD> 23 - 61 IPM </TD></TR>

File:Spindle-control-menu2.png

2017-11-09T14:24:07Z

Daddybird: Spindle Control Menu - must be open for spindle speed to change.

Spindle Control Menu - must be open for spindle speed to change.

Shopbot User Tips

2017-11-09T14:21:08Z

Daddybird: Updates setting up shopbot software to use feed rate information.

== Post-Processors ==
When creating toolpaths for the PS1 Shopbot, there are now '''two distinct''' options:
* Shopbot TC_PS1(Inch) and Shopbot TC_PS1(mm)
** For general usage of the Shopbot (typically cutting)
* Shopbot TC_PS1-NO_SPIN(Inch) and Shopbot TC_PS1-NO_SPIN(mm)
** For dragging, engraving, and other tasks where the bit (may not actually ''be'' a bit) must '''not''' spin.
Be careful when creating a toolpath file that you select the right post-processor!

== Positioning your work ==
== Feeds and speeds==

===Drilling===
Cutting Speed [CS] is based on Surface Feet per Minute [FPM or SFM].
RPM = (Cutting Speed(ft/min) x 12/1(in/fr))/Diameter of Cutter(in) x pi
RPM = (12CS)/(pixD)

<TABLE>
<table border="1">
<CAPTION ALIGN=TOP>Material and Cutting Feed</CAPTION>
<TR><TD>Material </TD><TD>Cutting Speed (FPM)</TD></TR>
<TR><TD>Low Carbon Steel </TD><TD ALIGN=CENTER>90 </TD></TR>
<TR><TD>Alloy Steel SAE 4140</TD><TD ALIGN=CENTER>50 </TD></TR>
<TR><TD>Cast Iron</TD><TD ALIGN=CENTER>70 </TD></TR>
<TR><TD>Aluminum </TD><TD ALIGN=CENTER>300</TD></TR>
</TABLE>

<TABLE>
<table border="1">
<CAPTION ALIGN=TOP>Drilling Feeds</CAPTION>
<TR><TD>Drill Dia.(in)</TD><TD>Feed per Revolution(in) </TD></TR>
<TR><TD>under 1/8 </TD><TD ALIGN=CENTER>.001 to .002</TD></TR>
<TR><TD>1/8 to 1/4 </TD><TD ALIGN=CENTER>.002 to .004</TD></TR>
<TR><TD>1/4 to 1/2 </TD><TD ALIGN=CENTER>.004 to .007</TD></TR>
<TR><TD>1/2 to 1 </TD><TD ALIGN=CENTER>.007 to .015</TD></TR>
<TR><TD>over 1 </TD><TD ALIGN=CENTER>.015 to .025</TD></TR>
</TABLE>

Example:
1/2 in drill, Low Carbon Steel

Dia = 0.50
Material LCS : 90

RPM = 12CS/pi*D = 12*90/.5pi = 2160/pi = 687.5<br>
Feed = .004-.007<br>
<TABLE>
<table border="1">

<TR><TD>Answer:</TD><TD>687.5 RPM </TD></TR>
<TR><TD> </TD><TD>.004-.007 in. per Rev</TD></TR>
</TABLE>

===REAMING===
Speed - 1/2 - 1/3 the speed for drilling
Feed - 2-3 times the feed for drilling

===MILLING===
====Spindle Speed====

'''My speeds aren’t changing on my Spindle when I run the warm-up routine and during cut files. What is the problem?'''

*Note: On ShopBot desktops and MAX, the RPM must be manually adjusted.

The Spindle RPM Control window needs to be open in order for the spindle to change speed. If you see this window pop up during the warm-up routine or software start-up, do not close it. To open it manually, type TR in the ShopBot console (the blank box next to the ShopBot CNC logo). Click on RPM to open the fill-in sheet, and make sure that the correct VFD is selected. Start when SB3 start is set to 1, and the Hz scale is set to 60 for a V1000 spindle and to 100 for a 74X spindle.

The RPM Control window is not available on software versions earlier than 3.6.X.

Perhaps the fact that this can be done via console means that it could also be added to Gcode files by the post-processor? I'm not really sure. I did just notice this, though, a bit lower down in the FAQ:

'''I want the RPM Control Window to open every time I start ShopBot 3'''

This can be accomplished in one of two ways:

1) ...blah blah blah...

2) Navigate to C:\Program Files (x86)\ShopBot\Virtual Tools. Open this file with a text
editor like Notepad or SBEdit. Edit this one line of code:

VT = Spindle [&R]PM Control, Virtual Tools\Spindle Control\Spindle Control.exe, 0, 0

Change the last number, which is a zero, to one. It will now look like this:

VT = Spindle [&R]PM Control, Virtual Tools\Spindle Control\Spindle Control.exe, 0, 1

Save the file, close and reopen the SB3 software to see the changes take effect.

'''''This needs to be done only once for your Shopbot login.'''''

====Recommended Feed and Speed Rates====
RPM = (12CS)/(pixD)

Feedrate = RPMxfxn<BR>
n = number of teeth<BR>
f = feed per tooth<BR>

<TABLE>
<table border="1">
<CAPTION ALIGN=TOP>Cutting Speed</CAPTION>
<TR><TD>Drill Dia.(in)</TD><TD>Feed per Revolution(in) </TD></TR>
<TR><TD>Material </TD><TD>High Speed Steel</TD><TD>Cemented Carbide</TD><TR>
<TR><TD>Aluminum </TD><TD>300-800 </TD><TD>1000-2000 </TD><TR>
<TR><TD>Brass </TD><TD>200-400 </TD><TD>500-800 </TD><TR>
<TR><TD>Bronze </TD><TD> 65-130 </TD><TD>200-400 </TD><TR>
<TR><TD>Cast Iron </TD><TD> 50-80 </TD><TD>250-350 </TD><TR>
<TR><TD>Low Carbon Steel </TD><TD> 60-100 </TD><TD>300-600 </TD><TR>
<TR><TD>Medium Carbon Steel</TD><TD> 50-80 </TD><TD>225-400 </TD><TR>
<TR><TD>High Carbon Steel </TD><TD> 40-70 </TD><TD>150-250 </TD><TR>
<TR><TD>Medium Alloy Steel </TD><TD>40-70 </TD><TD>150-350 </TD><TR>
<TR><TD>Stainless Steel </TD><TD> 30-80 </TD><TD>100-300 </TD><TR>

<TABLE>
<table border="1">
<CAPTION ALIGN=TOP>Feeds for End Mills (feed per tooth)</CAPTION>
<TR><TD>Cutter</TD><TD>Al. </TD><TD>Brass</TD><TD>Bronze</TD><TD>Cast </TD><TD>Low </TD><TD>Med </TD><TD>High </TD><TD>Stainless</TD><TR>
<TR><TD>Dia. </TD><TD>----</TD><TD>-----</TD><TD>------</TD><TD>Iron </TD><TD>Carbon</TD><TD>Carbon</TD><TD>Carbon</TD><TD>Steel </TD><TR>
<TR><TD>------</TD><TD>----</TD><TD>-----</TD><TD>------</TD><TD>-----</TD><TD>Steel </TD><TD>Steel </TD><TD>Steel </TD><TD>---------</TD><TR>
<TR><TD>1/8 </TD><TD>.002</TD><TD>.001 </TD><TD>.0005 </TD><TD>.0005</TD><TD>.0005 </TD><TD>.0005 </TD><TD>.0005 </TD><TD>.0005 </TD><TR>
<TR><TD>1/4 </TD><TD>.002</TD><TD>.002 </TD><TD>.001 </TD><TD>.001 </TD><TD>.001 </TD><TD>.001 </TD><TD>.0005 </TD><TD>.001 </TD><TR>
<TR><TD>3/8 </TD><TD>.003</TD><TD>.003 </TD><TD>.002 </TD><TD>.002 </TD><TD>.002 </TD><TD>.002 </TD><TD>.001 </TD><TD>.002 </TD><TR>
<TR><TD>1/2 </TD><TD>.005</TD><TD>.003 </TD><TD>.003 </TD><TD>.0025</TD><TD>.003 </TD><TD>.002 </TD><TD>.001 </TD><TD>.002 </TD><TR>
<TR><TD>3/4 </TD><TD>.006</TD><TD>.004 </TD><TD>.003 </TD><TD>.003 </TD><TD>.004 </TD><TD>.003 </TD><TD>.002 </TD><TD>.003 </TD><TR>
<TR><TD>1 </TD><TD>.007</TD><TD>.005 </TD><TD>.004 </TD><TD>.0035</TD><TD> .005 </TD><TD>.003 </TD><TD>.003 </TD><TD>.004 </TD><TR>
<TR><TD>1 1/2 </TD><TD>.008</TD><TD>.005 </TD><TD>.005 </TD><TD>.004 </TD><TD>.006 </TD><TD>.004 </TD><TD>.003 </TD><TD>.004 </TD><TR>
<TR><TD>2 </TD><TD>.009</TD><TD>.006 </TD><TD>.005 </TD><TD>.005 </TD><TD>.007 </TD><TD>.004 </TD><TD>.003 </TD><TD>.005 </TD><TR>

Example - 0.50 in HSS two flute end mill cutting aluminum<BR>

RPM = 12CS/piD = 12x300/.5pi = 2292 RPM<BR>
RPM = 12CS/piD = 12x800/.5pi = 6112 RPM<BR>

Feedrate = RPMxfxn = 2292x.005x2=23 IPM<BR>
Feedrate = RPMxfxn = 6112x.005x2=61 IPM<BR>

<TABLE>
<table border="1">
<CAPTION ALIGN=TOP>Answer:</CAPTION>
<TR><TD>RPM Range: </TD><TD>2292 - 6112 RPM</TD></TR>
<TR><TD>Feedrate Range:</TD><TD> 23 - 61 IPM </TD></TR>

BOSS Usage

2017-08-04T00:09:08Z

Daddybird:

==Safety First==

# Be sure your materials are suitable for lasering. See [[Laser Materials]].
# Know your settings for the materials. The wrong setting can set stuff on fire. Fire=bad. Don't play with fire. See [[Boss Laser Settings]]
# There is a halogen fire extinguisher by the lasers in the CNC room. Know where it is. Do NOT be afraid to use it, it is pure gas and will not leave a residue.
# While the BOSS has doors to accommodate materials that won't fit on the laser bed, they are not used. Opening the doors can allow laser light to escape and blind someone.
# If the lasered materials catch fire:
#* Open the enclosure to turn off the laser.
#* Grab the material or honeycomb bed to move it away from the laser head.
#* Use the halogen fire extinguisher if the materials stay on fire.

==Preparation to Use==
===Turn On Safety/Heat Dissipating Systems===
# Turn on the the rocker switch by the Boss computer. It turns on the air assist, the water cooler, and the exhaust fan.
#* Do NOT touch the cooler switch by the exhaust pipe. The cooler itself always stays on.

===Turn On The Laser===
# Lift up on the red panic button by the control panel.
# Turn the key.
# Turn on the laser computer.

==Job Preparation==
===Autofocus===
# Move the laser head over the materials using the arrow keys on the control panel. It's best not to autofocus at the edge of the materials - the head should plunge to touch a solid piece of material and not the edge.
# Press the U/P button.
# Press the down key until you reach the Autofocus selection.
# Press "Enter"
# The BOSS will lower the head to touch the material and focus.
# You're now ready to set the origin.

(Note that the focal length is 6.6mm. I have found that the "Z index" menu item can be used to set this to 6.3mm, which seemed to work better for cutting MDF core plywood.

===Setting the Origin===
The BOSS's origin is in the upper right of the drawing, as opposed to the Epilog, which has the origin in the upper left. Unlike the Epilog, there is no known origin, as the honeycomb bed is movable and doesn't have a set edge. Set up your materials reasonably square. Note that if the materials are too close to the edge of the bed, you'll get a "Frame Slop" warning. This unhelpful message means that the design you intend to cut will be truncated at the edge of the bed.

To set the origin:
# Move the laser head using the arrow keys.
# Press the origin button.

===Laser Software===
The laser software is called RDworks. Unfortunately it's a Chinese software with a crappy user manual.

The software will import Illustrator files, EPS and SVG?.

====Path Settings====
The way speed/power settings are applied is colors applied to "paths". Originally all paths have the black color applied. Once you have a color applied to a path, you can set up the path settings. Each path has 4 settings:
# Speed
# Power (While Power goes up to 100% in practice it's limited to 95%, and '''you shouldn't use above 80%''')
# Display (if the path shows in RDWorks layout
# Output (if the path selected is being output)

(TODO - what does min/max power mean?)

It's useful to set different colors - a few uses:
* Test jobs. There are several test files in the XXXX directory (TODO move here as attachments for download)
* When first starting your job, you may want to cut only a test piece first, so you can make sure it's cutting properly. Set all other paths to a different color, then set the "Output" setting to "No".
* You can also set a priority for a color. This is useful when dealing with plywood. Almost no 1/4" plywood is flat - it always warps. Additionally applying heat tends to make the plywood "cup" even more. By making your first cuts through the center of the board (from top to bottom or left to right), you're cutting the "cup" in half and helping the board fall much flatter.
* Set a path not to output, but preserve its location and preserve the location of the origin.

====Layout====
Notice the green rectangle in the upper right of the overall design. This is automatically set as the origin. Deleting paths on the top or right of the design will change the origin. In order to keep the same origin but add further cuts, change paths to not output.

====Illustrator Files====
RDworks can import Illustrator files. The issues:
# The layers all display, which can be an issue if you're using layers to store different cuts.
# It doesn't always properly clip paths, for example paths hidden by overlapping shapes.

====Cut====
# Close the lid.
# Double check that the air assist, air exhaust and cooler are all on.
# Click the "Output?" button on the laser computer. It's near the bottom right of the screen.
# Immediately watch from the edge of the lid to see it cutting. You didn't start a fire, did you - you pyromanic, you...

====Troubleshooting====
A "Frame Slop" error means your job is going to try cutting outside the X/Y the boss can do. You probably need to move your origin away from the edge.

==Finishing Up==
===Cleanup===
# The honeycomb grid comes out. You can vacuum in the center of the grid.
# Don't leave junk in/on the honeycomb!

===Shutdown===
# Turn off the air assist toggle switch by the computer.
# Don't touch the switch -on- the cooler. Instead turn off the switch behind the cooler.
# Turn off the air exhaust switch which is also behind the cooler.
# Turn off the key on the laser.
# Push down the red panic button.

==Cleaning==

To clean the lens:
# Have gloves. You must handle it only with gloved hands; clean, powderless, nitrile gloves are fine. So are cotton finger cots, but nitrile is easier to come by.
# Have a soft lint free cloth/surface (need to work the surface out).
# Take the lense out of its holder.
# Blow the lens off with clean condensed air. Do not use the "freon" sprays for camera lenses. ZnSe is somewhat sensitive to thermal shock: there is the possibility of spraying drops of liquid that will evaporate quickly and crater the lens.
# Since it can be difficult to focus on a mostly transparent surface, it's best to examine the lens under a small, bright light source like a desk lamp to look for contaminants. If you don't see any, you're done. Put the lens back in its holder and go.
# If there are contaminants, use isopropyl alcohol (not rubbing alcohol, too much water and possibly other contaminants) as a cleaning solvent. Acetone also works, but IPA is a lot more pleasant to work with, and most Boss owners use it.
# Either use Q-tips or lens tissues (preferred) wetted with solvent. With Q-tips, start at the middle of the lens and work outward, gently mopping the lens in a spiral motion moving out to the edge. With tissues or microfiber cloth, drag the wetted tissue over the lens. In either case, immediately blow any residual solvent off the lens with clean compressed air. Examine again, and repeat if necessary. Otherwise return the lens to its mount. Experience will teach us how often this should be done. (Do NOT use Kleenex or paper towels, they can contain bits of grit)

For mirrors:
Dust burns and degrades the mirror.
# For the mirrors, regularly blow the dust off with clean, dry air or freon (no thermal shock issues).
# Occasionally clean them like lenses. You should not have to remove them from their mounts.

Boss Laser Settings

2017-08-04T00:03:07Z

Daddybird: /* Known Settings */

The below is to help you figure out your settings for your cutting job. Please do not be creative with settings unless you know what you're doing, because you can easily set things on fire.

==Test Cuts==
There are several test cut pieces. These test various power/speed in a pie shape going from 10% to 100%. These are a good starting point.

==Known Settings==
These are known settings successfully used for cutting.
{| class="wikitable"
|-
! Material
! Speed (mm/second)
! Power
|-
| 1/4" Plywood
| 25?
| 80
|-
| 1/8" ABS
| 20
| 65
|}

BOSS Usage

2017-08-01T17:13:33Z

Daddybird: /* Turn On Safety/Heat Dissipating Systems */

==Safety First==

# Be sure your materials are suitable for lasering. See [[Laser Materials]].
# Know your settings for the materials. The wrong setting can set stuff on fire. Fire=bad. Don't play with fire. See [[Boss Laser Settings]]
# There is a halogen fire extinguisher by the lasers in the CNC room. Know where it is. Do NOT be afraid to use it, it is pure gas and will not leave a residue.
# While the BOSS has doors to accommodate materials that won't fit on the laser bed, they are not used. Opening the doors can allow laser light to escape and blind someone.
# If the lasered materials catch fire:
#* Open the enclosure to turn off the laser.
#* Grab the material or honeycomb bed to move it away from the laser head.
#* Use the halogen fire extinguisher if the materials stay on fire.

==Preparation to Use==
===Turn On Safety/Heat Dissipating Systems===
# Turn on the the rocker switch by the Boss computer. It turns on the air assist, the water cooler, and the exhaust fan.
#* Do NOT touch the cooler switch by the exhaust pipe. The cooler itself always stays on.

===Turn On The Laser===
# Lift up on the red panic button by the control panel.
# Turn the key.
# Turn on the laser computer.

==Job Preparation==
===Autofocus===
# Move the laser head over the materials using the arrow keys on the control panel. It's best not to autofocus at the edge of the materials - the head should plunge to touch a solid piece of material and not the edge.
# Press the U/P button.
# Press the down key until you reach the Autofocus selection.
# Press "Enter"
# The BOSS will lower the head to touch the material and focus.
# You're now ready to set the origin.

(Note that the focal length is 6.6mm. I have found that the "Z index" menu item can be used to set this to 6.3mm, which seemed to work better for cutting MDF core plywood.

===Setting the Origin===
The BOSS's origin is in the upper right of the drawing, as opposed to the Epilog, which has the origin in the upper left. Unlike the Epilog, there is no known origin, as the honeycomb bed is movable and doesn't have a set edge. Set up your materials reasonably square. Note that if the materials are too close to the edge of the bed, you'll get a "Frame Slop" warning. This unhelpful message means that the design you intend to cut will be truncated at the edge of the bed.

To set the origin:
# Move the laser head using the arrow keys.
# Press the origin button.

===Laser Software===
The laser software is called RDworks. Unfortunately it's a Chinese software with a crappy user manual.

The software will import Illustrator files, EPS and SVG?.

====Path Settings====
The way speed/power settings are applied is colors applied to "paths". Originally all paths have the black color applied. Once you have a color applied to a path, you can set up the path settings. Each path has 4 settings:
# Speed
# Power (While Power goes up to 100% in practice it's limited to 95%, and '''you shouldn't use above 80%''')
# Display (if the path shows in RDWorks layout
# Output (if the path selected is being output)

(TODO - what does min/max power mean?)

It's useful to set different colors - a few uses:
* Test jobs. There are several test files in the XXXX directory (TODO move here as attachments for download)
* When first starting your job, you may want to cut only a test piece first, so you can make sure it's cutting properly. Set all other paths to a different color, then set the "Output" setting to "No".
* You can also set a priority for a color. This is useful when dealing with plywood. Almost no 1/4" plywood is flat - it always warps. Additionally applying heat tends to make the plywood "cup" even more. By making your first cuts through the center of the board (from top to bottom or left to right), you're cutting the "cup" in half and helping the board fall much flatter.
* Set a path not to output, but preserve its location and preserve the location of the origin.

====Layout====
Notice the green rectangle in the upper right of the overall design. This is automatically set as the origin. Deleting paths on the top or right of the design will change the origin. In order to keep the same origin but add further cuts, change paths to not output.

====Illustrator Files====
RDworks can import Illustrator files. The issues:
# The layers all display, which can be an issue if you're using layers to store different cuts.
# It doesn't always properly clip paths, for example paths hidden by overlapping shapes.

====Cut====
# Close the lid.
# Double check that the air assist, air exhaust and cooler are all on.
# Click the "Output?" button on the laser computer. It's near the bottom right of the screen.
# Immediately watch from the edge of the lid to see it cutting. You didn't start a fire, did you - you pyromanic, you...

==Finishing Up==
===Cleanup===
# The honeycomb grid comes out. You can vacuum in the center of the grid.
# Don't leave junk in/on the honeycomb!

===Shutdown===
# Turn off the air assist toggle switch by the computer.
# Don't touch the switch -on- the cooler. Instead turn off the switch behind the cooler.
# Turn off the air exhaust switch which is also behind the cooler.
# Turn off the key on the laser.
# Push down the red panic button.

==Cleaning==

To clean the lens:
# Have gloves. You must handle it only with gloved hands; clean, powderless, nitrile gloves are fine. So are cotton finger cots, but nitrile is easier to come by.
# Have a soft lint free cloth/surface (need to work the surface out).
# Take the lense out of its holder.
# Blow the lens off with clean condensed air. Do not use the "freon" sprays for camera lenses. ZnSe is somewhat sensitive to thermal shock: there is the possibility of spraying drops of liquid that will evaporate quickly and crater the lens.
# Since it can be difficult to focus on a mostly transparent surface, it's best to examine the lens under a small, bright light source like a desk lamp to look for contaminants. If you don't see any, you're done. Put the lens back in its holder and go.
# If there are contaminants, use isopropyl alcohol (not rubbing alcohol, too much water and possibly other contaminants) as a cleaning solvent. Acetone also works, but IPA is a lot more pleasant to work with, and most Boss owners use it.
# Either use Q-tips or lens tissues (preferred) wetted with solvent. With Q-tips, start at the middle of the lens and work outward, gently mopping the lens in a spiral motion moving out to the edge. With tissues or microfiber cloth, drag the wetted tissue over the lens. In either case, immediately blow any residual solvent off the lens with clean compressed air. Examine again, and repeat if necessary. Otherwise return the lens to its mount. Experience will teach us how often this should be done. (Do NOT use Kleenex or paper towels, they can contain bits of grit)

For mirrors:
Dust burns and degrades the mirror.
# For the mirrors, regularly blow the dust off with clean, dry air or freon (no thermal shock issues).
# Occasionally clean them like lenses. You should not have to remove them from their mounts.

Nikon H-14A Optical Comparator

2017-05-11T11:56:29Z

Daddybird: Created page with "{{Template:EquipmentPage |owner = "PS:One" |hostarea = Cold_Metals |certification = "yes" OR "no" |hackable = "yes" OR "no" |model = Nikon H-14A |serial = SERIAL NUMBER |arriv..."

{{Template:EquipmentPage
|owner = "PS:One"
|hostarea = Cold_Metals
|certification = "yes" OR "no"
|hackable = "yes" OR "no"
|model = Nikon H-14A
|serial = SERIAL NUMBER
|arrived = DATE
|where = Cold Metals
|doesitwork = "yes" or "no" (if set to 'no", a banner will be displayed on the page indicating the tool is broken and it will be automatically added to the "Broken Equipment" category)
|contact = Link to user page of contact person
|value = $999
|image = "IMAGENAME.JPG" (case sensitive, this is whatever you named the image when you uploaded it)
}}