Need Help! Help! Mach3 emergency mode active when firing plasma torch


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Thread: Help! Mach3 emergency mode active when firing plasma torch

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    *Registered User* Bradnicent's Avatar
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    Default Help! Mach3 emergency mode active when firing plasma torch

    Hi all I need help ,I’ve just finished build a Cnc plasma table and using sheetcam and mach3 ,everything is goin fine except when I try firing the plasma torch via a relay, it causes a “emergency mode active” and status as “ external estop” and everything stops working,I’m using shielded cables on all 3 motors. My plasma cutter is a Promax cut 40, I have a threaded rod hammered 800mm into the ground at 1 corner of the table for my ground witch is connected,what could be the cause of this?

    Feedback will be highly appreciate.
    Thanx.


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    Default Re: Help! Mach3 emergency mode active when firing plasma torch

    Quote Originally Posted by Bradnicent View Post
    Hi all I need help ,I’ve just finished build a Cnc plasma table and using sheetcam and mach3 ,everything is goin fine except when I try firing the plasma torch via a relay, it causes a “emergency mode active” and status as “ external estop” and everything stops working,I’m using shielded cables on all 3 motors. My plasma cutter is a Promax cut 40, I have a threaded rod hammered 800mm into the ground at 1 corner of the table for my ground witch is connected,what could be the cause of this?

    Feedback will be highly appreciate.
    Thanx.


    Sent from my iPhone using Tapatalk
    You have a noise problem, you will have to check all the Grounds and shielded cable and the shields are correctly Grounded this is quite a normal to have this problem with a newly built Plasma machine

    Mactec54


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    Default Re: Help! Mach3 emergency mode active when firing plasma torch

    Only my motors have shielded cable ... and my relay cables from my driver box to my plasma machine are not shielded cables .. everything else is securely grounded, will this problem go away if I use shielded cable for my relay?


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    Default Re: Help! Mach3 emergency mode active when firing plasma torch

    Quote Originally Posted by Bradnicent View Post
    Only my motors have shielded cable ... and my relay cables from my driver box to my plasma machine are not shielded cables .. everything else is securely grounded, will this problem go away if I use shielded cable for my relay?


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    How have you Grounded the Shields, some photos of your wiring would help

    You can also try the Debounce settings in Mach3 this is in the General Configuration Page

    Look for Inputs Signal Denouncing / Noise Rejection this can help sometimes

    Mactec54


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    Default Re: Help! Mach3 emergency mode active when firing plasma torch



    The driver box is grounded from the table witch is grounded to the threaded rod and all motors are grounded from the screws to the driver box

    I will look into the debounce setting mach3 and see if it makes any difference


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    Default Re: Help! Mach3 emergency mode active when firing plasma torch

    I have been running my CNC plasma table for over 10 years now..I had these problems when I first got it going..XP computer..CNC4PC G-11 BOB..Gecko drives..

    What was happening is the ground was back feeding to the computer through it's ground..Isolation of the computer is important..The BOB isolates the computer from the all the heavy arc voltages..Except for one..The ground!!

    The power cord to the computer..I removed the ground male prong..That completed the total Isolation of the computer..All problems went away..I replaced the power cord with a 3 prong plug and the problems came back..went back to the 2 prong..It has never had a problem since..

    I am not even using shielded anything..My cables to my motors are 4 wire 16 gauge that I found at Home depot..It has a nice plastic covering on them..The table has a ground to it..My control box is a wooden cabinet that has the computer setting on the top and a sliding shelf with all the BOB and drives and power supply for the motors..No physical contact of the computer to the machine..



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    Default Re: Help! Mach3 emergency mode active when firing plasma torch

    Quote Originally Posted by Bradnicent View Post
    The driver box is grounded from the table witch is grounded to the threaded rod and all motors are grounded from the screws to the driver box

    I will look into the debounce setting mach3 and see if it makes any difference


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    By the look of the wiring you most likely have created a Ground Loop none of the wiring looks like it is suitable for what it has to do for this machine

    Mactec54


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    Default Re: Help! Mach3 emergency mode active when firing plasma torch

    I am a newbie to this so I’m not exactly sure what you mean by ground loop? To my understanding I must ground all electrical components as best as I can .... what would u have done in this case?


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    Default Re: Help! Mach3 emergency mode active when firing plasma torch

    Quote Originally Posted by Bradnicent View Post
    I am a newbie to this so I’m not exactly sure what you mean by ground loop? To my understanding I must ground all electrical components as best as I can .... what would u have done in this case?


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    You can only have ( 1 ) source for Ground, the input Main Power supply has a Ground and all Grounds have to connect at this one point, this is called a Star Point Ground, you have 2 Grounding points which you don't want to have this is forming a Ground Loop so you can't do this and expect things to work correct, your other wiring is also problematic as well, but start with fixing up all the Grounds

    Attached Thumbnails Attached Thumbnails Help! Mach3 emergency mode active when firing plasma torch-gounding-post-case-png   Help! Mach3 emergency mode active when firing plasma torch-ground-buss-png  
    Mactec54


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    Default Re: Help! Mach3 emergency mode active when firing plasma torch

    Ok I will ground all my components to the steel rod at the table.

    Thank you for your input


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    Default Re: Help! Mach3 emergency mode active when firing plasma torch

    Quote Originally Posted by Bradnicent View Post
    Ok I will ground all my components to the steel rod at the table.

    Thank you for your input


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    No that is not going to work, your Main Power supply Ground is the only Ground you can use

    Mactec54


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    Default Re: Help! Mach3 emergency mode active when firing plasma torch

    Quote Originally Posted by C.Michael View Post

    The power cord to the computer..I removed the ground male prong..That completed the total Isolation of the computer..
    Please excuse my directness but it seems you don't understand the life saving purpose of that ground prong you cut off.

    Normally current runs from the active/live wire, through the appliance, and returns on the neutral wire. Under normal conditions, the earth wire has no current flowing in it.

    However, if you have an appliance with an external conductive surface (like metal), and a circuit develops from the active/live wire to that conductive surface, the current should flow in the ground wire (which is connected to the metal case). Because the ground wire SHOULD be at ground potential, then the theory is that anyone touching the exterior surface will not get electrocuted if they touch the external case. Often, enough current flows from active/live to ground, to blow the fuse or trip the circuit breaker, or even trip an earth leakage circuit breaker if used.

    If you remove the ground prong, you've just allowed any conductive exterior case to become LIVE if a fault circuit develops to it from the live/active wire. Then when a person touches that case, the electric circuit is completed from the case, through the persons body to ground (i.e. where they are standing), and they get electrocuted. They may get very lucky if they are standing on a highly insulating surface, but it does not take that many milliamps to stop a heart beating.

    Just thought I'd better warn people about this. My advice - leave that ground prong as it is.

    You'll often find appliances with only the active and neutral prongs, and no earth prong. They are often termed "double insulated" and have no exterior surface that conducts electricity, and thus cannot prevent a live exterior surface to the user.



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Help! Mach3 emergency mode active when firing plasma torch

Help! Mach3 emergency mode active when firing plasma torch