7i96s Arc Voltage + Encoder Fault

I will double check for shorts on P1 and the shield terminate at 7i96s.

I will update

Both the 7I96S and the THCAD(if damaged) are likely repairable with a
single chip/card

sharp_reaper wrote:

I have an error with the reading of arc voltage (-45 V) after one piercing.
Before piercing I was reading 0 V.

The THCAD-300 is mounted inside of the plasma source connected directly to raw Arc Voltage.
The output from THCAD-300 is connected to the encoder from 7i96s (TB2.7 and TB2..

Already switch the THCAD-300 and 7i96s to brand new ones and at start the readings of arc voltage seems to be ok.
But when I put Torch On the Arc Voltage goes to -45 V, after that the value doesn't change. No matter if plasma is on or off.

Should have asked before doing all that...
And do not mount THCAD's inside plasma sources, mount it on the back of it, in a plastic box.
Using new equipment after a failed test, also not good.

The 200XT may be a HF start device. hyperthem machines that size are. This might mean you need to connect the thcad upstream of the HF generator. If not, It's likely to have damaged the THCAD or the 7l96 encoder. Tommy is the expert in this area.

But as PCW says, seeing 0 volt and 45 volts indicates it is working.

Rather than look at the reported voltage, check the encoder velocity pin in halshow. When not cutting, it should hover at or near the 0 volt frequency. Also it should be bouncing around. If it isn't and just a fixed value either there is an error on your encoder config in HAL or there is an issue on the high voltage side.

Using the plasma bit file, you have 3 encoders so damaging one encoder might have an easy  work around.

 

rodw wrote:

But as PCW says, seeing 0 volt and 45 volts indicates it is working.
 

As i understood, he had 0V before firing the torch, and after the first firing it drops to -45, that absolutely points to THCAD working prior to firing and fails miserably after the firing as be it THACD output or 7i96S inputs are gone from the huge amount of EMI the actual torch firing causes and THCAD being enclosed inside a metal case where the source of all that EMI is.
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The THCAD should be wired at the rectifier, not at the plasma output.
And yes, i have a THACD10 wired directly at the output lugs on an inverter plasma, but i would never advise that.
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Just to be clear, yes you can mount the THCAD inside the plasma source, but absolutely should be avoided by inexperienced members of the human race.
The plasma source has a plethora of warnings plastered all over it, and the manuals spend several pages describing just how dangerous those things are.

Thank you for your advice!

The THCAD is mounted inside of the plasma source near the control board.

I'm making the recommended change for a plastic box outside of the plasma source.

This is the first Thermal Dynamics equipment that I work.
I've worked with several Hyperthem plasma cutting systems. All of those got an THCAD inside working well.

The THCAD boards seems to be fine. I have to check the encoder inputs from 7i96s but appears to be usable.

I am making that change to the future plasma systems to guarantee the best care for the boards.

When I have the chance I will make the changes and update you.
Thanks