Openai/6936aa63-c09c-8013-ac55-d493c40443ef

This conversation was exported from ChatGPT

gpt-4o

User: What to change when a CNC plasma is cutting on an angle?

What to change when a CNC plasma is cutting on an angle?

Assistant: If your CNC plasma cutter is cutting on an angle bevelled edges instead of straight, square cuts, it's usually due to o…

If your CNC plasma cutter is cutting on an angle (bevelled edges instead of straight, square cuts), it's usually due to one or more of the following issues. Here’s what to check and change:

- Check if the torch is perfectly vertical to the material.

• Adjust the torch mount or machine calibration to ensure it’s perpendicular.
• Even a small tilt can cause angled cuts.

- Ensure the torch height control (THC) is set correctly.

• Too high or too low can cause uneven kerf and angled cuts.
• Example: On mild steel with 45A, cut height is typically around 1.5mm to 2mm.

- Inspect nozzle, electrode, and shield cap for wear or damage.

• A worn nozzle can cause the arc to deflect, leading to angled cuts.
• Replace consumables if the orifice is out of round or eroded.

- Incorrect speed can worsen bevel angles: - Too Slow = Excessive dross, larger bevel. - Too Fast = Narrow kerf, possible angled cut.

• Refer to your plasma cutter’s cut chart for optimal speed for the material thickness.

- Running at incorrect amperage for your material thickness can cause poor cut quality.

• Example: For 6mm mild steel, 45A is typical; higher thickness may need more amps.

- Ensure the torch is centered properly on the gantry and the nozzle hole is centered.

• Misalignment can cause angular cuts.

- If the material is warped or uneven, the torch height will vary, causing inconsistent bevels.

• Use material clamps or supports to keep sheets flat.

- Inspect for play or looseness in the machine’s axis bearings or torch holder.

• Mechanical looseness can create inconsistent angles.

✅ Re-align and level the torch.

✅ Verify correct torch height (use THC or manual check). ✅ Inspect and replace consumables if needed. ✅ Set correct cut speed and amperage from cut charts. ✅ Check for flat material and secure properly. ✅ Inspect for mechanical looseness.

Would you like me to help with specific settings for your machine (material thickness, amps, speed)? Let me know the details!

User: What speed to cut 6mm plate at 45amps

What speed to cut 6mm plate at 45amps

Assistant: For cutting 6mm mild steel plate at 45 amps with a CNC plasma cutter, typical recommended settings are:

For cutting 6mm mild steel plate at 45 amps with a CNC plasma cutter, typical recommended settings are:

- Speed: Around 1,000 to 1,200 mm/min

• Cut Height: 1.5mm to 2.0mm
• Pierce Height: 3.0mm to 3.5mm
• Pierce Delay: 0.5 to 1.0 seconds depending on machine

✅ Ensure new consumables (nozzle and electrode) for clean cuts

✅ Torch must be perpendicular to the plate ✅ Use THC (torch height control) if available to maintain correct height ✅ Watch for dross—too slow increases dross; too fast leaves incomplete cuts

Note: These are general guidelines based on common plasma systems like Hypertherm Powermax 45. Speeds can vary slightly with different machines, air pressures, and consumable conditions.

Want me to calculate for a different material or thickness? Just tell me!

User: What are the best parameters for torch height controller F1621P?

What are the best parameters for torch height controller F1621P?

Assistant: The F1621P Torch Height Controller THC is a commonly used system for CNC plasma cutters to maintain optimal torch heigh…

The F1621P Torch Height Controller (THC) is a commonly used system for CNC plasma cutters to maintain optimal torch height during cutting. While specific settings depend on your plasma cutter, material, and table, here are general best practice parameters for setting up an F1621P THC when cutting mild steel with a 45A plasma system:

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• 3.0 to 3.5mm
• Ensures safe clearance for arc ignition without damaging the nozzle.

- Typically 1.5mm to 2.0mm torch-to-material distance.

• The F1621P controls this using Arc Voltage, which varies by material and amps.

Example Arc Voltage Setpoints:

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Note: Exact voltage depends on your machine. It's often best to fine-tune while observing cut quality.

- 0.5 to 1.0 seconds after arc start.

• Prevents the THC from making adjustments during pierce and ramp-up phase.

- Moderate gain to balance smooth height control without overcorrection.

• Too aggressive = torch height fluctuates
• Too slow = torch cannot react to warping

✅ Run test cuts to fine-tune the Arc Voltage for your material and amps.

✅ Verify torch is square and consumables are good before calibrating. ✅ Monitor for excessive dross or bevel—adjust height or speed if needed. ✅ Keep material flat—THC can only compensate so much for warping.

Would you like me to help calculate exact arc voltage based on your plasma model? If so, share your plasma cutter brand and material details.

User: Looking for the settings with the torch height controller

Looking for the settings with the torch height controller

Assistant: Thanks for the clarification!

Thanks for the clarification! Here’s a practical, straightforward setup guide for your F1621P Torch Height Controller when cutting with 45A, focusing on mild steel around 6mm as an example.

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• 3.0mm to 3.5mm
• Keeps the torch clear during pierce to avoid damage.

- 1.5mm to 2.0mm

• Ideal torch-to-work distance for a stable arc and clean cut.

Arc voltage is how THC controls torch height—voltage corresponds to physical distance.

• For 45A, 6mm Mild Steel: Start with 118V to 122V, fine-tune based on cut quality. - Lower voltage = torch moves closer - Higher voltage = torch moves away

Tip: Run a test cut, adjust voltage in small steps (1V increments) for minimal bevel and clean edges.

- 0.5 to 1.0 seconds

• Lets pierce complete before THC activates—prevents erratic movement.

- Enabled

• THC disables during corners or slow moves to prevent torch diving into the plate.

- Start with medium sensitivity

• Too aggressive = torch "bounces"
• Too slow = THC can't keep up with warped material

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✅ Always start with new or good consumables—worn nozzles affect voltage readings.

✅ Fine-tune Arc Voltage while watching bevel quality. ✅ Flat material helps—THC compensates for warping, but prevention is better. ✅ Each machine varies—always dial in your specific system with test cuts.

Want settings for different thicknesses or materials? Let me know the details, I’ll send the numbers!

User: Looking for the optimum settings for these

Looking for the optimum settings for these

Assistant: Great, thanks for the clear image of the F1621P Torch Height Controller settings chart.

Great, thanks for the clear image of the F1621P Torch Height Controller settings chart. Below is a recommended starting point for optimal settings when cutting 6mm mild steel at 45A, which is a common application for CNC plasma systems like yours.

These settings can be fine-tuned, but they provide a reliable baseline for good cut quality, torch height control, and machine safety.

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✅ Ensure your Arc Voltage (P05 base value) matches your actual tested voltage for best cut height—typically around 118V to 122V for 6mm mild steel at 45A.

✅ Fine-tune P07 Sensitivity if torch reacts too aggressively or sluggishly.

✅ If cutting thicker materials, adjust voltages and times slightly higher.

✅ Replace consumables regularly—poor nozzle condition affects voltage readings.

Would you like me to help with different thicknesses or a dross troubleshooting guide next? Let me know!

User: What steps would I take to get the actual arc voltage to follow the set voltage closer?

What steps would I take to get the actual arc voltage to follow the set voltage closer?

Assistant: Great question — getting your actual arc voltage to track the set voltage more closely is key for improving cut quality…

Great question — getting your actual arc voltage to track the set voltage more closely is key for improving cut quality and ensuring consistent torch height with your F1621P THC.

Here’s a step-by-step approach to dial that in:

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✅ Torch Must Be Perpendicular

• Ensure the torch is 90° to the plate. Any tilt will skew arc voltage readings.

✅ Torch Height Calibrated Properly

• Confirm your cut height is set to around 1.5mm to 2mm during steady cutting.
• Run manual height tests to ensure the machine knows true torch height positioning.

Look at these specific settings on your F1621P:

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✅ Worn Nozzle or Electrode causes erratic voltage readings.

✅ Replace consumables if the nozzle hole is distorted or the electrode is worn.

• Damaged parts distort the arc shape, throwing off voltage feedback.

✅ Ensure your cut speed and amperage match recommendations.

• Too slow: Arc widens, voltage increases unpredictably.
• Too fast: Arc stretches, causing voltage instability.

Example for 6mm mild steel, 45A:

• Speed: 1000 to 1200 mm/min
• Cut Height: 1.5 to 2mm
• Arc Voltage Setpoint: ~118V to 122V (dial in with test cuts)

✅ Set the desired Arc Voltage based on measured voltage during a clean test cut.

✅ Observe the THC screen:

• If actual voltage lags above/below set voltage, adjust P07 Sensitivity and P06 Threshold accordingly. ✅ Repeat with small changes until actual voltage stabilizes within 1-2V of setpoint during straight cuts.

❗ Actual voltage fluctuates heavily → Check material warping, table grounding, consumables

❗ Torch moves erratically → Lower P07 Sensitivity ❗ Torch lags behind changes → Increase P07 Sensitivity, confirm mechanical tightness

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Would you like me to provide a test procedure to dial in your arc voltage with exact measurements? Let me know, I’ll walk you through it!

gpt-5-1

User: Cutting with the parameters on the THC given before the torch is very erratic, what to change to slow the adjustments

Cutting with the parameters on the THC given before the torch is very erratic, what to change to slow the adjustments

Assistant: If the torch is reacting too fast / too aggressively with the F1621P THC, there are a few specific parameters you can s…

If the torch is reacting too fast / too aggressively with the F1621P THC, there are a few specific parameters you can slow down to make the up/down motion smooth and stable. This is very common when sensitivity and auto-speed values are too high.

Below is exactly what to change:

These are the most effective ones to adjust on the F1621P:

This is the #1 cause of erratic / jumpy torch motion.

• Lower this number to slow adjustments.
• Recommended range for smooth cutting: 12–20
• If too high (25–50), torch reacts too aggressively.

👉 Try P07 = 15 to start.

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These control the speed of the physical Z-axis moves.

• Reduce both to slow the height corrections.
• Typical smooth range: 20–30
• If set to 40–50 = very snappy + jerky movements.

👉 Try P03 = 25, P04 = 25

- Increase this so the THC ignores tiny voltage variations.

• Too low = THC chases every 0.1–0.2V flicker… very erratic.

Recommended:

• P06 = 3 to 5 volts

👉 If torch is still twitchy, push it up to 6V.

These affect how quickly the motor accelerates/decelerates.

• High values = snappy, jumpy motion
• Lower values = smooth ramping

Recommended:

• P14 = 5–8
• P15 = 10–15

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These values will calm the THC down significantly.

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If consumables are worn → arc flickers → THC overreacts.

Just tell me:

• Material thickness
• Amps
• Machine model
• Lead-in type
• Cut speed you're using

And I’ll give you a dialled-in parameter sheet.

Let me know — happy to tune it further!

User: While it is a lot better I'm still getting big fluctuations away from the arc setting voltage

While it is a lot better I'm still getting big fluctuations away from the arc setting voltage

Assistant: Understood — if the torch motion is smoother now, but you're still getting large swings between Actual Arc Voltage and …

Understood — if the torch motion is smoother now, but you're still getting large swings between Actual Arc Voltage and Set Voltage, that points to a different issue:

👉 The THC isn’t the problem now — the ARC VOLTAGE itself is unstable. And if the voltage is unstable, the THC will chase it no matter how much we slow it down.

Let’s fix the root cause of the voltage fluctuating.

Even 0.5 mm too high/low will cause ±10–20 V of voltage change.

Do this test:

1. Disable THC
2. Set a manual cut height of 1.5–2.0 mm
3. Run a straight line test at correct speed
4. Read the ARC VOLTAGE during that line
5. THAT number becomes your new Set Voltage

If you're using 45 A on 6 mm mild steel: It should be roughly 118–122 V at 1.5–2.0 mm.

If the voltage is NOT stable during this test → the problem is in the plasma, consumables, air supply, or ground.

Erratic or wobbly voltage readings come from:

- Check the raw voltage input screws

• Check the voltage divider module
• Make sure wires are tight and not corroded
• Some machines have a 50:1 or 20:1 jumper — confirm correct setting

This causes the biggest voltage fluctuations of all.

• Clamp must be on CLEAN bare metal
• Clamp should be close to the cut (not 1m away)
• Tighten clamp springs
• Move the clamp to the plate and re-test

This can cause spikes on older plasmas.

If your plasma has HF start:

• Keep THC wires far from torch cable
• Use shielded cable for raw voltage lines
• Ground the table frame properly

Worn consumables create unstable arc and voltage swings.

Check these:

• Nozzle hole perfectly round?
• Electrode pit deeper than 1mm?
• Shield cap spatter inside?
• Swirl ring cracked?

Replace nozzle & electrode → test again.

Even slightly worn consumables can cause ±10–15 V fluctuations.

Arc voltage jumps wildly when:

• Air pressure drops under load
• Compressor cycles ON/OFF during cut
• Regulator is far from the plasma
• Water in the air line
• Moisture foaming the arc

Ideal:

• 90–120 psi in,
• Clean, dry, stable,
• Plasma internal regulator set to 5.5–6.0 bar (80–90 psi roughly)

If pressure dips even 5–10 psi = arc voltage swings.

Even small backlash can cause voltage instability.

Check:

• Leadscrew nut tight?
• No vertical play?
• Coupler tight?
• Rails clean?
• Z-axis drops slightly when torch stops?

Even 0.2 mm movement = voltage changes by 5–8V.

To give the THC MORE tolerance and ignore minor fluctuations:

• P06 = 6–8 V
• P07 = 10–12
• P03/P04 = 20

This tells the controller:

But again — this will NOT fix unstable voltage caused by plasma, air, grounding, or consumables.

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I cannot stress this enough — 70% of arc voltage issues come from this.

Clean a spot with a grinder → clamp directly → test again.

Tell me:

• Plasma machine brand/model
• Cut speed
• Material thickness
• Air setup (compressor + dryer?)
• Where your ground clamp is currently attached

I’ll help you isolate the exact cause.

User: Is there a way to set the THC to run all the time follow the set voltage, mine only runs on sharp corners, rest of the …

Is there a way to set the THC to run all the time follow the set voltage, mine only runs on sharp corners, rest of the time it's not doing anything

Assistant: Yes — the F1621P CAN run THC all the time and follow the set voltage continuously, BUT if yours is only adjusting durin…

Yes — the F1621P CAN run THC all the time and follow the set voltage continuously, BUT if yours is only adjusting during sharp corners, that means your THC is being disabled most of the time by one of the controller inputs or logic conditions.

This is a VERY common issue on these controllers, and the fix is straightforward once you know where to look.

Below are the exact things to check and change:

On the F1621P:

• H01 = CNC_AUTO
• L01 = CNC_AUTO (valid electrical level setting)

If the controller is only enabled during corners or slow speeds, then your CNC controller is only giving the THC enable signal during decel events.

Your CNC controller is likely sending AUTO = ON only during corner lock, instead of ON during straight cutting.

This is often a post-processor or wiring issue.

- Make sure AUTO enable signal stays HIGH during all cutting moves

• Only disable during pierce and hole mode

Depending on your controller, you may need to change the M-codes or post-processor.

This setting makes THC “wake up” only when the voltage differs by a threshold.

If P06 is set too HIGH, the machine won’t adjust because the voltage difference never crosses the threshold.

Set P06 = 2 to 4 volts

This will make the THC adjust more often.

If P05 is too close to your real arc voltage, the THC thinks it is “already correct” and stops moving.

Set P05 = set voltage + 5 volts

Example: If cutting at 118 V, then P05 = 123 V.

Many CNC controllers use anti-dive incorrectly and disable THC at anything below 99% of commanded feed rate.

This means:

In your CNC controller:

• Disable “feedrate based anti-dive”
• OR change the % threshold lower (e.g., 60–70%)

If ARC OK is flickering, the THC will not activate normally.

The THC will only run when:

• ARC OK high
• THC enable high
• Vehicle speed above anti-dive threshold
• Threshold voltage (P06) met

If ARC OK is unstable → it only reacts during slow-motion corner moments where the signal happens to be stable.

If your machine uses:

• Mach3
• Mach4
• UCCNC
• MyPlasm
• LinuxCNC
• Proma-compatible posts

Some post files enable THC only during G1 moves with NO CV (constant velocity).

That results in:

• CV on straight → THC off
• CV forced off at corners → THC on

1. Start a cut

1. Look at L01 / H01 status LEDs on the THC
2. If the LED goes OFF while torch is cutting → THC disabled by your controller
3. If LED stays ON but torch does nothing → parameters P05/P06 are blocking adjustments

This tells you exactly which part of the system is shutting the THC off.

User: Would any of these settings prevent it from running all the time

Would any of these settings prevent it from running all the time

Assistant: YES — this screen shows the exact reason your THC is NOT running all the time.

YES — this screen shows the exact reason your THC is NOT running all the time.

Your controller is locking/disabling THC based on feedrate and distance, so the THC only turns on in specific moments (like corners).

Below is the breakdown of the exact settings causing your problem and what to change for THC always-on continuous height control.

#

This means:

On almost every cut, the feedrate is never a perfect 100%. Even tiny speed changes from CV (constant velocity) or acceleration ramps make the THC shut off.

Set Speed to Lock THC to 50% (safe)

Or for aggressive THC, use 30%

This means:

Small segments, arcs, or tight geometry will disable the THC completely.

Set Distance to Lock THC = 0mm

(Sometimes 1mm if your machine requires it)

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During corners, feedrate typically slows down drastically (below 95%).

Some controllers reverse the logic and temporarily let THC run during these slow moments.

Because:

• On straight lines → feed rate below 95% briefly → THC OFF
• On corners → internal anti-dive logic triggers differently → THC ON

Once you set Speed lock lower and Distance lock to zero, your THC will run the entire time.

Just tell me:

• Your cut speed
• Plate thickness
• Amperage
• Plasma cutter model

I'll dial in the ideal numbers for the F2100B and the F1621P so they work perfectly together.

User: Cut speed 1400mm/mm

Cut speed 1400mm/mm 1.6mm plate 32amps Unimig razor cut 45

Assistant: Perfect — with 1.6 mm plate, 32 amps, 1400 mm/min, and a Unimig RazorCut 45, I can give you fully dialled-in parameters…

Perfect — with 1.6 mm plate, 32 amps, 1400 mm/min, and a Unimig RazorCut 45, I can give you fully dialled-in parameters for BOTH:

1. Your F2100B controller (THC enable/disable logic)
2. Your F1621P torch height controller (voltage + motion response)

These settings will make the THC run continuously, track voltage properly, and avoid over-reaction on thin material (1.6 mm is the MOST sensitive to erratic THC behaviour).

Let’s lock it all in:

✅ 1. F2100B Controller Settings (THC enable logic)

These are the ones from your screen.

Change these first (IMPORTANT):

| Setting | Value to Use | Why | | -------------------- | ------------ | ---------------------------------------------------------------------------------------------------------------- | | Speed to Lock THC | 30% | Ensures THC stays ON during straight cuts. Thin sheet = feed fluctuates constantly, 95% completely disables THC. | | Distance to Lock THC | 0.0 mm | Allows THC to run even on small segments. |

Recommended rest (for 1.6 mm plate):

| Setting | Value | Notes | | ---------------------------------- | ----- | -------------------------------------------- | | Delay Before Arc | 0.0 | Fine | | Pierce Time | 0.4 s | 1.5s is far too long for 1.6 mm plate. | | Torch Up Time | 1.00 | Fine | | Arcing Check Time | 3–5 s | The arc establishes instantly on thin sheet. | | IHS Check Time | 0.0 | Fine | | IHS Up Time | 0.0 | Fine | | Time to Disable THC After Piercing | 0.20s | Thin plate bends fast; THC must react early. | | Lose Arc Delay | 0.00 | Fine | | Watch Arc Enable | ✔ | Keep ON | | Use Cylinder THC | OFF | Correct |

✅ 2. F1621P THC Parameters (Voltage + Motion)

For 1.6 mm sheet, you want very smooth, low-aggression motion. Thin plate bends FAST with heat, so THC must respond — but gently.

Arc Voltage (most important)

At 32 amps on 1.6 mm, your correct arc voltage will be:

👉 Set Voltage = 104–112 volts (check with a test line; every machine varies slightly)

Here’s the general setting pack:

🎯 Critical THC Parameters (F1621P)

| Para | Setting | Notes | | ---------------------- | ---------------- | -------------------------------------------------- | | P05 – AVC Stop Voltage | Set Voltage + 5V | e.g. if set voltage is 110 → P05 = 115 | | P06 – Threshold | 3 V | THC reacts only if voltage differs more than 3V. | | P07 – Sensitivity | 10–15 | Thin sheet needs smooth motion, reduce aggression. | | P03 – Auto Up Speed | 20 | Slower = smooth height correction. | | P04 – Auto Down Speed | 20 | Prevents nose-dives into the plate. |

🧰 Other Support Parameters

| Para | Setting | Why | | ---- | ------- | -------------------------------------- | | P14 | 6 | Smooth braking | | P15 | 10 | Smooth reversing | | P08 | 1.0 s | Emergency retract | | P09 | 3–5 V | Small voltage bump after collision | | P10 | 1 | Enable IHSV (optional but recommended) |

🔍 3. Cut Speed & Heights

Cut Speed

1400 mm/min is perfect for 32A on 1.6mm.

Torch Heights

| Height | Value | | ------------- | ------ | | Pierce Height | 3.0 mm | | Cut Height | 1.5 mm |

Air Pressure

• Razor Cut 45 likes 70–75 psi / 4.8–5.2 bar while actually cutting (not idle).
• Maintain stable pressure: thin sheet is extremely sensitive.

🔥 FINAL DIALLED-IN VOLTAGE PROCEDURE (IMPORTANT)

To get your REAL correct arc voltage:

1. Disable THC.
2. Set cut height to 1.5 mm manually.
3. Cut a 300 mm straight line at 1400 mm/min.
4. Watch actual voltage on the THC: - It will stabilise around 104–112 V.
5. That number = your new Set Voltage.

Once you do this, voltage stability will improve massively.

✅ RESULT: After applying these settings

You will get:

✔ THC running ALL THE TIME ✔ Smooth corrections (no jerky Z-axis) ✔ No nose-dives into thin sheet ✔ Actual voltage tracking set voltage closely ✔ Clean cuts with minimal bevel ✔ Dramatically reduced warping compensation issues

If you want

I can also give you:

• A dedicated voltage table for the RazorCut 45 for all thicknesses
• A F2100B post-processor optimisation pack
• Settings for 6mm, 10mm, etc.

Just tell me the thicknesses you cut most.

User: Can you make a picture of where all the parameters should be

Can you make a picture of where all the parameters should be

User: And a picture of the THC F1521P

And a picture of the THC F1521P

User: A picture of what the parameters should be

A picture of what the parameters should be