Failure to detect material surface

I regularly get the following Error in VMD while cutting " IHS Error: Failed to detect material surface. Check work ground."

This error occurs intermittently but when it does i can't find what causes it. I check grounds, move the ground clamp, clean the material, clean the torch head, move the material on the table i even cancel the program and start over. Each of the above items works occasionally but there's time when none of them work.

Today for example i cut out 2 program with no issues then the error occurred and i was unable to rectify with the above steps.

Does anyone have any experience with this error?

 

The Initial Height Sense (IHS) is an electrical circuit. The same with troubleshooting a light switch you would do the same with the IHS, you need to first turn on the switch to test the circuit; to do that Login as Admin (password 1234) go to Machine Settings to open Configuration Menu. In your version of the software if the Configuration Menus does not open up automatically you can go to Main Menu in upper left click Open and select the Configuration.wap to open. Click on Advanced Tab and press Relay Output to set it to On. Check the IHS detection light on right side of main screen, if detected that means you have contact between Nozzle and Shield Cap, remove Ohmic wire from torch body to see if the connection goes away if so reconnect Ohmic wire and check debris inside Shield Cap, screw Cap back in place and check connection light if still lit unscrew Cap 1/8 to 1/4 turn also ensure Shield Cap matches rating on Nozzle.

On other hand if IHS light shows not detected, then jog torch down to touch material, ensure Shield Cap is making contact with material, if IHS still does not show detected then ground Ohmic wire on torch body to bus bar on side of table where the VFC box is grounded to. If IHS shows detected when you do this then it tells you there is no continuity between the material and the bus bar, normally due to rust, heavy mill scale or dirty/painted material.

 

I finally had time to get back to the table to trouble. When I set the relay out to on the ihs detection light stayed off. Then I ran the torch down to contact the steel and the detection light came on as soon as it is removed from the surface light goes off. I also connected the ohmic wire to the bus bar which also worked. I am using a fresh sheet of clean steel so there is no mill scale and as you can see the table little to no rust. I removed and reattached all the wires to the bar and still nothing do the table slats need to be ground clean. Seems like overkill if thats what it takes.

 

Not overkill at all, electricity follows the path of least resistance; it is ohms law, if your body has more resistance than ground you wont get shocked when you touch a live wire (I wouldn't recommend trying this). You already tested the circuit and it works so I dont get why you are having problems. In your statement "Then I ran the torch down to contact the steel and the detection light came on as soon as it is removed from the surface light goes off." this indicates the circuit is working.

 

After running through the diagnostics I tried to run the program and will attempting the very first cut I received the same error message. While looking through the setting under the input tab I noticed the homicide cap light was not on, could something not be getting detected? I'm shut down until I get this figured out.

 

Check the obvious first, does the torch contact the material you will know because either IHS will show Detected or Breakaway will Open, obviously if IHS doesn't detect then Breakaway will Open because it will press down on material till Breakaway trips. Is the metal Ohmic clip touching the copper shield cap, how are you supposed to get Ohmic if shield cap is touching material but the clip is not touching the shield cap, like a battery cable not touching the battery your car wont start.

 

I am having the same issues. The frustrating part is it happened right after we did all sorts of PM....

So I am going to go through all the consumables again to make sure things are just right. Never fails, it's the tiniest little thing that throws things off.....

Ended up calling tech support about IHS Error: Detecting Material before starting IHS and Execution Error Torch breakaway detected.


For the break away, tech support had us adjust the set screws to recess the magnet because it might have been too tight. This was tested by placing a piece of 1” paper strip between the torch head and the magnet - being careful not to have the paper getting bound up by the bearings.


For the IHS Error: Detecting material before starting IHS we adjusted the torch head height by loosening the two clamps. The height must have been readjusted and not noted by someone else helping with the PM.


The head was traveling down and “slamming” into the metal. Technical support had us loosen the clamps and manually lower the head to the bottom limits and then raise it up to get it to the right height.

If you are reading this in the forum, I would suggest calling them and letting them know. They will take good care of you and help you fix the issue!!


Once fixed, I will be marking on the torch head where the clamps should be…. Since multiple people use the machine.