General Quick Start Tips & Tricks

This guide provides practical tips to get the best performance, minimize downtime, and extend the life of your Starlab CNC plasma system.

Torch & Consumables

Use genuine Hypertherm consumables
Counterfeit parts are common and can cause poor cut quality, short life, or damage to the torch.
Rotate consumables
Keep sets together (electrode + nozzle) and rotate them out before they completely fail. This reduces the chance of double-arcing or torch damage.
Check nozzle orifice with magnification
A worn nozzle will show an oval opening instead of a perfect circle. Replace immediately for clean edges.
Pierce away from edges
Piercing too close to part edges dramatically reduces consumable life and may blow back metal into the nozzle.

Stable air pressure is critical
Hypertherm plasma units require clean, dry air at consistent pressure. Use a refrigerated dryer or desiccant dryer, not just a water trap.
Check air filters daily
Replace clogged filters and drain tanks to avoid moisture contamination.
Monitor gas pressure while cutting
Pressure should remain steady under load. Fluctuations often point to undersized compressors or long, restrictive hoses.

Verify ohmic sensing reliability
The FeatherTouch ohmic sensor must make clean contact. Dirt, rust, or paint on material can give false signals.
Set pierce height correctly
Too low → blowback into the torch.
Too high → arc misfires and incomplete pierces.
Fine-tune cut volts
Don’t rely only on charts — adjust cut voltage in small increments (+/- 1–2V) during test cuts to dial in kerf angle.
Watch for torch diving
If the torch dives during cut, it usually means incorrect volts setting, noisy arc voltage signals, or poor grounding.

Square the gantry regularly
Cut a large test square and measure diagonals. Adjust homing switches and re-home both sides if needed.
Keep rails clean
Dust, dross, or slag buildup on V-rails or bearings causes binding and lost steps. Wipe them down daily.
Check belt/gear lash
Excess play in belts or gear racks causes wavy edges. Tighten and lubricate as part of monthly maintenance.
Balance cut speed vs. quality
Hypertherm cut charts give good starting points, but every table has quirks. Too slow → dross buildup. Too fast → bevel or uncut edges.

Use proper grounding
Plasma cutting creates electrical noise that can cause random faults. Ensure the table, electronics cabinet, and plasma power supply are all tied to a solid earth ground.
Shield communication lines
RS485 and USB cables are prone to interference. Use shielded cables and keep them away from torch leads.
Separate high-voltage and low-voltage wiring
Route torch leads separately from motor/signal wiring. Cross at 90° angles when unavoidable.
Check hub connections
CandCNC RS485 hubs can cause intermittent issues if connections loosen. Periodically reseat or secure plugs.

Always dry-run a new program
Run “Disable Torch” mode in CommandCNC to confirm motion path before firing.
Use lead-ins and lead-outs
Avoid starting directly on part edges. Short arcs and tabs improve cut start reliability.
Nest parts for heat management
Spread pierces across the plate instead of clustering them. Heat buildup causes warping and arc instability.
Save successful cut profiles
When you find a voltage/speed combination that produces great results, save it with notes on material thickness and consumable set.

Arc won’t start?
- Check ground clamp
- Check air pressure
- Replace electrode/nozzle
THC not responding?
- Verify ohmic signal
- Inspect RS485 hub connection
- Reseat torch height control cable
Random cut interruptions?
- Look for moisture in air supply
- Check for electrical noise grounding issues
- Inspect worn consumables

✅ With these practices, you’ll extend consumable life, reduce downtime, and get the best cut quality from your Hypertherm + Starlab CNC system.