High Resistance/Loose Connections and Terminations

High Resistance/Loose Connections and Terminations


Main Power Issues

This is an example of thermal insult and runaway on a loose or poorly terminated connection at the main power switch



Here is a loose terminal on a contactor:



and one showing thermal insult on the contactor:



If a terminal is loose and/or corroded it becomes a high resistance connection and that generates heat. The hotter the terminal gets, the weaker it becomes, and this continues until it reveals itself as a critical failure.


Additionally, every switch, relay, contactor, etc... is prone to similar phenomena, especially if the current rating of the switch is met or exceeded. The switches can arc and the points can suffer spawling and other damage which lessens the contact area. The rocker switch is designed to actuate quickly, minimizing any arcing and ensuring positive contact so they are ideal for this application. Here is more about rocker switches:

 https://www.engineersgarage.com/insight/insight-how-rocker-switch-works/


Erratic/Inconsistent Laser Output


Sometimes the low voltage connections can be compromised which can cause erratic firing of the tube.



And the tube ground wire is another possibility:


Poorly Terminated / Arcing Laser Tube Ground Causes Anomalies


Here is more:

Electrical Noise, Ground Loops, and USB Communication


    • Related Articles

    • Nova Series Chiller Connections

      Preface: This article covers the standard connections from the Chiller to the Machine for a NOVA series laser The water flow connections are labeled relative to the machine. You do not connect the Chiller Inlet to the Machine Inlet or the Chiller ...
    • Aurora HF-75S Exhaust Fan Wiring, High and Low Speed selection

      This article covers the wiring of the HF-75S Exhaust fan for the Aurora Fiber Machines. For more information on the fan:HF-75S 3 Inch 27 CFM MIXED FLOW INLINE FAN Main Label: Factory wiring is for the High Speed, 29W, 120V, .50A and 27CFM Internal ...
    • Loose Optic Presents As Mechanical Backlash And/Or Offset Issue

      Preface: A Loose Optic can present itself as excessive mechanical backlash and/or scanning offset value issue. This article will address the symptom and possible cause. What The Client Reported, the symptoms: was in the middle of a water bottle and ...
    • Selecting Between Low and High Dual Air Assist Stages In LightBurn

      Selecting Between Low and High Dual Air Assist Stages In LightBurn If yours is working backwards please see this article: Thunder Laser Dual-Stage Air Assist Sequencing Issues
    • Poorly Terminated / Arcing Laser Tube Ground Causes Anomalies

      We have a small number of reports that a loose and/or arcing laser tube ground termination has caused x/y/z/and u motors to behave abnormally and result in erratic power output. if the high voltage circuit that energizes the tube suffers from high ...
    If you are a Thunder Laser USA client and still need Technical Support after exhausting the resources in the Knowledge Base, simply email support@thunderlaserusa.com and the Technical Support Team will promptly assist you!