Operation of Kyle Paavola's CNC plasma cutter

August 2014

Quick guide

Convert a drawing to GCODE with SheetCam

Start SheetCam. Open your DWF file. Select a tool corresponding to your material thickness. Run the postprocessor. Save the GCODE file (.tap extension) to a USB thumb disk.

Run the Plasma Cutter

Clear off old stock
 Ways are clear and unobstructed
 Electrical cables under the ways are clear and untangled
 Consumables are in good condition
 208V cord is not an underfoot hazard
 Load new stock, from the narrow end only. Check that end is past stops. Preferably, the stock is slightly below the water surface.
 Attach torch with electrical tape
 Tape down the trigger
 Connect 208V using the adapter for the TIG wilder
 Connect air hose from the compressor to the plasma cutter
 Power up the air compressor. Let it run until it stops. Pressure should be 125 PSI.
 Switch on the power bar. The computer and THC should power up.
 Load GCODE file using socket on keyboard support. Remove USB stick.
 Don eye protection
 Power up plasma cutter (switch is on the back)
 Check plasma cutter status
   - ground cable is attached
   - power is on
   - no yellow lights are showing
   - air pressure is at the arrow
   - mode switch is in the middle
   - current is about 45A
   - torch cable is clear and can run for the length of cut
 If the stock is somewhat rectangular, square it with the table
   - using the torch head
   - using the stainless steel panels
 Run MACH3
   - load GCODE file
   - manually position torch to (0, 0). Reset X=0, Y=0.
   - manually position torch nozzle about 2 mm above material. Set Z=0.
   - regenerate toolpath
    - check that your audience is protected
   - start cycle
 Debug your cut, repeat as necessary
 Power down plasma cutter
 Switch off power bar
 Switch off air compressor
 Unplug 208V cord, recoil it, and hang it up
 Remove leftover material and scraps

Creating GCODE

 - SheetCam (sheetcam.com)
 - accepted input formats
 - tool selection
   - dimension is material thickness
 - create a tool path
   - right click on Operations
     - leadout must be less than leadin
 - run the postprocessor

- save the GCODE file (.tap) to a USB stick

CNC details

 Units

Precision

 Material thickness
 Kerf
 Cutting speed
 Tool height
 Corners
Small holes
 Starting, stopping cuts

Plasma Cutting

 - What materials can be cut
 - Flood cutting
 - Steel versus aluminum

- Consumables Should last 3-5 hours of torch time Underwater cutting is slightly harder on consumables than cutting in air Air Liquide part numbers HYP-220669 electrode HYP-220718 nozzle Plasma Cutter System

   Table
     - water consideration
     	- beware of drain plugs

- periodic cleaning (every two months?)

     - ways
     	- do not pile anything on the ways

- lubrication

- coordinates

Plasma cutter

Hypertherm Powermax 45

      The manual (https://www.hypertherm.com/Xnet/library/library.jsp?file=HYP109170)
    Torch Height Controller
    Air compressor

Power requirements Capabilities Max pressure Max airflow

Computer

Mach3