View source for Operation of Kyle Paavola's CNC plasma cutter

= USING THE 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

== Appendices ==

== Safety ==

=== Electrocution hazard ===
=== Eye Protection ===

== 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