New build

[grgdmsn]

Here are some pics of my new plasma build. I own a fabricating shop so this is new and exciting to me. I am having trouble figuring out how to make it run, but working on learning Mach3 and Sheetcam. Spent day watching videos on Sheetcam setup. Reading all the mauals is hard on the eyes and mind. Hopefully the learning curve will start to become smaller! I still have not been able to make any type of workable G code to do something simple, but hopefully after today that may change. I am still confused on the post files and which ones need to be adjusted and where they are suppose to be stored for Sheetcam to use them. I am trying to follow Tom's THC test run to check the THC but not having much success getting code to make long straight cuts. Hopefully soon this will all come together. It took almost 6 weeks to build the plasma cart, the water table and the computer cart. The eventual goal is to have everthing on the moveable table since space is a big issue in my shop. I got a lot of the ideas for the water table from this site and thank everyone for posting the info they do. My set up is:
-Hypertherm 65 plasma w/ CDC port and serial card installed
-Precision Plasma 2' X 3' gantry. I want to thank Ron for the help and sending me the plans to build the basic 'C' frame table
-CandCNC Bladerunner CNC system with DTHC

[Danno]

Hey Greg;
Machine looks good !! Mine is working awesome
I know what you're saying about learning all this stuff. It can get overwhelming at times. The biggest problem I think is that we're playing with equipment that's not really designed for the masses, and the instructions that come with them are not the best.
You made the right choice by using the CandCNC controls, because IMHO it's the best out there. Tom is a very smart guy, but because of this, his instructions are very difficult to understand for the newcomers like us. A lot of the information he tries to tell us leaves us scratching our heads because we don't understand it inside and out like he does. In a few weeks, it will all make sense !!
I'm no expert at this either, but if there's something you're not sure about, ask me and I may be able to help.
Good Luck !
Dan

[grgdmsn]

Hey Danno, I agree. The manuals are hard to read because there is no table of contents and it covers many things that don't relate to my setup. I have been instructing adults for many years and I know that adult learners learn differently. I wrote a long post the other night on this subject but did not post it. I do not want to take the possibility of offending anyone. These forums have been the best thing for me. I learn the best by seeing and then doing, not reading a manual. Many people are not good readers anyway and don't retain from reading. I have a very good friend who is dyslexic. He can tear your car engine apart and put it back together and make if run better than it did before in four hours, but he does not read well or learn well from reading. You hit the nail on the head in that people who write manuals sometimes assume you know something that is basic to them or second nature but is not to the rest of the world. I had this discussion the other day with a friend. I am making great strides at the moment and cutting 16ga and 14 ga steel. I will start getting settings for other material and start working on AL. I do a lot of AL welding and machining. I also need to keep working on understanding the software. I am struggling with the layer thing at this moment and not sure about how to use layers and where to make them. I will keep in touch with you to see if you have run into what I am trying to learn. I appreciate your help. I also appreciated all your pictures of your build as I it helped me design my drain system. TTYL
Greg Mason
G&S Fabricating

[Danno]

I know exactly what you're saying. I'm almost 50 and there's not too much I can't , or haven't build.
Having said that, I have never read a book in my life !! Honest !
I've tried, but by the time I get to the second page I have to start over again because I forgot what I was reading. That's why I got into this CNC stuff, because it was so far out of my comfort zone.
I've been a Tool&Die maker for almost 30 years, but never had the opportunity to learn all this new stuff like CAD/CAM, and G-code and computers. I love machining, and I knew I was missing out on really cool technology, and the only way I was ever going to be able to use these tools was to jump into it 100 %.
A couple years ago I built my first CNC mill and learned CAD/CAM to the point that I can machine 2D parts comfortably. I don't even want to learn 3D because that would be too much.
I now just finished this CNC plasma machine, and it works way beyond my expectations.
I hope you enjoy this hobby as much as I do.
Dan

[grgdmsn]

Wow, we are very much alike. I am 57. I am an "old time machinist" since I started machining at 18YOA. I too do not know much about CNC but want to learn. I have two mills and a lathe in my shop but no CNC. I would love to have one but can't afford to buy one at this point and no place to put it if I did get one. Maybe after getting the plasma going, I may look into retrofitting one of the mills to CNC. I have been welding and fabricating for over ten years now. I too do not like to read and get confused by reading most of the time, the word "huh?" comes to mind when I think about reading things and trying to figure out what they are talking about. I too am jumping into this to force myself to learn some new things and push myself into the CNC stuff. I am also hoping to open up more markets for work since things are very slow at my shop and business is almost non-existent. It is all I can do in the last eight months to keep the doors open and pay the bills. My learning curve was very slow but is starting to get steeper very fast at this point. I just need to learn how to draw for CNC. I am now researching how to make letters. Have you done that yet? Also, do you know this. I have a new HT powermax65. After reading it's "manual" it appears it can be run in automatic or manual mode. If I am reading and understanding it correctly I am suppose to turn it all the way up to 65Amps in auto mode and it will handle itself from there. That is what I have been doing. It seems to be working fine so far and I have been using it that way on the thinner material, like 16 and 14ga. I am not sure if I am suppose to be adjusting the amps for thickness or not? There are no charts in the HT manual to show amperage per gauge or sheet thickness. What plasma cutter do you use? Hey, great talking with you. I am sure I will have other questions to bounce off of you. You said you built a CNC mill? How did you do that, retrofit an existing mill? If so, about how much did that run you? Thanks in advance.
Greg Mason
G&S Fabricating

[jimcolt]

Greg,

Your manual for the Powermax65 has very detailed charts for cutting with Fine Cut consumables (at a variety of amperages clearly stated in the cut charts for different thicknesses and types of materials) as well as 45 amp and 65 amp cutting using shielded consumables (part numbers and pictures listed at top of each page).

Follow the specs in these charts exactly (amperage, consumables, pierce height, pierce delay, cut height, cut speed) and you will get excellent cut quality and consumable life. If you just turn it to 65 amps to cut everything....don't expect much in terms of cut quality and consumable life.

"Rule of Thumb" for cutting.....shoose the lowest amp set of consumables that will cut the material and thickness that you need to cut.....this will provide best cut quality. 16 gauge should always be cut at 45 amps or less with either the 45 amp consumables or the FineCut consumables for best results. Using the 65 amp consumables will not do the best job on thin materials.

The "automatic" in a Powermax65 and 85 is simply the air pressure....set it to automatic and you don't have to adjust it as the consumables wear....as your shop air compressor cycles....or when you change to a different set of consumables.

When you have questions....I am here to help as is the entire Hypertherm company!


Best regards, Jim Colt Hypertherm

Wow, we are very much alike. I am 57. I am an "old time machinist" since I started machining at 18YOA. I too do not know much about CNC but want to learn. I have two mills and a lathe in my shop but no CNC. I would love to have one but can't afford to buy one at this point and no place to put it if I did get one. Maybe after getting the plasma going, I may look into retrofitting one of the mills to CNC. I have been welding and fabricating for over ten years now. I too do not like to read and get confused by reading most of the time, the word "huh?" comes to mind when I think about reading things and trying to figure out what they are talking about. I too am jumping into this to force myself to learn some new things and push myself into the CNC stuff. I am also hoping to open up more markets for work since things are very slow at my shop and business is almost non-existent. It is all I can do in the last eight months to keep the doors open and pay the bills. My learning curve was very slow but is starting to get steeper very fast at this point. I just need to learn how to draw for CNC. I am now researching how to make letters. Have you done that yet? Also, do you know this. I have a new HT powermax65. After reading it's "manual" it appears it can be run in automatic or manual mode. If I am reading and understanding it correctly I am suppose to turn it all the way up to 65Amps in auto mode and it will handle itself from there. That is what I have been doing. It seems to be working fine so far and I have been using it that way on the thinner material, like 16 and 14ga. I am not sure if I am suppose to be adjusting the amps for thickness or not? There are no charts in the HT manual to show amperage per gauge or sheet thickness. What plasma cutter do you use? Hey, great talking with you. I am sure I will have other questions to bounce off of you. You said you built a CNC mill? How did you do that, retrofit an existing mill? If so, about how much did that run you? Thanks in advance.
Greg Mason
G&S Fabricating

[Danno]

Hey Greg;
I'm running the Hypertherm 45. I bought it a couple years ago. The 65 was not available then. The 45 will do everything I need it to do, because most of the material I cut falls into the 3/8 or below range.
The mill I built was originally a Hurco KMB1. These can be had for cheap, because the weak link is the old electronics.
I got mine for $1200 including quite a few holders. I was able to sell the original electronics out of it for $500, so I only had $700 into the basic machine.
By the time I was done building it, I think I had about $3500 total invested.
If you search on my name, you'll find my build post on it from a few years ago.
You mentioned that you're having a problem "drawing" !! What CAD program are you using? The standard for industry is probably Autocad, but IMHO don't use it. This program is way too big and has too many capabilities that we will never use.
I ended up buying Dolphin Cad ! There's a few reasons why I did. The main reason is that it flows nicely with Mach3 with it's post processors. Also, there's excellent support via their forum, or here on CNCzone.
It's very easy to use. I would have to say that learning CAD was the most challenging part of learning CNC. What was great about building my plasma table, is that I could use the CAD program I already learned to use.
As far as the letters and numbers you need, go to CNC Plasma Cutters Ultimate Source for DXF files, cnc clip art, technical advice, plasma manufacturer support, and much more. • Index page and there you can join for $20 and download tons of DXF drawings. There's also a font pack you can purchase for another $20, and I think it will give you all the letters and numbers you'll ever need in DXF format.
Let me know if I can help in any way !
Dan

Edit; here's the link to the fonts I was talking about!
http://www.plasmaspider.com/viewtopic.php?f=6&t=53

[grgdmsn]

Jim, I am very confused. Nowhere do I see amperage settings on the charts. I am not using fine cut at this point so I have not looked at those charts. The chart for the 65, page 3-33 of manual shows settings for 1. Material Thickness 2. Torch-to-work distance 3. Initial Pierce height 4. Pierce delay time 5. Best quality settings (cut speed and VOLTAGE) and 6. Production Settings. In another post I saw this comment from you on the HT PM65 "Let me know what cut specs you are using.....and yes, the cut charts are designed for use at max amperage (65 amps for a 65 amp nozzle)....the exception to that is with the FineCut parts that use different amperages for different materials, as listed on the charts." Also the chart on 3-33 shows the 65 starting at 16ga and has settings for it. So now I am very confused. You say the chart is for use at the setting 65amps but you also say to use the charts and to adjust the amperage and that 16ga should be at 45amp? You also say I won't get best quality if I use the 65A setting on everything, but I don't see amp settings anywhere else and you say the chart is for using at 65Amps. I am not sure what to think at this point. Can you please get me straightened out. Thanks.
Greg Mason

[grgdmsn]

Dan, I am using TurboCad and have been using it for years. I have been pretty happy with it as it has done everything I need it to do. Thanks for the link on letters I will check it out. Also I will go and look at the mill you put together. That may be my next project after I get this plasma thing going well.
Greg

[Danno]

Jim, I am very confused. Nowhere do I see amperage settings on the charts. I am not using fine cut at this point so I have not looked at those charts. The chart for the 65, page 3-33 of manual shows settings for 1. Material Thickness 2. Torch-to-work distance 3. Initial Pierce height 4. Pierce delay time 5. Best quality settings (cut speed and VOLTAGE) and 6. Production Settings. In another post I saw this comment from you on the HT PM65 "Let me know what cut specs you are using.....and yes, the cut charts are designed for use at max amperage (65 amps for a 65 amp nozzle)....the exception to that is with the FineCut parts that use different amperages for different materials, as listed on the charts." Also the chart on 3-33 shows the 65 starting at 16ga and has settings for it. So now I am very confused. You say the chart is for use at the setting 65amps but you also say to use the charts and to adjust the amperage and that 16ga should be at 45amp? You also say I won't get best quality if I use the 65A setting on everything, but I don't see amp settings anywhere else and you say the chart is for using at 65Amps. I am not sure what to think at this point. Can you please get me straightened out. Thanks.
Greg Mason

I'm looking forward to Jim's reply on this one too !!

I tried cutting some fairly complex artwork the other day on some .060 aluminum, and I used the setting recommended by Hypertherm. Even though I dialed back the amperage (to 35amps using 45amp consumables) I was unable to get fine detail. What I mean by this, is that if a cut path was within .060 of an edge, the arc would just melt into the edge.
Another thing I'm confused at is the pierce height on real thin material. Tom at CandCNC told me to just ignore the pierce height and just use the cut height with no delay. The cuts were much better( no keyholing) but I'm concerned about spray back into my tip , thus reducing it's life. Thicker material doesn't seem to be an issue.
I would like to try the 30 amp consumables to see how small of a kerf it will produce. Afterall, cutting real thin material using 45 amp consumables is like using a 5 lb sledge hammer on a finishing nail
Dan