Plasma Hand Torch Conversion

[mattmu]

I have a hypertherm 1000 with a hand torch and would like to modify the hand torch to simulate a machine torch so I can use the built in cnc controls on the unit to switch the torch on and off. Does anyone know how this is done or where I might find resources on how this can be done. Keep in mind I am a laymen when it comes to electronics, but as long as I have directions on how to do it I can handle it.

Thanks for any help you might offer me.

[Jason Marsha]

PlasmaCam owners may be able to help you with this as their manual instructs on how to do this (to my knowledge).

Jason

[mcarvey]

I am in the process of making a CNC plasma cutter with the hypertherm 380 that had a hand torch. Taking apart the hand torch and mounting it to a plate of aluminum is very straightforward. I still have to make a cover and finish up the THC circuit. I don't know what is involved with the cnc controls on the 1000 since the 380 unit that I have doesn't have any tip voltage outputs or anything like that. Attached is a picture of the mounting bracket that I made. When I get it working in a week or so I'll do a quick writeup of what I did and the THC circuit that I'm using. Good luck.

-Matt

[DSL PWR]

That is one hell of a good idea!

[WeCheat]

I own a hypertherm 900 and did not have a wiring diagram so I just unscrewed the torch at the machine and just ohm the wires while pushing the switch to find the right two wires. I was never able to obtain a wiring diagram from either hypertherm or the local dealer. With yours being a 1000 series wiring is probably different but if you want I could take a photograph of where I spliced into mine. But I probably won’t be able to post it until Wednesday as I’m going to be out of town until then. Just let me know.

[Weldtutor]

Mcarvey,
Were you able to finish your hand torch to machine torch conversion? Any more details would be appreciated.
Thanks, WT

[trevorhinze]

I have done this with both a hypertherm 350 and 600. In both cases all I had to do is locate the two PURPLE wires coming into the unit from the handheld torch. If memory serves me correctly this is either a 24 or 28 volt ac circuit. I made a small board that used an opticially isolated relay to complete the circuit of the two purple wires using the 5volt signal from the parallel port. weldtutor if you need a picture of this little relay setup let me know. I think that I still have your email address from the other day. Good luck.

[Weldtutor]

Trevorhinze
Yes I'd appreciate seeing that circuit.
What drivers & voltage do you use to your motors?
Thanks, WT

[mcarvey]

Weldtutor,
Unfortunately, the motor controllers that I'm making for the plasma cutter are taking a whole lot longer than anticipated, and I haven't gotten a chance to test the THC circuit that I'm making for it yet. I plan on activating the torch with a 24 volt relay that bypasses the switch on the two purple wires. The Z up/down pulses will be controlled with a PIC16f877, and I'll use a hall effect based current sensor to monitor the current through the torch.
I'll give more details when I finally get around to working on that part of the project.

-Matt

[Weldtutor]

Matt, Thanks for the reply.
The torch conversion pictured was an interesting approach. I'll look for your future posts as the project progresses.
WT

[trevorhinze]

I just drive my stepper motors with linisteppers and a 12volt power supply. I can only achieve about 60ipm without missing steps which is plenty quick for cutting all but really thin metal, but I do wish that my machine could rapid quicker sometimes, maybee Gecko's and servos will fix the speed problem someday when the budget will allow.

[Dave257]

the way I did it was by following plasmacams video. follow the bunch of small wires coming into the plasma machine from the torch. should be a group of about 5 or so wires. they go to a plug. make sure you machine is not plugged in and has been off for at least 30 minutes. just be safe. pull the plug the wires go to. take an ohm meter, keep putting it between any two connections an the torch side. pull the trigger doing all the combinations off the plug till you find 2 wires that are closing the trigger. either one of these can be cut and splice the 2 wires from the cnc between the cut. put the plug back on, if you tiewrap the trigger closed, then connecting these 2 wires will start your torch, so connecting these to the cnc relay or wires will turn on the torch. You should also need a connection to read voltage. they are taking that off where the ground and electrode are connected in the machine., again using an ohm meter from the electrode to where it connects in the box and the ground where it connects in the box. i would have no idea where you would connect them on the cnc side to get the readings though..


Dave