Building a machine torch from scratch

[Danno]

I built a cnc mill 3 years ago, and I'm now in the planning stages for a cnc plasma table.
I purchased a Hypertherm 45 for this project, but I don't want to use the hand held torch for the table because I still want it to be portable.
The price here in Canada for the machine torch is just too high of a price to pay, so I want to build my own.
I'm fully capable to fabricate the parts needed because I'm a tool maker.
The part that I want to find out about is the wiring.
Does Hypertherm use any type of "special" sheilded wiring, or should it be easy to purchase somewhere?
Are there any printed circuits in the handle ?
Any input would be appreciated.
Dan

[Benderart]

You're joking right ?????
Please tell me you're joking...........
If not.....save your pennies and just buy one.

[Tensaiteki]

Try doing a search and reading older threads, especially these:

http://www.cnczone.com/forums/plasma...iy_plasma.html
http://www.cnczone.com/forums/hypert...ine_torch.html

[Danno]

No I'm not joking !! 95 % of the people (like yourself) would just go out and buy whatever they need, but there's 5 % of us out there that like to build things because of the challenge and it's great to learn something new.
Most of the members here on CNCzone are hobbiests that build their own cnc machines including cnc plasma cutters.
My question is directed at those 5% that understand what I'm attempting to do !!
G-day Mate !!

[Danno]

Thanks Tensaiteki ;
I already saw those posts, but they were just a hand held torch that was modified. Building the torch part that holds the consumables is straight forward, but would like to know if its at all possible to make the whip feeding the torch.
Dan

[Benderart]

Originally Posted by Danno No I'm not joking !! 95 % of the people (like yourself) would just go out and buy whatever they need, but there's 5 % of us out there that like to build things because of the challenge and it's great to learn something new. Most of the members here on CNCzone are hobbiests that build their own cnc machines including cnc plasma cutters. My question is directed at those 5% that understand what I'm attempting to do !! G-day Mate !!

As you've already found out, I'm not in the habit of "just buying whatever I need", I also have many happy customers making good use of the fruits of my labour.
Good luck with your venture, I really look forward to seeing the outcome...

[jimcolt]

Danno,

There is nothing special about the leads that go to the torch. In the Hypertherm torch there is the electrode lead....which handles DC current up to the maximum amperage of the plasma system output(45 amps)....the maximum open circuit voltage on this connection is 300 vdc. There also is the nozzle lead, same power and voltage rating. There are wires for the "parts in place" safety switch, and on a hand torch for the trigger switch....these are low voltage control circuitry (around 15 VDC). There is no RF shielding necessary as the Powermax45 is a blowback start system (no high frequency). The torch connector is a proprietary Hypertherm design.

Most of the difficult construction is in the torch body itself. Since the internal components are exposed to component temperatures (electrode emitter) of 3000 degrees F, and the plasma arc that exits the nozzle can approach 30,000 degrees F.....proper heat transfer is extremely critical so that conducted heat does not melt the necessary non-conductive bearing materials that are necessary for the moving electrode. Use of the wrong dialectric and bearing materials will contribute to very short torch life.

Materials used in the torch body are: Vespel, Machinable ceramic, Lava (volcanic), copper, brass, silver, glass filled epoxy, melamine.

Best bet....to get it right the first time....is to take one apart and copy it! And....in advance...no, I cannot send you the prints!

Best regards, Jim Colt

Originally Posted by Danno Thanks Tensaiteki ; I already saw those posts, but they were just a hand held torch that was modified. Building the torch part that holds the consumables is straight forward, but would like to know if its at all possible to make the whip feeding the torch. Dan

[Danno]

Thanks for the reply Jim;
I put the original question out there mainly because of curiosity. I haven't taken my 45 handle apart, and have only been looking at pictures from others that have.
It looked as though the power lead going to the handle was made up of a dozen or so leads and not just one large diameterone like a tig handle.
It's obviously not worth my while to do so, because the bottle neck would be to fabricate the connector that fits into the machine.
Other than the consumables, the rest of the torch should be doable.

You have to understand that some of us think outside the box, and there's always a better and more cost efficient way of doing something.
Here in Canada, the 45 machine torch is over $800, even though our dollar is worth more than yours. Figure that one out !!

One example is my Lincoln MIG. The consumables are way more expensive than Berhard's, so with about 20 minutes on the lathe I converted my Lincoln handle to accept the much cheaper Berhard consumables.

I may have to take a trip to the US in the near future for my new torch !!
Dan
Welcome to www.dantechfabricating.com

[jimcolt]

I don't know why the systems/torches are so pricey in Canada....we supply the same units, same pricing as we do in the U.S....maybe tax? I really don't know. We are working on some systems that will come with both a hand and machine torch....with attractive pricing. That will be announced in the not too distant future.

Jim

Originally Posted by Danno Thanks for the reply Jim; I put the original question out there mainly because of curiosity. I haven't taken my 45 handle apart, and have only been looking at pictures from others that have. It looked as though the power lead going to the handle was made up of a dozen or so leads and not just one large diameterone like a tig handle. It's obviously not worth my while to do so, because the bottle neck would be to fabricate the connector that fits into the machine. Other than the consumables, the rest of the torch should be doable. You have to understand that some of us think outside the box, and there's always a better and more cost efficient way of doing something. Here in Canada, the 45 machine torch is over $800, even though our dollar is worth more than yours. Figure that one out !! One example is my Lincoln MIG. The consumables are way more expensive than Berhard's, so with about 20 minutes on the lathe I converted my Lincoln handle to accept the much cheaper Berhard consumables. I may have to take a trip to the US in the near future for my new torch !! Dan Welcome to www.dantechfabricating.com

[Danno]

A lot of it is tax, but I think a lot has to do with greed from the suppliers.
I think you would be shocked at some of the prices we pay here north of the border.
Here's a few examples;

Large argon cylinder refill - $140
1 gallon of reg gasoline-$4.94
1 gallon of premium gasoline -$5.51
24 cans of Budweiser- $40.00
Hypertherm machine torch -$830.55 incl tax


I could go on, but I just get depressed thinking about it !!
Hope you feel better next time you're filling up your car !!

[jimcolt]

My diesel fuel is $4 gallon. But the Budweisers are cheaper.....lower alcohol content though!

Jim

[Danno]

Originally Posted by jimcolt My diesel fuel is $4 gallon. But the Budweisers are cheaper.....lower alcohol content though! Jim

FYI;
Diesel is $4.56 here, and so is home heating oil !! Figure that one out, since there's supposed to be no road tax on it !!