Hypertherm Powermax 1000 Training Download Page 4

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

DO NOT:



Put hands on the gantry rails. You will lose fingers!



Cut these materials due to TOXIC fumes :



Anything cleaned with chlorinated cleaner (e.g. brake cleaner)
–PHOSGENE gas is generated



Galvanized steel – causes “galvanize poisoning”



Heavily painted material – causes arc degradation and
unpleasant if not dangerous offgassing



Watch the arc without proper safety gear – AWS recommends
shade 8 or greater eyewear



Handle material without proper PPE/Tools – hot material after
cutting will BURN



Abuse the equipment (e.g. misusing the torch by placing the cutting
head over your hand & pulling the trigger)

Safety First!!!

Summary of Contents for Powermax 1000

Page 1: ...CNC Plasma Cutter Training Basics for using the PlasmaCAM Table and Hypertherm powermax 1000 CNC Plasma Cutter ...

Page 2: ... Safety First The Equipment PlasmaCAM Table The PlasmaCAM Software The Equipment Hypertherm Powermax 1000 Bringing it all together Other information Agenda ...

Page 3: ... You are responsible for your safety and the safety of the people around you This equipment may interfere with pacemakers hearing aids Use the machine at your own risk Safety First ...

Page 4: ...el causes galvanize poisoning Heavily painted material causes arc degradation and unpleasant if not dangerous offgassing Watch the arc without proper safety gear AWS recommends shade 8 or greater eyewear Handle material without proper PPE Tools hot material after cutting will BURN Abuse the equipment e g misusing the torch by placing the cutting head over your hand pulling the trigger Safety First...

Page 5: ...fiber garments instead of synthetics Wear proper PPE AWS recommends shade 8 or greater eyewear Cover exposed skin to protect from IR burn Use gloves and or tools to manipulate the material especially after cutting when it will be HOT Report any damages or issues immediately by creating an Issue or Request thread on Talk https talk dallasmakerspace org Safety First Next The Equipment The PlasmaCAM ...

Page 6: ...The Equipment Overview Exhaust fan Switch Hypertherm Powermax 1000 power supply PlasmaCAM computer PlasmaCAM table ...

Page 7: ...The Equipment PlasmaCAM Table Gantry Control Panel Torch carrier No Hands Along the Yellow Paths ...

Page 8: ...he Equipment Control Panel Power Switch Emergency STOP button Cutting Switch Z axis jog X Y axis jog Note the software MUST be launched and operating before this control panel will work See next section ...

Page 9: ...Equipment Control Panel Ready Power is on Z axis is selected Cutting is on auto Axis shuttle for minor movements usually used for Z axis in this class X Y movement can be done here but is better done in the software Emergency STOP button ...

Page 10: ...The Equipment Table Torch Carriage Detail Torch Carriage Torch holder clamp screw Torch handle holder clamp screw Business end of torch ...

Page 11: ...The Equipment Table Stanchion Detail These points which hold the stock are called stanchions and are indicated in the software as blue dots They are to be avoided when cutting ...

Page 12: ...the actual material If needed perform an Initialize in the software for the greatest bed clearance for loading stock see next section Largely place the material anywhere in the bed bearing in mind that all cuts should fall between support stanchions Most people opt to put their material in the bottom left closest to the control panel The Equipment Placing Stock on the Table Next The PlasmaCAM Soft...

Page 13: ...es Import or draw the design we will focus on import Create the cut paths Link design lines which might not be constrained from the drawing Define the start points lead in direction Define the cut order Select the portion of the design to cut Initiate cut The PlasmaCAM Software Steps to Cut ...

Page 14: ...function desired then use the mouse to direct to the location needed More on this as we progress All this work CAN be done without stock loaded in the bed but it seems like a better choice to load the material first and then walk through these steps to make sure the cuts will happen as desired on the actual material Perform an Initialize for the greatest bed clearance for loading stock Largely pla...

Page 15: ...The PlasmaCAM Software Launching These dots indicate the support stanchions These lines indicate the border of the bed ...

Page 16: ...The PlasmaCAM Software Stanchions The finger shows the real the arrow shows the software representation ...

Page 17: ...Software Importing Import the file containing your design Browse along the path to the saved file Here are some of the file types supported by PlasmaCAM some restrictions apply e g BMP can only be 256 colors or less ...

Page 18: ... design looks when it is selected You can try to move the design at this point but it is likely you will need to link the segments next section for a successful move Press ESC or right click to deselect We WILL want to move the design to avoid cut paths on the support stanchions blue dots ...

Page 19: ... cut they are linked or constrained Before the image can be moved we must ensure the cut paths are linked These white cut lines are not linked they are NOT constrained In this example we DO want the shapes to be cut in one motion so we will need to LINK the white segments to turn them purple ...

Page 20: ...ll parts are selected use Edit Link Segments or press K to link If they still will not link still seeing white segments try Zooming F1 key then click and drag the mouse to select the area into the area and then trying the above again OR use Machine Settings Drawing Settings Link Segments shown next slide to increase the tolerances for the Link Segments and try the above again The PlasmaCAM Softwar...

Page 21: ...s are not working Gap distance to jump can be lowered or raised to achieve the desired affect Delete overlapping segments can help when converting multiple lines in a drawing into a single cut for the torch These settings may take some practice to get right for each design The PlasmaCAM Software Linking Segments ...

Page 22: ...The PlasmaCAM Software Linking Segments Now that the lines have been linked all of the cut lines show purple are constrained or linked and will be cut in a single motion per line shape ...

Page 23: ...oftware Imported File Remember we wanted to move the design to avoid cut paths on the support stanchions Now we can select the whole image click and drag a window as indicated by the green line color Moving is up next ...

Page 24: ...ross hairs cursor Then click and release the mouse button to create an index point anywhere on the image choose carefully and it will make the move easier to see move the mouse to the new location of the index point and click and release again Ensure the cut lines are NOT on a support stanchion in addition to any other criteria ...

Page 25: ...of these cuts are a little close for thicker materials Thinner materials can tolerate closer cut lines Portions can be moved by clicking on them while holding CTRL Then move by Edit Move to or press M click once to index move and click again ...

Page 26: ...ping Snapping can be turned on in Machine Settings Drawing View Sometimes this makes arrangement easier Alternately sometimes it makes it more difficult so try it either way if getting a preferred position is proving problematic ...

Page 27: ...le for example click on the inside of the hole in the drawing For smaller precise holes edit the pierce point lead in so it is smaller than the diameter of the hole Keep in mind the smallest hole which can be cut depends on material thickness and the amperage used In 3 16 steel the smallest diameter possible is about 150 The PlasmaCAM Software Creating Cut Paths ...

Page 28: ...M Software Creating Cut Paths To create the cut path Open Machine Convert to Cut Path or press P Select the starting point Right click or press ESC Note the outline is now blue to indicate the cut path has been set ...

Page 29: ...t the design we have to tell it what order to cut the parts Cut smaller parts first Cut from the inside out to maintain electrical continuity to ground of the parts being cut If possible alternate which side of the stock is being cut to reduce heat warping The PlasmaCAM Software Cutting Order ...

Page 30: ...The PlasmaCAM Software Cutting Order Open Machine Reorder Path s Pick Order ...

Page 31: ...ross hairs Select the segments in order Once selected the segments become red Once completed right click or press ESC NOTE there is no indication of the order selected You must remember If you think you want to change it you have to re do the whole selection ...

Page 32: ...L and click function In this image the entire design is green indicating the entire design will be cut Remember the cut order That is the order which will be used Doing a dry run by leaving the PlasmaCAM table cutting setting OFF is recommended Then repeat the process with it on to actually make the cuts Next The Equipment Hypertherm PowerMax 1000 ...

Page 33: ...The Equipment Hypertherm powermax 1000 ...

Page 34: ...Power switch Gas Air hose inlet On the BACK The Equipment Hypertherm powermax 1000 Power cord Gas Air dryer filter ...

Page 35: ...The Equipment Hypertherm powermax 1000 Current amps adjustment knob Mode switch Status Indicators Gas air pressure gauge Gas air pressure regulator adjustment knob On the front ...

Page 36: ...y be started with air pressure too high but for best quality should be adjusted down keeping an eye on the indicator to avoid dropping too low Note Indicator usually shows high when first turned on Try a test fire to purge the line and recheck indicated pressure before adjusting ...

Page 37: ...e of the carriage Loosen the thumb bolt on the right The torch should slip out easily Remove the shield from the torch Remove the retaining cap from the torch Remove the nozzle from the torch Remove the electrode from the torch Remove the swirl ring from the torch Check each for any damage per the specifications Reinstall in the opposite manner Ensure proper torque no tools to tighten on the torch...

Page 38: ...e they the right parts Use the right consumables next section for the stock thickness Are they in good working order The head should be relatively clean The electrode should have a maximum pitting of 1 32 The nozzle output orifice should be round Not oval Not oblong Not the size of a pencil eraser ...

Page 39: ...The Equipment Hypertherm powermax 1000 Here are pictures of consumables notice the markings in very small print etching ...

Page 40: ...ly Closest branch to Space Address 1970 W Northwest Hwy Dallas TX 75220 Phone 972 556 0213 Order from an online supplier using part numbers for best price but be prepared to wait The Equipment Hypertherm powermax 1000 Standard PN Fine cut PN Shield 220818 220931 deflector Retaining Cap 220854 Nozzle 220941 220930 Electrode 220842 Long Life Electrode 220777 Swirl Ring 220857 220947 ...

Page 41: ...ut Minimum recommended material thickness will be 1 8 until we advise that Z Axis auto height control is operable Maximum recommend material thickness being mechanized for CNC reduces recommended capacity to 3 8 cut clean 1 2 max sever p39 in User Manual Material to be cut stock should be flat to avoid the torch hitting the material or the cut malfunctioning Attach the ground clamp directly to the...

Page 42: ...It is imperative that the work piece is grounded If it is not grounded it can ruin the torch and possibly the entire CNC system The Equipment Hypertherm powermax 1000 ...

Page 43: ...ounding is not properly done The arc found a ground other than the intended path tip of the electrode through the work piece and melted the side off the torch arcing to the carrier Arc Damage The Equipment Hypertherm powermax 1000 ...

Page 44: ...priate starting point However you should consult the wiki https dallasmakerspace org wiki CNC_Plasma_Cutter_Training Equip ment for more up to date information about the DuraMAX torch Always TEST Things can change so pick a scrap section of your stock and do a test cut or 2 or however many you need to make sure it s working as you desire ...

Page 45: ...ion of the control panel Front panel of the Hypertherm power supply for fault indications Yellow Torch LED Check the torch head cup for tightness Yellow Temp LED power supply is too hot Gas Pressure LED If flashing yellow check the air pressure Should be above 60 psi MINIMUM Remember the 2 LEDs on panel indicate pressure range Check for proper grounding of the table AND the stock ...

Page 46: ...ion on cutting reference holes so the stock may be repositioned after cutting those portions which are accessible and cut again Move the cut head using reference holes if applicable to locate the cutting torch as desired on the work piece Note the yellow crosshairs on the monitor mark the torch location To move the torch Machine Move To OR press V Click the new location and the torch will move Kee...

Page 47: ...gulator Adjust the amperage Adjust the cut settings in Machine Settings as needed see next section After changing ANY machine settings initialize to ensure the settings are good Make sure the ground clamp is well attached to the work and out of the way of the carriage as it follows the cut paths Move the torch with Machine Move to or press V over the work piece Check the stock can contain the desi...

Page 48: ...This height control overrides any auto torch height Select the parts to cut Using the click drag technique OR hold CTRL key click each line Notice the parts to be cut are highlighted in green as selected To initiate the cut use Machine Cut Dry run the cuts with the Cutting setting on the PlasmaCAM controller OFF Once finished turn everything off including the evacuation fan remove the air hose fro...

Page 49: ...ettings holds the settings for the PlasmaCAM This is the first screen that comes up and is for the speeds The cutting portion is where we really need to pay attention After changing any of the settings be sure to initialize the machine ...

Page 50: ...ne segments are smoothed into arcs Torch lead in is configured here Small cuts need smaller lead in Standard cuts need larger lead in for better finish quality Offset configures the offset of the kerf Other Information Path Conversion ...

Page 51: ...Other Information Height Control Auto torch height is not currently used In the near future we hope to have it working It will allow better control for thinner materials and help reduce warping ...

Page 52: ...lecting anything Make sure that it is a good speed and realize other items that may need to be set up when these are adjusted The black book kept with the Hypertherm power supply will be an appropriate starting point However you should consult the wiki https dallasmakerspace org wiki CNC_Plasma_Cutter_Training Eq uipment for more up to date information about the DuraMAX torch ...

Page 53: ...or reference before making any other cuts Select a scrap area of the stock When drawing the circle enter the size of the shield for the diameter Draw cut a second circle for more precise re location In the PlasmaCAM software move the torch to the reference position s Move the stock so the torch and the reference holes in the material line up whenever initiating a new series of cuts Other Informati...

Page 54: ...ch location 2 reference holes Use these points to maneuver the stock back into position If stock shifts during a cut create a break where the cut ended by with Edit Break OR press B then select the point click Re initiating the cut will pick back up where it left off ...

Page 55: ...t lines do not fall on the support stanchions Move the torch carriage using reference holes if applicable to locate the cutting torch as desired on stock Ensure the stock is properly positioned and sized by checking the corners Manually adjust the Z axis to about 1 16 1 8 above the work use a penny Adjust cut settings in PlasmaCAM software under Machine Settings Run Machine Initialize in the softw...

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