Hypertherm Powermax 1000 Installation guide

CNC Plasma Cutter Training
Basics for using the PlasmaCAM Table and Hypertherm powermax 1000 CNC Plasma Cutter

Safety First
The Equipment -- PlasmaCAM Table
The PlasmaCAM Software
The Equipment -- Hypertherm Powermax 1000
Bringing it all together
Other information
Agenda

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!!!

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!!!

DO:
Read/review the Operators manual for the Hypertherm 1000 and
the new torch (Duramax retrofit)
(https://dallasmakerspace.org/wiki/CNC_Plasma_Cutter_Training#
Equipment)
Proper attire
Closed toe shoes
Natural 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 Table

The Equipment –Overview
Exhaust fan Switch
Hypertherm Powermax
1000 power supply
PlasmaCAM computer
PlasmaCAM table

The Equipment –PlasmaCAM Table
Gantry
Control Panel
Torch carrier
No Hands Along the
Yellow Paths!

The 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)

Z-axis jog for large
movements
The 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

The Equipment –Table Torch Carriage Detail
Torch
Carriage
Torch holder
clamp screw
Torch handle
holder clamp
screw
Business
end of torch

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.

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
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 Software

Position the stock and torch as needed to clear stanchions, previous
cuts, or other obstacles
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

Launch the software (PlasmaCAM) from the desktop shortcut, or from the start menu
Accept the Windows UAC message to continue
Initialize the torch/software using Machine->Initialize
This sends the torch carrier to the top, left, and raises the Z axis full up
Should be used any time settings are changed to ensure proper communication
between gantry/torch and software.
Shortcut keys are HANDY to learn: Press the shortcut key for the 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, 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 PlasmaCAM Software –Getting Started

The PlasmaCAM Software -- Launching
These dots indicate
the support
stanchions
These lines indicate
the border of the bed

The PlasmaCAM Software -- Stanchions
The finger shows the real; the arrow
shows the software representation

The PlasmaCAM 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)

The PlasmaCAM Software –Imported Design
Notice the entire design is green.
This is how the 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)

The PlasmaCAM Software –Linking Segments
These purple cut lines will be a
full, uninterrupted 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

White segments appear if the cut lines are not linked. To select the parts to link:
click, hold, and drag the selection box to fully surround the parts to link
OR hold CTRL key while clicking the links to be added
Once all 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 Software –Linking Segments