Settings on PM 45

[Justme]

I am new to plasma machines, so letys just assume I know nothing at all. I have a PM45 that I just got to use with a PlasmaCam table. I have read the manuel, and gone through the cut charts in it. I am curious, because the manuel does not show any settings other than 30 or 45 amps. It shows from X to X thicknesses use 30 amps, and from XX to XX thicknesses use 45 amps, and only varies IPM. Yet I notice the machine had an infinite setting dial rather than a two position switch that clicks from one to the other.

I have asked some local people who use plasmas, as well as the LWS, and keep getting different stories. One guy said you want to always cut with 45 amps with 45 amp consumables, and 30 amps with the 30s. Another said you get the best cut by using the highest amp setting possible and cutting as fast as possible, and yet another said best cuts are from lowest amp that will cut at the recommended IPM.

When I asked the local Hypetherm dealer about settings, they said they were in the manuel. When I said it only showed 30 and 45 they pulled one out and looked and said, "Huh! Guess they want you to just trial and error."

So, my question is, what is the rule of thumb for adjusting amp settings? What do you look for? I have figured out the difference between high and low speed dross. I'm looking for pointers on fine tuning things.

[jimcolt]

There can be an infinite number of settings for each material thickness and type ....with almost any plasma system. If the manual had every combination for cutting every thickness of material....the cut charts would be hundreds of pages long. This type and volume of information would only add to the confusion level.

The cut specifications listed in Hypertherm's manuals are proven (and tested by cutting many lineal feet of each material listed)....and are the most complete set of cutting specifications that you will find for an air plasma cutting system.

To clarify a few "rules of thumb":

- You can use the 45 amp shielded consumables at any power level you would like. They are designed to have the highest energy density (stiff arc) at 45 amps...and likely will provide the best cut quality if you use them at 45 amps and follow the cut specifications (pierce height, pierce delay, cut height and recommended (not fastest) cut speed as listed in the manual.

-If you operate the consumables at less than their rated maximum amperage you will have to experiment with cut speeds....as the arc will have less density (softer arc)....often this is done on cnc macines that have an upper practical speed limit that is lower than the published speeds in the Hypertherm manual.

- Best cut quality with any plasma system is with using the lowest amperage rated nozzle at its maximum rated power for the material you are cutting. With systems larger than the Powermax45......such as the Powermax 85....there are consumable choices of FineCut, 45 amp shielded, 65 amp shielded and 85 amp shielded. To cut 1/4" steel....I would choose the 45 amp shielded if I wanted best cut quality (edge squareness and smoothness with minimal dross). If I wanted to cut parts extremely fast...I would use the 85 amp consumables.....but would expect edge taper and less accuracy on fine features. I could not use the FineCut consumables as the cut charts suggest a maximum thickness of 10 gauge. Again....best cut quality is with the lowest amperage set of consumables that the charts say will cut the material thickness you desire to cut.

-Pierce height is critical to make the consumables last longer....especially the shield and nozzle. Piercing too high can shorten the nozzle orifice life as the pilot arc circuit will stay active longer...putting more heat load on the nozzle. Piercing too close to the plate will allow molten metal to blow back inside the nozzle and shield orifices....causing shorter life.
-Pierce delay times are to allow for the arc to fully penetrate the material before any x, y or z movement starts.....again increasing consumable life.

- Cut height is the height that cut quality is best in terms of cut edge angularity and dross formation. In most cases with the Powermax45 on steel....the cut height is best at .06". If you adjust this too close....there will be plate collisions....too far away will cause cut edge angularity and dross to increase....and can cause warpage on thinner materials.


The plasma cutting process (just like laser, water jet, routing, machining, oxy-fuel cutting) does require a little bit of experimenting in order to get the best possible quality on the many different types and thicknesses of materials you will be cutting. No two pieces of steel will have the exact same chemical content (metalurgy) or surface (both top and bottom) finish or flatness......all of which can affect the cutting process.

Follow the specs in the Hypertherm manual as closely as possible....and your learning curve will be shorter! There are also many settings that affect cut quality in your cutting machine software. By stickning with known specs from the manual...it will allow you to get through learning the drawing side, the cutting software side as well as the plasma system settings much more efficiently. After some time the process becomes very easy!


Best regards, Jim Colt Hypertherm

PS....thanks for purchasing the Hypertherm Powermax45...from all of the employee / owners of Hypertherm!




I am new to plasma machines, so letys just assume I know nothing at all. I have a PM45 that I just got to use with a PlasmaCam table. I have read the manuel, and gone through the cut charts in it. I am curious, because the manuel does not show any settings other than 30 or 45 amps. It shows from X to X thicknesses use 30 amps, and from XX to XX thicknesses use 45 amps, and only varies IPM. Yet I notice the machine had an infinite setting dial rather than a two position switch that clicks from one to the other.

I have asked some local people who use plasmas, as well as the LWS, and keep getting different stories. One guy said you want to always cut with 45 amps with 45 amp consumables, and 30 amps with the 30s. Another said you get the best cut by using the highest amp setting possible and cutting as fast as possible, and yet another said best cuts are from lowest amp that will cut at the recommended IPM.

When I asked the local Hypetherm dealer about settings, they said they were in the manuel. When I said it only showed 30 and 45 they pulled one out and looked and said, "Huh! Guess they want you to just trial and error."

So, my question is, what is the rule of thumb for adjusting amp settings? What do you look for? I have figured out the difference between high and low speed dross. I'm looking for pointers on fine tuning things.

[Justme]

Thank you Jim! That gives me some clarity.

Here is another question relating to cut height: Is the .06 measured from the face of the shield, or from the electrode or nozzle? I am guessing it is from the shield, since the manuel says to drag the shield in contact with the metal when cutting by hand.

[Rbeckett]

Jim' Da Man on all things Plasma Cam and Hypertherm. If Jim sez, it is a fact, not he heard or was told anything. You can rely on Hypertherm and Jim to take care of you if you own a hypertherm machine. I'll never buy any other brand, ever.
Bob

[jimcolt]

Yes....cut height and pierce height is the distance from the assembled torch to the plate.

Jim


Thank you Jim! That gives me some clarity.

Here is another question relating to cut height: Is the .06 measured from the face of the shield, or from the electrode or nozzle? I am guessing it is from the shield, since the manuel says to drag the shield in contact with the metal when cutting by hand.