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The_Plasanator_Plasma_Cutter_Plans_2010.pdf

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   How I Made My Own Plasma Cutter From Junk By Joe Eichholz  Table of Contents  When I started assembling my cutter, I began with taking a good look at my parts. Asshown in Section 5  and Section 6, my parts are laid out so I can begin checking off frommy parts list. Once this was accomplished, I would study each the parts pictorial to getfamiliar with each part/component and they would be placed.The next step was to study my schematic and create a layout diagram. My board layoutdiagram is the most valuable piece in the building, repairing, and modifying process of my cutter.As I began mounting my parts, I organized my board into four sections. Those sectionsare Power Control, High Current DC, Low Voltage DC and High Voltage Arc Start. Power Control 3KVA step down transformer and contactor. The transformer is mounted off board because it is big and heavy, as you can see in Section 13 . The contactor became my first part on the board. I wired it so when the head trigger is pressed, it turns the contactor onand allows my DC components to come on line. Then I began with my next system,High Current DC. High Current DC Bridge Rectifier Large CapacitorsReed Switch (which I used as a current sensor), what it does is allow the high voltage arcsystem to fire and as soon as high current starts to travel to the head and cutting starts itshuts down the high voltage arc system while cutting since it’s not needed at this point.If you lose your fire it restarts the arc and gets you going again automatically.My next system was placed on board. Low Voltage DC The low voltage DC components are mixed with power switch and 120 volt terminals.Power Switch120-volt terminal blocks12 volt transformer Low voltage bridge rectifier Auto relaysTerminal strip, 4 position is all I needed but 5 position was what I had in my toy box. High Voltage Arc Start Microwave capacitor or run capacitor, a household dimmer switch rated for 15 amps. AFord or Chevy ignition coil. I used the Chevy on this cutter. As you can see, I haveterminals to all parts that get an external connection outside of their system so all I haveto do is run a piece of wire in-between. Now look at the pictorial of board mounted partsin Section 11 . It shows all the wires on the board, but here you can see all terminals and parts mounted, as I wanted. When wiring all my components, I used my Chevy boardlayout diagram to run my wires. How I began Making My Plasma Cutter  Page 1
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