CNC Plasma Cutter (Avid Pro)

The Avid Pro Plasma 4x8 CNC system plus Hypertherm PowerMax 65 plasma cutter can run cutting operations on sheet metal including mild steel, stainless steel, and aluminum.

Quick Facts

Clearance Required: CNC Plasma Proficiency Based Clearance.
Max cut size 1“ (at 65A)
🔷 Members need to supply their own plasma consumables

Manuals

Tool Anatomy

Power switches (motor & plasma cutter)
E-Stop
Amperage control (45A/65A)
Control Computer
Welding Goggles
Torch Head
Gantry
Water Table
Speeds & Feeds Chart

Initial Setup: Powering On

It's strongly recommended to reserve a timeslot so you know the machine is available.

Top up the water in the water table if there's >5mm of open space to the top of the slats
- Roll the trash bin by the plasma over to the sink, fill it, return to CNC plasma, and slowly pour water in the center of the water table using the included bucket.
Ensure a good nozzle and electrode are loaded in the torch head
- Disconnect the THC wire and unscrew the head
- Verify the amperage rating of the nozzle (45A or 65A printed on the side)
- Replace electrode and/or nozzle if the wear pattern is not symmetric
- Screw down the head until it gently stops, then reattach THC wire
Turn on the Hypertherm and ensure its amperage setting matches the nozzle rating
Turn on the control box and use Mach3 to move the head free of your work area
Load your material and attach the ground clamp nearby
Draw the curtain behind you to protect other members from arc flash

Preparing G-Code: SheetCam

Create/edit an existing tool for Material Type & Thickness by referencing the Hypertherm Torch Operator Manuall to your Material Type & Thickness:

Feed Rate
Pierce Delay
Pierce Height
Cut Height

Import your plasma .DXF file as “new part”
Select your part
Create new “Plasma Cut” Operation (Operation>Plasma Cut)
Select the layer that contains the vectors you want to cut
Choose Contour Method

Outside Offset is typical for jobs with a mix of closed/open profiles

Enter the feed rate based on your material type and thickness
Configure lead-in and lead-out settings and press OK
Verify that the cutting preview shows the appropriate direction & leads

To prevent the cutter from crashing into parts that flip up during operation, go to Options → Job Options and ensure the Rapid Clearance field is set to 3” or larger (a higher value takes longer to touch off when starting a cut, but is less likely to crash on already cut pieces)

Run the Post Processor to create your .TAP g-code file

Operation: Mach 3

Hit flashing red “Reset” button to clear Emergency Stop condition

If the button does not reset when clicked, check that E-Stops & Proximity Limit Switches are unlocked

Select “Reference All Home” (wait until all three axis lights are green)
Zero X, Y, and Z axis
Load your file (File>Load G-Code)
Jog the machine head to the left/front corner of the desired origin (arrow keys)

Before zeroing, make note of the coordinates so that, if you need to restart mid-cut, you’ll have the exact location to return to
If prefered, select ”MDI Alt 2” to manually jog to the nearest whole number for your desired origin

Zero X and Y on the left/front corner of the desired origin
Zero Z with torch approximately ¼” above the material surface (page up/down)
Trace the job location using jog/arrow keys to ensure your file fits where desired
Safety Check:

Identify nearest fire extinguisher
Ensure E-Stop is easily accessible
Put on appropriate eye protection

Select “Cycle Start” to begin cutting

Cleanup

Turn off the control box
Turn off the plasma cutter (Hypertherm)
Remove any remaining material from the table
Detach the ground clamp and store it clear of the water table
If using your own consumables, remove them from the nozzle and replace them with a spare from the workstation table.
If using one, remember to take your flash drive with you!

Protohaven Wiki

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