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How to Make Your own Plasma Cutter.... (Plasma Cutter Kits Coming Soon!!)
by Plasanator on March 21, 2011

Table of Contents
How to Make Your own Plasma Cutter.... (Plasma Cutter Kits Coming Soon!!) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Intro: How to Make Your own Plasma Cutter.... (Plasma Cutter Kits Coming Soon!!) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Step 1: Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Step 2: Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Step 3: Warning Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Step 4: Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Step 5: Another View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Step 6: Another schematic to looksy at . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Step 7: Board Lay Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Step 8: Transformer I used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Step 9: Transformer connected to board Terminals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Step 10: Power to Contactor Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Step 11: Reed Current sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Step 12: Low Voltage side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Step 13: Relay Connections By Color . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Step 14: Chevy HV Transformer Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Step 15: Arc tip assembly to head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Step 16: Head air coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Step 17: Air filter/ Element and solinoid Hook up View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Step 18: Final power connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Step 19: Extra Photos of Past Cutter Projects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Step 20:

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Step 21: Plasanator 3's First Cut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Step 22:

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Related Instructables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Advertisements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Comments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

http://www.instructables.com/id/How-to-Make-Your-own-Plasma-Cutter/

Author:Plasanator Homemade Tools & More

Hi I'm Joe and welcome.
I love to make Homemade Tools & More.
I will have many things to put on the instructables for you to gander at.
I hope you enjoy there educational value and have fun.
Come se my home site if you get a chance.
http://theplasmacutterman.com/
Take care and God Bless.

Intro: How to Make Your own Plasma Cutter.... (Plasma Cutter Kits Coming Soon!!)
Check out new video of the Plasanator on utube.com
http://youtu.be/enELHZ7dP2I
This Ebook is designed for Guys and Gals who like to create tools and machinery.
I hope my Ebook gives you hope that no matter how hard a project may seem, keep plugging away until you finish and you will succeed.
I spent 3 years putting this together and now finally all my hard work and research has paid off.
I studied diagrams from commercial venders, but to no luck. They tend to leave a lot out on purpose - so its hard to reproduce their design. Ive see different attempts
at people making their own on You Tube and other sites, but what a death trap. Messy water resistors and wiring like a darn Christmas tree.
So I began reading books and articles on their workings and took my home schooled-knowledge of electronics to build my own plasma cutter. I was determined; failure
was not an option.
I started by collecting parts from old microwaves, stoves, water heaters, air conditioners, car parts and more in the hopes of creating a low budget way to create a plasma
cutter for myself. I mounted it all on a simple piece of scrap wood; well its scrap wood now. We, didnt need that table anyway (shhhhhhh dont tell the wife).
Then one day it all came together. I hit the power switch, placed the head to the metal, started the arc, felt the air kick and then a second hard kick (the current being
drawn into play). Then BAM, it was slicing through quarter inch steel like a hot knife through butter.
How sweet it sounded! I felt the amazement of completing a project that I just couldnt let go of.
So, take your time, enjoy and be safe.
The Plasaman

http://www.instructables.com/id/How-to-Make-Your-own-Plasma-Cutter/

Step 1: Assembly
When I started assembling my cutter, I began with taking a good look at my parts. As shown in Section 5 and Section 6, my parts are laid out so I can begin checking off
from my parts list. Once this was accomplished, I would study each the parts pictorial to get familiar with each part/component and they would be placed.
The next step was to study my schematic and create a layout diagram. My board layout diagram 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 sections are 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 on and allows my DC components to come on line. Then I began with my next
system, High Current DC.
High Current DC
Bridge Rectifier
Large Capacitors
Reed Switch (which I used as a current sensor), what it does is allow the high voltage arc system to fire and as soon as high current starts to travel to the head and
cutting starts it shuts down the high voltage arc system while cutting since its 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 Switch
120-volt terminal blocks
12 volt transformer
Low voltage bridge rectifier
Auto relays
Terminal 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. A Ford or Chevy ignition coil. I used the Chevy on this cutter. As you can see, I have
terminals to all parts that get an external connection outside of their system so all I have to do is run a piece of wire in-between. Now look at the pictorial of board
mounted parts in 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 board layout diagram to run my wires.
I checked and re checked all wires before mounting external parts. If you go to the final wiring section, you will also find pictures of my rigging of these parts. I could have
done it many different ways, but this is what I chose at this time.
It took me about 3 hours of procrastination to finally assemble it all. You know how it is on a project, once you are ready with all your parts, your mind starts giving you a
million ways of doing something. And, at last you just pick a way and go with it.

http://www.instructables.com/id/How-to-Make-Your-own-Plasma-Cutter/

Once I got it all together, I connected my air tank hose and put the pressure setting at 28 for a safe point to start. I fired it up and BAM - that baby didnt need any more
adjusting. It was cutting!
You can imagine all the relief and pride I felt when the Plasanator started kicking ass. Yea, I said it Kicking Ass Baby. Oops Wife just told me I need to stop, hee hee and
for all you creators ah ah ah ahhhhhh.
I hope you enjoyed riding along with me in my journey.
Take care and be safe.
The Plasmaman

Step 2: Parts List

Parts List

http://www.instructables.com/id/How-to-Make-Your-own-Plasma-Cutter/

Step 3: Warning Warning

Step 4: Schematic
Chevy Pictorial Schematic

http://www.instructables.com/id/How-to-Make-Your-own-Plasma-Cutter/

Step 5: Another View

Step 6: Another schematic to looksy at

Step 7: Board Lay Out

Now this is to demenstrate how I set it up before putting it in a case configuration.
So dont think you would leave it like this for it would be to dangerous to do so.

http://www.instructables.com/id/How-to-Make-Your-own-Plasma-Cutter/

Step 8: Transformer I used

Its a control transformer I got off ebay for 50 bucks.
It's 220 to 120 3kva 25 amps and works great in power isolation.

http://www.instructables.com/id/How-to-Make-Your-own-Plasma-Cutter/

Step 9: Transformer connected to board Terminals.

Step 10: Power to Contactor Terminals

These are the contactor terminal conections on the transformer side and then the contactor to large bridge rectifier connections.
Also you will see Bridge rec to Capitor connections and how they are connected.
This is your Main Current set up.

http://www.instructables.com/id/How-to-Make-Your-own-Plasma-Cutter/

Step 11: Reed Current sensor

http://www.instructables.com/id/How-to-Make-Your-own-Plasma-Cutter/

http://www.instructables.com/id/How-to-Make-Your-own-Plasma-Cutter/

Step 12: Low Voltage side

http://www.instructables.com/id/How-to-Make-Your-own-Plasma-Cutter/

http://www.instructables.com/id/How-to-Make-Your-own-Plasma-Cutter/

Step 13: Relay Connections By Color

http://www.instructables.com/id/How-to-Make-Your-own-Plasma-Cutter/

Step 14: Chevy HV Transformer Connections

http://www.instructables.com/id/How-to-Make-Your-own-Plasma-Cutter/

Step 15: Arc tip assembly to head

http://www.instructables.com/id/How-to-Make-Your-own-Plasma-Cutter/

Step 16: Head air coupling

here is where you will connect your air line to your head if you dont have a fitting to do so then hook to board connections.

http://www.instructables.com/id/How-to-Make-Your-own-Plasma-Cutter/

Step 17: Air filter/ Element and solinoid Hook up View

Just showing temp hook up.

Step 18: Final power connections

Ok now you can put all your final connections together and keep going over your schematic to double or triple check everything.

http://www.instructables.com/id/How-to-Make-Your-own-Plasma-Cutter/

http://www.instructables.com/id/How-to-Make-Your-own-Plasma-Cutter/

http://www.instructables.com/id/How-to-Make-Your-own-Plasma-Cutter/

Step 19: Extra Photos of Past Cutter Projects

Here are some photos of past cutter projects for you to enjoy.
Now remember that you will need to put in a case for safty.
It can be would metal or plastic just enclose it.
My photos are in a testing stage and that is why you see them exposed.
The photos of the red cutter was a china one that burnt up on my neighbor and I ripped out the guts and replaced it with my design.
He just loves it.
The black box on side is the housing for 2 elements to draw more current.
You will also see here some other designs where I used a chevy control module as the hv arc start and my first plasma cutter on test stand using stove coils as current
resistors.
Have fun and be safe ya'll. Joe

http://www.instructables.com/id/How-to-Make-Your-own-Plasma-Cutter/

http://www.instructables.com/id/How-to-Make-Your-own-Plasma-Cutter/

http://www.instructables.com/id/How-to-Make-Your-own-Plasma-Cutter/

http://www.instructables.com/id/How-to-Make-Your-own-Plasma-Cutter/

http://www.instructables.com/id/How-to-Make-Your-own-Plasma-Cutter/

Step 20:
The new Plasanator (5) coming alive!.
It has better electronics, auto air off delay, more case room and more cutting power.
It also has voice module power on check and complete homemade head.
High frequency power and better stabilization dc control.
Onboard fault detection circuit and no more heavy transformer.
Plasanator (5) is not for pussies, it's for men and woman who want to get the job done right the first time.
If your afraid of power, then you need to be devoured.

Step 21: Plasanator 3's First Cut

http://www.youtube.com/watch?v=nA6zWHNn6zU
Goto link and watch it's first cut while listening to the mission impossible song.
Thanks for stopping by and God Bless.

Step 22:
Related Instructables

How to Use a
Plasma Cutter
by newdetroiter

Sheet Metal
Flower to
Practice Plasma
Cutting and
Welding by
newdetroiter

Projects With
Plasma Cutter
Using
PlasmaCam
Software by
happylue

7 Foot Axial
Flux Wind
Turbine by
brokengun

Homemade
Motor Arbor for
your Wind
Generator or
other needs by
Candroma

http://www.instructables.com/id/How-to-Make-Your-own-Plasma-Cutter/

How to- Wind

Turbine Made
from Scrap
Metal... by
Pushthatbolder

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Comments
50 comments Add Comment

JakubE says:

view all 140 comments

Jan 25, 2015. 10:28 AM REPLY

Hello,
please, have you some plans of Plasanator (5)? I need something with little more cutting power.

JakubE says:

Jan 26, 2015. 7:40 AM REPLY

Is it possible to use two 6kW heating elements with 230V?

bettina-sisr says:

Jan 2, 2015. 10:43 PM REPLY

YOU ROCK! (Or cut )with style! This is great, gotta a extra one of you? Anyway thanks for this inspiration, I'm not smart enough to create this, but I love that
other hard working people are!

Upaa27 says:

Dec 17, 2014. 8:29 PM REPLY

Correct me if I am wrong, but wouldn't something like this work? T1-3 are microwave oven transformers. If we wind these for 200v each, the rectification
should push the voltage to almost 300v to charge the caps. C2 dumps through T4 to ignite plasma and C1 can then discharge through the plasma. I would
imagine with 3000uf, it should maintain continuos discharge with 15 amps even if only 60hz. I used 3 ac mains so that no breakers blow. The air flow and fan
could be easily incorporated into the schematic I just didn't find any symbols for them.
What do you guys think?

Upaa27 says:

Dec 17, 2014. 8:59 PM REPLY

Sorry I mean to say the total voltage output is 200v from the transformers not 200v each. I'm really tired right now :O

astral_mage says:

Mar 12, 2014. 1:57 AM REPLY

this pic should've been fist page not third or forth in line.

Benjamin.M.Withrow says:

Nov 22, 2014. 7:51 AM REPLY

After all of this man's hard work, that's what you get out of this? Please, for your own sake, don't try building this lmao

Benjamin.M.Withrow says:

Nov 22, 2014. 7:47 AM REPLY

This is so helpful, Sir, thank you for sharing your hard earned knowledge. My buddy and I are in the collecting parts phase, and this is already very helpful.
Thanks again!
PS: I'm sure I'll be back with questions at some point, hope you don't mind!

dthompson32 says:

Oct 15, 2013. 8:53 PM REPLY

great job,, where can i salvage the high voltage bridge rectifier. i can't seem to find anything that uses one that can handle this much voltage,,other than just
buying a new one, thx

Plasanator says:
eBay has them for about 16 bucks.

http://www.instructables.com/id/How-to-Make-Your-own-Plasma-Cutter/

Sep 23, 2014. 10:05 PM REPLY

Plasanator says:

Dec 2, 2013. 9:25 PM

(removed by author or community request)

Plasanator says:

Sep 10, 2014. 8:50 AM REPLY

yhttp://www.ebay.com/itm/231266189909?_trksid=p2059210.m2749.l2649&ssPageName=STRK%3AMEBIDX%3AIT
This is link on eBay where I bought some rectifiers.
These work great and will handle all your power needs.

experimenter4life says:

Sep 21, 2014. 1:04 PM REPLY

Great project. I am in the works of constructing my own working from your design. I have two questions. Is the isolation transformer necessary? Also, what
are you using for your compressed air source? Just an air compressor? Thanks in advance!

Plasanator says:

Sep 22, 2014. 1:13 PM REPLY

I don't use one since all is shut down by gun trigger never had a problem or safety issue.
I just use a regular air compressor bigger the better if you have a lot of cutting to do air last longer and I use a 50 gallon hot water tank made in to an air
tank secondary.

experimenter4life says:

Sep 22, 2014. 7:28 PM REPLY

Great thanks. Sorry I have one more question I forgot to ask. When you turn the unit on, does it blow the breaker while the capacitors are charging
up? Seems like they would pull a looot of current to charge being so big and all. If so how do you work around that problem?

Plasanator says:

Sep 23, 2014. 10:04 PM REPLY

I have never had that problem.

Make sure you have a 30 amp breaker for 120 and at least a 50 amp for 220 use.
Also make sure the 120 power that comes out of your relays is not connected to the other side of ac connection.
Follow the yellow that goes to the two joined relays and comes out blue to high voltage set up and to air solenoid .

PetrieJ says:

Sep 15, 2014. 9:29 AM REPLY

Is is possible to make a 1A plasma cutter? I need to cut very thin pieces of 304, but because of the geometry and composition of the parts I am currently
stuck chemically etching the material away.

Plasanator says:

Sep 16, 2014. 7:45 AM REPLY

I wouldn't think so and plasma cutting would leave spray all over pcb board.
I recommend using A laser or Drexel tool.

V4V says:

Sep 1, 2014. 5:06 PM REPLY

i cant understand why you connect the caps at this strange way. after the bridge you have a plus and a minus full rectified source. so the caps should take this
dc voltage.
why do you connect the caps back to the AC line?

Plasanator says:

Sep 2, 2014. 7:36 AM REPLY

It forms a voltage doubler circuit.

rodalino says:

Sep 1, 2014. 2:05 PM REPLY

Can this cut aluminum and stainless sheets?

Plasanator says:
Yes it can and does very well.

http://www.instructables.com/id/How-to-Make-Your-own-Plasma-Cutter/

Sep 2, 2014. 7:34 AM REPLY

swampfox440 says:

Aug 23, 2014. 8:01 AM REPLY

What is the water heater element for ? Don't see it anywhere in these pictures.

Plasanator says:

May 9, 2014. 8:28 PM REPLY

Hey all just solder a wire to the hv coil instead of zip tying it and cover solder with silicone of any kind.

wkdavistx says:

Mar 13, 2014. 4:33 PM REPLY

If i am putting 240v to the contactor does that mean I'm putting 240v to the air solenoid? I am also reading 650v on the dc side of the rectifier. I am replacing
both of these parts (fried the 110v solenoid).
Thank you.

Plasanator says:

May 9, 2014. 8:27 PM REPLY

No then you have it hooked up wrong.

The air solenoid goes before the contactor on the input side through a relay.

pgladek says:

Oct 25, 2012. 2:12 PM REPLY

Sorry, I also forgot to ask...it might be hard to find a ford / chevy ignition coil out here, so is there anything specific I should look for when I pick one out, or
any minimum specs needed? Also, is there any purpose to mounting the stud on the ignition coil, other than as a place to attach the connections? And what
does the water heater element specifically do?

astral_mage says:

Mar 12, 2014. 2:00 AM REPLY

its a dump load. instead of a large amount of copper or aluminum. he went with that tho it needs a bigger heat sink tho.

Plasanator says:
here are some picures of one I done a few months ago.

http://www.instructables.com/id/How-to-Make-Your-own-Plasma-Cutter/

Oct 26, 2012. 11:11 AM REPLY

Plasanator says:

Oct 26, 2012. 11:04 AM REPLY

Yes the studd is just for mounting purposes but instead go ahead and solder a lead to coil and fill around it with silicone for protection.
I do that now for all my cutters.
The element is your load resister and is what draws and dictates the amount of current used.
Two in parallel will draw more current for cutting thicker material.
My new unit I used some square tubing from treadmill and a blower also from a microwave to cool coils down to last longer.

wkdavistx says:

Feb 4, 2014. 1:19 PM REPLY

If you were building one that was 40A, what would you use to control the output amperage while cutting? I was thinking about a solid state voltage regulator
like this one:
http://www.auberins.com/index.php?main_page=produc...
Thoughts?
Thanks,
Keith

Plasanator says:

Feb 18, 2014. 12:08 PM REPLY

I don't build them that big so I can't say, sorry.

pclifford says:

Feb 1, 2014. 7:43 PM REPLY

(Please correct me if im wrong)

i was wondering if your build is using a frequency from your instructions i dont see anything that would generate a frequency other than starting arc. the reason
im asking is i have a wire feed welder that im going to add the plasma cutting feature to it and use both welder and cutter. the welder is set up to use ac only
witch i can convert to dc by using your instruction and the add a separate hook up for the plasma cutter but in order to for the welder to work it needs to have
some sort of freq..
From my under standing a plasma cutter operates at 10khz or more how is yours working with converting it to dc it should be a pulsing dc at 60 HZ + or - and
you add the CAPS in there witch would add a smoothing affect to the frequencies and bring it down to almost nothing.
Thank you

http://www.instructables.com/id/How-to-Make-Your-own-Plasma-Cutter/

Plasanator says:

Feb 2, 2014. 12:28 PM REPLY

no just 60 hz

wkdavistx says:

Dec 10, 2013. 7:53 AM REPLY

Plasanator,
Thanks for all the time and effort put into this. Great job!
Any thoughts on using a 208V/208V transformer from a UPS system and 2 heating elements? I figure this will give me 24A at 208V at the torch and may be
able to cut 1/2" steel.
Thanks,
Keith

Plasanator says:

Jan 27, 2014. 4:06 PM REPLY

It will work fine if around 5kva but 3/8 inch will be most your gonna cut through.

Plasanator says:

Dec 11, 2013. 5:11 PM REPLY

Yep that's right 208v is just fine.

wkdavistx says:

Jan 21, 2014. 12:21 PM REPLY

So I was able to procure a 5kva transformer (240 primary - 240/120 secondary). If I run 240 to the contactor what happens to the capacitors when
connected to double the voltage? Are 350v capacitors ok? What other changes should I make besides using 2 heating elements?
Thanks again!

DanW13 says:

Jan 21, 2014. 3:40 PM REPLY

Joe I have to ask a few question, one is about those Heating elements which you say are just current resistors.Do these ever get hot to where a fan
may/might be needed to keep them cooled ? The other is about the Capacitors you show in your phots that are Blue in color but I don't recall seeing any
specs as to the size required for the plasma cutter, if you don't mind can you give me the specs on what the min/Max sizes are for those 2 Capacitors please
? Thank's, I hope to have one build by end of this month if all goes well with rounding up parts :)

Plasanator says:

Jan 27, 2014. 4:04 PM REPLY

Hey Dan yes they will so I mounted my new ones in a steel tube from a tread mill and put a blower from a microwave on it to cool them down.
1800 microfarads at 350 volts minumum the lager the better.

mattc172 says:

Dec 28, 2013. 6:52 PM REPLY

what type of equipment would you find the 2 cap in

Plasanator says:

Dec 31, 2013. 11:55 AM REPLY

the big caps are on ebay many to look at around 25 to 50 bucks

mattc172 says:

Dec 24, 2013. 10:15 AM REPLY

for my run capacitor can use a ge 97f9383, in place of the one you used. if i do what would be the out come.

Plasanator says:

Dec 25, 2013. 12:34 PM REPLY

NOOOOOOOOOOOOO this is not the right kind of cap and its way to low in microfarrads.

mattc172 says:

Dec 26, 2013. 2:25 AM REPLY

can i use it in place of the microwave cap

Plasanator says:

Dec 26, 2013. 1:01 PM REPLY

Yes that would be fine.

kennethagiusmosta says:
Hi kaolex, Thanks a millon

http://www.instructables.com/id/How-to-Make-Your-own-Plasma-Cutter/

Nov 20, 2013. 8:48 PM REPLY

kaoalex says:

Nov 20, 2013. 4:45 PM REPLY

Hi Kenneth,
I used this schematic.
You can found more details in the PowerLabs site.
http://www.powerlabs.org/flybackdriver.htm
I used this type of flyback with internal diode.

kaoalex says:

Nov 19, 2013. 4:00 PM REPLY

Plasanator, Thanks a lot for sharing this incredible project. I did some progress to construct mine own plasma cutter machine based on you schematic.
Check out the first cut.
http://www.youtube.com/watch?v=eM7arB8Gvoc
I used a TV flyback instead of a car coil. I plugged the HV+ to the tip of torch. As you can see in the video i still have some difficulty to start the plasma. Have
you any idea to improve my machine? Thanks a lot!

kennethagiusmosta says:

Nov 20, 2013. 9:22 AM REPLY

Hi,
Can you post schematics of you TV flyback setup? I'm having trouble with the car coil, maybe I can solve-it with your setup
Thanks

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http://www.instructables.com/id/How-to-Make-Your-own-Plasma-Cutter/