Odd Ball Plasma Cutter Questions..

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First, can you very the size of the intial hole that the cutter makes? LIke changing the tips out for different sizes? ( I.e. 1/16 hole or 1/32 etc.. etc..) or does they all have the same size? and if so, what diameter is that?Second question..  If you are cutting with it and there is concrete behind the metal, how will this affect the cutter... or will it have any issues?   or is this even possible...  sorry for the newb questions... just trying to make a tedious task easier and less mondane.
Reply:It won't cut Bondo. City of L.A. Structural; Manual & Semi-Automatic;"Surely there is a mine for silver, and a place where gold is refined. Iron is taken from the earth, and copper is smelted from ore."Job 28:1,2Lincoln, Miller, Victor & ISV BibleDanny
Reply:Originally Posted by tanglediverIt won't cut Bondo.
Reply:Most high end plasma systems offer different consumable sets depending on the thickness of the material to be cut...and the power level desired. The Hypertherm Powermax 1250...for example, has the following choices:1. Fine Cut consumables....for cutting from very thin gauge to 1/8" with the narrowest kerf, square edge, minimal dross at power levels typically less than 40 amps, at lower speeds in order to allow for more intricate cutting.2. 40 Amp shielded consumables. Designed for drag cutting (allows you to drag the torch on the plate or alongside a template...without damaging the torch nozzle)....for materials up to 1/4" atmedium cut speeds. 3/16" and 1/4" will have best cut quality, as you cut thinner expect more edge taper, but extremely fast speeds and wider kerf width.3. 60 Amp shielded consumables. Slightly wider arc with more power as compared to the 40 amp shielded, wider kerf, faster speeds, sweet spot in the 1/4" to 1/2" range for best cut quality.4. 80 Amp shielded consumables. Widest, most powerful arc. Extremely high speeds on thinner material, reasonable speeds on material thicker than 3/8". Sweet spot for best quality from 1/2" to 3/4".....edge start on thicker materials.It is best to match the power and consumable set to the material thickness.....if you are concerned with best edge quality in terms of smoothness and squareness. If you want high speed....and are less concerned with quality....turn the amps knob to full on, and install the largest nozzle! Do not overpower any given consumable set......if you exceed the amperage rating of a nozzle....you will dramatically shorten its life.Concrete cutting:  If you are planning to cut a steel plate laying on a concrete floor......it will not be a good thing. The effluent from the cutting process needs a place to go....and further, concrete has a tendency to fracture and kind of explode when the plasma arc gets to it!  There have been applications with steel pipe with a concrete coating (I have seen 1/4 " pipe with about a 3/4" layer of concrete)....this actually can be succesfully cut as long as you have enough power.....and cut with the torch on the steel side.....still, watch out for flying chunks of concrete!Jim Colt  Hypertherm
Reply:Jim, thanks for that info on the consumables.I never understood why some of our guys had big problems with consumable life with our 1250 at the shop.  I just attributed it to lack of skill.  I know that we have had both 40 and 60 amp stuff, and now i'm sure the guys were just cranking it up and blowing the tips apart.For myself, I guess I just found the sweet spot for what was on hand with out ruining a bunch of consumables. Some guys aren't so easy on equipment...You should see the torch. New guys gouging with it the first week we had it. It's a wonder it still works.
Reply:Well.....you should see some of the plasma torches that come back to Hypertherm's RMA department....its a hammer dammit!  And just like that stereo in my old college dorm room...it had a volume control labeled 1-10......it spent most of its time playing Zeppelin (I'm dating myself.....although my 21 year old son is a classic rock fan) at the 10 setting. Turn the plasma down.....it saves consumables and provides better cut quality...especially if you have the smaller sets of consumables.When you look at our high end mechanized (high definition class) plasma systems.....they have different consumables for 30, 50, 80, 130, 200, 260 and 400 Amp settings.......thats just for cutting steel......there are different sets for all the ranges when cutting aluminum or stainless. The result is laser like cut quality at faster speeds and lower cutting costs as compared to laser.jim
Reply:Hey Jim, since you brought this up, are there different sets of consumeables also for the Hyp. 1000? I'm still on the original set that came with mine years back (don't use it as much as I had hoped), but was just curious for when ever I need to replace them..No government ever voluntarily reduces itself in size. Government programs, once launched, never disappear. Actually, a government bureau is the nearest thing to eternal life we'll ever see on this earth! Ronald Reagan
Reply:The Powermax1250 and the Powermax1000 use the same consumables.....except the 1000 is limited to 60 Amps.....so the 80 Amp set is not needed. If you need part numbers....go to www.hypertherm.com  and look under products, then torch and consumables, then consumables by system.....and you can find the listings with all part numbers for your system. If you need a manual...go to the library tab at the top of the home page and you can search and download  a .pdf file of the system manual.Great consumable life! Can we now measure the nozzle life in years?Jim Originally Posted by DSWHey Jim, since you brought this up, are there different sets of consumeables also for the Hyp. 1000? I'm still on the original set that came with mine years back (don't use it as much as I had hoped), but was just curious for when ever I need to replace them.
Reply:Thanks Jim..No government ever voluntarily reduces itself in size. Government programs, once launched, never disappear. Actually, a government bureau is the nearest thing to eternal life we'll ever see on this earth! Ronald Reagan
Reply:I may have to cut some steel headers out and there may be some concrete behind them.   So this will be an over head cut. 4g LOL?   And as far as hole size..  I would need to make a 16 1/8 holes in 400 frames.
Reply:I have had some success cutting metal "skins" from concrete, but it is not fun. If the metal is thin enough, you can hold the torch at a 10 or 15 degree angle, depending up your torch design so that the torch arc is  barely skimming the surface. Almost like gouging.  This still does not prevent some problems.  But it won't work very well on thick metal.  You can use this same technique with a O/A torch, but it is still not easy.Oh, and wear every possible safety piece of equipment known to man kind.Esab Migmaster 250Lincoln SA 200Lincoln Ranger 8Smith Oxy Fuel setupEverlast PowerPlasma 80Everlast Power iMIG 160Everlast Power iMIG 205 Everlast Power iMIG 140EEverlast PowerARC 300Everlast PowerARC 140STEverlast PowerTIG 255EXT
Reply:i have been working on consumables.....but somehow got some problems over it ...thankx for the information o consumables...... i really liked that ...... thankx for sharing..........steel bar steel supplier