instructables

How to Make Your Own Plasma Cutter....

by Plasanator

Check out new video of the Plasanator on utube.com 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 it’s scrap wood now.
We, didn’t need that table anyway (shhhhhhh don’t
tell the wife).
//www.youtube.com/embed/enELHZ7dP2I

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
This Ebook is designed for Guys and Gals who like to
current being drawn into play). Then BAM, it was
create tools and machinery.
slicing through quarter inch steel like a hot knife
through butter.
I hope my Ebook gives you hope that no matter how
hard a project may seem, keep plugging away until
How sweet it sounded! I felt the amazement of
you finish and you will succeed.
completing a project that I just couldn’t let go of.

I spent 3 years putting this together and now finally all

So, take your time, enjoy and be safe.
my hard work and research has paid off.
The Plasmaman
I studied diagrams from commercial venders, but to
no luck. They tend to leave a lot out – on purpose - so
P.S.
it’s hard to reproduce their design. I’ve see different
attempts at people making their own on You Tube
Like Steam Punk?
and other sites, but what a death trap. Messy water
resistors and wiring like a darn Christmas tree.
Check out my Tesla Levitating Steam Punk Lamp
Video.
So I began reading books and articles on their
workings and took my home schooled-knowledge of
https://www.youtube.com/watch?v=jip8HYd39g0
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

How to Make Your Own Plasma Cutter....: Page 1

Step 1: Assembly

How to Make Your Own Plasma Cutter....: Page 2

When I started assembling my cutter, I began with High Current DC
taking a good look at my parts. As shown in Section 5 Bridge Rectifier
and Section 6, my parts are laid out so I can begin Large Capacitors
checking off from my parts list. Once this was Reed Switch (which I used as a current sensor), what
accomplished, I would study each the parts pictorial it does is allow the high voltage arc system to fire and
to get familiar with each part/component and they as soon as high current starts to travel to the head
would be placed. and cutting starts it shuts down the high voltage arc
system while cutting since it’s not needed at this
The next step was to study my schematic and create point.
a layout diagram. My board layout diagram is the If you lose your fire it restarts the arc and gets you
most valuable piece in the building, repairing, and going again automatically.
modifying process of my cutter. My next system was placed on board.

As I began mounting my parts, I organized my board Low Voltage DC

into four sections. Those sections are Power Control, The low voltage DC components are mixed with
High Current DC, Low Voltage DC and High Voltage power switch and 120 volt terminals.
Arc Start. Power Switch
120-volt terminal blocks
Power Control 12 volt transformer
3KVA step down transformer and contactor. The Low voltage bridge rectifier
transformer is mounted off board because it is big and Auto relays
heavy, as you can see in Section 13. The contactor Terminal strip, 4 position is all I needed but 5 position
became my first part on the board. I wired it so when was what I had in my toy box.
the head trigger is pressed, it turns the contactor on
and allows my DC components to come on line. Then High Voltage Arc Start
I began with my next system, High Current DC. Microwave capacitor or run capacitor, a household

dimmer switch rated for 15 amps. A Ford or Chevy last you just pick a way and go with it.
ignition coil. I used the Chevy on this cutter. As you
can see, I have terminals to all parts that get an Once I got it all together, I connected my air tank
external connection outside of their system so all I hose and put the pressure setting at 28 for a safe
have to do is run a piece of wire in-between. Now point to start. I fired it up and BAM - that baby didn’t
look at the pictorial of board mounted parts in Section need any more adjusting. It was cutting!
11. It shows all the wires on the board, but here you
can see all terminals and parts mounted, as I wanted. You can imagine all the relief and pride I felt when the
When wiring all my components, I used my Chevy Plasanator started kicking ass. Yea, I said it Kicking
board layout diagram to run my wires. Ass Baby. Oops Wife just told me I need to stop, hee
hee and for all you creators – ah ah ah ahhhhhh.
I checked and re checked all wires before mounting
external parts. If you go to the final wiring section, you I hope you enjoyed riding along with me in my
will also find pictures of my rigging of these parts. I journey.
could have done it many different ways, but this is
what I chose at this time. Take care and be safe.

It took me about 3 hours of procrastination to finally The Plasmaman

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

How to Make Your Own Plasma Cutter....: Page 3

Step 2: Parts List

Parts List

Step 3: Warning Warning

How to Make Your Own Plasma Cutter....: Page 4

Step 4: Schematic

Chevy Pictorial Schematic

How to Make Your Own Plasma Cutter....: Page 5

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.

How to Make Your Own Plasma Cutter....: Page 6

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.

Step 9: Transformer Connected to Board Terminals.

How to Make Your Own Plasma Cutter....: Page 7

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.

How to Make Your Own Plasma Cutter....: Page 8

Step 11: Reed Current Sensor

How to Make Your Own Plasma Cutter....: Page 9

Step 12: Low Voltage Side

How to Make Your Own Plasma Cutter....: Page 10

Step 13: Relay Connections by Color

How to Make Your Own Plasma Cutter....: Page 11

How to Make Your Own Plasma Cutter....: Page 12
Step 14: Chevy HV Transformer Connections

How to Make Your Own Plasma Cutter....: Page 13

Step 15: Arc Tip Assembly to Head

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.

How to Make Your Own Plasma Cutter....: Page 14

Step 17: Air Filter/ Element and Solinoid Hook Up View

Just showing temp hook up.

How to Make Your Own Plasma Cutter....: Page 15

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.

How to Make Your Own Plasma Cutter....: Page 16

How to Make Your Own Plasma Cutter....: Page 17
Step 19: Extra Photos of Past Cutter Projects

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

How to Make Your Own Plasma Cutter....: Page 18

How to Make Your Own Plasma Cutter....: Page 19
How to Make Your Own Plasma Cutter....: Page 20
How to Make Your Own Plasma Cutter....: Page 21
Step 20: 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.

My isolation transformer made of a old welder machine. It will be capable to supply 40A at 220vac.
I will try to remove the heater element an include a pwm controller. For HV i designed a coupling
coil to isolate the HV side of the high current side. Soon as i test i will publish here. Wish me luck!

I wish you Best of luck, be safe

Did you ever get your HV start working?

Be nice to see it. good luck God speed

Plasanator, I have a question for you and the rest of the community. Have you figured out how to
change amperage? And a way to rid the design of the wasteful resistors? Like a simple pwm circuit
to control amps?
As it stands now I just parallele 2 or 3 elements together for more current cutting power.
I am just about done with COMPLETELY NEW PLASMA CUTTER where all you do is turn
selector for more power eleminating resistor elements. Stay Tuned Folks.
I wanted to post some info for anyone wanting to use a flyback transformer for the HV start. A
flyback transformer needs some type of driver to conduct voltages. It acts more like a choke with
coupled windings than a true transformer. It needs a pulsed, generally high frequency source to
conduct the high voltages. If it doesn't have a collapsing or changing field at a higher than line
frequency (60hz) it will not conduct voltages very well if at all.
The driver can be a simple spark gap, a 555 timer circuit, simple mosfet switching circuit, pwm
circuit, a florescent light ballast (even one from a compact cfl). I am unsure if a lc or rc circuit would
work. You don't need very much current for the HV (mA is ok), the voltage alone is enough to start
the plasma.
What are the values of the components of your measurements?

I have a parts list that will tell you everything you need.

If anyone would like to have: switch, breaker, allen bradley contactor, relay, din rail, enclosure box,
psi meter (manometer), selenoid valve, hose fittings, hp hose, a allanson 120 to 6000v natural gas
ignition transformer, a 200 amp welder plug like the link under that I can add the big breaker
already fixed to with the enclosure box... and lot of things... for really fair price and the best
industrial grade quality you would not think possible for the price i will do, just message me back
How to Make Your Own Plasma Cutter....: Page 22
please.

https://www.reynoldsonline.com/ASSETS/DOCUMENTS/ITEMS/EN/AP204612_Spec.pdf
I’d like to Ernst least some of these parts if you still have.

does this change the wiring or component?

wiring still could change back to get 120 less thickness of cut

so, is this now a 220 unite or is it still a 120 unite?

Sir some problem in plasma cutter every two or three time use then short a rectifier I use rectifier
50amp. 600volt x 3 pies
Some of the cheapy rectifiers are junk get you a 90 to 120 amp rect and you should be good to go.

Thanks great work Good explanation There is only something I did not understand
Chevy HV Transformer Connections 14 Thank you
If it's about the hv lead coming off the bolt to capacitors and lead going to torch head ? it's set up
this way to cause arc to electrode when trigger is pressed.
Hi Saraa, if it's the bolt on it and how it's mounted , you can just solder 10 guage wire directly to
coil spot.
Don't need bolt set up at all. this was first time using this kind of coil and later found out the flat
spot wasnt aluminum but was able to be soldered to.
I do not understand How much is needed from the current I have coil Bipolar 8 kv Per pole Is it
enough and thank you
it will be great should give you about 36 amps and you will want to run at about 25 amps for 1/4
inch cuts and if just thin sheet metal 16 to 18 amps will be great.
thanks for your wonderful work
but there is a QUESTION
what‘s the heater element for in this design
hope anyone could help me with that question thanks
sorry i am not good at electric thing
It is a load resistor which pulls your current need to cut

it adds resistance to the circuit.

Thank you for sharing your knowlegde. I would like to make my own plasanator but the step down
transformer is very expensive to bought it. I have a transformer rescued from a old stereo. Its
marked as +63v / -63v out, 120 volt in. I supose 120v in - 120v out . Do you think I can use it? I
want to cut carbon steel 18 gage with a CNC machine I made. here is a video

//www.youtube.com/embed/bEs9bxv-p5E

Thank you
Abraham Montemayor
Monterrey, MX.
For 18 gauge it will work great. great video

How to Make Your Own Plasma Cutter....: Page 23

hi And it all shuts Abraham I just use mains since I run it on a contactor.
Release trigger an all is shut down.
I never had one problem.
Your t former wont work.
Would like to build this as a 220 volt unit. I understand that I wont need the step down(up) xformer,
and will need two heater elements, also a double pole main power switch. Are there any other
changes that will need to be made to the circuit? also, you don't specify if the reed switch is NO or
NC. From your description of the circuit, I'm assuming NC. Correct? Thanks for an interesting
project!
It is nc because you want it on until current flows then it opens to turn off high voltage arc.

That is correct and good luck have fun. Joe

Hello; Anyone needing some of these parts I have alot of those items

hello.am felix in kenya.and yes am interested to have some parts.

Alot of rectifiers, connectors,relays etc

That is so cool to see all the places of the world Ive helped someone with one of there dreams.
Aweome
Thank you for sharing all this information. I was able to build my own Plasma cutter. It was fun.
Here's link to my video
https://youtu.be/e_Ocq96N5rU

Your very welcome great video.

Where are you from? I think it's great to see people from all over the world enjoy making something
I made. Congratulations. Plasanator
This project is worth the effort.
I am from India.
We, didn’t need that table anyway (shhhhhhh don’t tell the wife). xD

Forgive me if this questions has been asked before, but I am in ths uk and we have 13amp at 230
volt, so do i need that 110v 3kva transformer?
no you do not

Works great!
With a higher pressure and a HV capacitor (1,5 nF) in the output of flyback finally my the plasma
cutter is working perfectly. I will not publish a picture of my creature because it's only a lot of wires
on the floor. Soon as assemble it properly i will post some photos.
Thank you Plasanator!

Plasma cutter video!

//www.youtube.com/embed/F1l72neIPyQ

How to Make Your Own Plasma Cutter....: Page 24

Congratulations!!! Super great don't it feel good?
Would you mind if I put your video on my site?
Yes. I'm feeling like a boy with brand new toy.
Feel free to use any of my videos on your site.
My plasma cutter (almost) works! Unfortunately the plasma do not start when i press the button. My
arc starter is made of a TV FLYBACK with the positive HV wire is connected in external tip of the
torch and the negative HV connected with the (-) high current in the interior of the torch.
I have to scratch the torch several times to iniciate the plasma and finally cut something.
Please any help or suggestion will be welcome!
I WILL NEVER GIVE UP UNTIL MY PLASMA CUTTER BE WORKING 100%.
Tks All!
make sure electrode has negative and work clamp is positive like dc welder on reverse

adjust air to 70 psi.

Let me know how it goes and what voltage are you using 120 or 220?
Hi Joe Eichholz,
Yes the work clamp is positive and the electrode is negative.
I will try with 70 psi of pressure i was using 40 psi or less. I have small air compressor!
I builded with 120V AC inlet and the voltage doubler. I measured +/- 320V DC.
I'm using 6 resistor and 10.000uf capacitors.
I need high power hv to start the plasma? The flyback system have only 24W.

Thanks for helping. I will post the results soon.

Hi I wish to work on the modification of the work you have done. So I get the opportunity to work on
it. I wish to get the documents or any material regarding the project. If yes I wish to get your e-mail.
Thank you
thanks

thanks

very nice,what are the specs of the bridge rectifier the you used

How to Make Your Own Plasma Cutter....: Page 25