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Don't try this at home: Wiring a plasma cutter for CNC | Hypertherm Powermax 30 XP


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Today we’re rewiring a Hypertherm Powermax 30 XP plasma cutter for use on a CNC plasma table. Don’t do this. It’s dangerous. It’s also easy, and it works great.

Tools used in this video:

Hypertherm Powermax 30 XP Plasma Cutter (eBay*): http://ebay.to/2JgTrK6
Rhino Cart Welding Fixture Table (Amazon*): https://amzn.to/3za8aez
Wera Kraftform Screwdriver Set (Amazon*): https://amzn.to/2UzK6CL
Milwaukee Brushless Impact Driver (Amazon*): https://amzn.to/2Xgcjjc
Fluke 375 FC True-RMS Clamp Meter (Amazon*): https://amzn.to/3C6aeoW
Dewalt Step Drill Bit Set (Amazon*): https://amzn.to/3kb9VmJ
Assorted Waterproof Cable Glands (Amazon*): https://amzn.to/3Efr5HL
Knipex Pliers Wrench 3-Piece Set (Amazon*): https://amzn.to/2ruzS8m
Beelink T34 M Mini PC (Amazon*): https://amzn.to/3nwjy1m
ASUS 21.5″ Touch Monitor (Amazon*): https://amzn.to/3B7MbW4
Rhino Cart Welding Fixture Table (Amazon*): https://amzn.to/3za8aez
California Air Tools Ultra Quiet 2HP Compressor (Amazon*): https://amzn.to/2TQ926q
Dewalt Retracting Hose Reel (Amazon*): https://amzn.to/3lFx8NB

*These are affiliate links. When you click one of these links and make a purchase, it helps to support projects like this one.

Raw Kevin MacLeod (incompetech.com)
Licensed under Creative Commons: By Attribution 3.0 License



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  1. Followed your video to wire up my new Crossfire…worked perfect! Thanks much. One question.. any idea how to load .nc files in to Firecontrol? Only seems to recognize .tap files

  2. The Powermax 45 I have has an integral CPC port and has a voltage divider on the main board wired to the CPC. (I'm still wary of non divided current going towards my systems control box on my CNC, so I would have still used a divider circuit) *I also made my own CPC cable, because they're using off the shelf parts you can get at digikey…

    The problem with Hypertherm machine torch operation from the CPC, is that the wiring of the torch to the connector is different, and is required. (They built a failsafe wire that isn't in a hand torch, and is wired to different pins.

    So either you pay their high priced fee for a machine torch (about a grand)
    Or you hack your hand torch, and make it much harder to use as just a hand torch.

    I opted to use a lathe to make an acetal housing for a custom connector (the brass fitting is the real challenge bit, and the DIN pin alignment and indexing SUCKS)
    Then I could purchase a machine torch head from eBay, and then proceed to make my own lead for it. (It even offers the ability to use better and more robust materials for the lead…)

    Instead of their high priced machine torch, I opted to buy a lathe, and make my own connector…
    Glad we can all hack our stuff and make it do what we need it to.

  3. Thanks for the video i followed the video to the tee but with one expected because i dont have that part and my question is if i dont have that part which the high frequency device that you connect to the electro negative and electro positive ( ground ) I tried it but could not get any conductivity . Well does this mean my plasma wont work ? And hows is it still running for you the plasma 30 air ? Well thanks for the great video your a professional thanks

  4. I spent a week rewiring someones Langmuir system to be compliant with even the most basic of CNC standards and fixed numerous safety issues. Not to mention these beginner tables should have physical limit switch’s for safety reasons but they can’t for numerous reasons. mainly because they have so much EMI/EMF noise they get false triggers. The solution wasn’t proper wire/cables, wiring practices/management, grounding, and adequate power sources…. it was to remove all accessories and just make more money.

    Snake oil. Cheep. Shameful. The Langmuir consumer just throws more and more money at their sub par equipment!
    I’m going to start a business building better machines for the same price point just to kick in Langmuir’s front door.

  5. While you were at it you should have rerouted the power switch to the front panel, instead of the idiotic place on the back panel… Never understood why they put them there.

    For when you are using it manually you could have installed a safety CNC disable firing switch so you know it cannot be set off.
    Thanks for showing this. It is close to what I would be likely to setup. On your power, it doesn't matter if you only have 100A, you can install much more output than available because they are not likely to all be running at the same time. So the only real limitation would be the wire size to the plug.

  6. Phew that was close, I did this at "home" a few years ago. Luckily it was on the older powermax 30, not the XP, so it's ok right?

    Cool to finally see someone else do this, and their approach. Mine didn't have one of those voltage dividers since the cnc was shop built, but it wasn't too hard to build and I shoved the circuit for it into the case so that it didn't bring the high voltage outside the case other than torch/work clamp…

    Then I got lazy with the height probe circuit ("ohmic" or contact probe) and brought it outside the case anyway because space inside the plasma case was getting tight (it's almost like they don't want you shoving extra circuitry in there?) and I'd already installed and wired up a 6 pin plug and would need a 10/12 pins at least to shove the probe circuit inside the case, and I couldn't be bothered. I'm glad I did this way since the probe circuit tends to blow a chip every now and then, and having it easily accessible outside the case ended up being very useful. The probe circuit for me went in with the rest of the control electronics

    Side note for anyone following along at home the powermax 30 (not sure about the XP) actually has two relatively beefy leads in the torch. I believe the second one is for the pilot arc, and if memory serves you can only connect one of them to your voltage divider, the other will have a pretty much constant voltage with regards to the work clamp regardless of torch height.

  7. Several things: First great video and clear explanation of what you are doing I love watching your videos. Second, do you have a connection with Langmuir Systems that benefits you when I purchase one of their systems? Third, I like the computer setup you have and I must have missed your video where you discussed the details of the one you’re using. Would you be able to provide info on the details of the Asus you are using?

  8. Would absolutely love to see you pull out the circuitboard of that machine and go over it… “Big Clive style”……

    or even better.., do it “AvE style”!
    hook it up backwards and blow it up before you get a chance to use it ?

  9. As usual another great video James. I have my Crossfire over a year now and love it. Using the PrimeWeld CUT60 successfully. I'm running Mach3 (I don't like being "locked-in" to a manufacturer's control system) on my shop-floor Dell Optiplex 780 PC. Built my own CNC controller and integrated my own Torch Height Control (THC) using the RobotT3T and built my own floating head Z-axis. I 3D print my machine torch holders in PLA (they last about 1-year). Great machine the Langmuir Crossfire, and they have a great and very informative and active forum.

  10. you used a meter to check the voltage of the caps? damn, I always thought standard procedure to check for voltage was bridging the leads with a screwdriver

  11. Just cause the house is 100 amp only is no sign you cant put a 50 amp in the garage just a little common sense and don't run everything at the same time

    Stop playing with sheet metal toys and go 45 XP with a Duramax machine torch. CPC connector is ready to rock.

  12. I had a nice 76 f150 almost burn down because the previous owner used those insulation piercing connectors. I absolutely hate them! Please take a few extra minutes to do the job correctly, they remind me of the stab connections on the back of outlets which imo should be outlawed! There again almost had a house fire because previous owner decided to save 10 seconds and use the stabs instead of the screw lugs.

  13. Do things in this order:
    1. Unplug, remove cover
    2. Use voltmeter rated for 400+VDC, with good insulation on the leads, to verify that lethal voltages are not present
    3. Touch anything inside
    Someone I know once touched the inside of a camera strobe that had been off for two weeks. His scream was clearly audible at the other end of the house.
    Perhaps battery-powered camera strobes are a special case; storage capacitors should have bleeder resistors — and 'should' is not the same as 'do, and Purchasing didn't get crappy ones that failed, and the assembler put them in place, and the terminals didn't corrode, and they still work'. I like to limit the number of people and pieces of equipment that I trust my life to.

  14. I have a cutmaster 42 by victor. Doesn’t have a Cnc port so I need to first tap into mine to fire like you mention. Then I have a thc like you mentioned that I need to hook up! From what I hear is if you use a thc and a floating head attachment that’s the best way that way you would not need a ohmic sensor. Also I’m up in the air if I should use millrights supplied board that runs UGS or one of the following
    1. Myplasma
    2. Masso
    3. Centroid acorn (which I currently run on my Bridgeport but they are currently in beta on the plasma. If they release it soon this may be my go to board)

  15. Also get hypertherm powermax 45 Mchanized consumables this works on the 30 xp torch also kirf on cutting use the powermax 45 chart and dial feed and speeds while cutting it will be alott better cutting process also fine cut consumables work good but don't try cutting hot rolled a36 use pno cold roll it won't blowback mill scale back up into your Torch tip. As for size of plasma machine I used powermax 85 on 50 amp service off my miller bobcat 225 with no problems and at home to I also run powermax 45xp it cuts great cnc plasma table.
    There are two guys on YouTube tool junkie and another Joshua Zimmerman guy are subject matter experts with langmuir tables. And hypertherm plasma cutter.

  16. "Don't do it… It's easy but don't do it" ??

    Clean install ??

    I actually have the 45XP for manual cuts but when I bought it I intended to put it on a table (not yet had the time in almost 2 years… But it's on its way ?) so I took the CNC package with the mech torch and the preinstalled communication module and added the manual torch… In Belgium it was cheaper than buying the "manual package" and add the mech torch and the module (and you then have to install it yourself…)
    Good machine by the way ?

    What I found odd on the 30xp is that the filter is inside the box… On the 45xp it is recessed but accessible from the outside (with tiny hands… But still…) And it needs cleaning every now and then… Are you "allowed" to open the box to clean the filter?

  17. Another outstanding tutorial and dialog. As you rightfully explain, no mater what it is; or how simple it seems; SAFETY, SAFETY, SAFETY 1ST !!!!! Check, double check and check again…..a body part or your life aren't worth the chance.

  18. Hi James
    In regards to plasma cutting you might want to invest in line desecant air dryer filter it will prolonged your Consumables and results will be alot better in the long run.
    I built my cnc plasma table.
    I am going to get in the future a refrigerator dryer.
    This will help with moisture in the air.

  19. Hi sorry to bother you. I most say love your channel. But I have a little question I have a cnc 2.5m l by 1.10m w and a 80 amp plasma.. My only problem is I only have my garage to electric box which is a common box UK. How many amps should my breaker board have to sopport the plasmas on the cnc? I would extremely appreciate your help as I have no clue what I should do… I rather work on mechanical systems than electric hahaha I feel safer

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