Thread: plasma cutter advice

I've built my own cnc plasma cutting table and have been frequenting plasma related forums for at least five years. I've got a Hypertherm and it's one of the most recommended brands out there. Lots of stories of how their machine has not gave them any problem for years on end. I have never seen one single person complain about their Hypertherm. I have seen lots talk about how they had brand X then upgraded to their Hypertherm and are glad they did.

The latest models which have the Duramax torch give very good cut quality and the consumables last much longer. So even if the consumeables cost more maybe the length of time they last negates that.

Something to remember though, if you want good consumable life your air needs to be clean and dry. Moisture really stuffs up you consumables fast.

Keith.

Plasma cutters are the invention of the devil, they can be the most cantankerous, problematic beast you have ever laid your hands upon. Having said that, they do some things rather well - cutting clean material in the thinner thickness ranges and some things really poorly - cutting dirty material in increased thicknesses.
Before you buy a Plasma Cutter, you need to ensure that you have a really good air supply - clean, moisture and oil free and in abundance. Don't forget that your power supply needs to run the Plasma unit and the compressor simultaneously, both usually 15A rated units.
I cannot stress enough the need for clean air. Moisture and oil will destroy your tips and electrodes.
All manufacturers overstate their machines capabilities. For example, our 100A Lincoln Plasma will sever, (hack), 25mm material, but honestly 12-16mm is a more realistic capacity if all is running well - if not, 6mm is pushing it.
Quite frankly unless you are working with either Aluminium, Stainless Steel or Steel under 3mm thick, I would steer you away from a Plasma and towards Oxy Acetylene or Oxy LPG. A Plasma can perform but one task, that is cutting. Oxy fuel gas can heat, cut, braze, solder, weld and doesn't need a compressor or object overly to rust, grease and grime.
I challenge the supposed cost benefits of Plasma in many environments also. If one takes into account the purchase cost of a Plasma, consumable costs and the head scratching time when they misbehave - it worked fine yesterday - then for most they aren't as cheap as they appear.
Oh, stay well away from cheap 3 in one units - Plasma does not play well with other processes in the same machine.

Ha Ha, I have to agree with Karl about the cost. I've got a Hypertherm 1250 (80 amp 3 phase unit) and paid $6000 for it (hand torch only). Later on I got a Duramax machine torch and paid another $1100. You can also get gouging tips for mine.

They are full of electronics so potentially lots to go wrong I suppose.

Keith.

thanks I have a twin cylinder compressor (cant remember the cfm) also oxy gear had both for years so guess the plasma would just be the next step. Just ordered the steel to make a comb trailer for a 36' header front so the thinking was after procrastinating for the last couple of years I should just get one before the latest project. All info appreciated hypertherm is at the top of the list at this stage but would really like as much info as I can get before buying. Cheers Mon

June andJuly BOC have their 40 amp plasma cutter on special. I purchased one a few weeks ago. The price is $385 without the torch which is listed at $300 but the local branch sold me the torch at a hot price so all up it cost me a bit under $600. I thought this was a pretty good price for a locally available machine as they were usually going for about $900 to $1000 for competing brands. Apparently it is good for 10mm cuts and I have cut 6mm easily so far so don't doubt it will do 10mm.

I have done a couple of jobs with it and knew nothing about them when I bought i and found it pretty easy. This one has a tip designed to drag and my 15 amp compressor handles it easily. The best part is, I have not even paid for it yet as I have an account with them!

Sounds like a reasonable deal and the boc outlet is about 100km from me while the hypertherm outlet is 500km so that would suit but I guess my real question is how do I compare the build quality. You know what its like talking to a salesman who is either too busy to bother with someone they think is a tyre kicker or are telling you what you want to hear to get a sale. Probably a bit of a generalisation but I have found in the past I have had better results with a recommendation about a business than just waltzing in of the street. Thanks for the replies and the opportunity to ramble. Mon

Without criticising anyone's choices directly, I would not consider a drag torch as they are a very limiting factor and make it very hard to follow scribed lines etc. Pilot arc is the way to go, although it does cost more.
Honestly, unless I was doing a lot of work sub 3mm or using Ally or Stainless, I would give a plasma a wide berth.
One other caution, Sunglasses/ tinted safety glasses are not adequate for plasma cutting nor are shade 5 oxy goggles. A light tinted arc welding lens, say shade 8-10 is far safer and more appropriate.

Originally Posted by Karl Robbers

Without criticising anyone's choices directly, I would not consider a drag torch as they are a very limiting factor and make it very hard to follow scribed lines etc. Pilot arc is the way to go, although it does cost more.
Honestly, unless I was doing a lot of work sub 3mm or using Ally or Stainless, I would give a plasma a wide berth.
One other caution, Sunglasses/ tinted safety glasses are not adequate for plasma cutting nor are shade 5 oxy goggles. A light tinted arc welding lens, say shade 8-10 is far safer and more appropriate.

No need to be diplomatic Karl, I know that as always in this business you get what you pay for. It became pretty clear from the specs etc that the 40 amp plasma I bought is a baby compared with others out there but it is more than adequate for my casual home shop needs. And yes, I do have appropriate eye protection. I think though for a small plasma the shade 8-10 is a bit over the top as it is hard to see v's a lower shade. Maybe not the case with more powerful industrial ones.

Originally Posted by rodweb

No need to be diplomatic Karl, I know that as always in this business you get what you pay for. It became pretty clear from the specs etc that the 40 amp plasma I bought is a baby compared with others out there but it is more than adequate for my casual home shop needs. And yes, I do have appropriate eye protection. I think though for a small plasma the shade 8-10 is a bit over the top as it is hard to see v's a lower shade. Maybe not the case with more powerful industrial ones.

I am diplomatic for a very good reason. I despise the "ooh you shouldn't have done that" mentality, usually expressed after somebody has made the best choice they can based upon information/knowledge or finances.
A drag torch certainly exposes you to less radiation and harmful light than a pilot arc torch, so tinted safety glasses or oxy goggles are probably adequate. The amperage of the unit is proportional to the thickness cut for sure, but a quantum leap is made when choosing a pilot arc torch unit over a drag type.
I haven't always had access to top end units and understand budgetary constraints, so I always try to balance performance with cost when giving advice. Unfortunately when people buy a lower grade unit, they often wish they had gone to the next level and paid more for a unit that performs greatly in excess of the cheaper unit so I try to provide at least a snapshot of what the pitfalls and/or benefits of a particular course of action may be.
A 40A unit will be quite capable as it will handle the type of work that a Plasma excels at, sub 3mm work, quite easily. Plasmas are certainly capable of more, but sub 3mm they shine. The only thing better is a laser profile cutter - and I love these.
Many people believe that a Mig, Tig or Plasma will miraculously transform their lives. They are only a tool, one of many, and have their own strengths and weaknesses. Good knowledge and practices will always outclass technology.

I have a Lincoln PC210 the one with the onboard compressor and find it a tad small for what I do. Lincoln Electric
Always liked the Hyperterm products and had an eye for the powermax 45
New 2013 Hypertherm POWERMAX 45 Single Phase Plasma Cutters in WINGFIELD, SA Price: $2,648 <44652>

How does the BOC rate? at $350 sounds like a steal ? how does it compare with my Lincoln? They rate it a t 40A mine is max 25Amp...

Originally Posted by Marc

I have a Lincoln PC210 the one with the onboard compressor and find it a tad small for what I do. Lincoln Electric
Always liked the Hyperterm products and had an eye for the powermax 45
New 2013 Hypertherm POWERMAX 45 Single Phase Plasma Cutters in WINGFIELD, SA Price: $2,648 <44652>

How does the BOC rate? at $350 sounds like a steal ? how does it compare with my Lincoln? They rate it a t 40A mine is max 25Amp...

Something of a fortunate coincidence. I was talking to my local Lincoln dealer only last week and the PC210 came up in conversation. Apparently their capabilities jump up a reasonable amount if you plumb your workshop air into them rather than use the onboard compressor. Might be worth a shot to save you buying a new machine.