Plasma cutter consumables...

[BellyUpFish]

Hey guys-

Just picked up a plasma cutter and I'm looking at getting some consumables to keep on hand..

Just curious the "average life span" of consumables seeing "average use" might last?

Obviously, there are many variables..

But for those of you who have plasma cutters in your home shop and do lets say, 3-5 hours of plasma cutting a month, how many sets of consumables do you like to keep on hand?

 

[koditten]

I wish I could tell you how much I use mine, but I know it is alot. I have 6 sets of consumables. With that said, I haven't changed anything out in over 2 years.

The secret is to have a very good prefilter. Before I installed my prefilter I would go thru tips every other month. The onboard filters are not very robust.

I have a constant purge coming out of the prefilter bottom via a micro valve. This drains off any water that accumulates. The filter takes care of the rest of the nasties in the air.

My filter looks similar to a whole house water filter, the only difference is the filter media is designed to ulra purify gasses. (origanally nitrogen)

 

[Jackfre]

I have a Hypertherm 380. It's been a great little machine. For a prefilter I installed a Motorgard M-26 filter ahead of the unit. Has worked well.

 

[22george]

what kind of filter is it?
Is it a water separator?
Any pictures?

Thanks

 

[Hghgrad]

I went through a few in the beginning before I realized how far away I can hold the torch. I couldn't tell you the last time I changed any tips, been a year probably.

 

[Strouty]

If you have any moisture issues, it will eat consumables. Ask me how I know.

 

[wnstwolf]

I found that learning through error is expensive. One thing that quickly cut my cost of tips was to buy one that had a built in offset to it rather than one that manually had the user keep the nozzel off the piece your cutting. I have a Miller unit and this was a great "ohh yeah" moment. I also bought all kinds of add-ons to cut circles and other tricks. It's one of the tools that you may not use every day but wow when you need it it is amazing..

 

[BellyUpFish]

I shouldn't have moisture issues. Not getting any moisture while sandblasting.

I bought a fair cheap plasma cutter, so who know how long it'll be around. Figured it would be a cheap experiment to see how often is use a plasma cutter.

Wanted to grab a decent supply of consumables and hope for the best.

 

[kazlx]

It's a **** shoot. Good plasma, nice, clean air, they will last a long time. All day cutting for hours on end on my CNC. I've heard the cheaper ones, not so much. Has a lot to do with the torch design, consumable quality and design and use. Based on your use, you should get a couple months out of a set.

It also matters what kind of quality you care about. If you are using to sever pieces it doesn't matter as much and you can get away with more use than if you are doing art or something and need a super clean edge.

The biggest killer of consumables is water and/or **** in your air. Filtration is the best money you can spend.

 

[venturesomerite]

I get a few months out of mine. I have two water traps right out of the compressor and one right before the plasma.

 

[BellyUpFish]

Sweet.. Sounds like I should be ok.

 

[Guster]

My 50A unit came with a 30A torch which was great for general sheetmetal until I wanted to cut some 3/8". Tips would fuse or blow out and the hafnium insert would dissipate quite quickly. I've since found an inexpensive compatible P80-style torch but was weary of it's bottom end performance with sheetmetal(ie. 1/4" and less) due to not having as small an orifice as the torch I used to date. However my fears were unwarranted, the consumables appear to last forever by comparison and I soon sold the smaller torch and spares I had on hand. The consumables for the larger torch is more prevalent, hence cheaper too.

 

[A**holes Garage]

I have a Hypertherm 380. It's been a great little machine. For a prefilter I installed a Motorgard M-26 filter ahead of the unit. Has worked well.

ditto

 

[J Persons]

I wish I could tell you how much I use mine, but I know it is alot. I have 6 sets of consumables. With that said, I haven't changed anything out in over 2 years.

The secret is to have a very good prefilter. Before I installed my prefilter I would go thru tips every other month. The onboard filters are not very robust.

I have a constant purge coming out of the prefilter bottom via a micro valve. This drains off any water that accumulates. The filter takes care of the rest of the nasties in the air.

My filter looks similar to a whole house water filter, the only difference is the filter media is designed to ulra purify gasses. (origanally nitrogen)

Please share the brand name and specifics of your prefilter and where did you get it?

 

[Kevin54]

KAZLX......weren't you the one that built the CNC plasma table? If so, just that you might be interested, I got a price on one the other day without the Plasma cutter. $9800.

They did show though that you can put in a RotoZip or something similar, and cut 3D wood patterns. JUST AN FYI.

BellyUp......What projects are you planning on making that prompted you to get a plasma cutter? I've been looking at some, but don't know if I want to pull the trigger as I don't know how much I would use it.When I don't have things it seems like I need things, then when I have them, it seems that they don't get utilized as much as they should.

 

[Jackfre]

what kind of filter is it?
Is it a water separator?
Any pictures?

Thanks

No pics. Beyond my capabilities. I went on the Millerwelds forum and asked about filtration. The Motorgard cartridge filter was highly recommended. It is about 6" diameter and 6' tall. Pretty big on a little machine. I hard piped it with 1/4" fittings/*******. I ordered it from the LWS. It was about $100. The 380 is a hand held outfit. I never use it unless I've had six cups of coffee. The filter has made me better with it.

 

[koditten]

Give me a bit to look up the info. Not at home for a while-vacation.

 

[BellyUpFish]

BellyUp......What projects are you planning on making that prompted you to get a plasma cutter? I've been looking at some, but don't know if I want to pull the trigger as I don't know how much I would use it.When I don't have things it seems like I need things, then when I have them, it seems that they don't get utilized as much as they should.

Well, to be honest, I don't have any real projects in mind. Lots of small projects I've considered.. Off the top of my head, I know I'll use it to cut the floor plans out of an old Bronco with it this fall. I'll also use it to chop and section the top on the same Bronco for a "metal safari top" project I have in mind. I'll probably use it to make the brackets to hold the top to the roll cage. I'd like to cut out some steel targets as well.. Lots of random stuff..

I've started keeping a list of uses for a few tools I'd like to have.. Plasma cutter, larger lathe, better mill, etc.. When I find myself thinking "If I had X, this task would be much simpler.." I'll type that into the list and then revisit it when I get the itch..

I totally understand the hesitancy to not drop $1,800 on a Hypertherm, which is why I went with this Lotos LTP5000D. Everything I have read about it has been positive. The reviews on Amazon are good. There have been rumors of "free consumables for positive reviews" which, I will take them up on, if I'm happy with it.. Lots of videos on YouTube about it..

So, I figured, I was willing to spend $400 to "see if I'd use it." So, I waited on eBay until I found one from a reputable dealer and could get it for $400.. Threw a bid out there last week and boom.. LOL..

 

[wnstwolf]

I picked up a Miller Spectrum 125c at a Hot Rod Nationals show many years back. It was the show demo unit and out the door (gate) was $1k with a bunch of consumables and template accessories. I bought it for auto body work and it has exceeded my expectations. 3/8 is about the thickest it can ever hope to cut but I am fine with that. This model comes with built in compressor and has no filters to mess with that I know of.

Aside from cost and I am sure the capabilities of the machine to cut thicker material is there a reason the machines you are referring to need separate air supplies? I have taken my cutter and a generator in the back of the truck to many a “salvage” yard to cut the pieces I need for restorations. Not sure that is so easy with those needing the added compressor. Sorry for being uneducated on these things. Always looking to learn..

 

[J Persons]

I have a Hypertherm 380. It's been a great little machine. For a prefilter I installed a Motorgard M-26 filter ahead of the unit. Has worked well.

That Motorguard M-26 looks very similar to the TP Tools coalescing air filter. http://www.tptools.com/1and2-Coalescing-Air-Filter,74.html

 

[A**holes Garage]

I built a portable frame for my Hypertherm which has the M-26 filter attached;

 

[Rickedstyles]

Which hypertherm is that ..30?

 

[A**holes Garage]

Which hypertherm is that ..30?

Yes, Powermax 30

 

[metalmagpie]

I used to eat consumables on my PowerMax 1000. Then I rebuilt my cracked and abused torch head. Now it cuts perfectly and I'm expecting a lot longer consumable life.

I suggest you buy consumables when they're cheap, like if you see a deal on *bay.

Make sure you're set up with a drag shield (the kind that can touch the work) for cutting by hand. Make sure you aren't trying to cut metal when your machine is set up for gouging (i.e. make sure you have cutting consumables to cut and/or gouging consumables for gouging).

Read your manual.

If you have a Hypertherm machine, don't bother with finecut consumables. They're really for machine torches.

metalmagpie

 

[Jackfre]

I built a portable frame for my Hypertherm which has the M-26 filter attached;

Nice kit. What is the thickest mild steel you've cut with the 30? What do you see as its hand held cutting limits? I was just in the LWS shop yesterday picking up some steel for my new welding table and was looking at the 30 & 45 Hypertherms.

 

[A**holes Garage]

I bought this for my hobby, light metal fabrication, etc.

I've cut a lot of 1/4" plate, angle etc. Not sure I'd go much thicker, cycle duty, etc.

 

[jimcolt]

There is a huge variation in consumable life between plasma system models and manufacturers. With the low cost import plasma's.....(which use generic torches that typically are copied technology from older designs from the major plasma manufacturers), expect a low purchase price for the system, but higher consumable usage as compared to a similarly powered system from Hypertherm. You may use 6 to 10 times the number of sets of consumables with these low cost plasma's as you would with the modern design major brands. Pay more for the major units, pay less over time to use them.

Of course air purity is an issue, but again, on the newest designs from companies like Hypertherm ...a little moisture has minimal effect on the life of consumables....with the imports moisture often has extreme effects on consumable life.

Just wanted to point out that when talking consumable life....there is a huge difference in cost and consumption between systems.


Jim Colt