New Powermax 45XP! Crap... I was just about to pull the trigger!

dragoneggs · Nov 3, 2016

Shield Arc said:
The filter on the right is: M-60. Replacement filter M-723. Some people use a roll of toilet paper.
This system can only take up to 125-PSI. I use this system for my nail gun. I use the air dryer for plasma cutting, and painting.

I'm going to have to check but I don't think Costco TP that I buy is rated for 125psi! :laughing:

jimcolt · Nov 5, 2016

OK, I'll try to clarify a few things!

- The way moisture in air lines affects plasma torches and the life of the consumable parts varies widely based on the torch design as well as the consumable design. Older technology plasma torches could destroy an electrode (which in turn will destroy the nozzle (some call it a tip) when a few drops of water pooled in an air line....and made its way to the torch in seconds or minutes. On the opposite end of the spectrum a little moisture in the newest Hypertherm torches has an effect on consumable life....but nowhere near the type of wear seen with older technology. Much of this has to do with the manufacturing and design of the consumables themselves.

-Air Plasma systems use air in similar pressure and flow characteristics as compared to many automotive spray painting operations. Paint applications require even lower levels of moisture content as compared to plasma. There is a ton of moisture, oil and particulate filters and drying systems that are typically used for painting....that can also be used for plasma.

- Oil drops in the airline are your worst enemy in regards to plasma consumable life. Worn out compressors with oil blowing by the piston rings are often the culprit.

-With all the Hype online (here included) about the devastating effects of a bit of moisture in an air system used with a Hypertherm plasma cutter....by far most of the problems I help solve have nothing to do with the moisture itself. Rather.....problems with error codes and occasional ugly cut quality are more often caused by restricted flow capability of the inlet air connection for the plasma....and often this flow limitation is caused by overkill on the filtration system that is often suggested by online experts.

Here are my suggestions if you are using a Hypertherm air plasma system to ensure adequate air flow, pressure and purity:

1. First and foremost, drain the compressor tank daily. Even better, install an auto drain that removes water from the tank (receiver) on every on/off pressure cycle. This is my entire moisture removal system (no additional filters, separators, drains) for my Powermax85, Powermax45, Powermax45XP in my home shop....and I get exceptional consumable life and cut quality. I am in NH....it is extremely humid here during the summer.

2. Next, install a good air pressure gauge, hard plumbed to the inlet on your plasma system. Do not rely on pressure gauges anywhere else in the system. This gauge is 100% necessary in order to read dynamic (air flowing at the torch) pressure to the system. It will read the same as other gauges in the entire air system with no flow at the torch, and I guarantee it will read a lower pressure than other gauges in the system when the air is flowing. If you don'y have a good gauge at the inlet...then you have no idea what the dynamic inlet pressure is. This can and will cause error codes and cut quality as well as consumable life problems.

3. If you find a lot of water when you drain your compressor tank (daily, right?)....then maybe you should consider additional water separation. If in a tropical, humid climate....you may need to use either a refrigerated dryer or a self regenerating dessicant dryer. These units are costly, but require very low maintenance......and do the job of removing moisture without your supervision. A good automotive body shop will have one or both of these types of systems. In 99.9% of air plasma applications you do not need these. I hear good things about the harbor freight unit in the $450 range.....but again, not usually needed if you have a Hypertherm torch.

4. If after a days cutting you only see a mist or a teaspoon of water when you drain your air tank, then you could choose to do nothing (that is what I do....I rely on the coalescing water / oil separator in each of my Hypertherm systems). If you want to spend some money on a separator, make sure it is sized properly (its CFM rating should be larger than the airflow requirement for the plasma cutter being used....good rule is at least 2x the rating), install it with at least 20' of copper or iron pipe between the compressor and the separator (pipe should be minimum of 1/2" ID). This length of pipe allows the hot air from the compressor to cool a few degrees....which makes the job of the moisture separator easier. (water condenses into larger droplets and the separator can remove them easier from the air. Keep in mind that with this separator you have now added a restriction between the pressure at the compressor and the pressure at the inlet to the plasma under dynamic (flowing) conditions.

5.Less expensive (than a good quality separator) is a filter such as the Motorguard. These use a paper element and while are most effective as a particulate filter....they will absorb moisture. When they become saturated with moisture.....the restriction of air flow becomes higher, you will see lower pressure at the gauge you installed at the plasma (when air flows at the torch). When these type of filters become wet...they will pass a little moisture. Do not be tempted to use a roll of toilet paper as the element unless you plan on disassembling you air system on the plasma cutter to remove all the fine particles of toilet paper....which is designed to break down over time when wet.

6. Rule of thumb. If there are no filters or separators between the air compressor and the plasma....you can use hose or pipe with a 3/8" inside diameter up to 50 feet long. If you need longer than 50', or add filters, separators....then go up to a minimum of 1/2" ID plumbing.

7. After installing your plumbing system and any additional filtration.....watch the pressure gauge at the plasma when air flows at the torch.....compare the pressure on that gauge with a gauge back at the compressor. Watch it especially at the bottom of the pressure cycle (right when the compressor kicks on to rebuild pressure)...and ensure that it stays above 90 psi (on a Hypertherm, other systems may have different minimum input pressures). Once your filters get some moisture or particulate in them....this gauge will read lower. If it is below the plasma manufacturers minimum...then it is time to change or clean your filtration systems. Keep in mind that even a 200 HP compressor with a 500 gallon tank will not have any effect on flow to the plasma if the plumbing system has too many restrictions.

8. The Hypertherm units all have a particulate filter with a coalescing moisture / oil separator and an auto drain. Check the clear coalesce bowl periodically....if you see moisture or oil in it, then that means you are getting moisture or oil through your system to the plasma.

Where do I get my info, what provides me the expertise to make these suggestions? I have worked for Hypertherm for 39 years, but even more than that I have been doing metal fabrication in my home (hobby) shop for over 30 years. I use plasma for hand cutting, for cnc machine cutting. I have a refrigerated dryer that I turn on only when I need to paint something......I do not need it for the plasma cutters. Draining the tank daily or with an auto drain is adequate and I have never had an issue caused by moisture in my system. This is not the case with older technology plasma torches that you might find on a 20 year old Hypertherm, or on the new torches that come with most of the low cost import plasma's....this is because most of the import torches (not all) are copies of older technology torch designs that moisture will definitely have a larger effect on.

Jim Colt Hypertherm

jimcolt · Nov 5, 2016

Dragoneggs,

In regards to the Powermax45 XP......I have been using one extensively in my home shop for close to 3 months now. It was a Beta prototype from our engineering and production teams. Beta units are the first build on the assembly cells that are designed specifically for the product. The beta build often numbers 25 or so units.....which are then distributed to our field reps to demo the un released new product to dealers. The build is also to determine any bottlenecks or issues with the manufacturing cell. So...I got my hands on one a few months before we released the 45 XP as a product to the world.

I have a number of hours on it and used it on my cnc machine to cut all the components for some demo tables as well as speaker podiums that will be at the Fabtech show in Vegas in a couple weeks (I'll be lurking around there somewhere!). I have done some hand cutting , machine cutting, plasma marking and some gouging on a variety of materials. I also have an original Powermax45.....this unit has noticeably more cutting power than the older one (both at 45 amps)....and this is due to a Power supply that is designed to output a higher output wattage (6525 watts vs 5950 for the old 45), as well as the 45 XP's ability to use the newer Duramax torch style (same as used on the Powermax65, 85 and 105 plasma systems). I would rate its cutting power firmly in between the old Powermax45 and the Powermax65......and because of that we were able to bump up its production rating to 5/8" from the original units 1/2".

The advances over the original 45 : More wattage (true measure of cutting power), the ability to use Finecut consumables for 10 gauge and thinner materials (narrower cuts, better edge quality on thin materials), A new Plasma marking process for doing accurate layout on your work...and even alpha numeric part numbers, etc. (this is not a replacement for a pneumatic marker on a cnc machine.....but it can do a pretty good job with letters or numbers down to about 1/2" height (or larger) if needed...and definitely has advantages over other marking processes (no x or y offset is one)), much improved gouging processes (precision gouging for spot weld removal) and higher powered gouging for weld removal and dismantling), Auto air.....no need to set cut air pressure. The unit is lighter and has a higher duty cycle rating as compared to the original 45. And, similarly equipped (same torch lead length) it is priced the same as the original 45.

New product reliability? The reliability testing at Hypertherm includes 12 to 24 months of HALT (highly accelerated life testing) with as many as a dozen units running and producing a plasma cutting arc (not just a resistive load). The units run at higher output voltage and amperage than they will be sold with, at increased ambient temperatures, as well as in multi axis vibration chambers...designed to literally shake components of the PC boards. The HALT testing is designed to stress units and break them.....and when that happens they are autopsied, the design is improved and the tests resume......until they no longer break. This same type of reliability testing is done on all of our products.

If anyone makes their way to NH...I'd be happy to provide a tour of our facilities where these units are made.

Hope that answers the questions regarding the Powermax45 XP. Jim Colt Hypertherm

dragoneggs said:
Gents, yes I am using the term loosely. I have been researching and procrastinating for a long time on the purchase of my first plasma cutter. Also hoping it is my last. Had pretty much settled on the Miller 625Xtreme over the Powermax 45 after narrowing down my decision to two. I really like the versatility of 120v/240v operation (same as my Miller 211 MIG) and have the capability to change torch and add to a plasma cutting table in the future.

Just as I was about to tell the better half what my xmas present was going to be... I see that Hypertherm just released a new 45XP model. Now it doesn't have the dual voltage which disappointed me, it does have auto air/gas flow adjustment, etching/marking ability, and the company is USA and employee owned. I had decided going with the Miller because of the dual voltage but these new features on the 45XP have me questioning whether I should go for the latest/greatest.

Looking forward to your biased comments!

dragoneggs · Nov 16, 2016

I visited the FabTech show in Las Vegas today and had the pleasure of meeting Jim Colt and Vince Tucker from Hypertherm! I also got a chance to cut some metal with the new Powermax 45XP and talk about CNC tables, software, etc. Really appreciated the time they spent with me. Although it doesn't have the dual voltage I would really like, I think the part marking (low voltage) option opens up a world of capability for artistic design.

They also put me in touch with a few CNC table folks near my locale that are good with tech/service support, etc.

Just by trying out the new 45XP I was entered into a drawing for a free one... but one must be present to win. Thing is... odds are probably pretty dang good compared to most drawings because you have to suit up and actually use it before they 'enter' you. BUT... My time is short in Vegas and I owe my better half a nice dinner & show... so for the first time in my life I hope I don't win a lottery! :laughing: Jim, please don't tell me if I did.

Again, thanks Jim and Vince! Can't wait for Xmas!

Big Barn · Nov 16, 2016

dragoneggs said:
I visited the FabTech show in Las Vegas today and had the pleasure of meeting Jim Colt and Vince Tucker from Hypertherm! I also got a chance to cut some metal with the new Powermax 45XP and talk about CNC tables, software, etc. Really appreciated the time they spent with me. Although it doesn't have the dual voltage I would really like, I think the part marking (low voltage) option opens up a world of capability for artistic design.

They also put me in touch with a few CNC table folks near my locale that are good with tech/service support, etc.

Just by trying out the new 45XP I was entered into a drawing for a free one... but one must be present to win. Thing is... odds are probably pretty dang good compared to most drawings because you have to suit up and actually use it before they 'enter' you. BUT... My time is short in Vegas and I owe my better half a nice dinner & show... so for the first time in my life I hope I don't win a lottery! :laughing: Jim, please don't tell me if I did.

Again, thanks Jim and Vince! Can't wait for Xmas!

Mark-- Don't forget to look for Jody " Welding Tips and Tricks"!

Have fun for me!
Terry

dragoneggs · Nov 28, 2016

Big Barn said:
Mark-- Don't forget to look for Jody " Welding Tips and Tricks"!

Have fun for me!
Terry

Dang it... I missed Jody. And Chucky2009 (Lanse) as well but I sure did enjoy the show. Wish I would have spent a second day but I am convinced the 45XP will be more than adequate for any need I may have. Now I am wondering if I should scab a shelf on the side of my MIG cart or???

Going to get the hand torch but order (I mean put on my xmas list) the machine with the CPC outlet for the eventual Plasma table.

Big Barn · Nov 28, 2016

dragoneggs said:
Dang it... I missed Jody. And Chucky2009 (Lanse) as well but I sure did enjoy the show. Wish I would have spent a second day but I am convinced the 45XP will be more than adequate for any need I may have. Now I am wondering if I should scab a shelf on the side of my MIG cart or???

Going to get the hand torch but order (I mean put on my xmas list) the machine with the CPC outlet for the eventual Plasma table.

Mark, here's a couple ideas to consider for cart-mounting your new plasma cutter.

My carts have a tilt and slide design to secure the machine without fasteners, straps or tools.