Max200 Upgrade...

[KilroyNo1]

Now that my plasma table has proven itself to work, I need to focus on upgrading it to get the best value per inch until such a time that I am financially ready to upgrade to an HT2000 or HD/HPR system.

My table is a C&G Mustang, 12' x 24' with Burny 5 controller and Max200 torches.

The table will primarily be cutting chromium carbide wear plate products and high definition results are not necessary. (Example: www.trimay.com)

I'll be needing new consumables soon (today!), are the HT2000 consumables the same as the ones for the Max200 torch?
What would be the best torch upgrade that will still work with the Max200 power supply?
I realize that the technology within the Max200 is a limiting factor to consumable life, so will a torch/consumable upgrade help at all?
I've been seeing a lot of consumables with the word "Silver" kicked around, would these consumables be worthwhile on these power supplies?

Any additional information is greatly appreciated.

[jimcolt]

The Max200 torch is still as original. There are a few aftermarket companies offering their versions of torch upgrades for this system, however they generally do not bring any advantages to the cutting process, rather they are a ploy to switch you over to their brand of consumables.

Hypertherm did introduce "Silver Plus" electrodes in the past couple of years, and if you are cutting with oxygen as the plasma gas (best cut quality, fastest cut speeds, less dross formation, better edge metallurgy) thenthe Silver electrodes will provide dramatically longer consumable life. The consumables for the HT2000 and Max200 are not identical....there are a few shared parts but the different gas flow technology requires a bit of a different torch design.

The Silver Plus electrode uses a pure silver interfcae between the hafnium element and the copper body of the electrode. The silver bonds well to both materials, creating a far superior heat transfer as well as electrical connection. It is common to double the electrode life, which also increases the nozzle life of the system. Attached is a link to a complete listing of the consumables available for your system.
MAX200 Plasma Cutting System | Hypertherm

Depending on the maximum thicknesses you are cutting, you may want to take a look at upgrading to an HSD130 system. These systems were designed to replace Max200's for those users that desired longer consumable life, but did not need to step up to the cut quality of an HPR (high definition) class plasma. If you are operating your machine two shifts per day the HPR will generally save enough in consumables cost to pay for itself in less than a years time!

Best regards, Jim Colt

[KilroyNo1]

Thanks for the informative reply, Jim.

I found the consumable list for Air/Air Max200 vs. HT2000 shortly after I posted, 3 of the 5 parts are the same number.

I suppose I have to look at the cost of consumables with air/air vs. bottled oxygen/air. We've been doing our testing (up to 1.375" so far) with air/air and the cut quality and mild dross have been well within acceptable limits. Bear in mind the testing has been with an old shop air compressor with no air dryer (just several in-line separators) and used consumables. I have no idea at this point how long a bottle of oxygen will last, but if it doubles the life of the consumables I will then have to look at the cost of the oxygen vs. the cost of the consumables.

The table will only be running one shift per day. We are a fair size shop, but there are only 4 skilled employees at this time. We will most likely be doing some production cuts on large sheets of 3/4" wear plate starting next week, so we'll be able to start tracking consumable life on air/air at that point.

If anyone has looked at this cost comparison already, please let me know how it turned out.

[jimcolt]

Oxygen will not double the life on the consumables....unless the silver electrode is used. The silver electrode is not recommended for use with air as it does not work well with any contamination, or with nitrogen (air is 80% nitrogen). Oxygen will provide squarer, cleaner, faster cuts....with less secondary operations. If you figure your total cutting costs oxygen use will be cheaper, as there will be less cleanup and fitup.

Jim