Max200 Upgrade...

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. :D

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

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.

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

well, In my case I have 3 Hpr260 and 1 max200 and I´d like to use the same consumables in all power-supplies, is it possible, can I change the max200 torch upgrading to Hpr torch, or it´s necessary change any PCBoard? how could I do it? Sometimes it´s difficult to find max200 consumables, even knowing that wouldn´t increase tips lifes, that changing would help me! Tks

Quote:

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Originally Posted by 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

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Well, In my case I have 3 Hpr260 and 1 max200 and I´d like to use the same consumables in all power-supplies, is it possible? can I only change the max200 torch for Hpr torch, or it´s necessary change any PCBoard? how could I do it? Sometimes it´s difficult to find max200 consumables, even knowing that wouldn´t increase tips lifes, that changing would help me! Tks

Since the HPR260's are High Definition class plasma systems it is not possible to use the same torch on the Max200. In theory it could be made to work...however the gas flows and current (pilot arc and cutting current ramp ups and ramp downs) would not be properly engineered.....which would result in poor consumable life and cut quality.

There is an available torch upgrade for the Max200 called the HyPro torch that will dramatically improve cut quality, consumable life and cut speed....here is a link to the details for that torch: HyPro2000 retrofit torch for MAX200 | Hypertherm

As far as availability of consumables for a Max 200....any Hypertherm distributor can get them for you....they are always in stock at the Hypertherm factory in Hanover NH, USA, and orders ship the same day recieved. If you use quite a lot ask your local dealer to keep some quantity in stock for you.


Best regards, Jim Colt

Quote:

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Originally Posted by Franklin Alves

Well, In my case I have 3 Hpr260 and 1 max200 and I´d like to use the same consumables in all power-supplies, is it possible? can I only change the max200 torch for Hpr torch, or it´s necessary change any PCBoard? how could I do it? Sometimes it´s difficult to find max200 consumables, even knowing that wouldn´t increase tips lifes, that changing would help me! Tks

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In fact, I saw that upgrade in a machine here in Brazil, so I got interest of doing the same, but I have no knowledge about so I´m asking for specialists how could I do it, Cuz I saw it and it was working!

Best regards

It is simple....remove the old torch and leads from the Max200....and put the new ones on. There are new cut charts and new consumables for the new torch. This is the same torch we have been upgrading the HT2000 with for a couple of years.

Jim Colt

Quote:

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Originally Posted by Franklin Alves

In fact, I saw that upgrade in a machine here in Brazil, so I got interest of doing the same, but I have no knowledge about so I´m asking for specialists how could I do it, Cuz I saw it and it was working!

Best regards

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