Why not more built-in compressors?

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Miller has a compressor built into its smallest plasma cutter and one in its most expensive generator but nothing in between. One in a Bluestar generator spec'd to run a bigger plasma cutter or one in the Spectrum 375 plasma cutter itself would sure be nice. Is it just not do-able at a reasonable price? Or is there not enough power available from a 50A 240V circuit?And just how big is the compressor in the Air Pak? The dimensions and weights for the Big Blue Turbo and the Big Blue Air Pak are the same.A man who can't weld is as poorly educated as a woman who can't sew
Reply:If you have a machine that does two things, you get the best of neither.Lets say you have a plasma that has compressor in it.  Now the compressor takes a dump.  You have nothing.  Can you run a blow gun from your plasma cutter?  Die grinder?Easier analogy.  Washer/Dryer unit.  Washer dies.  Get washer fixed.  In the mean time you have nothing.  Washer really dies, needs big bucks to fix.  If they were separate units, just buy a new washer.  Now you have to spend the big bucks or buy another washer/dryer.  Make sense?Guy goes to welding supply shop.  Needs plasma cutter.  Has compressor like most of us.  Why pay MORE for the plasma with compressor when you already have one?DavidReal world weldin.  When I grow up I want to be a tig weldor.
Reply:Originally Posted by David RIf you have a machine that does two things, you get the best of neither.Lets say you have a plasma that has compressor in it.  Now the compressor takes a dump.  You have nothing.  Can you run a blow gun from your plasma cutter?  Die grinder?Easier analogy.  Washer/Dryer unit.  Washer dies.  Get washer fixed.  In the mean time you have nothing.  Washer really dies, needs big bucks to fix.  If they were separate units, just buy a new washer.  Now you have to spend the big bucks or buy another washer/dryer.  Make sense?Guy goes to welding supply shop.  Needs plasma cutter.  Has compressor like most of us.  Why pay MORE for the plasma with compressor when you already have one?David
Reply:I personally don't like integrated units, they never use the best components that draws me into buying a tool. Plus like David said an air compressor is it's own tool. Most people that make a living out of portable welding have truck mounted compressors, generators welders, and the ability to add a plasma cutter, other people just keep it in their shop. If you want it go for it but I will keep them separate.
Reply:I use Arc air as much as plasma.  I need a compressor for both.DavidReal world weldin.  When I grow up I want to be a tig weldor.
Reply:Quite a few plasma manufacturers produce a small unit (around 10 to 12 Amps output) that is designed for portability for sheet metal ductork and roofing applications...with a built in compressor. Most of these units will operate on a 20 Amp, 120 volt outlet. These low powered plasmas do not require much air flow to develop the ionized plasma arc....and for cooling of the torch and consumables....so a very small (around 1.5 cfm @ 40 psi) compressor is adequate.When you increase the Amperage requirements of the torch so that you can cut above gauge thickness materials....you dramatically increase the torch and consumable cooling requirements....as well as the flow requirement for forming the plasma. A typical 60 Amp plasma like the Hypertherm Powermax1000 requires about 6 cfm @ 70 psi ...which would require about a 3 hp compressor. Integrating a compressor of this size would add weight, cost and power consumption that would make the plasma system far less portable.On top of these issues....compressors can produce very wet air when used in humid climates.....water is detrimental to cut quality and consumable life in a plasma torch....so additional air drying equipment would also need to be included in many cases. In reality, most locations with heavy (thicker than gauge) cutting requirements have available compressed air that is often already set up to minimize moisture content.Jim Colt
Reply:I can see the reasons for not having integrated plasma cutter and compressor units on the larger machines.   It would be nice though to have a compressor pump integrated into the self-generating welding machine, with a seperate storage tank that can be mounted wherever.  The self-generating welding machine, in the case of most modern machines with 6000 or more watts of aux power, is both a welding machine and a power generator for running our power tools, why not make it an air compressor as well?   Most mobile welders carry a compressor anyways, it might be nice to have it all in one box.  Whoever invented the self-generating welding machine probly thought to themselves, hey, we carry a generator and a welding machine, why not put them together in the same machine (?), and then a great idea was born!An integrated, high volume (say, 15cfm @ 90psi, 150psi max) rotary compressor pump in a Bobcat, Trailblazer or Ranger with a 25-30hp engine and 10KW generator would save alot of weight and space on the truck, and could be built to cost less than buying 2 seperate machines.   The welding machine would need a little more powerful motor to run the pump and the generator, but all the generator power would be available for use when the compressor is running instead of an electric compressor motor taking up most of the generator power, or having to run a seperate gas motor compressor to free up the generator power.  Gas motor compressors are large, heavy, expensive, and require additional maintenance that would be nice not to have to contend with.  My one-ton truck is overweight hauling the utility body, Bobcat, gas-driven compressor and all the other tools and stuff needed.  Almost all of the usable bedspace on the truck is taken up by those two machines and the small tool box I have mounted in there.   An integrated welder/generator/compressor might save a couple hundred pounds, free up a good amount of hauling space on the truck and save some money on initial cost as well as time/money on maintenance.  Yes, the pump still needs to be maintained, but at least one gas engine is eliminated.MM350P/Python/Q300MM175/Q300DialarcHFHTP MIG200PowCon300SMHypertherm380ThermalArc185Purox oaF350CrewCab4x4LoadNGo utilitybedBobcat250XMT304/Optima/SpoolmaticSuitcase12RC/Q300Suitcase8RC/Q400Passport/Q300Smith op