Air Dryer for plasma cutter

admin

New to the forum. Did a quick search and couldn't find a lot about air dryers. I bought a used Hypertherm 1100 and need advice about air dryers. I have a Motorguard M30 filter that I plan to hook up close to the cutter. I have a 60 gal 5 hp compressor with a water/oil interceptor attached but no other drying equipment. I live in Michigan, so fairly humid. Do I need more than just an M30 to run the Hypertherm?
Reply:I use this and pretty happy with ithttp://www.harborfreight.com/38-desi...ter-69923.htmlTorchmate 2x2 CNC with Flashcut CNC controlsHypertherm Powermax45 Esab ET220i Razorweld 195 MigRazorweld 200ac/dc TigTormach 770, Tormach xstechRazorweld, Vipercut/Vipermig, SSC Foot Pedal Dealer
Reply:Welcome.I have a refrigerated air dryer but I still take a multi forked approach to drying air. I've posted some of my system in the past.http://weldingweb.com/vbb/showthread.php...-plasma-cutterIf your compressor is turned up to 175 psi, drop it to around 125 psi unless you really need the extra. You compressor may cycle a little more often but the air will be cooler and the cycle will be shorter. Hot air carries moisture. I also saw a drop in my electrical usage. If you plumb air in your shop use that largest diameter pipe you can afford. 1/2" pipe will carry more moisture than 1" pipe due to the velocity. Interestingly, I have never found water in my storage tank just after the air dryer but I have trapped water at the plasma cutter when I was using 100' of 1/2" hose. When it comes to air... dry is tricky.
Reply:Thanks for the advice. Is there an easy method to tell if I ham removing enough water?
Reply:Originally Posted by forhireWelcome.I have a refrigerated air dryer but I still take a multi forked approach to drying air. I've posted some of my system in the past.http://weldingweb.com/vbb/showthread.php...-plasma-cutterIf your compressor is turned up to 175 psi, drop it to around 125 psi unless you really need the extra. You compressor may cycle a little more often but the air will be cooler and the cycle will be shorter. Hot air carries moisture. I also saw a drop in my electrical usage. If you plumb air in your shop use that largest diameter pipe you can afford. 1/2" pipe will carry more moisture than 1" pipe due to the velocity. Interestingly, I have never found water in my storage tank just after the air dryer but I have trapped water at the plasma cutter when I was using 100' of 1/2" hose. When it comes to air... dry is tricky.
Reply:Originally Posted by mlewisThanks for the advice. Is there an easy method to tell if I ham removing enough water?
Reply:Originally Posted by mlewisThanks for the advice. Is there an easy method to tell if I ham removing enough water?
Reply:I shamelessly plagiarized the following, probably from here, several months ago, just in case.  Happy reading. . . . . . . . . .Before I got my Hypertherm 45 recently, I never worried too much about the air quality in my compressed air. I knew that I needed to do something so that I could use my new HVLP automotive spray guns, but I did not know what. The Hypertherm put me into high gear about it, since I don't have the desire or the bucks to buy another one if I screwed it up with bad air. So, after scouring the net for a few days, I got a sense of what to do and I thought I'd share some of the results of the searching.Here is the thread where I really reaized just how much I didn't know:http://weldingweb.com/vbb/showthread.php...41#post3405841Here are a couple of links for some industry basic tutorials on filtration theory, and design. They are written (mostly) for the end user, not an engineer.http://www.omega.com/auto/pdf/CompressedAirTips.pdfhttp://resources.norgren.com/documen...ressed_air.pdfhttp://www.mig-welding.co.uk/air-system.htmhttp://us.kaeser.com/Images/USGUIDE2...-tcm9-9594.pdfhttp://hydraulicspneumatics.com/200/...irFiltersandFRhttp://star4d.org/about/news/the-eff...-restrictions/http://www.jgbhose.com/technical-ref...d-air-flow.asphttp://www.glauber.com/Products/Comp...ilx/is08573stdhttp://www.wilkersoncorp.com/products.asp
Reply:The word of the day is "Franzinator"https://www.google.co.uk/search?q=fr...w=1242&bih=719Oh, and welcome to the forum.SqWave 200Millermatic 190Airco 200 ACHypertherm PM45Boice-Crane Band SawVictor O/A
Reply:Im not to impressed with the motorgard filter, I had one come apart and totally plug everything on my Hypertherm 825 with dessicant powder. Ive since gone to a cheaper centrifugal coalescing filter with a clear bowl. I actually can see that one working.
Reply:Originally Posted by pin2hotI shamelessly plagiarized the following, probably from here, several months ago, just in case.  Happy reading. . . . . . . . . .
Reply:I've had zero problems with a motor guard on my pm45.  2 years now.  I think moisture ruins the consumables faster, but in don't think it ruins the machine.  Every now and then I open the filter and let the element dry out.
Reply:I went ahead and bought the Hypertherm filter: Hypertherm Air Filtration Kit #128647.   It's a bit pricy but is self draining.
Reply:Here is a link to an air quality article that I wrote a while back that covers air systems for plasma:  Air systems link   http://www.nxtbook.com/nxtbooks/fabs.../index.php#/22   With a Hypertherm air plasma.....moisture in the air system....which is common during humid weather and in humid climates, will have an effect on consumable parts life. All Hypertherm Powermax systems have a small coalescing filter and auto drain assembly built in. In highly humid or regions where humidity is year round, it is normal to have to make some changes to an air system to minimize moisture....just as you must for paint spraying and you should for any air operated Many users "overkill" filtration, or use incorrect types of treatment for their air systems. A motor guard filter is primarily a particulate filter....it will absorb some moisture, however it will become saturated over time and will cause air flow issues and will start allowing moisture to pass. A particulate filter works best for particulates! There are a variety of low cost dessicant dryers....if they do not have onboard particulate filters on the output side, expect fines from the dessicant to eventually work its way into the plasma or other air tool....which will clog orifices and affect operation.Bottom line, the best practice is always to install an auto drain on your compressor. There should be a coalescing filter with an auto drain as well....it needs to be more than 20 feet away from your compressor (this allows the air to cool a bit , which increases the droplet sizes....which makes the coalescing filters job easier), and this coalescing filter should have an auto drain.In many locations with low humidity (Arizona as an example)...often no filtration or treatment is necessary with a Hypertherm plasma. In my NH shop I use no air treatment during the dry winter months, and a refrigerated dryer during the humid summer season.Read the article, look at the drawing of a high tech air system....you don't need all of this but there are great ideas regarding where to locate thins, to take air off your high points in the plumbing and to have drains in the low points. Drain the compressor tank often (auto drain is best), install a pressure gauge at the plasma inlet for troubleshooting purposes.Jim Colt  Hypertherm Originally Posted by mlewisNew to the forum. Did a quick search and couldn't find a lot about air dryers. I bought a used Hypertherm 1100 and need advice about air dryers. I have a Motorguard M30 filter that I plan to hook up close to the cutter. I have a 60 gal 5 hp compressor with a water/oil interceptor attached but no other drying equipment. I live in Michigan, so fairly humid. Do I need more than just an M30 to run the Hypertherm?
Reply:I'm just building this system today:The coiled copper will be connected to the compressor output.  The coils will reside inside an oil drum filled with water to cool the air.  Then they go up to a 3/4 copper distribution line where the air comes off of the top of the line into 1/2" copper drops with drains at the bottom.My system is in West Africa, and right now is the rainy season.  If the system can dry this air out, it can work anywhere.I don't assume that 3/4" copper is the best for the barrel part of the system, I think a split pair of smaller lines would've been better to maximize air to copper surface area for cooling - but I found a great deal on a clearance spool of 3/4" type L at home depot - so that's what I'm using.I'm doing this for the 5x10 plasma table I'm just finishing up (using a Htherm Powermax 1000).
Reply:I've got the following setup:3.7 hp, 60 gal compressorSMC AF40-N04-Z 5-micron prefilter (helps keep crap out of the refrigerated dryer) (~$30)Ingersoll-Rand D18IN refrigerated dryer (~$700)All three have drains and I get water out of each of them (compressor and prefilter are manual drains, dryer has a built-in programmable).  I've never measured the moisture content of the air coming out of the dryer, but it seems to work okay for sandblasting, plasma, and powdercoating.
Reply:Originally Posted by forhireIf your compressor is turned up to 175 psi, drop it to around 125 psi unless you really need the extra. You compressor may cycle a little more often but the air will be cooler and the cycle will be shorter. Hot air carries moisture. I also saw a drop in my electrical usage.
Reply:I built an air dryer system years ago. Inner cooler, and after cooler. Attached ImagesDon’t pay any attention to meI’m just a hobbyist!CarlDynasty 300V350-Pro w/pulseSG Spool gun1937 IdealArc-300PowerArc 200ST3 SA-200sVantage 400
Reply:Originally Posted by CEPI built an air dryer system years ago. Inner cooler, and after cooler.
Reply:Originally Posted by GravelDo you put water in the trash can?
Reply:Thanks. My local welding shop said it was all I needed. Glad I didn't believe them
Reply:Originally Posted by CEPYes. Also use that water bed conditioner so things don't grow.
Reply:Originally Posted by GravelGood idea. Had thought about the water in a bucket idea but you took it to another scale.
Reply:Originally Posted by CEPIn your neck of the woods you may have to drop some ice in the garbage can.
Reply:Originally Posted by CEPYes. Also use that water bed conditioner so things don't grow.Originally Posted by GerryMDo you have drop with a drain on the bottom of the copper coil ???