The new SmartSYNC plasma cutting system

[Black Forest]

Is there any new information on the new system? The little bit of info I have been able to obtain is quite vague. What I am really interested in knowing is how the smart end of things works. As in the amp settings. Do you have to have a cap for each amp setting? That seems not right in my head somehow. Does the cap actually change the amp settings on the machine for instance. We need more exact info on this new system! I want one!

[weldguy]

Haven't seen too much but it is my understanding that the torch reads the cap/consumable assembly once installed and sets the amps and everything for you. I for one am not a fan of this and feel for the small shop the cost of these consumable assembly's is going to be far too high. No doubt great for a new user, could eliminate some common beginner mistakes but other than that I see no advantage. My biggest issue is that I use approx. 2 nozzles to every electrode and change my cap, swirl ring, and o-rings annually. This would eliminate all those savings and put that money into Hypertherms pocket. Great idea for them and cool technology but not good for most of us, I know when to changes my consumables. May be a good thing for Thermal Dynamics, their due for a resurgence.

[djreiswig]

Here's a link to the unveiling video.
https://www.hypertherm.com/en-US/learn/ ... nouncement

[HypHyDef]

Is there any new information on the new system? The little bit of info I have been able to obtain is quite vague. What I am really interested in knowing is how the smart end of things works. As in the amp settings. Do you have to have a cap for each amp setting? That seems not right in my head somehow. Does the cap actually change the amp settings on the machine for instance. We need more exact info on this new system! I want one!

Hi Black Forest, Thanks for the questions. let me see if I can give you some information. We have "Cartdriges" for each application as well as amperage. Meaning we have drag cutting cartridges, gouging cartridges, fine cut, flush cut. When you put one of these cartridges on your torch the system will read the cartrdige and set the power supply to the correct amperage and airflow as well as set the applicaton. So when you put on gouging cartdrige it will set the system for gouging. There is also the option of changing the amperage on the torch as well so you do not need to go back to the power suply to turn up or down the amperage, you can simply press the button on the torch. In most cases you get the best cut quality and life when you cut at the designated amperage of the cartridge. So 85amp cartridge runs best at 85amps. Imagine a scenario scenario where someone is working on scaffolding and they are not able to cut at the IPM the 85amps would need to be moved they can turn down the amperage thus reducing their IPM. They wouldn’t need to change consumables but be able to cut at a lower amperage without having to go back to the system. The way the cartdriges are designed they are wearing at a more constant rate then the individual components of previous consumables. This is why we say you can see up to 2x cutting life through the use of the cartridges. While we understand not everyone would benefit from this technology those who desire to track the data through this system can find out where they can find savings. I hope this helps some. if you need more information please don't hesitate to reach out to us or check out our webpage to watch more videos and read more about the systems.

[adbuch]

So I would assume that Hypertherm will offer some sort of Deluxe cartridge kit - containing maybe 12 to 15 separate cartridges to cover each combination. So maybe around $600 to $800 for this kit?
David

[HypHyDef]

So I would assume that Hypertherm will offer some sort of Deluxe cartridge kit - containing maybe 12 to 15 separate cartridges to cover each combination. So maybe around $600 to $800 for this kit?
David

Hi David, at this time we do not have plans to release a multi cartridge kit like you describe. Great idea thought

[mechanicjon]

45amp SmartSYNC in the future?

[HypHyDef]

45amp SmartSYNC in the future?

At this time we are not planning on releasing a new 45amp system with SYNC.

[adbuch]

45amp SmartSYNC in the future?

At this time we are not planning on releasing a new 45amp system with SYNC.

Very happy to hear that. Can the new SYNC 65 and 85 be fitted with Duramax torch to use the older standard consumables (not the cartridge)?
Thanks,
David

[djreiswig]

45amp SmartSYNC in the future?

At this time we are not planning on releasing a new 45amp system with SYNC.

Very happy to hear that. Can the new SYNC 65 and 85 be fitted with Duramax torch to use the older standard consumables (not the cartridge)?
Thanks,
David

What would be the advantage of doing that? You would lose all of the perks of the SYNC.

[adbuch]

At this time we are not planning on releasing a new 45amp system with SYNC.

Very happy to hear that. Can the new SYNC 65 and 85 be fitted with Duramax torch to use the older standard consumables (not the cartridge)?
Thanks,
David

What would be the advantage of doing that? You would lose all of the perks of the SYNC.

Not everyone whats the SYNC with it's $50 - $60 cartridges. This could end up being $800 to $1000 in cartridges alone, not to mention the replacement cost when they wear out. It looks like Hypertherm is no longer manufacturing the Powermax 65/85/etc. so this would (or could) be a viable option for those wishing to continue using the "older technology" consumables.
David

[djreiswig]

Well, that's a bummer. I guess my 65 probably just increased in value. Hopefully they don't force people into the cartridge system.

[adbuch]

Well, that's a bummer. I guess my 65 probably just increased in value. Hopefully they don't force people into the cartridge system.

Looks to me like that's exactly what they are doing. I'm sure glad I bought a new 85 several years ago. It work great, and consumables are pretty inexpensive - about $5 or $6 each for nozzle and electrode. Why would I want to buy the whole cartridge with nozzle, electrode, swirl ring, shield, and cap when all I really need it the parts that wear out. They say they have designed the cartridge so everything wears out at the same time. Unless these new cartridges last 5 or 6 times as long as my current electrode and nozzle, I really don't see the point. I know the new machine has some other "bells and whistles" like keeping track of number of pierces and so on - but Design Edge will do that for me, and it's not normally something I am too interested in.
David

[HypHyDef]

45amp SmartSYNC in the future?

At this time we are not planning on releasing a new 45amp system with SYNC.

Very happy to hear that. Can the new SYNC 65 and 85 be fitted with Duramax torch to use the older standard consumables (not the cartridge)?
Thanks,
David

Thats a great question, let me check on that before I answer.

[HypHyDef]

Well, that's a bummer. I guess my 65 probably just increased in value. Hopefully they don't force people into the cartridge system.

Looks to me like that's exactly what they are doing. I'm sure glad I bought a new 85 several years ago. It work great, and consumables are pretty inexpensive - about $5 or $6 each for nozzle and electrode. Why would I want to buy the whole cartridge with nozzle, electrode, swirl ring, shield, and cap when all I really need it the parts that wear out. They say they have designed the cartridge so everything wears out at the same time. Unless these new cartridges last 5 or 6 times as long as my current electrode and nozzle, I really don't see the point. I know the new machine has some other "bells and whistles" like keeping track of number of pierces and so on - but Design Edge will do that for me, and it's not normally something I am too interested in.
David

There is more to the SYNC system than being able to track your pieces. Being able to set the pressure and amps automatically, being able to control the amps from the torch handle without going back to the power supply. These benefits are geared more towards hand cutting of course and not mechanized.

[djreiswig]

My 65 has the cpc so I can set amps and air pressure from gcode. When I do hand cutting I just set the amps when I start and leave the air pressure on auto. I also don't really track pierces either.
I like the ability to decide for myself when the parts are worn out. Sometimes I use "worn out" parts when I'm just hacking something up and don't care about cut quality.
The PowerMax is a great system, so I'm with adbuch. I hope there is a still a way to use the standard consumables with the new power supply.
Other than the consumables, what are the benefits for mechanized cutting?

[adbuch]

My 65 has the cpc so I can set amps and air pressure from gcode. When I do hand cutting I just set the amps when I start and leave the air pressure on auto. I also don't really track pierces either.
I like the ability to decide for myself when the parts are worn out. Sometimes I use "worn out" parts when I'm just hacking something up and don't care about cut quality.
The PowerMax is a great system, so I'm with adbuch. I hope there is a still a way to use the standard consumables with the new power supply.
Other than the consumables, what are the benefits for mechanized cutting?

That's a really good question! Too bad we can't get Jim Colt to chime in here. He is still active (from time to time) on the Plasmacam Facebook Group, but haven't seen him around here in quite a while. But - yes, I agree. That's why I have been telling folks to buy a new 45xp while they are still available.
David

[robertspark]

the cartridge system also means that for a while there will be less copied / non hypertherm consumables in the market place and higher revenue going to hypertherm for consumables.

maybe I'm being cynical.

until someone copies them like printer cartridges with chips in them.

I am still running a powermax 45 non xp, they brought out the pmx45xp about 3 months after I bought my 45 and I was really annoyed.

progress does not always equal better, just a different way to skin that same cat, and there is normally a reason, such as to refresh or maintain market share or revenue. in this case I suspect that hypertherm looked at where they were loosing revenue (the sale of consumables), and then engineered a solution by providing an idiot proof control and a sale point of providing longer consumable life, and no longer putting the wrong consumables in the torch.

you probably loose the option to use old consumables to do all your dimpling and pierce points now I guess.

yes cynical, I know.....

(I am not adverse to progress. I use a semi synergnic mig welder (set material, thickness and pull trigger), and a tig welder that has pre set settings (set current flow, voltage and go), but they still have the ability to adjust settings if I want to..... but I'm not fixed to specific consumables or buying anything else from the same manufacturer....)

[adbuch]

the cartridge system also means that for a while there will be less copied / non hypertherm consumables in the market place and higher revenue going to hypertherm for consumables.

maybe I'm being cynical.

until someone copies them like printer cartridges with chips in them.

I am still running a powermax 45 non xp, they brought out the pmx45xp about 3 months after I bought my 45 and I was really annoyed.

progress does not always equal better, just a different way to skin that same cat, and there is normally a reason, such as to refresh or maintain market share or revenue. in this case I suspect that hypertherm looked at where they were loosing revenue (the sale of consumables), and then engineered a solution by providing an idiot proof control and a sale point of providing longer consumable life, and no longer putting the wrong consumables in the torch.

you probably loose the option to use old consumables to do all your dimpling and pierce points now I guess.

yes cynical, I know.....

(I am not adverse to progress. I use a semi synergnic mig welder (set material, thickness and pull trigger), and a tig welder that has pre set settings (set current flow, voltage and go), but they still have the ability to adjust settings if I want to..... but I'm not fixed to specific consumables or buying anything else from the same manufacturer....)

[kenosh]

I’m seeing the new cutting charts with smartsync the kerf width is half of old hypertherm charts. Is the new system that fine of a cutting machine?

[adbuch]

I’m seeing the new cutting charts with smartsync the kerf width is half of old hypertherm charts. Is the new system that fine of a cutting machine?

I haven't looked at the new cut charts, but be sure to compare to the FineCut consumables for narrow kerf.
David

[motoguy]

I'd be curious to see if the kerf is that much thinner.

First thing I thought of when this came out is all the nozzles I blew out learning how THC worked on my machine. That would cost a FORTUNE in the new setup. As it was I was was blowing through nozzles, but not electrodes, swirl rings, retaining caps, etc.

As mentioned, the "automated air and amps" stuff is great...but largely a non-issue for CNC use. I control all that from G code anyway.

The 2x higher cut height would be nice, especially when piercing thicker stuff (and then dragging on the debris as you cut).

Call me cynical, but I think this is mostly about getting away from the plethora of counterfeit consumables in the marketplace.

IF the kerf is 1/2 the size of my PM85, and IF the cut height is 2x my current setup...those would be bonuses for me. And I crash the torch rarely enough these days that I'm not worried about blowing out a 50 cartridge on a screw up. I guess the good thing is that I can adapt these to my PM85 / Duramax torch as-is.

[HypHyDef]

I'm not sure if this has been mentioned before by me or not but the SYNC system as a whole including the cartridges has been in developement for nearly a decade. The product was the result of listening to customers who were complaining about a growing trend of losing long time knowlegeable labor to retirement and not being able to fill those postions, and when filling them the length of time to train and the money lost in consumables due to error was a concern. The PMX45 was introduced in 2008 and we still to this day make and sell consumables for that system. We will continue to build and sell consumables for the PMX 65, 85 and 105 for a long time for those who are not ready or do not see any benefit in the new SYNC system.

[kenosh]

Thanks for the info Randy can you confirm any info on the kerf width or did I see misprinted cut sheets

[HypHyDef]

Thanks for the info Randy can you confirm any info on the kerf width or did I see misprinted cut sheets

Hi Kenosh,
Cut height on the SYNC systems are .125 vs .06 on the previous model. Kerf width is thinner on 10ga and 3/16 but a little thicker on 1/4" and up, Definitely not half the thickness you stated. One of the main focus points of our new system is to lessen down time in production. Down time costs money. This system will help streamline inventory, less parts to keep and sort. The ability to know if your current cartridge will last during a big job and not force you to stop the job prematurely to change out consumables. If you have multiple guys who work for you and run the same table you will have the abilty to track the data and see why this one guy got 700 cuts out of one cartridge and the other guy got 400. Again trying to minimize downtime and knowing why you are down quickly is the goal.