My problems with my Razor 45 have returned. It’s very puzzling and sporadic. I probably only use my system every few months to cut a couple of things and then it sits dormant. So this is extra frustrating since it causes “mental friction”, i.e. when contemplating drawing something that I would cut in metal I have have to ask myself if I’m ready to potentially fight with my system. Do I want this project enough to endure the frustration?
So, all that to say, I’m strongly considering the upgrade to a Hypertherm 45XP (or similar). I’m especially interested in the fine cut capability since I’m often working with 10-16ga steel. I see that there is a SYNC system now and understand that those consumables are more expensive. Since my usage is pretty infrequent and I’m not using my system to make a profit, but rather for rapid prototyping, I don’t think that’s a major factor for me.
I’d appreciate any guidance as to how (or where) to purchase a system that I can connect to my Crossfire Pro with minimal hassle.
What problems is there with the razor weld?
Just a side note I saw on another forum there is a aftermarket adapter to let you run the regular consumables on the sync model. Would I recommend it I doubt it.
It may be best to buy from s local welding shop. I would recommend alto make sure it has the cpc if getting a sync model.
I sporadically have problems with the torch height lifting while cutting until it breaks connection. I have THC and have run (and passed) the THC test multiple times. I ground directly on the piece I’m cutting. At times I can cut for 10 minutes without any failures, then suddenly it won’t cut for more than 10-20 seconds without failing. If I turn it off for a few hours and come back with no other changes, it will cut once again just fine. This has been like this since I purchased it 5 years ago.
The reason I asked is you could have a underlying condition.
Hypertherm is a great machine. I made the same upgrade but to a 65 so I could cut thick material more frequent.
I believe my table would get more emi from the hypertherm over the razorweld. You may have emi issues. Have you completely eliminated that possibility?
I hate for you to spend that kinda money and the same problem exist.
I think I have experienced more problems when my laptop was plugged into AC power so I typically try to avoid that. I’ll look into emi troubleshooting guidance in the forum since I have a project underway at the moment that I’ll have to complete with my current system. The fine cut capability of the Hypertherm is also very intriguing to me. I have a fair amount of circumstances where my designs are limited by the cutting “resolution” of my existing setup.
Having the laptop charging is the number one culprit. That is when I seen emi as well.
I have two Hypertherms and I have/had the same problem.
I like THC, I don’t like Langmuir application of it.
EMI noise is the biggest problem. Sharing the same power source is a close second.
You can read for days about THC problems and possible fixes.
When the problem arrives, just turn it (THC) off.
Switching from a Razorweld to a Hypertherm will not solve issues you’re having with your table.
Take it from someone that would make great quality cut parts using a PrimeWeld CUT60 only to see nothing more than just a higher pierce count with a Hypertherm 45XP.
The finecut consumables are definitely nice, but they can be problematic on the Sync system with many users experiencing a failure to fire. The spring mechanism throws fits for a lot of people.
Regarding EMI, I use ferrite beads on all my cables, serial & USB:
https://www.amazon.com/dp/B07SKK9PGD
I’m running a Hypertherm 65, pre-sync. When I first got the system I used a laptop connected to AC as the battery was shot and never had an EMI issue. I’ve since switched to a mini-pc as my old ‘pentium inside’ laptop just couldn’t keep up.
I am with the chorus here that you might continue with some issues even switching to Hypertherm.
I have the Hypertherm 45XP but it is hard to find them now since Hypertherm is no longer selling that model. But for you being an occasional user, the SYNC is not a bad way to go as the system is suppose to monitor the consumables which would help isolate your problems.
Going back to the laptop: Battery is all fine and dandy when it is charged up but most don’t hold a charge for even half a day if the screen is awake. I found that I had a step problem caused due to the laptop limiting resources to the USB connection and thus missing its turn to move the torch adequately. This resulted in the pattern re-cutting in areas that the design was finished. I have since plugged it in but isolated the ground with those simple two prong adapters.
But digging further, your laptop could be the issue. Try hooking up another laptop or a desktop. All you need is to load FireControl on the computer to try. There are not really many settings to even worry about because FireControl gets its information from the table and the gcode file. I recently helped someone but thankfully I brought my laptop. We finally got the table running with his laptop and left him for two hours. When I came back, he could not get it to work again. I loaded the design into my computer, hooked to the table and instantly cut perfect. Conclusion: His laptop was the problem.
You might seriously look at your laptop and if you want to limit some of the issues, get a stand alone mini-computer that always stays with the table. Get it set up correctly and don’t allow it to update and plan to bring a thumb drive with your cut file. This will isolate the computer problem and updates from Windows that can cause strange things to go awry.
But don’t get me wrong: I would never try to talk someone out of getting a Hypertherm machine. I am very happy I have one. Good luck, which ever way to decide. I just don’t want you to think that first day with the Hypertherm machine will be all roses and sunshine.
Thanks, that’s great input. I hadn’t thought about trying to swap my laptop when I’m having trouble. I’ll add that to the list of possibilities. I may try your suggestion to dedicate a small PC to my table and use a UPS to isolate it by unplugging it when I’m cutting.
I made a switch to a mini PC. I believe it was the best decision I made. Under 200 bucks if you have a monitor. They don’t have a ground plug so no worries about the emi from the charger.
@gregoryjwells I have had basically the same journey.
THC was failing, and it was eventually discovered the little spring under the floating torch head was kicked over and shorting the THC to the Z-axis guide rails. Reset that spring and all issues went away.
I have a new Hypertherm 45 SYNC w/machine torch sitting next to my pro, and I am waiting to swap out the RW45. I must dedicate time to test out and redo my cut programming before disabling the table.
I also have the Bee-link mini PC. I love that I was able to mount it to the back of the monitor. 4 USBs are wireless mouse and KB, connection to LS controller, and open for using USB drive to move files from laptop in the house (F360) to the garage for cutting.
Power supply connected with ground plug to the same outlet box as the LS controller and no issues.
Thanks for the lengthy reply, and especially setting my expectations in advance that the Hypertherm will magically solve my problems. I did pull the trigger on the purchase (from Langmuir) but I will continue to work on resolving, or attempting to minimize, my THC/emi problem(s). I’ll probably also convert to a mini-PC solution.
Thanks again.
I appreciate the warning. I did decide to proceed with a Hypertherm 45 sync with the fine cut capability. My fingers are crossed. You can own the rights to tell me “I told you so” when I’m crying in my beer 
I see the spring you’re referring to and mine seems to be properly in place. Thanks.
Congrats on the purchase.
Just make sure to fix the issues on your table, as mentioned, a new Hypertherm won’t magically make the issues on your table disappear.
As for the Sync finecut, just mentioned it as a heads up. It isn’t just what I’ve read a lot about on the forums and on FB, but also something my friend experiences with his own Sync setup.
He runs a 5’ x 10’ table 5-6 days a week non-stop, and the regular consumables give him no issues at all at 2,000 to 2,500 pierces per.
When I read about people having so many issues I have to scratch my head. I run my Pro table with a plugged in HP laptop, mounted on the Langmuir stand with the control box mounted to the frame of the table as designed. I run an XP45 in a pole barn, non climate controlled, with dry air in soggy NW Oregon and in the several years only had one transient torch issue that has not returned. I have no ferrite beads or any other special EMI protection. Everything just works. The one thing I think some people might miss is that the control box enclosure needs to be electrically isolated from the table frame. Langmuir provides spacer washers but it is an easy step to miss. Given my good luck (I guess), it is all I have to offer.
Everyone’s wiring is different (home/shop).
Everyone’s environment is different.
We cannot account for every single shop/building one’s setup is in which is why there are so many suggestions to combat EMI and other such things.
I too have been running my laptop plugged into the same circuit my table is connected to, both on my Crossfire and Crossfire Pro.
There is not a single ferrite choke, shielded usb cables, nothing at all implemented in my system, and I have been running a CUT60 and 45XP for the total of 2.5 years.
What is my point? It’s easy to be baffled as to why others have such issues while we don’t. For some, a ferrite choke works. For others, using a different power source for their laptop fixes an issue. Be surprised what others have done to fix EMI issues that otherwise would never apply to us.