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Answers for choosing, using and looking after a hand-held plasma cutting torch.
The first sign is usually a drop in cut quality: a wider kerf, more dross on the underside, a ragged edge or the arc wandering. On inspection, a worn nozzle often has an enlarged or out-of-round hole, and a worn electrode has a pit forming in the tip.Cracks in the swirl ring or retaining cap, and heavy slag on the shield, are also reasons to clean or replace. Nozzle and electrode should normally be changed together, because mismatched worn and new parts give inconsistent cutting. Do not wait until the torch fails, as a burnt-through electrode can damage the torch head.
Moisture and oil in the supply air cause an unstable arc, poor cuts and faster wear of the electrode and nozzle. Trade guidance on plasma cutting advises clean, dry air and notes that moisture filters or dryers help extend consumable life.Fit the filtration the cutter's manual calls for, keep it drained and replace filter elements when they are due. Short consumable life that comes and goes with the weather can point to damp air, since humidity changes through the year. Check the pressure and flow at the cutter against the manual, as both affect the arc.
Run your hand and eye along the lead from the handle to the connector and look for cuts, cracks, kinks, crushed sections and exposed wires. Also look at the torch body for cracks. Do this with the cutter disconnected from the mains supply.A lead that is cut or cracked should not stay in use, and a damaged lead or body should be replaced by a qualified service technician. Maker guidance suggests regular inspections at intervals set in the manual. Avoid driving vehicles over the lead, pulling it round sharp edges or leaving it in a tight coil while working.
Plasma cutting gives off fume, gases and noise, and the arc is bright and gives off ultraviolet light as well. The HSE has guidance on controlling fume, gases and noise from plasma cutting, and the right controls depend on the metal, any coatings and where you are working.Use suitable eye and face protection with the correct filter shade for the current, as the cutter's manual describes, and protect others nearby. Treat cutting fume like welding fume, which can cause cancer: when cutting indoors use local extraction at the cut, with respiratory protection where your risk assessment says extraction alone is not enough. Coated or galvanised metal needs particular care, and hearing protection may be needed.
