Hypertherm Hand Torches FAQs
Answers for choosing, using and looking after a hand-held plasma cutting torch.
How do I tell when plasma consumables are worn out?
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.
Why does clean, dry air matter for my plasma torch?
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.
What travel speed and torch height should I use for hand cutting?
Move at a steady speed. Going too slowly tends to leave dross and a wide cut, while going too fast can leave the arc lagging and the cut unfinished. Look at the sparks beneath the plate: they should trail slightly behind the torch.
Hand cutting is normally done with the torch held at the height the consumables are designed for, which depends on the type of shield and the material thickness. When you need to start in the middle of a plate, a pierce takes more clearance than cutting, so start from the edge where you can. Stretching the arc to reach the metal wears consumables sooner. The cutter's manual has cut charts for your machine.
What should I look for when inspecting the torch lead?
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.