Hypertherm Hand Torches FAQs
Answers for choosing, using and looking after a hand-held plasma cutting torch.
How do I know which hand torch fits my plasma cutter?
A hand torch has to be matched to the power source it connects to, so start with the data plate and the operator manual for your cutter. They give the model, the maximum cutting current and the type of torch connection, and the torch listing should name the cutters it suits.
The torch and its consumables are a matched set. A torch that fits the connector but is designed for a different current range can run badly or wear parts quickly, so do not rely on the plug fitting alone. Our team can help you match a torch to your machine if you give them the details from the data plate.
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.
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 are the main risks of hand plasma cutting that I should plan for?
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.