How to Troubleshoot Plasma Cutting
Plasma cutting machines have made their way into the home hobbyist's price range. No longer are these metal cutting torches an industry-only machine. Newer plasma cutters are now stand-alone units that incorporate a built-in air compressor. The high voltage arc that melts the metal is blown from the cut by air pressure. These newer machines allow the unit to be completely portable and have the capability of being powered by a common household outlet. Problems still arise in the process of cutting. By following a set method, you can eliminate these problems and cut metal with a clean non jagged edge. Does this Spark an idea?
Things You'll Need
- Plasma cutter
- Air supply (air compressor)
- Steel brush
- Bristle brush
- Emery cloth
- Replacement cutting tip parts
Instructions
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1
Ensure that the power outlet you are plugging the plasma cutter into is a fully grounded, three prong connection. The electrical pathway must also follow the full earth safety ground of the electrical system. Check the ground connection of the plasma cutter unit itself. This clamp must make a good mechanical and electrical connection to the metal piece you are cutting.
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2
Supply the correct air pressure to the plasma unit. Along with air pressure, the CFM (cubic feet per minute) must also be maintained during the cutting cycle. Read the specifications of the machine. As the plasma arc cuts the metal, the air must push the molten liquid quickly from the cut.
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3
Clean the tip of the torch often to keep it free of dust and metal slag. The operation of the torch tip will cause the metal end to become covered in a layer of dust. This dust can inhibit the electrical flow of the plasma. Remove any built up metal on the tip with the steel brush. Use the bristle brush to wipe away any dust from the copper electrode. Shine the flat tip with a piece of emery cloth for good conductivity.
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4
Keep new replacement torch tip parts on hand at all times. The outside electrode tip can burn back from the main center hole of the torch. A properly sized hole must be maintained so the interior torch parts are not damaged.
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5
Clean the metal work piece your are cutting. Grease, dirt and rust can interfere with the conductive path of the electrical arc. The errant material can also build up on the torch tip and cause premature burn out of the metal parts.
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Tips & Warnings
Follow all manufacturers cycle times for on and off cycles. Exceeding the on cycle time can over heat the plasma cutters transformer. This practice can lead to premature failure of the machine. Install an air filter and an air dryer on the compressed air line before it enters the machine. Dirty air and moisture can cause a cut to be erratic.
