The following occurs when a start input is given to the plasma system:

Double Arc
A double arc is a condition which allows the nozzle to stay in the plasma circuit. As described
above, the nozzle should only be in the circuit during the pilot arc phase. If left in the circuit, the
nozzle will carry cutting amperage which will destroy it.
Double arcing is caused by:
 Standing pierce. The torch has to be positioned close enough to the work-piece to allow the pilot
arc to contact the plate, so the main arc can transfer. Pierce spatter is ejected at a shallow angle
during the initial pierce. As the arc penetrates the material the spatter becomes more vertical. This
debris may connect the plate and nozzle, keeping the nozzle in the circuit even when the relay
opens to remove it. This scenario may damage the front end of the torch.
 Torch in contact with the plate. Cutting thin material. All automatic torch positioning systems
utilize some initial height sensing method to position the torch above the plate. One method is the
touch and retract method. The torch travels until it makes contact with the plate and retracts to the
initial start height utilizing a timer or encoder. If the touch is not sensed properly, the torch may
still be in contact with the material due to springing up or material warping. The nozzle will remain
in the plasma circuit carrying cutting amperage, damaging it.
 Pilot arc malfunction. This can occur if the pilot arc relay circuit fails to remove the nozzle. This
can happen either with a shorted relay or resistor. Again the nozzle is left to carry more current
than intended, damaging it.
Preventing the Double Arc
Double arcing usually occurs during the piercing sequence.
Some techniques which can help avoid double arcing are:
 Creep move. The cutting machine is programmed at a reduced speed to begin machine movement
on arc transfer. This speed is usually 5 to 10% of normal cutting speed and is for a given time
period. Pierce spatter is being ejected away from the nozzle during this time. This reduces double
arcing possibility.
 Torch rising during standing pierce. On arc transfer the torch begins to pull away from the
work- piece. This allows the pierce spatter to clear the nozzle. This retraction continues for a timed
period, and then lowers to correct cutting height after the machine is moving at cutting speed.
 Higher than normal initial height pierce (standing pierce). This allows the pierce spatter to
miss the nozzle reducing the chances for a double arc. This method of prevention is the least
effective.
Plasma Process Variables
The variables involved in plasma cutting must all be closely controlled to achieve maximum cut
quality, maximum nozzle/electrode life and maximum production. A balance must be maintained
between them.
Gas
Gas Purity
 The purity of gas is essential for good cut quality and long electrode life. Minimum purity
requirements for nitrogen at 99.995% and 99.5 % for oxygen. If purity levels are less than
recommended minimum the following could occur.
 Inability of the arc to penetrate thin materials at any current level.
 Depending on the degree contamination, variation in cut quality.
 Extreme short electrode life.
 When cutting with N2, appearance of a black film residue on the face of the electrode and in the
nozzle bore. The worse the contamination, the more the residue. If the gas is pure, the electrode
and nozzle bore will take on a sand blasted appearance.
Gas Pressure/Flows
Each nozzle is designed to perform at an optimum current based on a given gas pressure/flow.
Increasing this pressure can result in a decrease in electrode life. This is evident by a drilled
appearance in the tungsten insert. With nitrogen there will be a problem with torch starting. If the
torch fails to start at high pressure, a sputtering pilot arc may be observed. Where high gas pressure
may create problems, low gas flow will usually result in a double arc failure.
Water
Water Purity
The Water Injection plasma process requires de-ionized and filtered water. Suspended solids,
dissolved minerals and other factors affect the conductivity of water and nozzle life and increase
the possibility of high frequency interference.
Cut Water Pressure/Flows
Cut water flow rate should be set to the amount specified in your torch literature. Excessive water
flow will result in short electrode life and an unstable arc. Low water flow will result in insufficient
cooling affecting nozzle life.
Kerf
Kerf is the width of material (perpendicular to the torch and cut axis) removed during the plasma
cutting process. Kerf is affected by three major variables.
 Cutting Speed. Faster cutting speeds with other variables constant will result in a narrower kerf.
The kerf will continue to narrow until loss of penetration occurs. Slower travel speeds will result in
a wider kerf until loss of arc occurs.
 Cutting Amperage. Increasing cutting amperage with the other two variables constant will result
in a wider kerf. Continuing to increase current will widen kerf until the nozzle is destroyed.
Lowering amperage will result in a narrower kerf, a more positive cut angle until penetration is lost.
 Standoff. Standoff is the distance maintained between torch and work-piece after piercing (while
cutting). Most modern systems use an arc voltage feedback system. Increasing the arc voltage
increases the standoff distance and widen the kerf. Continuing to increase standoff will eventually
lead to loss of cut. Lowering standoff will lead to a narrower kerf and even- tually loss of cut.
Arc Voltage
Arc voltage is not a independent variable.
 It is dependent on:
 Current (amperage)
 Nozzle orifice size
 Standoff
 Cut gas flow rate
 Cut water flow rate (if applicable)
 Cutting speed
Gases required for most applications are a start gas, shield gas, and cut gas. A few situations require
a second shield gas. Results vary with different combinations of nitrogen, oxygen, air, methane, and
H-35 (a combination of 35% hydrogen - 65% argon). Argon gas is used for plasma marking.
Material type and thickness, cutting quality, speed, and production cost are variables to consider
when selecting gas combinations. All gases are not appropriate for some applications and torches.
Consult your torch literature for more information.

How To Select And Operate A Hand-Held Plasma Cutter

Print Article
The actual process of operating a hand-held air plasma cutter unit is relatively simple. In fact, the
hardest part comes before ever striking an arc: selecting a machine that best matches your
application and choosing the right accessories.

Plasma arc cutting benefits

One cut and they were hooked. Fabricators, contractors, maintenance personnel, artists and do-it-
yourselfers who experience the benefits of a hand-held air plasma arc cutting machine rarely want
to return to oxy-acetylene cutting or mechanical cutting processes such as saws, cut-off wheels,
shears and snips.

Plasma cutting improved their Plasma 101

productivity and lowered the
cost of cutting. It cut faster, did
not require a pre-heat cycle, cut
any metal that conducted
electricity (unlike oxy-fuel, which
cannot cut stainless steel or
aluminum), permitted portability
around job sites, minimized the
heat-affected zone and yielded a
cut with a small kerf (cut width).
Their plasma units also gouged,
pierced, beveled, cut holes and
traced shapes.
The actual process of operating a
Plasma looks and behaves
like a high-temperature gas,
but with an important
difference; it conducts
electricity and cuts any
electrically conductive
metal. The plasma arc
results from electrically
heating a gas, typically air,
to a very high temperature.
This ionizes its atoms and
enables them to conduct
electricity. A plasma arc
torch uses a "swirl ring"
hand-held air plasma cutter unit
is relatively simple. In fact, the
hardest part comes before ever
striking an arc-selecting a
machine that best matches your
application and choosing the
right accessories.
Three Questions to Start
The first questions to ask when selecting a plasma cutter relate to cutting capacity:
that spins the gas around
an electrode. The gas is
heated in the chamber
between the electrode and
torch tip, ionizing the gas
and creating plasma. This
causes the plasma gas to
greatly expand in volume
and pressure. The small,
narrow opening of the
torch tip constricts the
plasma and accelerates it
toward the work piece at
very high speeds (20,000
ft./s) and temperatures (up
to 30,000° F).
The high-intensity plasma
jet melts a very localized
area. The force of the jet
(or arc) pushes through the
work piece and removes
the molten metal. This jet
easily cuts through metals
with poor heat
conductivity (stainless
steel) or excellent
conductivity (aluminum).
The flame created by an
oxy-fuel torch lacks
plasma's concentration and
cuts stainless steel or
aluminum so poorly
(excess warping or dross)
that professionals don't
bother to use it; they
consider plasma arc cutting
the standard process for
these metals.
Watch Plasma Cutting
Demo Videos
 What thickness of metal will you routinely cut?
 What is the maximum thickness you might cut?
 How fast do you want to cut?

Like a welding machine, a plasma cutter's amperage and voltage capacities determine its "size."
Note that the plasma process requires relatively high voltage and low amperage levels, the opposite
of welding. Many people erroneously judge a plasma machine solely by amperage. While this is an
important indicator, remember that total output power (in watts) equals amperage times voltage.
Do the math to obtain a more accurate product comparison.
For instance, Miller Electric's Spectrum 125C is 12-amp unit rated at 110 VDC (1,320 watts total).
This provides a quality cut on 3/16-in. steel and will sever 1/4-in. steel. The cutting capacity of a
particular "size" plasma machine varies greatly by manufacturer. The following table provides an
indication of the maximum cutting performance you can expect from a Miller hand-held unit.

Spectrum Model Machine Output Quality Cut Rating

 Spectrum 125C
12 A @ 110 VDC
3/16 in.
 Spectrum 375
27 A @ 90 VDC 3/8
in.
 Spectrum 625
40 A @ 140 VDC
5/8 in.

Cutting Speeds and Quality Ratings

Knowing cutting speeds for the thickness of metal being cut allows you to calculate production
rates, typically in parts per hour. This helps ensure that the cutting portion of the operation does
not become a bottleneck. While cutting speeds often become critical to throughput in an
automated application, they relate most to cut quality and operator satisfaction (or frustration) in
hand-held applications.

Cutting Speed Chart

To determine the maximum rated cutting

thickness of mild steel, follow the line from the
10 IPM (inches per minute) point on the cutting
chart. The point at which this line intersects the
cutting curve determines the maximum
recommended production cutting thickness of
the unit.
 Note: the rating is based on 10 IPM because this is the
minimum speed at which the operator achieves a smooth,
steady cut when using a hand-held torch.
Many manufacturers provide cutting speed charts that allow you to compare cutting speed
performance. While there is no universal standard, Miller facilitates an "apples-to-apples"
comparison by qualifying capacity with three standards: rated cut, quality cut and sever cut.

Rated Cut
Rated cut is the thickness of metal that an
operator can manually cut mild steel at a rate of
10 IPM. This is considered the minimum speed
at which an operator achieves a smooth, steady
cut and the best possible cut quality. For
example, a 55-amp plasma cutter has a rated cut
of 7/8 in.; you can cut 10 in. of 7/8-in. thick
steel plate in one minute.
 Quality Cut
With a quality cut rating, the operator can cut
thicker material, but at a slower rate. For
example, a 55-amp plasma cutter provides a
quality cut on 1-in. steel, but at speeds less than
10 IPM.

Sever Cut
A sever cut rating means the operator is pushing
the machine to its maximum thickness
capabilities (1-1/4 in. for a 55-amp unit). Cutting
speeds will be very, very slow and the cut will
require significant clean-up. Fortunately, cutting
speeds increase as the material gets thinner.

As with cutting thickness, cutting speed varies greatly between models. Tests on a mechanized
cutting table showed that a 55-amp Spectrum plasma cutter cuts 1/2 in. at 38 IPM with an
extended tip and at 30 IPM with a drag shield. Some competitive units of the same amperage only
cut at 24 or 28 IPM.

Primary Power
Plasma cutting requires two basic elements, air and electricity, so the next question to ask when
selecting a plasma cutter is what type of input power is available. If you only have 115V primary
service, don't worry. Several 12- and 25-amp plasma cutters, such as the Spectrum 125C or
Spectrum 375, operate using 115 or 230 V power. If your input circuit has a 30-amp breaker, you
even get equal cutting capacity at both voltages (with a 20-amp breaker, cutting capacity drops by
20 percent).
Miller Electric offers a primary power management technology called Auto-Line™. Auto-Line
allows a machine to accept input voltages ranging 190 through 630 V, single or three-phase, 50 or
60 Hz. This means you can plug this plasma cutter in anywhere in the world. And even if the
primary power spikes and dips, but stays within the 190 to 630 V range, units with Auto-Line
technology provide a steady, consistent arc and full cutting power.
When working in the field, many contractors and fabricators only source of power comes from an
engine-driven welding generator's auxiliary power. Especially for cutting aluminum and stainless
steel (which oxy-fuel can't cut), many mechanical contractors opt for a lightweight plasma cutter
that permits mobility. Units in the 27 to 80-amp class weigh between 55 and 92 lbs., torch included.
The Spectrum 375 will run off an engine drive providing at least 4 kW of auxiliary power. Because
of its 15 percent line voltage compensation feature and power factory correction technology (which
reduces draw from 34 to 28 amps), this unit is much less susceptible to nuisance breaker trips.
Spectrum plasma cutters provide decent cutting power (5/8-in. steel) when paired with an 8 kW
engine drive. When paired with 15 kW auxiliary power, certain models provide full cutting power
(approximately 7/8 in. and 1-1/8 in. capacity, respectively).
If you plan to use an engine drive's auxiliary power, strongly consider a unit with Auto-Line
technology. Similar units without Auto-Line experience erratic cutting arcs, frequent breaker trips,
blown circuit boards and are prone to premature transformer failure. These problems typically
occur because the plasma cutter, once triggered, places such a load on the line that voltage levels
drop below the plasma cutter's operating range.

Dirty Environments
In environments with heavy dust and metal shavings (such as from grinding), machines with Wind
Tunnel Technology™ and Fan-On-Demand™ provide better reliability. With Wind Tunnel
Technology, the cooling air flows through the machine in such a way that it doesn't blow over the
electronic components, so grinding dust can't settle on the PC boards and other critical
components. Fan-On-Demand means that the cooling fan runs only when needed, reducing the
amount of debris entering the unit.
With traditional technology units, the fan works constantly, sucking in any air-borne particles. If
you opt to purchase such a unit, position it as far away from the particle source as possible.

Air Supply
Most manufacturers of hand-held plasma cutters recommend using ordinary air as the cutting gas.
In mobile applications, contractors often opt for bottled nitrogen because it costs less than bottled
air. When cutting stainless steel, some people believe nitrogen produces slightly less oxidation, as it
is drier than compressed air. For cutting thinner materials in the field, contractors involved with
HVAC, sign making and maintenance often select a plasma cutter like the Spectrum 125C because
of its built-in air compressor. This lightweight package provides superior mobility.
Take a Tip
Different consumables and torch accessories enable configuring a plasma cutter for a variety of
applications and operator skill levels. For cutting, select a regular or an extended cutting tip. With
plasma units greater than 40 amps, a built-in drag shield protects the regular tip and automatically
holds it 1/8 in. off the surface of the work piece (with units less than 40 amps, the tip can be
placed directly on the work piece). For following straight edges or tracing stencils or patterns, many
people select this arrangement because it allows them to simply brace the edge of the drag shield on
a guide (a ruler, piece of wood, cardboard pattern, etc.) and start cutting.

For beveling, cutting in

corner and a better view of
the cutting arc, some
operators prefer an
extended tip. This tip
protrudes 1/2 to 1 in
beyond the retaining cup,
enabling the operator to
better direct the flow of
plasma jet and reach into
corners. Having a steady Roller Guides - For Straight Lines
hand is important because
touching the tip to the
work piece three or four
times enlarges the hole in
the tip to the point where
it no longer constricts the
arc sufficiently.
If you do not have a steady
hand (remember that the Circle Cutting Guide
cut will reflect any hand
movement (consider using
roller guides and circle
cutting guides). These
guides hold the torch in
position so that it
maintains consistent
standoff height, prevent
the tip from touching the
work piece and make it Beveled Cut - Adjust Wheel Height
easier to travel in a straight
line or cut a perfect circle.
For easy beveling, roller
and circle cutting guides
permit independently
adjusting wheel height to
set the bevel angle.
For removing old or
imperfect welds, use a
gouging tip. The hole on a
gouging tip is three to four
times wider than a regular
tip. Its cone shape pushes
out the plasma arc, which
removes much more
material than the
constricted orifice of the
regular tip.
Many people do not
believe that plasma works
well for gouging, but that
perception is based on
older machines with
weaker arcs. More
powerful Spectrum plasma
cutters feature a much
stronger design that creates
an arc 1 to 1-1/2 in. long.
Although carbon arc
gouging removes metal
faster, plasma arc gouging
produces much less smoke
and noise, as well as offers
more control over the arc.
As with cutting capacity
and speeds, consumable
life varies greatly between
manufacturers. In a test
comparing the number of
12-in. long, 1/2-in. thick
strips of mild steel cut with
a single set of
consumables, Miller
outperforms many of its
competitors. A 55-amp
Spectrum plasma
cutter cuts 450 strips with
an extended tip and 330
with a drag shield. Miller's
efficient design reduces
consumables cost by up to
500 percent compared to
competitive machines.

HF or Contact Start
Plasma cutters use either "high frequency start" or "contact start" technology to initiate the pilot
arc. If you plan to use a plasma cutter near telephones, computers, CNC machines or other
electronic equipment, be aware that high frequency (HF) often interferes with electronic controls.
To avoid potential HF problems, all Miller machines feature contact start design that does not
cause interference. Even better the contact start method creates a visible pilot arc that helps you
better position the torch.

Pre-Cut Checklist
A few final words of advice before cutting:

 Follow proper safety procedures and wear personal safety equipment — read the Owner's
Manual!
 Inspect the torch tip, electrode and shield cup and replace worn items. The expense is well
worth avoiding the poor cutting performance (and operator frustration) caused by worn parts.
 Check gas/air pressure at the compressor or bottle gauge.
 Turn on the plasma machine.
 Set the amperage control (generally to maximum) and check the air pressure.
 Grind off rust or paint where you plan to secure the ground clamp. This step is critical with 12-
amp machines; they just don't have the power to drive through rust and paint like larger units
do.
 Place the ground clamp as close to the cut as possible, and place the clamp on the work piece
itself when possible. Check for any loose connections between the work cable and the clamp.
 Relax-don't hold the torch too firmly or your hand will shake more.
 Begin cutting.

Cutting Technique

Step 1. Place the drag shield on the edge

of the base metal, or hold the correct
standoff distance (typically 1/8 in.). Direct
the arc straight down. (Dragging the tip
will reduce tip life).
 The arc starts immediately when
trigger is pressed.
Step 2. Raise the trigger lock, press the
trigger and the pilot arc starts immediately.

Step 3. Once the cutting arc starts, begin

to slowly move the torch across the metal.

Step 4 . Adjust your speed so sparks go

thru metal and out bottom of cut.
If the sparks are not visible at the bottom
of the plate, the arc is not penetrating the
metal. This can be caused by moving the
torch too quickly, insufficient amperage or
directing the plasma stream at an angle
(not straight down). Insignificant
grounding can also cause this problem.

Step 5 . At the end of a cut, angle the

torch slightly towards the final edge or
pause briefly before releasing trigger to
completely sever the metal.

Step 6 . To cool torch, post-flow air

continues for 20 - 30 seconds after
releasing the trigger; pressing the trigger
during post-flow instantly restarts the arc.

Traveling at the right speed produces a very clean cut with less dross on the bottom of the cut, as
well as little or no distortion to the metal. If the travel speed is too slow, the material you are
cutting may become hot and accumulate more dross. To minimize dross, increase travel speed or
reduce amperage (for an indication of how fast to move the torch, refer to the machine's cutting
speed graph or check the speed for a rated cut). Dross also accumulates when you push a machine
to its maximum thickness. The only cure for this is a bigger machine.

Gouging and Piercing Techniques

To gouge — to remove old welds or imperfections — hold the torch at a 40 to 45° angle to the
base metal. Establish an arc length of 1 to 1-1/2 in. and move the torch across the metal, adjusting
torch speed, arc length and angle as needed. Direct sparks away from the torch, and do not gouge
too deeply on one pass. Make multiple passes if needed.
To pierce metal — creating a hole, such as to start coping or insert a valve — place the torch at a
40 to 45° angle to the work piece. Press the trigger. After the machine initiates the cutting arc, bring
the torch tip to a 90° angle and the arc will pierce the base metal. Generally, a machine can pierce
metal up to one-half of its maximum cutting thickness. Powerful machines pierce 1/4 in. steel
within a second or two.
If you select the appropriate plasma cutter and service it properly, you can experience years of
trouble-free performance. In fact, most "problems" with plasma cutting relate to other systems (air,
consumables), not the machine itself. Most importantly, almost every person who cuts with a
plasma machine gets hooked on the technology. They couldn't be paid to go back to other cutting
methods.