Plasma technical tip: How to properly maintain the O-rings in your plasma torch: Due to their small size, low cost, and straightforward design, the vital function of an O-ring is frequently overlooked and regular maintenance checks are often ignored, but operators can avoid serious downtime by getting into the daily habit of properly maintaining the O-rings on their consumables and in the plasma torch.

Plasma technical tip: How to properly maintain the O-rings in your plasma torch

By Ann Thompson, Hypertherm

Posted on 01/22/2019 in  SPARK the blog,  Plasma cutting

Due to their small size, low cost, and straightforward design, the vital function of an O-ring is frequently overlooked and regular maintenance checks are often ignored, but operators can avoid serious downtime by getting into the daily habit of properly maintaining the O-rings on their consumables and in the plasma torch.

Two key factors are critical, the silicone application and O-ring condition. Damaged, worn, dirty, dry, or over-lubricated O-rings can cause unwanted disruptions to production. Here are some common signs of O-ring trouble.

• The torch assembly is tight fitting and does not glide together easily
• Gas blockage or inconsistent gas flow
• Coolant is leaking from the torch
• Cut quality is prematurely diminished
• Your consumable life is shorter than normal

O-rings need to be replaced anytime there is visible wear or damage. If an O-ring is cracked, then it needs to be replaced. This applies not only to HyPerformance systems, but to air and conventional plasma systems as well. Check to make sure the O-rings on your consumable parts are securely situated and have not rolled out of place. If you have a HyPerformance system or conventional plasma (with the exception of the original torch found on our older MAX200 systems) you also need to inspect, and if necessary replace, the O-rings found on the bullet plugs inside the torch. We recommend routine visual inspections to determine replacement frequency.

When re-installing or replacing the O-rings, you may find it helpful to use a silicone lubricant. Put a small amount on your index finger and then rub it together with your thumb, as shown in the photos on the opposite page. Now apply the thin film to all the torch and consumable O-rings. You only want to give the O-ring a “wet” look. If you can see a physical build-up of silicone left behind, you have applied too much. Silicone can clog or plug ports and for that reason you need to be especially careful with its application around the swirl-ring so that the gas flow will work properly.

Hypertherm does offer silicone lubricant, part number 027055, through its network of authorized distributors. At around $7 a tube, the lubricant is affordable and should last for months. In addition, a tube is included in our preventative maintenance, torch rebuild, and starter kits. Hypertherm’s silicone is specifically formulated to condition and maintain consumable O-rings. Hypertherm does not recommend the use of substitutes, like petroleum based lubricants, as they can lead to burning or spark fires within the torch.

Questions about this tip? Contact Plasma Systems Inc. 

Posted in  SPARK the blog,  Plasma cutting
Tagged with  Powermax,  XPR,  HPRXD,  plasma consumables

Plasma tips & tricks: Installing Hypertherm HyPerformance consumables correctly

Plasma tips & tricks: Installing Hypertherm HyPerformance consumables correctly: Our Technical Service Team sometimes gets calls from HyPerformance Plasma owners having trouble with their torch. In the vast majority of cases the problems are traced back to the way the consumables were installed.

Installing HyPerformance consumables

By Ann Thompson, Hypertherm

Posted on 01/14/2019 in  SPARK the blog,  Plasma cutting

Our Technical Service Team sometimes gets calls from HyPerformance Plasma owners having trouble with their torch. In the vast majority of cases the problems are traced back to the way the consumables were installed. Though building a consumable stack up is easy to do, it is critical that you fit the swirl ring and nozzle together before inserting these two parts into the torch. This step is critical as it helps to correctly align the consumables. The proper installation method then is this:

1. Insert the electrode into the torch.

2. Fit the nozzle and swirl ring together, then insert this new combined subassembly onto the electrode.

3. Add the nozzle retaining cap to the torch, followed by the shield and shield cap.

4. Gently tighten the entire assembly together, taking care not to over-tighten.

First fit your nozzle and swirl ring together (photo, top) then install this new combined subassembly (photo, bottom). 

If you experience any of the following issues, misaligned consumables are a possible culprit and you should probably start by reassembling your consumable stack-up.

• Torch will not fire at all
• Pilot arc will ignite and then quickly extinguish
• Retaining cap will not screw on all the way
• Swirl ring is cracked, crushed, or melted
• Poor cut quality

Posted in  SPARK the blog,  Plasma cutting 

Don’t tighten XPR QuickLock electrodes by hand; use the tightening tool (part number: 104119)

Last year we did a Tech Tip in Hypertherm’s SHAPING eMagazine on the importance of using a consumable tool when removing consumables in your XPR, HPRXD, HPR and MAXPRO plasma cutting systems. This tool is so critical, we include one with every single system that leaves our facility. In addition to removing consumables, the tool is also used to install the electrode on the above systems, including our XPR plasma systems.

Although the new QuickLock electrode used on those systems is quick and easy to install (and feels like it should be tool-less), you still need the consumable tightening tool to ensure that electrode is secure. When an XPR electrode is tightened by hand, it is too loose and can’t make proper electrical contact. An arcing current will damage your consumables and maybe even your torch body, the receptacle, and/or torch connect console.

You need to use the hexagonal-shaped socket in the middle of this tool to completely tighten the electrode. This center hollow fits perfectly over the electrode and it is used like a wrench, to tighten and properly seat the electrode in place. Please refer to this video and article for more information on consumable installation and removal using this tool:

• Video: Hypertherm how to: Hypertherm Technical Service Engineer Bob Chorney demonstrates proper use of our consumable removal tool.
• Article: Don’t get dinged: There is a right way to use the consumable removal tool that comes with your XPR, HPRXD, HPR and MAXPRO power supplies.

If you have misplaced your XPR tightening tool, you can order a new one from Plasma Systems, Inc. Ask for Hypertherm part number: 104119.

Original article posted in :  SPARK the blog,  Plasma cutting 

Houstex 2019

We had the opportunity to visit Houstex this year and had a great time looking at all the new technology out there. Below are just a few pictures we took of some good looking booths and fine people at the event. 

Our 2019 Brochure has arrived!

The new year is coming to a great start. We received our new brochures and our sales team has started to promote with them. Inside our new brochure you will find information regarding the technology which powers our system and puts us a cut above the rest. Feel free to visit and download the brochure via our website http://www.plasmasystemsinc.com/reference-library.html

January has come and gone and we are moving into February excited about the year still ahead. As a company, our aim is to keep innovating and growing our capabilities. InSight remains one of the most impressive controllers in the industry exceeding both ours and customer expectations. We remain open to industry feedback and would love to have you and your team visit us for a demonstration. If you're curios about our cut quality and beveling capabilities, don't hesitate to give us a call and drop by.

Plasma Systems, Inc.
Joseph Steinhauer / Sales Engineer
Phone: 832.243.9900


Our January Open House

We are happy to say our first open house of the year was a complete success! Plasma Systems Inc. would like to thank everyone who made the time to stop by and visit with us. If you were not able to make it to the open house, we would love to schedule a private demo for you and your team. For those who have already rescheduled, we look forward to seeing you soon!

Wishing everyone a Happy Holiday!

We had the opportunity to go out and visit a few friends this past week. A big thank you for everyone who took the time to pose for our photos. On behalf of Plasma Systems, Inc family, we would like to thank you for your continued support and are grateful for your continued consideration and business. Please visit the link below and feel free to share with your team!

Wishing both you and your teams a Happy Holiday Season!

Plasma Systems, Inc.

PS: Look out for our Open House in January!

Entering the New Year with some Preventative Maintenance!

Hello friends!  We are down to the last couple weeks of the year. We would like to encourage everyone to take some time out of this busy season and treat your CNC plasma cutter to an end of year service check. Here we will go over just a few tips and tricks.

Let’s get started! Why are we recommending an end of year service check? Because we love our CNC machines and we want them to run smooth and efficiently in order to save and make you money. Sounds great right! As we transition into the New Year everyone is looking for ways to build better habits both at work and in their private lives at home. Whether it is a new diet, a new filing system or a new organizational productivity enhancing procedure at work……we want to start the new year with better habits. Let’s go over a few pointers.

We recommend you create your baseline for the New Year. If you start the New Year knowing your CNC machine is running at optimal performance, you can create and follow a maintenance protocol, which should keep your system service cost lower than last years. This is absolutely something your team can do without any additional service cost to you. (Technically we all should be running a daily, weekly and monthly check on our CNC machine already.) So each maintenance program should be geared specifically for your CNC machine. Each program should touch on the following key components:

 1)  Plasma – Each plasma will have a manufacturer recommended maintenance schedule, which we recommend you follow. A clean plasma cutter will provide cleaner cuts and should be given a daily maintenance review. Recommended daily coolant checks and a six-month coolant replacement are some of the important preventative maintenance actions your team should be taking.

 2)  The Machine – The Cutting Edge custom design CNC machine is a beast. Built with the highest quality parts, the machine will run for years on end with accurate and precise movement (we have machines in the field which have been running for over 20 years). Maintenance is key and we recommend always checking your carriage and lifter for debris and obstruction. Simple things like cleaning your rails once a month with a wire brush can help prevent future issues.

 3)  Drive Maintenance – Drive maintenance is also one of the most important pieces on the CNC to maintain. Checking and cleaning the exterior components of the drives goes a long way. Ensuring the wires are secure, clean, and unobstructed assists in keeping the gearboxes sealed, this will keep your CNC working at a high level of precision.

 4)  Insight Controller – The controller is engineered to function in a harsh environment. Recommended maintenance for the controller is as easy as routinely cleaning the touch screen and removing any layers of dust from the keyboard, wires and exterior components.

 5)  Cut Table – Whether you have a water table or downdraft table, keeping the slats, bins and interior of your table clean are highly recommended. Maintaining the table will provide for a safer work environment and will help prevent major accidents.

The best operators know their machine and can let you know the minute something goes awry. We offer or recommend these best practices because we believe knowing your machine is essential. If your operator is following a monthly, weekly or daily preventative maintenance program, they will become aware of any discrepancies that may appear before they escalate to bigger issues (<--- this saves you money). Of course there are some shops that act reactively to issues instead of taking pro-active actions. If you are one of these shops, don’t worry you are not alone!

In closing, thank you for taking the time read through the article. Feel free to give us a call, one of our sales engineers would be more than happy to answer any questions regarding a preventative maintenance check for your CNC flame cutter.

Happy Holidays from Plasma Systems Inc.