User Manual

Version Number: ZS-CUT50DP-20210204A1

2.9 Electrode condition

A fixed gap is established between the electrode and the inside of the cutting tip. Electrons arc across the gap,

ionizing and super heating the air creating the plasma stream. The electrode contains an insert in the end made of a

highly

conductive material called hafnium. This insert erodes with use and develops a pit in the end of the electrode, when

the pit becomes too much poor quality cuts will result and necessitate replacement of the electrode.

2.10 Air pressure and volume

Air pressure, flow rate and air quality are critical to quality plasma cutting and consumable life span.The required

air pressure and volume can vary from model to model and the manufacturer will provide the specs.The CUT35 air

pressure is preset at 4.5 psi and requires a flow rate of 6.0 CF/M. The volume capacity of your compressor is

important, if you have a small compressor with exactly the same l/min rating as the plasma, then the compressor will

run continuously when

you are plasma cutting, a compressor with a l/min rating slightly higher than the plasma would be more adequate. If

you are doing a lot of cutting, cutting thick plate (same air consumption but slower cut speeds = longer cut time) then

choose a compressor at 1.5 to 2 times the plasma system requirement.

2.11 Air quality

Good air quality is essential to quality plasma cutting and consumable life span. Compressors take in air at

atmospheric pressure and increase the pressure and store it in a tank. Humidity in the air is condensed in the tank

and in the airlines producing water, more so in humid environments. Moisture that forms in air lines has a tendency to

condense into larger drops when the air pressure decreases as it is entering the plasma torch. When these droplets

enter into the high temperatures (as much as 19832°f) in the plenum of the torch, they immediately break down into

oxygen and hydrogen, which alters the normal chemical content of air in the torch. These elements will then

dramatically change the plasma arc which causes the torch consumable parts to wear very quickly, alters the shape

of the nozzle orifice, dramatically affecting cut quality in terms of edge squareness, dross formation, and edge

smoothness. Minimising the moisture in the air supply is absolutely critical to quality plasma cuts and longevity of

consumable parts. As a minimum be sure to drain the receiver (tank) on the air compressor at least daily. Most air

plasma systems from reputable manufacturers have an on board particulate filter and or a coalescing filter with an

auto drain that will remove some

moisture from the air supply. For home workshop and light industrial users the on board air filter is adequate. Most

situations however will require additional filtration to prevent moisture from affecting the quality of the plasma cutter

and in most cases it is recommended to install a sub micronic particulate filter that is designed to trap water through

absorption. This style of filter has a replaceable filter cartridge that absorbs water and must be changed after it is near

saturation, it should be installed close as possible to the air intake of the plasma cutter.

2.12 Technique Tips

• It is easier to pull the torch through the cut than to push it.

• To cut thin material reduce the amperage until you get the best quality cut.

• Use the correct size tip orifice for the amperage being used.

• For Straight cuts use a straight edge or cutting buggy as a guide. For circles, use a template or circle cutting

attachment.

• Check that the front end consumable parts of the plasma cutting torch are in good condition.