Thermadyne Products FAQs
Practical answers about the cables, torch parts, coolers, carts and covers that go with plasma cutting and arc welding systems, written for the type of equipment rather than one range.
How do I tell when a lead needs replacing?
Inspect the lead before use. Look along the torch lead for kinks, cracks, cuts or other damage and replace it if you find them. Also check that leads do not twist or kink in use, that they stay within the bend radius given in the manual, and that connections are tight but not over-tightened.
The torch, return cables and clamps should be kept in good condition. Cuts, crushed sections, exposed conductors, signs of heat and loose or discoloured connectors are all reasons to take a lead out of use, and taping over damage is not a proper repair. Isolate the system before inspecting, and have repairs and tests done by a competent person.
When does a torch need a water cooler instead of air cooling?
A water cooler circulates coolant through a liquid-cooled torch and its cable so that heat is carried away. Air-cooled torches suit lower currents and are simpler and easier to move between jobs, while liquid-cooled torches are generally chosen for higher currents and sustained work. Torches are rated by current and duty cycle together, and there is no single industry figure, so two torches with the same headline rating can differ.
Liquid-cooled torches can be lighter and smaller because the cable needs less copper, which reduces fatigue, but they need a coolant flow system and more maintenance, and a leak can damage equipment. Your torch's rated current and duty cycle in the manual decide which you need, and the cooler must be one the maker approves for your system.
What coolant should I use in a welding water cooler?
Use the coolant the equipment maker specifies. Torch and cooler makers generally call for a coolant made for welding rather than plain tap water, because hard water leaves mineral scale and untreated water allows algae to grow in the narrow passages of the torch and cooler.
Do not assume other fluids are acceptable. Some manuals warn against car or RV antifreeze and home-made mixtures, and some warn against deionised or demineralised water, because the additives, or the lack of them, can harm seals, pumps and passages. Only use a mix or additive that your maker approves. Check the level and hose connections before starting, look for leaks, and follow the change intervals in the manual, because coolant type, mix and capacity differ between machines.
How can I tell when plasma torch consumables are worn?
The first sign is usually in the cut: more dross, a wider kerf, an angled edge or a cut that no longer goes cleanly through. The nozzle and electrode wear fastest, so check them first. Look for a nicked, oval or enlarged nozzle orifice and a pitted electrode, and use the pit depth limit in the manual rather than a general figure.
Many guides suggest replacing the nozzle and electrode together so that a new part is not paired with a worn one. Parts that wear much faster than usual point to a cause such as moisture or oil in the air supply or the wrong torch height, which are worth fixing. Do not run parts to failure, as severely worn consumables can damage the torch.