stiff plasma torch cable

[monsoon-mech]

Now that I'm doing the semi retired thing my ol Miller Spectrum 2050 Plasma hasn't been getting used as much as it used to, I went to set it up the other day and the torch cable is so stiff it won't unwind, several sites say to soak in brake fluide has anyone tried this on welding cables? any other ideas?

[acourtjester]

What was the temperature where you have it stored, could be you just need to put it in a warm place for a day or so.

[Lis2323]

I wonder if UV’s affected it?

I wrap my plasma torch cables with hydraulic spiral wrap for protection from mechanical damage.






Enjoy the new chapter of your life. I took early retirement to raise my young daughter (ten years ago) and don’t regret a day!


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[monsoon-mech]

What was the temperature where you have it stored, could be you just need to put it in a warm place for a day or so.

Its just been in my ol shop trailer here in Tucson, Az.... its plenty warm


Lis2323; I like that wrap idea! I suspect the rubber has accelerated its natural tendacy to dry out maybe as a result of the conditions out here in the Southwest? its the stock Miller ICE-55C torch and 25' cable, thought bout buyin a new cable until I saw that I can actually buy a whole new torch AND cable for about the same price, I tried wipeing it down with DOT3 brake fluid on a rag earlier and it did seem to help rolled it into a big coil for storage afterwards rather than the tight roll it was in when I last used it about 2 months ago...

I got it all fired up yesterday to start cutting some stainless for yard art project, and could hardly get the cable un coiled and it kept trying to return to a coil like a spring...

[Stick-man]

Tagged stiff plasma torch

I have the same issue with my Hypertherm Powermax 600.

[Lis2323]

Slightly unrelated but I absolutely HATED the light gauge ground/work cable Miller and Hypertherm provide on their under 100 amp plasma cutters.

Virtually impossible to wind up neatly when done. Same for the voltage sensing cables for wire feeders.

I upgraded mine to 6 gauge wire which is WAAAY more flexible.



But then I got really smart (well smarter) and used aforementioned hydraulic spiral wrap and integrated the ground and torch cable together.






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[mechanic416]

That is normal for the older torch's used on Hypertherm plasma cutters. The air hose is nylon and gets really hard and trying to straighten it will crack the air line and if you run soapy water over the cable it will bubble. Best thing to do is buy a new duramax torch that will fit the plasma cutter.

[2strokeforever]

What we really need is to get get on CKs case to build us some superflex cables like they use on their tig torches.

I emailed hypertherm about buying just the threaded ends and another plastic plug and they were real uncooperative about it.

They told me I cant modify it, well if they dont want it modified there going to have to build it better....

[ronsii]

What we really need is to get get on CKs case to build us some superflex cables like they use on their tig torches.

I emailed hypertherm about buying just the threaded ends and another plastic plug and they were real uncooperative about it.

They told me I cant modify it, well if they dont want it modified they're going to have to build it better....

But then they won't be able to sell you a replacement torch and cable every few years...

[Oscar]

What we really need is to get get on CKs case to build us some superflex cables like they use on their tig torches.

I emailed hypertherm about buying just the threaded ends and another plastic plug and they were real uncooperative about it.

They told me I cant modify it, well if they dont want it modified there going to have to build it better....

The air hose needs to be stiff because of the air pressure needed. Superflex cables would balloon too much and you would lose pressure at the torch head.

[Hobbytime]

The air hose needs to be stiff because of the air pressure needed. Superflex cables would balloon too much and you would lose pressure at the torch head.

that has no bearing on air pressure through the softer hose, it will balloon a small amount ,maybe , but with constant air pressure it wont matter.....that would be saying you get more pressure from a 1/2 inch line than a 1 inch line....

[2strokeforever]

Theres hardly any flow, a superflex cable will be fine.
The plasma cable is under pressure, lets say 6 bar.
That means the flow is 6x slower inside the cable because the pressure drop is at the nozzle

[mechanic416]

This is really not true. You must use a hose of the same size that will not expend/swell and has the same flow rate as the factory hose or it will not work properly. Mainly this is for the pilot arc to work. This is only on blow back plasma cutters. High frequency plasma cutters does not matter as much on air line size.

[monsoon-mech]

Lis2323, now we're gonna have to talk bout your timing with puttin out the pics!! LOL! I already bought (and installed) the hydraulic protective cover that just fit my torch cable... now that adding the ground cables a great idea... but ya were a lil too slow sharin it!

[Lis2323]

Lis2323, now we're gonna have to talk bout your timing with puttin out the pics!! LOL! I already bought (and installed) the hydraulic protective cover that just fit my torch cable... now that adding the ground cables a great idea... but ya were a lil too slow sharin it!

Heh heh. Sorry about that! BTW did you have FUN winding that spiral wrap???


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[Rondo]

Heh heh. Sorry about that! BTW did you have FUN winding that spiral wrap???


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I just put this wrap on a 20' mig gun today. Wrapped and wrapped til my arms fell of. I'll finish it tomorrow.

[Lis2323]

Hydraulic shops usually have a homemade winder setup to turn the hydraulic hose and feed the wrap.

No way to easily do it for torch hose setups unless you disconnect the torch (Mig or plasma).

Even then it may get dicey. Believe me I've tried.


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[monsoon-mech]

Heh heh. Sorry about that! BTW did you have FUN winding that spiral wrap???


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that stuffs a pain! I finally figured out to use a cord wrap to keep the bulk of it rolled up and just fed off a foot or so at a time to keep it from getting all twisted and tangled... that helped some as only hadda toss a short section and the coil around the cable instead of the total leangth etc...