Plasma cutting fume filter

Types of plasma cutting fume filters

A plasmac cutting fume filter is a device designed to purify and safeguard the environment from harmful plasma cutting smoke and fume emissions. There are various types of plasma cutting fume filters, which can be classified according to their design, work principle, purpose, and packaging.

• In terms of design and installation, plasma cutting fume filters can be wall-mounted or independent. The wall-mounted filters are fixed to the wall and are used for plasma cutters with insufficient space for the filter to stand alone. On the other hand, independent filters are generally mounted on casters and can be easily moved to other locations.
• According to the working principle, plasma cutting fume filters can be active or passive. Active filters employ motors to extract cutting fumes. On the contrary, the passive filter relies on natural airflow.
• Plasma cutting fume filters can be primary or secondary, depending on their purpose. Primary filters are directly beneath the plasma cutter and collect the cutting fumes. Additionally, they are combined with a filter cartridge and a dust collector. On the other hand, secondary plasma fume filters are located further away from the source.
• Plasma cutting fume filters come in portable, stationary, and centralized packaging. Centralized filters have a ducting system used in industries that carry out heavy-duty cutting applications. These filters are located far away from the source and generally have a more complex cartridge change and cleaning process. Additionally, centralized filters are more extensive and are used for multiple pieces of equipment. On the other hand, portable plasma fume filters are used in workshops. They are mounted on the caster wheels of plasma cutters, soldering iron, and smoke extractor. They are easy to move around. Finally, stationary plasma fume filters are fixed in one position and are generally used in industries with heavy cutting applications.

Specifications and maintenance of plasma cutting fume filters

The crucial component of a plasma cutting dust extractor is the filter itself. Plasma cutting fume filters can be classified into two categories according to how they are cleaned: automatic or manual cleaning. Manual cleaning entails operating levers or buttons to start the cleaning process, whereas automatic cleaning entails a pre-programmed, timed pulse jet filter. The plasma cutting fume extractors' fan motors are another option. They may be of three types: side channel blowers, centrifugal motors, and inline or tube motors. For high vacuum applications, side channel blower motors are employed to produce high suction at a low power rating. For general-purpose use, disc-shaped centrifugal fan motors are suited. Designed to be slim and compact, inline or tube motors are installed in tight spaces. The filter units themselves come with carbon filter units, HEPA filter units, or both. Gas filters that employ the adsorption concept to remove gaseous contaminants from the air are carbon filter units. Particulate matter is captured by HEPA (High-Efficiency Particulate Air) filter units. Depending on their capacity, some dust extractors have a storage bag or container for the dust waste.

Plasma cutting fume extractor maintenance is crucial to ensuring optimal performance and protecting the health of users. The filters must be cleaned on a weekly or monthly basis, depending upon the type of extractor and frequency of its usage. Used in plasma cutting fume extractors, HEPA filters are to be replaced every 3 to 5 years generally. The carbon filters, their longevity depending on the type of extractor and material being extracted, may need early replacement if they begin to smell after being cleaned. Parts like the fan and the motor must be checked individually. The fume extractor's external casing should be washed every 1 to 2 months. A deep cleaning of the device can be done every 6 months. Regular maintenance of plasma cutting fume extractor not only helps its better functioning but also increases its longevity.

Scenarios of plasma cutting fume filters

Since the fume extraction system for welding and plasma cutting is designed to collect and eliminate fumes resulting from welding, cutting, or related activities, it proves useful across many industries.

• Manufacturing industry: Plasma cutting fume extractors find widespread use in the manufacturing industry. They extract cutting and welding fumes generated during operations using plasma cutters, welders, or workshops. Such industries may include metal fabrication, automobile manufacturing, shipbuilding, and construction machinery.
• Repair and maintenance: Plasma cutting fume extractors prove beneficial in repair and maintenance centers, including automotive repair shops, motorcycle repair shops, aircraft maintenance facilities, and metal product repair centers. The extractors can be used to suck up welding and plasma cutting fumes, ensuring a quality repair service and a cleaner and safer workplace environment.
• Construction industry: In the construction industry, plasma cutting fume extractors can be used in many places, including those used to cut and weld pipes, rebar, and metal plates, which emit a lot of fumes. Extraction tubes can be conveniently applied in various scenarios. The use of extractors helps to protect workers' health and maintain good indoor air quality in construction sites.
• Jewelry industry: The jewelry-making industry employs various techniques to create high-quality and intricate works. Plasma cutting helps artisans achieve superior craftsmanship when cutting or welding metals. Using a plasma cutting fume extractor can protect jewelry makers and customers from the hazardous fumes generated during the welding process.
• Electronic manufacturing: In electronic manufacturing, there is considerable use of wire stripping and welding, which generates a lot of smoke. A plasma cutting fume extractor can ensure that electronics manufacturing workers are not exposed to harmful smoke.

How to choose plasma cutting fume filter

When selecting a plasma cutting fume extractor, the key is to choose a machine that provides proper filtration for all present contaminants, including the ones released during plasma cutting.

• Consider the filter cartridges:

The cutting fumes contain a considerable amount of welding smoke. Hence, the extractor must have filters capable of handling this flux. Look for Extractor Filters with cartridges that have the following attributes:

• HEPA filters: Ensure the chosen extractor has HEPA filters. HEPA filters can capture particles as small as 0.3 microns, removing at least 97.5% of tiny particulate matter. This characteristic makes them great for dealing with hazardous metal particles that might arise from plasma cutting fumes.
• Pre-filters: Look for pre-filters alongside the HEPA ones. Typically, pre-filters are designed to capture larger particles. While they might not seem as important as the HEPA filters, they nonetheless play a crucial role. By capturing larger particles, pre-filters prevent rapid clogging of the HEPA filters. This enables the extraction unit to maintain its optimal performance for a more extended period before filter replacement becomes necessary.

Therefore, both filters work together to ensure air cleaning and prolong the extractor's functionality.

• Check the air flow:

In this context, air flow refers to the volume of air extracted by the extractor unit and is usually measured in cubic meters per hour (m3/h). The extractor's primary purpose is to remove cutting fumes from the work area, ensuring operators' safety. To achieve this goal, the extractor must maintain a sufficient air flow rate. A fast air flow rate ensures that fumes are captured from the source and properly filtered before the cleaned air is returned to the environment.

Determining the required air flow for a work task depends on a few factors, such as the number of cutting tasks performed in a given period and the frequency with which those tasks are conducted. Using cutting equipment with suction nozzles can also affect the extraction required. Conducting an assessment based on these parameters will enable a more accurate determination of the air flow needed to handle specific cutting tasks efficiently.

• Assess system noise:

Certain extractor units can produce high levels of noise due to their powerful motors. Prolonged exposure to this loud noise can have harmful impacts on users' health. Therefore, while selecting a plasma cutting extractor, consider the unit's noise level. Choose a model that has a noise level measured in decibels (dB), which is within a safe range for users.

Moreover, selecting a model with a relatively low noise level enhances users' comfort. This decision leads to more productivity on the cutting worktasks.

Plasma cutting fume filter Q&A

Q1: What are the plasma cutting filter cartridges composed of?

A1: Filter cartridges for plasma cutting are typically composed of dust collecting bags manufactured from fabric. The fabric is a combination of polyester and other protective membranes or coatings, resulting in a material both robust enough to filtering hazardous particles and capable of withstanding high temperatures.

Q2: Does the filter in a plasma cutter fume extractor need to be replaced?

A2: Ideally, the filter in a plasma cutter fume extractor will not need to be replaced frequently if it is properly maintained. The lifespan of the filter depends upon the handling of the plasma cutter and the type and amount of material being cut. Regular cleaning of the filter, as mentioned before, is important to its continued use, but eventually, all filters will become too saturated with particles to be effective and will need to be replaced.

Q3: How do plasma cutting fume filters work?

A3: The plasma cutting fume filter works by physically trapping the particles within its fabric. Micro-fibers in the filter bags capture and hold particulates while allowing clean air, or filtered air, to pass through and be released back into the atmosphere or redirected into the workspace via ducting.

Q4: How often should the fume extractor filter be cleaned?

A4: The frequency with which to clean the extractor filter is dependent on the plasma cutter in use, the material being cut, and the amount of plasma cutting carried out. Filters should be inspected regularly, and cleaning should occur whenever there is a build-up of dust or debris.

Q5: What are some maintenance tips for plasma cutting fume filters?

A5: Maintenance tips include the following: always following the manufacturer's instructions to ensure proper cleaning and filter handling; using the right extractor for the plasma cutter being used; ensuring the correct filtering cartridge is selected; keeping the filter dry whenever the extractor is not in use; and inspecting the filter regularly for any damage or signs of wear.