BOC Smoothcut Plasma 40 Manuel utilisateur

Plasma 40

Operating manual

Important Notice

This document has been prepared by BOC Limited ABN 95 000 029 729 (‘BOC’),

as operating instructions and has been prepared in good faith. Information in this

document has been derived from third parties, and though BOC believes it to be

reliable as at the time of printing, BOC makes no representation or warranty as

to the accuracy, reliability or completeness of information in this document and

does not assume any responsibility for updating any information or correcting

any error or omission which may become apparent after the document has been

issued. The information in this document is commercial in conﬁdence and is not

to be reproduced. The recipient acknowledges and agrees that it must make

its own independent investigation and should consider seeking appropriate

professional advice in reviewing the information. This document does not take

into account the particular circumstances of the recipient. Except insofar as

liability under any statute cannot be excluded, BOC and its afﬁliates, directors,

employees, contractors and consultants do not accept any liability (whether

arising in contract, tort or otherwise) for any error or omission in this document

or for any resulting loss or damage (whether direct, indirect, consequential

or otherwise) suffered by the recipient of this document or any other person

relying on the information contained herein. The recipient agrees that it shall not

seek to sue or hold BOC or their respective agents liable in any such respect for

the provision of this document or any other information.

This operating manual provides the basic knowledge required for plasma

cutting, as well as highlighting important areas of how to operate the

BOC Smoothcut Plasma Cutting machine.

With normal use and by following these recommended steps, your

BOC Smoothcut Plasma Cutting machine can provide you with years of

trouble‑free service. BOC equipment and technical support is available

through our national BOC Customer Service Centre or contact your local

Gas&Gear outlet.

2BOC Smoothcut Plasma 40 Operating manual

Contents.

1.0 Recommended Safety Guidelines and Precautions 4

1.1 Health Hazard Information 5

1.2 Personal Protection 5

1.3 Electrical Shock 6

1.4 User Responsibility 6

2.0 Smoothcut Plasma Cutters 7

2.1 Fundamentals of Plasma Cutting 7

2.2 Process Operation 7

3.0 Plasma Cutting Components 8

3.1 Plasma Cutting Power Sources 8

3.2 Plasma Cutting Capacity 8

3.3 Air Supply 8

3.4 Process Comparisons 9

3.5 Work Return Cable Assembly 9

4.0 Cutting Technique 10

4.1 Cutting 10

4.2 Piercing and Gouging 11

5.0 Operating Controls 12

6.0 Installing your Plasma Machine 13

6.1 Installing the Air Pressure Regulator 13

6.2 Attaching the Plasma Torch 13

6.3 Setting up the power source 13

7.0 Torch Assembly, Attachment and Consumables 14

7.1 Fitting the consumables 14

7.2 Fitting the torch to the power source 14

7.3 Selecting the correct air pressure and ﬂow rate 14

8.0 Package Contents & Technical Speciﬁcations 16

9.0 Periodic Maintenance 17

9.1 Power Source 17

10.0 Warranty Information 18

10.1 Terms of Warranty 18

10.2 Limitations on Warranty 18

10.3 Warranty Repairs 18

3BOC Smoothcut Plasma 40 Operating manual

1.0 Recommended Safety Guidelines

and Precautions

Diagram and safety explanation

Cutting sparks can cause explosion or ﬁre.

Keep ﬂammable materials away from cutting. Do not cut

near ﬂammable materials.

Cutting sparks can cause ﬁres. Have a ﬁre extinguisher

nearby, and have a watchperson ready to use it.

Do not cut on drums or any closed container.

The plasma arc can cause injury and burns.

Turn off power before disassembling torch.

Do not grip material near cutting path.

Wear complete body protection.

Electric shock from torch or wiring can kill.

Wear dry insulating gloves. Do not wear wet or damaged

gloves.

Protect yourself from electric shock by insulating yourself

from work and ground.

Disconnect input plug or power before working on machine.

Breathing cutting fumes can be hazardous to your health.

Keep your head out of fumes.

Use forced ventilation or local exhaust to remove fumes

Use ventilating fan to remove fumes.

Arc rays can burn eyes and injure skin.

Wear hat and safety glasses.

Use ear protection and button

shirt collar. Use welding helmet

with correct shade of ﬁlter.

Wear complete body protection.

Become trained and read the

instructions before working on the

machine or cutting.

Do not remove or paint over (cover) the label.

Some safety precautions BOC

recommends are as follows:

• Repair or replace defective cables immediately.

• Never watch the plasma arc except through

lenses of the correct shade.

• In conﬁned spaces, adequate ventilation

and constant observation are essential.

• Leads and cables should be kept clear

of passageways.

• Keep ﬁre extinguishing equipment at a handy location

in the workshop.

• Keep primary terminals and live parts effectively covered.

• Never strike an electrode on any gas cylinder.

• Never use oxygen for venting containers.

4BOC Smoothcut Plasma 40 Operating manual

5BOC Smoothcut Plasma 40 Operating manual

1.1 Health Hazard Information

The actual process of plasma cutting is one that can cause a variety of

hazards. All appropriate safety equipment should be worn at all times,

i.e. headwear, hand and body protection. Electrical equipment should be

used in accordance with the manufacturer’s recommendations.

Eyes

The process produces ultra violet rays that can injure and cause

permanent damage. Fumes can cause irritation.

Skin

Arc rays are dangerous to uncovered skin.

Inhalation

Cutting fumes and gases are dangerous to the health of the operator and

to those in close proximity. The aggravation of pre‑existing respiratory or

allergic conditions may occur in some workers. Excessive exposure may

cause conditions such as nausea, dizziness, dryness and irritation of eyes,

nose and throat.

1.2 Personal Protection

Respiratory

Conﬁned space cutting should be carried out with the aid of a fume

respirator or air supplied respirator as per AS/NZS 1715 and AS/NZS 1716

Standards.

• You must always have enough ventilation in conﬁned spaces. Be alert

to this at all times.

• Wear a respirator when natural or forced ventilation is insufﬁcient.

Eye protection

Protective eyewear should be worn when plasma cutting. The minimum

lens requirements are as follows:

Recommended ﬁlter shades for plasma cutting

Arc Current Minimum Protective Shade Suggested Shade*

Less than 20 amps Shade 4 Shade 4

20–40 amps Shade 5 Shade 5

40–60 amps Shade 6 Shade 6

60–80 amps Shade 10 Shade 10

80–200 amps Shade 11 Shade 11

*One shade darker lens should be used for Aluminium cutting.

Refer to WTIA Tech Note 7-13 Health and Safety in Welding.

Clothing

Suitable clothing must be worn to prevent excessive exposure to UV

radiation and sparks. An adjustable helmet, ﬂameproof loose ﬁtting

cotton clothing buttoned to the neck, protective leather gloves, spats,

apron and steel capped safety boots are highly recommended.

6BOC Smoothcut Plasma 40 Operating manual

1.3 Electrical Shock

• Never touch ‘live’ electrical parts.

• Always repair or replace worn or damaged parts.

• Disconnect power source before performing any maintenance

or service.

• Earth all work materials.

• Never work in moist or damp areas.

Avoid electric shock by:

• Wearing dry insulated boots.

• Wearing dry leather gloves.

• Working on a dry insulated ﬂoor where possible.

1.4 User Responsibility

• Read the Operating Manual prior to installation of this machine.

• Unauthorised repairs to this equipment may endanger the technician

and operator and will void your warranty. Only qualiﬁed personnel

approved by BOC should perform repairs.

• Always disconnect mains power before investigating

equipment malfunctions.

• Parts that are broken, damaged, missing or worn should be

replaced immediately.

• Equipment should be cleaned periodically.

BOC stocks a huge range of personal protective equipment. This,

combined with BOC’s extensive Gas and Gear network, ensures fast,

reliable service throughout the South Paciﬁc.

STOP

PLEASE NOTE that under no circumstances should any

equipment or parts be altered or changed in any way from

the standard speciﬁcation without written permission given

by BOC. To do so, will void the Equipment Warranty.

Further information can be obtained from Welding Institute of Australia

(WTIA) Technical Note No.7.

Health and Safety Welding

Published by WTIA,

PO Box 6165 Silverwater NSW 2128

Phone (02) 9748 4443

2.0 Smoothcut Plasma Cutters

7BOC Smoothcut Plasma 40 Operating manual

2.1 Fundamentals of Plasma Cutting

A plasma can be created by adding energy to an electrically neutral

gas. In the case of air plasma cutting the air is dry, clean compressed

air delivered from an air compressor or an air line. By adding electricity

through an electrode (Hafnium), the gas becomes imbalanced and

conducts electricity. The greater the level of electricity the higher the

temperature of the plasma.

Plasma cutting torches control energy by constricting the arc and forcing

it through a constricting nozzle ﬁtted to the torch. By increasing air

pressure and intensifying the arc with higher voltages, the arc becomes

hotter and more capable of blasting through thicker metals and blowing

away the cuttings, leaving minimal cleanup.

2.2 Process Operation

• Compressed air ﬂows through the torch.

• A pilot arc is established inside the head of the plasma torch.

• The high voltage of the pilot arc changes the air stream into a

plasma stream.

• The plasma stream is constricted and forced through a tip with a

small oriﬁce.

• The constricted plasma stream exiting from the tip is termed a

plasma jet.

• The plasma jet is allowed to touch the work.

• An arc is initiated between the hafnium electrode and the work.

• The arc passes through the oriﬁce of the tip.

• The constricted arc so formed is a stiff, columnated and narrow arc.

• The intense heat of arc melts the plate.

• The plasma jet blows away the metal to produce a cut.

Cross Section of Plasma TorchTypical Plasma Cutting Set-Up

Pressure regulating

control valve (on back)

Air compressor

(sold seperately)

Work lead

and connector

Main power supply

Plasma Torch

Workpiece

Amperage

control knob

Torch connector

Air supply hose

Power On/Off

switch (on back)

Airﬂow

Constricting nozzle

Electrode

Constricted Plasma Stream

Workpiece

3.0 Plasma Cutting Components

3.1 Plasma Cutting Power Sources

The plasma arc cutting power source changes the relatively high voltage,

low amperage primary power into low voltage, high amperage secondary

power suitable for plasma cutting.

The size of the power source depends on the cutting amperage it is

expected to deliver. Cutting of heavy section materials requires more

amperage than does cutting of thinner sections.

3.2 Plasma Cutting Capacity

Rated Output (A) Cutting thickness (mm)

Steel Stainless Steel Aluminium

40A Single phase 10 9 4

60A Three phase 20 18 6

80A Three phase 25 22 8

100A Three phase 32 25 12

160A Three phase 50 35 20

3.3 Air Supply

The supply of air to the cutting process plays an important role. The force

of the air is used to blow the molten material (created by the plasma arc)

away from the cut area thereby creating separation. Air pressure and

amperage are two variables that are changed when increasing the

cut thickness.

Compressed air from compressed air lines is often contaminated with

moisture and oil residue. Contaminants such as these shorten the life of

the consumable torch parts, it is therefore recommended that an inline

ﬁlter drying system is ﬁtted to all air delivery lines.

When air is supplied from a portable air compressor it is important

to ensure that the compressor has adequate pressure and airﬂow

rate capacity.

Typical air supply requirements

Pressure 4.5–6 bar

Draw‑off rate 150–200 L/min

8BOC Smoothcut Plasma 40 Operating manual

9BOC Smoothcut Plasma 40 Operating manual

3.4 Process Comparisons

Process comparisons

Characteristic Air plasma cutting Oxy-fuel cutting

Metals Any conductive material. Cutting thickness depends on power

source capacity. Typically very thin to 50mm

Restricted to steel. The formation of an oxide during cutting

of Aluminium and SS prevents the process being used

Industries All forms of metal fabrication, art sculptures, hobby and DIY All forms of metal fabrication, art sculptures, hobby and DIY

Pre‑heating Not required Required on most steel to prevent cracking

Productivity • Due to the fact that no pre‑heating is required the

overall cutting process time is reduced.

• High speed cutting of thin materials.

• Produces a small, thin kerf width and minimal post

cut cleaning is required

Highly portable and relatively low cost to set up

Versatility Highly versatile, stack cutting of material and combinations of

different materials can be cut.

No additional gas cylinders required

The process can be adopted to welding, brazing and

heating of materials

Safety concerns Electrical process, therefore a risk of electrocution exists.

Appropriate safety clothing must be worn

Gas process therefore a risk of ﬂashbacks occurring leading

to explosion of cylinders.

Appropriate safety clothing must be worn

3.5 Work Return Cable Assembly

The work return cable and clamp forms an integral part of the plasma

cutting process and if it does not make proper contact the efﬁciency of

the process is greatly reduced.

It is therefore essential to ensure that the correct size cable and clamp

is ﬁtted to the machine and that the work return clamp is properly

connected to the workpiece to be cut.

4.0 Cutting Technique

10 BOC Smoothcut Plasma 40 Operating manual

Diagram 1

4.1 Cutting

As a general rule for cutting amperages below 40A the cutting tip can

be dragged on the cutting surface. Higher amperages require a stand‑

off distance and torch manufacturers normally supply a stand‑off guide

or ‘drag shield’. Some operators prefer to use an extended electrode

to improve visibility when cutting. BOC supplies guides that can be

purchased to assist in straight line, circular and bevel cutting.

For straight edge cutting the torch should be held at a 90° angle to the

plate and dragged along the plate (Refer to Diagram 1). The cutting

speed will depend on the material thickness, amperage and airﬂow rate.

For bevel cutting the torch should be angled on the plate to the required

bevel angle and dragged on the plate surface. (Note that the bevel angle

will inﬂuence the material thickness).

Typical Plasma Cutting Guide Kit

90°

Cutting Direction

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