Smoothcut Plasma 100 Bedienungsanleitung
Plasma 100
Operating manual
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.
Important Notice
This document has been prepared by BOC Limited ABN 95 000 029 729 (‘BOC’), as general information and does not contain and is not to be taken as containing any specific recommendation. The document has been prepared in good faith and is
professional opinion only. 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. Neither BOC nor any of its agents has independently
verified the accuracy of the information contained in this document. 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 recommendation in reviewing and evaluating the information. This document does not take into account the particular circumstances of the recipient and the recipient should not rely on this document
in making any decisions, including but not limited to business, safety or other operations decisions. 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.
2BOC Smoothcut Plasma 100 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 Package Contents 12
6.0 Operating Controls 13
7.0 Installing your Plasma Machine 14
7.1 Installing the Air Pressure Regulator 14
7.2 Attaching the Plasma Torch 14
7.3 Input Power Requirements 14
8.0 Technical Specifications 15
9.0 Periodic Maintenance 16
9.1 Power Source 16
10.0 Warranty Information 17
10.1 Terms of Warranty 17
10.2 Limitations on Warranty 17
10.3 Warranty Repairs 17
3BOC Smoothcut Plasma 100 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 100 Operating manual
5BOC Smoothcut Plasma 100 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 100 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 100 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
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 100 Operating manual
9BOC Smoothcut Plasma 100 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 •Duetothefactthatnopre-heatingisrequiredthe
overall cutting process time is reduced.
•Highspeedcuttingofthinmaterials.
•Producesasmall,thinkerfwidthandminimalpost
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 100 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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