BOC Smoothcut Plasma 25 Torch User manual

Plasma 25 Torch
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.
2BOC Smoothcut Plasma 25 Torch Operating manual

Contents.
1.0 Description 4
2.0 Torch breakdown and cutting consumables 5
3.0 Torch Ratings 6
4.0 Torch assembly 7
4.1 Fitting the consumables 7
4.2 Fitting the torch to the power source 7
4.3 Selecting the correct air pressure and flow rate 7
5.0 Cutting Technique 8
5.1 Cutting 8
5.2 Piercing and Gouging 9
6.0 Warranty 10
7.0 Safety Guidelines 11
3BOC Smoothcut Plasma 25 Torch Operating manual

The Smoothcut Plasma 25 torch is designed for plasma cutting
applications up to 40amps.
The torch requires air pressure of 5 bar for optimum operation. It has
been designed for quality cutting up to 9mm in thickness (mild steel).
The Smoothcut Plasma 25 torch has a 6m torch lead length, making it
suitable to reach even the most difficult places.
It is recommended to use the MagMate Cut 25 machine with this torch to
form one of the most portable cutting units on the market.
1.0 Description
4BOC Smoothcut Plasma 25 Torch Operating manual

2.0 Torch breakdown and cutting consumables
Torch breakdown and cutting consumables
Description Part No.
Smoothcut Plasma 25 Torch 6m BOC25/706HT
1Electrode BOC9/6506
2Gas distributor BOC9/6507
3Cutting tip 20-40A BOC9/6500
4Shield cup BOC9/6003
Accessories
Description Part No.
Complete cutting guide BOC–CP1011
Roller cutting guide BOC–TJ1511
Circle cutting guide BOC–TJ1093
Spares
Description Part No.
Torch head assembly BOC9/7000
Handle & trigger assembly BOC9/7002
5BOC Smoothcut Plasma 25 Torch Operating manual
2
3
4
1

3.0 Torch Ratings
Torch Ratings
Ambient temperature 40°C
Duty Cycle 60% @ 40A
Maximum current 40A
Cooling requirement Air or Nitrogen
Gas type Air or Nitrogen
CAUTION Never use Oxygen
Gas/air operating pressure 4.8–5.0 bar
Gas/air flowrate 100 L/min
6BOC Smoothcut Plasma 25 Torch Operating manual

4.0 Torch assembly
A
Rubber boot fitted to the end of the
Smoothcut Plasma 25 torch to cover the
Air/Electrical outlet.
CAUTION
This is a safety device and must
be fitted over the air/electrical
connection prior to use
BAir/electrical connection nut
(inside rubber boot).
CContactor/trigger switch cable
connector
B
C
A
7BOC Smoothcut Plasma 25 Torch Operating manual
4.1 Fitting the consumables
1 Place the electrode 1 into the torch head
2 Place the gas distributor 2 over the electrode
3 Place the tip 3 onto the gas distributor
4 Screw the shield cup 4 over the parts and hand tighten onto the torch
head. Do not over tighten the shield cup
IMPORTANT
As a safety feature of the torch, the cutting torch will not operate
unless the shield cup is fitted properly.
4.2 Fitting the torch to the power source
1 Connect the air/electrical connection Bby fixing the hexagon nut
to the terminal indicated as . Tighten the nut firmly but do
not overtighten.
2 IMPORTANT SAFETY NOTICE
Push the rubber boot Aover the terminal and ensure that it is
completely covered.
3 Connect the contactor/trigger Cswitch cable connector by fitting the
plug to the terminal indicated as .
4 Fit the work return lead and clamp to the terminal indicated as
.
4.3 Selecting the correct air
pressure and flow rate
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 be 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 such as the BOC 14 (and upwards) air compressors.
Air supply requirements for BOC Smoothcut Plasma 25 Torch
Pressure 4.8–5.0 bar
Draw-off rate 100 L/min
NOTE
The Smoothcut Plasma 25 torch is a contact start torch. Therefore the
cutting tip must be in contact with the work piece before the torch
switch is operated.
The contact start mechanism means that stand-off guides cannot be
used with the Smoothcut Plasma 25 torch.
2
3
4
1

5.0 Cutting Technique
8BOC Smoothcut Plasma 25 Torch Operating manual
Diagram 1
5.1 Cutting
As a general rule for cutting amperages below 40 A 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

9BOC Smoothcut Plasma 25 Torch Operating manual
5.2 Piercing and Gouging
To pierce material the cutting torch should be held at an angle of 45°
to the pierce surface (Refer to Diagram 2). Once the arc is established
the torch is turned to 90° (Refer to Diagram 3) and cutting is carried out
in a normal manner. Piercing thickness is dependent on the output of
the machine and is generally 50% of the rated cutting thickness of the
power source.
It is important to direct the arc away from the operator when establishing
the arc as sparks and molten material will be ejected from the point
of contact. Care must also be taken to protect the surrounds from
these sparks.
When gouging with plasma it is advisable to use a plasma gouging tip
supplied by the torch manufacturer. The torch should be held at an angle
of 40–45° from the plate surface (Refer to diagram 4). An arc length of
up to 15mm can be employed whilst the torch is moved in the direction
of the material to be removed. Several small passes should be made to
remove the unwanted material.
Diagram 3
Diagram 4
Diagram 2
90°
45°
Gouging Direction
40–45°

6.0 Warranty
The BOC Smoothcut Plasma 25 torch carries a 12 month warranty from
the date of purchase.
This warranty excludes any consumables and apparent misuse of
the torch.
10 BOC Smoothcut Plasma 25 Torch Operating manual