BOC Smoothcut Plasma 40 User manual

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 [phone]

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
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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

11BOC Smoothcut Plasma 40 Operating manual
4.2 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 cuts should be made to remove
the unwanted material.
Diagram 3
Diagram 4
Diagram 2
90°
45°
Gouging Direction
40–45°

12 BOC Smoothcut Plasma 40 Operating manual
Smoothcut Plasma 40
5.0 Operating Controls
Thermal overload indicator
On/Off switch
Torch connector
Amperage control knob
Work return lead connector
Gas post-flow Selector switch
Plasma torch (not shown)
Work return lead (not shown)

13BOC Smoothcut Plasma 40 Operating manual
6.1 Installing the Air Pressure Regulator
An air pressure regulator assembly is included with the BOC Smoothcut
Plasma 40.
To install follow the steps listed below:
1 Fix the mounting bracket with the screws as supplied to the back of
the machine.
2 Fix the air inlet and outlet connectors to the air pressure regulator.
3 Fit the air hose to the air outlet connector on the air pressure
regulator and the other side to the machine inlet connector. Ensure
that all connections are tight.
4 Fit the pressure indicating dial to the main body of the regulator and
ensure that it is screwed in tight.
5 Fit the air pressure regulator to the mounting bracket.
6 Adjust pressure adjusting screw till correct air pressure is achieved.
6.2 Attaching the Plasma Torch
1 Attach the plasma torch to the machine torch connector outlet.
2 Attach the work return lead and connector to the machine.
3 Connect power source and switch machine on.
4 Set the required amperage.
5 Ensure proper PPE is worn before operating.
6.3 Setting up the power source
1 Connect primary cable to the power supply (15Amps).
2 Connect the air supply. Ensure that the air pressure regulator is
properly installed as per section 6.1 of this manual.
3 Connect the work return lead and clamp.
4 Select the appropriate amperage.
5 Ensure that you are wearing the correct PPE.
6 Begin cutting.
7 The cutting process works on the principle of a contact start
i.e. the cutting tip needs to touch the work piece before cutting
wil commence.
6.0 Installing your Plasma Machine
Side View of Smoothcut Plasma 40
Vapour collection
container
Vapour drain plug
Air hose
Air Pressure
adjustment knob
Mounting bracket
Air outlet connector
Machine inlet
connector
Pressure
Indicating dial
Air inlet connector

2
3
4
1
7.1 Fitting the consumables
1 Place the electrode 1into the torch head
2 Place the gas distributor 2over the electrode
3 Place the tip 3onto the gas distributor
4 Screw the shield cup 4over 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.
NOTE
The Smoothcut Plasma 40 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 40 torch.
7.2 Fitting the torch to the power source
5 Fit torch connection Ato connection point on machine indicated as
. Screw torch connection in firmly but do not overtighten.
6 Fit the work return lead and clamp to the terminal indicated as
.
7.3 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 40 Torch
Pressure 4.8–5.0 bar
Draw‑off rate 100 L/min
A
7.0 Torch Assembly, Attachment and
Consumables
14 BOC Smoothcut Plasma 40 Operating manual

Torch breakdown and cutting consumables
Description Part No.
Smoothcut Plasma 40 Torch 6m BOC40/706HTC
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
2
3
4
1
15BOC Smoothcut Plasma 40 Operating manual

8.0 Package Contents & Technical
Specifications
Specifications Smoothcut Plasma 40
Part No. CUT40C
Power voltage (V) Single Phase AC 240V±15%
Input power rating (A) 18.8
No‑load voltage (V) 246
Current range (A) 15–40
Output voltage (V) 96
Duty cycle (%) 60
Efficiency (%) 80
Insulation grade F
Housing protection grade IP21
Arc initiation Contact
Air pressure requirement (bar) 4
Cutting thickness 9mm Mild Steel,
8mm Stainless Steel,
4mm Aluminium
Weight (kg) 8
Dimensions (mm) 350 x 150 x 260
Package consists of the following:
• Plasma 40 power source
• Air pressure regulator
• Air hose and connectors
• Plasma torch
• Work return lead and clamp
• Operating manual
16 BOC Smoothcut Plasma 40 Operating manual

9.0 Periodic Maintenance
WARNING
Only authorised electricians should carry out repairs and internal
servicing.
The working environment or amount of use the machine receives should
be taken into consideration when planning maintenance frequency of
your BOC Smoothcut Plasma 40.
Preventative maintenance will ensure trouble‑free cutting and increase
the life of the machine and its torch consumables.
9.1 Power Source
• Check electrical connections of unit at least twice a year.
• Clean oxidised connections and tighten.
• Inner parts of machine should be cleaned
with a vacuum cleaner and soft brush.
• Do not use any pressure‑washing devices.
• Do not use compressed air as pressure may pack dirt even more tightly
into components.
• Only authorised electricians should carry
out repairs.
17BOC Smoothcut Plasma 40 Operating manual

10.0 Warranty Information
10.1 Terms of Warranty
BOC provides a warranty for the BOC Smoothcut Plasma 40 sold by it
against defects in manufacture and materials.
Valid for 18 months from date of purchase.
• An authorised BOC Service Agent must carry out warranty repairs.
• Freight, packaging and insurance costs are to be paid for by the
claimant.
• No additional express warranty is given unless in writing signed by an
authorised manager of BOC.
• This warranty is in addition to any other legal rights you may have.
• Plasma torch consumables, earth leads and their connectors, are not
covered in these warranty terms.
• Air pressure regulator assemblies are not covered in these
warranty terms.
10.2 Limitations on Warranty
The following conditions are not covered:
• Non compliance with operating and maintenance instructions such as
connection to incorrect faulty voltage supply including voltage surges
outside equipment specs, and incorrect overloading.
• Natural wear and tear, and accidental damage
• Transport or storage damage.
The warranty is void if:
• Changes are made to the product without the approval of the
manufacturer.
• Repairs are carried out using non‑approved spare parts.
• A non‑authorised agent carries out repairs.
10.3 Warranty Repairs
BOC or their Authorised Service Agent must be informed of the warranty
defects, and the product returned within the warranty period.
• Before any warranty work is undertaken, the customer must provide
proof of purchase and serial number of the equipment in order to
validate the warranty.
• The parts replaced under the terms of the warranty remain the property
of BOC.
18 BOC Smoothcut Plasma 40 Operating manual

MP12‑0064 . FDAUS . 0614
© BOC Limited 2014. BOC is a trading name of BOC Limited, a Member of The Linde Group. Reproduction without permission is strictly prohibited. Details given in this document are
believed to be correct at the time of printing. Whilst proper care has been taken in the preparation, no liability for injury or damage resulting from its improper use can be accepted.
BOC Limited
10 Julius Avenue, North Ryde NSW 2113, Australia
970–988 Great South Road, Penrose, Auckland, New Zealand
For more information contact the BOC Customer Service Centre.
BOC Australia
131 262
www.boc.com.au
BOC New Zealand
0800 111 333
www.boc.co.nz