Linde BOC Raptor CUT 30C User manual

CUT 30C
Operating Manual
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2
Welcome to a better way of cutting
Congratulations on puchasing the RaptorCUT 30C plasma cutter.
This operating manual provides the basic knowledge required for plasma cutting,
aswell as highlighting important areas of how to operate the Raptor machine.
With normal use, and by following these recommended steps, this machine
canprovide you with years of trouble-free service.
Raptor equipment and technical support is available through the national
BOCCustomer Engagement 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 specic
instructions. 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 veried the accuracy of the
information contained in this document. The information in this
document is commercial in condence 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 a󹟾liates, 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) su󹟽ered 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.

3
1.0 Recommended Safety Guidelines 4
2.0 Recommended Safety Precautions 6
2.1 Health Hazard Information 6
2.2 Personal Protection 6
2.3 Cylinder Safety 7
2.4 Electrical Shock 8
2.5 User Responsibility 8
Switch on to electrical safety 9
3.0 Package Contents & Assembly 12
3.1 Package Contents 12
3.2 Installing Adjustable Shoulder Strap 12
4.0 Torch Assembly, Attachment and
Consumables 13
4.1 Fitting the consumables 13
4.2 Fitting the torch to the power source 13
4.3 Selecting the correct air pressure and
ow rate 13
6.0 Installing your Plasma Machine 15
6.1 Installing the Air Pressure Regulator 15
6.2 Attaching the Plasma Torch 15
6.3 Setting up the power source 15
7.0 Operating Controls 16
8.0 Operating Connections 17
9.0 Machine Specifications 18
10.0 Plasma Cutters 19
10.1 Fundamentals of Plasma Cutting 20
10.2 Process Operation 20
11.0 Plasma Cutting Components 21
11.1 Plasma Cutting Power Sources 21
11.2 Plasma Cutting Capacity 21
11.3 Air Supply 21
11.4 Process Comparisons 22
11.5 Work Return Cable Assembly 22
12.0 Cutting Technique 23
12.1 Cutting 23
12.2 Piercing and Gouging 23
13.0 Periodic Maintenance 25
13.1 Power Source 25
13.2 Looking after your machine 25
14.0 Troubleshooting and Fault Finding 26
15.0 Warranty Information 27
15.1 Terms of Warranty 27
15.2 Limitations on Warranty 27
15.3 Warranty Period 27
15.4 Warranty Replacement 27
Contents

4
1.0 Recommended Safety Guidelines
Diagram and safety explanation
Cutting sparks can cause explosion
or re.
Keep ammable materials away
from cutting. Do not cut near
ammable materials.
Cutting sparks can cause res. Have
a re 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 o󹟽 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 lter. 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.

5
• Repair or replace defective cables immediately.
• Never watch the arc except through
lenses of the correct shade.
• In conned spaces, adequate ventilation
andconstant observation are essential.
• Leads and cables should be kept clear
of passageways.
• Keep re extinguishing equipment at a handy
location in the shop.
• Keep primary terminals and live parts
e󹟽ectivelycovered.
• Never strike an electrode on any gas cylinder.
• Never use oxygen for venting containers.
Some safety precautions BOC recommends are as follows:

6
2.0 Recommended Safety Precautions
2.1 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.
2.2 Personal Protection
Respiratory
Conned 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
conned spaces. Be alert to this at all times.
• Wear a respirator when natural or forced
ventilation is insu󹟾cient.
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, ameproof loose tting cotton clothing
buttoned to the neck, protective leather gloves,
spats, apron and steel capped safety boots are
highly recommended.

7
2.3 Cylinder Safety
1Cylinder valve hand-wheel
2Back-plug
3Bursting disc
Back view of typical
cylinder valve
1
2
3
Operator wearing personal
protective equipment (PPE)
in safe position
Ten Points about Cylinder Safety
1Always read the labels and Safety Data Sheet
(SDS) before use.
2Store cylinders upright and use in
well-ventilated, secure areas away from
pedestrian or vehicle thoroughfares.
3Ensure cylinders are appropriately secured
and guarded against being knocked violently
or being allowed to fall.
4Wear safety shoes, glasses and gloves when
handling, connecting and using cylinders.
5Ensure cylinders are appropriately restrained
to mechanical lifting/handling devices prior
to movement.
6Keep in a cool, well-ventilated area, away
from heat sources, sources of ignition and
combustible materials, especially ammable
gases.
7Keep full and empty cylinders separate.
8Keep ammonia-based leak detection
solutions, oil and grease away from cylinders
and valves.
9Never use force when opening or closing
valves.
10 Never repaint or disguise markings and
damage on cylinders. If damaged, return
cylinders to BOC immediately.
Cylinder Valve Safety
When working with cylinders or operating cylinder
valves, ensure that you wear appropriate protective
clothing – gloves, boots and safety glasses.
Ensure cylinder value is closed before moving or
disconnecting equipment.
Before operating a cylinder valve:
Ensure that the system you are connecting the
cylinder into is suitable for the gas and pressure
involved.
Cylinder valves should not be open unless a
pressure regulator has been tted.
Ensure that any accessories (such as hoses attached
to the cylinder valve, or the system being connected
to) are securely connected. Ahose, for example,
can potentially ail around dangerously if it is
accidentally pressurised when not restrained at
both ends.
Stand to the side of the cylinder so that neither
you nor anyone else is in line with the back of the
cylinder valve. This is in case a back-plug is loose or
a bursting disc vents. The correct stance is shown in
the diagram above.
When operating the cylinder valve
Open it by hand by turning the valve hand-wheel
anti-clockwise. Use only reasonable force.
Ensure that no gas is leaking from the cylinder
valve connection or the system to which the
cylinder is connected. DO NOT use ammonia-
based leak detection uid as this can damage
the valve. Approved leak detection uid, can be
obtained from a BOC Gas & Gear centre.
When nished with the cylinder, close the cylinder
valve by hand by turning the valve hand-wheel in a
clockwise direction. Use only reasonable force.
Remember NEVER tamper with thevalve. If
you suspect the valve is damaged, DONOT
use it. Report the issue to BOC and arrange
for the cylinderto be returned to BOC.

8
2.4 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
• Never changing electrodes with bare
handsorwet gloves
• Never cooling electrode holders in water
• Working on a dry insulated oor where possible
• Never hold the electrode and holder under
yourarm.
2.5 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 qualied 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 Pacic.
PLEASE NOTE that under no circumstances should
any equipment or parts be altered or changed in any
way from the standard specication without written
permission given by BOC. To do so, will void the
EquipmentWarranty.
Further information can be obtained from
Weld Australia (WTIA) Technical Note No.7
‘Health and Safety Welding’
Published by Weld Australia,
PO Box 6165 Silverwater NSW 2128
Phone [phone].
STOP

9
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BOC welding machines are designed and manufactured to conform
to IEC 60974 or AS 60974. This Standard not only covers themachine
but also the input cable and plug requirements including the size of
theplug that should be used.
X
Rated duty cycle
I0
Rated no-load
supply current
I1
Rated
supply current
AS 60974-1
Formula in clause 3.33
Maximum effective supply current
I1eff = √I12×X+ I02(1-X)
The I1e󹟽 determines thecorrect plug, input cable
andinput current required for each machine.
10A
I1eff ≤
I1eff ≤
I1eff ≤
I1eff ≤
1. 5 – 2 . 5 m m 2
min – max cable size
size must be indicated
on the cable
15A 1. 5 – 4 m m 2
25A 2 . 5 – 6 m m 2
32A 4 – 10 m m 2
Before operating your welding machine, follow the instructions in the operating manual.
For more information refer to WTIA TN 22 – Welding Electrical Safety (Revised 2003) and
WTIA TN 07 Health &Safety in Welding. If you have any queries please contact BOC 131
262 (AU), 1800 111 333 (NZ).
Remember…
Switch on to
electrical safety
for single-phase equipment

10
DO
Example
How important is the correct input cable and
plug on a welding machine?
The size of the plug depends on a formula that
not only uses the maximum current draw but also
the duty cycle of the power source. Theuse of
any welding power source will not only cause the
machine itself to heat up, but the input cable, plug
and mains power circuit will increase in temperature
as well. That’s why it’s important to understand
input and output currents and to make sure that the
input circuit is correctly rated to supply the required
input draw. Thisallows the machine to operate at or
near maximum output and protects the circuit board
from tripping, overheating and/or catchingre.
For your safety, BOC meets AS/NZS Standards
for safe electricalcompliance.
Regulatory Compliance Mark
(RCM) andnumber
All BOC welding machines undergo an independent
certication process to meet Australian and New
Zealand regulations regarding electrical safety.
The triangle-circle-tick (RCM) symbol signies that
BOC has taken the necessary steps to have the
product comply with the electrical safety and/
or electromagnetic compatibility (EMC) legislative
requirements as specied by the Electrical
Regulatory Authorities Council (ERAC). Depending
on the machine, BOC may be required to have a 32A
single phase plug to ensure that when the machine
runs at its maximum output, the input supply plug
and lead will not overheat. For your safety, please
check for this symbol before buying any welding
machine in Australia and NewZealand.
✓ Use the correct input current, ✓cable and
✓ plug in accordance with AS60974-1 for your
safety and to get the maximum performance
from your welding machine.
If the I1e󹠢 rating on your machine is 27A
then you must use a 32A plug as a 15A
is undersized for the welding current
being used and may cause the cable to
overheat.

11
Always
DON‘T
Example of BOC rating plateCheck the rating plate onyourmachine.
All welding machines that comply with IEC 60974
or AS 60974 must have a rating plate similar to the
one shown. Welding machines draw some current
when idle (not welding) and a higher current
when welding. E󹟽ective rated primary current (I1e󹟽 )
combines the conductor heating due to these two
levels of current. I1e󹟽 is the maximum rated e󹟽ective
supply current that determines the minimum plug
and input cable rating as well as the minimum
capacity of the input circuit that the machine gets
plugged into to safely operate the machine. Look
for the I1e󹟽 on the welding machine’s rating plate
and ensure that you have the correct input circuit to
support this powerdraw.
What if I don’t have a 240 volt 15 amp or
32 ampoutlet?
If you don’t have a suitable power outlet, you should
contact a qualied electrician to advise whether
the wiring in your building will cater for a 15 amp or
32 amp outlet. You mayalso need to upgrade your
circuit breakers and possibly switchboard to suit.
Failure to do this may cause an electrical re in the
building which may voidinsurances.
✖ Don’t risk damage to your machine or cause
tripping and/or re by using the wrong input
current, cable orplug.
✖ Don’t tamper with plugs or ledown earth
pins. Doing so willvoidwarranty.
✓ Inspect cables and plugs regularly.
✓ Contact a qualied electrician for advice and/
or upgrade and, if needed, to replace any
damaged plugs orcables.
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12
3.0 Package Contents & Assembly
3.1 Package Contents
• Power source
• Air lter assembly
• Plasma torch PCH-35 style
• Work return lead
• Operating manual
3.2 Installing Adjustable Shoulder Strap
1. 2.
3. 4.

13
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tted properly.
NOTE
The Plasma 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-o󹠢 guides
cannot be used with the Raptor Cut 30C.
4.2 Fitting the torch to the power source
1 Fit torch connection A to connection point on
machine indicated as . Screw torch
connection in rmly but do not overtighten.
2 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 lter drying system
betted 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 airow rate capacity.
Air supply requirements for BOC Smoothcut
Plasma 40 Torch
Pressure 4.8–5.0 bar
Draw-o󹟽 rate 100 L/min
A
4.0 Torch Assembly, Attachment and
Consumables
234 1

14
Torch breakdown and cutting consumables
Description Part No.
Smoothcut Plasma 40 Torch 6m BOC40/706HTC
1 Electrode BOC9/6506
2Gas distributor BOC9/6507
3 Cutting tip 20-40A BOC9/6500
4 Shield cup BOC9/6003
2
3
4
1

15
6.1 Installing the Air Pressure Regulator
An air pressure regulator assembly is included with
the Raptor Cut 30C package.
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 Ensure proper PPE is worn before operating.
6.3 Setting up the power source
1 Connect primary cable to the power supply
(10 A m p s).
2 Connect the air supply. Ensure that the air
pressure regulator is properly installed as per
section 6.1 of this manual.
3 Turn the machine on.
4 Select the appropriate amperage.
5 Begin cutting.
6 The cutting process works on the principle of a
contact start i.e. the cutting tip needs to touch
the work piece before cutting will commence.
Current Nozzle
10 – 30 A 1.0 mm
30 – 40 A 1.2 mm
6.0 Installing your Plasma Machine
PLEASE NOTE
For better results, always cut from the edge of the workpiece. This will protect your torch from
damage caused by spatter.

16
11
22
4433
Control Panel
1 Thermal overload Indicator
2 Power light
3 Amperage control Knob
4 Gas post ow control Knob
7.0 Operating Controls

17
55
66
77
99
1010
88
2211
44
33
Front Connections of Raptor Cut 30C Back Connections of Raptor Cut 30C
1 Torch connector
2 Work return lead connector
3 Air Pressure Adjustment Knob
4 Mounting Bracket
5 Air Inlet Connector
6 Pressure Indicating Dial
7 Moisture trap
8 Drain Plug
9 Air Hose
10 Machine Inlet Connector
8.0 Operating Connections

18
9.0 Machine Specifications
Raptor Cut 30C
Part No. CUT30C
Power voltage Single Phase AC 240 V ± 15 %
Rated maximum supply current(I1max)26.2 A
No-load voltage 300 V
Rated output current range 12.5–40 A
Output voltage range 96 V
Duty cycle 15 %
E󹟾ciency 84 %
Power factor 0.72
Insulation grade F
Housing protection grade IP21
Arc initiation Contact
Air pressure requirement 3.5–4 kgf/cm2
Limited cutting thickness 16 mm
Recommended cutting thickness 1– 10 mm
Weight 7.1 kg
Dimensions (L × W × H) 365 × 172 × 320 mm
Standards AS/NZS 60974-1, IEC/EN 60974-10

19
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/O󹠢
switch (on back)
10.0 Plasma Cutters
Typical Plasma Cutting Set-Up

20
10.1 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 tted
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.
10.2 Process Operation
• Compressed air ows 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orice.
• 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 orice of the tip.
• The constricted arc so formed is a sti󹟽, 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 Torch
Airow
Constricting nozzle
Electrode
Constricted Plasma Stream
Workpiece