Xcel-arc Razor cut80 User manual

Razor

ut8O

YEA

MACHINE

WARRANTY

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Cut

XA-CUT80RZ | Operating Manual

Please read and understand this instruction manual carefully

before the installation and operation of this equipment.

WARRANTY

• 3 Years from date of purchase.

• Esseti NZ Ltd warranties all goods as specified by the manufacturer of those goods.

• This Warranty does not cover freight or goods that have been interfered with.

• All goods in question must be repaired by an authorised repair agent as appointed by this company.

• Warranty does not cover abuse, mis-use, accident, theft, general wear and tear.

• New product will not be supplied unless Esseti NZ Ltd has inspected product returned for warranty

and agree to replace product.

• Product will only be replaced if repair is not possible

• Please view full Warranty term and conditions supplied with machine or at the back of this manual.

Thank you for choosing to purchase this RAZORCUT Plasma Cutting Machine.

We are proud of our range of welding & cutting equipment that has a proven track record of innovation, per-

formance and reliability. Our product range represents the latest developments in inverter technology put

together by our professional team of highly skilled engineers. The expertise gained from our long involve-

ment with inverter technology has proven to be invaluable towards the evolution and future development of

our equipment range. This experience gives us the inside knowledge on what the arc characteristics, perfor-

mance and interface between man and machine should be. Within our team are specialist welders that have

a proven history of welding knowledge and expertise, giving vital input towards ensuring that our machines

deliver control and performance to the utmost professional level. We employ an expert team of professional

sales, marketing and technical personnel that provide us with market trends, market feedback and customer

comments and requirements. Secondly they provide a customer support service that is second to none,

thus ensuring our customers have condence that they will be well satised both now and in the future.

RAZORCUT Plasma Cutters are manufactured and compliant with - CAN/CSAE60974-1 &

ANSI/IEC 60974-1, AS/NZ60974-1 guaranteeing you electrical safety and performance.

• Air quality

Good air quality is essential to quality plasma cutting and consumable life span.

Compressors take in air at atmospheric pressure and increase the pressure and store it in a tank. Humidity in

the air is condensed in the tank and in the airlines producing water, more so in humid environments. Moisture

that forms in air lines has a tendency to condense into larger drops when the air pressure decreases as it is

entering the plasma torch. When these droplets enter into the high temperatures (as much as 11,000°C) in the

plenum of the torch, they immediately break down into oxygen and hydrogen, which alters the normal chemi-

cal content of air in the torch. These elements will then dramatically change the plasma arc which causes the

torch consumable parts to wear very quickly, alters the shape of the nozzle ori ce, dramatically a󰀨ecting cut

quality in terms of edge squareness, dross formation, and edge smoothness. Minimising the moisture in the

air supply is absolutely critical to quality plasma cuts and longevity of consumable parts. As a minimum be

sure to drain the receiver (tank) on the air compressor at least daily.

Most air plasma systems from reputable manufacturers have an on board particulate  lter and or a coalesc-

ing  lter with an auto drain that will remove some moisture from the air supply. For home workshop and light

industrial users the on board air lter is adequate. Most situations however will require additional ltration to

prevent moisture from a󰀨ecting the quality of the plasma cutter and in most cases it is recommended to install

a sub micronic particulate lter that is designed to trap water through absorption.

This style of  lter has a replaceable  lter cartridge that absorbs water and must be changed after it is near

saturation, it should be installed close as possible to the air intake of the plasma cutter.

ATTENTION! - CHECK FOR CLEAN DRY AIR

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CONTENTS PAGE

Warranty 2

Safety - Cautions 4-6

Air Plasma Cutting Technology 7

Technical Data, Product Information 8

Machine Layout & Descriptions 9

Set Up and Operating Procedure 10-11

Plasma Cutting Procedure & Techniques 12-14

SC80 Plasma Torch Parts Breakdown 15

Machine Warranty 16-17

Notes 18-19

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ADDITIONAL 6 MONTHS ON YOUR WARRANTY

Visit XcelArc.nz/warranty-registration to register your machine.

SAFETY IMPORTANT: BEFORE INSTALLING, OPERATING OR CARRYING OUT

MAINTENANCE ON THE PLASMA CUTTER, READ THE CONTENTS OF THIS

MANUAL CAREFULLY, WHICH MUST BE STORED IN A PLACE FAMILIAR TO ALL

USERS FOR THE ENTIRE OPERATIVE LIFE-SPAN OF THE MACHINE.

PAY PARTICULAR ATTENTION TO THE SAFETY RULES.

THIS EQUIPMENT MUST BE USED SOLELY FOR PLASMA CUTTING.

Electric shock: It can kill. Touching live electrical parts can cause fatal shocks or severe

burns. The plasma nozzle and work circuit is electrically live whenever the output is on.

The input power circuit and internal machine circuits are also live when power is on.

Do not touch live electrical parts or electrodes with bare skin, gloves or wet clothing.

Incorrectly installed or improperly grounded equipment is dangerous.

• Connect the primary input cable according to Australian and New Zealand standards and regulations.

• Disconnect power source before performing any service or repairs.

• Avoid all contact with live electrical parts of the welding circuit, torch nozzle and work piece with bare

hands. The operator must wear dry welding gloves while he/she performs the plasma cutting task.

• Isolate yourselves from both the earth and the work piece.

• Keep cords dry, free of oil and grease, and protected from hot metal and sparks.

• Frequently inspect input power cable for wear and tear, replace the cable immediately if damaged,

bare wiring is dangerous and can kill.

• Do not use damaged, under sized, or badly joined cables.

• Do not drape cables over your body.

• We recommend (RCD) safety switch is used with this equipment to detect any leakage of current to earth.

Fumes and gases are dangerous. Plasma cutting produces fumes and gases. Harmful

fumes and metallic powders are produced during the cutting operation. Metals which are

painted or coated or which contain mercury, zinc, lead and graphite may produce harmful

concentrations of toxic fumes during cutting. Breathing these fumes and gases can be haz-

ardous to your health.

• Do not breathe the smoke and gas generated whilst welding or cutting, keep your head out of the fumes

• Keep the working area well ventilated, use fume extraction or ventilation to remove fumes and gases.

• In conned or heavy fume environments always wear an approved air-supplied respirator.

Cutting fumes and gases can displace air and lower the oxygen level causing injury or death.

Be sure the breathing air is safe.

• Do not cut in locations near de-greasing, cleaning, or spraying operations. The heat and rays of the arc

can react with vapours to form highly toxic and irritating gases.

• Materials such as galvanized, lead, or cadmium plated steel, containing elements that can give o󰀨 toxic

fumes when cuttung. Do not cut these materials unless the area is very well ventilated, and or wearing

an air supplied respirator.

• Always read the Material Safety Data Sheets (MSDS) that should be supplied with the material you are

using.These MSDSs will give you the information regarding the kind and amount of fumes and gases that

may be dangerous to your health.

Arc rays: harmful to people’s eyes and skin. Arc rays from the plasma cutting process

produce intense visible and invisible ultraviolet and infrared rays that can burn eyes and

skin. Protect your eyes with welding masks or goggles tted with ltered lenses, and protect

your body with appropriate safety garments. Protect others by installing adequate shields or

curtains.

• Always wear a helmet or goggles with correct shade of lter lens and suitable protective clothing including

welding gloves, appron, leg and foot protection whilst the plasma cutting operation is performed.

• Measures should be taken to protect people in or near the surrounding working area. Use protective

screens or barriers to protect others from ash,glare and sparks; warn others not to watch the arc.

MACHINE OPERATING SAFETY

Plasma cutting equipment can be dangerous to both the operator and people in or near the surrounding

working area, if the equipment is not correctly operated. Equipment must only be used under the strict and

comprehensive observance of all relevant safety regulations. Read and understand this instruction manual

carefully before the installation and operation of this equipment.

Fire hazard. Plasma cutting on closed containers, such as tanks,drums, or pipes, can cause

them to explode. Flying sparks from the welding arc, hot work piece, and hot equipment can

cause res and burns. Accidental contact of electrode to metal objects can cause sparks, ex-

plosion, overheating, or re. Check and be sure the area is safe before doing any cutting.

• The cutting sparks may cause re, therefore remove any ammable materials well away from the working

area. Cover ammable materials and containers with approved covers if unable to be moved from the

welding area.

• Do not Plasma Cut closed containers such as tanks, drums, or pipes, unless they areproperly prepared

according to the required Safety Standards to insure that ammable or toxic vapors and substances are

totally removed, these can cause an explosion even though the vessel has been “cleaned”. Vent hollow

castings or containers before heating, cutting or welding. They may explode.

• Do not cut where the atmosphere may contain ammable dust, gas, or liquid vapours (such as petrol)

• Have a re extinguisher nearby and know how to use it. Be alert that cutting sparks and hot materials

from cutting can easily go through small cracks and openings to adjacent areas. Be aware that cutting

on a ceiling, oor, bulkhead, or partition can cause re on the hidden side.

Gas Cylinders. Do not cut in the vicinity of pressurised gas cylinders or in the presence of

explosive dust, gases or fumes. Gas cylinders contain gas under high pressure. If damaged,

a cylinder can explode. Because gas cylinders are normally part of the welding process, be

sure to treat them carefully. CYLINDERS can explode if damaged.

• Protect gas cylinders from excessive heat, mechanical shocks, physical damage, slag, open ames,

sparks, and arcs.

• Insure cylinders are held secure and upright to prevent tipping or falling over.

• Never allow the plasma nozzle or earth clamp to touch the gas cylinder, do not drape welding cables

over the cylinder.

• Never plasma cut on a pressurised gas cylinder, it will explode and kill you.

• Open the cylinder valve slowly and turn your face away from the cylinder outlet valve and gas regulator.

Electronic magnetic elds. The magnetic elds created by the high currents generated by

plasma cutting may a󰀨ect the operation of pacemakers and other vital electronic medical

equipment.

•Wearers of Pacemakers and other Implanted Medical Devices should keep away.

•Implanted Medical Device wearers should consult their doctor and the device manufacturer before going

near any electric welding, cutting or heating operation.

Noise can damage hearing. Noise from some processes or equipment can damage hearing.

This machine does not directly produce noise exceeding 80dB. The plasma cutting/welding

procedure may produce noise levels beyond said limit; users must therefore implement all

precautions required by law. Wear approved ear protection if noise level is high.

Hot parts. Items being plasma cut generate and hold high heat and can cause severe burns.

Do not touch hot parts with bare hands. Allow a cooling period before working on the plasma

torch. Use insulated welding gloves and clothing to handle hot parts and prevent burns.

CAUTION

1. Working Environment.

1.1 The environment in which this Plasma Cutter equipment is installed must be free of grinding dust,

corrosive chemicals, ammable gas or materials etc, and at no more than maximum of 80% humidity.

1.2 When using the machine outdoors protect the machine from direct sun light, rain water and snow etc;

the temperature of working environment should be maintained within -10°C to +40°C.

1.3 Keep this equipment 30cm distant from the wall.

1.4 Ensure the working environment is well ventilated.

2. Safety Tips.

2.1 Ventilation

This equipment is small-sized, compact in structure, and of excellent performance in amperage output.

The fan is used to dissipate heat generated by this equipment during the welding operation.

Important: Maintain good ventilation of the louvers of this equipment. The minimum distance between

this equipment and any other objects in or near the working area should be 30 cm. Good ventilation is

of critical importance for the normal performance and service life of this equipment.

2.2 Thermal Overload protection.

Should the machine be used to an excessive level, or in high temperature environment, poorly

ventilated area or if the fan malfunctions the Thermal Overload Switch will be activated and the

machine will cease to operate. Under this circumstance, leave the machine switched on to keep the

built-in fan working to bring down the temperature inside the equipment. The machine will be ready for

use again when the internal temperature reaches safe level.

2.3 Over-Voltage Supply

Regarding the power supply voltage range of the machine, please refer to “Main parameter” table.

This equipment is of automatic voltage compensation, which enables the maintaining of the voltage

range within the given range. In case that the voltage of input power supply amperage exceeds the

stipulated value, it is possible to cause damage to the components of this equipment. Please ensure

your primary power supply is correct.

2.4 Do not come into contact with the output terminals while the machine is in operation. An electric shock

may possibly occur.

MAINTENANCE

Exposure to extremely dusty, damp, or corrosive air is damaging to this plasma cutter. In order to prevent

any possible failure or fault of this welding equipment, clean the dust at regular intervals with clean and dry

compressed air of required pressure.

Please note that: lack of maintenance can result in the cancellation of the warranty; the warranty of this

plasma cuting equipment will be void if the machine has been modied, an attempt to take apart the

machine or open the factory-made sealing of the machine without the consent of an authorized

representative of the manufacturer.

TROUBLE SHOOTING

Caution: Only qualied technicians are authorized to undertake the repair of this Plasma cutter equipment.

For your safety and to avoid Electrical Shock, please observe all safety notes and precautions

detailed in this manual.

Note:

• Our equipment as described in this manual conforms to all applicable rules and regulations of the

‘LowVoltage Directive’ (European Council Directive 73/23/EEC) as set out and amended by Council

Directive 93/68/EEC) and to the National legislation for the enforcement of this Directive.

• Our equipment as described in this manual conforms to all applicable rules and regulations of the

European Council Directive 89/336/EEC, (EMC Directive) and to the National legislation for he

enforcement of this Directive.

Plasma cutters work by passing an electric arc through a gas that is passing through a constricted opening. The gas

can be air, nitrogen, argon, oxygen. etc. The electric arc elevates the temperature of the gas to the point that it enters a

4th state of matter. We all are familiar with the rst three: i.e., Solid, liquid, and gas. Scientists call this additional state

plasma. As the metal being cut is part of the circuit, the electrical conductivity of the plasma causes the arc to transfer to

the work. The restricted opening (nozzle) the gas passes through causes it to squeeze by at a high speed, like air passing

through a venturi in a carburettor. This high speed gas cuts through the molten metal.

Plasma cutting was invented as the result of trying to develop a better welding process. Many improvements then led to

making this technology what it is today. Plasma cutters provide the best combination of accuracy, speed, and a󰀨ord ability

for producing a variety of at metal shapes. They can cut much ner, and faster than oxy-acetylene torches.

How a plasma cutter works:

Basic plasma cutters use electricity to superheat air into plasma (the 4th state of matter), which is then blown through the

metal to be cut. Plasma cutters require a compressed air supply and AC power to operate.

Operation:

1. When the trigger is squeezed, DC current ows through the torch lead into the nozzle.

2. Next, compressed air ows through the torch head, through the air di󰀨user that spirals the air ow around the

electrode and through the hole of the cutting nozzle.

3. A xed gap is established between the electrode and the nozzle. (The power supply increases voltage in order to

maintain a constant current through the joint.) Electrons arc across the gap, ionizing and super heating the air

creating a plasma stream.

4. Finally, the regulated DC current is switched so that it no longer ows to the nozzle but instead ows from the

electrode to the work piece. Current and airow continue until cutting is stopped.

Notes:

The nozzle and electrode require periodic replacement. The electrode has an insert of tough high conductive material

such as hafnium and cerium. This insert erodes with use, also the nozzle orice will erode with use. Quality of the air

used is paramount to longer life of electrodes and nozzles, in short clean dry air gives longer parts life, the cleaner and

dryer the better. We recommend use of a Plasma Air Filter.

What kinds of materials can the plasma cut?

Virtually any metal can be plasma cut including steel, stainless steel, aluminium, brass, copper, etc. Any thickness from

30 gauge through 30mm can be cut, depending on the power of the plasma cutter used.

How Does Plasma Cutting Compare to Oxy-fuel (gas) cutting?

Plasma cutting can be performed on any type of conductive metal - mild steel, aluminium and stainless are some

examples. With mild steel, operators will experience faster, thicker cuts than with alloys. Oxy-fuel cuts by burning, or

oxidizing the metal it is severing. It is therefore limited to steel and other ferrous metals which support the oxidizing

process. Metals like aluminium and stainless steel form an oxide that inhibits further oxidization, making conventional

oxy-fuel cutting impossible. Plasma cutting however does not rely on oxidation to work and thus it can cut aluminium,

stainless and any other conductive material. While di󰀨erent gasses can be used for plasma cutting, most people today

use compressed air for the plasma gas. In most shops, compressed air is readily available, and thus plasma does not

require fuel gas and compressed oxygen for operation. Plasma cutting is typically easier for the novice to master, and on

thinner materials, plasma cutting is much faster than oxy-fuel cutting. However, for heavy sections of steel (25mm and

greater), oxy-fuel is still preferred since oxy-fuel is typically faster and, for heavier plate applications high powered plasma

machines are required for plasma cutting applications.

What are the limitations to Plasma Cutting? Where is Oxyfuel preferred?

The plasma cutting machines are typically more expensive than oxy/acetylene. Also, oxy/acetylene does not require

access to electrical power or compressed air which may make it a more convenient method for some users. Oxyfuel can

generally cut thicker sections (>25mm) of steel more quickly than plasma

Electrode

Air Diffuser

Nozzle

Plasma Stream

Electrode Insert

Shield Cup

AIR PLASMA CUTTING TECHNOLOGY

Razor

RAZOR CUT80 PLASMA

80 Amp Inverter Plasma Cutter

Cuts: Steels, Stainless, Cast Iron, Brass, Copper.Aluminium

Product Code: XA-CUT80RZ-K

Standard Package includes: RAZOR CUT80 Machine, SC80 Plasma Torch 6m, Earth Lead & Spares Kit

Overview

The RAZOR CUT80 is a high quality industrial-rated three phase inverter Plasma Cutting machine produced using the latest in IGBT in-

verter technology and incorporating advanced MCU intelligent software technology. The machine automatically monitors and controls all

critical functions and compensates for possible inconsistencies caused by wear in torch components, environmental temperature or humid-

ity. The resulting cutting performance is greatly improved compared to traditional plasma cutting machines. The RAZOR CUT80 is reliable,

robust and stacked with features that you can expect from a high quality plasma cutter including full CNC connection. The RAZOR CUT80

is equipped with a high quality Suregrip SC80 Plasma Torch with Euro Style connection and 6mtr cable. The SC80 Plasma Torch provides

e󰀨ortless starting of the cut with powerful, fast and accurate stand-o󰀨 cutting with drag cutting capability. The SC80 Plasma Torch uses

low-cost wear consumables with the additional benet of longer life cycle of both Electrodes and Cutting Tips. The RAZOR CUT80 is an

exceptional machine that is well suited to a wide range of applications including industrial and general engineering, forestry and agriculture,

site work, heavy transport and marine repair, general demolition and maintenance work. The RAZOR CUT80 provides great portability, with

stacks of cutting power to get the job done with outstanding speed and a great nish.

Built to our specication and manufactured in compliance to AS/NZ60974-1

Features

■Latest IGBT Inverter Technology

■Heavy Industrial application

■CNC-Ready

■Outstanding performance from three-phase

■ HF Arc Ignition (non-contact)

■ Stand-o󰀨 cutting with drag cut capability

■Maximum sever cutting thickness (steel) 35mm

■High quality Surecut SC80 Plasma Torch 6mtr

■Euro Style torch connection, low-cost consumables

■ Auto protection for over Voltage & over current

■Auto protection for low air & thermal overload

■Integral pre-set air regulator, self-drain type

■Suitable to cut all electrically conductive materials

■Lightweight & compact design

■Strong metal housing with plastic front & rear panels

■Tolerant to variable power supply

80Amp 415V Inverter Plasma Cutter

Industrial Rated with CNC Compatibility

30mm Cut on Mild Steel

RAZOR CUT80RAZOR CUT80

Optional machine accessories available - refer www.xcelarc.nz

XA-CUT80RZ

Standard Package

Technical Data

Power Supply / Phases (V-Ph) 415V - 3 +/- 10%

Rated Input Power 15.0 kVA

e as per AS/NZ60974-1 12.6 Amps

IMax 20.0 Amps

Plasma Cut Current Range 20-80Amps

Duty Cycle @ 40°C as per AS/NZ60974-1 40% @ 80Amps

Duty Cycle @ 25°C (approximate) 80% @ 80Amps

No Load Voltage 310V

Plasma Arc Start Pilot Arc

Air Flow Draw O󰀨 6.7 cfm

Air Pressure 75 psi

Steel Cut Thickness 30mm

Steel Sever Thickness 35mm

Aluminium Cut Thickness 16mm

Aluminium Sever Thickness 20mm

Stainless Cut Thickness 16mm

Stainless Sever Thickness 20mm

Insulation Class F

Protection Class IP21S

Dimensions (LxWxH) 560x220x415mm

Weight Power Source 16.0kg

Certication Approval AS/NZ60974-1

Front & Rear Panel Layout

Front Panel Layout Rear Panel Layout

Power indicator It illuminates when the machine is powered on,

and it glitters after arc is successfully ignited.

Overheating indicator It illuminates when the working temperature

of the machine is overly high. Meanwhile, the machine stops working.

Digital Amperage metre

2T indicator It illuminates when the machine is under 2T status.

Air Pressure Gauge

Amperage Control Dial.

Output connector (DC+) connect to the work piece.

Torch connection (DC-).

Primary power input cable.

On/Off switch.

Air supply connector

4T indicator: It illuminates when the machine is under 4T status.

Gas-check indicator It illuminates when the machine is under

gas-check status. At this moment, the machine cannot cut.

Normal cutting mode, the machine can cut when this

indicator illuminates.

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(1) Connect the SC80 Plasma Torch to the machine. Insert the torch connection into the torch connection

receptacle at the front of the machine and screw up hand tight.

Caution: Be careful not to bend the pins located inside the torch connector.

(2) Connect the earth lead to the output terminal of the machine and tighten.

(3) Connect the air supply to the air connection located at the rear of the machine.

Turn on the air supply

(4) Connect the machine to the correct power supply and switch on the machine using the on/o󰀨 switch

located at the rear of the machine.

(5) Select 2T / 4T operation

Operating procedure using the 2T / 4T Function with SC80 torch.

Set torch operation 2T / 4T.

• When 2T operation is selected press triggerArc starts, release trigger Arc stops.

• When 4T operation is selected press and release triggerArc starts,

press and release trigger Arc stops.

(6) Set amperage dial.

Set Up Procedure for PLASMA Cutting

2. Connect the earth lead to the output

terminal of the machine and tighten.

(1) Connect the SC80 Plasma Torch to the

machine. Insert the torch connection into the

torch connection receptacle at the front of the

machine and screw up hand tight.

Caution: Do not to bend the pins located inside the

torch connector.

(4) Connect the machine to the

correct power supply and switch

on the machine using the on/o󰀨

switch located at the rear of the

machine.

(3) Connect the air supply to the

air connection located at the rear

of the machine. Turn on the air

supply.

(5) select 2T or 4T torch control (6) Set the amperage dial

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Operating Procedure for PLASMA Cutting

5) Correct amperage and travel speed

are important and relevant to material

thickness and are correct when sparks

are exiting from the work piece.

If sparks are spraying up from the work

piece there is insu󰀩cient amps selected

or the travel speed is too fast.

6) To nish the cutting release the torch

switch. The air ow will continue for 30

seconds to cool the torch head.

2) Connect the Earth Clamp securely to

the work piece or the work bench. 3) Place and hold the torch vertical at the

edge of the plate

4) Pull the trigger to energise the pilot

arc. The cutting arc will start when the

nozzle is moved closer to the edge of

the work piece. When the cutting arc has

cut through the edge of the plate start

moving evenly in the direction you wish

to cut,

1) Wear your safety gear. Generally you want the

same type of protective gear as when welding.

Plasma has high arc voltage if the job or bench is

wet and you place your hand or arm on it you can

become part of the circuit and receive a shock, be

sure you are wearing leather gloves, Full length

pants and covered shoes, Wear eye protection a

#5 shade is the minimum eye protection with other

shades required depending on amperage. A face

shield is also recommended,

Operating procedure using the Stand O󰀨 Guide mounted to SC80 torch.

The feet of the stando󰀨 guide are placed on the cutting surface. This maintains an

optimal 2mm stando󰀨 distance between the plasma cutting tip and the work, this is

especially suitable if your hands are unsteady, or if you wish to use a straight edge

guide or pattern guide. It also helps extend tip life.

Cut Quality

A clean cut depends on several factors:

● amperage

● travel speed

● tip height & position

● tip and electrode quality

● air pressure and quality

● technique

The best quality cut will be produced when all these variables are set correctly for the material thickness

and type of material being cut.

Poor quality cut

Good quality cut

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Operating Procedure & Techniques

for PLASMA Cutting

● Amperage

Standard rule of thumb is the thicker the material the more amperage required.

On thick material, set the machine to full output and vary your travel speed. On thinner material, you need to turn down the

amperage and change to a lower-amperage tip to maintain a narrow kerf. The kerf is the width of the cut material that is removed

during cutting.

● Speed

Amperage and speed are critical to producing a good quality cut. The faster you move (especially on aluminium), the cleaner your

cut will be. To determine if you're going too fast or too slow, visually follow the arc that is coming from the bottom of the cut.

The arc should exit the material at a slight angle away from the direction of travel. If it's going straight down, that means you're

going too slow, and you'll have an unnecessary buildup of dross or slag. If you go too fast, it will start spraying back onto the

surface of the material without cutting all the way through. Because the arc trails at an angle, at the end of a cut, slow your cutting

speed and angle the torch in to cut through the last bit of metal.

● Direction

It is easier to pull the torch towards you than push it. The plasma stream swirls as it exits the tip, biting one side and nishing o󰀨

on the other leaving a bevelled edge and a straight edge. The bevel cut e󰀨ect is more noticeable on thicker material and needs to

taken into consideration before starting your cut as you want the straight side of the cut to be on the nished piece you keep.

● Torch tip height & position

The distance and postion of the plasma torch cutting tip has an a󰀨ect on the quality of the cut and the extent of the bevel of the cut.

The easiest way to reduce bevel is by cutting at the proper speed and height for the material and amperage that is being cut.

Correct torch height and

square to the material.

Minimum bevel & equal bevel

Longest consumable life

Torch angled to the material.

Unequal bevel, one side may

be excessively beveled.

Torch height too high.

Excessive bevel, plasma

stream may not cut all the

way through the material

Torch height too low.

Reverse bevel. Tip may

contact the work and short

out or damage the tip.

● Tip size and condition

The tip orices focus the plasma stream to the work piece. It is important to use the correct size tip for the amperage being used,

for example a tip with a 1.0mm orice is good for 0-40 amps whereas a 1.3mm orice is better for 40-80 amps. The low-amp tip has

a smaller orice which maintains a narrow plasma stream at lower settings for use on thin-gauge material. Using a 25 amp tip at an

60 amp setting will blow out and distort the tip orice and require replacement. Conversely, using an 80-amp tip on the lower

settings will not allow you to focus the plasma stream as well and creates a wide kerf. The condition of the tip orice is critical to

the quality of the cut result, a worn or damaged tip orice will produce a distorted plasma stream resulting in a poor cut quality.

● Electrode condition

A xed gap is established between the electrode and the inside of the cutting tip. Electrons arc across the gap, ionizing and super

heating the air creating the plasma stream. The electrode contains an insert in the end made of a highly conductive material called

hafnium. This insert erodes with use and develops a pit in the end of the electrode, when the pit becomes too much poor quality

cuts will result and necessitate replacement of the electrode.

New Tip Worn Tip

New Electrode Worn electrode

Razor

RAZOR CUT8O

Operating Procedure & Techniques

for PLASMA Cutting

● Air pressure and volume

Air pressure, ow rate and air quality are critical to quality plasma cutting and consumable life span.

The required air pressure and volume can vary from model to model and the manufacturer will provide the specs.

The volume capacity of your compressor is important, if you have a small compressor with exactly the same l/min rating as the

plasma, then the compressor will run continuously when you are plasma cutting, a compressor with a l/min rating slightly higher

than the plasma would be more adequate. If you are doing a lot of cutting, cutting thick plate (same air consumption but slower cut

speeds = longer cut time) then choose a compressor at 1.5 to 2 times the plasma system requirement.

● Air quality

Good air quality is essential to quality plasma cutting and consumable life span.

Compressors take in air at atmospheric pressure and increase the pressure and store it in a tank. Humidity in the air is condensed

in the tank and in the airlines producing water, more so in humid environments. Moisture that forms in air lines has a tendency

to condense into larger drops when the air pressure decreases as it is entering the plasma torch. When these droplets enter into

the high temperatures (as much as 11,000°C) in the plenum of the torch, they immediately break down into oxygen and hydrogen,

which alters the normal chemical content of air in the torch. These elements will then dramatically change the plasma arc which

causes the torch consumable parts to wear very quickly, alters the shape of the nozzle orice, dramatically a󰀨ecting cut quality in

terms of edge squareness, dross formation, and edge smoothness. Minimising the moisture in the air supply is absolutely critical to

quality plasma cuts and longevity of consumable parts. As a minimum be sure to drain the receiver (tank) on the air compressor at

least daily.

Most air plasma systems from reputable manufacturers have an on board particulate lter and or a coalescing lter with an auto

drain that will remove some moisture from the air supply. For home workshop and light industrial users the on board air lter is

adequate. Most situations however will require additional ltration to prevent moisture from a󰀨ecting the quality of the plasma cutter

and in most cases it is recommended to install a sub micronic particulate lter that is designed to trap water through absorption.

This style of lter has a replaceable lter cartridge that absorbs water and must be changed after it is near saturation, it should be

installed close as possible to the air intake of the plasma cutter.

● Technique Tips

• It is easier to pull the torch through the cut than to push it.

• To cut thin material reduce the amperage until you get the best quality cut.

• Use the correct size tip orice for the amperage being used.

• For Straight cuts use a straight edge or cutting buggy as a guide. For circles, use a template or circle cutting attachment.

• Check that the front end consumable parts of the plasma cutting torch are in good condition.

Sub Micronic Filter Filter Element

● Starting a cut

Hold the torch vertical at the edge of the

work piece and place the stand o󰀨 guide on

the workpeice.

Pull the trigger to start the arc.

Start cutting on the edge until the arc has

cut completely through.

Then, proceed with the cut.

Razor

RAZOR CUT8O

● Piercing

Hold the torch at an angle to the work piece,

pull the trigger to start the arc and slowly

rotate it to an upright position.

When sparks are exiting from the bottom of

the work piece, the arc has pierced through

the material.

When the pierce is complete, proceed with

cutting.

● Safety Trigger Operation

The Suregrip SC80 torch supplied with the RazorCut 45 machine has a new design of safety trigger.

Just pull back on the trigger whilst increasing your grip and you will feel the trigger move to the on position.

When you release the pressure it will return to the o󰀨 position.

o󰀨 on o󰀨

Operating Procedure & Techniques

for PLASMA Cutting

Razor

RAZOR CUT8O

SC80SC80 Plasma Torch & SparesPlasma Torch & Spares

PLASMA CUTTING TORCHES

Air Cooled 80 Amp

Razor

RAZOR CUT8O

Spare Parts

# Part Number Description

SC80-60-CC1 Surecut 80 Plasma Torch x 6m

SCM80R-60-CC1 Surecut 80 Machine Torch x 6m

1 SC8001 SC80 70 Torch Head Kit

2 SC8014 Plasma Handle Kit

3 SCSP1 Screw Pack

4 SC2516 Plasma Safety Trigger

5 SC8015 Location Block

6 SC8019-60-CF4 Cable Assembly Complete x 6mt

7 SC8050 Circle Cutting Attachment Kit

8 SC8002 Cooling Tube

9 SC8004 Electrode

10 SC8006 Swirl Ring

11 SC8020-10 Cutting Tip 1.0mm

Spare Parts

# Part Number Description

SC8020-13 Cutting Tip 1.3mm

11a SC8022-09 Cutting Tip 0.9mm Cross Groove

12 SC8026-10 Contact Cutting Tip 1.0 mm, 40-50A

SC8026-11 Contact Cutting Tip 1.1 mm, 50-60A

SC8026-12 Contact Cutting Tip 1.2 mm, 60-70A

SC8026-13 Contact Cutting Tip 1.3 mm, 70-80A

13 SC8028-16 SC80 Gouging Tip 1.6mm

14 SC8030 Retaining Cap

15 SC8031 Shield Cap Body

16 SC8051 SC80 Cutting Buggy

17 SC8040 SC80 Stand Off Guide

18 SC8041 Contact Cutting Shield Cap

19 SC8043 Gouging Shield Cap

Technical Data

Max Current 80A Gas Pressure 4.5-5.0 Bar (65-75psi)

Duty Cycle 60% Gas Flow 110 l/min

Gas Air/N with Pilot Arc

Rating: 80A Air/N2 Gas, @ 60% duty cycle.

For use on RAZOR CUT 40, CUT45 & CUT80

SurecutSC80SurecutSC80

Contact cuttingGouging Stand off cutting

13 12

19 18

11a

ESSETI (NZ) LIMITED WARRANTY & RETURNS POLICY

We understand that sometimes you may need to return a product that you have purchased from our Esseti NZ Ltd.

Authorised Distributor Network. To assist you, we have set out below the Esseti NZ Ltd Warranty Returns Policy that you should know about. These terms and condi-

tions supersede and exclude all former and other representations and arrangements relating to any warranties on these products, irrespective of whether expressed

or implied.

ESSETI New Zealand Limited (‘us’, ‘we’) warrants that the products bearing the brand names ESSETI, XCEL-ARC, RAZORWELD, RAZORCUT, JASIC, VIPER, T&R,

XCEL-GAS, Otos, Servore, TECNA& HIT-8SS supplied by us and purchased by you from anAuthorised ESSETI (NZ) Ltd. Distributor are free of Material and Faulty

Workmanship Defects except for those products listed under ‘Warranty Exclusions’and whilst any claim is made subject to the following terms and conditions.

Your rights under the New Zealand Consumer Law may not be limited by a dened time. However, New Zealand Consumer Law does recognise that the relevant time

period can vary from product to product, depending on factors such as the nature of the product and the price. Esseti NZ Ltd. adopts the same approach.As you can

appreciate, the type of remedy we can offer you may also vary depending on how long it takes you to return the product to us.

WARRANTY PERIOD

We offer the following ‘Warranty Periods’effective from the ‘date of purchase’:

- XCEL-ARC, Inverter MIG/SWF/MTS, MMA/TIG, TIGACDC, Plasma (Power Source Only*) 2 Years

- RAZORWELD, Inverter MIG/SWF/MTS, MMA/TIG,TIGACDC (Power Source Only*) 3 Years

- RAZORCUT, Inverter Plasma (Power Source Only*) 2 Years

- JASIC, Inverter MIG/SWF/MTS, MMA/TIG, TIGACDC, Plasma (Power Source Only*) 2 Years

- XCEL-ARC & RAZORWELD, Water Coolers, PAPR Air Blower Unit 1 Year

- XCEL-GAS, Gas Cutting and Welding Torches 3 Months

- XCEL-GAS, Straight Line & Gas Cutting Machines (Power Source Only*) 1 Year

- XCEL-GAS, RegulatorsArgon/Acetylene / Oxygen / LPG / Bobbin Flowmeter 1 Year

- XCEL-ARC,Automatic Welding Helmet 2 Years

- RAZORWELD,Automatic Welding Helmets / Goggles 1 Year

- SERVORE,Automatic Welding Helmets / Goggles 1 Year

- OTOS,Automatic Welding Helmets 2 Years

- TECNA, Spot Welding Machines (Power Source Only*) 1 Year

- HIT-8SS, Automatic Carriage (Power Source Only*) 1 Year

- ALLWELDING TORCHES – GMAW / GTAW / MMAW / PLASMA 3 Months

- ALLEARTH LEADS, INTERCONNECTING CABLES, GAS HOSES 3 Months

(*)This only covers manufacturing faults on any torches, cables and other accessories, either included with a machine kitset or sold separately, for the rst three months

after date of purchase.

WARRANTY / RETURNS / EXCHANGES

Our Warranty Returns Policy recognises all and any rights you have under New Zealand Consumer Law and other relevant laws.

Youshallinspect thegoodsondelivery andshallwithinseven (7)daysofdelivery (timebeingofthe essence)notifytheEssetiNZLtd.AuthorisedDistributorfromwhom

you purchased the goods of any alleged defect, shortage in quantity, damage or failure to comply with the description or quote.

You shall also afford Esseti NZ Ltd. the opportunity to inspect the goods within a reasonable time following delivery if you believe the goods are defective in any way.

If you shall fail to comply with these provisions the goods shall be presumed to be free from any defect or damage.

For defective goods and where permissible by law, Esseti NZ Ltd. reserves the right to repair or otherwise remedy the defect prior to issuing replacement goods or

refunding the purchase price.

If the goods are being purchased for a business purpose then the purchaser acknowledges that the Consumer GuaranteesAct will not apply.

The New Zealand Sales of GoodsAct applies when goods are not covered by the Consumer GuaranteesAct. You may be able to get a full refund or compensation if

the trader doesn’t have the right to sell the goods, or the goods are:

- not of ‘merchantable quality’ (so defective that most people wouldn’t want them)

- not t for their normal purpose

- poorer quality than a sample you were shown

- not suitable for what you told the trader you wanted the goods for

- not matching their description

Ifthere has been a misrepresentation you may haverightsunder the Fair TradingActor the Contractual RemediesActand therefore also entitled to,attheconsumer’s

discretion, either a refund of the purchase price of the goods, or repair of the goods, or replacement of the goods.

Returns will only be accepted provided that:

(a) You have complied with the provisions outlined above, and

(b) where the goods are unable to be repaired, the goods are returned at your cost within thirty (30) days of the delivery date, and

(d) the goods are returned in the condition in which they were delivered and with all packaging material, brochures and instructional material in as new condition as

is reasonably possible in the circumstances.

EssetiNZLtd.Acceptsnoresponsibilityforanyproductslost,damagedormislaidwhilstintransit.EssetiNZLtd.may(attheirsolediscretion)acceptthereturnofgoods

for credit but this may incur a handling fee of up to fteen percent (15%) of the value of the returned Goods plus any freight costs.

MAKINGA CLAIM

If you wish to make a claim under this Warranty, you should:

• Return the product to the point of purchase either in person or via prepaid courier; or

• Contact us by Telephone - Esseti NZ Ltd, 06 355 1103

When returned, the product must be accompanied with the original Receipt or Tax Invoice clearly showing the purchase date and disclosing the purchase price.

All costs of installation, cartage, freight, travelling expenses, hiring tools and insurance are paid by the Customer. To the extent permitted by law, our total liability for

loss or damage of every kind related to the goods in any way whatsoever is limited to the amount paid to the retailer by you for the goods or the value of the goods. No

responsibility will be taken for any products lost, damaged or mislaid whilst in transit.

WARRANTY EXCLUSIONS

This Warranty covers Material and Faulty Workmanship defects only. This Warranty does not cover damage caused by:

• Normal wear and tear due to usage

•Misuse or abusive use of the machine and/or failure to correctly follow set up or operating instructions supplied with these products

•Failure to clean or improper cleaning of the product

•Failure to maintain the equipment such as regular services, etc.

•Incorrect voltage or non-authorised electrical connections

•Improper installation

•Use of non-authorised/non-standard parts

•Abnormal product performance caused by any ancillary equipment interference or other external factors

•Failure or any breakage caused by overload, dropping or abusive treatment or use by the customer

• Repair, modications or other work carried out on the product other than by an Esseti-Authorised Service Agent

Unless it is a manufacturing fault, this Warranty does not cover the following parts:

•All Batteries, including Button Type and Cell Type Batteries

•MIG Welding Torch Consumables, such as:

Gas Nozzles, Gas Diffusers, Contact Tip Holders, Contact Tips, Swan Necks, Triggers, Handles, Liners, Euro Block, Shroud Springs, Knobs,

All XCEL-ARC / Magmaweld Mig Welding Wires & Electrodes,Arc Leads, Welding Cable, Electrode Holder, Earth Clamps

•MMA& TIG Welding Torch Consumables, such as:

Tungsten Electrodes, Collet, Collet Body, Alumina Nozzle, Torch Head, Torch Head water Cooled, Torch Head Flexible, Back Caps, Gas Lens, Torch Handle,

CupGasket,TorchBodyGasValve,O-ring,AllXCEL-ARC TIGWeldingRods,AllXCEL-ARC/MagmaweldElectrodes,ArcLeads,WeldingCable,ElectrodeHolder,

Earth Clamps

•PLASMACutting Torches Consumables, such as:

All Cutting Tips, All Diffuser/Swirl Ring, All Electrodes, Retaining Caps, Nozzle Springs, All Spacers, All Shield Caps, All Air and Power Cables, All Switches,