Xcel-Arc VIPER Plasma CUT30 User manual

PLASMA CUT3O
YEA
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MACHINE
WARRANTY
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1
Please read and understand this instruction manual carefully
before the installation and operation of this equipment.
© Xcel-Arc 2020
XA-CUT30V | Operating Manual

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WARRANTY
• 1 Year 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 VIPER 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.
VIPER Plasma Cutters are manufactured and compliant with - CAN/CSA E60974-1 &
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
PLASMA CUT30

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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
SC40 Plasma Torch Parts Breakdown 15
Trouble Shooting 16
Machine Warranty 17-18
Notes 19
PLASMA CUT30
REGISTER YOUR MACHINE ONLINE TO RECEIVE AN
ADDITIONAL 6 MONTHS ON YOUR WARRANTY
Visit XcelArc.nz/warranty-registration to register your machine.

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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.

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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.

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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.

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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

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VIPER CUT30 PLASMA
30 Amp Inverter Plasma Cutter
Cuts: Steels, Stainless, Cast Iron, Brass, Copper.Aluminium
VIPER CUT30
Optional machine accessories available - refer www.xcelarc.nz
XA-CUT30V
Standard Package Technical Data
Power Supply / Phases (V-Ph) 230V - 1 +/- 10%
Rated Input Power 7.50 kVA
I
i e as per AS/NZ60974-1 10.0 Amps
IMax 25.0 Amps
Plasma Cut Current Range 20-30 Amps
Duty Cycle @ 40°C as per AS/NZ60974-1 15% @ 30Amps
Duty Cycle @ 25°C (approximate) 35% @ 30Amps
No Load Voltage 310V
Plasma Arc Start Pilot Arc
Air Flow Draw O󰀨 6.7 cfm
Air Pressure 70-87 psi
Steel Cut Thickness 12mm
Steel Sever Thickness 14mm
Aluminium Cut Thickness 6mm
Aluminium Sever Thickness 8mm
Stainless Cut Thickness 6mm
Stainless Sever Thickness 8mm
Insulation Class F
Protection Class IP21S
Dimensions (LxWxH) 460x160x320mm
Weight Power Source 11.6kg
Certication Approval AS/NZ60974-1
Features
■Modern IGBT inverter technology
■Non-commercial application
■Excellent performance from single-phase
■Pilot Arc Ignition (non-contact)
■ Drag-Tip cutting with Stand-O󰀨 capability
■Maximum sever cutting thickness (steel) 12mm
■High quality Surecut CBR150 Plasma Torch 4mtr
■Direct-Connect Plasma Torch, low-cost consumables
■In-built adjustable air regulator
■Suitable to cut all electrically conductive materials
■Lightweight & compact design
■Strong metal housing
■Generator compatible (recommend 7.5KVA minimum)
■Tolerant to variable power supply
Entry Level Inverter Plasma Cutter
30Amp 230V Single Phase
12mm Cut on Mild Steel
Product Code: XA-CUT30V-K
Standard Package includes: VIPER CUT30 Machine, Direct connect SC40 Plasma Torch 4m, Direct Connect 3m Earth Lead
Overview
The VIPER CUT30 from Xcel-Arc is a new generation, low cost single phase Plasma Cutting machine produced using modern IGBT
inverter technology. Designed to meet the needs of the price conscious non-commercial user without compromising on quality, this ma-
chine is as reliable and robust as you would expect a machine bearing the Xcel-Arc name to be. The VIPER CUT30 produces a high tem-
perature plasma stream enabling e󰀩cient cutting of all electrically conductive materials including steel, cast Iron, stainless steel, copper,
aluminium brass etc. The high quality Suregrip SC40 Plasma Torch provides non contact PilotArc Ignition allowing for postive clean starts
everytime. The Direct-Connect SC40 Plasma Torch with 4mtr cable uses low-cost wear consumables with the additional benet of longer
life cycle of both Electrodes and Cutting Tips. The VIPER CUT30 is an exceptional machine for the price and is suitable for a wide range
of applications including light engineering, sheet metal fabrication, site work, automotive panel repair, ducting work and general repair and
maintenance work. The VIPER CUT30 o󰀨ers great portability with the power to get the job done at a great price.
Built to our specication and manufactured in compliance to AS/NZ60974-1

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Front & Rear Panel Layout
Front Panel Layout Rear Panel Layout
2
3
4
1
8
9
6
5
7
PLASMA CUT30
(1) Mains Power LED
(2) Over Current - Thermal Overload LED
a. Abnormal or over current supply - LED ON
b. Overheating of the machine - LED ON
(3) Amperage Control Dial
(4) Torch connection
(5) Output connector, connect to the work piece
(6) On/O󰀨 switch
(7) Primary power input cable
(8) Regulator
(9) Air supply connector inlet connection
(Note: the air regulator must be set to 5-6 Bar and the air compressor you are using must
be able to continually supply this pressure and a ow rate of 170 l/min)
Plasma Cutter Air Filter
AT1000
See page 13
Recommended Accessories

10
(1) Connect the earth clamp to the work piece.
(2) Connect the air supply to the air connection located at the rear of the machine.
(3) Set the Air Pressure at 5-6 Bar using the pressure adjusting knob.
(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 machine to the
correct power supply and switch on
the machine using the on/o󰀨 switch
located at the rear of the machine.
1. Connect the earth lead
to the work piece
(2) Connect the air supply hose to the regulator
located at the rear of the machine and turn on
the air supply.
(3) Set the Air Pressure at 5-6 Bar using the
pressure adjusting knob.
Set Up Procedure for PLASMA Cutting PLASMA CUT30

11
Operating Procedure for PLASMA Cutting PLASMA CUT30
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 SC40 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

12
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 0.9mm 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
PLASMA CUT30

13
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.
AT1000 Sub-Micronic Filter Filter Element
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.
● Hand torch cutting technique
When cutting make sure that sparks are
exiting from the bottom of the work piece. If sparks are spraying up from the work piece, you are moving the torch too fast, or
you don't have enough amps set.
Hold the torch vertical and watch the arc as
it cuts along the line.
● Starting a cut
PLASMA CUT30

14
● 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 SC40 torch supplied with the Viper Cut 30 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󰀨
PLASMA CUT30
Operating Procedure & Techniques
for PLASMA Cutting

15
PLASMA CUT30
SC30SC30 Plasma Torch & SparesPlasma Torch & Spares
PLASMA CUTTING TORCH
Air Cooled 30 Amp
1
3
2
4
5
6
7
8
9
10
Spare Parts
# Part Number Description
SC40-40-M16X1.5 SC40 Plasma Torch 4m
1 SC2514 Handle Kit
2 SC2516R Trigger
3 SC4001 Torch Head
4 SC2504 SC40 Electrode
5 SC2506 SC40 Swirl Ring
Spare Parts
# Part Number Description
6 SC2520-09 SC40 Cutting Tip 0.9mm
7 SC2530-6 SC40 Retaining Cap
8 SC2551 SC40 Cutting Buggy
9 SC2540 SC40 Stand Off Guide
10 SC2550 SC40 Circle Cutting Attachment
11 SCSP1 Screw Pack
Technical Data
Max Current 40A Gas Pressure 4.5-5.0 Bar (65-75psi)
Duty Cycle 60% Gas Flow 100 l/min
Gas Air/N2with PilotArc
SurecutSC40SurecutSC40
Rating: 40AAir/N2Gas, @ 60% duty cycle.
For use on VIPER CUT30

16
PLASMA CUT30
A. The cutting torch fails to ignite the arc, when torch trigger is pressed.
1. Gas pressure too high or too low, check and adjust gas pressure to 5bar/70psi.
2. The shield cup is not installed correctly, turn o󰀨 the power source, install and screw it down properly, then turn
on the power source.
3. The electrode, swirl ring or cutting tip is not installed correctly, turn o󰀨 the power source, install the electrode,
swirl ring or cutting tip correctly, and screw shield cup down properly, then turn on the power source.
B. The cutting torch fails to ignite the arc, when torch trigger is pressed the temperature lamp is on.
1. Power Supply is overheated (OC/OT lamp on), let unit cool down for at least 5 minutes. Make sure the unit
has not been operated beyond Duty Cycle limit. Refer to page 8 for duty cycle specications.
2. Faulty components in unit return for repair.
C. No cutting output; Torch activated, power source on; Gas ows; Fan operates
1. Torch not properly connected to power supply, check that torch leads are properly connected to power supply.
2. Work cable not connected to work piece, or connection is poor, make sure that work cable has a proper
connection to a clean, dry area of the work piece.
3. Faulty components in unit return for repair
4. Faulty Torch, return for repair
D. Low cutting output
1. Incorrect setting of CURRENT (A) control, check and adjust to proper setting.
2. Faulty components in unit, return for repair.
E. Di󰀩cult Starting
1. Worn torch parts (consumables), shut o󰀨 input power. Remove and inspect torch shield cup, cutting tip, swirl
ring and electrode. Replace electrode, cutting tip or swirl ring if worn; replace shield cup if excessive spatter
has adhered to it.
F. Arc shuts o󰀨 during operation; arc will not restart when torch switch is activated.
1. Power Supply is overheated (OC/OT lamp on), let unit cool down for at least 5 minutes. Make sure the unit
has not been operated beyond Duty Cycle limit. Refer to Section 2 for duty cycle specications.
2 Torch consumables worn, check torch shield cup, swirl ring, cutting tip and electrode; replace as needed.
3. Faulty components in unit return for repair.
G. No gas ow; the power is lamp on; Fan operates
1. Gas not connected or pressure is too low, check gas connections. Adjust gas pressure to proper setting.
2. Faulty components in unit return for repair.
H. Torch cuts but low quality
1. Current (A) control set too low, increase current setting.
2. Torch is being moved too fast across work piece, reduce cutting speed.
3. Excessive oil or moisture in torch, hold torch 1/8 inch (3mm) from clean surface while purging and observe oil
or moisture buildup (do not activate torch). If there are contaminants in the air, additional ltering
may be needed. Refer to sub-micronic air lter page 13.
Trouble Shooting

17
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
- VIPER, 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
- ALLWELDINGTORCHES – GMAW / GTAW / MMAW / PLASMA - REMOTE CONTROLS 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.
Youshallinspectthegoodsondeliveryandshallwithinseven(7)daysofdelivery (time beingoftheessence)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 hasbeena misrepresentationyoumay haverightsunder the FairTradingActorthe ContractualRemediesAct andthereforealso entitledto,at theconsumer’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
(c) Esseti NZ Ltd. will not be liable for goods which have not been stored or used in a proper manner, 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.

18
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,
All O-rings,All Springs,All Circle Guides and Cutting Kits, Torch Bodies, Air Filter Regulator, Welding Cable, Earth Clamps
•Gas Welding & Cutting Torch and Straight Line Cutting Machine Consumables and Fittings, such as:
All Cutting, Welding & Brazing Tips,Adaptors, Hoses, Fittings, Tracks and associated parts
•Automatic Welding & Cutting Carriage Machine Parts, such as:
Input Cord, Inter-connecting Power Cord, Triggering Cable
This Warranty does not cover products purchased:
•Without the provision of a suitable Receipt or Tax Invoice that clearly provides proof of purchase as outlined above
•At an auction or from a private seller
•Unless it is a manufacturing fault, this Warranty does not apply to any products sold to Hire Companies.
These conditions may only be varied with the written approval of the Directors of Esseti NZ Limited.
REMEMBER TO RETAIN YOUR ORIGINAL INVOICE FOR PROOF OF PURCHASE.
ESSETI (NZ) LIMITED WARRANTY & RETURNS POLICY - CONTINUED

19
NOTES

20
Esseti New Zealand Limited
PO Box 4189, Palmerston North - 4442
Phone: [phone]
Fax: [phone]
Email: [email protected]
www.esseti.co.nz
Xcel-Arc © Esseti NZ LTD - 2020
New Zealand Limited