BOC Plasma 40 Torch User manual

Plasma 40 Torch

Operating manual

Important Notice

This document has been prepared by BOC Limited ABN 95 000 029 729 (‘BOC’),

as operating instructions and has been prepared in good faith. Information in this

document has been derived from third parties, and though BOC believes it to be

reliable as at the time of printing, BOC makes no representation or warranty as

to the accuracy, reliability or completeness of information in this document and

does not assume any responsibility for updating any information or correcting

any error or omission which may become apparent after the document has been

issued. The information in this document is commercial in conﬁdence and is not

to be reproduced. The recipient acknowledges and agrees that it must make

its own independent investigation and should consider seeking appropriate

professional advice in reviewing the information. This document does not take

into account the particular circumstances of the recipient. Except insofar as

liability under any statute cannot be excluded, BOC and its afﬁliates, directors,

employees, contractors and consultants do not accept any liability (whether

arising in contract, tort or otherwise) for any error or omission in this document

or for any resulting loss or damage (whether direct, indirect, consequential

or otherwise) suffered by the recipient of this document or any other person

relying on the information contained herein. The recipient agrees that it shall not

seek to sue or hold BOC or their respective agents liable in any such respect for

the provision of this document or any other information.

Important Notice

This document has been prepared by BOC Limited ABN 95 000 029 729 (‘BOC’), as general information and does not contain and is not to be taken as containing any speciﬁc recommendation. The document has been prepared in good faith and is

professional opinion only. Information in this document has been derived from third parties, and though BOC believes it to be reliable as at the time of printing, BOC makes no representation or warranty as to the accuracy, reliability or completeness of

information in this document and does not assume any responsibility for updating any information or correcting any error or omission which may become apparent after the document has been issued. Neither BOC nor any of its agents has independently

veriﬁed the accuracy of the information contained in this document. The information in this document is commercial in conﬁdence and is not to be reproduced. The recipient acknowledges and agrees that it must make its own independent investigation

and should consider seeking appropriate professional recommendation in reviewing and evaluating the information. This document does not take into account the particular circumstances of the recipient and the recipient should not rely on this document

in making any decisions, including but not limited to business, safety or other operations decisions. Except insofar as liability under any statute cannot be excluded, BOC and its afﬁliates, directors, employees, contractors and consultants do not accept any

liability (whether arising in contract, tort or otherwise) for any error or omission in this document or for any resulting loss or damage (whether direct, indirect, consequential or otherwise) suffered by the recipient of this document or any other person

relying on the information contained herein. The recipient agrees that it shall not seek to sue or hold BOC or their respective agents liable in any such respect for the provision of this document or any other information.

2BOC Smoothcut Plasma 40 Torch Operating manual

Contents.

1.0 Description 4

2.0 Torch breakdown and cutting consumables 5

3.0 Torch Ratings 6

4.0 Torch assembly 7

4.1 Fitting the consumables 7

4.2 Fitting the torch to the power source 7

4.3 Selecting the correct air pressure and ﬂow rate 7

5.0 Cutting Technique 8

5.1 Cutting 8

5.2 Piercing and Gouging 9

6.0 Warranty 10

7.0 Safety Guidelines 11

3BOC Smoothcut Plasma 40 Torch Operating manual

The Smoothcut Plasma 40 torch is designed for plasma cutting

applications up to 40amps.

The torch requires air pressure of 5 bar for optimum operation. It has

been designed for quality cutting up to 9mm in thickness (mild steel).

The Smoothcut Plasma 40 torch has a 6m torch lead length, making it

suitable to reach even the most difﬁcult places.

It is recommended to use the BOC Smoothcut Plasma 40 machine with

this torch to form one of the most portable cutting units on the market.

1.0 Description

4BOC Smoothcut Plasma 40 Torch Operating manual

2.0 Torch breakdown and cutting consumables

Torch breakdown and cutting consumables

Description Part No.

Smoothcut Plasma 40 Torch 6m BOC40/706HTC

1Electrode BOC9/6506

2Gas distributor BOC9/6507

3Cutting tip 20-40A BOC9/6500

4Shield cup BOC9/6003

Accessories

Description Part No.

Complete cutting guide BOC–CP1011

Roller cutting guide BOC–TJ1511

Circle cutting guide BOC–TJ1093

Spares

Description Part No.

Torch head assembly BOC9/7000

Handle & trigger assembly BOC9/7002

5BOC Smoothcut Plasma 40 Torch Operating manual

3.0 Torch Ratings

Torch Ratings

Ambient temperature 40°C

Duty Cycle 60% @ 40A

Maximum current 40A

Cooling requirement Air or Nitrogen

Gas type Air or Nitrogen

CAUTION Never use Oxygen

Gas/air operating pressure 4.8–5.0 bar

Gas/air ﬂowrate 100 L/min

6BOC Smoothcut Plasma 40 Torch Operating manual

4.0 Torch assembly

7BOC Smoothcut Plasma 40 Torch Operating manual

4.1 Fitting the consumables

1 Place the electrode 1 into the torch head

2 Place the gas distributor 2 over the electrode

3 Place the tip 3 onto the gas distributor

4 Screw the shield cup 4 over the parts and hand tighten onto the torch

head. Do not over tighten the shield cup

IMPORTANT

As a safety feature of the torch, the cutting torch will not operate

unless the shield cup is ﬁtted properly.

NOTE

The Smoothcut Plasma 40 torch is a contact start torch. Therefore the

cutting tip must be in contact with the work piece before the torch

switch is operated.

The contact start mechanism means that stand-off guides cannot be

used with the Smoothcut Plasma 40 torch.

4.2 Fitting the torch to the power source

1 Fit torch connection A to connection point on machine indicated as

. Screw torch connection in ﬁrmly but do not overtighten.

2 Fit the work return lead and clamp to the terminal indicated as

4.3 Selecting the correct air

pressure and ﬂow rate

Compressed air from compressed air lines is often contaminated with

moisture and oil residue. Contaminants such as these shorten the life of

the consumable torch parts. It is therefore recommended that an inline

ﬁlter drying system be ﬁtted to all air delivery lines.

When air is supplied from a portable air compressor, it is important to

ensure that the compressor has adequate pressure and airﬂow rate

capacity such as the BOC 14 (and upwards) air compressors.

Air supply requirements for BOC Smoothcut Plasma 40 Torch

Pressure 4.8–5.0 bar

Draw-off rate 100 L/min

5.0 Cutting Technique

8BOC Smoothcut Plasma 40 Torch Operating manual

Diagram 1

5.1 Cutting

As a general rule for cutting amperages below 40A the cutting tip can

be dragged on the cutting surface. Higher amperages require a stand-

off distance and torch manufacturers normally supply a stand-off guide

or ‘drag shield’. Some operators prefer to use an extended electrode

to improve visibility when cutting. BOC supplies guides that can be

purchased to assist in straight line, circular and bevel cutting.

For straight edge cutting the torch should be held at a 90° angle to the

plate and dragged along the plate (Refer to Diagram 1). The cutting

speed will depend on the material thickness, amperage and airﬂow rate.

For bevel cutting the torch should be angled on the plate to the required

bevel angle and dragged on the plate surface. (Note that the bevel angle

will inﬂuence the material thickness).

Typical Plasma Cutting Guide Kit

90°

Cutting Direction

9BOC Smoothcut Plasma 40 Torch Operating manual

5.2 Piercing and Gouging

To pierce material the cutting torch should be held at an angle of 45°

to the pierce surface (Refer to Diagram 2). Once the arc is established

the torch is turned to 90° (Refer to Diagram 3) and cutting is carried out

in a normal manner. Piercing thickness is dependent on the output of

the machine and is generally 50% of the rated cutting thickness of the

power source.

It is important to direct the arc away from the operator when establishing

the arc as sparks and molten material will be ejected from the point

of contact. Care must also be taken to protect the surrounds from

these sparks.

When gouging with plasma it is advisable to use a plasma gouging tip

supplied by the torch manufacturer. The torch should be held at an angle

of 40–45° from the plate surface (Refer to diagram 4). An arc length of

up to 15mm can be employed whilst the torch is moved in the direction

of the material to be removed. Several small passes should be made to

remove the unwanted material.

Diagram 3

Diagram 4

Diagram 2

90°

45°

Gouging Direction

40–45°

6.0 Warranty

The BOC Smoothcut Plasma torch carries a 12 month warranty from the

date of purchase.

This warranty excludes any consumables and apparent misuse of

the torch.

10 BOC Smoothcut Plasma 40 Torch Operating manual

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