CUT 25 Plasma - BOC

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CUT 25 PlasmaO P E R AT I N G M A N U A L

Welcome to a better wayCongratulations on purchasing a MagMate Cut25 Plasma.The products in BOC's plasma cutting machine range perform with reliability andhave the backing of the South Pacific's leading industrial supplier.This operating manual provides the basic knowledge required for plasma cutting,as well as highlighting important areas of how to operate the MagMate Cut25Plasma machine.BOC equipment and technical support is available through our national BOCCustomer Service Centre or contact your local Gas & Gear outlet.Important Notice: This document has been prepared by BOC Limited ABN 95 000 029 729 ('BOC'), asgeneral 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 documenthas been derived from third parties, and though BOC believes it to be reliable as at the time of printing, BOCmakes no representation or warranty as to the accuracy, reliability or completeness of information in thisdocument and does not assume any responsibility for updating any information or correcting any error oromission which may become apparent after the document has been issued. Neither BOC nor any of its agentshas independently verified the accuracy of the information contained in this document. The information in thisdocument is commercial in confidence and is not to be reproduced. The recipient acknowledges and agreesthat it must make its own independent investigation and should consider seeking appropriate professionalrecommendation in reviewing and evaluating the information. This document does not take into account theparticular circumstances of the recipient and the recipient should not rely on this document in making anydecisions, including but not limited to business, safety or other operations decisions. Except insofar as liabilityunder any statute cannot be excluded, BOC and its affiliates, directors, employees, contractors and consultantsdo not accept any liability (whether arising in contract, tort or otherwise) for any error or omission in thisdocument or for any resulting loss or damage (whether direct, indirect, consequential or otherwise) suffered bythe recipient of this document or any other person relying on the information contained herein. The recipientagrees that it shall not seek to sue or hold BOC or their respective agents liable in any such respect for theprovision of this document or any other information. 2

Contents1.0 Recommended Safety Precautions46.0 Operating Controls121.1Health Hazard Information46.1MagMate 1.2Personal Protection46.2Package Contents1.3Electrical Shock51.4User Responsibility57.0 Air pressure regulator installation2.0 MagMate Cut25 Plasma62.18.0 Setting up your MagMate Cut25 Plasma14Cut25 Plasma121213Fundamentals of Plasma Cutting62.2 Process operation for transferred arcapplications78.2 Setting up the power source3.0 Plasma cutting components88.3 Selecting the correct air pressure and flow rate(when using an external air compressor)153.1Plasma cutting power sources83.2Plasma cutting capacity89.0 Periodic Maintenance163.3Plasma cutting torches (general)89.1163.4Air supply93.5Process comparisons910.0 Warranty Information17910.1 Terms of Warranty1710.2 Limitations on Warranty1710.3 Warranty Repairs1711.0 Recommended Safety Guidelines183.6Work return cable assembly8.14.0 Cutting Technique104.1Cutting104.2Piercing and Gouging*105.0 Technical Specifications11Fitting the torch to the power sourcePower Source1415 3

1.0 Recommended Safety Precautions1.1 Health Hazard Information1.2 Personal ProtectionThe actual process of plasma cutting isone that can cause a variety of hazards.All appropriate safety equipment should beworn at all times, i.e. headwear, hand and bodyprotection. Electrical equipment should beused in accordance with the manufacturer’srecommendations.RespiratoryEyes: Wear a respirator when natural or forcedventilation is not good enough.The process produces ultra violet rays thatcan injure and cause permanent damage.Fumes can cause irritation.Skin:Arc rays are dangerous to uncovered skin.Inhalation:Cutting fumes and gases are dangerous to thehealth of the operator and to those in closeproximity. The aggravation of pre-existingrespiratory or allergic conditions may occur insome workers. Excessive exposure may causeconditions such as nausea, dizziness, drynessand irritation of eyes, nose and throat.Confined space cutting should be carried outwith the aid of a fume respirator or air suppliedrespirator as per AS/NZS 1715 and AS/NZS1716 Standards. You must always have enough ventilation inconfined spaces. Be alert to this at all times.Eye protectionProtective eyewear should be worn whenplasma cutting. The minimum lens requirementsare as follows:Recommended filter shades forplasma cuttingArc de* 204420-405540-606660-808880-30089* One shade darker lens should be used for Aluminium cutting. 4

ClothingSuitable clothing must be worn to preventexcessive exposure to UV radiation andsparks. An adjustable helmet, flameproof loosefitting cotton clothing buttoned to the neck,protective leather gloves, spats, apron and steelcapped safety boots are highly recommended.1.3 Electrical Shock Never touch ‘live’ electrical parts. Always repair or replace worn ordamaged parts. Disconnect power source beforeperforming any maintenance or service.BOC stock a huge range of personal protectiveequipment. This combined with BOC’s extensiveGas and Gear network ensures fast, reliableservice throughout the South Pacific.STOPPLEASE NOTE that under no circumstancesshould any equipment or parts be alteredor changed in any way from the standardspecification without written permissiongiven by BOC. To do so, will void theEquipment Warranty. Earth all work materials. Never work in moist or damp areas.Avoid electric shock by: Wearing dry insulated boots. Wearing dry leather gloves. Working on a dry insulated floor wherepossible.Further safety information can beobtained from Welding Institute ofAustralia (WTIA) Technical Note No.7‘Health and Safety Welding’Published by WTIA,PO Box 6165 Silverwater NSW 2128Phone (02) 9748 4443.1.4 User Responsibility Read the Operating Manual prior toinstallation of this machine. Unauthorised repairs to this equipment mayendanger the technician and operator and willvoid your Warranty. Only qualified personnelapproved by BOC should perform repairs. Always disconnect mains power beforeinvestigating equipment malfunctions. Parts that are broken, damaged, missing orworn should be replaced immediately. Equipment should be cleaned periodically. 5

2.0 MagMate Cut25 Plasma2.1 Fundamentals of PlasmaCuttingA plasma can be created by adding energy toan electrically neutral gas. In the case of airplasma cutting the air is dry, clean compressedair delivered from an air compressor or an airline. By adding electricity through an electrode(Hafnium), the gas becomes imbalanced andconducts electricity. The greater the levelof electricity the higher the temperature ofthe plasma.Typical Plasma cutting set-up123456Main power supplyAmperage control knobAir/Electricity outlet connectorAirflow switchPlasma TorchWorkpiece7891011Plasma cutting torches control energy byconstricting the arc and forcing it througha constricting nozzle fitted to the torch. Byincreasing air pressure and intensifying the arcwith higher voltages, the arc becomes hotterand more capable of blasting through thickermetals and blowing away the cuttings, leavingminimal cleanup.For plasma cutting, the air supply can bedelivered via an external air compressor or, insome cases, plasma cutting units (such as theMagMate Cut25 Plasma) will have inbuilt aircompressors.Power On/Off switch (on back)Air pressure regulatorAir compressor (sold seperately)Air supply hoseEarth lead and connector17829 *10311456 6* Itemssold seperately

2.2 Process operation fortransferred arc applications3412512345 AirflowConstricted Plasma StreamElectrodeConstricting nozzleWorkpieceCompressed air flows through the torch.A pilot arc is established inside the head ofthe plasma torch.The high voltage of the pilot arc changes theair stream into a plasma stream.The plasma stream is constricted and forcedthrough a tip with a small orifice.The constricted plasma stream exiting fromthe tip is termed a plasma jet.The plasma jet is allowed to touch the work.An arc is initiated between the hafniumelectrode and the work.The arc passes through the orifice of the tip.The constricted arc so formed is a stiff,columnated and narrow arc.The intense heat of arc melts the plate.The plasma jet blows away the metal toproduce a cut. 7

3.0 Plasma cutting components3.1 Plasma cutting power sources3.2 Plasma cutting capacityThe plasma arc cutting power source changesthe relatively high voltage, low amperageprimary power into low voltage, high amperagesecondary power suitable for plasma cutting.The size of the power source depends onthe cutting amperage it is expected to deliver.Cutting thicker materials requires moreamperage than does cutting of thinner materials.Cutting thickness (mm)Rated Output (A)SteelStainlessSteelAluminium25A Single phase75340A Single phase98460A Three phase2018680A Three phase25228100A Three phase322512160A Three phase5035203.3 Plasma cutting torches (general)Plasma torches are rated in accordance to themaximum current that the consumable tipswill handle. The diagram below shows a typicalplasma torch with it’s consumable items.123123454BOC stocks a range of plasma torches and consumables to suit any need. 8Shield cupTipAir electrodeStandard air plungerPlasma torch body5

3.4 Air supplyThe supply of air to the cutting process playsan important role. The force of the air is usedto blow the molten material (created by theplasma arc) away from the cut area therebycreating separation. Air pressure and amperageare two variables that are changed whenincreasing the cut thickness.of the consumable torch parts, it is thereforerecommended that an inline filter drying systemis fitted to all air delivery lines.When air is supplied from a portable aircompressor it is important to ensure that thecompressor has adequate pressure and airflowrate capacity.Typical air supply requirementsCompressed air from compressed air lines maybe contaminated with moisture and oil residue.Contaminants such as these shorten the lifePressure4.5–6 barDraw-off rate150–200 L/min3.5 Process comparisonsCharacteristicAir plasma cuttingOxy-fuel cuttingMetalsAny conductive material. Cuttingthickness depends on power sourcecapacity. Typically very thin to 50 mmRestricted to steel. The formation ofan oxide during cutting of aluminium andstainless steel prevents the process being usedIndustriesAll forms of metal fabrication, artsculptures, hobby and DIYAll forms of metal fabrication, art sculptures,hobby and DIYPre-heatingNot requiredRequired on most steel to prevent crackingProductivity Due to the fact that no pre-heating isrequired the overall cutting process timeis reduced. High speed cutting of thin materials. Produces a small, thin kerf width andminimal post cut cleaning is requiredHighly portable and relatively low cost toset upVersatilityHighly versatile, stack cutting ofmaterial and combinations ofdifferent materials can be cut.No additional gas cylinders requiredThe process can be adopted to welding,brazing and heating of materialsSafety concernsElectrical process, therefore a risk ofelectrocution exists.Appropriate safety clothing must be wornGas process therefore a risk of flashbacksoccurring leading to explosion of cylinders.Appropriate safety clothing must be worn3.6 Work return cable assemblyThe work return cable and clamp forms anintegral part of the Plasma cutting processand if it does not make proper contact theefficiency of the process is greatly reduced.It is therefore essential to ensure that thecorrect size cable and clamp is fitted tothe machine and it earth clamp is properlyconnected to the workpiece to be cut. 9

4.0 Cutting Technique4.1 Cutting4.2 Piercing and Gouging*As a general rule for cutting amperages below40A the cutting tip can be dragged on thecutting surface. Higher amperages require astand-off distance and torch manufacturersnormally supply a stand-off guide or'drag shield'. Some operators prefer to use anextended electrode to improve visibility whencutting.To pierce material the cutting torch shouldbe held at an angle of 45 to the piercesurface (Refer to Diagram 1 ). Once the arc isestablished the torch is turned to 90 (Referto Diagram 2 ) and cutting is carried out in anormal manner. Piercing thickness is dependenton the output of the machine and is generally50% of the rated cutting thickness of thepower source.For straight edge cutting the torch should beheld at a 90 angle to the plate and draggedalong the plate. The cutting speed will dependon the material thickness, amperage andairflow rate.For bevel cutting the torch should be angledon the plate to the required bevel angle anddragged on the plate surface. (Note thatthe bevel angle will influence the materialthickness).90 It is important to direct the arc away from theoperator when establishing the arc as sparksand molten material will be ejected from thepoint of contact. Care must also be taken toprotect the surrounds from these sparks.145 2Cutting Direction90 * Gouging is dependant on the availability of the correct gougingtip and the size of the power source. 10

5.0 Technical SpecificationsModel No.MagMate Cut25 PlasmaInternalAir SourceExternalAir Source15–2520–4040% @ 25A40% @ 40A79Stainless Steel58Aluminium34Part No.MAGCUT25Input voltage (V)Single Phase220V 15%Plug15AInput power rating (A)26No-load voltage (V)260Current range (A)Output voltage (V)96Duty CycleEfficiency (%)80Insulation classFHousing protection classIP21SArc initiationContactAir pressure requirement (bar)4 (Min)Cutting thickness (mm)Mild SteelWeight (kg)27Dimensions (mm)546 x 272 x 268 11

6.0 Operating Controls6.1 MagMate Cut25 Plasma1263456.2 Package Contents Plasma power source Air pressure regulator Air hose (3m) and connectors Plasma torch Work return lead and clamp Operating manual 1271234567Thermal overload indicatorOn/Off switchInternal/external air supply selectorAir/electricity connectorContactorAmperage control knobEarth return lead (cable) connector

7.0 Air pressure regulator installationNB:This is only required if an external aircompressor is used.12345678An air pressure regulator assembly is includedwith the MagMate Cut25 Plasma.To install follow the steps listed below:1 Fix the mounting bracket with the screws assupplied to the back of the machine.Presure adjusting knobMounting bracketAir inlet connectorPressure indicating dialVapour collection containerAir hoseVapour drain plugOutlet marked on regulator2 Fix the outlet air hose to the air pressureregulator and the inlet to the machine.Ensure that all connections are tight.3 Fit the pressure indicating dial to the mainbody of the regulator and ensure that it isscrewed in tight.4 Fit the air pressure regulator to themounting bracket.5 Fit the air hose (supplied) to the air pressureregulator inlet and couple to the air supply.6 Adjust pressure adjusting screw till correctair pressure is achieved.123458676 13

8.0 Setting up your MagMate Cut25Plasma8.1 Fitting the torch to the power sourceA BCARubber boot fitted to the end of the MagMate Cut25Plasma torch to cover the Air/Electrical outlet. Air/electricalconnection nut B (inside rubber boot).IncorrectcautionThis is a safety device and must be fitted over theair/electrical connection prior to useC Contactor/trigger switch cable connector CorrectTorch fitted to the MagMate Cut25 Plasmapower sourceWarningFront end MagMate Cut25 Plasma1 Connect the air/electrical connection Bby fixing the hexagon nut to the terminalindicated as. Tighten the nut firmlybut do not overtighten.2 Important safety noticePush the rubber boot A over the terminaland ensure that it is completely covered.3 Connect the contactor/trigger C switchcable connector by fitting the plug to the.terminal indicated as4 Fit the work return lead and clamp to theterminal indicated as 14.Care must be taken that the Rubber boot is pushedover the air/electrical outlet and that all electricalcontact wires are properly insulated as illustrated.

8.2 Setting up the power source1 Connect primary cable to the power supply(15Amps).2 Select the air supply mode (internal/external).NB: If using an external air supply ensurethat the air pressure regulator is properlyinstalled as per section 7 of this manual.3 Connect the work return lead and clamp.4 Select the appropriate amperage.6 Begin cutting.7 The torch is fitted with a trigger safety latchwhich needs to be lifted in order to depressthe torch trigger.8 The cutting process works on the principleof a contact start i.e. the cutting tip needsto touch the work piece before cutting willcommence.5 Ensure that you are wearing the correct PPE.8.3 Selecting the correct air pressure and flow rate(when using an external air compressor)Compressed air from compressed air lines maybe contaminated with moisture and oil residue.Contaminants such as these shorten the lifeof the consumable torch parts. It is thereforerecommended that an inline filter drying systembe fitted to all air delivery lines.When air is supplied from a portable aircompressor, it is important to ensure thatthe compressor has adequate pressure andairflow rate capacity such as the BOC 14 (andupwards) air compressors.External air supply requirements forMagMate Cut25 Plasma torchPressure70 psi / 480 kPaDraw-off rate90–100 L/min 15

9.0 Periodic MaintenanceThe working environment and amount of usethe machine receives should be taken intoconsideration when planning maintenancefrequency of your MagMate Cut25 Plasma.Preventative maintenance will ensure troublefree cutting and increase the life of the machineand its torch consumables.9.1 Power Source Check electrical connections of unit at leasttwice a year. Clean oxidised connections and tighten. Inner parts of machine should be cleanedwith a vacuum cleaner and soft brush. Do not use any pressure-washing devices. Do not use compressed air as pressure maypack dirt even more tightly into components. Only authorised electricians should carryout repairs. 16

10.0 Warranty Information10.1 Terms of Warranty10.2 Limitations on WarrantyBOC provides a warranty for the MagMateCut25 Plasma sold by it against defects inmanufacture and materials.The following conditions are not covered: Powersource: Valid for 18 months from dateof purchase. Torch: Valid for 12 months from date ofpurchase. Leads and work return lead: Valid for onemonth from date of purchase. Non compliance with operating andmaintenance instructions such as connectionto incorrect faulty voltage supply includingvoltage surges outside equipment specs, andincorrect overloading. Natural wear and tear, and accidental damage Transport or storage damage. An authorised BOC Service Agent must carryout warranty repairs.The warranty may be voided if: Freight, packaging and insurance costs are tobe paid for by the claimant. Changes are made to the product withoutthe approval of the manufacturer. No additional express warranty is givenunless in writing signed by an authorisedmanager of BOC. Repairs are carried out using non-approvedspare parts. A non-authorised agent carries out repairs. This warranty is in addition to any other legalrights you may have.10.3 Warranty RepairsBOC or their Authorised Service Agent mustbe informed of the warranty defects, and theproduct returned within the warranty period. Before any warranty work is undertaken, thecustomer must provide proof of purchase andserial number of the equipment in order tovalidate the warranty. The parts replaced under the terms of thewarranty remain the property of BOC. 17

11.0 Recommended Safety GuidelinesSome safety precautions BOCrecommends are as follows:Key1Cutting sparks can cause explosion or fire. Repair or replace defective cablesimmediately.1.1Keep flammable materials away from cutting.Do not cut near flammable materials. Never watch the plasma arc except throughlenses of the correct shade.1.2Cutting sparks can cause fires. Have a fireextinguisher nearby, and have a watchpersonready to use it.1.3Do not cut on drums or any closed container. Leads and cables should be kept clear ofpassageways.2The plasma arc can cause injury and burns.2.1Turn off power before disassembling torch. Keep fire extinguishing equipment at a handylocation in the shop.2.2Do not grip material near cutting path.2.3Wear complete body protection.3Electric shock from torch or wiring can kill.3.1Wear dry insulating gloves. Do not wear wetor damaged gloves.3.2Protect yourself from electric shock byinsulating yourself from work and ground.3.3Disconnect input plug or power beforeworking on machine.4Breathing cutting fumes can be hazardous toyour health.4.1Keep your head out of fumes.4.2Use forced ventilation or local exhaust toremove fumes.4.3Use ventilating fan to remove fumes.5Arc rays can burn eyes and injure skin.5.1Wear hat and safety glasses. Use earprotection and button shirt collar. Usewelding helmet with correct shade offilter. Wear complete body protection.6Become trained and read the instructionsbefore working on the machine or cutting.7Do not remove or paint over (cover)the label. In confined spaces, adequate ventilation andconstant observation are essential. Keep primary terminals and live partseffectively covered. Never strike an electrode on any gas cylinder. Never use oxygen for venting containers. 18


For more information on MagMate products or service,call the BOC Customer Service Centre on:AU S TRA L I A131 262Website: Z EA L AN D0800 111 333Website: is distributed by:BOC LimitedABN 95 000 029 72910 Julius AvenueNorth Ryde, NSW 2113AUSTRALIABOC Limited970 – 988 Great South RoadPenrose, AucklandNEW ZEALANDBOC is a trading name of BOC Limited, a member of The Linde Group, BOC Limited 2014. Reproduction without permission is strictlyprohibited. Details given in this document are believed to be correct at the time of printing. Whilst proper care has been taken in theno liability for injury or damage resulting from its improper use can be accepted.MP13-0332 . FDAUS . 0414 2preparation,0

2.0 MagMate Cut25 Plasma 6 2.1 Fundamentals of Plasma Cutting 6 2.2 Process operation for transferred arc applications 7 3.0 Plasma cutting components 8 3.1 Plasma cutting power sources 8 3.2 Plasma cutting capacity 8 3.3 Plasma cutting torches (general) 8 3.4 Air supply 9 3.5 Process comparisons 9 3.6 Work return cable assembly 9

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