For more information on any BOC product or service call

the BOC Customer Service Centre on:

AU S T R A L I A

131 262
Email: [email protected]
Website: www.boc.com.au

NEW ZEALAND Smoothcut

0800 111 333 40 / 80 Plasma Cutter
Email: [email protected]
Website: www.boc.co.nz O P E R AT I N G M A N U A L

BOC Limited BOC Limited

ABN 95 000 029 729 970 – 992 Great South Road
Riverside Corporate Park Penrose, Auckland
10 Julius Avenue NEW ZEALAND
North Ryde, NSW 2113
*
AUSTRALIA IP 21983 FDAUS 0806 500

BOC is a trading name of BOC Limited, which is an operating company within The BOC Group, the parent company of which is
The BOC Group plc. The stripe symbol and the word BOC are a registered trademark of The BOC Group plc and used under licence
by BOC Limited. © BOC Limited 2006. Reproduction without permission is strictly prohibited. * Torch sold seperately
Welcome to a better way of welding

Congratulations on purchasing a BOC Smoothcut Plasma

Cutting machine.
The products in BOC's Plasma Cutting machine range perform with reliability
and have the backing of the South Pacific's leading welding supplier.
This operating manual provides the basic knowledge required for plasma cutting,
as well as highlighting important areas of how to operate the BOC Smoothcut
Plasma Cutting machine.
With normal use and by following these recommended steps, your
BOC Smoothcut Plasma Cutting machine can provide you with years of
trouble‑free service.
BOC equipment and technical support is available through our national BOC
Customer 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'), 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.

­­­
Contents
1.0 Recommended Safety Precautions 6 5.0 Technical Specifications 14
1.1 Health Hazard Information 6
1.2 Personal Protection 6 6.0 Operating Controls 15
1.3 Electrical Shock 7 6.1 Smoothcut 40 15
1.4 User Responsibility 7 6.2 Smoothcut 80 15

2.0 Smoothcut Plasma Cutters 8 7.0 Air pressure regulator installation 16

2.1 Fundamentals of Plasma Cutting 8
2.2 Process operation 9 8.0 Periodic Maintenance 17
8.1 Power Source 17
3.0 Plasma cutting components 10
3.1 Plasma cutting power sources 10 9.0 Warranty Information 18
3.2 Plasma cutting capacity 10 9.1 Terms of Warranty 18
3.3 Plasma cutting torches 10 9.2 Limitations on Warranty 18
3.4 Air supply 11 9.3 Warranty Repairs 18
3.5 Process comparisons 11
3.6 Earth cable Assembly 11 10.0 Recommended Safety Guidelines 20

4.0 Cutting Technique 12

4.1 Cutting 12
4.2 Piercing and Gouging 12

­­­
 1.0 Recommended Safety Precautions Clothing
Suitable clothing must be worn to prevent
BOC stock a huge range of personal protective
equipment. This combined with BOC’s extensive
excessive exposure to UV radiation and Gas and Gear network ensures fast, reliable
sparks. An adjustable helmet, flameproof loose service throughout Australia.
1.1 Health Hazard Information 1.2 Personal Protection
fitting cotton clothing buttoned to the neck,
The actual process of plasma cutting is Respiratory protective leather gloves, spats, apron and steel
one that can cause a variety of hazards. capped safety boots are highly recommended.
Confined space cutting should be carried out
All appropriate safety equipment should be
with the aid of a fume respirator or air supplied
worn at all times, i.e. headwear, hand and body 1.3 Electrical Shock
respirator as per AS/NZS 1715 and AS/NZS
protection. Electrical equipment should be
1716 Standards. • Never touch ‘live’ electrical parts.
used in accordance with the manufacturer’s
• You must always have enough ventilation in • Always repair or replace worn or
recommendations. PLEASE NOTE that under no circumstances
confined spaces. Be alert to this at all times. damaged parts.
Eyes: should any equipment or parts be altered
• Wear a respirator when natural or forced • Disconnect power source before or changed in any way from the standard
The process produces ultra violet rays that ventilation is not good enough. performing any maintenance or service. specification without written permission
can injure and cause permanent damage. Eye protection • Earth all work materials. given by BOC. To do so, will void the
Fumes can cause irritation.
Protective eyewear should be worn when • Never work in moist or damp areas. Equipment Warranty.
Skin: plasma cutting. The minimum lens requirements
are as follows: Avoid electric shock by:
Arc rays are dangerous to uncovered skin. Further information can be obtained
• Wearing dry insulated boots
Recommended filter shades for from Welding Institute of Australia
Inhalation: • Wearing dry leather gloves (WTIA) Technical Note No.7
plasma cutting
Cutting fumes and gases are dangerous to the • Working on a dry insulated floor where ‘Health and Safety Welding’
health of the operator and to those in close Arc Current Minimum Suggested possible. Published by WTIA,
(Amperes) Protective Shade*
proximity. The aggravation of pre-existing Shade PO Box 6165 Silverwater NSW 2128
respiratory or allergic conditions may occur in Phone (02) 9748 4443.
some workers. Excessive exposure may cause <20 4 4 1.4 User Responsibility
conditions such as nausea, dizziness, dryness 20-40 5 5 • Read the Operating Manual prior to
and irritation of eyes, nose and throat. installation of this machine.
40-60 6 6
• Unauthorised repairs to this equipment may
60-80 8 8
endanger the technician and operator and will
80-300 8 9 void your Warranty. Only qualified personnel
approved by BOC should perform repairs.
* One shade darker lens should be used for Aluminium cutting. • Always disconnect mains power before
investigating equipment malfunctions.
• Parts that are broken, damaged, missing or
worn should be replaced immediately.
• Equipment should be cleaned periodically.

­­­ ­­­
 2.0 Smoothcut Plasma Cutters 2.2 Process operation

2.1 Fundamentals of Plasma energy by constricting the arc and forcing it

Cutting through a constricting nozzle fitted to the 3
torch. By increasing air pressure and intensifying
A plasma can be created by adding energy to the arc with higher voltages, the arc becomes
an electrically neutral gas. In the case of air hotter and more capable of blasting through
plasma cutting the air is dry, clean compressed thicker metals and blowing away the cuttings,
air delivered from an air compressor or a air leaving minimal cleanup. 4
line. By adding electricity through an electrode
1
(Hafnium), the gas becomes imbalanced and
conducts electricity. The greater the level of 2

electricity the higher the temperature of the 5

plasma. Plasma cutting torches control this
Typical Plasma cutting set-up
1 Main power supply 7 Power On/Off switch (on back)
2 1 Airflow
Amperage control knob 8 Pressure regulating control valve (on back)
3 2 Constricted Plasma Stream
Air/Electricity outlet connector 9 Air compressor (sold seperately)
4 3 Electrode
Airflow switch 10 Air supply hose
5 4 Constricting nozzle
Plasma Torch (sold seperately) 11 Earth lead and connector
6 5 Workpiece
Workpiece

■ Compressed air flows through the torch

1
■ A pilot arc is established inside the head of
the plasma torch
■ The high voltage of the pilot arc changes the
air stream into a plasma stream
7
8 ■ The plasma stream is constricted and forced
through a tip with a small orifice
2
9 * ■ The constricted plasma stream exiting from
the tip is termed a plasma jet
■ The plasma jet is allowed to touch the work.
10 ■ An arc is initiated between the hafnium
electrode and the work
■ The arc passes through the orifice of the tip
3
■ The constricted arc so formed is a stiff,
columnated and narrow arc
■ The intense heat of arc melts the plate
11 ■ The plasma jet blows away the metal to
4 produce a cut.
5 *
6
* Items sold seperately

­­­ ­­­
 3.0 Plasma cutting components 3.4 Air supply the life of the consumable torch parts, it is
therefore recommended that an inline filter
The supply of air to the cutting process plays drying system is fitted to all air delivery lines.
an important role. The force of the air is used
3.1 Plasma cutting power sources 3.2 Plasma cutting capacity to blow the molten material (created by the When air is supplied from a portable air
plasma arc) away from the cut area thereby compressor it is important to ensure that the
The plasma arc cutting power source changes compressor has adequate pressure and airflow
Cutting thickness (mm) creating separation. Air pressure and amperage
the relatively high voltage, low amperage rate capacity.
  Stainless
are two variables that are changed when
primary power into low voltage, high amperage
Rated Output (A) Steel Steel Aluminium increasing the cut thickness
secondary power suitable for plasma cutting
Typical air supply requirements
40A Single phase 10 9 4 Compressed air from compressed air lines
The size of the power source depends on Pressure 4.5–6 bar
is often contaminated with moisture and oil
the cutting amperage it is expected to deliver. 60A Three phase 20 18 6
residue. Contaminants such as these shorten Draw-off rate 150–200 L/min
Cutting of heavy section materials requires
80A Three phase 25 22 8
more amperage than does cutting of thinner
sections. 100A Three phase 32 25 12 3.5 Process comparisons
160A Three phase 50 35 20
Characteristic Air plasma cutting Oxy-fuel cutting

Metals Any conductive material. Cutting Restricted to steel. The formation of an

thickness depends on power source oxide during cutting of Aluminium and SS
3.3 Plasma cutting torches capacity. Typically very thin to 50 mm prevents the process being used
Plasma torches are rated in accordance to the 1 Stand off guide 6 Air electrode Industries All form of metal fabrication, art sculptures, All form of metal fabrication, art sculptures,
2 Shield cup 7 Extended electrode
maximum current that the consumable tips hobby and DIY hobby and DIY
3 Electrode and air tool 8 Standard air plunger
will handle. The diagram below shows a typical 4 Tip 9 Extended air plunger Pre-heating Not required Required on most steel to prevent cracking
plasma torch with it’s consumable items 5 Extended cutting tip 10 Plasma torch body
Productivity •D  ue to the fact that no pre-heating is Highly portable and relatively low cost to
required the overall cutting process time set up.
is reduced.
1 2 3 4 5 6 7 8 9 10
• High speed cutting of thin materials.
• Produces a small, thin kerf width and
minimal post cut cleaning is required

Versatility Highly versatile, stack cutting of The process can be adopted to welding,
material and combinations of brazing and heating of materials
different materials can be cut.
No additional gas cylinders required

Safety concerns Electrical process, therefore a risk of Gas process therefore a risk of flashbacks
electrocution exists. occurring leading to explosion of cylinders.
Appropriate safety clothing must be worn Appropriate safety clothing must be worn

3.6 Earth cable assembly It is therefore essential to ensure that the

correct size cable and clamp is fitted to
The earth cable and clamp forms an integral the machine and it earth clamp is properly
part of the Plasma cutting process and if it does connected to the workpiece to be cut.
not make proper contact the efficiency of the
BOC stock a range of plasma torches and consumables to suit any need.
process is greatly reduced.

­­­10 ­­­11
 4.0 Cutting Technique 4.2 Piercing and Gouging When gouging with plasma it is advisable to
use a plasma gouging tip supplied by the torch
To pierce material the cutting torch should manufacturer. The torch should be held at an
be held at an angle of 45° to the pierce angle of 40–45° from the plate surface. An
4.1 Cutting For straight edge cutting the torch should be surface (Refer to Diagram 1 ). Once the arc is arc length of up to 15 mm can be employed
held at a 90° angle to the plate and dragged established the torch is turned to 90° (Refer to
As a general rule for cutting amperages below whilst the torch is moved in the direction
along the plate. The cutting speed will depend Diagram 2 )
40 A the cutting tip can be dragged on the of the material to be removed. Several small
on the material thickness, amperage and and cutting is carried out in a normal manner.
cutting surface. Higher amperages require a cuts should be made to remove the unwanted
airflow rate. Piercing thickness is dependent on the output
standoff distance and torch manufacturers material.
of the machine and is generally 50% of the rated
normally supply a stand off guide or For bevel cutting the torch should be angled
cutting thickness of the power source.
'drag shield'. Some operators prefer to use an on the plate to the required bevel angle and
extended electrode to improve visibility when dragged on the plate surface. (Note that the It is important to direct the arc away from the
cutting. Manufacturers will also supply a variety bevel angle will influence the material thickness) operator when establishing the arc as sparks
of guides to assist in straight line, circular and and molten material will be ejected from the
bevel cutting. point of contact. Care must also be taken to 40-45°
protect the surrounds from these sparks.
1

90° Gouging Direction

45°

Typical Plasma Cutting Guide Kit

Cutting Direction

90°

­­­12 ­­­13
 5.0 Technical Specifications 6.0 Operating Controls

Model No. Smoothcut 40 Smoothcut 80 6.1 Smoothcut 40 1 Thermal overload indicator

2 On/Off switch
Part No. CUT40 CUT80 3
Digital Amperage Indicator
(Smootharc 80 only)
Input Voltage (V) Single Phase 220V ± 15% AC Three Phase 380V ± 10% 4 Gas post-flow Selector switch
5 Air/electricity connector
Input power rating (A) 18.8 15.9
6 Air control connector
No-load voltage(V) 246 269 1 7 Amperage control knob
8 Earth return lead (cable) connector
Current Range (A) 15–40 20–80 2 7
Arc control connector
9
4 (Smootharc 80 only)
Output voltage (V) 96 112
Earth lead and connector
10
Duty Cycle (%) 60 60 (now shown)

Efficiency (%) 80 85
Insulation class F F
Housing protection class IP21 IP21 5 8
Arc initiation Contact Standoff 6

Air pressure requirement (bar) 4 5.5

Cutting thickness (mm) 1–12 1–30
Weight (kg) 8 38
Dimensions (mm) 350 x 150 x 260 515 x 263 x 372
6.2 Smoothcut 80

3
7

6 8

­­­14 ­­­15
 7.0 Air pressure regulator installation 8.0 Periodic Maintenance
An air pressure regulator is in cluded with all 1 Presure adjusting knob The working environment or amount of use
BOC Smoothcut Plasma Cutters. To install 2 Mounting bracket the machine receives should be taken into
3 Air inlet connector
follow the steps below: consideration when planning maintenance
4 Pressure indicating dial
1� Fix the mounting bracket with the screws as 5 Vapour collection container frequency of your BOC Plasma Cutter
supplied to the back of the machine 6 Air hose
7 Vapour drain plug Preventative maintenance will ensure trouble
2� Fix the outlet air hose to the air pressure 8 Outlet marked on regulator free cutting and increase the life of the machine
regulator and the inlet to the machine.
and its torch consumables.
Ensure that all connections are tight
3� Fit the pressure indicating dial to the main 8.1 Power Source
body of the regulator and ensure that it is
screwed in tight • Check electrical connections of unit at least
twice a year.
4� Fit the air pressure regulator to the
mounting bracket • Clean oxidised connections and tighten.
5� Fit the air hose (supplied) to the air pressure • Inner parts of machine should be cleaned
regulator inlet and couple to the air supply. with a vacuum cleaner and soft brush.
• Do not use any pressure-washing devices.
6� Adjust pressure adjusting screw till correct
air pressure is achieved. • Do not use compressed air as pressure may
pack dirt even more tightly into components.
• Only authorised electricians should carry
out repairs.

3
8
4
6
5
6
7

­­­16 ­­­17
 9.0 Warranty Information

9.1 Terms of Warranty 9.2 Limitations on Warranty

BOC provides a Warranty for the BOC The following conditions are not covered:
Smoothcut Plasma cutter sold by it against
• non compliance with operating and
defects in manufacture and materials.
maintenance instructions such as connection
• Valid for 16 months from date of purchase. to incorrect faulty voltage supply including
• An authorised BOC Service Agent must carry voltage surges outside equipment specs, and
out Warranty repairs. incorrect overloading
• Freight, packaging and insurance costs are to • natural wear and tear, and accidental damage
be paid for by the claimant. • transport or storage damage.
• No additional express Warranty is given
unless in writing signed by an authorised
The Warranty is void if:
manager of BOC.
• This Warranty is in addition to any other legal • changes are made to the product without the
rights you may have. approval of the manufacturer
• Plasma torch consumables, earth leads and • repairs are carried out using non-approved
their connectors, are not covered in these spare parts
Warranty terms. • a non-authorised agent carries out repairs.
• Regulators are not covered in these
Warranty terms.
9.3 Warranty Repairs
BOC or their Authorised Service Agent must
be informed of the Warranty defects, and the
product returned within the Warranty Period.

• Before any Warranty work is undertaken, the

customer must provide proof of purchase and
serial number of the equipment in order to
validate the Warranty.
• The parts replaced under the terms of the
Warranty remain the property of BOC.

­­­18 ­­­19
 10.0 Recommended Safety Guidelines

Some safety precautions BOC Key

recommends are as follows: 1 Cutting sparks can cause explosion or fire.
• Repair or replace defective cables 1.1 Keep flammable materials away from cutting.
immediately. Do not cut near flammable materials.
• Never watch the plasma arc except through 1.2 Cutting sparks can cause fires. Have a fire
lenses of the correct shade. extinguisher nearby, and have a watchperson
ready to use it.
• In confined spaces, adequate ventilation and
constant observation are essential. 1.3 Do not cut on drums or any closed container.

• Leads and cables should be kept clear of 2 The plasma arc can cause injury and burns.
passageways. 2.1 Turn off power before disassembling torch.
• Keep fire extinguishing equipment at a handy 2.2 Do not grip material near cutting path.
location in the shop. 2.3 Wear complete body protection.
• Keep primary terminals and live parts 3 Electric shock from torch or wiring can kill.
effectively covered.
3.1 Wear dry insulating gloves. Do not wear wet
• Never strike an electrode on any gas cylinder. or damaged gloves.
• Never use oxygen for venting containers. 3.2 Protect yourself from electric shock by
insulating yourself from work and ground.
3.3 Disconnect input plug or power before
working on machine.
4 Breathing cutting fumes can be hazardous to
your health.
4.1 Keep your head out of fumes.
4.2 Use forced ventilation or local exhaust to
remove fumes.
4.3 Use ventilating fan to remove fumes.
5 Arc rays can burn eyes and injure skin.
5.1 Wear hat and safety glasses. Use ear
protection and button shirt collar. Use
welding helmet with correct shade of
filter. Wear complete body protection.
6 Become trained and read the instructions
before working on the machine or cutting.
7 Do not remove or paint over (cover)
the label.

­­­20 ­­­21
 Notes

­­­22