STEEL VISION TOOLS PLASMA-CUT-40/45 110/ 230V SINGLE PHASE PLASMA CUTTER

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 first 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 carburetor. 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 affordability for producing a variety of flat metal shapes.They can cut much finer, and faster than oxy-acetylene torches.

How a plasma cutter works:

Basic plasma cutters use electricity to super heat 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 flows through the torch lead into the nozzle.
2. Next, compressed air flows through the torch head, through the air diffuser that spirals the air flow around the electrode and through the hole of the cutting nozzle.
3. A fixed 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 flows to the nozzle but instead flows from the electrode to the work piece. Current and air flow continue until cutting has 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 orifice 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 13/16" 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 faster, thicker cuts than with alloys. Oxy fuel cuts by burning, oroxidizing the metal it is severing. It is therefore limited to steel and on any type of conductive metal -mild steel , aluminium and stainless are some examples. With mild steel, operators will experience 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 different 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 (1"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 Oxy fuel 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. Oxy fuel can generally cut thicker sections (>63/64inch) of steel more quickly than plasma.

STEEL VISION TOOLS PLASMA-CUT-40/45 110/230V PLASMA CUTTER MANUAL

1) Connect the Plasma Torch to the machine. Insert the torchconnection into the torch connection receptacle at the front of the machine and screw up hand tight.

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

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

(4) Connect the machine to the correct power supply and switch on the machine using the on/off switch located at the rear of the machine.

(5) Select 2T/4T operation

Operating procedure using the 2T/4T Function with Plasma torch. Set torch operation 2T/4T.

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

• When 4T operation is selected press and release trigger Arc starts, press and release trigger Arc stops.

(6) Set amperage dial.

Operating procedure using the stand off guide mounted to the plasma torch. The feet of the stand off guide are placed on the cutting surface. This maintains an optimal 5/64" stand off distance between the plasma cutting tip and the work. This is especially ideal if your hands are unsteady, or if you prefer to use a straight edge guide or pattern guide. It also helps extend tip life.

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.



2) Connect the earth clamp securely to the work piece or the workbench.



3) Place and hold the torch vertical at the edge of the plate.



Please note: Torch and lean shape varies from machine to machine.

4) Pull the trigger to energize the pilot arc. The cutting arc will start when the nozzle is moved closer to the edge of the workpiece. When the cutting arc has cut through the edge of the plate, start moving evenly in the direction you want to cut.



5) Correct amperage and travel speed are important and relevant to material thickness and are correct when sparks are exiting from the workpiece. If sparks are spraying up from the workpiece there is insufficient amps selected or the travel speed is too fast.



6) To finish the cutting, release the torch switch. The air flow will continue for 30 seconds to cool the torch head.

Tip size and condition

The tip orifices focus the plasma stream to the workpiece. It is important to use the correct size tip for the amperage being used, for example a tip with a 3/64" orifice is good for 0-40 amps whereasa 1/16" orifice is better for 40-80amps. The low-amp tip has a smaller orifice which maintains a narrow plasma stream at lowersettings for use on thin-gauge material. Using a 25 amp tip at an 60 amp setting will blow out and distort the tip orifice 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 orifice is critical to the quality of the cut result, a worn or damaged tip orifice will produce a distorted plasma stream resulting in a poor cut quality.

Electrode condition

Air pressure, flow rate and air quality are critical to quality plasma cutting and consumable lifespan. The required air pressure and volume can vary from model to model and the manufacturer will provide the specs. The Vipercut30 air pressure is adjustable but requires a minimum of 6CFM and 75 psi. The volume capacity of your compressor is important, if you have a small compressor with exactly the same rating as the plasma, then the compressor will run continuously when you are plasma cutting, a compressor with al/min rating slightly higher than the plasma would be more adequate.If you are doing a lot of cutting, cutting thickplate (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 air lines 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 19832° f) in the plenum of the torch, they immediately break down into oxygen and hydrogen, which alters the normal chemical content of air inthetorch.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 orifice, dramatically affecting cut quality in terms of edge squareness, dross formation, and edge smoothness. Minimizing the moisture in the air supply is absolutely critical to quality plasmacuts 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 manufacturer shave a nonboard particulate filter and or a coalescing filter with an auto drain that will remove some moisture from the air supply. For homeworkshop and light industrial users the on board air filter is adequate. Most situations however will require additional filtration to prevent moisture from affecting the quality of the plasma cutter and in most cases it is recommended to install a submicronic particulate filter that is designed to trap water through absorption.This style of filter has a replaceable filter cartridge that absorbs water and must be changed after it is near saturation, it should be installed as close as possible to the air intake of the plasma cutter.

Note:  The dryer the air, the longer your consumable life!



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 orifice 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.

Starting a cut



Hold the torch vertical at the edge of the workpiece. (above left)
Pull the trigger to start the pilot arc. The cutting arc will initiate when the torch tip is close enough to the work piece. Start cutting on the edge until the arc has cut completely through, exiting from the bottom of the work piece. (above middle)
Then, proceed with the cut. (above right)

Note: Torch design varies from machine to machine

Hand torch cutting technique



When cutting make sure that the sparks are spraying down. (above left)
If sparks are spraying up from the work piece, you are moving the torch too fast, or you don't have enough ams set. (above middle)
Hold the torch vertical and watch the arc as it cuts along the line. (above right)


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 workpiece, the arc has pierced through the material.
When the pierce is complete, proceed with cutting.