AIR PLASMA CUTTERS AIR PLASMA CUTTING TECHNOLOGY. Section 4 1 HOW AIR PLASMA CUTTING TECHNOLOGY WORKS
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1 AIR PLASMA CUTTERS HOW AIR PLASMA CUTTING TECHNOLOGY WORKS AIR PLASMA CUTTING TECHNOLOGY 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 fi 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 afford ability for producing a variety of flat metal shapes. They can cut much fi 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 fl ows through the torch lead into the nozzle. 3. Next, compressed air fl ows through the torch head, through the air diffuser that spirals the air fl ow around the electrode and through the hole of the cutting nozzle. 4. 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. 5. Finally, the regulated DC current is switched so that it no longer fl ows to the nozzle but instead fl ows from the electrode to the work piece. Current and airfl ow continue until cutting is stopped. Electrode Insert Plasma Stream Nozzle Air Diffuser Electrode Shield Cup 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 orifi 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 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 (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 Section 4 1
2 Plasma - 40Amp DC Inverter Plasma Cutter SITECUT 10 Built In Air Compressor - 40 Amp 25 Amp 230v DC Inverter Plasma Cutter Industrial Rated, Lightweight and Portable 12 MONTH Machine Built in air compressor - eliminating the need for external compressor Advanced Inverter Technology Compact and ergonomic design Light industrial application Adjustable Amperage High quality Italian Plasma torch with drag tip technology Post flow torch cooling with auto stop for rapid restrike Non HF Arc Start for reduced electrical interference Pilot arc control allows uninterrupted arc across gaps Maximum sever cutting thickness 10mm (steel) 12 month warranty machine only Power Supply / Phases (V-Ph) 230v - 1 +/- 15% Duty 40 c as per AS/NZ Amps Duty 25 c (approximate) 25 Amps Rated Power (KVA) 3.10 Output Current Range (A) Plasma Max OCV Range (V) 460 Max Current (A) 25 Insulation Class - Inverter H Insulation Class - Compressor F IP23 HF Air Flow (l/min) 80 Max Cutting Thickness (mm) Dimensions (mm) 420 x 185 x 380 Weight (kg) month machine only The SiteCut 10 is a 230V Plasma cutting system produced using the latest Inverter Technology. The SiteCut 10 has a built in air compressor - eliminating the need for external air compressor. The SiteCut 10 produces a high temperature Plasma stream, enabling effortless cutting of all electrically conductive materials including steel, cast Iron, stainless steel, copper, aluminium brass etc. The SiteCut 10 is equipped with a high quality Italian manufactured Plasma Torch developed specifi cally to provide a non HF start of the Plasma arc for reduced interference to other electronics. The SiteCut 10 has outstanding performance with powerful, fast and accurate cutting capability, the Pilot Arc control provides uninterrupted cutting across gaps such as in expanded mesh. The SiteCut 10 is ideal for a wide range of applications including sheet metal contractors and fabricators, plumbing, site work, automotive, ducting work, farm maintenance and metal artwork industries. The Site Cut 10 is packaged with a tough PT-25C Plasma Torch including parts package, earth lead and air regulator. The fi tted PT-25C Plasma torch is the latest in Plasma torch design and provides drag tip technology allowing constant contact with the work piece during the cutting process providing fast accurate cuts with minimal material distortion. The SiteCut 10 is the ultimate in plasma cutting portability. Built to our specification and manufactured in compliance to IEC Product Code: V0266AA SiteCut 10 package includes: SiteCut 10 Machine, PT25C Plasma Torch 4m, Torch Spares Kit, Earth Lead 16mm x 3m Section 4 2
3 Plasma - 40 Amp DC Inverter Plasma Cutter XA-CUT40E 40 Amp - 12mm Cut on Steel 230v DC Inverter Plasma Cutter Industrial Rated, Lightweight and Portable Latest Inverter Technology Instant cut start, no preheat required Light industrial application Light weight and compact Strong metal housing Safe torch connection High quality Italian Plasma torch Tolerant to variable power supply HF Contact Arc Start Tip can be contacted and dragged on cutting material Maximum cutting thickness 12mm (steel) 24 month machine only 24 MONTH Machine Power Supply / Phases (V-Ph) 230v - 1 +/- 15% Duty 40 c as per AS/NZ Amps Duty 25 c (approximate) 40 Amps Rated Power (KVA) 3.50 Output Current Range (A) Plasma Rated Output Voltage (V) 96 Efficiency (%) 85 Insulation Class B IP21S HF Touch Air Flow Draw Off (l/min) Air Flow Pressure (Bar) 5-6 (70-87 psi) Max Cutting Thickness (mm) Dimensions (mm) 371x155x295 Weight (kg) months machine only Certification Approval AS/NZ XA-CUT40E PLASMA CUT OPTIONS Part No. M26AIR The XA-CUT40 is an inverter-based Plasma cutting machine produced using the latest in IGBT technology. Low cost and portable this machine is reliable, robust and stacked with features that you can expect from a quality Plasma Cutter. The XA-CUT40 produces a high temperature plasma stream enabling effortless cutting of all electrically conductive materials including steel, cast Iron, stainless steel, copper, aluminium brass etc. The XA-CUT40 is equipped with a high quality Italian manufactured Plasma torch with Euro connection, developed specifically to enhance and improve the cut quality of the XA-CUT40 machine. Connection of the TD35 Plasma torch provides effortless starting of the cut with powerful, fast and accurate cutting capability, additional is the benefi t of longer life cycle consumable electrodes and cutting tips. The HF contact start function allows the torch tip to be placed directly onto the work piece during start up and also during the cutting process helping to provide more accurate cutting and cleaner start of the cut. The XA-CUT40 is an exceptional machine that is suitable for a wide range of applications including sheet metal fabrication, light industrial use, site work, automotive, ducting work, repair and maintenance services. The XA-CUT40 is packaged with a tough TD35 Plasma torch including parts package, earth lead and air regulator. The XA-CUT40 gives you the best of both worlds great portability, with the power to get the job done. Built to our specification and manufactured in compliance to AS/NZ Product Code: XA-CUT40E-K CUT40K includes: XA-CUT40 Machine, TD35 Plasma Torch 4m, Torch Spares Kit, Earth Lead 16mm x 4m and Air Regulator Section 4 3
4 Plasma - 55 Amp DC Inverter Plasma Cutter XA-CUT55 55 Amp - 20mm Cut on Steel 415v DC Inverter Plasma Cutter Industrial Rated, Lightweight and Portable Latest Inverter Technology Instant cut start, no preheat required Industrial application Safe Euro style torch connection High performance Italian torch Strong metal housing Auto protection of over-voltage and over current supply Auto protection of short air pressure and thermal overload Tolerant to variable power supply HF Start Maximum cutting thickness 20mm (steel) 24 months machine only warranty 24 MONTH Machine Power Supply / Phases (V-Ph) /- 15% Duty 40 c as per AS/NZ Amps Duty 25 c (approximate) 55 Amps Rated Power (KVA) 11.0 No Load Voltage (V) 270 Output Current Range (A) Plasma Rated Output Voltage (V) 104 Air Flow Draw Off (l/min) Air Flow Pressure (Bar) 5-6 (70-87 psi) Efficiency (%) 85 Power Factor 0.93 Insulation Class F IP23 HF Max Cutting Thickness (mm) Dimensions (mm) 540x220x370 Weight (kg) months machine only Certification Approval AS/NZ XA-CUT55 PLASMA CUT OPTIONS Part No. M26AIR Circle Cutting Kit Part No The XA-CUT55 is an inverter-based Plasma cutting machine produced using the latest in IGBT technology. Low cost and portable this machine is reliable, robust and stacked with features that you can expect from a quality Plasma cutter. The XA-CUT55 produces a high temperature plasma stream enabling effortless cutting of all electrically conductive materials including steel, cast Iron, stainless steel, copper, aluminium brass etc. The XA-CUT55 is equipped with a high quality Italian manufactured Plasma torch developed specifi - cally to enhance and improve the cut quality of the XA-CUT55 machine. Connection of the T100 Plasma torch provides powerful, fast and accurate cutting performance, additional benefi t is the T100 longer life cycle consumable electrodes and cutting tips. The HF start function allows effortless and clean cut start and stand off cutting, contact cutting is possible by installing the contact cutting torch parts. The XA-CUT55 is an exceptional machine that is suitable for a wide range of applications including general engineering, fabrication, site work, agricultural, repair and maintenance services. The XA-CUT55 is packaged with a tough T100 Plasma torch including parts package, earth lead and air regulator. The XA-CUT55 gives you the power and performance to get the job done. Built to our specification and manufactured in compliance to AS/NZ Product Code: XA-CUT55-K CUT55K includes: XA-CUT55 Machine, T-100 Plasma Torch 6m, Torch Spares Kit, Earth Lead 25mm x 4m and Air Regulator Section 4 4
5 Plasma Amp DC Inverter Plasma Cutter XA-CUT Amp - 28mm Cut on Steel 415v DC Inverter Plasma Cutter Industrial Rated, Portable 24 MONTH Machine Latest Inverter Technology Instant cut start, no preheat required Industrial application Safe Euro style torch connection High performance Italian torch Strong metal housing Auto protection of over-voltage and over current supply Auto protection of short air pressure and thermal overload Tolerant to variable power supply HF Start Maximum cutting thickness 28mm (steel) 24 months machine only warranty Power Supply / Phases (V-Ph) /- 15% Duty 40 c as per AS/NZ Amps Duty 25 c (approximate) 105Amps Rated Power (KVA) 16.5 No Load Voltage (V) 340 Output Current Range (A) Plasma Rated Output Voltage (V) 124 Air Flow Draw Off (l/min) Air Flow Pressure (Bar) 5-6 (70-87 psi) Efficiency (%) 85 Power Factor 0.93 Insulation Class F IP23 HF Max Cutting Thickness (mm) Dimensions (mm) 580 x 335 x 590 Weight (kg) months machine only Certification Approval AS/NZ XA-CUT105 PLASMA CUT OPTIONS Part No. M26AIR Circle Cutting Kit Part No The XA-CUT105 is an inverter-based Plasma cutting machine produced using the latest in IGBT technology. Low cost and portable this machine is reliable, robust and stacked with features that you can expect from a quality Plasma cutter. The XA-CUT105 produces a plasma stream enabling effortless cutting of all electrically conductive materials including steel, cast Iron, stainless steel, copper, aluminium brass etc. The XA-CUT105 is equipped with a high quality Italian manufactured Plasma torch developed specifi cally to enhance and improve the cut quality of the XA-CUT105 power source. Connection of the T150 Plasma torch provides powerful, fast and accurate cutting performance, and additional benefit is the T150 longer life cycle consumable electrodes and cutting tips. The HF start function allows effortless and clean cut start and stand off cutting, contact cutting is possible by installing the contact cutting torch parts. The XA-CUT105 is an exceptional machine that is suitable for a wide range of applications including heavy fabrication, general engineering, site work, agricultural, repair and maintenance services. The XA-CUT105 is packaged with a tough T150 Plasma torch including parts package, earth lead and air regulator. The XA-CUT105 gives you the power and performance to get the job done. Built to our specification and manufactured in compliance to AS/NZ Product Code: XA-CUT105-K CUT105K includes: XA-CUT105 Machine, T-150 Plasma Torch 6m, Torch Spares Kit, Earth Lead 25mm x 4m and Air Regulator Section 4 5
6 PLASMA AIR FILTERS Sub-Micronic Compressed Air Filters PLASMA AIR FILTERS Contaminants in your compressed air system - dust, scale, condensed moisture and oil mist - seriously effect the quality of your plasma cuts. M-26 / M-60 Sub-Micronic Compressed Air Filter Contaminants in your compressed air system - dust, scale, condensed moisture and oil mist - seriously effect the quality of your plasma cuts. Installation of a Motor Guard on your plasma machine will effectively remove these contaminants; eliminating arc sputter and producing cleaner faster smoother cuts. In addition, Motor Guard filters virtually pay for themselves by reducing wear and prolonging the life of expensive tips and electrodes. New! Ideal for small plasma cutters, air tools, blow guns and spray equipment Removes oil aerosols, condensed moisture and particulates Lightweight and disposable Mounts directly on tool for ultimate protection Cleaner, faster, smoother plasma cutting with ultra-clean air Prolongs the life of expensive plasma gun tips Removes oil aerosols, condensed moisture and particulates Installs on or near equipment for ultimate protection Ideal for plasma cutters and all air consuming equipment D-13 Disposable DD-1008 Disposable In-Line Desiccant Filter Unique point-of-use desiccant dryer Ideal for small plasma cutters, air tools, blow guns and spray equipment Removes oil aerosols, condensed moisture and particulates Exclusive color-change indicator signals when replacement is needed Mounts directly on tool for ultimate protection M-723 Replacement Filter Element for M-26/M60 SPECIFICATIONS PART # DESCRIPTION PIPE SIZE MAX PSI MAX PRESSURE MAX TEMP REMOVAL RATING (Nom) SIZE REPLACEMENT ELEMENT M-26 Sub-Micronic Compressed Air Filter 1/4 NPT 2700 SCFH 125 PSI 175 F.01 Microns 5 x 7 M-723 Mounting bracket included M-60 Sub-Micronic Compressed Air Filter 1/2 NPT 6000 SCFH 125 PSI 175 F.01 Microns 5 x 7 M-723 Straight-through piping design D-13 Disposable 1/4 NPT 1800 SCFH 100 PSI 175 F.01 Microns 2-1/2 x 3 None DD-1008 Disposable In-Line Desiccant Filter 1/4 NPT 1200 SCFH 100 PSI 120 F 5 Microns 1-1/2 x 3-1/2 None Section 4 6
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