Alfain PEGAS 101 PLASMA Bedienungsanleitung

ALFA IN a.s © www.alfain.eu PEGAS 101 PLASMA manual EN 12

PLASMA CUTTING MACHINE

PEGAS 101 PLASMA

OPERATING MANUAL

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CONTENT

1. INTRODUCTION ...................................................................................... 3

2. SAFETY INSTRUCTIONS AND WARNINGS ........................................... 4

3. CONDITIONS OF USE ............................................................................. 7

4. TECHNICAL DATA ................................................................................... 8

5. MAIN PARTS OF THE MACHINE .......................................................... 11

6. ACCESSORIES ..................................................................................... 13

7. GETTING STARTED .............................................................................. 15

8. CUTTING ............................................................................................... 17

9. MAINTENANCE ..................................................................................... 20

10. STATEMENT OF WARRANTY .............................................................. 23

11. DISPOSAL ............................................................................................. 24

12. WARRANTY LIST .................................................................................. 24

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1. INTRODUCTION

Congratulations on your new ALFA IN product. We are proud to have you as our

customer and will strive to provide you with the best service and reliability in the

industry.

This Operating Manual has been designed to instruct you on the correct use and

operation of your ALFA IN product. Your satisfaction with this product and its

safe operation is our ultimate concern. Therefore please take the time to read

the entire manual, especially the Safety Precautions. They will help you to avoid

potential hazards that may exist when working with this product.

Read and understand this entire Manual and your employer’s safety practices

before installing, operating, or servicing the equipment. While the information

contained in this Manual represents the Manufacturer's best judgement, the

Manufacturer assumes no liability for its use.

Machine PEGAS 101 PLASMA is designed for cutting metal on the basis of

modern technology cutting material through a thin beam plasma gas.

PEGAS 101 PLASMA is designed for high-quality cutting of materials up to 40

mm thick carbon steel (for more information, see instructions below). Productive

cutting of carbon steel can be to a thickness of 25 mm.

At lower demands on the quality of the cut can be cut through (separate) the

material thickness to 50 mm.

We reserve the law of adjustments and changes in case of printing errors,

change of technical paramaters, accessories etc. without previous notice. These

changes may not be reflected in the manuals for use in paper or electronic form.

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2. SAFETY INSTRUCTIONS AND WARNINGS

1. OPERATION AND MAINTENANCE OF PLASMA ARC EQUIPMENT CAN

BE DANGEROUS AND HAZARDOUS TO YOUR HEALTH.

2. Plasma arc cutting produces intense electric and magnetic emissions that

may interfere with the proper function of cardiac pacemakers, hearing aids,

or other electronic health equipment. Persons who work near plasma arc

cutting applications should consult their medical health professional and the

manufacturer of the health equipment to determine whether a hazard exists.

3. Once the packing has been opened, make sure that the machine is not

damaged. If in any doubt, call the service centre.

4. This equipment must only be used by qualified personnel.

5. During installation, any electric work must only be carried out by trained

personnel.

6. The machine must be used in a dry place with good ventilation.

7. Make sure that no metal dust can be drawn in by the fan inside the machine,

as this could cause damage to the electronic circuits.

8. It is prohibited to connect more than one INVERTER generator in series or in

parallel.

9. When installing the machine, follow the local regulations on safety.

10. The position of the machine must allow easy access by the operator to the

controls and connectors.

11. When the cutting machine is operating, all its covers and doors must be

closed and well fixed.

12. Do not expose the cutting machine to direct sunlight or to heavy rain. This

equipment conforms to protection rating IP 23 S.

13. The operator must wear gloves, clothes, shoes, and a helmet or a welder’s

helmet, which protect and are fire-resistant in order to protect him against

electric shock, flashes and sparks from cutting.

14. The operator must protect his eyes with safety visor or mask designed for

welding, fitted with standard safety filters. He should also be aware that during

plasma cutting ULTRAVIOLET RADIATION is emitted. Therefore it is vital

that his face is also protected from radiation. Ultraviolet rays produce the

same harmful effect as sun burning on unprotected skin.

15. The operator is obliged to warn anyone near the cutting area of the risks

that cutting involves and to arrange to provide adequate protection

equipment.

16. Keep all fumes and gases from the breathing area.

17. Keep your head out of the fume plume.

18. Use an air-supplied respirator if ventilation is not adequate to remove all

fumes and gases.

19. The kinds of fumes and gases from the plasma arc depend on the kind of

metal being used, coatings on the metal, and the different processes. You

must be very careful when cutting or welding any metals which may contain

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one or more of the following:

Antimony Chromium Mercury

Nickel

Cobalt

Arsenic

Barium

Copper

Selenium

Beryllium Lead Silver

Cadmium

Manganese

Vanadium

20. Always read the Material Safety Data Sheets (MSDS) that should be

supplied with the material you are using. These MSDSs will give you the

information regarding the kind and amount of fumes and gases that may be

dangerous to your health.

21. It is very important to arrange for sufficient ventilation, especially when

cutting in enclosed spaces. We suggest using suitable fume extractors to

prevent the risk of intoxication by fumes or gas generated by the cutting

process.

22. Noise can cause permanent hearing loss. Plasma arc processes can

cause noise levels to exceed safe limits. You must protect your ears from loud

noise to prevent permanent loss of hearing.

23. To protect your hearing from loud noise, wear protective ear plugs and/or

ear muffs. Protect others in the workplace.

24. Noise levels should be measured to be sure the decibels (sound) do not

exceed safe levels.

25. The operator must ensure all flammable materials are removed from the

work area to avoid any risk of fire.

26. The operator must NEVER cut containers that have previously contained

petrol, lubricants, gas or similar flammable materials, even if the container

has been empty for a considerable time. THERE IS A VERY HIGH RISK OF

EXPLOSION.

27. The operator must be aware of all the special regulations which he needs

to conform to when cutting in enclosed spaces with a high risk of explosion.

28. To prevent electric shock, we strongly suggest the following rules:

a) Do not work in a damp or humid environment.

b) Do not use the machine if its cables are damaged in any way.

c) Make sure that the earthing system of the electric equipment is correctly

connected and operational.

d) The operator must be insulated from the metal components connected

to the return wire.

e) The earthing of the piece being worked could increase the risk of injury

to the operator.

29. EN 60974-1 Standard: Open-circuit voltage. During the operation of the

machine, the highest voltage, with which it is possible to come into contact, is

the open-circuit voltage between the clamps. In our generator this voltage is

380V.

30. The maximum open-circuit voltage of the plasma machines is established

by national and international standards (EN 60974-1) depending on the type

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of current to be used, on its waveform and on the hazards arising from the

work place. These values are not applicable to the strike currents and those

for stabilisation of the arc that could be above it.

31. The open-circuit voltage, for as many adjustments as possible, must never

exceed the values relating to the various cases shown in the following table:

Case

Working conditions

Open

circuit voltage

1 Places with increased risk of

electric shock

DC current: 113V

peak value

AC current: 68V

peak value and

48V effective

2 Places without increased risk

of electric shock

DC current: 113V

peak value

AC current: 113V

peak value and

80V effective

Torches held mechanically

with increased protection for

the operator

DC current: 141V

peak value

AC current: 141V

peak value and

100V effective

4 Plasma cutting DC current: 500V

peak value

32. In case 1, the dc machines with rectifier must be built in such a way that,

in case of a fault developing in the rectifier (for example open circuit, short

circuit or lack of power), the permitted values cannot be exceeded. The

plasma cutting machines of this type can be marked with the symbol:

33. Before opening the machine switch off the machine and disconnect it from

the power socket.

34. Only personnel authorised by this company can carry out maintenance on

the machine.

PROTECTIVE UTTILITIES

1. Welding helmet with filter shade at least 10

2. Welding gloves

3. Welding apron and cloth

4. Welding boots

RISK OVERVIEW

1. Risk of electric shock

2. Ultraviolet light and light radiation

3. Risk of inhaling gas fumes and dust particles

4. Burns

5. Noise

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NOTE

The Machine Torches (AUT) must not be used with PEGAS 101 PLASMA.

It may only be used together with PEGAS 101 PLASMA CNC.

NOTE

1. It is forbidden to operate a machine with damaged insulation of the cutting

torch or supply cable.

2. Never operate the machine taken down or damaged covers.

3. It is forbidden to operate the machine in wet environments and outdoors in

rain or snow.

4. Ensure proper grounding clamping pliers, which also reduces the risk of

electric shock.

5. Use prescribed protective utilities, keep them dry.

6. Plasma arc cutting produces intense electric and magnetic emissions that

may interfere with the proper function of cardiac pacemakers, hearing aids,

or other electronic health equipment. Persons who work near plasma arc

cutting applications should consult their medical health professional and

the manufacturer of the health equipment to determine whether a hazard

exists.

7. Never aim the torch against the eyes, body or other person.

3. CONDITIONS OF USE

1. This equipment must only be used by qualified personnel.

2. During installation, any electric work must only be carried out by trained

personnel.

3. Device complies with IEC 61000-3-12.

4. Do not expose the plasma machine to direct sunlight or to rain or snow. This

equipment conforms to protection rating IP 23 S.

5. Working ambient temperature between -10 and +40 °C.

6. Relative humidity below 90% at +20 °C.

7. Up to 3000 m altitude.

8. Place the machine the way that the cooling air can enter the vents without

restriction to. It is necessary to ensure that no impurities, especially metal

particles, are not drawn into the machine.

9. Cutting machine in terms of interference suppression is intended primarily for

industrial premises. In the case of use of other areas may be need for special

measures (see EN 60974-10).

10. The machine must be protected against:

a. Moisture and rain and snow

b. Mechanical damage

c. Draft and any ventilation of neighbouring machine

d. Excessive overloading - crossing technical parameters

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e. Rough handling

ELECTROMAGNETIC COMPATIBILITY

The welding device is in terms of interference designed primarily for industrial

areas. It meets the requirements of EN 60974-10 class A and it isn’t designed

for using in residential areas, where the electrical energy is supplied by public

low-voltage power supply network. It can be here potential problems with

ensuring of electromagnetic compatibility in this areas, due to interference

caused by power lines as well as the radiated interference.

During operation, the device may be the source of interference.

Caution

We warn users, that they are responsible for possible interference from welding.

4. TECHNICAL DATA

PEGAS 101 PLASMA

Method

Plasma cutting

Mains voltage V/Hz 3 x 400/50-60

Cutting current range A 20 - 100

Open-circuit voltage U20 V 380

Mains protection A 32 @

Max. effective current I1eff A 27,8

Cutting current (DC=100%) I2 A 100

Cutting current (DC=60%) I2 A 100

Cutting current (DC=x%) I2 A 100%=100

Max. productive cut. thickness - carbon steel mm 25

Max. cutting thickness - carbon steel

(separate mat.)

mm 50

Quality cutting thickenss

Carbon steel mm 40

Stainless steel mm 30

Aluminium mm 20

Copper mm 15

Max. Input pressure (torch SVH-105) bar 8,5

Working pressure (torch SVH-105) bar 5,0 – 5,5

Air consumption (torch SVH-105) l/min 295

Arc ignition

pneu-mechanic

Current regulation

continuous

Protection

IP 23 S

Standards

EN 60974-1, EN 60974-10 cl. A

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Dimensions (w x l x h) mm 240 x 440 x 675

Weight kg 32,4

PEGAS 101 PLASMA CNC

Method

Plasma cutting

Mains voltage V/Hz 3 x 400/50-60

Cutting current range A 20 - 100

Open-circuit voltage U20 V 380

Mains protection A 32 @

Max. effective current I1eff A 27,8

Cutting current (DC=100%) I2 A 100

Cutting current (DC=60%) I2 A 100

Cutting current (DC=x%) I2 A 100%=100

Mild steel

Production pierce/cut (I2max) mm 12

Production pierce/cut

@DC=100%) mm 12

Maximum pierce/cut (I2max) mm 15

Edge start/cut (I2max) mm 30

Max. Input pressure bar 8,5

Working pressure (torch TM 125/6m) bar 5,5

Air consumption (torch TM 125/6m) l/min 295

Arc ignition

pneu-mechanic

Current regulation

continuous

Protection

IP 23 S

Standards

EN 60974-1, EN 60974-10 cl. A

Dimensions (w x l x h) mm 240 x 440 x 675

Weight kg 32,4

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EXPLANATION OF TERMS (VALID ONLY WHILE USING ALFA IN

ALFATEC CNC SYSTEM)

Productive Pierce / cutting (I2 max) means a cutting process whereby the plasma

is set to the maximum cutting current and a good cut quality is achieved.

Productive Pierce / cutting (DC=100%) means a cutting process whereby the

plasma is set to the current equal to 100% of duty cycle and a good cut quality

is achieved.

Maximum Pierce / cutting (I2 max) means a cutting process whereby the plasma

is set to the maximum cutting current and an acceptable cut quality is achieved.

Edge Start / cutting (I2 max) means a cutting process whereby the plasma is set

to the maximum cutting current and an acceptable cut quality is achieved starting

the cut form the edge of the material.

CNC CONNECTOR CONNECTION

Only for machines equipped with a CNC interface.

Pin Description

8 Torch button

9 Torch button

6 Divider output arc voltage (+)

7 Divider output arc voltage (-)

13 Start of machine movement

14 Start of machine movement

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