Alfain PEGAS 41 PLASMA PFC Manuel utilisateur

ALFA IN a.s © www.alfain.eu PEGAS 41 PLASMA PFC manual EN 06

PLASMA CUTTING MACHINE

PEGAS 41 PLASMA PFC

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 .......................................................... 10

6. ACCESSORIES ..................................................................................... 11

7. GETTING STARTED .............................................................................. 16

8. CUTTING ............................................................................................... 18

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

10. STATEMENT OF WARRANTY .............................................................. 22

11. DISPOSAL ............................................................................................. 23

12. WARRANTY LIST .................................................................................. 23

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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 41 PLASMA PFC is designed for cutting metal on the basis of

modern technology cutting material through a thin beam plasma gas.

PEGAS 41 PLASMA PFC is equipped by Power Factor Correction (PFC), which

allows operation on single phase voltage networks 110 V – 230 V.

PEGAS 41 PLASMA PFC is designed for high-quality cutting of materials up to

15 mm thick carbon steel (for more information, see instructions

below). Productive cutting of carbon steel can be to a thickness of 10 mm.

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

material thickness to 20 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 YOURHEALTH.

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 IP23S.

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

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processes. You must be very careful when cutting or welding any metals

which may contain 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 320V.

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

established by national and international standards (EN 60974-1)

depending on the type 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

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5. Noise

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 IP23S.

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

e. Rough handling

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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

Method

Plasma cutting

Mains voltage V/Hz 1x110/50-60 1x230/50-60

Cutting current range A 20 - 30 20 - 40

Open-circuit voltage U20 V 320

Mains protection A 25 @ 16 @

Max. effective current I1eff A 20,4 15,4

Cutting current (DC=100%) I2 A 20 28

Cutting current (DC=60%) I2 A 22 33

Cutting current (DC=x%) I2 A 35%=30 50%=40

Max. productive cut. thickness - carbon steel mm 8 10

Max. Cutting thickness - carbon steel

(separate mat.)

mm 15 20

Quality cutting

thickenss

Carbon steel mm 10 15

Stainless steel mm 8 12

Aluminium mm 6 10

Copper mm 3 4

Max. Input pressure bar 8,5

Working pressure (torch PT-60/ABICUT 45) bar 4,4 – 5,0/5,0

Air consumption (torch PT-60/ABICUT 45) l/min 150/119

Arc ignition

pneu-mechanic

Current regulation

continuous

Protection

IP 23S

Standards

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

Dimensions (w x l x h) mm 148 x 490 x 295

Weight kg 8,4

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IMPORTANT NOTICE 

Please keep in mind that at the set maximum cutting current parameters, the

current consumption from the mains increases significantly when the distance

between the torch and the material is increased (arc extension).

This can cause unwanted tripping of the circuit breaker. This phenomenon can

also occur if the consumable material (nozzle, electrode) is worn out.

Precautions:

It is recommended to cut at a constant distance from the material (as small as

possible) and to maintain select an adequate cutting current (do not use high

cutting current values unnecessarily).

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5. MAIN PARTS OF THE MACHINE

FRONT AND REAR PANELS

Fig. 1 Main parts of the machine

Pos. Description

A1 Connector - torch

A2 Quick connector – earthing cable

A3 Potentiometer-set cut current

A4 LED indicator – when illuminated, the machine is ON

A5 LED indicator. If the LED illuminates the thermo-switch is

disconnected. In such a case leave the machine on to cool down.

Second warning is when the mains voltage is over 270 V.

A6 LED Error

1. LED illuminates and the air valve regularly opens and closes

there is a shortcut among the shield cup and the cutting tip.

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