Telwin Superior Plasma 70 Instruction Manual

INSTRUCTION MANUAL
WARNING! BEFORE USING THE PLASMA CUTTING SYSTEM READ THE INSTRUCTION MANUAL
CAREFULLY!
PLASMA CUTTING SYSTEMS DESIGNED FOR PROFESSIONAL AND INDUSTRIAL USE
1. GENERAL SAFETY INSTRUCTIONS FOR PLASMA ARC CUTTING
The operator should be properly trained to use plasma cutting systems safely and should be informed
about the risks related to arc welding procedures and associated techniques, about relevant safety
measures and emergency procedures.
(Please refer to the applicable standard "EN 60974-9: Arc welding equipment. Part 9: Installation and
Use).
- Prevent direct contact with the cutting circuit; the no-load voltage supplied by the plasma cutting
system may be dangerous under certain circumstances.
- When the cutting circuit cables are being connected or checks and repairs are carried, out the cutting
system should be switched off and disconnected from the power supply.
- Switch off the plasma cutting system and disconnect it from the power supply before replacing worn
torch parts.
- Make the electrical connections and installation according to the health and safety standards and
legislation in force.
- The plasma cutting system should be connected only and exclusively to a power supply network
with the neutral lead connected to earth.
- Make sure that the power supply plug is correctly connected to the earth protection outlet.
- Do not use the plasma cutting system in damp or wet places or in the rain.
- Do not use cables with worn insulation or loosened connections.
- Do not cut on containers, receptacles or piping that contains or has contained inflammable liquids
or gases.
- Do not work on materials cleaned with chlorinated solvents or in the vicinity of such substances.
- Do not cut on containers under pressure.
- Remove all flammable materials (e.g. wood, paper, cloth etc.) from the working area.
- Provide adequate ventilation or facilities for the removal of fumes produced by plasma cutting
work; a systematic approach is needed in evaluating the exposure limits for fumes produced by
cutting work, which will depend on their composition, concentration and the length of exposure
itself.
- Ensure there is adequate electrical insulation with regard to the plasma cutting torch nozzle, the
workpiece and any (accessible) earthed metal parts in the vicinity.
This is normally achieved by wearing gloves, shoes, head coverings and clothing designed for this
purpose and by using insulating platforms or mats.
- Always protect your eyes with the relative filters, which must comply with UNI EN 169 or UNI EN 379,
mounted on masks or use helmets that comply with UNI EN 175.
Use the relative fire-resistant clothing (compliant with UNI EN 11611) and welding gloves (compliant
with UNI EN 12477) without exposing the skin to the ultraviolet and infrared rays produced by the
arc; the protection must extend to other people who are near the arc by way of screens or non-
reflective sheets.
- Noise levels: if particularly intensive cutting operations cause daily personal noise exposure (LEPd)
of 85 dBA or more, suitable personal protection equipment must be worn (Tab. 1).
ELECTRIC AND MAGNETIC FIELDS CAN BE DANGEROUS
Electric current flowing through any conductor generates localised electric and magnetic fields (EMF).
Cutting current creates an EMF around the cutting circuit and the cutting system.
Electromagnetic fields can interfere with certain electrical devices (e.g. pacemakers, breathing
apparatuses, metal prostheses, etc.).
Adequate safety measures must be taken for wearers of such equipment. For example, prohibit access
to the use area of the plasma cutting system or assess the individual risk for operators.
This cutting system complies with the technical standards for products to be exclusively used in
industrial environments for professional purposes. Compliance with the basic limits of human
exposure to electromagnetic fields in domestic environments is not guaranteed.
All operators must follow the rules listed below, to reduce to a minimum exposure to EMF from the
cutting circuit:
- keep cutting cables close to one another. Fasten them with adhesive tape, when possible;
- keep head and torso as far as possible from the cutting circuit;
- never wind the cutting cables around metal objects or body;
- do not weld with body in the middle of the cutting circuit;
- keep both cutting cables on the same side of body;
- connect the cutting current return cable as close as possible to where you intend to work;
- do not cut near the plasma cutting system;
- all operators should comply with the minimum distances required as indicated in the EMF data
sheet;
- distance from the EMF source in the point over which exposure is less than 20% of the minimum
permitted value: d = 1.5 cm.
- Class A equipment:
This plasma cutting system conforms to the technical product standards for exclusive use in
an industrial environment and for professional purposes. It does not assure compliance with
electromagnetic compatibility in domestic dwellings and in premises directly connected to a low-
voltage power supply system feeding buildings for domestic use.
EXTRA PRECAUTIONS
PLASMA CUTTING OPERATIONS
- In environments with heightened risk of electric shock;
- In confined spaces;
- In the presence of inflammable or explosive materials;
MUST be evaluated in advance by an "Expert supervisor" and must always be carried out in the
presence of others who have been taught how to intervene in emergencies.
All protective technical measures MUST be taken as provided in 7.10; A.8; A.10 of the applicable
standard EN 60974-9: Arc welding equipment. Part 9: Installation and Use".
- Cutting operations MUST BE PROHIBITED if the operator is supporting the weight of the power
source (using slings for example).
- The operator MUST NEVER BE ALLOWED to carry out cutting operations if above ground level, unless
safety platforms are used.
- WARNING! USING THE PLASMA CUTTING SYSTEM SAFELY.
The safeguards provided by the manufacturer (interlocking system) can only be guaranteed to work
properly if the torch model and corresponding power source as indicated in the "TECHNICAL DATA"
(EN)
are used.
- DO NOT USE non-original torches or consumable parts.
- DO NOT ATTEMPT TO USE THE POWER SOURCE with torches that are made for cutting or WELDING
procedures but are not contemplated in this instruction manual.
- FAILURE TO COMPLY WITH THESE RULES may give rise to a SERIOUS safety hazard for the user and
may also damage the apparatus.
RESIDUAL RISKS
- TIPPING: place the plasma cutting power source on a horizontal surface with adequate load-bearing
capacity; otherwise (e.g. sloping or uneven floor etc.) the apparatus is in danger of tipping over.
- IMPROPER USE: it is dangerous to use the plasma cutting system for any work other than that for
which has been designed.
- Never lift the plasma cutting system without first disconnecting and removing all interconnection
and power supply cables and piping.
- RISK OF BURNS
Some parts of the plasma cutting system (torch) and adjacent areas can reach temperatures over
65°C: adequate protective clothing must be worn.
Allow the just cut workpiece to cool before touching it!
- MISUSE: it is dangerous for more than one operator to simultaneously use the plasma cutting
system.
- Do not use the handle to hang the plasma cutting system.
ENVIRONMENTAL CONDITIONS (EN 60974-1)
- Use the machine with the following environmental conditions only:
• ambient temperature between -10°C and 40°C;
• relative humidity of the air not exceeding 50% at 40°C;
• relative humidity of the air not exceeding 90% at 20°C;
• The surrounding air must be free of dust, acid, gas or corrosive substances, etc.
STORAGE
- Position the machine and its accessories (with or without packaging) in closed premises.
- The ambient temperature must be between -20°C and 55°C.
If the machine is planned with liquid cooling and an ambient temperature under 0°C: use the anti-
freeze liquid suggested by the manufacturer or completely empty the hydraulic circuit and the tank
of liquid.
Always use adequate measures to protect the machine from humidity, dirt and corrosion.
DISPOSAL
Do not dispose of this machine as normal household waste at the end of its life cycle.
The user is responsible for disposing of this electrical equipment in collection points designated for
disposal and recycling of electrical equipment or contact the shop where you purchased the product.
This provision only refers to disposal of the equipment within the European Union (WEEE).
2. INTRODUCTION AND GENERAL DESCRIPTION
Plasma cutting system with compressed air 3-phase, with fan. Used for fast cutting without deformation on
steel, stainless steel, galvanized steel, aluminium, copper, brass etc. The cutting cycle is enabled by a pilot arc.
MAIN CHARACTERISTICS
- Adjusts the cutting current.
- Torch voltage control device.
- Air pressure, torch short-circuit control device.
- Thermostatic safeguard.
- Air pressure display.
- Torch cooling control.
- Overvoltage, undervoltage, phase failure.
- Remote control connector.
STANDARD ACCESSORIES
- Plasma cutting torch.
- Compressed air connection fitting kit.
OPTIONAL ACCESSORIES
- Spare electrodes-nozzles kit.
- High air flow torch.
- Spare electrodes-nozzles kit for high air flow torch.
- Gouging kit.
3. TECHNICAL INFORMATION
DATA PLATE
The most important information regarding use and performance of the plasma cutting system is summarised
on the rating plate and has the following meanings:
1- EUROPEAN standard of reference, for safety and construction of arc welding and plasma cutting
machines.
2- manufacturer's name and address.
3- product model.
4- Symbol referring to the internal structure of the machine.
5- Symbol referring to plasma cutting procedure.
6- S symbol: indicates that cutting operations may be carried out in environments with heightened risk of
electric shock (e.g. close to large metal masses).
7- Symbol indicating the main power supply:
1~: single phase alternating voltage
3~: 3-phase alternating voltage
8- Casing protection rating.
9- Technical specifications for main power supply:
- U
: Alternating voltage and frequency of power supply to the machine (allowed limits ±10%):
1
- I : Maximum current absorbed by the line.
1 max
- I : Effective current supplied
1 eff
10- Performance of cutting circuit:
- U : maximum no-load voltage (open cutting circuit).
0
- I /U
: Current and corresponding normalized voltage that the machine is able to supply during
2 2
cutting.
- X : Duty cycle: indicates the time for which the machine is able to supply the corresponding current
(same column). It is expressed in %, based on a 10 min. cycle (e.g. 60% = 6 minutes work, 4 minutes
pause; and so on).
If the usage factors (on the plate, referring to a 40°C environment) are exceeded the thermal cutout
will trigger (the machine will remain in standby until its temperature returns within the allowed
limits).
- A/V-A/V : indicates the range over which the cutting current may be adjusted (minimum -
maximum) at the corresponding arc voltage.
11- Machine serial number (indispensable identification when asking for technical assistance, ordering spare
parts or discovering the origin of the product).
12-
: Size of delayed action fuses to be provided to protect the power line.
13- Symbols referring to safety standards, the meaning of which is explained in chapter 1 "General safety
instructions for plasma arc cutting".
- 3 -
Fig. A