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Instruction Manual
Read this instruction manual carefully before using the welding machine.
The Plasma cutting systems referred to herein as "welding machines" are for industrial
and professional use.
Make sure that the machine is installed and repaired only by qualified persons or experts,
in compliance with the law and with the accident prevention regulations.
Make sure that the operator is trained in the use and risks connected to the arc-welding
processs and in the necessary measures of protection and emergency procedures.
Detailed information can be found in the "Installation and use of arc-welding equipment"
brochure: IEC or CLC/TS 62081.
Safety warnings
Make sure that the power socket to which the machine machine is connected is protected
by suitable safety devices (fuses or automatic switch) and that it is grounded.
Make sure that the plug and power cable are in good condition.
Before plugging into the power socket, make sure that the machine is switched off.
Switch the machine off and pull the plug out of the power socket as soon as you have
finished working.
Switch the machine off and pull the plug out of the power socket before connecting the
welding cables, installing the continuous wire, replacing any parts in the torch or wire
feeder, carrying out maintenance operations, or moving it (use the carrying handle on
the machine).
Do not touch any electrified parts with bare skin or wet clothing. Insulate yourself
from the electrode, the piece to be cut and any grounded accessible metal parts.
Use gloves, footwear and clothing designed for this purpose and dry, non-flammable
insulating mats.
Use the machine in a dry, ventilated space. Do not expose the welding machine to
rain or direct sunshine.
Use the machine only if all panels and guards are in place and mounted correctly.
Do not use the machine if it has been dropped or struck, as it may not be safe. Have
it checked by a qualified person or an expert.
Eliminate any cutting fumes through appropriate natural ventilation or using a smoke
exhauster. A systematic approach must be used to assess the limits of exposure
to cutting fumes, depending on their composition, concentration and the length of
exposure.
Do not cut materials that have been cleaned with chloride solvents or that have been
near such substances.
Use a welding mask with inactinic glass suitable for cutting operations. Replace the
mask if damaged; it may let in radiation.
Wear fireproof gloves, footwear and clothing to protect the skin from the rays produced
by the welding arc and from sparks. Do not wear greasy garments as a spark could set
fire to them. Use protective screens to protect people nearby.
Do not allow bare skin to come into contact with hot metal parts, such as the torch,
electrode holder grippers, electrode stubs, or freshly cut pieces.
Metal-working gives off sparks and splinters. Wear safety goggles with protective side
eye guards.
Welding sparks can trigger fires.
Do not weld or cut anywhere near inflammable materials, gasses or vapours.
Do not weld or cut containers, cylinders, tanks or piping unless a qualified technician
or expert has checked that it is possible to do so, or has made the appropriate
preparations.
Remove the electrode from the electrode holder gripper when you have completed
the welding operations. Make sure that no part of the electrode holder gripper electric
circuit touches the ground or earth circuits: accidental contact could cause overheating
or trigger a fire.
EMF Electromagnetic Fields
Welding current creates electromagnetic fields (EMF) near the welding circuits and
the welder. Electromagnetic fields may interfere with medical prostheses such as
pacemakers.
Suitable and sufficient measures should be implemented to protect those operators
having such aids. For instance, they should not be allowed to enter that area where
welding equipment is used. Any operator having such aids should consult their doctor
before coming close to an area where welding equipment is used.
This device meets the specific requirements of the product technical standard and is
intended for professional use in an industrial environment only. Compliance to expected
limits for human exposure to electromagnetic fields at home is not ensured.
Follow these strategies to minimise exposure to electromagnetic fields (EMF):
Do not place your body between the welding cables. Both welding cables should be
on the same side of your body.
Twist both welding cables together and secure them with tape when possible.
Do not wrap the welding cables around your body.
Connect the earth cable to the workpiece as close as possible to the area to be
welded.
Do not work with the welder hanging from your body.
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Keep your head and trunk as far as possible from the welding circuit. Do not work
close to the welder, or seated or leaning on it. Minimum distance: Fig 6 Da = cm 50;
Db = cm.20
Class A equipment
This equipment has been designed to be used in professional and industrial
environments.
If this equipment is used in domestic environments and those directly connected to a
low voltage power supply network which supplies buildings used for domestic purposes,
it may be difficult to ensure compliance to electromagnetic compatibility as the result of
conducted or radiated disturbances.
Welding in conditions of risk
If cutting operations need to be done in conditions of risk (electric discharges, suffocation,
the presence of inflammable or explosive materials), make sure that an authorised expert
evaluates the conditions beforehand. Make sure that trained people are present who
can intervene in the event of an emergency. Use the protective equipment described
in 5.10; A.7; A.9 of the IEC or CLC/TS 62081 technical specification.
If you are required to work in a position raised above ground level, always use a safety
platform.
If more than one machine has to be used on the same piece, or in any case on pieces
connected electrically, the sum of the no-load voltages on the electrode holders or on
the torches may exceed the safety levels. Make sure that an authorised expert evaluates
the conditions beforehand to see if such risk exists and adopt the protective measures
described in 5.9 of the IEC or CLC/TS 62081 technical specification if required.
Additional warnings
Do not use the machine for purposes other than those described, for example to thaw
frozen water pipes.
Place the machine on a flat stable surface, and make sure that it cannot move. It must
be positioned in such a way as to allow it to be controlled during use but without the
risk of being covered with sparks.
Do not lift the machine. No lifting devices are fitted on the machine.
Do not use cables with damaged insulation or loose connections.
Description of the machine
The welding machine is a current source for manual Plasma arc cutting, fitted with a
torch with pilot arc.
The machine is built using electronic INVERTER technology.
The machine delivers a direct current output.
The electrical characteristic of the transformer is of the falling type.
Main parts Fig. 1
A) Mains input lead
B) ON/OFF switch
C) Machine connected led
D) Adjustment of the cut-off current/ air pressure test. (Mod.1)
E) Low air pressure warning light (Mod. 1)
F) Thermal protector intervention light
Technical data
A rating plate is fixed or printed on each machine. Fig. 2 shows an example of this
plate.
A) Manufacturer name and address
B) European reference standard for the construction and safety of welding equipment
C) Symbol of the machine internal structure
D) Symbol of the involved welding/cutting process
E) Symbol of the output current: DC (Direct Current)
F) Input power symbol:
˜ alternate single phase voltage, frequency: F1: from electrical power supply;
F2: from motor generator
G) Degree of protection against penetration of solid bodies and liquids
H) Symbol indicating that the machine can operate in environments with increased
hazard of electric shock
I) Welding circuit performance
U0V
Minimum and maximum open circuit voltage (open welding circuit).
I2, U2 Current and corresponding normalised voltage delivered by the machine.
X
Duty cycle. Indicate how long the welding machine can work for and how
long it must rest for in order to cool down. The time is expressed in % on the
basis of a 10 minute cycle (e.g. 60% means 6 min. work and 4 min. rest).
A/V
Current adjustment field and corresponding arc voltage.
J) Power supply data
U1
Input voltage (permitted tolerance: +/- 10%)
I1 eff Effective absorbed current
I1 max Maximum absorbed current
K) Serial number
L) Weight
M) Safety symbols: Refer to Safety Warnings
Connections to the mains must be made by expert or qualified personnel.
Make sure that the machine is switched off and disconnected from mains before
carrying out this procedure.
Make sure that the power socket that the machine is plugged into is protected by safety
devices (fuses or automatic switch) and grounded.
Assembly and electrical connections
Assemble the detached parts found in the packaging (Fig.5).
5
Starting up
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