Sistor 142

ISTRUZIONI PER L’USOINSTRUCTION MANUALBETRIEBSANWEISUNGMANUEL D’INSTRUCTIONSINSTRUCCIONES DE USOMANUAL DE INSTRUÇÕES

GEBRUIKSAANWIJZINGBRUKSANVISNINGBRUGERVEJLEDNINGBRUKSANVISNINGKÄYTTÖOHJEET

ITALIANO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

ENGLISH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

DEUTSCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

FRANÇAIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

ESPAÑOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

PORTUGUÊS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

NEDERLANDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

SVENSKA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59

DANSK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67

NORSK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75

SUOMI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91

Targa dati, Nominal data, Leistungschilder, Plaque donées, Placa de características, Placa de dados,Technische gegevens, Märkplåt, Dataskilt, Identifikasjonsplate, Arvokilpi, . . . . . . . . . . . . . . . . . . . . . 99

Significato targa dati del generatore, Meaning of power source data plate, Bedeutung der Angaben aufdem Leistungsschild des Generators, Signification des données sur la plaque du générateur, Significadoda chapa de dados do gerador, Significado da chapa de dados do gerador, Betekenis gegevensplaatje vande generator, Innebörden av uppgifterna på generatorns märkplåt, Betydning af dataskiltet forStrømkilden, Betydning av informasjonsteksten på Generatorns skilt, Generaattorin arvokilven tiedot, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100

Schema, Diagram, Schaltplan, Schéma, Esquema, Diagrama, Schema, kopplingsschema, Oversigt,Skjema, Kytkentäkaavio, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101

Lista ricambi, Spare parts list, Ersatzteilverzeichnis, Liste de pièces détachées, Lista de repuestos, Listade peças de reposição, Reserveonderdelenlijst, Reservdelslista, Liste med reservedele, Liste over reser-vedeler, Varaosaluettelo, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102

Legenda simboli, Key to Sumbols, Legende der Symbole, Legende des Symboles, Legenda dos símbolos,Legenda dos símbolos, Legenda van de symbolen, Teckenförklaring, Symbolforklaring,Symbolbeskrivelse, Merkkien selitykset, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104

ENGLISH

USE AND MAINTENANCE MANUALThis manual is an integral part of the unit or machine and must accompany it when it changes location or is resold.The user must assume responsibility for maintaining this manual intact and legible at all times.SELCO s.r.l. reserves the right to modify this manual at any time without notice.All rights of translation and total or partial reproduction by any means whatsoever (including photocopy, film, and microfilm) are reser-ved and reproduction is prohibited without the express written consent of SELCO s.r.l.

Edition ‘02

CONFORMITY CERTIFICATE CE

Company SELCO s.r.l. - Via Palladio, 19 - 35010 ONARA DI TOMBOLO (Padova) - ITALY

Tel. +39 049 9413111 - Fax +39 049 94313311 - E-mail: selco@selco.it

hereby declares that the apparatus type SISTOR 142

to which this declaration pertains conforme to the : 73/23/CEE89/336 CEE92/31 CEE93/68 CEE

and that the regulations have been duly applied : EN 50199EN 60974-1

Any operation or modification that has not been previously authorized by SELCO s.r.l. shall invalidate this certificate.

Onara di Tombolo (PADOVA) Selco's legal representative

..................................

Lino Frasson

CONTENTS

11

1.0 SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . .121.1 Operator and other persons’ protection . . .121.2 Fire/explosion prevention . . . . . . . . . . . . .121.3 Protection against fumes and gases . . . . . .121.4 Positioning the power source . . . . . . . . . .121.5 lnstalling the apparatus . . . . . . . . . . . . . . .121.6 Precautions against risks connectedwith the use of compressed air . . . . . . . . . . .12

1.7 Attention: method of lifting . . . . . . . . . . . .132.0 ELECTROMAGNETIC COMPATIBILITY (EMC) 13

2.1 Installation, use and area examination . . . .132.2 Emission reduction methods . . . . . . . . . . .13

3.0 RISK ANALYSIS . . . . . . . . . . . . . . . . . . . . . .134.0 MACHINE DESCRIPTION . . . . . . . . . . . . . . .14

4.1 Front control panel . . . . . . . . . . . . . . . . .144.2 Rear control panel . . . . . . . . . . . . . . . . . .154.3 Technical characteristics . . . . . . . . . . . . . .15

5.0 TRANSPORT - UNLOADING . . . . . . . . . . . .156.0 INSTALLATION . . . . . . . . . . . . . . . . . . . . . .157.0 CONNECTION . . . . . . . . . . . . . . . . . . . . . . .15

7.1 Mains supply voltage . . . . . . . . . . . . . . . .157.1.1 Selection of the mains voltage . . . . . . . .157.1.2 Earthing . . . . . . . . . . . . . . . . . . . . . . .16

7.1.3 Electric connection to the supply mains .168.0 CONNECTING THE EQUIPMENT COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . .169.0 SETTING UP . . . . . . . . . . . . . . . . . . . . . . . .1610.0 PROBLEMS - CAUSES . . . . . . . . . . . . . . . .17

10.1 Possible cutting defects . . . . . . . . . . . . . .1710.2 Possible electrical failures . . . . . . . . . . . .17

11.0 NECESSARY ROUTINE MAINTENANCE . . .1712.0 THEORETICAL OUTLINE OF PLASMA CUTTING . . . . . . . . . . . . . . . . . . . .17

12.1 Plasma cutting process . . . . . . . . . . . . . .1813.0 CUTTING SPECIFICATIONS . . . . . . . . . . . .18

SYMBOLS

lmminent danger of serious bodily harm and dan-gerous behaviours that may lead to serious bodilyharm.

lmportant advice to be followed in order to avoidminor injuries or damage to property.

The notes preceded by this symbol are mainlytechnical and facilitate operations.

1.0 SAFETY

Prior to performing any operation on the machine, make sure that youhave thoroughly read and understood the contents of this manual.Do not perform modifications or maintenance operations which are notprescribed.For any doubt or problem regarding the use of the machine, even if notdescribed herein, consult qualified personnel.The productor cannot be held responsible for damage to persons or pro-perty caused by the operator's failure to read or apply the contents ofthis manual.

1.1 Operator and other persons' protectionThe welding (cutting) process is a noxious source of radiations, noise,heat and gas emissions. Persons fitted with pacemakers must consulttheir doctor before undertaking arc welding or plasma cut operations. Ifthe above prescription is not observed, the manufacturer accepts no lia-bility for any damages sustained in the event of an accident.

Personal protection:- Do not wear contact lenses!!!- Keep a first aid kit ready for use.- Do not underestimate any burning or injury.- Wear protective clothing to protect your skin from the arc rays, sparks

or incandescent metal, and a helmet or a welding cap.- Wear masks with side face guards and suitable protection filter (at

least NR10 or above) for the eyes.- Use headphones if dangerous noise levels are reached during the

welding (cutting).Always wear safety goggles with side guards, especially during themanual or mechanical removal of welding (cutting) slags.lf you feel an electric shock, interrupt the welding (cutting) operationsimmediately.

Other persons' protection:- Position a fire-retardant partition to protect the surrounding area from

rays, sparks and incandescent slags.- Advise any person in the vicinity not to stare at the arc or at the incan-

descent metal and to get an adequate protection.- lf the noise level exceeds the limits prescribed by the law, delimit the

work area and make sure that anyone getting near it is protected withheadphones or earphones.

1.2 Fire/explosion preventionThe welding (cutting) process may cause fires and/or explosions.- Compressed gas cylinders are dangerous; consult the supplier befo-

re handling them.Protect them from:- direct exposure to sun rays;- flames;- sudden changes in temperature;- very low temperatures.Compressed gas cylinders must be fixed to the walls or to other sup-ports, in order to prevent them from falling.

- Clear the work area and the surrounding area from any infiammableor combustible materials or objects.

- Position a fire-fighting device or material near the work area.- Do not perform welding or cutting operations on closed containers or

pipes.- lf said containers or pipes have been opened, emptied and carefully

cleaned, the welding (cutting) operation must in any case be perfor-med with great care.

- Do not weld (cut) in places where explosive powders, gases orvapours are present.

- Do not perform welding (cutting) operations on or near containersunder pressure.

- Don’t use this machine to defrost pipes.

1.3 Protection against fumes and gasesFumes, gases and powders produced during the welding (cutting) pro-cess can be noxious for your health.- Do not use oxygen for the ventition.- Provide for proper ventilation, either natural or forced, in the work

area.- In case of welding (cutting) in extremely small places the work of the

operator carrying out the weld should be supervised by a colleaguestanding outside.

- Position gas cylinders outdoors or in places with good ventilation.- Do not perform welding (cutting) operations near degreasing or pain-

ting stations.

1.4 Positioning the power sourceKeep to the following rules:- Easy access to the equipment controls and connections must be pro-

vided.- Do not position the equipment in reduced spaces.- Do not place the generator on surfaces with inclination exceeding 10°

with respect to the horizontal plane.

1.5 lnstalling the apparatus- Comply with the local safety regulations for the installation and carry

out the maintenance service of the machine according to the con-structor's directions.

- Any maintenance operation must be performed by qualified person-nel only.

- The connection (series or parallel) of the generators is prohibited.- Before operating inside the generator, disconnect the power supply.- Carry out the routine maintenance on the equipment.- Make sure that the supply mains and the earthing are sufficient and

adequate.- The earth cable must be connected as near the area to be welded

(cut) as possible.- Take the precautions relevant to the protection degree of the power

source.- Before welding (cutting) , check the condition of the electric cables

and of the torch, and if they are damaged repair or change them.- Neither get on the material to be welded (cut), nor lean against it.- The operator must not touch two torches or two electrode holders

at the same time.

1.6 Precautions against risks connected with theuse of compressed airConnect the air supply to the coupling provided, making sure pressureis at least 6 bars (0.6 MPa) with a minimum flow rate of 200 l/min. If theair supply comes from pressure reducer of a compressor or a centralsystem, the reducer must be set to the maximum outlet pressure thatmust not, however, exceed 8 bars (0.8 MPa). If the air supply comesfrom a compressed air canister it must be equipped with a pressureregulator.

A compressed air canister must never be directlycoupled to the machine pressure reducer. Pressuremight exceed the capacity of the reducer which mightconsequently explode.

12

WARNING

3.0 RISK ANALYSIS

13

2.0 ELECTROMAGNETIC COMPATIBILITY (EMC)

This device is built in compliance with the indications contained in theharmonized standard EN50199, to which the operator must refer for theuse of this apparatus.- lnstall and use the apparatus keeping to the instructions given in

this manual.- This device must be used for professional applications only, in

industrial environments It is important to remember that it maybe difficult to ensure the electromagnetic compatibility in otherenvironments.

2.1 Installation, use and area examination- The user must be an expert in the sector and as such is responsible

for installation and use of the equipment according to the manufac-turer's instructions. lf any electromagnetic disturbance is noticed, the user must soave theproblem, if necessary with the manufacturer's technical assistance.

- In any case electromagnetic disturbances must be reduced until theyare not a nuisance any longer.

- Before installing this apparatus, the user must evaluate the potentialelectromagnetic problems that may arise in the surrounding area, con-sidering in particular the health conditions of the persons in the vicinity,for example of persons fitted with pacemakers or hearing aids.

2.2 Emission reduction methods MAINS POWER SUPPLY

- The welding power source must be connected to the supply mainsaccording to the manufacturer's instructions.

In case of interference, it may be necessary to take further precautionslike the filtering of the mains power supply.lt is also necessary to consider the possibility to shield the power supplycable.

WELDING POWER SOURCE MAINTENANCE The welding power source needs routine maintenance according to themanufacturer's instructions.When the equipment is working, all the access and operating doors andcovers must be closed and fixed.The welding power source must not be modified in any way.

WELDING AND CUTTING CABLESThe welding (cutting) cables must be kept as short as possible, positio-ned near one another and laid at or approximately at ground level.

EQUIPOTENTIAL CONNECTIONThe earth connection of all the metal componente in the welding (cut-ting) installation and near it must be taken in consideration.However, the metal componente connected to the work-piece willincrease the risk of electric shock for the operator, if he touches saidmetal componente and the electrode at the same time.Therefore, the operator must be insulated from all the earthed metalcomponente.The equipotential connection must be made according to the nationalregulations.

EARTHING THE WORKPIECEWhen the workpiece is not earthed for electrical safety reasons or dueto its size and position, the earthing of the workpiece may reduce theemissione. It is important to remember that the earthing of the work-piece should neither increase the risk of accidents for the operators, nordamage other electric equipment.The earthing must be made according to the national regulations.

SHIELDINGThe selective shielding of other cables and equipment present in thesurrounding area may reduce the problems due to interference. Theshielding of the entire welding (cutting) installation can be taken in con-sideration for special applications.

WARNING

Risks posed by the machine Risk of wrong installation.

Electrical risks.Risks connected with electromagnetic disturbances produced by thewelding power source and induced on the welding power source.

Solutions adopted to pervent themA manual with the instructions for use has been pro-duced for this purpose.Application of the EN 60974-1 Standard.Application of the EN 50199 Standard.

1.7 Attention: method of lifting

To correctly lift the machine, follow the diagram in Figure A. Avoid absolutely lifting it at any angle different from 90°.

Never lift the machine in the way shown in figure B : this could damage the eyebolts.

Be careful not to cause damage during lifting.

The manufacturer accepts no liability if the above prescription is not duly observed and complied with at all times.

Figura A Figura B

The contents of this chapter are of vital importance and the-refore necessary for operation of the warranties. The manu-facturer accepts no liability if the operator fails to observethe above precautions and instructions.

4.0 MACHINE DESCRIPTIONSistor 142 is a generator for plasma cutting, which is ideal formedium and heavy structural work.Sistor 142 uses compressed air as its only gas source, which canbe supplied from a normal compressor or from a suitably sizedcentralized plant. It is able to carry out, cheaply, cuts of a highquality up to a thickness of 40/50 mm in carbon steel, stainlesssteel and aluminium. Nitrogen can also be used as gas withreduced thickness and greater cutting precision. The current is stable, precise and unaffected by variations in thesupply voltage, the height of the cutting arc, the progressionspeed and the thickness of the metal to be cut.This high performance is made possible thanks to the use ofstate-of-the-art technology, which employs the high commuta-tion speed possible with the latest electronic components.There are safety systems that cut off the power circuit when theoperator comes into contact with live parts of the machine, aswell as controls to reduce the wear on the electrode and nozz-le at the moment of striking the cutting arc. The ignition of thecutting arc takes place with the use of a high frequence voltagedischarge, that becomes automatically cut off when the opera-tion is complete, thus limiting the emission of radio interferen-ce in the rest of the cutting process.The generator is equipped with:- one torch fitting,- an earth socket, - front panel,- rear panel.

4.1 Front control panel (Fig.1)

Fig. 1

* I1: Off/On switchTurns on the electric power to the welder.It has two positions, "O" off, and "I" on.

* With the I1 switch in the "I" on position, the welder isoperational.

* The welder is connected to the mains supply even if the I1switch is in the "O" position, and therefore there are elec-trically live parts inside it. Carefully follow the instruc-tions given in this manual.

* L1 : Voltage warning light green led.Comes on with the start switch (Fig.1) "I1" in position "I" andindicates that the plant is on and there is voltage.

* L2: Power output light red led.Comes on when the arc is sparked, both during cutting andwhen not cutting, and goes out as soon as the arc finishes.

* L3: torch cap alarm green led.Means that the torch cap has not been properly tightened.The generator has no power output.

* L4: compressed air alarm green led.Means that the pressure of compressed air is below 3 bar, toolow for proper functioning. The generator has no power output.

* L5 : Safety device warning light yellow led.lndicates that the safety devices like thermal cutout.With "L5" on, the power source remains connected to thesupply mains, but does not supply output power. "L5" remains on until the fault has been removed and in anycase until the inner temperatures are not within the normalvalues; in this case it is necessary to leave the power sourceon to exploit the operating ventilator and reduce the timewhen it is not active.

* E1: Encoder for setting the cutting current.Allows you to continuously adjust the cutting current. Thiscurrent stays unchanged during cutting when the supply andcutting conditions vary within the allowed ranges.

* T1 : VOLT-AMP reading selection key.Its permits display of either the welding voltage or current onDISPLAY “D1”. If LED “V” is on, the last voltage reading taken during the lastcutting operation is displayed. If you do not begin cuttingwithin 5 sec. the system automatically switches to A, displa-ying the set current. Vice versa if you begin cutting within 5sec., the voltage is displayed during the entire cutting opera-tion after which the reading remains displayed for a further 5seconds. If LED “A” is lit up on display D1, the set or cutting current isdisplayed if the operation is in progress. The display is main-tained for 5 seconds after the end of the operation.

* T2: gas test pushbutton.Allows impurities to be removed from the compressed air cir-cuit and preliminary capacity and pressure settings to bemade with no power output.

* D1 : displays the set current, cutting current and cutting vol-tage or the letters GEN (at switch-on) and ERR (blinking in theevent of an alarm).

* D2 : displays the air pressure value for the cutting process. Atswitch-on it displays the software version. In the event of analarm, it displays the alarm code in blinking mode:01 IIC error02 torch cap open03 air pressure too low11 thermal switch

In the event of an alarm, the operating condi-tions are restored only if the cause is removed.

14

WARNING

4.2 Rear control panel (Fig. 2-3)

Fig. 2

Fig. 3* 1: Supply cable.* B1: 4A, 250V TYPE T (slow-blowing) auxiliary protec-

tion fuse .* B2: 4A, 250V TYPE T (slow-blowing) auxiliary protec-

tion fuse .* Pressure regulator F1: is located on the rear of the

machine, on the left corner; allows the compressed airpressure to be adjusted so as to take it to the value mostsuitable for cutting, and filters the air from any impurity(e.g. humidity).

* A1: Centralised coupling.The cable bundle of the torch is connected to this socket.

* A2: Ground cable socket.

4.3 Technical characteristics

SISTOR 142Power supply voltage (50/60 Hz) 3x230/400VDelayed fuse 25A (400V) - 40A (230V)Rated power 22.6 kWCutting current (x=40%) 140A

(x=60%) 120A(x=100%) 90A

Cutting voltage (x=40%) 116VNo-load voltage 272VPilot arc current 22AOperating pressure 5 barFlow rate 200 l/minTorch to be used PLASMA torch 81.20.020Protection class IP21SInsulation class HConstruction regulations EN60974-1/EN50199Dimensions (lxpxh) 400x700x780 mmWeight 144.5 Kg

Above data are referred to environment al 40°C

5.0 TRANSPORT - UNLOADING

See “1.7 Attention: method of lifting“

Never underestimate the weight of the equipment,(see technical specifications).

Never make the cargo pass or leave it suspendedover people or things.

Neither let the equipment or the single unit fall,nor put it down with force.

6.0 INSTALLATION

Choose an adequate installation area by followingthe criteria provided in Section "1.0 SAFETY" and“2.0 ELECTROMAGNETIC COMPATIBILITY (EMC)”.

Do not position the power source and the equip-ment on surfaces with inclination exceeding 10°with respect to the horizontal plane. Protect theinstallation from heavy rain and sun.

The fan only starts once the system has warmed up.

7.0 CONNECTION7.1 Mains supply voltage

The generator is pre-set for 400V ~ mains voltage, fordelivery.The equipment is guaranteed to operate for voltagesranging ±10% above or below the nominal value;(e.g.: NomV 400V ~ the working voltage ranges from360V~ to 440V~).CAUTION: to avoid damaging people or the instal-lation, you need to control the selected mains volt-age and the fuses BEFORE connecting the machineto the mains. Furthermore, you need to make surethat the cable is connected to a socket fitted withan earth contact.

7.1.1 Selection of the mains voltage

CAUTION: before carrying out any operationinside the generator, physically disconnect themachinery from the mains electricity supply, byremoving the plug.

The voltage of the network should only be modified by qualifiedpersonnel and while the machine is disconnected from thepower source, by simply removing the lateral panel and cor-rectly positioning the connections onto the terminal box (fig. 4).

Fig. 4 Voltage change terminal box configuration.

For connection to mains 230Vac, the power supplycable must be replaced using the kit code73.11.008.

15

16

7.1.2 EarthingFor the protection of the users, the plant must be correctly con-nected to the earth. The power supply lead is provided with a(green and yellow) conductor for earthing, which must be con-nected to a plug fitted with an earth connection.

7.1.3 Electric connection to the supply mainsThe equipment is provided with a single electric connection with6mmq cable positioned in the rear part of the power source.Size table of the power source input cables and fuses:

SISTOR 142Rated voltage 400 V ±15% - 230 V ±15%Voltage range 340/460 V - 195/265 VDelayed fuses 25 A 400 V - 40 A 230VPower supply cable 4x6 mm2 - 4x10 mm2

* The electrical system must be made by skilled technicianswith the specific professional and technical qualificationsand in compliance with the regulations in force in thecountry where the equipment is installed.

* The welding power source supply cable is provided with ayellow/green wire that must ALWAYS be earthed. This yel-low/green wire must NEVER be used with other voltageconductors.

* Verity the existence of the earthing in the used plant andthe good condition of the socket/s

* lnstall only plugs that are homologated according tothe safety regulations.

8.0 CONNECTING THE EQUIPMENT COM-PONENTS

Keep to the safety regulations contalned in section“1.0 SAFETY”.

Connect the componente carefully, in order toavoid power losses.

9.0 SETTING UP

For installation of the system, follow the instructions below:1. Place the generator in a dry, clean place with suitable venti-

lation.2. Connect up the compressed air supply with a 1/4 inch to the

air inlet P1 in the filter unit F1 (Fig.2). The pressure mustensure at least 5 bars with a flow rate of at least 200 litres aminute.Securely connect the earth cable connector to the generatoras shown in figure 6.

3. Position the earthing clamp onto the piece to be cut, ensuringthat it makes a good electric connection (Fig. 6).

4. Check that all the components of the torch are present andcorrectly fitted and connect the torch fitting to the connectoron the generator as shown in figure 5. Insert the male fitting (torch side) into the correspondingfemale fitting (machine side). Align the locating tooth (A) onthe housing and insert the ring nut (B) which must be com-patible.

To permit screw-tightening of the ring nut (B), the tool provi-ded (D) must be first inserted and pressed into the hole (C)in order to release the anti-rotation lock. This operation mustbe performed until the ring nut has been completely tighte-ned. To disconnect the torch, first release the anti-rotationlock by inserting the tool provided (D) into the hole (C).

Fig. 5

5. Switch on the system, ensuring the LED's are working cor-rectly and some display. If operating faults occur in the generator it will be inhibiteduntil normal operating conditions are restored. Press the gastest pushbutton (T2 in Fig 1) in order to remove residualimpurities from the compressed air circuit, then lift and turnthe knob to adjust the pressure (F1 Fig.2) until the display D2shows a pressure reading of 5 bars (carry out the operationkeeping the gas test button pressed down, so as to make theadjustment with air circulating in the piping).

6. Set the value of the cutting current with the potentiometer,keeping in mind the thickness to be dealt with.

7. Press for a moment the torch button so as to generate thepilot arc; release the control, checking the machine is cor-rectly operating with the display panel. It is advisable not tokeep the arc lit to no purpose without making contact, so asto prevent wear on the electrode and the nozzle. If you con-tinue to use it like this the apparatus itself will turn off thepilot light after about 6 seconds.In the case where a fault is found during the above phases,check the LED's, the display and if necessary consult thechapter "Possible electrical faults" in the manual.

Fig. 6

WARNING

17

10.0 PROBLEMS - CAUSES

10.1 Possible cutting defects

10.2 Possible electrical failures

See also chapter 4.1 for problems with alarm code. If you have any doubts or problems, do not hesitate to con-sult your nearest technical service centre.

11.0 NECESSARY ROUTINE MAINTENANCE

Prevent metal powder from accumulating near the aeration finsand over them.

Disconnect the power supply before every opera-tion!

Carry out the following periodic controls on thepower source:* Clean the power source inside by means of low-

pressure compressed air and soft bristel brushes.* Check the electric connections and all the connec-

tion cables.

For the maintenance or replacement of torchcomponente and/or earth cables:

* Disconnect the power supply before every operation.* Check the temperature of the componente and make

sure that they are not overheated.* Always use gloves in compliance with the safety stan-

dards.* Use suitable spanners and tools.* For torch maintenance, keep carefully to the directions

shown under instructions for use of the torch enclosedwith this manual.

NOTE: Failure to perform said maintenance will invalidate allwarranties and exempt the manufacturer from all liability.

12.0 THEORETICAL OUTLINE OF PLASMACUTTING

A gas assumes the plasma state when it is brought to an extre-mely high temperature and ionizes wholly or partly, thus beco-ming electrically conductive.Although the plasma exists in every electric arc, by the term"plasma arc" we refer specifically to a torch for welding or cut-ting that uses an electric arc, made to pass through the constric-ting neck of a suitable nozzle, to heat a gas coming out of this,so as to take it to the plasma state.

Fig. 7 Manual plasma cutting plant

FAULT

Insufficient penetration

The cutting arc goes out

Substantial burr formation

Nozzle overheating

CAUSE

- Cutting speed too high- Current set too low- Earth clamp with inefficient

contact- Thickness of piece excessive

- Electrode, nozzle or diffuserworn

- Air pressure too high- Cutting speed too low- Insufficient air flow- Defective pressure switch- Supply voltage too low

- Inadequate air pressure- Cutting speed too low- Nozzle eroded

- Electrode eroded- Insufficient air quantity

FAULT

Apparatus fails to come on(Green LED L1 off)

Pilot arc fails to ignite (with green LED L1 on)

Pilot arc fails to ignite (with green LED L1 and redLED L2 on)

Fails to transfer from pilot arcto cutting arc

Lack of power output

CAUSE

- Incorrect mains supply- Fuses interrupted

- Break in the contacts of thetorch button (check the con-nection of the torch attach-ment is working after havingcut off the power supply)

- Torch parts subject to wearout of action

- Air pressure too high- Possible problems in control

circuits

- Possible problems in controlcircuits

- Arc sensors faulty (board15.14.084)

- Protective devices triggered(see chapter on "Functions ofcontrols")

- Possible problems in controlcircuits

18

12.1 Plasma cutting processThe cutting action is obtained when the plasma arc, made veryhot and highly concentrated by the design of the torch, transfersonto the conductive piece to be cut, closing the electrical circuitwith the generator. The material is first melted at a high tempe-rature of the arc, and then removed by the high exit velocity ofthe ionized gas from the nozzle.The arc can have two different states: that of the transferred arc,when the current passes through the piece to be cut, that of thepilot arc or non-transferred arc, when this is sustained betweenthe electrode and the nozzle.

13.0 CUTTING SPECIFICATIONSIn plasma cutting, the thickness of the material to be cut, thespeed of cutting and the current supplied by the generator havevalues which are related to each other; these depend on the typeand quality of the material, type of torch as well as the type andcondition of the electrode and nozzle, distance between nozzleand piece, pressure and impurity of the compressed air, cut qua-lity required, temperature of the piece to be cut, etc.In the diagrams as in Fig.8,9,10, we can see that the thicknessto be cut is inversely proportional to the cutting speed, and thatboth these values can be increased with an increase in current.

The cutting tests have been performed in standard operatingconditions using a Trafimet torch at 140A.

MILD STEEL

STAINLESS STEEL

ALUMINIUM

* High quality cut

Fig. 8

Fig. 9

Fig. 10

Thickness (mm)36

10206

102030401020304050

Current (A)50505050

100100100100100140140140140140

Speed (mm/min)4300*1500*750*200

3700*1800*750*400*200

2800*1200*650*350*200*

Thickness (mm)36

10206

102030401020304050

Current (A)50505050

100100100100100140140140140140

Speed (mm/min)2500*1000*550200

3400*1800*550*300130

2700*900*500*300*150

Thickness (mm)36

10206

102030401020304050

Current (A)50505050

100100100100100140140140140140

Speed (mm/min)4300*1900*800300

4000*3000*900*600300

3600*1600*1000*600*300*

CUTTING SPEED WITH 50A

SPEE

D (m

m/m

in)

SPEE

D (m

m/m

in)

CUTTING SPEED WITH 140A

CUTTING SPEED WITH 100A

SPEE

D (m

m/m

in)

THICKNESS (mm)

THICKNESS (mm)

THICKNESS (mm)

MILD STEELSTAINLESS STEELALUMINIUM

MILD STEELSTAINLESS STEELALUMINIUM

MILD STEELSTAINLESS STEELALUMINIUM

99

Targa dati, Nominal data, Leistungschilder, Plaque des données, Placa de características, Placa de dados,Technische gegevens, Märkplåt, Dataskilt, Identifikasjonsplate, Arvokilpi,

100

DEUTSCH1 Marke2 Herstellername und -adresse3 Gerätemodell4 Seriennr.5 Symbol des Schweißmaschinentyps6 Bezugnahme auf die Konstruktionsnormen7 Symbol des Schweißprozesses/Schneidprozesses8 Symbol für die Schweißmaschinen, die sich zum

Betrieb in Räumen mit großer Stromschlaggefahr eignen

9 Symbol des Schweißstroms/Schneidstroms10 Zugeteilte Leerlaufspannung11 Bereich des zugeteilten Höchst- und

Mindestschweißstroms/Mindestschneidstroms und der entsprechenden Ladespannung

12 Symbol für den intermittierenden Zyklus13 Symbol des zugeteilten Schweißstroms/

Schneidstroms14 Symbol der zugeteilten Schweißspannung/

Schneidspannung15-16-17 Werte des intermittierenden Zyklus15A-16A-17A Werte des zugeteilten Schweißstroms/

Schneidstroms15B-16B-17B Werte der üblichen Ladespannung18 Symbol der Versorgung19 Zugeteilte Versorgungsspannung20 Zugeteilter, maximaler Versorgungsstrom21 Maximaler, wirksamer Versorgungsstrom22 Schutzart

IP21 S Schutzart des Gehäuses in Konformität mit EN 60529:IP2XX Gehäuse mit Schutz vor Zutritt zu gefährli-chen Teilen mit einem Finger und vor Fremdkörpern mit einem Durchmesser von/über 12.5 mm.IPX1X Gehäuse mit Regenschutz auf 0° an der Vertikalen.

ITALIANO1 Marchio di fabbricazione2 Nome ed indirizzo del costruttore3 Modello dell’apparecchiatura4 N° di serie5 Simbolo del tipo di saldatrice6 Riferimento alle norme di costruzione7 Simbolo del processo di saldatura/taglio8 Simbolo per le saldatrici idonee a lavorare in un

ambiente a rischio accresciuto di scossa elettrica9 Simbolo della corrente di saldatura/taglio10 Tensione assegnata a vuoto11 Gamma della corrente assegnata di saldatura/taglio

massima e minima e della corrispondente tensione convenzionale di carico

12 Simbolo del ciclo di intermittenza13 Simbolo della corrente assegnata di saldatura/taglio14 Simbolo della tensione assegnata di saldatura/taglio15-16-17 Valori del ciclo di intermittenza15A-16A-17A Valori della corrente assegnata di

saldatura/taglio15B-16B-17B Valori della tensione convenzionale di carico18 Simbolo per l’alimentazione19 Tensione assegnata d’alimentazione20 Massima corrente assegnata d’alimentazione21 Massima corrente efficace d’alimentazione22 Grado di protezione

IP21 S Grado di protezione dell'involucro in confor-mità alla EN 60529:IP2XX : Involucro protetto contro l'accesso a parti pericolose con un dito e contro corpi solidi estranei di diametro maggiore/uguale a 12.5 mm.IPX1X : Involucro protetto contro pioggia a 0° sulla verticale.

FRANÇAIS1 Marque de fabrique2 Nom et adresse du constructeur3 Modèle de l'appareil4 Numéro de série5 Symbole du type de soudeuse6 Référence aux normes de construction7 Symbole du processus de soudure/decoupage8 Symbole pour les soudeuses en mesure de travailler

dans un local où il y a un gros risque de secousse électrique

9 Symbole du courant de soudure/decoupage10 Tension attribuée à vide11 Gamme du courant de soudure/decoupage maxi-

mum et minimum attribué et de la tension conven-tionnelle de charge correspondante

12 Symbole du cycle d'intermittence13 Symbole du courant attribué de soudure/decoupage14 Symbole de la tension attribuée de soudure/

decoupage15-16-17 Valeurs du cycle d'intermittence15A-16A-17A Valeurs du courant attribué de soudure/

decoupage15B-16B-17B Valeurs de la tension conventionnelle de charge18 Symbole pour l'alimentation19 Tension attribuée d'alimentation20 Courant maximum attribué d'alimentation21 Courant maximum efficace d'alimentation22 Degré de protection

IP21 S Degré de protection du boîtier conformé-ment à la norme EN 60529:IP2XX Boîter de protection contre l’accès aux partiesdangereuses avec un doigt et contre les corps solidesétrangers ayant un diamètre supérieur/égal à 12.5 mm.IPX1X Boîter de protection contre la pluie à 0° sur la verticale.

ENGLISH1 Trademark2 Name and address of manufacturer3 Machine model4 Serial no. 5 Welder type symbol6 Reference to construction standards7 Welding/cutting process symbol8 Symbol for welders suitable for operation in environ-

ments with increased electrical shock risk 9 Welding/cutting current symbol 10 Assigned loadless voltage 11 Range of maximum and minimum assigned welding

/cutting current and corresponding conventional loadvoltage

12 Intermittent cycle symbol 13 Assigned welding/cutting current symbol 14 Assigned welding/cutting voltage symbol 15-16-17 Intermittent cycle values 15A-16A-17A Assigned welding/cutting current values 15B-16B-17B Conventional load voltage values 18 Power supply symbol 19 Assigned power supply voltage20 Maximum assigned power supply current 21 Maximum effective power supply current 22 Protection rating

IP21 S Casing protection rating in compliance with EN 60529:IP2XX Casing protected against access to dange-rous parts with fingers and against solid foreign.bodies with diameter greater than/equal to 12.5 mm.IPX1X Casing protected against rain hitting it at 0°.

ESPAÑOL1 Marca de fabricación2 Nombre y dirección del fabricante3 Modelo del aparato4 N° de serie5 Símbolo del tipo de soldadora6 Normas de construcción de referencia7 Símbolo del proceso de soldadura/corte8 Símbolo para las soldadoras adecuadas para trabajar

en un ambiente en donde existan riesgos de descar-gas eléctricas

9 Símbolo de la corriente de soldadura/corte10 Tensión en vacío asignada11 Gama de la corriente de soldadura/corte máxima y

mínima asignada y de la tensión convencional de carga correspondiente

12 Símbolo del ciclo de intermitencia13 Símbolo de la corriente de soldadura/corte asignada14 Símbolo de la tensión de soldadura/corte asignada15-16-17 Valores del ciclo de intermitencia15A-16A-17A Valores de la corriente de soldadura/corte

asignada15B-16B-17B Valores de la tensión convencional de carga18 Símbolo para la alimentación19 Tensión de alimentación asignada20 Corriente de alimentación máxima asignada21 Corriente de alimentación máxima eficaz22 Clase de protección

IP21 S Grado de protección de la envoltura en conformidad con EN 60529:IP2XX Envoltura protegida contra el acceso a par-tes peligrosas con un dedo y contra cuerpos sóli-dos extraños de diámetro mayor/igual a 12.5 mm.IPX1X Envoltura protegida contra la lluvia a 0° en la vertical.

Significato targa dati del generatore, Meaning of POWER SOURCE data plate, Bedeutung der Angaben auf demLeistungsschild des Generators, Signification des données sur la plaque du générateur, Significado da chapa de dados dogerador, Significado da chapa de dados do gerador, Betekenis gegevensplaatje van de generator, Innebörden av uppgifter-na på GENERATORNS märkplåt, Betydning af dataskiltet for Strømkilden, Betydning av informasjonsteksten på Generatornsskilt, Generaattorin arvokilven tiedot,

101

Schema, Diagram, Schaltplan, Schéma, Esquema, Diagrama, Schema, kopplingsschema, Oversigt, Skjema,Kytkentäkaavio,

102

Lista ricambi, Spare parts list, Ersatzteilverzeichnis, Liste de pièces détachées, Lista de repuestos, Lista depeças de reposição, Reserveonderdelenlijst, Reservdelslista, Liste med reservedele, Liste over reservede-ler, Varaosaluettelo,

54.01.140 SISTOR 142

103

ITALIANOPOS.DESCRIZIONE CODICE1 Cofano superiore 01.02.0862 Ruota girevole 04.03.0013 Pannello laterale sinistro 03.07.0724 Pannello laterale destro 03.07.0735 Ruota 04.04.0016 Pannello comandi FP135 15.22.135

(scheda 15.14.283+targa serigrafata)7 Manopola 09.11.0108 Maniglia 01.15.0309 Adattatore centralizzato 19.06.00710 Presa fissa 10.13.02011 Pannello plastico frontale 01.04.26712 Pressacavo 08.22.01213 Controdado 08.22.01314 Scheda filtro 15.14.28115 Teleruttore arco pilota 09.02.00816 Teleruttore linea 09.02.01417 Scheda H.F. 15.14.19218 Scheda logica 15.14.08719 Trasformatore ausiliario 05.11.20320 Elettrovalvola gas 09.05.00621 Elettrovalvola gas flusso ridotto 09.05.00122 Supporto per filtro regolatore 01.14.23523 Filtro-regolatore 24.02.01024 Scheda sensori di corrente 15.14.08425 Trasformatore H.F. 05.03.01626 Condensatore 12.06.11627 Induttanza di livellamento 05.04.21028 Raddrizzatore 14.10.14229 Gruppo chopper 14.60.14230 Interruttore 09.01.00131 Portafusibile 08.25.25032 Cavo alimentazione 49.04.0090133 Motore del ventilatore 07.13.00534 Ventola 07.11.01135 Trasformatore di potenza 05.01.15336 Scheda filtro out 15.14.214

- Kit cavo alimentazione 230 V 73.11.008

ENGLISHPOS.DESCRIPTION CODE1 Upper cover 01.02.0862 Rotating wheel 04.03.0013 Side panel left 03.07.0724 Side panel right 03.07.0735 Wheel 04.04.0016 Control panel FP135 15.22.135

(board 15.14.283+silk screen panel)7 Knob 09.11.0108 Handle 01.15.0309 Centralized adapter 19.06.00710 Fixed socket 10.13.02011 Front plastic panel 01.04.26712 Cable clamp 08.22.01213 Counter-nut 08.22.01314 Filter board 15.14.28115 Pilot arc contactor 09.02.00816 Line contactor 09.02.01417 H.F. board 15.14.19218 Logic board 15.14.08719 Auxiliary transformer 05.11.20320 Solenoid valve gas 09.05.00621 Reducer flux solenoid valve 09.05.00122 Regulator-filter holder 01.14.23523 Regulator-filter 24.02.01024 Hall PC board 15.14.08425 H.F. transformer 05.03.01626 Capacitor 12.06.11627 Leveling inductor 05.04.21028 Rectifier 14.10.14229 Chopper unit 14.60.14230 Switch 09.01.00131 Fuse carrier 08.25.25032 Supply main cable 49.04.0090133 Fan motor 07.13.00534 Propellers 07.11.01135 Power transformer 05.01.15336 Out filter board 15.14.214

- Kit input cable 230 V 73.11.008

DEUTSCHPOS.BESCHREIBUNG CODE1 Obere Haube 01.02.0862 Drehbares Rad 04.03.0013 Seitenteil links 03.07.0724 Seitenteil rechtd 03.07.0735 Rad 04.04.0016 Bedienungsfeld FP135 15.22.135

(Platine 15.14.283+siebdruck Schild)7 Drehknopf 09.11.0108 Griff 01.15.0309 Zentralisierter Adapter 19.06.00710 Feste Steckdose 10.13.02011 Stirnplastiktafel 01.04.26712 Kabelklemme 08.22.01213 Gegenmutter 08.22.01314 Filterplatine 15.14.28115 Pilotbogenschutz 09.02.00816 Hauptschutz 09.02.01417 H. F. - Platine 15.14.19218 Logik - Platine 15.14.08719 Hilfstrafo 05.11.20320 Elektroventil gas 09.05.00621 Solenoidventil riduzierte flussigkeit 09.05.00122 Halterung für Reglerfilter 01.14.23523 Regler-Filter 24.02.01024 Hallsensorplatine 15.14.08425 Transformator H.F 05.03.01626 Kondensator 12.06.11627 Glättungsdrosselspule 05.04.21028 Gleichrichter 14.10.14229 Chopper einheit 14.60.14230 Schalter 09.01.00131 Sicherungshalter 08.25.25032 SpeiseKabel 49.04.0090133 Ventilatormotor 07.13.00534 Fluegelrad 07.11.01135 Leistungstransformator 05.01.15336 Filterplatine out 15.14.214

- Netzkabel kit 230 V 73.11.008

FRANÇAISPOS.DESCRIPTION CODE1 Capot supérieur 01.02.0862 Roue pivotante 04.03.0013 Panneau lateral gauche 03.07.0724 Panneau lateral droit 03.07.0735 Roue 04.04.0016 Panneau de reglage FP135 15.22.135

(platine 15.14.283+panneau avec serigraphie)7 Bouton 09.11.0108 Poignée 01.15.0309 Adaptateur central 19.06.00710 Prise fixe 10.13.02011 Panneau plastique antérieur 01.04.26712 Serre-cable 08.22.01213 Ecrou de blocage 08.22.01314 Carte filtre 15.14.28115 Télérupteur arc pilote 09.02.00816 Télérupteur ligne 09.02.01417 Carte H.F 15.14.19218 Carte logique 15.14.08719 Transformateur auxiliaire 05.11.20320 Soupape electrique gaz 09.05.00621 Soupape flux d’aire reduit 09.05.00122 Support pour filtre-régulateur 01.14.23523 Filtre-régulateur 24.02.01024 Platine capteur courant 15.14.08425 Transformateur H.F. 05.03.01626 Condensateur 12.06.11627 Inductance d’écrêtage 05.04.21028 Redresseur 14.10.14229 Groupe chopper 14.60.14230 Interrupteur 09.01.00131 Tableau de fusibles 08.25.25032 Câble d’alimentation 49.04.0090133 Moteur ventilateur 07.13.00534 Helices 07.11.01135 Transformateur de puissance 05.01.15336 Platine filtre out 15.14.214

- Kit cable d’alimentation 230 V 73.11.008

ESPAÑOLPOS.DESCRIPCION CODIGO1 Cofre superior 01.02.0862 Rueda giradoria 04.03.0013 Panel lateral izquierdo 03.07.0724 Panel lateral derecho 03.07.0735 Rueda 04.04.0016 Panel de control FP135 15.22.135

(tarjeta 15.14.283+panel con serigrafia)7 Botón 09.11.0108 Mango 01.15.0309 Adaptador central 19.06.00710 Enchufe fijo 10.13.02011 Panel plastico anterior 01.04.26712 Abrazadera 08.22.01213 Contratuerca 08.22.01314 Tarjeta filtro 15.14.28115 Telerruptor arco piloto 09.02.00816 Telerruptor linea 09.02.01417 Ficha H.F. 15.14.19218 Tarjeta lógica 15.14.08719 Transformador auxiliar 05.11.20320 Electrovalvula 09.05.00621 Electrovalvula flujo reducido 09.05.00122 Soporte para filtro regulador 01.14.23523 Filtro regulador 24.02.01024 Tarjeta sensor de corriente 15.14.08425 Transformador H.F. 05.03.01626 Condensador 12.06.11627 Bobina de inductancia

stabilizadora de corriente 05.04.21028 Rectificador 14.10.14229 Grupo chopper 14.60.14230 Interruptor 09.01.00131 Portafusibles 08.25.25032 Cable de alimentación 49.04.0090133 Motor helice 07.13.00534 Helice 07.11.01135 Transformador de potencia 05.01.15336 Tarjeta filtro out 15.14.214

- Kit cable de alimentación 230 V 73.11.008

104

ITALIANO

Spegnimento generatore

Accensione generatore

Alimentazione del generatore

Allarme sovratemperatura

Protezione cappuccio torcia

Impostazione di corrente

Impostazione di tensione

Alimentazione gas

Test gas

Procedimento di taglio plasma

ENGLISH

Power source switch-off

Power source switch-on

Power source power supply

Overtemperature alarm

Torch cap protection

Current setting

Voltage setting

Gas feeding

Gas test

Plasma cutting process

DEUTSCH

Ausschalten des Generators

Einschalten des Generators

Versorgung des Generators

Übertemperaturalarm

Brennerkappenschutz

Stromeinstellung

Spannungseinstellung

Gasleitung

Gasprüfung

Plasmaschneideverfahren

FRANÇAIS

Arrêt générateur

Allumage générateur

Alimentation du générateur

Alarme surchautle

Protection capuchon torche

Réglage de courant

Réglage de tension

Alimentation gaz

Test gaz

Procédé de coupeau plasma

ESPAÑOL

Apagado del generador

Encendido del generador

Alimentación del generador

Alarma sobretemperatura

Protección capuchón antorcha

Configuración de corriente

Configuración de tensión

Alimentación gas

Test gas

Procedimiento de corte plasma

Legenda simboli, Key to Sumbols, Legende der Symbole, Legende des Symboles, Legenda dos símbolos, Legenda dos sím-bolos, Legenda van de symbolen, Teckenförklaring, Symbolforklaring, Symbolbeskrivelse, Merkkien selitykset,

SELCO s.r.l. - Via Palladio, 19 - 35010 ONARA DI TOMBOLO (PADOVA) ITALYTel. +39 049 9413111 - Fax +39 049 9413311 - http://www.selco.it - E-mail:selco@selco.it

SELCO 2 - Via Macello, 61 - 35013 CITTADELLA (PADOVA) ITALY

Codice 91.07.011