Alfa Network SVAROG 125 PLASMA Manual

ALFA IN a.s © www.alfain.eu SVAROG 125 PLASMA (CNC) manual EN 01
CUTTING MACHINE
SVAROG 125 PLASMA
SVAROG 125 PLASMA CNC
OPERATING AND MAINTENANCE INSTRUCTIONS

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CONTENTS
1. INTRODUCTION ...................................................................................... 3
2. WORK SAFETY ....................................................................................... 4
General requirements .................................................................................... 4
Protective equipment ..................................................................................... 4
Risks - overview ............................................................................................ 4
Prohibited activities ....................................................................................... 6
3. OPERATING CONDITIONS ..................................................................... 6
Electromagnetic compatibility ........................................................................ 7
4. TECHNICAL DATA ................................................................................... 7
Torchs ........................................................................................................... 8
Cutting parameters - SVH/SVS-160 torch (fine grain steel) ........................... 8
Operation on the power generator ................................................................. 9
Pressure air source requirements.................................................................. 9
Connection to the central air distribution system ......................................... 10
Pre-set Water Separator and Air Filter for SVAROG PLASMA .................... 11
5. DESCRIPTION OF MACHINE AND FUNCTIONS .................................. 12
Main parts ................................................................................................... 12
Control panel ............................................................................................... 13
6. MACHINE ACCESSORIES .................................................................... 16
Part of delivery SVAROG 125 HAND PLASMA ........................................... 16
Accessories to order .................................................................................... 16
7. HAND TORCH AND CONSUMABLE PARTS ........................................ 17
SV-FIT system ............................................................................................ 17
Lifetime of consumable parts ....................................................................... 18
How to choose the right consumable parts .................................................. 19
Names of SVH torch parts ........................................................................... 19
SVH-125 torch (DZ 60% = 125 A) ............................................................... 19
SUPER LONG NOZZLE .............................................................................. 22
SVH-160 torch (DZ 100% = 125 A) ............................................................. 23
8. MACHINE COMMISSIONING ................................................................ 24
9. HAND CUTTING .................................................................................... 25
Causes of poor quality cuts ......................................................................... 27
10. MACHINE CNC CUTTING ..................................................................... 28
11. TORCH WIRING DIAGRAM ................................................................... 28
12. MAINTENANCE ..................................................................................... 28
13. ERROR MESSAGES ............................................................................. 29
14. SERVICE ............................................................................................... 30
Provision of a guarantee ............................................................................. 30
Warranty and post-warranty repairs ............................................................ 31
15. DISPOSAL OF ELECTRICAL WASTE ................................................... 31
16. WARRANTY LETTER ............................................................................ 32

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1. INTRODUCTION
Dear Consumer,
ALFA IN a.s. thanks you for purchasing our product and believes that you will be
satisfied with our machine.
The SVAROG 125 PLASMA machine is designed for metal cutting based on
modern technology of material cutting by means of a thin beam of plasma gas.
This technology has several advantages over other methods:
1. High cutting speed
2. Quality cut with minimal area of altered material structure
3. Less thermal deformation of the material to be cut
4. Possibility of cutting carbon and high alloy steels, stainless steels and non-
ferrous metals
5. The method does not require any special gases
6. Smaller costs
The SVAROG 125 PLASMA is equipped with a proportional valve that allows
precise setting of the desired working gas pressure and display of the pressure
value on the display. The proportional valve allows precise adjustment of the
required pressure or gas flow and enables high cutting accuracy and stability.
The machine is equipped with an eco-friendly "fan on demand" function. When
cooling is not needed, the machine automatically switches off the fan.
SVAROG 125 PLASMA is designed for quality cutting of materials up to a
maximum thickness of 50 mm carbon steel (for more information see 4.
TECHNICAL DATATECHNICAL DATA). Productive cutting of carbon steel is
possible up to a thickness of 25 mm.
With lower cutting quality requirements, material up to 55 mm thick can be cut
(separated).
We reserve the right to make modifications and changes in case of printing
errors, changes in technical parameters, accessories, etc. without prior notice.
Such changes may not be reflected in the user manuals in paper or electronic
form.

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2. WORK SAFETY
General requirements
1. The machine must only be operated by personnel thoroughly familiar with
the plasma cutting of material and who have received the appropriate
training.
2. The device must be disconnected from the mains before any electrical
work, removal of the cover or cleaning.
3. The cutting machine must be subjected to a periodic inspection once every
six months by an authorised person in accordance with ČSN 331500 and
ČSN 050630.
4. For safety reasons, protective gloves must be worn when cutting with
plasma. These gloves protect you from heat radiation and from splashing
droplets of hot metal.
5. Wear sturdy insulated footwear. Open shoes are not suitable as droplets
of hot metal can cause burns.
6. Do not look into the cutting arc without face and eye protection. Always
wear a good quality welding helmet with the protective filter intact.
7. Persons in the vicinity of the cutting site must also be informed of the
danger and be provided with protective equipment.
8. When cutting, especially in small spaces, it is important to ensure a
sufficient supply of fresh air, as cutting produces harmful fumes.
9. Do not carry out cutting work on gas, oil, fuel etc. tanks (even when empty)
as there is a risk of explosion.
10. Special regulations apply in areas with explosion hazards.
Protective equipment
1. Welding helmet with protective filter min. 10
2. Welding gloves
3. Welding clothing, apron
4. Closed shoes
Risks - overview
1. Risk of electric shock
2. Ultraviolet and light radiation
3. Danger of inhalation of gaseous fumes and dust particles
4. Danger of burns
5. Noise
Warning There is a risk of electric shock, especially if the insulation of
the torch and the supply cable is damaged and the machine covers are broken.
Note that voltages of up to 330 volts can occur at the torch.
The torch complies with the EN 60974-7 standard, voltage class M.

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Notice
Machine torch cannot be used for non-CNC versions!
Notice
1. It is forbidden to operate the machine with damaged insulation of the torch
or the supply cable.
2. Never operate the machine with dismantled or damaged covers. In
addition to the risk of injury, cooling efficiency decreases and interference
levels increase.
3. It is forbidden to operate the machine in wet conditions and outdoors in
rain or snow.
4. Ensure that the earth clamps are properly clamped, which also reduces
the risk of electric shock.
5. Use prescribed work equipment, keep it dry.
6. People with pacemakers are exposed to an increased magnetic field and
are briefly exposed to an electromagnetic field during ignition, which could
affect the pacemaker's function. A doctor should be consulted beforehand.
7. The cutting and piling arc is a source of very intense light and especially
ultraviolet radiation. This radiation can cause considerable damage to
vision in a very short time and, if exposed for a longer period, can cause
redness and even burns to uncovered parts of the skin.
8. Use a welding helmet equipped with an intact filter with a protection level
of at least 10.
9. The danger of burns arises when cutting from flying particles of hot metal,
from the plasma arc and from hot cutting material. A thin beam of hot
plasma (4th state of matter) reaches up to 10,000°C in its core!
10. Never point the torch towards your eyes, body or another person
when lighting.
11. Always use good quality and undamaged welding gloves, apron and
welding clothing including closed shoes and headgear.
12. Cutting produces large amounts of gaseous emissions and dust
particles from the material being cut.
13. High temperatures cause chemical reactions and the formation of
various oxides and other compounds, some of which are harmful to health.
14. Particularly hazardous fumes are produced when cutting materials
containing lead, beryllium, cadmium (coated parts) and materials with a
paint coating.
15. Ultraviolet radiation and high temperatures also produce significant
amounts of ozone and nitrogen oxides.
16. Exceeding the concentration of these gases above the values set by
the hygiene standards can cause damage to health, especially with
prolonged exposure.
17. The workplace must be well ventilated and equipped with an efficient

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extraction system.
18. In addition, a respiratory mask is required when cutting material that
produces particularly dangerous fumes.
19. The machine produces a noise level of 80-85 dB.
20. For prolonged work, we recommend the use of hearing protectors.
Prohibited activities
1. It is forbidden to use the machine in explosive areas and areas where
flammable and combustible substances may be present.
2. It is forbidden to carry out cutting of containers with residues of any
flammable or unknown substances.
3. It is not permissible to carry out cutting on closed pressure vessels without
first releasing the pressure and leaving them open.
3. OPERATING CONDITIONS
1. The commissioning of the instrument may only be carried out by trained
personnel and only within the technical provisions. The manufacturer is not
liable for damage caused by improper use and operation. Only use original
ALFA IN spare parts for maintenance and repair.
2. The device complies with IEC 61000-3-12.
3. The cutting machine is tested according to the standard for protection class
IP 23 S, which provides protection against the ingress of solid bodies with
a diameter greater than 12 mm and against the ingress of water falling in
a vertical to oblique direction up to an inclination of 60°.
4. Operating ambient temperature between -10 and +40 °C.
5. Relative humidity below 90% at +20 °C.
6. Up to 3000 m altitude.
7. The machine must be positioned in such a way that cooling air can enter
and exit through the cooling vents without restriction. Care must be taken
to ensure that no mechanical particles, especially metal particles (e.g.
during grinding), are drawn into the machine.
8. If the machine overheats, cutting is automatically interrupted.
9. All interventions in the el. equipment, as well as repairs (removal of the
mains plug), may only be carried out by an authorised person.
10. SVAROG 125 PLASMA is designed for a mains voltage of 3x400 V.
11. The relevant mains voltage and input power must be matched to the
mains plug.
12. The cutting machine must be subjected to a periodic inspection once
every 6 months by an authorised person in accordance with ČSN
331500,1990 and ČSN 050630,1993.
13. The cutting machine is primarily designed for industrial environments
in terms of interference. Special precautions may be necessary for use in
other areas (see EN 60974-10).
14. Above all, the machine must be protected from:

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a. Through moisture and rain
b. Mechanical damage
c. Draughts and possible ventilation of neighbouring machines
d. Excessive overloading - exceeding technical parameters
e. Rough handling
Electromagnetic compatibility
The welding equipment is designed primarily for industrial premises in terms of
suppression. It complies with the requirements of EN 60974-10 class A and is
not intended for use in residential areas where electricity is supplied by the public
low-voltage supply network. There may be potential problems with ensuring
electromagnetic compatibility in these areas, caused by line propagated
interference as well as radiated interference.
During operation, the device may be a source of interference.
Notice 
Users are advised that they are responsible for any interference from welding.
4. TECHNICAL DATA
Method
Plasma cutting
Mains voltage
V/Hz
3 x 400/50
-
60
Cutting current range
A/V
20/88,0
-
125/170
,0
No
-
load voltage U
20
V
400
Protection
A
@
50
Max. effective current I1eff A 44
Cutting current (DZ=100%) I
2
A
125
Cutting current (DZ=60%) I
2
A
125
Cutting current (DZ=x%) I2 A 100%=125
Current regulation
Continuous
Cover
IP 23 S
Standards EN IEC 60974-1, EN
60974
-
10 ar. A
Dimensions (w x d x h)
mm
378 x 810
x 619
Weight
kg
49
Efficiency
%
92
Standby power
P
10
W
37
Operating ambient temperature °C -10 ÷ +40
Relative
humidity
%
90
Altitude
m
max. 1000 m
DZ - load time. The parameter indicates in percentage the time of a ten-minute
interval (at ambient temperature and machine temperature 40o C) during which
the machine thermal protection or circuit breaker does not switch off the burning
process.

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Torches
Max. inlet air pressure
bar
8,5
Working pressure (cutting, SVH/SVS
125/6,7-9m torch) bar 5,0 - 6,0
Working pressure (grooving, SVH-125
6.7m torch)
bar 4,0 - 4,5
Air consumption at 125 A (SVH/SVS
125/6,7-9m torch) l/min 295
Working pressure (cutting, SVH/SVS
160/6,7
-
9m torch)
bar 5,0 - 6,0
Working pressure (grooving, SVH-160
6.7m torch) bar 3,0 - 3, 5
Air consumption at 125 A (torch
SVHSVS 160/6,7
-
9m)
l/min 370
Arc ignition
pneu
-
mechanic
Cutting parameters - SVH/SVS-160 torch (fine grain steel)
Productive piercing/cutting (I2max)* mm 25*
Productive piercing/cutting (I2 DZ=100%)** mm 25**
Maximum piercing/cutting (I2max)*** mm 35***
Max. cut (separation) (side start) (I2max) mm 55
Quality
cut (I2max)

Fine grain steel mm 50
Stainless steel mm 45
Aluminium mm 35
Copper mm 30
Max. productive speed (material thickness) 
6 mm m/min 5,96

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12 mm m/min 2,51 
25 mm m/min 0,76
Parameters were measured under test conditions on ALFATEC CNC tables,
not necessarily the maximum values.
* A burning process where the plasma is set to the maximum cutting current and
good cut quality is achieved at a relatively high cutting speed.
** A burning process where the plasma is set to a cutting current corresponding
to 100% of the load and good cut quality is achieved at a relatively high cutting
speed.
*** A burning process where the plasma is set at maximum cutting current and
satisfactory cut quality is achieved.
 A burning process where the plasma is set to the maximum cutting current and
a good quality cut is achieved.
 Max. cutting speed to ensure good cutting quality at maximum cutting current.
Operation on the power generator
Cutting current Sustained performance of power
generator
125 A 50 kVA
105 A
39 kVA
85 A
26 kVA
70 A 20 kVA
40 A
16 kVA
30 A
11 kVA
The continuous power of the central unit is given only for the connection of the
plasma as the only appliance.
Pressure air source requirements
The supply air pressure must not exceed 8.5 bar and must not be less than 6.5
bar. The operating pressure and air consumption for the prescribed torch are
given in chapter 4 TECHNICAL DATA.
For reliable operation of the plasma cutter and quality cuts, we recommend the
following recommendations when selecting the appropriate type of compressor:
1. The compressor must be capable of delivering a minimum of 295/370
litres/min of compressed air on a continuous basis (for SVH/SVS-125/
or SVH/SVS-160 torches). In the catalogues, this parameter is referred to
as "filling quantity". Caution Not to be confused with "suction
quantity"!
2. The aerator must be equipped with a drain valve.
3. It is essential that the compressor is equipped with a compressed air cooler
or a sufficiently large air receiver. Otherwise, heated air enters the

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distribution system and may contain significant amounts of water that
cannot be captured in the separators. As the air cools after it passes
through the ducts, it may reach the dew point, causing water droplets to
be expelled, which may be after the separator. The optimum size of the
airbox is at least 100 litres.
4. An efficient filter with sufficient capacity, an oil and condensate separator
or a pressure regulator must be installed at the outlet if the compressor
operating pressure is higher than 8.5 bar. These elements must be rated
for a flow rate of at least 370 l/min so as not to cause a drop in outlet
pressure during cutting.
5. The inside of the airbox should be coated against corrosion.
6. The compressor intake should be fitted with an efficient intake air filter,
especially for mobile compressors when operating in dusty environments.
Caution Some compressors have a built-in pressure air mixer at the
outlet. Under no circumstances must the plasma cutter be connected to
this outlet! This would contaminate the entire pneumatic system and could
damage the torch.
Connection to the central air distribution system
1. Before connecting, determine the working pressure in the system and the
extent of its fluctuation.
2. During cutting, the working pressure must be between 5.0 and 6.0 bar. To
achieve maximum cutting performance, we recommend that the pressure
does not drop below 5.5 bar.
3. Check the performance and technical condition of the central
compressor(s). The same requirements as above apply here.
4. Check the design and condition of pressure air filtration and condensate
trapping.
5. Ensure that the system is not centrally lubricated.
6. Include an additional filter and separator at the connection point closest to
the cutter. This is particularly important for older pipes made of
conventional steel pipes where the inner walls may be badly corroded. A
filter and separator is essential for systems with long ducts that pass
through cold environments where the compressed air may cool to the dew
point, causing condensation of water droplets.