Alfa Network SVAROG 85 PLASMA User manual

ALFA IN a.s ©www.alfain.eu SVAROG 85 PLASMA SYN (CNC) manual EN 07
PLASMA CUTTING MACHINE
SVAROG 85 PLASMA
SVAROG 85 PLASMA CNC
OPERATING MANUAL

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CONTENT
1. INTRODUCTION......................................................................................3
2. SAFETY...................................................................................................4
General requirements....................................................................................4
Protective equipment.....................................................................................4
Risks - overview............................................................................................4
Prohibited activities .......................................................................................6
3. CONDITIONS OF USE.............................................................................6
4. TECHNICAL DATA...................................................................................7
Torchs...........................................................................................................8
Cutting parameters........................................................................................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. ACESSORIES........................................................................................17
Part of delivery SVAROG 85 HAND PLASMA.............................................17
Accessories to order....................................................................................17
7. HAND TORCH AND CONSUMABLE PARTS ........................................18
SV-FIT system ............................................................................................18
Lifetime of consumable parts.......................................................................19
How to choose the right consumable parts..................................................19
Names of SVH torch parts...........................................................................20
Hand torch SVH-105 and consumables ......................................................20
Consumable parts.......................................................................................20
Superlong nozzle ........................................................................................22
Bevel tools and circle cutting.......................................................................23
Single-use cartridges...................................................................................23
8. MACHINE COMMISSIONING................................................................24
9. HAND CUTTING....................................................................................25
Important rules............................................................................................25
Causes of poor quality cuts.........................................................................26
10. MACHINE CNC CUTTING .....................................................................27
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. Thank you for purchasing our product and we believe that you will
be satisfied with our machine.
The SVAROG 85 PLASMA CNC machine is designed for cutting metals on the
basis of modern technology of material cutting by means of a thin jet of plasma
gas. This technology has several advantages over other methods
1. High cutting speed
2. Quality cut with a minimum area of the changed material structure
3. Smaller thermal deformations of the cut material
4. Possibility of cutting carbon and high-alloy, stainless steels and non-
ferrous metals
5. The method does not require any special gases
6. Lower costs
SVAROG 85 PLASMA CNC is equipped with a proportional valve that allows
precise automatic and synergic settings of the required working pressure of the
cutting gas (according to the cutting mode and the cutting current). As well the
manual settings of the cutting gas pressure can be adjusted right from the control
panel.
The machine is equipped with the ecological function "fan on demand". If cooling
is not required, the machine automatically shuts off the fan.
The CNC models support the cutting arc remote control of the CNC table
controllers.
SVAROG 85 PLASMA CNC is designed for high-quality cutting of materials up
to 30 mm thick mild steel. Productive cutting of carbon steel can be to a
thickness of 20 mm. At lower demands on the quality of the cut can be cut
through (separate) the material thickness to 35 mm. Maximal piercing is 25 mm
(mild steel). For more data see TECHNICAL DATA.
We reserve the law of adjustments and changes in case of printing errors,
change of technical parameters, 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
General requirements
1. The machine may only be operated by a worker who is thoroughly familiar
with the issue of plasma cutting and who has received appropriatetraining.
2. Disconnect the device from the mains before any work on the electrical
part, removal of the cover or cleaning.
3. For the cutting machine, it is necessary to perform a periodic inspection
once every 6/12 months by an authorized employee –see paragraph
Maintenance.
4. For safety reasons, protective gloves must be worn when plasma cutting
These gloves protect you from heat radiation and splashes of hot metal.
5. Wear solid insulated shoes. Open shoes are not suitable as drops of hot
metal can cause burns.
6. Do not look into the cutting arc without face and eye protection. Always
use a high-quality welding helmet with an intact protective filter.
7. Persons in the vicinity of the cutting site must also be informed of the
danger and must be provided with protective equipment.
8. When cutting, especially in small spaces, a sufficient supply of fresh air
must be ensured, as harmful fumes are produced during cutting.
9. Do not perform cutting work on gas, oil, fuel, etc. tanks (even empty ones)
as there is a risk of explosion.
10. Special regulations apply in potentially explosive atmospheres.
Protective equipment
1. Welding helmet with filter shade at least 10
2. Welding gloves
3. Welding apron and cloth
4. Welding boots
Risks - overview
1. Risk of electric shock
2. Ultraviolet light and light radiation
3. Risk of inhaling gas fumes and dust particles
4. Burns
5. Noise
NoteDanger of electric shock, especially if the insulation of the torch, the
supply cable fails and if the machine covers are damaged. be aware that the
torch can have a voltage of up to 330 volts.
The parameters of the torch comply with the EN 60974-7 standard,voltage class
M.

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Note
The machine torch cannot be used for versions without CNC!
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. In addition to the risk of injury, the cooling efficiency decreases and the
level of interference increases.
4. It is forbidden to operate the machine in wet environments and outdoors
in rain or snow.
5. Ensure proper grounding clamping pliers, which also reduces the risk of
electric shock.
6. Use prescribed protective utilities, keep them dry.
7. 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.
8. The cutting and pilot arc is a source of very intense light and especially
ultraviolet radiation. This radiation can significantly damage the eyesight
in a veryshort time and,with prolonged exposure, causes redness to burns
of uncovered parts of the skin.
9. Use a welding helmet equipped with an intact filter with a degree of
protection of min. 10.
10. The risk of burns arises when cutting from flying hot metal particles,
plasma arc and hot cut material. A thin beam of red-hot plasma (4th state
of matter) reaches up to 10,000 ° C in its core!
11. Never point the torch at the eyes, body or other person during
ignition.
12. Always wear good quality and undamaged welding gloves, apron
and welding clothing, including closed shoes and headgear.
13. During cutting, a large amount of gaseous emissions and dust
particles is formed from the material being cut.
14. High temperatures lead to chemical reactions and the formation of
various oxides andothercompounds, some of which are harmfulto health.
15. Particularly hazardous fumes are produced when cutting material
containing lead, beryllium, cadmium (cadmium-plated parts) and painted
materials.
16. Ultraviolet radiation and high temperatures also produce significant
amounts of ozone and nitrogen oxides.

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17. Exceeding the concentration of these gases above the values given
by hygienic standards can cause damage to health, especially with
prolonged exposure.
18. Workplaces must be well ventilated and equipped with an effective
extraction system.
19. In addition, a breathing mask must be used when cutting material
where particularly hazardous fumes are generated.
20. During its operation, the machine produces noise, the level of which
reaches the value of 80-85 dB.
21. We recommend using hearing protection for longer work.
Prohibited activities
1. It is forbidden to use the machine in areas with a risk of explosion and in
areas with the possibility of easily flammable and flammable substances.
2. It is forbidden to cut containers with residues of any flammable or unknown
substances.
3. It is forbidden to cut on closed pressure vessels without first releasing the
pressure and leaving it open.
NoticePersons with implanted pacemakers must not operate the
machines or move in close proximity to them! There is a risk of impaired
pacemaker function!
3.CONDITIONS OF USE
1. 1st Putting into operation may only be performed by trained personnel and
only in the technical provisions. The manufacturer is not liable for damage
caused by improper use and operation. Only use original spare parts from
ALFA IN for maintenance and repairs.
2. The device complies with IEC 61000-3-12.
3. The cutting machine is tested according to the standard for degree of
protection IP 23 S, which provides protection against the ingress of solid
bodies with a diameter greater than 12 mm and protection against the
ingress of water falling in a vertical to oblique direction up to 60
4. Working 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 so that cooling air can enter and exit the
cooling vents without restriction. Care must be taken to ensure that no
mechanical particles, especially metal particles, are sucked into the
machine (during grinding).
8. When the machine overheats, cutting is automatically interrupted.
9. All interventions in the el. equipment as well as repairs (disassembly of the

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mains plug) may only be carried out by an authorized person.
10. SVAROG 85 PLASMA is designed for mains voltage 3x400 V.
11. The mains voltage and power input must correspond to the mains
plug.
12. For the cutting machine, it is necessary to perform a periodic
inspection once every 6/12 months by an authorized employee –see
paragraph Maintenance.
13. 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).
14. 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
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 cutting.
4.TECHNICAL DATA
Method
Plasma cutting
Mains voltage
V/Hz
3 x 400/50-60
Cutting current range
A/V
20/88,0 - 85/140,0
Open-circuit voltage U20
V
330
Mains protection
A
@32
Max. effective current I1eff
A
26,7
Cutting current (DC=100%) I2
A
85
Cutting current (DC=60%) I2
A
85
Cutting current (DC=x%) I2
A
100%=85
Current regulation
continuous
Protection
IP 23 S
Standards
EN IEC 60974-1, EN
60974-10 ar. A

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Dimensions (w x l x h)
mm
378 x 696 x 619
Weight
kg
39,6
Efficiency
%
90
Input power in idle mode P10
W
24
Ambient temperature
°C
-10 ÷ +40
Relative humidity
%
90
Altitude above the see level
m
max. 1000 m
DC –(Duty Cycle) load time. The parameter specifies the time of the ten-minute
interval as a percentage (at surrounding temperature and machine temperature
40oC), during which the thermal protection of the machine or the circuit breaker
does not switch off the cutting process.
Torchs
Max. Input pressure
bar
8,5
Working pressure (Cutting, torch
SVH/SVS 105/6,7-9m)
bar
5,0 - 5,5
Working pressure (Gauging, torch SVH-
105/6,7m)
bar
3,5-4,5
Air consumption at 85 A (torch
SVH/SVS 105/6,7-9m)
l/min
205
Arc ignition
pneu-mechanic
Cutting parameters
Productive Pierce/Cut (I2max)*
mm
20*
Productive Pierce/Cut (I2 DC=100%)**
mm
20**
Max. Pierce/Cut (I2max)***
mm
25***
Max. cut (separate mat.) (Edge start) (I2max)
mm
35
Quality
Cut (I2max)

Mild steel
mm
30
Stainless steel
mm
26
Aluminium
mm
20
Cupper
mm
16
Max. productive cut speed (material thickness)
6 mm
m/min
5,09
12 mm
m/min
2,06
25 mm
m/min
0,58
Parameters were measured on laboratory conditions on CNC ALFATEC
machines. Actual cutting speeds and thicknesses may vary based on different
cutting applications.
*Cutting process whereby the plasma is set to the maximum cutting current and
a good cut quality is achieved at a relatively good speed.

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** Cutting process whereby the plasma is set to the current equal to 100% of
duty cycle and a good cut quality is achieved at a relatively good speed.
*** Cutting process whereby the plasma is set to the maximum cutting current
and an acceptable cut quality is achieved.
Cutting process whereby the plasma is set to the maximum cutting current and
a good cut quality is achieved.
 Cutting process whereby the plasma is set to the maximum cutting current
and a good cut quality is achieved.
Operation on the power generator
Cutting current
Sustained performance of power
generator
85 A
26 kVA
70 A
20 kVA
40 A
16 kVA
30 A
11 kVA
The continuous power of the control panel is stated only for the connection of
the plasma, as a single 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 Chyba! Nenalezen zdroj odkazů..
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 able to deliver a minimum of 295/370 litres/min
of compressed air permanently. This parameter is referred to in the
catalogues as the so-called "compressed air capacity“.
NoticeNot to be confused with „suctioned quantity"!
2. The aerator must be equipped with a drain valve.
3. It is essentialthat the compressor is equippedwith acompressed air cooler
or a sufficiently large air receiver. Otherwise, heated air enters the
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.

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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.

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Pre-set Water Separator and Air Filter for SVAROG PLASMA
To achieve high quality cutting and to avoid serious malfunctions on the torch, it
is strongly recommended that a water separator or at least a filter is always
included in the water supply.
Fig. 1 Air Filter and Water Separator
Pos.
Code
Description
S1
5304
Filter - set AT 1000 k SVAROG PLASMA
S2
5302
Air filter AT 1000
S3
7704
Water separator including fittings
S4
6079
Condensate drain
NoteMax. operating pressure of the AT 1000 filter is 8.5 bar.

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5.DESCRIPTION OF MACHINE AND FUNCTIONS
Main parts
Fig. 2 Main parts of the machine, front and rear view
Pos.
Description
A1
Quick connector - earthing cable
A2
Connector - remote control (CNC version only)
A3
Connector - torch
A4
Control panel
A5
Cleaner
A6
Air connection
A7
Network cable
A8
Main switch

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Control panel
Fig. 3 Control panel
Pos.
Icon
Description
V1
---
Encoder with button
V2-
V11
---
Display with overal icon layout
V2
Cuttin current
•Always active after switching
on the machine
V3
Gas test
•active when encoder V1 is
pressed for 5 sec
•The value is changed by

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turning the encoder V1
•Exit the gas test by briefly
pressing encoder V1
V4
Pressure
Cutting solid material
Cutting of perforated material
Grooving
V6
Change of units
V7
Display brightness 1 - 10
V8
Current voltage
•this value cannot be changed
V9
Consumable catalogue
•If a torch is not recognised,
this icon does not appear.
•If a torch is recognised, you
can reach this icon by means
of short presses of the
encoder V1.
•Then first window of the
consumable catalogue will be
displayed.
•By means of turning the
encoder you scroll through the
consumable catalogue.
•To get out of this catalogue,
press the encoder or wait for 5
s.

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V10
Automatic/manual pressure setting
mode selector.
The selector switches between
automatic and manual mode.
•If the torch is not recognised,
the machine will be only in the
manual mode. AUTO mode
cannot be selected.
•AUTO mode is the default
mode if the torch is
recognised.
In the automatic mode, the power
supply automatically sets the gas
pressure based upon the torch,
cutting current and cutting mode.
In the AUTO mode the pressure is
displayed, but cannot be changed.
In the MAN mode the pressure can
be changed.
When you switch from a manual
mode to an automatic mode, the
power supply automatically sets the
gas pressure and the amperage
setting is unchanged. When you
switch from an automatic mode to a
manual mode, the machine
remembers the previous manual gas
pressure setting and the amperage
setting is unchanged.
When you switch off the power and
then ON, the machine remembers
the previous mode, gas pressure,
and amperage settings.
V11
Selecting the language of the
ERROR codes legend. (Czech,
English, German, Polish, Russian,
Spanish)

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V12
The consumable parts on the torch
are complete
Gas flow is active
Remote current setting is active.
The arc is active
There is tension on the arc
The S mark indicates that the
machine and torch are suitable for
operations in environments with an
increased risk of electric shock in
accordance with EN 60974-1
CE mark declaration of the
manufacturer's stairs with European
directives and standards
EAC brand of product safety and
meeting EMC requirements for
export to the Russian Federation,
Belarus and Kazakhstan.
Read the operating manual carefully
before use.
Warning - general danger.
Note:
Switch between individual parameters / modes by pressing encoder V1. The
active parameter / mode is highlighted in orange, when switching to another
parameter / mode the original quantity will be highlighted in gray and the new
one in orange.

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6.ACESSORIES
Part of delivery SVAROG 85 HAND PLASMA
Pos.
Code
Description
Fig. 8
7037-1
Torch Plasma SVH-105 hand 75°
Fig. 6 A
7076
Cable Package 6,7 m SV-105, SV-125 6 PIN
V9030092
Earthing cable 6m 10-25 200 A 16 mm2
Accessories to order
Pos.
Code
Description
7192
Starting Kit for SVH-105 Hand (85A)
7195
Starting Kit for SVS-105 Machine (85A)
Fig. 6 B
7088
Cable koax. extension 6,0 m SV-105, SV-125 6 PIN
Fig. 6 A
7076
Cable Package 6,7 m SV-105, SV-125 6 PIN
7101
Lubricant silicon WSF-2 brutto 6 g
Fig. 8
7037-3
Torch Plasma SVH-105 hand 75°
Fig. 8
7038-3
Torch Plasma SVH-105 hand 15°
Fig. 8
7094-3
Torch Plasma SVH-105 hand, handle 80 cm 90°
Fig. 8
7095-3
Torch Plasma SVH-105 hand, handle 130 cm 90°
Fig. 8
7096-3
Torch Plasma SVH-105 hand, handle 80 cm 15°
Fig. 8
7097-3
Torch Plasma SVH-105 hand, handle 130 cm 15°
7088
Cable koax. extension 6,0 m SV-105, SV-125 6 PIN
5872
Bevel Tolls PT 40, 60, SCP 60, TH-70,125
7175
Circle cutting attachment - set SVH-105,125
Fig. 5
5.0545
Cart SVAROG 85 Plasma
Fig. 4
5.0508
Welding carriage P 80
5302
Air filter AT 1000
5304
Filter - set AT 1000 k SVAROG PLASMA
S777c.
Welding Helmet Barracuda S777C

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Fig. 4 Carriage P 80
Fig. 5 Cart SVAROG 85 Plasma
7.HAND TORCH AND CONSUMABLE PARTS
SV-FIT system
The SV-FIT system allows great variability when using different ends of
welding torches or allows to extend the torch length from the standard 6.7 m to
12.7 m by purchase. (Extensions up to a total length of 16 m are available on
request).

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Fig. 6 SV-FIT system
Fig. 7 Torches SVH witch long handles, SV-FIT system
Lifetime of consumable parts
The need to change consumables on your torch depends on the thickness of the
material to be cut, the length of the cut, the air quality (presence of moisture, oil
and dirt), the way the cut is started (side or puncture), the appropriate piercing
height, cutting mode (solid material or perforated).
In general, the current set of consumables lasts an average of 1 to 3 hours of
cutting (ignited arc). Under normal conditions, the nozzle wears first when cutting
by hand, the electrode lasts about half as long.
How to choose the right consumable parts
All 6 types of torch SVH-105 use the same consumables that are protected, so
the nozzles can be pulled over the cut material.
For the best cut quality, it is necessary to use suitable sets of consumable
parts. The individual assemblies by power and type, including order numbers,
are listed in the table below.

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Names of SVH torch parts
Nozzle
Nozzle body
Cutting tip
Diffuser
Electrode
You can use the SUPERLONG NOZZLE SET for cutting in very hard-to-reach
areas, Fig. 9.
Hand torch SVH-105 and consumables
Fig. 8 Hand torch SVH-105
Consumable parts
CONSUMABLE PARTS STANDARD 20-70 A