Alfa Network SVAROG 105 PLASMA User manual

ALFA IN a.s © www.alfain.eu SVAROG 105 PLASMA manual EN 07
PLASMA CUTTING MACHINE
SVAROG 105 PLASMA
SVAROG 105 PLASMA CNC
OPERATING MANUAL

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CONTENT
1. INTRODUCTION ...................................................................................... 3
2. SAFETY ................................................................................................... 4
General requirements .................................................................................... 4
Protective uttilities ......................................................................................... 4
Risk overview ................................................................................................ 4
Prohibited activities ....................................................................................... 6
3. CONDITIONS OF USE ............................................................................. 6
Electromagnetic compatibility ........................................................................ 7
4. TECHNICAL DATA ................................................................................... 7
Torches ......................................................................................................... 8
Cutting parameters - SVH/SVS-105 torch (fine grain steel) ........................... 8
Operation on the power generator ................................................................. 9
Pressure air source requirements................................................................ 10
Connection to the central air distribution system ......................................... 10
Pre-set Water Separator and Air Filter for SVAROG PLASMA .................... 11
5. MAIN PARTS OF THE MACHINE .......................................................... 12
Main parts ................................................................................................... 12
Control panel ............................................................................................... 13
6. ACESSORIES ........................................................................................ 16
Part of delivery ............................................................................................ 16
Accessories to order .................................................................................... 16
7. HAND TORCH AND CONSUMABLES ................................................... 17
SV-FIT system ............................................................................................ 17
Lifetime of consumable parts ....................................................................... 18
How to choose the right consumable parts .................................................. 18
Names of svh torch parts ............................................................................ 19
Torch SVH-105 ........................................................................................... 19
Consumable parts ....................................................................................... 19
Starting kit ................................................................................................... 21
Superlong nozzle ........................................................................................ 21
Bevel tolls and circle cutting ........................................................................ 22
8. COMMISSIONING THE MACHINE ........................................................ 22
9. HAND CUTTING .................................................................................... 23
Important rules ............................................................................................ 24
Causes of poor quality cuts ......................................................................... 25
Conical cut .................................................................................................. 25
10. MACHINE CNC CUTTING ..................................................................... 26
11. TORCH WIRING DIAGRAM ................................................................... 26
12. MAINTENANCE ..................................................................................... 26
13. ERROR MESSAGES ............................................................................. 27
14. SERVICE ............................................................................................... 28
15. DISPOSAL OF ELECTRICAL WASTE ................................................... 30
16. WARRANTY LETTER ............................................................................ 30

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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 105 PLASMA 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 105 PLASMA is equipped with a proportional valve that allows precise
setting of the required working pressure of the gas and display of the pressure
value on the display. The proportional valve allows you to precisely set the
required pressure or gas flow and allows high accuracy and stability of cutting.
The machine is equipped with the ecological function "fan on emand". If cooling
is not required, the machine automatically shuts off the fan.
SVAROG 105 PLASMA is designed for high-quality cutting of materials up to 45
mm thick carbon steel (for more information, see instructions below). Productive
cutting of carbon steel can be to a thickness of 32 mm.
At lower demands on the quality of the cut can be cut through (separate) the
material thickness to 50 mm.
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 appropriate training.
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 six months by an authorized worker according to ČSN 331500
and ČSN 050630.
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 uttilities
1. Welding helmet with filter shade at least 10
2. Welding gloves
3. Welding apron and cloth
4. Welding boots
Risk 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 ČSN 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 very short 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 and other compounds, some of which are harmful to 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
mains plug) may only be carried out by an authorized person.

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10. SVAROG 105 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 months by an authorized worker according to ČSN
331500,1990 and ČSN 050630,1993.
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 – exceeding 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 20 - 105
Open-circuit voltage U20 V 330
Mains protection A @ 32 (@40)
Max. effective current I1eff A 31,9 (36,7)
Cutting current (DC=100%) I2 A 95 (105)
Cutting current (DC=60%) I2 A 105
Cutting current (DZ=x%) I2 A 100%=95 (100%=105)
Current regulation continuous
Protection IP 23 S

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Standards ČSN EN IEC 60974-1, ČSN EN
60974-10 cl. A
Dimensions (w x l x h) mm 377 x 802 x 621
Weight kg 46,7
Efficiency % 87
Standby power P10 W 25
Operating ambient temperature °C 5,0 - 5,5
Relative humidity % 90
Altitude m max. 1000 m
DZ – 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 burning process.
Torches
Max. inlet air pressure
bar
8,5
Working pressure (cutting, SVH/SVS
105/6,7
-
9m torch)
bar 5,0 - 5,5
Working pressure (grooving, SVH-105
6,7m torch)
bar 4,8
Air consumption at 105 A (SVH/SVS
105/6,7
-
9m torch)
l/min 240
Air ignition
pneu
-
mechanic
Cutting parameters - SVH/SVS-105 torch (fine grain steel)
Productive piercing/cutting (I2max )* mm 22*
Productive piercing/cutting (I2 DZ=100% )** mm 22**
Maximum piercing/cutting (I2max )*** mm 32***

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Max. cut (separation) (side start) (I2max ) mm 50
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 5,09 
12 mm m/min 2,06 
25 mm m/min 0,58 
32 mm m/min 0,31 
40 mm m/min 0,21
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
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.

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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 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 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 essential that the compressor is equipped with a compressed 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.
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

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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.
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
Item. Code Description
S1 5304 Set for filter AT 1000 to SVAROG PLASMA
S2 5302 Air filter AT 1000
S3 7704 Water separator including fittings
S5 6079 Condensate evacuator
Please note The maximum operating pressure of the AT 1000 is 8.5 bar.

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5. MAIN PARTS OF THE MACHINE
Main parts
Fig. 2 Main parts of the machine, front and rear view
Po
s
.
Description
A1
Quick
connector
-
earthing cable
A2
Connector
-
remote control (CNC version only)
A3
Connector
-
torch
A4
Control panel
A5
C
leaner
A6
Air connection
A7
Network cable
A8
Main switch

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Control panel
Fig. 3 Control panel
Po
s
.
Icon
Description
V1
---
Encoder with
a
button
V2-
V11
--- Display with overall icon layout
V2
Cutting current
 Always active after switching
on the machine
 The value is changed by
turning the encoder V1
V3
Gas test
 active when encoder V1 is
pressed for 5 sec
 The value is changed by
turning the encoder V1

Exit the gas test by briefly

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pressing encoder
V1
V4
Pressure
 active after a short press on
encoder V1
 change the value by turning
encoder V1; the selection does
not need to be confirmed, it
will be saved automatically
 after 5 s of inactivity, the
machine switches back to the
cutting current setting
V5
Cutting modes
 active after 2 short presses of
encoder V1
 change the mode by turning
encoder V1; the selection does
not need to be confirmed, it
will be saved automatically
 after 5 s of inactivity, the
machine switches back to the
cutting current setting
Cutting solid material
Cutting of perforated material
Gauging
V6
Change of units
 active after 3 short presses of
encoder V1
 change units by turning
encoder V1; the selection does
not need to be confirmed, it
will be saved automatically
 after 5 s of inactivity, the
machine switches back to the
cutting current setting

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V7
Display brightness
 active after 4 short presses of
encoder V1
 change the value by turning
the encoder V1, the selection
does not need to be
confirmed, it is saved
automatically
 after 5 s of inactivity, the
machine switches back to the
cutting current setting
V8 Current voltage

this value cannot be changed
V9
Manual / machine mode
 the icon is displayed according
to the type of torch connected
V10 Active cutting input
V11
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

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EAC brand of product safety and
meeting EMC requirements for
export to the Russian Federation,
Be
larus 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 grey and the new
one in orange.
6. ACESSORIES
Part of delivery
Pos. Code Description
Fig. 8 7037 Torch Plasma SVH-105 hand 75°
Fig. 6 7076 Cable koax. 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
7112
Starting Kit for SVH
-
105
Fig
.
5
5.0542
Cart SVAROG Plasma
Fig
.
4
5.0508
Welding
carriage
P 80
Fig
.
6
, B
7088
Cable
koax.
extension
6,0 m SV
-
105, SV
-
125 6 PIN
7101
Lubri
c
ant silicon WSF
-
2 brutto 6 g
Fig
.
8
7038
Torch
Plasma SVH
-
105
hand
15°
Fig
.
8
7094
Torch Plasma SVH
-
105 hand, handle 80 cm 90°
Fig
.
8
7095
Torch Plasma SVH
-
105 hand, handle 130 cm 90°
Fig
.
8
7096
Torch Plasma SVH
-
105 hand, handle 80 cm 1
5°
Fig
.
8
7097
Torch Plasma SVH
-
105 hand, handle 130 cm 15°
Fig
.
10
5872
Bevel Tolls
PT 40, 60, SCP 60, TH
-
70,125
Fig
.
10
7175
Circle cutting attachment
-
set
SVH
-
105,125
Fig
.
1
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 Plasma
7. HAND TORCH AND CONSUMABLES
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 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.
Torch SVH-105
Fig. 8 Hand torch SVH-105
Consumable parts
CONSUMABLE PARTS STANDARD 20-70 A

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CONSUMABLE PARTS STANDARD 85-105 A
CONSUMABLE PARTS GROOVING 20-70 A
CONSUMABLE PARTS GOUGING 80-105 A
CONSUMABLE PARTS EXTENDED 20-70 A