Alfain SVAROG 105 PLASMA User manual

ALFA IN a.s © www.alfain.eu SVAROG 105 PLASMA návod EN 01
PLASMA CUTTING MACHINE
SVAROG 105 PLASMA
OPERATING MANUAL

2/27
ALFA IN a.s © www.alfain.eu
CONTENT
1. INTRODUCTION ...................................................................................... 3
2. SAFETY ................................................................................................... 4
3. CONDITIONS OF USE ............................................................................. 6
4. TECHNICAL DATA ................................................................................... 7
5. MAIN PARTS OF THE MACHINE ............................................................ 9
6. ACESSORIES ........................................................................................ 13
7. HAND TORCH AND CONSUMABLES ................................................... 14
8. FIRST STEPS ........................................................................................ 19
9. CUTTING ............................................................................................... 21
10. TORCH CONNECTION SCHEMA .......................................................... 23
11. MAINTENANCE ..................................................................................... 24
12. ERROR MESSAGES ............................................................................. 25
13. STATEMENT OR WARRANTY .............................................................. 26
14. DISPOSAL ............................................................................................. 27
15. WARRANTY LIST .................................................................................. 27

3/27
ALFA IN a.s © www.alfain.eu
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.

4/27
ALFA IN a.s © www.alfain.eu
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.

5/27
ALFA IN a.s © www.alfain.eu
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.

6/27
ALFA IN a.s © www.alfain.eu
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.
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.
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

7/27
ALFA IN a.s © www.alfain.eu
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 – 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 20 - 105
Open-circuit voltage U20 V 330
Mains protection A @ 40 (@32)*
Max. effective current I1eff A 36,7
Cutting current (DC=100%) I2 A 105 (95)*
Cutting current (DC=60%) I2 A 105 (105)*
Max. Input pressure bar 8,5
Working pressure (torch SVH-105) bar 5,0 - 5,5
Air consumption (torch SVH-105) l/min 240
Arc ignition pneu-mechanic
Current regulation continuous
Protection IP 23 S

8/27
ALFA IN a.s © www.alfain.eu
Standards EN 60974-1, EN 60974-10 cl. A
Dimensions (w x l x h) mm 377 x 802 x 621
Weight kg 46,7
* Parameters in parentheses are for 32 A mains protection. The machine is
equipped from the factory with a 32 A plug, if you need cutting at DZ 100% with
a current greater than 95 A, it is necessary to replace the fork with 63 A and
operate the machine under a 40 A circuit breaker. For normal manual cutting, a
32 A plug under a 32 A @ circuit breaker is sufficient in most cases.
The fork may only be replaced by a person with electrical qualification which
checks the network status at the connection point and decides, if it will be
possible to connect the machine in this way.
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.
CUTTING PARAMETERS OF MANUAL CUTTING
Max. productive cut. thickness - carbon steel mm 32
Max. cutting thickness - carbon steel
(separate mat.)
mm 50
Quality cutting thickness
Carbon steel mm 45
Stainless steel mm 40
Aluminium mm 30
Copper mm 25
Maximum pierce/cut (I2max) mm 22
Recommended cutting speed for thicknesses (fine-grained steel)
32 mm mm/min 500
38 mm mm/min 250
50 mm mm/min 125
Recommended maximum cutting speeds for thicknesses (fine grain steel)
6 mm mm/min 5600
12 mm mm/min 2450
20 mm mm/min 1300
25 mm mm/min 770

9/27
ALFA IN a.s © www.alfain.eu
TRAFFIC ON POWER GENERATOR
Cutting current Performance of power gen.
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 control panel is stated only for the connection of
the plasma, as a single appliance.
5. MAIN PARTS OF THE MACHINE
FRONT AND REAR PANELS
Pic. 1 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
Regulator with cleaner
A6
Air connection
A7
Network cable
A8
Main switch

10/27
ALFA IN a.s © www.alfain.eu
CONTROL PANEL
Pic. 2 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

11/27
ALFA IN a.s © www.alfain.eu
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
Grooving
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

12/27
ALFA IN a.s © www.alfain.eu
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

13/27
ALFA IN a.s © www.alfain.eu
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 grey and the new
one in orange.
6. ACESSORIES
PART OF DELIVERY
Pos. Code Description
1 pic. 5 7037 Torch Plasma SVH-105 hand 75°
A pic. 3 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
5.0508
Welding
carriage
P 80
Pic
.
4
, B
7088
Cable
koax.
extension
6,0 m SV
-
105, SV
-
125 6 PIN
7101
Lubri
c
ant silicon WSF
-
2 brutto 6 g
7038
Torch
Plasma SVH
-
105
hand
15°
Pic
.
5
7094
Torch
Plasma SVH
-
105
hand
,
handle
80 cm 90°
Pic
.
5
7095
Torch
Plasma SVH
-
105
hand
,
handle
130 cm 90°
Pic
.
5
7096
Torch
Plasma SVH
-
105
hand
,
handle
80 cm 15°
Pic
.
5
7097
Torch
Plasma SVH
-
105
hand
,
handle
130 cm 15
°
5872
Bevel Tolls
PT 40, 60, SCP 60, TH
-
70,125
7175
Circle cutting attachment
-
set
SVH
-
105,125
5302
Air filter
AT 1000
5304
Filter
-
set
AT 1000 k SVAROG PLASMA
S777c.
Welding Helmet
Barracuda S777C

14/27
ALFA IN a.s © www.alfain.eu
Pic. 3 Carriage P 80
7. HAND TORCH AND CONSUMABLES
SYSTEM SV-FIT
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.)
Pic. 4 SV-FIT system

15/27
ALFA IN a.s © www.alfain.eu
Pic. 5 Burners SVH witch long handles, SV-FIT system
LIFE ENDURANCE OF CONSUMABLE PARTS
The need to change consumables on your torch depends on the thickness of the
material being 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.
NAMES OF SVH BURNER PARTS
Nozzle
Nozzle body
Cutting tip
Diffuser
Electrode

16/27
ALFA IN a.s © www.alfain.eu
You can use the SUPERLONG NOZZLE SET for cutting in very hard-to-reach
areas, Pic. 7.
Torch SVH-105
Pic. 6 Hand torch SVH-105
CONSUMABLE PARTS
CONSUMABLE PARTS STANDARD 20-70 A
CONSUMABLE PARTS STANDARD 80-105 A

17/27
ALFA IN a.s © www.alfain.eu
CONSUMABLE PARTS GROOVING 20-70 A
CONSUMABLE PARTS GROOVING 80-105 A
CONSUMABLE PARTS EXTENDED 20-70 A
CONSUMABLE PARTS EXTENDED 20-70 A
Parts with * are mounted on the burner upon delivery.

18/27
ALFA IN a.s © www.alfain.eu
START SET
6 5832 Cutting tip 20-50A 2pc
7
7001
Cutting tip
105A
2
pc
6
5937
Cutting tip
70A
2
pc
7 7000 Cutting tip 85A 2pc
3
5830
Electrode
10
pc
10
7073
Nozzle
20
-
70A
1
pc
8 7070 Nozzle body 20-70A 1pc
4
5936
Diffuser
20
-
70A (
pack
.2)
1
pc
SUPERLONG NOZZLE
Pic. 7 Superlong Nozzle – consumable parts
Consumable parts of torch
(
see
pic
.
6
)
A1
7168
Complete super long set
70A SVH
-
105
A2 7166 Nozzle 20-70A
A3
7163
7164
7165
Cutting tip 15-30A
Cutting tip 45A
Cutting tip
70A
A4 7162 Ring A SVH
A
5
7161
Nozzle super long
body
A
6
7160
Super long Electrode
A8 5936 Diffuser (bal.2)

19/27
ALFA IN a.s © www.alfain.eu
BEVEL TOLLS AND CIRCLE CUTTING
Pic. 8 Bevel tolls and circle cutting
20
5872
Bevel Tolls
21 7175 Circle cutting – set SVH-105,125
8. FIRST STEPS
Commissioning of the machine must be in accordance with the technical data
and operating conditions.
Note This equipment must only be used by qualified personnel.
1. Before beginning work is necessary to connect the machine to the mains.
2. Check completeness of the mounted cutting torch.
3. Fit the burner and secure the burner well by turning the nut clockwise.
4. Connect the compressed air on connector A7 on the rear wall of the
machine.
5. Connect the compressed air on connector A6 on the rear wall of the
machine.
6. SVAROG 105 PLASMA has a pressure regulator A5 on the rear panel.
7. Set the pressure with the regulator on the rear panel of the machine to 5.5
bar.
8. After turning on the ON / OFF switch A8 the display will illuminate
9. Connect the work lead cable to the material being cut and to the
connector A1.
10. Check up the input air pressure (min 5,0 bar, max 8,5 bar) and make
a regulation if necessary.
11. Set potentiometer to the cutting power you need.
12. Fit the torch to the appropriate nozzle diameter according to the
selected cutting current.
13. Press the trigger on the cutting torch, the pre gas will flow for 1 s.
14. The pilot arc will start.
15. Shift the torch with the pilot arc close to the material, the pilot arc
will change to cutting arc automatically. If you do not start cutting within

20/27
ALFA IN a.s © www.alfain.eu
2 s, the arc will snuff off. If the torch delays during the cutting from the
material, the arc will snuff off. In case that the machine is in mode
Cutting material with gaps – switch A5 position , cutting arc will
change to pilot arc and if you do not start cutting within 2 s, this arc will
snuff off.
16. To finish the cutting process, release the torch trigger.
REQUIREMENTS FOR SOURCE OF COMPRESSED AIR
1. Delivered air pressure must be max. 8,5 bar and min. 5,0 bar.
2. Air consumption minimal 320 l/min.
3. Compressed air for the plasma must be clean and dry.
4. Pressure dew point +3 °C.
5. Maximum oil content 0.1 mg/m3.
6. Maximal size of solid particles 15 microns.
7. The minimal size of an air tank is 100 l.
8. No additional oiling if the pressure air is permitted. That could damage the
plasma machine and the cutting torch.
Note Some compressors have a built-in compressed air lubricator
at the outlet. The plasma cutter must never be connected to this output!
This would contaminate the entire pneumatic system and damage the
burner.
BALANCE AIR FILTER FOR SVAROG 105 PLASMA
In order to achieve high cutting quality and to avoid serious faults on the torch,
it is strongly recommended that a filter be always included in the inlet - Pic. 4.
Pos. Code Description
25 5304 Set for filter AT 1000 k SVAROG PLASMA
24 5302 Air filter AT 1000
Note Max. allowable pressure of filter AT 1000 is 8,5 bar.