Alfain SVAROG 85 PLASMA User manual

ALFA IN a.s © www.alfain.eu SVAROG 85 PLASMA (CNC) manual EN 03
PLASMA CUTTING MACHINE
SVAROG 85 PLASMA
SVAROG 85 PLASMA CNC
OPERATING MANUAL

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Content
1. INTRODUCTION ...................................................................................... 4
2. SAFETY ................................................................................................... 5
GENERAL REQUIREMENTS ....................................................................... 5
PROTECTIVE EQUIPMENT ......................................................................... 5
RISKS - OVERVIEW ..................................................................................... 5
PROHIBITED ACTIVITIES ............................................................................ 7
3. CONDITIONS OF USE ............................................................................. 7
ELECTROMAGNETIC COMPATIBILITY ....................................................... 8
4. TECHNICAL DATA ................................................................................... 8
TORCHES..................................................................................................... 9
CUTTING PARAMETERS (MILD STEEL) ..................................................... 9
TRAFFIC ON POWER GENERATOR ......................................................... 10
5. REQUIREMENTS FOR SOURCE OF COMPRESSED AIR ................... 10
CONNECTION TO CENTRAL DISTRIBUTION ........................................... 10
6. MAIN PARTS OF THE MACHINE .......................................................... 12
FRONT AND REAR PANELS ..................................................................... 12
CONTROL PANEL ...................................................................................... 13
7. ACESSORIES ........................................................................................ 16
PART OF DELIVERY SVAROG 85 PLASMA (HAND) ................................ 16
PART OF DELIVERY SVAROG 85 PLASMA CNC ..................................... 16
ACCESSORIES TO ORDER ....................................................................... 16
8. HAND CUTTING .................................................................................... 17
SYSTEM SV-FIT ......................................................................................... 17
LIFE ENDURANCE OF CONSUMABLE PARTS ......................................... 18
HOW TO CHOOSE THE RIGHT CONSUMABLE PARTS .......................... 19
DESCTIPTION OF SVH TORCH PARTS .................................................... 19
HAND TORCH SVH-105 HAND AND CONSUMABLES ............................. 19
CONSUMABLE PARTS .............................................................................. 20
SUPERLONG NOZZLE ............................................................................... 21
BEVEL TOLLS AND CIRCLE CUTTING ..................................................... 22
SINGLE-USE CARTRIDGES ...................................................................... 22
9. HAND CUTTING – FIRST STEPS .......................................................... 23
10. SOURCES OF POOR QUALITY CUTS.................................................. 24
CUTTING ARC IS UNSTABLE, GOES OFF AND “SHOOTS” ..................... 24
11. MACHINE CNC CUTTING ..................................................................... 25
SYSTEM SV-FIT ......................................................................................... 25
VITALITY OF CONSUMABLE PARTS ........................................................ 26
HOW TO CHOOSE THE RIGHT CONSUMABLE PARTS .......................... 26
TORCH SVS-105 MACHINE AND CONSUMABLES .................................. 26
NAMES OF SVS TORCH PARTS ............................................................... 26
STARTING KIT for SVS-105 (85 A) ............................................................. 27
12. MACHINE CUTTING - FIRST STEPS .................................................... 27
13. INDICATIVE PARAMETERS – CUTTING GAPS ................................... 28

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14. INDICATIVE CUTTING PARAMETERS ................................................. 28
MILD STEEL 85 A ....................................................................................... 28
STAINLESS STEEL 85 A ............................................................................ 29
ALUMINIUM 85 A ........................................................................................ 29
MILD STEEL 65 A ....................................................................................... 30
STAINLESS STEEL 65 A ............................................................................ 30
ALUMINIUM 65 A ........................................................................................ 30
MILD STEEL 45 A ....................................................................................... 31
STAINLESS STEEL 45 A ............................................................................ 31
ALUMINIUM 45 A ........................................................................................ 31
15. THE MOST COMMON MISTAKES IN MACHINE CUTTING .................. 32
16. MAINTENANCE ..................................................................................... 33
17. TORCH CONNECTION SCHEMA .......................................................... 34
18. CNC REMOTE CONTROL CONNECTION SCHEMA + DIVIDER .......... 34
19. ERROR MESSAGES ............................................................................. 35
20. STATEMENT OF WARRANTY .............................................................. 36
WARRANTY AND POST-WARRANTY REPAIRS ....................................... 37
21. DISPOSAL ............................................................................................. 37
22. WARRANTY CERTIFICATE ................................................................... 37

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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 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 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 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 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 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.
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 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

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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/V
20/88,0
-
85/140,0
Open
-
circuit voltage U
20
V
330
Mains protection
A
@32
Max. effective current I
1eff
A
26,7
Cutting current (DC=100%) I
2
A
85
Cutting current (DC=60%) I
2
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
Dimensions (w x l x h)
mm
378 x 696 x 619
Weight
kg
39,6
Efficiency
%
90
Input power in idle mode P
10
W
24

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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.
TORCHES
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 (MILD STEEL)
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.
** 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.

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 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.
TRAFFIC ON POWER GENERATOR
Cutting current
Performance of power gen.
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. REQUIREMENTS FOR SOURCE OF COMPRESSED AIR
1. Delivered air pressure must be max. 8,5 bar and min. 6,5 bar.
2. Air consumption minimal 240 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
Torch.
CONNECTION TO CENTRAL DISTRIBUTION
1. Before connecting, determine the working pressure in the system and the
extent of its fluctuations
2. When cutting, the working pressure must be in the range of 5.0 - 6.0 bar.
To achieve maximum cutting power, we recommend that the pressure
does not fall below 5.5 bar (for gouging 4,8 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 the compressed air filtration and
condensate trap.
5. Make sure the system is not centrally lubricated.
6. Insert an additional filter and separator at the connection point as close as

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possible to the cutter. This is especially important for older distribution
systems made of conventional steel pipes, where the inner walls can be
considerably corroded. It is necessary to use a filter with a sludge trap in
systems with long distributions that pass through a cold environment, where
compressed air can cool to the dew point and thus condense water droplets.
AIR FILTER AND WATER SEPARATOR FOR SVAROG PLASMA
In order to achieve high cutting quality and to avoid serious faults on the torch,
it is strongly recommended that a separator or at least a filter be always included
in the inlet (
Fig. 1).
Fig. 1 Air Filter and Separators
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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6. MAIN PARTS OF THE MACHINE
FRONT AND REAR PANELS
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
.
I
con
Description
V
1
---
Encoder with button
V2-
V11
--- Display with overal icon layout
V2
Cuttin 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
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

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
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
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

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
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
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.

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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.
7. ACESSORIES
PART OF DELIVERY SVAROG 85 PLASMA (HAND)
Pos. Code Description
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
PART OF DELIVERY SVAROG 85 PLASMA CNC
Pos. Code Description
6990-2 Torch Plasma SVS-105 0,2 m machine
Fig. 6 A 7103 Cable koax. 9,0 m SV-125 6 PIN
V9030092 Earthing cable 6 m 10-25 200 A 16 mm2
ACCESSORIES TO ORDER
Po
s
.
Code
Description
7192
Starting Kit for SVH
-
105
Hand
(85A)
7195 Starting Kit for SVS-105 Machine (85A)
Fig
.
6
B
7088
C
a
ble
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
Lubri
c
ant silicon WSF
-
2 brutto 6 g
7037
Torch
Plasma SVH
-
105
hand
75°
7038
Torch Plasma SVH
-
10
5
hand
15°
7094
Torch
Plasma SVH
-
105
hand
,
handle
80 cm 90°
7095
Torch
Plasma SVH
-
105
hand
,
handle
130 cm 90°
7096
Torch
Plasma SVH
-
105
hand
,
handle
80 cm 15°
7097
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

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5302
Air filter
AT 1000
5304
Filter
-
set
AT 1000 k
SVAROG
PLASMA
S777c.
Welding Helmet
Barracuda S777C
Fig. 4 Carriage P 80
Fig. 5 Cart SVAROG 85 Plasma
8. HAND CUTTING
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).

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Fig. 6 SV-FIT system
Fig. 7 Torches 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.

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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.
DESCTIPTION 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 HAND AND CONSUMABLES
Fig. 8 Hand torch SVH-105

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CONSUMABLE PARTS
CONSUMABLE PARTS STANDARD 20-70 A
CONSUMABLE PARTS STANDARD 80-105 A
CONSUMABLE PARTS EXTENDED 20-70 A
CONSUMABLE PARTS EXTENDED 20-70 A