Alfain PEGAS 40 PLASMA PFC User manual

ALFA IN a.s © www.alfain.eu NA124-103
PLASMA CUTTING MACHINE
PEGAS 40 PLASMA PFC
OPERATING MANUAL

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Content:
1.
INTRODUCTION......................................................................................3
2. SAFETY INSTRUCTIONS AND WARNINGS...........................................4
2.1 ELECTROMAGNETIC COMPATIBILITY (EMC).................................6
2.2 PROTECTIVE UTTILITIES.................................................................7
2.3 RISK OVERVIEW...............................................................................7
3. CONDITIONS OF USE.............................................................................7
4. TECHNICAL DATA...................................................................................8
5. OPERATOR CONTROLS.........................................................................9
5.1 FRONT AND REAR PANELS.............................................................9
6. ACCESSORIES .....................................................................................10
6.1 PART OF DELIVERY........................................................................10
6.2 ON REQUEST..................................................................................10
6.3 COMMENTS ON CONSUMABLES ..................................................12
7. GETTING STARTED..............................................................................12
7.1 FIRST STEPS...................................................................................12
7.2 REQUIREMENTS FOR SOURCE OF COMPRESSED AIR..............13
7.3 OPTIONAL AIR FILTERS.................................................................14
7.4 CUTTING..........................................................................................14
7.5 IMPORTANT RULES........................................................................15
7.6 SOURCES OF POOR QUALITY CUTS............................................15
8. MAINTENANCE.....................................................................................16
9. STATEMENT OF WARRANTY ..............................................................17
10. DISPOSAL.............................................................................................18

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1. INTRODUCTION
Congratulations on your new ALFA IN product. We are proud to have you as
our customer and will strive to provide you with the best service and reliability
in the industry.
This Operating Manual has been designed to instruct you on the correct use
and operation of your ALFA IN product. Your satisfaction with this product and
its safe operation is our ultimate concern. Therefore please take the time to
read the entire manual, especially the Safety Precautions. They will help you to
avoid potential hazards that may exist when working with this product.
Read and understand this entire Manual and your employer’s safety practices
before installing, operating, or servicing the equipment. While the information
contained in this Manual represents the Manufacturer's best judgement, the
Manufacturer assumes no liability for its use.
Machine PEGAS 40 PLASMA PFC is designed for cutting metal on the basis of
modern technology cutting material through a thin beam plasma gas.
PEGAS 40 PLASMA PFC is equipped by Power Factor Correction (PFC),
which allows operation on single phase voltage networks 110 V – 230 V.
PEGAS 40 PLASMA PFC is designed for high-quality cutting of materials up to
20 mm thick carbon steel (for more information, see instructions
below). Productive cutting of carbon steel can be to a thickness of 12 mm.
At lower demands on the quality of the cut can be cut through (separate) the
material thickness to 25 mm.

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2. SAFETY INSTRUCTIONS AND WARNINGS
•OPERATION AND MAINTENANCE OF PLASMA ARC EQUIPMENT CAN
BE DANGEROUS AND HAZARDOUS TO YOURHEALTH.
•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.
•Once the packing has been opened, make sure that the machine is not
damaged. If in any doubt, call the service centre.
•This equipment must only be used by qualified personnel.
•During installation, any electric work must only be carried out by trained
personnel.
•The machine must be used in a dry place with good ventilation.
•Make sure that no metal dust can be drawn in by the fan inside the
machine, as this could cause damage to the electronic circuits.
•It is prohibited to connect more than one INVERTER generator in series or
in parallel.
•When installing the machine, follow the local regulations on safety.
•The position of the machine must allow easy access by the operator to the
controls and connectors.
•When the cutting machine is operating, all its covers and doors must be
closed and well fixed.
•Do not expose the cutting machine to direct sunlight or to heavy rain. This
equipment conforms to protection rating IP23S.
•The operator must wear gloves, clothes, shoes, and a helmet or a welder’s
helmet, which protect and are fire-resistant in order to protect him against
electric shock, flashes and sparks from cutting.
•The operator must protect his eyes with safety visor or mask designed for
welding, fitted with standard safety filters. He should also be aware that
during plasma cutting ULTRAVIOLET RADIATION is emitted. Therefore it
is vital that his face is also protected from radiation. Ultraviolet rays
produce the same harmful effect as sun burning on unprotected skin.
•The operator is obliged to warn anyone near the cutting area of the risks
that cutting involves and to arrange to provide adequate protection
equipment.
•Keep all fumes and gases from the breathing area.
•Keep your head out of the fume plume.
•Use an air-supplied respirator if ventilation is not adequate to remove all
fumes and gases.

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•The kinds of fumes and gases from the plasma arc depend on the kind of
metal being used, coatings on the metal, and the different processes. You
must be very careful when cutting or welding any metals which may contain
one or more of the following:
Antimony Chromium Mercury
Nickel Cobalt Arsenic
Barium Copper Selenium
Beryllium Lead Silver
Cadmium Manganese Vanadium
•Always read the Material Safety Data Sheets (MSDS) that should be
supplied with the material you are using. These MSDSs will give you the
information regarding the kind and amount of fumes and gases that may be
dangerous to your health.
•It is very important to arrange for sufficient ventilation, especially when
cutting in enclosed spaces. We suggest using suitable fume extractors to
prevent the risk of intoxication by fumes or gas generated by the cutting
process.
•Noise can cause permanent hearing loss. Plasma arc processes can cause
noise levels to exceed safe limits. You must protect your ears from loud
noise to prevent permanent loss of hearing.
•To protect your hearing from loud noise, wear protective ear plugs and/or
ear muffs. Protect others in the workplace.
•Noise levels should be measured to be sure the decibels (sound) do not
exceed safe levels.
•The operator must ensure all flammable materials are removed from the
work area to avoid any risk of fire.
•The operator must NEVER cut containers that have previously contained
petrol, lubricants, gas or similar flammable materials, even if the container
has been empty for a considerable time. THERE IS A VERY HIGH RISK
OF EXPLOSION.
•The operator must be aware of all the special regulations which he needs
to conform to when cutting in enclosed spaces with a high risk of explosion.
•To prevent electric shock, we strongly suggest the following rules:
•Do not work in a damp or humid environment.
•Do not use the machine if its cables are damaged in any way.
•Make sure that the earthing system of the electric equipment is
correctly connected and operational.
•The operator must be insulated from the metal components
connected to the return wire.
•The earthing of the piece being worked could increase the risk of
injury to the operator.
•EN 60974-1 Standard: Open-circuit voltage. During the operation of the
machine, the highest voltage, with which it is possible to come into contact,

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is the open-circuit voltage between the clamps. In our generator this
voltage is 380V.
•The maximum open-circuit voltage of the plasma machines is established
by national and international standards (EN 60974-1) depending on the
type of current to be used, on its waveform and on the hazards arising from
the work place. These values are not applicable to the strike currents and
those for stabilisation of the arc that could be above it.
•The open-circuit voltage, for as many adjustments as possible, must never
exceed the values relating to the various cases shown in the following
table:
Case
Working conditions Open-circuit voltage
1 Places with increased risk of
electric shock DC current: 113V peak value AC current: 68V peak value and
48V effective
2 Places without increased risk
of electric shock DC current: 113V peak value AC current: 113V peak value and
80V effective
3 Torches held mechanically
with increased protection for
the operator
DC current: 141V
peak value AC current: 141V peak value and
100V effective
4 Plasma cutting DC current: 500V
peak value
•In case 1, the dc machines with rectifier must be built in such a way that, in
case of a fault developing in the rectifier (for example open circuit, short
circuit or lack of power), the permitted values cannot be exceeded. The
plasma cutting machines of this type can be marked with the symbol:
S
•Before opening the machine switch off the machine and disconnect it from
the power socket.
•Only personnel authorised by this company can carry out maintenance on
the machine.
2.1 ELECTROMAGNETIC COMPATIBILITY (EMC)
•This machine conforms to EN 60974-10 standard. However, the
electromagnetic emissions generated could prove not be compatible with
the maximum permitted levels for some classes of electrical equipment,
such as the following:
•Domestic electronic appliances (radios, TVs, videos, telephones,
burglar alarms, etc.).
•Computers, robots, electro-medical instruments and life-support
systems.
•Radio-television transmitters and receivers.
•Pacemakers and hearing aids.

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•All very sensitive electrical equipment.
•The operator is responsible for the installation and use of the cutting
machine. If there should be any fault in operations of other systems located
in the immediate vicinity of the generator, we recommend suspending
operations and consulting the manufacturers.
2.2 PROTECTIVE UTTILITIES
•Welding helmet with filter shade at least 10
•Welding gloves
•Welding apron and cloth
•Welding boots
2.3 RISK OVERVIEW
•Risk of electric shock.
•Ultraviolet light and light radiation
•Risk of inhaling gas fumes and dust particles
•Burns
•Noise
 NOTE 
• It is forbidden to operate a machine with damaged insulation of the
cutting torch or supply cable.
•Never operate the machine taken down or damaged covers.
• It is forbidden to operate the machine in wet environments and outdoors
in rain or snow.
• Ensure proper grounding clamping pliers, which also reduces the risk of
electric shock.
• Use prescribed protective utilities, keep them dry.
• 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.
• Never aim the torch against the eyes, body or other person.
3. CONDITIONS OF USE
•This equipment must only be used by qualified personnel.
•During installation, any electric work must only be carried out by trained
personnel.
•Do not expose the plasma machine to direct sunlight or to rain or snow.
This equipment conforms to protection rating IP23S.

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•Place the machine the way that the cooling air can enter the vents without
restriction to. It is necessary to ensure that no impurities, especially metal
particles, are not drawn into the machine.
•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).
• 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
4. TECHNICAL DATA
PEGAS 40 PLASMA PFC Unit
Method Plasma cutting
Mains voltage V/Hz 1 x 110/50-60 1x230/50-60
Mains protection A 20 T 16 T
Max. input power I
1
A 33,7 23,4
Max. effective current I
1eff
A 19,9 14,8
Cutting current range A/V 20/88,0 - 30/92,0
20/88,0 - 40/96,0
Open-circuit voltage U
20
V 380
Cutting current (DC=100%) I
2
/U
2
A/V 20/88 21/88,4
Cutting current (DC=60%) I
2
/U
2
A/V 23/89,2 26/90,4
Cutting current (DC=x%) I
2
/U
2
A/V 35%=30/92 40%=40/96
Max. Productive cutting
thickness - carbon steel mm 8 12
Max. Cutting thickness -
carbon steel mm 15 20
Carbon
steel mm 10 15
Stainless
steel mm 8 12
Aluminium
mm 6 10
Quality cutting
thickenss
Copper mm 3 4
Working pressure bar 5
Max. Input pressure bar 8
Air consumption l/min 119
Arc ignition Contact
Curent regulation Continuous
Insulation class F
Protection IP 23S
Standards EN 60974-1
Dimensions (w x l x h) mm 170x430x270
Weight kg 12,6

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5. OPERATOR CONTROLS
5.1 FRONT AND REAR PANELS
Pos. Description
1 LED ON when the machine is switched on by the mains switch
2 LED. If the LED illuminates the thermo-switch is disconnected. In
such a case leave the machine on to cool down. Second warning
is when the mains voltage is over 270 V.
3 Cutting current potentiometer
4 LED Error
1. LED illuminates and the air valve regularly opens and
closes - there is a shortcut among the shield cup and the
cutting tip.
2. LED illuminates and the air valve regularly opens and
closes - the cutting tip and the electrode are not fitted
properly.
3. LED flashes – there is not shield cup or the shield cup is

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not fitted properly.
4. LED illuminates – low air pressure
5 LED torch burning – illuminates when the torch trigger is pressed.
On the torch is voltage.
6 Switch CUT – cutting mode/AIR setting the air
7 Torch central connector
8 Work leads with the plagues
9 Mains supply cable
10 ON/OFF switch
11 Air quick connector
12 Storage space for cutting tips or electrodes.
6. ACCESSORIES
6.1 PART OF DELIVERY
•Plasma cutting torch ABICUT45 6 m with cutting tip 0,8 mm and shield cup
35 A.
6.2 ON REQUEST
Pos. Item No Description
V9030038 Earthing cable with clamp 3m 10-25 150A
4314 Quick connector Pegas 160/40
VM0329 Air Supply Adapter PEGAS Plasma
742.D121.1 Circular Cutting Attachment ABICUT 45
24 D640710 Filter for plasma DFP 6 R3/8
25 VM0328 Set for addition filter DFP to plasma
S777a Light Reactive Welding Helmet ALFA IN S777
Circular Cutting
Attachment ABICUT
45
Air Supply Adapter
PEGAS Plasma Quick connector Pegas 160/40