Alfain PERUN 40 PLASMA PFC User manual

ALFA IN a.s © www.alfain.eu PERUN 40 PLASMA PFC manual EN 04
PLASMA CUTTING MACHINE
PERUN 40 PLASMA PFC
OPERATING MANUAL

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CONTENT
1. INTRODUCTION ...................................................................................... 3
2. SAFETY INSTRUCTIONS AND WARNINGS ........................................... 4
3. CONDITIONS OF USE ............................................................................. 7
4. TECHNICAL DATA ................................................................................... 8
5. MAIN PARTS OF THE MACHINE .......................................................... 10
6. ACCESSORIES ..................................................................................... 12
7. GETTING STARTED .............................................................................. 17
8. CUTTING ............................................................................................... 19
9. MAINTENANCE ..................................................................................... 21
10. STATEMENT OF WARRANTY .............................................................. 23
11. DISPOSAL ............................................................................................. 24
12. WARRANTY LIST .................................................................................. 24

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1. INTRODUCTION
Dear consumer,
Company ALFA IN a.s. thanks you for buying our product and believe that you
will be satisfied with our machine.
Machine PERUN 40 PLASMA PFC is designed for cutting metal on the basis of
modern technology cutting material through a thin beam plasma gas.
This technology has several advantages over other methods:
1. High cutting speed
2. Quality cut with minimal area of changed material structure
3. Less thermal deformation of the cut material
4. Possibility of cutting carbon and high-alloy, stainless steel and
non-ferrous metals
5. Method does not require any special gases
6. Less costs
PERUN 40 PLASMA PFC is equipped by Power Factor Correction (PFC),
which allows operation on single phase voltage networks 110 V – 230 V.
PERUN 40 PLASMA PFC is designed for high-quality cutting of materials up to
15 mm thick carbon steel (for more information, see instructions
below). Productive cutting of carbon steel can be to a thickness of 10 mm.
At lower demands on the quality of the cut can be cut through (separate) the
material thickness to 20 mm.
We reserve the law of adjustments and changes in case of printing errors,
change of technical paramaters, 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 INSTRUCTIONS AND WARNINGS
1. OPERATION AND MAINTENANCE OF PLASMA ARC EQUIPMENT CAN
BE DANGEROUS AND HAZARDOUS TO YOURHEALTH.
2. 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.
3. Once the packing has been opened, make sure that the machine is not
damaged. If in any doubt, call the service centre.
4. This equipment must only be used by qualified personnel.
5. During installation, any electric work must only be carried out by trained
personnel.
6. The machine must be used in a dry place with good ventilation.
7. 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.
8. It is prohibited to connect more than one INVERTER generator in series or
in parallel.
9. When installing the machine, follow the local regulations on safety.
10. The position of the machine must allow easy access by the operator
to the controls and connectors.
11. When the cutting machine is operating, all its covers and doors must
be closed and well fixed.
12. Do not expose the cutting machine to direct sunlight or to heavy rain.
This equipment conforms to protection rating IP23S.
13. 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.
14. 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.
15. 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.
16. Keep all fumes and gases from the breathing area.
17. Keep your head out of the fume plume.
18. Use an air-supplied respirator if ventilation is not adequate to remove
all fumes and gases.
19. 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

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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
20. 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.
21. 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.
22. 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.
23. To protect your hearing from loud noise, wear protective ear plugs
and/or ear muffs. Protect others in the workplace.
24. Noise levels should be measured to be sure the decibels (sound) do
not exceed safe levels.
25. The operator must ensure all flammable materials are removed from
the work area to avoid any risk of fire.
26. 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.
27. 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.
28. To prevent electric shock, we strongly suggest the following rules:
a. Do not work in a damp or humid environment.
b. Do not use the machine if its cables are damaged in any way.
c. Make sure that the earthing system of the electric equipment is correctly
connected and operational.
d. The operator must be insulated from the metal components connected
to the return wire.
e. The earthing of the piece being worked could increase the risk of injury
to the operator.
29. 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, is the open-circuit voltage between the clamps. In our generator
this voltage is 330V.

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30. 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.
31. 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
32. 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
33. Before opening the machine switch off the machine and disconnect
it from the power socket.
34. Only personnel authorised by this company can carry out
maintenance on the machine.
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

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5. Noise
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. It is forbidden to operate the machine in wet environments and outdoors in
rain or snow.
4. Ensure proper grounding clamping pliers, which also reduces the risk of
electric shock.
5. Use prescribed protective utilities, keep them dry.
6. 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.
7. Never aim the torch against the eyes, body or other person.
3. CONDITIONS OF USE
1. Putting the machine into operation can be performed only by trained
personnel and only within the technical provisions. The manufacturer is not
liable for damages resulting from improper use or handling.
For maintenance and repair, use only original spare parts from ALFA IN.
2. Device complies with IEC 61000-3-12.
3. Do not expose the plasma machine to direct sunlight or to rain or snow.
This equipment conforms to protection rating IP23S.
4. Working ambient temperature between -10 and +40 °C.
5. Relative humidity below 90% at +20 °C.
6. Up to 3000 m altitude.
7. 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.
8. 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).
9. 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

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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 welding.
4. TECHNICAL DATA
Method Plasma cutting
Mains voltage V/Hz 1 x 110/50-60 1x230/50-60
Cutting current range A 20 - 30 20 - 40
Open-circuit voltage U20 V 330
Mains protection A 25 @ 16 @
Max. effective current I1eff A 20,4 14,6
Cutting current (DC=100%) I2 A 20 28
Cutting current (DC=60%) I2 A 22 33
Cutting current (DC=x%) I2 A 35%=30 50%=40
Max. productive cut. thickness - carbon steel mm 8 10
Max. Cutting thickness - carbon steel (separate mat.) mm 15 20
Quality
cutting
thickness
Carbon steel mm 10 15
Stainless steel mm 8 12
Aluminium mm 6 10
Copper mm 3 4
Max. Input pressure bar 8,5
Working pressure (torch HS-60/ABICUT 45) bar 4,4 – 5,0/5,0
Air consumption (torch HS-60/ABICUT 45) l/min 150/119
Arc ignition pneu-mechanic
Current regulation continuous
Protection IP 23S
Standards EN 60974-1,
EN 60974-10 cl. A
Dimensions (w x l x h) mm 160 x 510 x 280
Weight kg 8,0

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Note on SW limitations of loaders:
For current I2 = 28 A
The running time of the machine is limited to 7,5 minutes. Subsequently the LED
of overheating the machine A4 lights up and the output current is blocked for 1
minutes. After this time, the LED of overheating the machine A4 goes out and
the operation of the machine is unlocked.
For current I2 = 40 A
The running time of the machine under load I2max is limited to 5 minutes.
Subsequently the LED of overheating the machine A4 lights up and the output
current is blocked for 5 minutes. After this time, the LED of overheating the
machine A4 goes out and the operation of the machine is unlocked.
Important Notice
Please keep in mind that at the set maximum cutting current parameters, the
current consumption from the mains increases significantly when the distance
between the torch and the material is increased (arc extension).
This can cause unwanted tripping of the circuit breaker. This phenomenon can
also occur if the consumable material (nozzle, electrode) is worn out.
Precautions
It is recommended to cut at a constant distance from the material (as small as
possible) and to keep the consumables in a non-worn condition. Select an
adequate cutting current (do not use high cutting current values unnecessarily).

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5. MAIN PARTS OF THE MACHINE
FRONT AND REAR PANELS
Fig. 1 Main parts of the machine
Pos. Description
A1 Connector - torch
A2 Potentiometer-set cut current
A3 LED indicator – when illuminated, the machine is ON
A4 LED indicator. 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.
A5
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 not
fitted properly.
4. LED illuminates – low air pressure
A6 LED torch burning – illuminates when the torch trigger is