PLASMATECH SHARK 155 User manual

1020HB85C-EN-03/2019 SN - AQ xxxxxx
EN Operator’s manual READ CAREFULLY
CEA COSTRUZIONI ELETTROMECCANICHE ANNETTONI S.p.A.
C.so E. Filiberto, 27 - 23900 Lecco - Italy
Tel. ++39.0341.22322 - Fax ++39.0341.422646
Cas. Post. (P.O.BOX) 205
e-mail: [email protected] - web: www.ceaweld.com
SHARK 155

2
ENGLISH
EN
Introduction 2
Description 2
SK and SKM torches 3
CS - Original spare parts 3
Usage limits (IEC 60974-1) 3
Technical characteristics 4
Opening the packaging 4
How to lift up the machine 4
Plasma cutting 4
Installation 5
Connection to the electrical supply 5
Usage norms 5
Connection of plasma torch and ground wire 7
Connection of compressed air 8
Switching on the equipment and initial screens 9
Displaying the software version installed 9
Sequence of operations to perform before cutting 10
Energy saving 10
Configuring the torch for manual cutting 11
Using the torch for manual cutting 12
Configuring the torch for automatic cutting 15
Using the torch for automatic cutting 19
Automatic CNC cutting tables 21
Maintenance 40
Possible problems and remedies 41
Error condition 41
Main troubleshooting table 42
Changing the digital interface board 43
Common cutting defects 44
Meaning of graphic symbols on machine 45
Wiring diagram 46
Introduction
Thank you for buying our product.
In order to get the best performance out of the machine and
ensure the maximum lifespan of its parts, the use and mainte-
nance instructions contained in this manual must be read and
strictly complied with, as well as the safety instructions con -
tained in the relevant folder. If repairs to the machine are
required, we recommend that our clients contact our service
centre workshops, as they have the necessary equipment and
personnel that are specifically trained and constantly updated.
All our machines and equipment are constantly developed and
so changes may be made in terms of their construction and
features.
Description
After significant investments and resources put into research,
these inverter generators, with new technology torches, make
a significant increase in the quality and speed of the cutting pro-
cess possible. This quality takes the form of precise outlines,
edges without burrs, a limited thermally altered zone, and a
sufficiently square edge.
Our SHARK systems are an efficient solution when it comes
to cutting any metal and perforated plates. The inverter’s elec-
tronic control, precision, and flexibility make it possible to de-
termine the most correct parameters, in order to ensure high
quality cutting specifically related to the thickness and type of
material to be cut.
Thanks to the new SK torches for manual cutting, and SKM
for automated CNC cutting, the SHARK models make it pos-
sible to make cuts without using high frequencies to ignite the
arc, thereby reducing disturbance of the external environment.
Our powerful SHARK generators, with a professional, high flow
rate, air system, guarantee perfect cuts.
The salient technical characteristics that are common to all ma-
chines, are as follows:
• Three-phase power supply.
•
Stability of cutting parameters, despite power supply fluc-
tuations.
•
Automatically resetting protective devices against undervolt-
ages and overvoltages on the electricity mains.
• Trip switches to protect against overloading.
• Reduced energy consumption.
• Digital control for arc parameters for excellent cut quality.
• Professional, high flow rate air system.
• Torch with pilot arc.
• Centralised torch connection.
•
Electrical protective device on the torch to guarantee the op-
erator’s safety.
• Capacity to cut meshes and perforated plates.
•
Capacity for contact cutting with currents less than 50A, with-
out using slides or other spacers.
•
Air filter and regulator unit with automatic expulsion of im-
purities.
• Digital pressure gauge for measuring the air pressure.
•
Innovative, functional design, with an inclined front panel,
making it clearly visible from any angle, for easy reading and
setting of parameters.
• Metal loadbearing structure, with front panels on impact-re-
sistant fibre, and commands protected against accidental
impacts.
• Strong handle built into the frame.

3
• IP23S protection level and electronic parts protected against
dust, thanks to the innovative “tunnel” ventilation system,
which allows the unit to be used in the most problematic
working environments.
• Smart Start Transfer function, for better control over the ini-
tial cutting phase. Innovative electronic circuit that allows op-
timum, gradual transferring of the pilot arc to the main arc,
while the cutting arc is being ignited, ensuring immediate sta-
bility of the plasma flow and longer duration of consumables
used for the torch.
•
Smart End Cutting function, for better control over the final
cutting phase. Once cutting has been completed, the current
reaches an optimum value, which allows definitive detach-
ment of the pieces. In addition to reducing the noise when
cutting ends, this device means that the operator does not
have to separate the pieces manually, thereby ruining the fi-
nal portion of the cut surface.
SK and SKM torches
The SK and SKM torches, used with the SHARK machines,
are the result of research done over the last decade, aimed at
improving the performance of the plasma beam, in order to in-
crease control and thermal energy.
More specifically, the SK 165 and SKM 165 torches are charac-
terised by High Performance Cutting (HPC) technology, which
makes it possible to increase the quantity and speed of the air,
enhance concentration of the plasma beam, and stabilise the
cutting arc, which allows:
• High cutting speeds.
• Optimum quality and cleanliness of the cutting surfaces.
• High concentration of the Plasma beam.
• Absence of burrs.
• Reduction of the thermally altered zone.
• Longer lifespan for consumables.
• Piercing of plating more quickly.
•
Gouging to remove material with the help of a plasma beam.
All SK and SKM torches are fitted with a coaxial cable that en-
sures great flexibility, combined with significant strength and
resistance to crushing.
The High Performance Cutting - HPC technology, makes it
possible to generate radial and vortex gas flows about the arc’s
axis, thereby creating a Plasma beam at very high tempera -
ture that pierces and vaporises the surface being worked more
efficiently.
This technology also makes it possible to avoid double arcs
from forming - two arcs in series between the cathode and the
workpiece’s surfaces - which is mainly responsible for damag-
ing the nozzle and instability of the arc - ensuring execution of
very high quality cuts, along with longer duration of consum-
ables.
Vortex gas flows and collimation of the beam
The new SK torches, equipped with High Performance Cut-
ting, increase the density of the Plasma beam’s energy, while
reducing the width of the arc’s area of action, producing a nar-
rower cut path, at less of an angle, easily removing molten
material. This results in a better quality cut that has neat sur-
rounding without burrs, a limited extent of the thermally altered
zone, and a sufficiently squared edge.
The main advantages include:
• Better cut quality.
• Higher cutting speed.
• Narrower cuts.
• Long duration of consumables.
CS - Original spare parts
CS is our guarantee mark for all PlasmaTECH consumables.
The CS mark is to be found on all original spare parts for SK
and SKM torches, used for the SHARK machines.
The presence of the CS mark on all consumables, is a guar-
antee for those buying a cutting machine, that the machine’s
declared performance levels will be delivered.
The geometric shapes, quality of the materials used, and preci-
sion of the machining and coupling of the same, resulting from
years of experience, form the basis for developing the SK and
SKM torches, and use of the same with our cutting generators.
We highly recommend the use of original spare parts marked
CS. In addition to compromising optimum function of the ma-
chine, using pirate parts could result in overheating and fluctu-
ations in electrical voltages, which is turn can cause:
• Overheating and damaging of the torch.
• Malfunctions and faults on the generator.
• Worsening of cut quality.
• Lessening of machine safety.
In light of the above, using any parts other than CS not only
causes the warranty on the machine to be null and void, but it
also means that CEA PlasmaTECH cannot be held responsi-
ble in case of any accidents.
Usage limits (IEC 60974-1)
The use of plasma equipment for cutting is typically disconti-
nuous as it consists of periods of effective operation (cutting)
and rest periods (while the piece is being positioned, etc.). The
size of the equipment is suitable for safe use of max. nominal
current I
2
for a working time that is 30% of the total time of use.
The regulations in effect stipulate that 10 minutes is the maxi-
mum total time of use. For the work cycle, 30% of that time is
considered. Any excess of the permitted work cycle triggers a
thermal circuit breaker which protects the internal components
of the equipment against dangerous overheating. Activation of
thermal protection is signaled by “t° C” flashing on control pan-
el display. After a few minutes the trip switch resets itself au-
tomatically and the cutting equipment is once again ready for
use. This equipment is built to have a protection level of IP 23
S, which means:
•
That it is protected against the penetration of solid foreign
bodies with diameters in excess of Ø 12 mm.
•
That it is protected against water spray hitting the surface
with an angle of incidence up to 60°.
• That the equipment has been tested for withstanding harm-
ful effects due to water getting in when the moving parts on
the equipment are moving.

4
Technical characteristics
Pure cutting power - of the entire range, the SHARK 155 mod-
el provides the highest performance. The powerful, compact
SHARK 155 model is a plasma unit that satisfies the needs of
medium / light metalwork most fully.
The unit comes with a display for digital control of all cutting
parameters. Smart Start Transfer and Smart End Cutting func-
tion, for better control over the initial and final cutting phases.
The cuts are always precise and ensure high cutting stand-
ards in any situation.
High quality and cutting speed thanks to the SK 165 torch, with
(HPC) High Performance Cutting technology, which ensures a
concentrated, powerful plasma beam.
Further particular features of this machine include:
•
SK 165 torch with (HPC) High Performance Cutting technol-
ogy and coaxial cable.
• Powerful, compact and light-weight, only 48 kg.
• High productivity thanks to high cutting quality and speed.
•
Lower operating costs due to the long lifespan of consum-
ables.
• “Energy Saving” function that starts ventilation of the gener-
ator only when necessary.
•
Electrical protective device on the torch to guarantee the op-
erator’s safety.
•
Possibility of automated CNC cutting, using the SHARK
155/M and 155/MR version, fitted with a straight SKM 165
torch.
The technical data for this equipment is summarized in the ta-
ble 1.
Table 1
Model SHARK 155
Three-phase power supply 50/60 Hz V400
Mains supply: Zmax Ω0,017
Power input @ I2Max kVA 27,5
Delayed fuse (I2@ 100%) A30
Power factor / cosφ 0,89/0,99
Efficiency degree η86%
Open circuit voltage (peak) V320
Current range A25 ÷ 150
Duty cycle @ 100% (40°C) A100
Duty cycle @ 60% (40°C) A120
Duty cycle @ 30% (40°C) A150
Cutting capacity
recommended
maximum
severance
piercing
mm
mm
mm
mm
45
50
60
25
Type of machine intake air/gas
AIR - Clean, dry,
oil-free for ISO 8573-1
Class 1.2.2
N2 - 99.95%
Air pressure (cutting mode) 5,0 ÷ 6,0
Air flow (cutting mode) 360 ÷ 410
Standards
IEC 60974-1
IEC 60974-7
IEC 60974-10
Protection class IP 23 S
Insulation class F
Dimensions mm 730-515-290
Weight kg 48
WARNING: This equipment complies with EN/IEC 61000-3-12 pro-
vided that the maximum permissible system impedance Z
max
is less
than or equal to 0,017 Ω at the interface point between the user’s sup-
ply and the public system. It is the responsibility of the installer or user
of the equipment to ensure, by consultation with the distribution net-
work operator if necessary, that the equipment is connected only to a
supply with maximum permissible system impedance Zmax less than
or equal to 0,017 Ω.
This system, tested according to EN/IEC 61000-3-3, meets the re-
quirements of EN/IEC 61000-3-11.
Opening the packaging
The standard composition of this plasma cutting system is
made up of:
• Plasma cutting units.
•
Plasma torch with centralised connection and initial supply
spare parts kit.
• Ground cable.
• Trolley for transportation (optional).
On receipt of the unit, perform the following operations:
• Remove the plasma cutting unit and all relative accessories
and components from the packaging.
•
Check that the plasma cutting unit is in good condition. If it is
not, inform your dealer immediately.
•
Make sure that all the ventilation louvers are open and that
the airflow is not obstructed.
How to lift up the machine
This equipment has a handle specifically for carrying the ma-
chine by hand.
NOTE: These hoisting and transportation devices conform to
European standards. Do not use other hoisting and transpor-
tation systems.
Plasma cutting
The cutting system used by this equipment is a low current sys-
tem that uses compressed air as its plasma equipment as well
as for cooling. The air normally used is a mixture of 79% nitro-
gen and 21% oxygen. These two biatomic gasses have almost
identical enthalpy and form a highly energetic blend. The low
current also makes it possible to use torches with a low air ca-
pacity and moderate cutting speed, that are more suitable for
manual procedures.
CUTTING PARAMETERS
In analyzing the parameters that characterize manual plasma
cutting it is necessary to note that they depend on the material
to be cut, its thickness and the skill of the operator in following
the cutting line. Optimum speed depends largely on the skill of
the operator and amount of material to be cut and is achieved
when the fused material flows through the groove and is not
projected in the direction of the torch. If the latter occurs, cut-
ting speed has to be reduced.
The parameters that affect cutting are:
•
Electric power. Any increase in electric power will permit
higher cutting speed and greater thickness of the material
to be cut
• Compressed air capacity. Increasing the air capacity ena-
bles cutting thicker material and ensures better quality at
any thickness
•
Distance between the nozzle and workpiece. The appear-
ance of the cut and wear of the torch’s working parts, de-
pend on the correct distance between the nozzle and the
workpiece.
NOTE: The width of the cut path is equal to about twice the di-
ameter of the hole in the nozzle.
Respect of the above recommendations ensures greatly redu-
ced thermal alterations of the material due to cutting, that are in
any case always fewer than those caused by oxygen torches.
The thermally altered zone is in any case smaller than the zone
on which the weld is effective, so that in welding pieces that
have been cut by plasma it is not necessary to perform any
cleaning or grinding operations.

5
Installation
The place where the equipment is installed should be selected
with care so as to ensure satisfactory, safe use.
The user is responsible for installation and use of the equip-
ment according to the instructions provided by the manufactu-
rer in this manual.
Temperatures must be between -25 °C e +55 °C. during tran-
sportation and/or storage in stores.
Before installing the equipment the user should take into con-
sideration any possible electromagnetic problems in the work
area.
In particular, we recommend that the equipment not be instal-
led in the vicinity of:
• Signalling, control and telephone cables.
• Radiotelevision transmitters and receivers.
• Computers or controlling and measuring instrument.
• Safety and protection devices.
If the operator wears a pacemaker, hearing aid or other sim-
ilar device, he should consult his doctor before approaching
the equipment while it is running. The environment where the
equipment is installed must conform with the degree of protec-
tion of the chassis that is IP 23 S (IEC publication 60529). The
system is capable of working in environments where working
conditions are particularly hard.
This equipment cools water by forced circulation of air and must
therefore be positioned in such a way that the air can easily
be drawn in and expelled through the openings in the chassis.
Connection to the electrical supply
Connection of the machine to the user line (electrical cur-
rent) must be performed by qualified personnel.
Before connecting the cutting equipment to the mains sup-
ply, check that the data on the machine plate correspond
to the supply voltage and frequency and its main switch
is on the “0” position.
This system has been designed for nominal voltage 400 V -
50/60 Hz.
The connection to the supply, should be made with four core
cable which is supplied with the machine, connecting:
• Three wires the supply.
• The fourth one, YELLOW-GREEN, to ground.
Connect a suitable plug (3p+e) of proper capacity to the
mains cable and fix to a socket fitted with fuses or auto-
matic switch: the proper ground terminal must be con-
nected to the ground connector (yellow-green) of the main
supply.
Table 2 shows the capacity values that are recommended for
fuses in the line with delays.
Table 2
Model SHARK 155
Power input @ I2Max kVA 27,5
Delayed fuse (I2@ 100%) A30
Duty cycle @ 30% (40°C) A150
Mains supply connection cable
Length
Section
m
mm2
4
6
Ground cable
Length
Section
m
mm2
4
25
NOTE: If extensions of the power supply cable are used, they
must be of adequate cross section and never inferior to that of
the cable supplied.
Usage norms
COMMAND AND CONTROL DEVICES (Fig. A)
Pos. 1 Control panel (Fig. B).
Pos. 2 Snap-in connector for ground line.
Pos. 3 Centralised torch attachment.
Pos. 4 Connector, 14 pole, for CNC control interface (option-
al extra).
Pos. 5 Filter and cutting air pressure regulator. The air filter
automatically expels impurities.
Pos. 6 Fast coupling to connect compressed air tube.
Pos. 7 Cutting machine power supply cable.
Pos. 8 Power supply switch.
Pos. 9 Robomat1 interface (optional).
1
2
3
88
5
466
5
9
4
7
7
FIG. A
SHARK 155
SHARK 155/M SHARK 155/MR

6
CONTROL PANEL (Fig. B)
Pos. 1 Cutting parameter regulating knob (cur-
rent, voltage and air pressure), accord-
ing to the LED that is on.
Pos. 2 Compressed air button.
When this button is pushed and released, the cutting
air valve opens, allowing the operator to regulate the
compressed air pressure, using the filter / regulator
knob (Pos. 5, Fig. A) located on the back panel.
The display shows the real-time cutting air pressure
(in bar or psi).
If the air pressure value shown in the display flashes,
this means that it is outside the optimum range for the
cutting mode selected.
Rotate the filter / regulator knob until the display
shows the optimum pressure, as indicated in the ta-
ble below. The pressure value is displayed continu-
ously, without flashing.
Cutting mode Optimum pressure
Minimum /
Maximum pressure
alarm
5,5 bar
80 psi
4,5÷6,5 bar
65÷94 psi
3,7 bar
54 psi
3,0÷4,5 bar
44÷65 psi
The operation is ended manually by pushing and then
releasing the key (or automatically after a delay of 10
seconds).
Pos. 3 RoboMAT LED.
This switches on when the equipment is connected
to the “RoboMAT 1” analogue / digital robot interface
and this is powered by the automatic system connect-
ed up.
NOTE: The generator automatically recognises the
robot interface connection.
Pos. 4 Display selection key.
Used for cyclical selection of the following 3 cutting
parameters, according to the corresponding LED
switched on:
CUTTING CURRENT (variable from
25A to 150A).
The cutting current can be set before-
hand by rotating the parameter setting
knob.
CUTTING VOLTAGE - The display
shows the cutting voltage. LED “V” is
on.
AIR PRESSURE - When this LED is
switched in this means that the DIS-
PLAY is showing the real-time AIR
PRESSURE (in bars) measured at the
equipment intake (adjustable value).
You can change the unit of measure
of air pressure between bar and psi by
doing the following:
• Hold the display selection key down
for about 3 seconds.
•
Rotate the parameter regulating
knob, to change to the required unit
of measurement (bar or psi).
•
Confirm the choice made, by pushing
the display selection key.
NOTE: When the LED for the CUTTING CURRENT,
the CUTTING VOLTAGE, or the AIR PRESSURE
flashes, this means that during the HOLD function,
the display shows the last value read at which the
operator was cutting. When the LED stays on, this
means that the display is showing the preset value for
the CUTTING CURRENT, or the real value measured
for the CUTTING CURRENT, the CUTTING VOLT-
AGE, or the AIR PRESSURE.
Pos. 5 Cutting mode selection button.
This can be used to select one of the 3 cutting modes,
as indicated by the corresponding LED that switches
on:
• Solid material mode (when the torch
button is pushed, when the opera-
tor goes out of the workpiece during
cutting, the arc switches off automat-
ically).
• Mesh material mode (when the torch
button is pushed, when the opera-
tor goes out of the workpiece during
cutting, the pilot arc ignites again au-
tomatically, to allow cutting to contin-
ue).
• Gouging mode to remove material
with the help of a plasma beam.
NOTE: Each time the cutting mode is changed, the
display shows the cutting pressure, to allow the op-
erator to check that this value is correct.
Cutting mode Optimum pressure
5,5 bar
80 psi
3,7 bar
54 psi
5
1
2
3
4
FIG. B

7
Connection of plasma torch
and ground wire
IMPORTANT: Before performing any operation regarding con-
nection of the torch and ground wire, disconnect the power to
the system.
IMPORTANT: Do not connect to the Plasma equipment any
other torch different from the standard supplied unes; the utili-
sation of other non suitable torches might be dangerous for
the operator.
To obtain elevated cutting quality, the torch must transform
the power generated by the machine into a high energy den-
sity plasma jet, so that it can efficiently melt metal and guar-
antee sufficient strength to remove the meted part from the
cutting zone, impeding the formation of burrs. The torch is this
a fundamental, indispensable component of the plasma cut-
ting machine.
The standard supplied Plasma torch has special CEA elec-
trical connections in the central adaptor. Before fitting a
new equipment, make sure that the torch central adaptor
electrical connectios are matching the ones of the Plas-
ma equipment.
The following plasma torches are supplied with the machine:
Torch
manual cutting mechanised cutting
SHARK 155 SK 165 SKM 165
To assemble the plasma torch, proceed as follows:
•
Screw the male connection on the plasma torch clockwise all
the way into the corresponding centralised female connec-
tion, located on the front of the plant.
•
Align the male polarisation pin (n° 8) with the correspond-
ing pin (n° 8) on the plasma torch’s male coupling (Fig. C).
To disconnect the torch, proceed in the reverse order.
To assemble the earth cable, proceed as follows:
•
Connect the earth cable to the rapid coupling on the positive
pole as indicated in figure C.
•
The earth cable must be connected to the workpiece to be
cut, using the relevant terminal, so that the workpiece is ef-
fectively earthed along with the cutting bench.
To connect the earth cable correctly:
•
Make sure that the metal-to-metal contact between the earth
clamp and the steel plate is adequate. Remove any rust, dirt,
paint, coating or other debris, in order to ensure correct con-
tact between the generator and the steel plate.
•
In order to achieve an excellent quality cut, connect the earth
clamp as close as possible to the area to be cut.
•
Do not connect the earth clamp to the piece of material to
be removed.
n. 8
FIG. C

8
Connection of compressed air
Connect the compressed air hose to the rapid coupling (Fig. D).
Use a compressed air hose with a minimum internal diame-
ter of 8 mm.
Make sure that the gas feed pressure does not exceed 8,6
bar / 861 kPa. If the pressure is higher than this value, the fil-
ter could explode.
The plant must be fed with a constant air flow, with the follow-
ing characteristics:
Equipment SHARK 155
Torch SK 165
SKM 165
Air / gas AIR - Clean, dry, oil-free for ISO 8573-1
Class 1.2.2
N2- 99.95%
Cutting mode Optimum pressure
5,5 bar
80 psi
3,7 bar
54 psi
Having pressed the compressed air button (Pos. 2, Fig. B),
set the pressure regulator to obtain the value indicated on the
table above, by raising and then rotating the ring nut, as indi-
cated in figure D. Once regulation has been completed, low-
er the ring nut.
The compressed air consumption in relation to the pressure,
the cutting mode, and the nozzle fitted, is shown in table 3.
NOTE: The pressure must be set with the pressure rising, while
the air / gas is flowing.
If the quality of the air / gas supply is not good, the cutting
speed diminishes, the cut quality worsens, the cuttable thick-
ness diminishes, and the working lifespan of consumables is
reduced.
If moisture, oil or other pollutants get into the air line, due to
the general compressor, use the additional CEA filtration sys-
tem, code 427529 (Fig. D) with a filtration grade of 0,01 μinch
- 0,25 μm available via CEA PLASMATECH distributors (the
order code for replacement filters is 427530).
The additional filtration system must be installed between the
air / gas supply and the filter located on the generator’s back
panel. Additional filtration could increase the minimum feed
pressure required.
Ø ≥ 8 mm
Aria compressa
Compressed air only
max 125 psi
(8.6 bar / 861 kPa)
ATTENZIONE
WARNING
427529
FIG. D
Table 3
Pressure Nozzle Pressure Nozzle
160 A 125 A 105 A 85 A 65 A 45 A 160 A 105-125 A
4,5 bar
65 psi
315 l/min
667 cfh
310 l/min
655 cfh
305 l/min
645 cfh
300 l/min
635 cfh
265 l/min
560 cfh
235 l/min
500 cfh
3,0 bar
44 psi
250 l/min
530 cfh
225 l/min
475 cfh
5,0 bar
72 psi
345 l/min
730 cfh
340 l/min
720 cfh
335 l/min
710 cfh
330 l/min
700 cfh
285 l/min
605 cfh
250 l/min
530 cfh
3,5 bar
51 psi
285 l/min
605 cfh
255 l/min
540 cfh
5,5 bar
80 psi
375 l/min
795 cfh
365 l/min
775 cfh
360 l/min
760 cfh
355 l/min
750 cfh
310 l/min
655 cfh
275 l/min
580 cfh
4,0 bar
59 psi
315 l/min
667 cfh
285 l/min
605 cfh
6,0 bar
87 psi
405 l/min
860 cfh
395 l/min
835 cfh
390 l/min
825 cfh
385 l/min
815 cfh
335 l/min
710 cfh
295 l/min
625 cfh
4,5 bar
65 psi
350 l/min
740 cfh
315 l/min
665 cfh

9
Switching on the equipment
and initial screens
1) Start the equipment by turning the switch on the rear pan-
el to position I.
2) A brief MACHINE CHECK operation is run automatically
(all the LEDs switch on and off simultaneously).
3) Next the control panel displays the machine’s INITIAL
SCREEN, and the machine is now ready to cut and the
DISPLAY shows the last numerical value set (for example:
80) for the CUTTING CURRENT. Remember that, since
the equipment is on stand-by, this value (in Ampere) is not
real but is that SET.
Displaying the software
version installed
The SHARK 155 has a digital control with software prepared in
the factory in it. This software is subject to continuous evolution
and improvement. The software is identified by a specific num-
ber that can be viewed on the DISPLAY as follows:
1) With the equipment switched off, hold down the DISPLAY
SELECTION key (T1).
2) Start the equipment by turning the power switch to posi-
tion I.
3) For about 7seconds the DISPLAY shows the type of soft-
ware installed (e.g. A.01) where:
•
A indicates the YEAR the software installed was created.
• 0 indicates the RELEASE of the software installed.
• 1 indicates the VERSION of the software installed.
T1

10
Sequence of operations to
perform before cutting
IMPORTANT: Before switching on the equipment follow these
instructions carefully:
• Make sure the voltage and frequency of the supply network
correspond to the data on the rating plate.
• Make sure all the torch components are correctly installed.
•
Do not point the torch toward yourself or other persons near-
by. If switched on accidentally the pilot arc spark would ignite
and cause dangerous burns.
1) Turn the power switch (Pos. 8, Fig. A) to position I.
2) The equipment has just been started. The equipment’s
built-in checking device runs a series of programmed tests
(see the “Switching on the equipment and initial screens”
paragraph) during which the fan motor switches on for a
few seconds.
3) By pushing the cutting mode selection key (Pos. 5, Fig. B),
according to the corresponding lit LED, the operator can
select one of the following operating modes:
•
Solid material mode: when the torch button is pushed,
when the operator goes out of the workpiece during cut-
ting, the arc switches off automatically.
•
Mesh material mode: when the torch button is pushed,
when the operator goes out of the workpiece during cut-
ting, the pilot arc ignites again automatically, to allow cut-
ting to continue.
•
Gouging mode to remove material with the help of a
plasma beam.
4) Press the COMPRESSED AIR TEST Key and check:
• That air comes out of the torch.
•
If the air pressure value shown in the display flashes, this
means that it is outside the optimum range for the cut-
ting mode selected. Rotate the filter / regulator knob un-
til the display shows the optimum pressure, as indicated
in the table below. The pressure value is displayed con-
tinuously, without flashing.
Cutting mode Optimum pressure
Minimum /
Maximum pressure
alarm
5,5 bar
80 psi
4,5÷6,5 bar
65÷94 psi
3,7 bar
54 psi
3,0÷4,5 bar
44÷65 psi
5) Press the DISPLAY SELECTION key until the DISPLAY
shows the current value (CUTTING CURRENT LED
switched on and fixed). The value indicated by the DIS-
PLAY is referred to as the PRESET CUTTING CURRENT.
Adjust the cutting current using the ENCODER KNOB. In-
creasing the current makes faster cutting possible or great-
er thicknesses can be cut at the same speed.
6) Move the torch close to the workpiece (Fig. E) and, keep-
ing the shield supported without exerting pressure, push
the torch button, thereby igniting the pilot arc and the air
supply. Introduce the flame to the workpiece, and begin the
cut. Go with the flame to the piece and start cutting. Do not
keep the pilot arc in the air, to avoid needless consumption
of the electrode and nozzle.
7) In special cases if the arc is switched off when the work-
piece enters, observe the correct angle of inclination be-
tween the torch and the metal (Fig. E). A special control
device prevents arc transfer in case of incorrect inclination
between the torch and the workpiece.
8) Cut taking care that the fused material flows through the
groove and is not projected in the direction of the torch. If
this occurs, reduce cutting speed.
9) Upon completion of the cutting operation, the air will conti-
nue to issue from the torch for about one minute so as to
cool the torch components. Wait for the air to stop flowing
before switching the equipment off. During this time, you
can also start a new cutting operation. If you have to per-
form circular cuts, it is advisable to use the special com-
pass supplied on request.
Energy saving
This function manages correct functioning of the fan motor,
which is switched on for a predefined time and only when strict-
ly necessary, to guarantee lower energy consumption, that is:
• When the equipment is switched on.
• During the cutting phase.
• On completion of the cutting phase.
• When the thermostat intervenes or after it has been reset.
90-95°
FIG. E

11
45-85A 105-160A 105-160A
105-160A
45-85A
105A
45A 125A
65A 160A160A 105-125A
85A
45-85 A CONTACT CUT
105-160 A CONTACT CUT
105-160 A GOUGING
SK 165
487633 486021 425024
408642
408641
408640
482137
487634 486022 425024
408645
408644
408643
482137
487641 486022 425024
408633
408632
482137
FIG. F
Configuring the torch
for manual cutting
INTRODUCTION
These machines are supplied with the following standard torch-
es for manual cutting:
Torch Length
SHARK 155 SK 165 6 m
Other lengths are available by request.
The torches are air cooled, and do not require special cooling.
The main nominal characteristics of the torches supplied, are
as follows.
SK 165
SK 165 = 6 m (standard)
(Other lengths are available by request)
160 A @ 60%
(10 min. 40°C)
DC
Cutting: 5,0-6,0 bar / 72-87 psi
Gouging: 3,5-4,0 bar / 50-58 psi
Gas flow @ 160 A: 420 l/min - 890 cfh
AIR - Clean, dry, oil-free for ISO 8573-1 Class
1.2.2
N2- 99.95%
M
Without HF
IEC 60974-7
WORKING LIFESPAN OF CONSUMABLES
The following factors affect the frequency with which consum-
ables need to be replaced:
• Thickness of the metal cut.
• Average cut length.
• Air quality (presence of oil, moisture, or other pollutants).
• Execution of piercing of the metal or cutting from the edge.
• Correct piercing depth.
•
Cutting done using mesh or solid material cutting mode. Cut-
ting done in mesh mode give rise to more wear of consum-
ables.
Under normal conditions, the nozzle wears out before the oth-
er consumables during cutting operations.
CONSUMABLES FOR MANUAL CUTTING
Figure F shows the consumables used for the plasma torches
supplied, complete with the CEA order codes.
These torches use shielded consumables and so the point of
the torch can be dragged over the metal to be cut.

12
FITTING CONSUMABLES ON THE TORCH FOR
MANUAL CUTTING
WARNING: changing consumables, check that the machine’s
main switch is in the O position.
To use the torch for manual cutting, a complete set of consum-
ables must be fitted, as shown in figure G.
Using the torch for manual cutting
WARNING
Torch with immediate ignition
A plasma arc can cause injuries and burns.
The plasma arc ignites immediately, when the torch button is
pushed.
The plasma arc passes through gloves and the skin quickly.
Use appropriate equipment to protect your head, eyes, ears,
hands, and body.
Keep away from the tip of the torch.
Do not hold the plate and keep your hands away from the cut-
ting path.
Never point the torch at yourself or other people.
TORCH SAFETY
Torches for manual cutting have a safety guard to prevent in-
voluntary ignition. When you are ready to use the torch, rotate
the button’s safety guard (towards the tip of the torch) and push
the red torch button, as shown in figure H.
SUGGESTIONS FOR USING THE TORCH FOR
MANUAL CUTTING
• Drag the torch slightly over the plate to maintain a set cut.
• While cutting, make sure that the sparks come out from the
underside of the plate.
•
If the sparks come out from the upper side of the plate, move
the torch more slowly, or set the output current to a higher
value.
• When using SK series torches for manual cutting, keep the
nozzle on the torch perpendicular to the plate, so that the
nozzle forms a 90-95° angle with the cutting surface. Watch
the cutting arc while the torch is cutting.
~ 90-95°
WARNING: If the torch is ignited when not necessary, the work -
ing lifespan of the nozzle and the electrode is reduced.
For cutting straight lines, using a straight edge as a guide, or
the carriage supplied.
FIG. H
FIG. G
electrode
air diffuser
nozzle
outer nozzle holder
shield

13
For circular cuts, using the compass kit supplied.
CUTTING FROM THE EDGE OF THE PLATE
With the earth clamp connected to the plate, keep the torch
nozzle perpendicular (90-95°) to the edge of the plate.
Push the torch button to ignite the arc. Wait at the edge until
the arc has cut the plate completely.
Drag the torch over the plate to do the cut. Maintain a regu-
lar, linear pace.
CUTTING FROM WITHIN THE PLATE (PIERCING)
WARNING: Sparks and hot metal can cause injuries to the
eyes and the skin.
When the torch is ignited in an inclined position, the sparks and
hot metal are projected away from the nozzle. Do not point the
torch at yourself or other people nearby.
■Cutting thin material
With the earth clamp connected to the plate, keep the torch at
about 30° to the plate, with the torch shield about 1,5 mm from
the plate, before pushing the torch button.
Push the torch button. Slowly rotate the torch to a perpendic-
ular position (90°).
Keep the torch in this position, while continuing to push the but-
ton. When the sparks come out from the underside the plate,
the arc has pierced the material.
On completion of piercing, drag the nozzle lightly over the plate
to make the cut.

14
■Medium / thick material cuts
With the earth clamp connected to the plate, keep the torch
raised above the plate.
Push the torch button and move slowly towards the plate.
When the sparks come out from the underside the plate, the arc
has pierced the material. Once the material has been pierced,
the torch’s shield can be rested on the material to be cut.
Drag the nozzle lightly over the plate to make the cut.
GOUGING THE PLATE
WARNING: The plant must be fed with a constant air flow, with
the following characteristics: pressure 3,0-4,5 bar (44-65 psi).
WARNING: Sparks and hot metal can cause injuries to the
eyes and the skin.
When the torch is ignited in an inclined position, the sparks and
hot metal are projected away from the nozzle. Do not point the
torch at yourself or other people nearby.
With the earth clamp connected to the plate, keep the torch at
about 45° to the workpiece, with the torch shield about 1,5 mm
from the plate, before pushing the torch button.
45°
Keep the torch at 45° to the plate, leaving a small gap between
the torch shield and the plate. Push the trigger to ignite the pi-
lot arc. Transfer the arc to the plate.
Maintain the 45° angle to the plate, while executing gouging.
Push the plasma arc in the direction of the gouge you wish to
form. Maintain a small gap between the torch shield and the
molten metal, to avoid reducing the lifespan of consumables or
damaging the torch. If the torch angle is changed, the dimen-
sions of the gouge also change.
The gouge profile can be varied by varying the speed at which
the torch passes over the plate, changing the distance be-
tween the torch and the plate, changing the angle between
the torch and the plate, and by changing the output current on
the generator.

15
The following actions have the relevant effect on the gouge
profile:
Gouge profile
width
Gouge profile
depth
Torch speed
Distance
between torch
and plate
Torch angle
Generator
current
= increase (or more vertical angle)
= decrease (or less vertical angle)
COMMON ERRORS FOR MANUAL CUTTING
Problem Cause
The torch does not cut the
plate completely.
The cutting speed is too high.
The consumables are worn.
The metal to be cut is too thick
for the voltage selected.
Gouging consumables are
fitted, instead of cutting
consumables.
The earth clamp is not
connected to the plate
correctly.
The gas pressure or flow rate
is too low.
The quality of the cut is poor. The metal to be cut is too thick
for the voltage.
The wrong consumables are
being used (e.g. gouging
consumables are used instead
of cutting consumables).
The torch is being moved too
fast or too slow.
The arc splutters and the
lifespan of consumables is
shorter than envisaged.
Moisture in the gas supply.
Incorrect gas pressure.
Consumables fitted incorrectly.
Configuring the torch for
automatic cutting
INTRODUCTION
These machines are supplied with the following standard torch-
es for automatic cutting:
Torch Length
SHARK 155/M
SHARK 155/MR SKM 165 6-12 m
Other lengths are available by request.
The torches are air cooled, and do not require special cooling.
The main nominal characteristics of the torches supplied, are
as follows:
SKM 165
SKM 165 = 6/12 m (standard)
(other lengths by request)
160 A @ 60%
(10 min. 40°C)
DC
Cutting: 5,0-6,0 bar / 72-87 psi
Gas flow @ 160 A: 420 l/min - 890 cfh
AIR - Clean, dry, oil-free for ISO 8573-1 Class
1.2.2
N2- 99.95%
M
Without HF
IEC 60974-7
WORKING LIFESPAN OF CONSUMABLES
The following factors affect the frequency with which consum-
ables need to be replaced:
• Thickness of the metal cut.
• Average cut length.
• Air quality (presence of oil, moisture, or other pollutants).
• Execution of piercing of the metal or cutting from the edge.
• Correct piercing depth.
•
Cutting done using mesh or solid material cutting mode. Cut-
ting done in mesh mode give rise to more wear of consum-
ables.
Under normal conditions, the nozzle wears out before the oth-
er consumables during cutting operations.

16
90°
FIG. M
FIG. L
electrode
air diffuser
nozzle
outer nozzle holder
outer nozzle holder
with Ohmic sensor
Shield
CONSUMABLES FOR AUTOMATIC CUTTING
Figure I shows the consumables used for the plasma torches
supplied, complete with the CEA order codes.
FITTING CONSUMABLES ON THE TORCH FOR
AUTOMATIC CUTTING
WARNING: Before changing consumables, check that the ma-
chine’s main switch is in the O position.
To use the torch for automatic cutting, a complete set of con-
sumables must be fitted, as shown in figure L. An outside noz-
zle holder is available with an Ohmic sensor, which is to be
used with shielded consumables.
EQUIPPING THE TORCH FOR AUTOMATIC CUTTING
The SKM series of torches for automatic cutting can be fitted on
a wide range of X-Y-Z benches, motorised equipments, bevel-
lers for tubes, and other equipment. Install the torch according
to the manufacturer’s instructions.
Fit the SKM torch perpendicular to the plate, to achieve a verti-
cal cut. Use a square to align the torch at 90° (Fig. M).
105-160A
105-160A45-85A
105-160A45-85A
45-85A
105A
45A 125A
65A 160A
85A
45-85 A
105-160 A
SKM 165
487637 425024482137
486021
486023
408642
408641
408640
487638 425024482137
486022
486024
408645
408644
408643
FIG. I

17
FIG. N
13
12
4
14
6
3 5
Signal Type Notes Pole n° Wire colour
Start cut Input An isolated contact has to be closed for activation to
occur. The characteristics of this contact are: voltage >
20 Vdc; current > 10 mA.
3
4
Green
Green
Arc transferred
Start machine
movement
Output Closure of isolated photo relay contact. This contact’s
characteristics are as follows:
• Max voltage 60 Vdc
• Max current 400 mAdc
Alternating current (AC) is not allowed.
12 (+)
14 (-)
White (+)
Brown (-)
Earth protection (PE) Earth 13 Yellow Green
Reduced cutting
voltage
Output Signal proportional to the cutting voltage, not
galvanically isolated, according to the following ratios:
1:50 (factory setting); 1:20; 1:21; 1:30; 1:40.
5 (-)
6 (+)
Black (-)
Red (+)
SHARK 155/M - SHARK 155/MR
CNC Female 14 pole connector
Vd Green wire
Nr Black wire
Rs Red wire
Bc White wire
Mr Brown wire
GV Yellow / green wire
If the cutting bench’s guides and transmission system are
cleaned, checked and optimised, the torch moves easily. Un-
steady movement of the machine can give rise to an undulat-
ing, irregular path on the cutting surface.
Make sure that the torch does not touch the plate while cut-
ting. Contact could damage the shield and nozzle, and affect
the cut surface.
Having connected to the torch to the X-Y-Z bench, screw it to
the centralised connection on the SHARK system generator.
The two-pole cable that sticks out about 2 m from the central-
ised connection for the SKM plasma torch, is in series with the
start cut button.
Depending on the type of X-Y-Z bench and the software used,
the two-pole cable can be used as:
•
An additional emergency stopping unit for the mechanised
cutting machine.
•
A short-circuit for the 2 wires of the two-pole cable, if not used
as an emergency stopping unit.
INTERFACE WITH A CNC CONTROLLER PLANT
The special SHARK 155/M - SHARK 155/MR plasma versions,
are already complete with an interface for CNC controller equip-
ments, such as X-Y-Z cutting benches, for example.
On the back of the SHARK 155/M - SHARK 155/MR plant there
is a 14-pole female connector (CPC TE Connectivity series) for
connecting the CNC interface cable.
This socket makes the following signals available:
•
Arc voltage reduced to 1:50 (factory setting) (NOT galvani-
cally isolated signal). Inside the SHARK machine there is a
dip-switch that can be used to set other reduced arc voltages:
1:20 1:21 1:30 1:40
• Arc transfer / start machine movement signal
• Start cut signal.
The machine interface cable must be installed by a technician
from an authorised service centre.
To install the machine’s interface cable:
• Disconnect the power supply to the machine, by shifting the
switch to the O position.
•
Connect the machine’s interface cable to the 14-pole CNC
controller socket located on the back panel of the SHARK
155/M - SHARK 155/MR plants. The male 14-pole interface
connector (CPC TE Connectivity series) is available from our
Company, using order code 460180.
FEMALE 14-POLE MACHINE INTERFACE
CONNECTOR OUTPUTS
On the back of the SHARK 155/M - SHARK 155/MR plant there
is a 14-pole female connector (CPC TE Connectivity series) for
connecting a CNC controller or a height controller.
The signals available on the machine interface connector, are
indicated in figure N.

18
VOLTAGE DIVIDER SETTINGS
The secondary voltage divider is set in the factory at a value
of 1:50.
Inside the machine there is a dip-switch (SW1) that can be used
to set 4 other secondary voltage values:
1:20 1:21 1:30 1:40
To access the dip-switch (SW1) proceed as follows (Fig. O):
1) Disconnect the power supply from the system by turning
the line switch on the back panel to the O position. Discon-
nect the machine’s power supply cable from the main pow-
er supply socket in the wall.
2) Remove the plant’s metal lid to access the plant’s second-
ary board.
3) Set the dip-switch (SW1) to one of the configurations avail-
able.
4) Reassemble the machine, following the points above in re-
verse order.
ROBOMAT1 INTERFACE
The SHARK 155 plants, in their special MR version, can eas-
ily be integrated with automatic robotics cutting plants, via the
ROBOMAT 1 interface, which handles all process signals and
regulates the main cutting parameters.
ROBOMAT 1 is a flexible, efficient interface system that satis-
fies all Analogue / Digital connection requirements.
Go to the website http://www.ceaweld.com/portal/cea/down-
load/manuali to download the instruction manual and docu-
mentation available for the equipment being used.
In addition to the ROBOMAT 1 interface, on the back of the
SHARK 155/MR plant there is a 14-pole female connector
(CPC TE Connectivity) for connecting a CNC controller or a
height controller.
The signals available on the machine interface connector, are
indicated in figure N.
USING THE MANUAL PLASMA TORCH ON PLASMA
SHARK, “M / MR” VERSION PLANTS
Manual torches can be used on SHARK “M / MR” version plas-
ma plants for automatic plants as well:
Automatic
cutting torch Manual torch Length
SHARK 155/M
SHARK 155/MR SKM 165 SK 165 6-12 m
FIG. O
ALL OFF SW1 ON SW2 ON SW3 ON SW4 ON
1:20 1:21 1:30 1:40 1:50

19
The manual torches can work in SHARK “M / MR” version
plants only if terminals 3 and 4 are short-circuited on the 14
pole male connector used to interface with the CNC control-
ler plants (Fig. P).
Code 460180: buying code for the 14 pole male connector used
to interface with CNC controller plants.
Using the torch for automatic cutting
WARNING
Torch with immediate ignition
A plasma arc can cause injuries and burns.
The plasma arc ignites immediately, when the torch button is
pushed.
The plasma arc passes through gloves and the skin quickly.
Use appropriate equipment to protect your head, eyes, ears,
hands, and body.
Keep away from the tip of the torch.
Do not hold the plate and keep your hands away from the cut-
ting path.
Never point the torch at yourself or other people.
SUGGESTIONS FOR USING THE TORCH FOR
AUTOMATIC CUTTING
For a better quality cut, the following parameters must be ex-
amined:
• Cut angle / cut inclination.
• Burr.
•
Straightness of the cut surface. Concave or convex cutting
surfaces.
■Cut angle / cut inclination
This gives the angle of the cut edge, and can be:
Positive angle
This is achieved when a
greater quantity of material is
removed from the upper part
of the cut.
Cause
Torch too high
Solution
Lower the torch.
If a torch height control is
being used, increase the
cutting arc voltage.
Negative angle
This is achieved when a
greater quantity of material is
removed from the lower part of
the cut.
Cause
Torch too low
Solution
Raise the torch.
If a torch height control is
being used, reduce the cutting
arc voltage.
The angle closest to a right angle will be on the right in relation
to the movement of the torch. The left side will always be char-
acterised by an angle other than 90° (Fig. Q).
Often a cutting angle problem is caused by the cutting bench
system, and is not due to the plasma machine. Use a square
to check the right angle between the torch’s position and the
plate to be cut.
Set the torch at 90° in the respective torch holder, or reverse
the direction of movement, to check whether the cutting prob-
lem disappears.
Cutting angle problems can occur if the material to be cut is
hardened or magnetised.
■Burr
Each time a cut is made, some burrs will be formed. The quan-
tity and type of burr can be reduced, by setting the machine
correctly in relation to the application.
If the torch is too low or, when using a height control system,
the cutting voltage is too low, an excessive burr will be formed
on the upper edge of the plate to be cut. To resolve this prob-
lem, adjust the torch of the voltage in small steps of about 5V,
until the burr is reduced.
In other cases, the excessive burr occurs due to the speed be-
ing too low or too high.
Type of burr Cause Solution
Heavy deposit on
the underside of
the cut (can be
removed easily).
Speed too low. Increase the speed.
Slight deposit on
the underside of
the cut (difficult to
remove).
Speed too high. Reduce the speed.
Gap between torch
and plate too big.
Reduce the gap
between the torch
and the plate or
the cutting voltage,
when using height
control systems.
CUTTING FROM WITHIN THE PLATE (PIERCING)
As happens for manual cutting, a cut can be made starting
from inside the plate (piercing), instead of from the outer edge.
It is worth remembering that cutting from inside the plate can
shorten the working lifespan of consumables.
When cutting a plate from inside, the following parameters must
be considered:
• Initial piercing height: about 2-2,5 times the cutting depth,
depending on the thickness of the material to be cut.
•
Piercing delay: period of time for which the ignited torch
stays at the piercing height, before it begins moving. A suffi-
ciently long piercing delay must be applied to allow the cut-
ting arc to pierce the material. Subsequently, the torch can
be lowered to the normal cutting height. In addition, as wear
α°
90°
FIG. Q
4
3
FIG. P

20
COMMON ERRORS FOR AUTOMATIC CUTTING
Problem Cause
The pilot arc ignites, but is not transferred. The earth cable is not making good contact
with the cutting bench, or the cutting bench is
not making good contact with the plate.
The torch / plate gap is too big.
The plate has not been penetrated completely and excessive
sparks are produced on the upper side of the plate.
Rust or paint on the surface of the plate.
The consumables are worn and must be replaced.
The earth cable is not making good contact
with the cutting bench, or the cutting bench is
not making good contact with the plate.
The cutting voltage is too low.
The cutting speed is too high.
The cutting thickness is too great.
Burrs formed at the bottom of the cut. The air settings are incorrect.
The consumables are worn and must be replaced.
The cutting speed is incorrect.
The voltage is too low.
The cutting angle is not perpendicular. The torch is not perpendicular to the plate.
The air settings are incorrect.
The consumables are worn and must be replaced.
The direction of movement of the torch is incorrect.
The high quality cut is always to the right in relation
to the forward movement of the torch.
The gap between the torch and plate is incorrect.
The cutting speed is incorrect.
The lifespan of consumables is short. The air settings are incorrect.
The arc current, arc voltage, cutting speed, and
other variables are not configured correctly.
Ignite the arc in the air (start of end the cut outside the
plate's surface). It is possible to start from the edge,
provided the arc is in contact with the plate when ignited.
Beginning of piercing with the torch at the wrong height.
The piercing time is incorrect.
The air quality is poor (oil or water in the air). Use
the additional filtration system, CEA code 427529
(Fig. D) with a filtration grade of 0,01 μinch - 0,25 μm
available via CEA PLASMATECH distributors (the
order code for replacement filters is 427530).
on the materials increases, it may be necessary to increase
the piercing delay.
For optimum execution of a hole, it is worth considering that the
diameter must be more than twice the thickness of the plate.
The chemical properties of the materials, can have an impact
on the piercing capacity. For example, a high-strength steel
with a high manganese or silica content, may reduce the max-
imum piercing capacity.