SIP 05175 Plasma 46 User manual

20
FOR HELP OR ADVISE ON THIS PRODUCT PLEASE CONTACT YOUR DISTRIBUTOR
Please dispose of packaging for the product in a responsible
manner. It is suitable for recycling. Help to protect the
environment, take the packaging to the local amenity tip
and place into the appropriate recycling bin.
Never dispose of electrical equipment or batteries in with
your domestic waste. If your supplier offers a disposal facil-
ity please use it or alternatively use a recognised re-cycling
agent. This will allow the recycling of raw materials and help
protect the environment.
Ref:210111
1
05175
Plasma 46
Inverter Cutter
Please read and fully understand the instructions in
this manual before operation. Keep this manual

219

18
NOTES
3
CONTENTS
Page No. Description
3 Contents
4 Safety
5 Safety
6 Safety
2 Safety
8 Safety
9 Safety
10 Introduction
11 Introduction
11 Technical Specification
12 Installation
13 Operating Instructions
14 Torch Diagram
15 Torch Assembly
15 Maintenance
16 Guarantee
17 Notes
18 Notes
19 Notes

4
SAFETY
INTRODUCTION:
WE LEARN BY EXPERIENCE Learning safety through personal experience, like a child
touching a hot stove is harmful. wasteful. and unwise. Let the experience of others
teach you.
SAFE PRACTICES DEVELOPED FROM EXPERIENCE
in the use of welding and cutting are described in this manual. Research, develop-
ment, and field experience have evolved reliable equipment and safe installation,
operation, and servicing practices. Accidents occur when equipment is improperly
used or maintained The reason for these sole practices may not always be given.
Some are based on common sense, others may require technical volumes to ex-
plain, it is wiser to follow the rules.
READ AND UNDERSTAND THESE SAFE PRACTICES
before attempting to install, operate or service the equipment. Comply with these
procedures as applicable to the particular equipment used and their instruction
manuals, for personal safety and for the safety of others.
FAILURE TO OBSERVE THESE SAFE PRACTICES
may cause serious injury or death. When safety becomes a habit, the equipment
can be used with confidence.
GENERAL:
The plasma cutting machine is simple and safe to operate under normal circum-
stances. If the unit is to be used under unusual circumstances, e.g. in wet or damp
conditions, on boats or oil rigs, or in an elevated position. Then extra thought must
be given to any possible hazard introduced by the situation.
ELECTRICAL:
A. DO NOT operate the machine with any of the panels removed.
B. DO NOT attempt any repairs unless you are a competent electrician.
C. Ensure that the machine is connected to the correct supply voltage through the
recommended fuse.
NB: This unit must be earthed.
D. DO NOT dismantle the protection nozzle from the torch without first switching off
the machine.
ELECTRIC SHOCK
Either AC or’ DC voltages associated with the cutting environment can cause
severe burns to the body or fatal shock. Severity of electrical shock is deter-
mined by the path and amount of current through the body.
17
NOTES

16
GUARANTEE
Guarantee:
This plasma cutter is covered by a 24 month parts and labour warranty covering
failure due to manufacturers defects. This does not cover consumable items or fail-
ure due to misuse or operating the machine outside the scope of this manual.
In the unlikely event of warranty claims, contact your distributor as soon as possible.
Proof of purchase will be required before any warranty can be honoured.
Note: Proof of purchase will be required before any warranty can be
honoured.
5
SAFETY….cont
IN-
TO PROTECT AGAINST SHOCK
1. Keep body and clothing dry. Never work in a damp area without ade-
quate insulation against electrical shock. Stay on a dry duck board, or rub-
ber mat when dampness or sweat can not be avoided. Sweat, sea water.
or moisture between body and an electrically HOT part, or grounded metal
reduces the body surface electrical resistance, enabling dangerous and
possibly lethal currents to flow through the body.
2. Never allow live metal parts to touch bare skin or any wet clothing. Be sure
gloves are dry.
3. Before welding, check for continuity. Be sure the ground cable is con-
nected to the work piece as close to the welding areas as possible.
Grounds connected to building frame work or other remote locations from
the welding area reduce efficiency and increase the potential electric
shock hazard. Avoid the possibility of the welding current passing through
lifting chains, crane cables or various electric paths.
4. Frequently inspect cables for wear, cracks, and damage. IMMEDIATELY RE-
PLACE those with worn or damaged insulation to avoid a possibly lethal
shock from bare cables.
FIRE:
All inflammable materials must be removed from the area.
DO NOT cut containers which have held inflammable materials or gases.
Have a suitable fire extinguisher available close by.
GLARE AND BURNS:
The electric plasma arc should not be observed with the naked eye. Always
wear goggles of the type used for oxyacetylene welding. Gloves should be
worn to protect the hands from burns. Non-synthetic overalls with buttons at
neck and wrist, or similar clothing, should be worn. Greasy overalls should not
be worn. Wear suitable protective footwear.
COMPRESSED AIR:
Compressed air is potentially dangerous.
Refer to the relevant safety standards for safety guidelines.

6
SAFETY….cont
INTRODUCTION:
WE LEARN BY EXPERIENCE Learning safety through personal experience, like a child
touching a hot stove is harmful. wasteful. and unwise. Let the experience of others teach
you.
SAFE PRACTICES DEVELOPED FROM EXPERIENCE
in the use of welding and cutting are described in this manual. Research, development, and
field experience have evolved reliable equipment and safe installation, operation, and servic-
ing practices. Accidents occur when equipment is improperly used or maintained The reason
for these sole practices may not always be given. Some are based on common sense, others
may require technical volumes to explain, it is wiser to follow the rules.
READ AND UNDERSTAND THESE SAFE PRACTICES
before attempting to install, operate or service the equipment. Comply with these procedures
as applicable to the particular equipment used and their instruction manuals, for personal
safety and for the safety of others.
FAILURE TO OBSERVE THESE SAFE PRACTICES
may cause serious injury or death. When safety becomes a habit, the equipment can be used
with confidence.
GENERAL:
The plasma cutting machine is simple and safe to operate under normal circumstances. If the
unit is to be used under unusual circumstances, e.g. in wet or damp conditions, on boats or
oil rigs, or in an elevated position. Then extra thought must be given to any possible hazard
introduced by the situation.
ELECTRICAL:
A. DO NOT operate the machine with any of the panels removed.
B. DO NOT attempt any repairs unless you are a competent electrician.
C. Ensure that the machine is connected to the correct supply voltage through the recom-
mended fuse.
NB: This unit must be earthed.
D. DO NOT dismantle the protection nozzle from the torch without first switching off the
machine.
ELECTRIC SHOCK
Either AC or’ DC voltages associated with the cutting environment can cause severe
burns to the body or fatal shock. Severity of electrical shock is determined by the path
and amount of current through the body.
VENTILATION:
Ventilation must be adequate to remove the smoke and fumes during cutting. See
the relevant safety standard for acceptable levels.
FUMES:
Toxic gases may be given off when cutting, especially if zinc or cadmium coated
materials are involved. Cutting should be carried out in a well ventilated area, and
the operator should always be alert to fume build-up.
In small or confined places use a fume extractor.
VAPORS:
Vapors of chlorinated solvents can form the toxic gas phosgene when exposed to
U.V radiation from an electric arc. All solvents, degreasers and potential sources of
these vapors must be removed from the arc area.
NB: IF IN DOUBT SEEK PROFESSIONAL ADVICE.
GENERAL PRECAUTIONS:
BURN PREVENTION
1. Wear Protective Clothing leather gauntlet gloves, hat, and high safety toe
shoes. Button shirt collar and pocket flaps, and wear cuff less trousers to avoid entry
of sparks and slag.
2. Wear Helmet with Safety Goggles or glasses with side shields underneath, appro-
priate filter lenses or plates (protected by clear cover glass). This is a MUST for weld-
ing or cutting (and chipping) to protect the eyes from radiant energy and flying
metal. Replace cover glass when broken. pitted, or spattered.
3. Avoid oily or greasy clothing. A spark may ignite them.
4. Hot metal such as electrode stubs and work pieces should never be handled
without gloves.
5. Medical first aid and eye treatment. First aid facilities and a qualified first aid
person should be available for each shift unless medical facilities ore close by
for immediate treatment of flash burns to the eyes and skin.
Flammable hair preparations should not be used by persons intending to weld or
cut.
15
TORCH ASSEMBLY
Under no circumstances must the plasma nozzle be removed or any other work be
carried out on the torch with the machine switched on. Ignoring this precaution
could lead to serious burns or contact with high DC voltages.
If the machine has just been used for cutting, allow the cooling air to stop before
switching the machine off for torch servicing.
The torch should be kept free of slag at all times to ensure the free passage of air.
To assemble / dismantle the torch:
1. Invert the torch so the tip points upwards.
2. Unscrew and remove the shield cup.
3. Remove the Tip ,swirl baffle and electrode.
4. Ensure the torch head thread is upper most.
5. Fit electrode into end of torch head.
6. Fit swirl baffle onto electrode, ensure is it seated fully onto the electrode.
7. Fit tip onto the swirl baffle.
8. Fit shield cup and screw on.
The Tip and electrode need replacing when worn.
Indication of wear are a loss off cutting capacity or that the cut is no longer 90 de-
grees.
When inspecting the Tip look for erosion of the hole in the centre of the tip or a
build up of metal residue.
When inspecting the electrode look for erosion in centre of the electrode
MAINTENANCE
1. Clear dust from machine at regular intervals use clean dry compressed air,
if use in a dirty environment the machine should be cleaned once a
month.
2. Check all connections are clean and tight, if there is any oxidization clean
the connection with a mild abrasive or wire brush.
3. If the machine is not to be used for a long time, store it in the original pack-
ing a dry place.

14
TORCH CONSUMABLES
1 TORCH COMPLETE 05516
2 ELECTRODE SHORT 05184
2 ELECTRODE LONG 05193
3 TIP SWIRL BAFFLE 05185
4 TIP SHORT 05186
4 TIP LONG 05196
5 SHEILD CUP 05188
Ref DESCRIPTION SIP CODE
2-5 CONSUMABLE SET SHORT 05190
2-5 CONSUMABLE SET LONG 05198
7
SAFETY….cont
FIRE AND EXPLOSION PREVENTION
1. Causes of fire, and explosion are: Combustibles reached by the arc, flame, fly-
ing sparks, hot slag or heated material, misuse of compressed gases and cylin-
ders, and short circuits. BE AWARE THAT: flying sparks or falling slag can pass
through cracks along pipes, through windows or doors, and through wall or floor
openings and out of sight of the operator. Sparks and slag can fly up-to 35
feet.
2. Keep equipment clean and operable, free of oil. grease, and (in electrical
parts) of metallic particles that can cause short circuits
3. If combustibles are in the area. DO NOT weld or cut, move the work if practical
to on area free of combustibles. Avoid paint spray rooms, dip tanks, storage ar-
eas, ventilators. If the work can not be moved, move combustibles at least 35
feet away out of reach of sparks and heat, or protect against ignition with suit-
able and snug fitting, fire-resistant covers or shields.
4. Walls touching combustibles on opposite sides should not be welded on (or
cut). Walls, ceilings, and floor near work should be protected by heat resistant
covers or shields.
5. A fire watcher must be standing by with suitable fire extinguishing equipment
during and for some time after welding or cutting if:
A. Appreciable combustibles (Including building construction) are within 35 feet.
B. Appreciable combustibles are further than 35 feet but can be ignited by sparks.
C. Openings (concealed or visible) In floors or walls within 35 feet may expose
combustibles to sparks.
D. Combustibles adjacent to walls, ceilings, roofs. or metal partitions can be ig-
nited by radiant or conducted heat.
6. After Work is done, check that area is free of sparks, glowing embers, and
flames.
7. An empty container that held combustibles. Or that can produce flammable or
toxic vapors when heated, must never be welded on or cut, unless container
has first been cleaned as described in AWS Standard A6.0 listed 3 in Standards
Index. This includes a thorough steam or caustic cleaning (or a solvent or water
washing, depending on the combustible’s solubility) followed by purging and
inserting with nitrogen or carbon dioxide, and using protective equipment as
recommended in A6.0 Water filling just below working level may substitute for

8
SAFETY….cont
8. A container with unknown contents should be cleaned (see paragraph above),
DO NOT depend on sense of smell or sight to determine if it is safe to weld or
cut
9. Hollow items must be vented before welding or cutting they can explode.
10. Explosive atmosphere. Never weld or cut where the air may contain flammable
dust, gas or liquid vapors (such as gasoline).
HOSE.
1. Use ferrules or clamps designed for the hose (not ordinary wire or other substi-
tute) as binding to connect hoses to fittings.
2. No copper tubing splices. Use only standard brass fittings to splice hose.
3. Avoid long runs to prevent kinks and abuse. Suspend hose off ground to keep it
from being ran over, stepped on, or otherwise damaged.
4. Coil excess hose to prevent kinks and tangles.
5. Protect hose from damage by sharp edges, and by sparks, slag, and open
flames.
6. Examine hose regularly for leaks, wear and loose connections. Immerse pres-
sured hose in water bubbles indicate leaks.
7. Repair leaking or work hose by cutting area out and splicing. DO NOT use tape.
8. Never leave Equipment unattended. When not cutting, turn off the equipment.
DO NOT coil or loop the cutting torch or earth cable around parts of the body.
Turn unit off when left unattended.
Flash goggles with side shields MUST be worn under the helmet to give some pro-
tection to the eyes should the helmet not be lowered over the face before an arc
is struck. Prevent looking at the arc momentarily with unprotected eyes (particularly
at high intensity) as the arc can cause a retinal burn that may leave a permanent
dark area in the field of vision.
PROTECTION OF NEARBY PERSONNEL
1. Warn bystanders not to watch the arc and not to expose themselves to the
welding-arc rays or to hot metal
13
OPERATING INSTRUCTIONS
1. Check all safety instructions have been observed.
2. Check correct air supply is connected.
3. Drain any water from bowl on the filter regulator.
4. Set machine to required current range according to the thickness of metal to
be cut.
DO NOT change range while cutting.
CAUTION: DO NOT attempt to cut material beyond the range specified, as this will
damage the torch.
1. Check the torch consumables are in good condition.
2. Check torch and earth lead connections are tight.
3. Connect return lead to the work piece, using an area free of rust and paint, for
a good contact.
4. Connect to mains supply and switch on. The green light will come on.
5. Adjust air pressure to 4.5 Bar.
6. Set the cutting current via the current control, an indication of the setting will be
shown on the digital display
7. Adjust the post gas control, if cutting at a high current setting or making a long
cut set the control near maximum, this will give a longer cool time for the torch.
8. Place the torch at the edge of the work piece with the center of the tip slightly
beyond the edge. Press the torch trigger. The air will flow after a short delay the
arc will ignite. The torch should be moved steadily along the work piece at a
rate slow enough for the metal to be cut right through in one pass. If the cut
penetration is incomplete, then the torch could be damaged. (While the air is
flowing, check it is still 4.5 Bar.)
9. When the cut is complete, release the torch trigger button. The arc will immedi-
ately extinguish, but air will continue to flow for a short time. DO NOT turn the
machine off until this cooling air has stopped flowing as this is necessary to pre-
vent damage to the torch.
PIERCING
When piercing, the torch head should be angled back so as to allow the mol-
ten material to escape to one side. The normal angle of cut can be resumed
once the metal has been pierced.
NOTE piercing will reduce the life of the torch consumables.

12
INSTALLATION
Contents
1 * Inverter based power unit 1 * Length braided air hose
1 * Cutting torch 2 * Hose clip
1 * Regulator 1 * Pressure gauge
1 * Earth return lead 1 * Regulator Bracket
1* Brass pipe fitting
Contents
1. Remove all parts from box.
2. Screw the pressure gauge into the 1/8" bsp hole on the regulator
3. Screw the brass fitting into the port marked "out" and fit your required fitting
into the port marked "in". NOTE you will need to used ptfe tape to seal the threads
4. Fit the regulator bracket onto rear of Plasma.
5. Remove locking ring from top of regulator and fit the regulator onto the fixing
bracket hole, re-fit the locking ring.
6. Connect the regulator port marked out to fitting on the rear of the plasma, use
the supplied pipe you can cut it to the required length, clamp the hose into posi-
tion with the hose clips supplied.
7. Fit earth return lead into the terminal marked ‘EARTH CLAMP’.
8. Fit the insulator into the torch nut and screw the torch onto the Plasma's torch
connection.
9. Connect compressed air to the regulator and set the air pressure to approxi-
mately 4.5 bar.
10. Connect the plasma to the electrical supply using a suitably rated plug.
9
SAFETY….cont
2. Keep children away while welding. They are not aware that looking at an arc ray
can cause serious eye damage.
3. Protect other nearby personnel from arc rays and hot sparks with a suitable non-
flammable partition
4. Bystanders should also wear safety glasses or goggles.
TOXIC PREVENTION
1. Adequate ventilation. Severe discomfort, illness or death can result from fumes,
vapors, heat, or oxygen enrichment or depletion that welding (or cutting) may
produce. Prevent them with adequate ventilation. NEVER ventilate with oxygen.
2. Lead.. Cadmium.. Zinc.. Mercury. and Beryllium. bearing and similar materials,
when welded (or Cut) may Produce harmful concentrations of toxic fumes.
Adequate local exhaust ventilation must be used. Or each person in the area
as well as the operator should wear an air-supplied respirator. For beryllium,
both must be used.
3. Metals coated with or containing materials that emit toxic fumes should not be
heated unless coating is removed from the work surface. The area should be
well ventilated, or the operator should wear an air supplied respirator.
4. Work in a confined space only while it is being ventilated and if necessary, while
wearing an air supplied respirator.
5. Gas leaks in a confined space, should be avoided. Leaking gas in large quanti-
ties can change oxygen concentration dangerously. DO NOT bring gas cylin-
ders into a confined space.
6. Leaving confined space, shut OFF gas supply at source to prevent possible ac-
cumulation of gases in the space if down stream valves are left open. Check to
be sure that the space is safe before re entering it.
7. Vapors from chlorinated solvents can be decomposed by the heat of the
arc (or flame) to form PHOSGENE, a highly toxic gas, and other lung and eye-
irritating products. The ultra violet (radiant) energy of the arc can also decompose
Trichloroethylene and Perchlorethylene. vapors to form phosgene. DO NOT WELD or
cut where solvent vapors can be drawn into the welding or cutting atmosphere, or
where the radiant energy can penetrate to atmospheres containing even minute
amounts of Trichloroethylene or perchlorethylene

10
INTRODUCTION
The Equipment
Your plasma cutting set consists of:
•A inverter based power unit.
•A air filter regulator.
•A air cooled plasma torch.
The sequence of operation is started by pressing the torch trigger. Air will flow from
the torch, if the torch is in position on the work piece the arc will then start and cut-
ting begin.
When the cut is finished and the trigger released, the torch cooling air will continue
to flow for a short time.
The power unit has a variable current control, current should be set according to
the thickness of the material to be cut, a higher current than required will lead to a
shorter consumable life but a higher rate of cutting.
The Process
Plasma cutting relies on the fact that, if a gas or mixture of gases, such as air, is
subjected to a very high temperature it becomes ionized, i.e. negative electrons
are separated from the atom which is then positively charged.
This ionized state of the gas is called plasma and, in this state, the gas is electrically
conductive. The high temperature necessary to create the ‘plasma’ is achieved, in
the case of Plasma cutting, by a standing electric arc. This is constricted by forcing
the ‘plasma’ through a small nozzle which increases the temperature of the arc to
over 24,000°C, and concentrates it into a very small area.
When this ‘plasma’ is directed at a conductive material the arc is transferred
through the ‘plasma’ (transferred arc operation) to the material. The high energy of
the arc melts the material which, so long as it is within the cutting range of the
equipment, will be displaced by the gas flow.
In order to initiate the standing arc it is necessary to produce an ionized path in the
gas.
This is achieved by applying a very high voltage, at a high frequency, between the
electrode and the nozzle. As soon as the air is ionized, the pilot arc will ignite. This
transfers the arc to the workpiece, and the main arc will now start cutting.
11
INTRODUCTION….cont
Model 05175
Input Current 16 amps
Input Voltage AC230V 50Hz
OCV 230 v
Output Current Range 10-40 amps
Cutting Voltage 96 v
Duty Cycle 40 amps @ 60%
No Load Consumption 35 watts
Arc starting Contact
Efficiency 85%
Power Factor 0.93
Insulation Class F
Protection IP23
Weight 8 Kg
Unit Dimensions 380x178x295
Compressed Air 150 L/min 4.5 bar
TECHNICAL SPECIFICATIONS
The Plasma 45 is made with advanced inverter technology.
The inverter works by converting the mains supply at 50Hz to a high frequency volt-
age at 100KHz, this voltage is then controlled by a PWM system before passing to the
transformer and then the rectifier.
By using inverter technology the weight and volume of product can be reduced,
while the efficiency is raised to 85%.
The Plasma 45 is capable of cutting mild steel, carbon steel, stainless steel, alloy
steel, copper and other nonferrous metals.
They are very portable, controllable and energy efficient.