SPT Plasmateknik AB SPLITFIRE User manual

INSTRUCTIONS FOR USE
SPLITFIRE
SPEEDFIRE
UPPERCUT
With PTA 121 hand torch
TO THE OPERATOR: PLEASE READ AND UNDERSTAND THIS MANUAL
BEFORE USING THE SPLITFIRE, SPEEDFIRE OR UPPERCUT. IT IS
ABSOLUTELY VITAL TO KNOW THE INFORMATION PRESENTED IN THIS
MANUAL IN ORDER TO USE THE MACHINES IN THE BEST WAY.
WITH THIS KNOWLEDGE AND A PROFESSIONAL APPROACH, YOU WILL BE
ABLE TO SOLVE MANY COMPLICATED CUTTING APPLICATIONS WITH THESE
SYSTEMS.
Rev. 4.2, 2012-11-01
STATE OF THE ARC PLASMA CUTTING TECHNOLOGY
Telephone
Email
SPT Plasmateknik AB
Transportvägen12
SE-241 38 Eslöv
Sweden
Internet
[phone]
[email protected]
www.spt.se

SPLITFIRE SPEEDFIRE UPPERCUT
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CONTENTS
Page
1. TECHNICAL DATA 3
2. INSTALLATION 4
3. OPERATING INSTRUCTIONS 5
4. CHANGING CONSUMABLES 6
5. MAINTENANCE 8
6. TROUBLE SHOOTING 9
7. SAFETY INSTRUCTIONS 10
8. WARRANTY 14
9. RECYCLING 15

SPLITFIRE SPEEDFIRE UPPERCUT
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1. TECHNICAL DATA
UPPERCUT
Power supply 400 V, 3~50 Hz
Mains fuse 32 A slow blow
Maximum power 17,6 kVA
Process power 120 V, 20-120 A
Duty cycle @ 40°C 30% @ 120 A
60% @ 100 A
100% @ 80 A
Power factor
Open circuit voltage
Protection class
Cooling
Temperature class
Dimensions LxWxH
Weight
0,95
240 VDC
IP 23
F
F
560x190x320
18kg
Maximum cutting capacity
Quality cut
Air pressure
45 mm
35 mm
5,5 bar
Air flow PTA 121 190 l/min
Standard torch length
SPLITFIRE
400 V, 3~50 Hz
16 A slow blow
10,4 kVA
120 V, 20-80 A
50% @ 80 A
60% @ 60 A
100 % @ 45 A
0,95
240 VDC
IP 23
F
F
560x190x320
17kg
25mm
20 mm
4,5 bar
160 l/min
6 m
SPEEDFIRE
400 V, 3~50 Hz
32 A slow blow
14,5 kVA
120 V, 20-100 A
40% @ 100 A
60% @ 80 A
100% @ 70 A
0,95
240 VDC
IP 23
F
F
560x190x320
17kg
35 mm
30 mm
5,5 bar
190 l/min
6 m 6 m

SPLITFIRE SPEEDFIRE UPPERCUT
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2. INSTALLATION
Connect the torch to the power source. After connecting electric power and compressed
air, the machine is ready for use. Please read the enclosed instructions on how to use the
central connector.
Power supply
Connect the machine to 3-Phase, 50 Hz, 400 V only.
Use with generators
SPLITFIRE, SPEEDFIRE and UPPERCUT are equipped with filters for use with mobile
generators. The generator should be of at least 15 kVA for SPLITFIRE, 22 kVA for
SPEEDFIRE and 27 kVA available exclusively for the plasma cutting system.
Air supply
Connect dry, clean and oil free compressed air to the filter regulator on the rear of the
machine and adjust to 4,5 bar for SPLITFIRE and 5 bar for SPEEDFIRE/UPPERCUT. When
cutting at lower amperage than 70 A with SPEEDFIRE/UPPERCUT it may be necessary to
lower the air pressure to 4,5 bar in order to get the best cutting capability. Don’t forget to raise
the pressure again if returning to amperage above 70 A.

SPLITFIRE SPEEDFIRE UPPERCUT
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3. OPERATING INSTRUCTIONS
Check that the machine has been properly connected to power supply and compressed air
according to chapter 2, INSTALLATION.
Check that the torch is fitted with appropriate consumables for the job at hand.
Connect the earth lead clamp directly at the work piece, ensuring that a good contact is
obtained. If necessary, clean the surface from paint, rust, dirt, etc.
Cutting
Switch the machine’s main power switch on. The READY lamp will light and the fan
will start working.
Choose process power, 20-80 for SPLITFIRE, 20-100 A for SPEEDFIRE or 20-120 A
for UPPERCUT.
Manouver the torch in position for cutting or gouging.
Press the START-switch on the torch handle.
Air will flow for one second before the pilot arc strikes. The pilot arc will burn for
about 3 seconds. If contact with the work piece is not obtanined within this time, the
pilot arc goes out. Then make a new try.
To end the process, release the START-switch. The plasma arc goes out
instantaneously. Air will continue to flow for about 30 seconds.
NOTE! When the machine is not in use or is only working at long intervals, switch off
the machine. It contains mechanical components that should not be exposed to unnecessary
wear. It also protects against unvoluntarily firing the pilot arc.

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4. CHANGING CONSUMABLES

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Consumables/torchparts for PTA 120/121
Part No. Description
899044 Torch head PTA 121
899003 Electrode standard PTA 120/121
899017 Electrode long PTA 120/121
899004 Swirl ring PTA 120/121 for 20-80 A
899023 Swirl ring PTA 120/121 for 80-120 A
899005 Nozzle 1,0 20-50 A PTA 120/121
899006 Nozzle 1,2 50-90 A PTA 120/121
899007 Nozzle 1,4 90-120 A PTA 120/121
899008 Nozzle 1,6 120 A PTA 120/121
899016 Nozzle 2,5 gouging PTA 120/121
899031 Nozzle 1,0 20-50 A long PTA 120/121
899032 Nozzle 1,2 50-90 A long PTA 120/121
899018 Nozzle 1,4 90-120 A long PTA 120/121
899033 Nozzle 2,5 gouging long PTA 120/121
899047 Protective cup PTA 120/121
899037 Spatter shield threaded PTA 120/121
899036 Contact cutting shield PTA 120/121
899010 Spatter shield PTA 120/121
899012 Distance cutting guide PTA 120/121
899013 Bevel cutting guide PTA 120/121
899038 Contact cutting shield long PTA 120/121
899014 Circle cutting guide PTA 120/121
899045 Handle PTA 121
899314 Button PTA 25/121
899049 Hose assembly PTA 121 6m
899050 Hose assembly PTA 121 15m
899015 Spanner PTA 120/121
899040 Torch PTA 121 6m complete
899041 Torch PTA 121 15m complete
N.B. Don’t use consumables for more than 80 A with the SPLITFIRE or 100 A
with the SPEEDFIRE. The result will be poor cutting capability.

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5. MAINTENANCE
DAILY
Inspect and, if necessary, change the torch consumable parts.
Inspect and, if necessary, empty the moisture trap on the filter regulator on the rear side of the
machine. The trap is emptied by pressing the bottom sealing while compressed air is
connected. If cleaning the trap is necessary, completely unscrew the glass cup after
disconnecting compressed air.
Carefully inspect the hose assembly and torch body with regard to any leak or damage.
Never use a damaged torch.
EVERY SIX MONTHS
Disconnect the machine from compressed air and electricity. Remove the cover. Clean
the machine with dry, clean and oil free compressed air. Inspect cable connections and gas
system.
In unusually dirty environments this procedure should be carried out every month.

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6. TROUBLE SHOOTING.
Thermal overload / Air supply failure
If the fan is working, but the green READY-lamp is not lit, the air supply is not
sufficient or the thermal overload protection is active. Check the compressed air supply. If the
machine is overheated, let it cool down while switched on until the lamp lights again. Then
the machine is in working order.
Malfunction
If the pilot arc does not strike:
•The safety switch of the torch is not closed. Check that the protective cup is
properly tightened.
•Check the air pressure on the filter regulator on the rear of the machine. The
pressure should be approx. 4,5/5,5 bar.
If the pilot arc is unstable:
•Check the air pressure on the filter regulator on the rear of the machine. The
pressure should be approx. 4,5/5,5 bar.
•The machine is working two phase. Check electrical supply.
Inferior cut quality or performance:
•Check the torch consumables. Replace if necessary.
•Inspect the torch body and hose assembly with regard to any damage or leak.
•Check the air pressure on the filter regulator on the rear of the machine. The
pressure should be approx. 4,5/5,5 bar.
•Check the earth lead connection. Place the earth lead clamp directly on the work
piece. If necessary, clean from paint, dirt, rust etc.

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7. SAFETY INSTRUCTIONS
All endangerments through plasma cutting are related with the process itself. Endangerments
may occur due to:
High contact voltage
HV ignition
Electromagnetic interferences
Heat and light radiation
Gases, fumes and smoke
Noise
Hot metal and spatter
Handling of pressure cylinders
The Plasma Cutting Machine has been developed in conformity with following standards:
EN 60974-1 safety requirements for installations for arc welding and welding power
sources
Endangerment due to high contact voltage
Warning!
Before opening the plasma rectifier generally the input power has to be disconnected
physically from the mains (unplug mains cable)! Only advised personnel are allowed to
carry out any repairs to the machine.
Attention! Connect the work piece cable and earth the workplace before starting the
machine!
The power source is equipped with a cooling unit and there is an electric potential between
the housing and work piece in case the work piece isn't earthed and the machine is switched
on. Because of the high resistance of more than 10 kOhm in the coolant the contact voltage is
absolute not dangerous but sensible.
Special hints:
Connect power source only to correctly earthed mains socket with proper connected
safety conductor
Wear insulating protective clothing (safety shoes, leather apron, gloves), place torch
on insulated holder,
Make sure that they cutting area and plasma machine components are dry and clean,
arrange regular inspections.
Never short safety circuits.
Working under elevated electrical endangerment
This plasma cutting machine in conformity with valid standards (EN 60974) can be used for
operation under elevated electrical endangerment
The power source and the plasma torches are forming a safety-proofed installation
which can be separated only by using tools.
The patented design of the torch prevents electrical danger when the torch
consumables are disassembled.
Therefore the power source is marked with the S-sign and operation under elevated electrical
endangerment is allowed.
Attention! Always follow the local safety rules!

SPLITFIRE SPEEDFIRE UPPERCUT
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Endangerment through high voltage (HV)
A HV-igniter starts the pilot arc. The HV-supply is cut-off automatically after pilot arc has
struck.
Attention! Never touch nozzle or nozzle cap when power source is switched ON!
HV-ignition may establish electromagnetic fields and can influence:
heart pace-makers
electronic devices
Endangerment through electromagnetic interferences
The plasma cutting unit is in conformity with the conditions of the EN 50199
“Electromagnetic compatibility”. This standard is valid for arc welding and related processes
(plasma cutting) that come in use in commercial and private fields.
Warning!
Special precautions may be required if the plasma unit is used in private fields (for instance
screened cables etc.)
The user takes the full risk when installing and using the machine. He has to follow strictly
the instructions of the supplier. If electromagnetic interferences are noticed the user is to
contact the producer to solve the problem.
Recommendations to classify the environment (EN 50199):
Before the installation takes place the user has to value the environment for electromagnetic
problems and to take into consideration:
Other mains supplies, control cables, signal and telecommunication lines along, above,
below or beside the installation
Broadcasting or television installations
Computers or other controls
Safety devices, protection circuits
The health of people in the area (heart pace makers, hearing aids etc.)
Devices for measuring and calibrating
The noise immunity of equipment around the installation, so that they are compatible
with electromagnetic interferences. Special measures may be required.
The time of day that plasma cutting is performed
Recommendations to minimise interferences:
If interferences take place, the following should be done:
Apply filter for mains connection
Screening of mains cable of the plasma installation (safe contact between screen and
housing required)
Constant maintenance

SPLITFIRE SPEEDFIRE UPPERCUT
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Always keep cover plates and doors of the plasma machines closed
Avoid excessive length of cutting cables
Arrange potential equalisation between metallic parts around the installation (the
operator has to be electrically isolated from those parts)
Earthing of the work piece
Selective screening of other cables and installations
Endangerment through heat and light radiation
The plasma arc produces intense ultraviolet and infrared radiation that can hurt the eyes and
skin. Therefore the following precautions have to be arranged:
Wearing of flame-retardant welding clothes (helmet, apron, gloves, safety shoes)
Hand or head shield with protective glasses of medium shade for watching the cutting
process
Preparing the cutting area so that reflection and transmission of ultraviolet light is
reduced:
painting of walls in dark colour
use of protective walls and screens
Endangerment through fumes and smoke
Due to the plasma process itself hazardous substances may be produced. To avoid risks on
health the following has to be done:
Keep cutting place well ventilated
Remove fumes and smoke by exhaustion devices
Remove all chlorinated and other solvents from the cutting area. They could form
phosgene gas when exposed to ultraviolet radiation
Wear a breathing mask when cutting galvanised materials
Ensure that toxic limits are not exceeded
Endangerment through noise
Be aware that during plasma cutting a high noise level arises.
Cutting current
Thickness
Noise level in distance of
0,5 m
1,0 m
No load
56dB(A)
80A
4mm
82 dB(A)
79 dB(A)
160A
l6mm
86 dB(A)
83 dB(A)
240A
l6mm
96 dB(A)
92 dB(A)
Above levels are general. Variations may occur.
Therefore wear proper ear protection.
Endangerment through spatter
During plasma cutting sparks, slag and hot metal are produced. The risk of burns and fire
exists! To avoid these endangerments the following has to be advised:
Remove all potential flammable materials from cutting area, at least in a 10 m
distance.

SPLITFIRE SPEEDFIRE UPPERCUT
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Allow cut material to cool down before handling.
Make fire extinguisher available in the cutting area.
Handling of pressure cylinders
In some cases compressed gases are required for the plasma cutting process. To avoid
endangerments the following has to advised:
Place cylinders upright in secured position.
Never use damaged cylinders, pressure reducers and armatures.
Use pressure reducers only for the gas it is determined.
Never lubricate pressure reducers with grease or oil.
All parts coming in contact with oxygen must be free from oil and grease.
When using oxygen and/or flammable gases the pressure reducer must be equipped
with an explosive-proofed device (backfire-device)
Regularly check the gas hoses and other equipment for leaks etc.
Always follow local regulation regarding gas equipment.

SPLITFIRE SPEEDFIRE UPPERCUT
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8. WARRANTY
SPT Plasmateknik AB grants a 24 month warranty for its products.
Validity
The warranty applies to power sources manufactured by SPT Plasmateknik AB
(SPT). The warranty period is 24 months from date of delivery to end user, but not
more than 30 months from delivery from factory. If the product is used more than
normal 1-shift work, the warranty period is shortened accordingly.
Any warranty claim should be accompanied by proof of purchase.
Coverage
SPT will take responsibility to repair a machine to the state it was in before the fault
occurred.
The warranty covers spare parts and reimbursement for work carried out by an
authorised service point. Labor costs are limited to a fixed rate for each action carried
out.
Upon replacement of parts, SPT reserves the right to invoice parts. The invoices will
be credited upon the return of faulty parts to SPT.
When a warranty claim occurs, the customer should immediately turn to an
authorised service point, or SPT directly. SPT requires detailed information about the
conditions under which the machine was in use when the fault occurred, such as
location (indoor/outdoor), ambient temperature, power supply (generator/normal
power supply –if generator, information is needed about the rating and type of
generator).
When a machine is taken in for warranty repair it is required that the torch also is
brought in with the consumables mounted that were there when the fault occurred.
The serial number must be clearly visible.
The user is responsible for limiting the damage by immediately stopping using the
machine if a problem is suspected.
Warranty repair may only be carried out by authorised service points. SPT reserves
the right to deny warranty claims where work has been carried out by non-authorised
service personnel.
Should SPT find that the product has been used inappropriately and it is likely that
such inappropriate use may continue, SPT reserves the right to refuse warranty
repair and refund the customer, with a deduction for the use the customer has had of
the product. SPT also reserves the right to restore the product to working order on
the customer’s expense.
Limitations
The following is not covered by warranty:
Defects caused by natural wear.
Defects caused by non-compliance of use and maintenance recommendations.
Improper gas pressure settings.
Improper electrical power supply.
Overload.
Damage caused by transport, handling and improper storage.
Fire
Damage caused by natural causes such as lightning, flooding etc.

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Further, the warranty does not cover:
Fault finding, direct or indirect travel costs, transport costs, travel costs, allowances,
accommodation and such.
SPT bears no responsibility whatsoever for consequential damages caused by fault
in its products, such as, but not limited to, loss of revenue, damages to 3rd party,
production delays, penalties etc.
The warranty is not valid if modifications of any kind has been made to the product,
without the written approval from SPT. Repairs made by non-authorised service
personnel renders the warranty void.
A modified product will be restored to the original state at the expense of the
customer prior to any repair, as SPT can not be responsible for the function of its
products otherwise.
Warranty on replaced parts
A replaced part will be covered by the original warranty. If less than 6 months
remains from the warranty period, a replaced part will be covered for maximum
months.
Disputes
Disputes will be handled according to the general terms in Orgalime S 2000.
9. RECYCLING
Do not throw electrical equipment in the regular rubbish! According
to EU-directive 2002/96/EG regarding waste that contains electric or
electronic parts (WEEE) and its implementation with national laws
products must be collected separately and brought to approved
recycling facilities after their useful life. As the owner of the product
you should find out the location of an approved recycling facility from
your local dealer.