T&R Site Cut 10 User manual

COMPRESSOR
PLASMA CUTTING
EQUIPMENT
OPERATING MANUAL PLASMA CUTTING
GB
Inglese
GB
Site Cut 10

OPERATING MANUAL PLASMA CUTTING
GB
Inglese
GB
INDEX
WARNING
1. Conformity declaration pag. 2
1.1. RAEE Norm pag. 2
2. Safety precautions pag. 2
3. General description pag. 3
3.1. Description of devices on the machine pag. 3
Site Cut 10 power source pag. 4
3.2. Safety devices pag. 4
 3.3.
Explanation  of technical specications pag. 4
 3.4.
Technical specications table pag.5
4. Star-up and use pag. 5
4.1
Main supply connection pag. 5
4.2
Cutting start-up pag. 5
5. Replacement consumer parts pag. 8
6.Cuttingproblems  pag.8
6.1
Insufcient  penetration  pag.8
6.2 Cutting arc goes off
pag. 8
6.3 Shorter life of consumer parts
pag. 8
7. Maintenence pag. 8
7.1. Generator maintenance pag. 9
7.2. Plasma torch maintenance pag. 9
8. Spare parts list pag. 9
9. Wireing diagram pag. 10
Cap. Par. DESCRIPTION PAGES
PAGE 1

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ELECTRICSHOCK–Maybefatal.
Install and earth the welding machine according to the applicable
regulations.
Do not touch live electrical parts or eletrodes with bare skin, gloves
or wet clothing.
Isolate yourselves from both the earth and the workpiece.
Make sure your working position is safe.
FUMEANDGASES–Maybehazardoustoyourhealth.
Keep your head away from fumes.
Work in the presence of adequate ventilation, and use ventilators
around the arc to prevent gases from forming in the work area.
ARCRAYS–Mayinjuretheeyesandburntheskin.
Protect your eyes with welding masks tted with ltered lenses, and
protect your body with appropiate safety garments.
Protect others by installing adequate shields or curtains.
RISK OF FIRE AND BURNS
Sparks (sprays) may cause res and burn the skin; you should the-
refore make sure there are no ammable materials in the area, and
wear appropriate protective garments.
WARNING
IMPORTANT: BEFORE STARTING THE EQUIPMENT, READ THE CONTENTS
OF THIS MANUAL, WHICH MUST BE STORED IN A PLACE FAMILIAR TO ALL
USERS FOR THE ENTIRE OPERATIVE LIFE-SPAN OF THE MACHINE.THIS
EQUIPMENT MUST BE USED SOLELY FOR CUTTING OPERATIONS.
1. Conformity declaration
The machines descripted in this manual, Site Cut 10 must be used solely
for professional purposes in an industrial environment and they are manufactured
in compliance with the instructions contained in the harmonized standard EN50199
(electromagnetic compatibility) and EN60974-1.
IN CASE OF BAD OPERATION YOU DEMAND THE ATTENDANCE OF QUALI-
FIED STAFF.
1.1 RAEE Norm
The symbol on the product or on its packaging indicates that this product may not
be treated as household waste. Instead it shall be handed over to the applicable
collection point for the recycling of electrical and electronic equipment. By ensuring
this product is disposed of correctly, you will help prevent potential negative conse-
quences for the environment and human health, which could otherwise be caused
by inappropiate waste handling of this product. For more detailed information about
recycling of this product, please contact your local city ofce, your household wa-
ste disposal service or the shop where you purchased the product.
2. SAFETY PRECAUTIONS
WELDING AND ARC CUTTING CAN BE HARMFUL TO YOURSELF ANDJ
OTHERS. The user must therefore be educated against the hazards, summarized
below, deriving from welding operations.
PAGE 2
Keep your body away from nozzle and plasma
arc.
Operate the pilot arc with caution. The pilot arc
is capable of burning the operator, others even
piecing safety clothing.
injure
PLASMA ARC can

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Picture 3 : Site Cut 10 front and
rear view
Figure 3
3.1 3.1 Description of devices on the machine
Site Cut 10 power source
3.2Safety devices
This system comes equipped with the following safety devices: (see table 1 )
Overload cutout:To avoid overload while cutting
* In the event of the machine termpretrue too high.
* In the event of torch maintenance with main power on. In this event all cutting
function are preventHG
•
•
NOISE
This machine does not directly produce noise exceeding 80dB. The
plasma cutting/welding procedure may produce noise levels beyond
said limit; users must therefore implement all precautions required by
law.
PACEMAKERS
The magnetic elds created by high currents may affect the operation
of pacemakers. Wearers of vital electronic equipment (pacemakers)
should consult their physician before beginning any arc welding, cut-
ting, gouging or spot welding operations.
Do not weld in the vicinity of containers under pressure, or in the pre-
sence of explosive dust, gases or fumes. All cylinders and pressure
regulators used in welding operation should be handled with care.
3. General description
This machine is a constant direct current power source, designed for cutting
electrically conductive materials (metals and alloys) using the plasma arc procedu-
re. The plasma gas may be compressed air or nitrogen.
PAGE 3
1. Power indicator
2. OK indicator
3. Over-heat protect indicator
4. Current adjustment knob
5. Power switch
6. Positive output terminal
7. Negative output terminal
Electrical:
EXPLOSIONS

OPERATING MANUAL PLASMA CUTTING
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Table1:Safetydevicesignal.
SIGNAL
FUNCTION
ON/OFF ON/OFF Reset function,blink for 5 sec.
torch tiigger cutting
Pilot arc on
Fast blinking for 10 sec.
- Fast blinking
Thermal failure
ON
Torch Maintenance Fast blinking Fast blinking
Do not remove or short-circuit the safety devices.
Use only original parts.
Always replace any damaged parts of the machine with original materials.
Do not run the machine without its housings. This would be dangerous to the ope-
rator and anyone else in the work area, and would prevent the machine from being
cooled properly.
3.3Explanationoftechnicalspecication
EN 60974.1 The machine has been built according to this European stan-
dards
EN 50199
EN 50192
N............ Serial number. Always indicate this for any request
Single phase static transformer-
rectier frequencyconverter, inverter.
Drooping characteristic.
Suitable for plasma cutting.
TORCH TYPE.. Type of torch that may be used with this machine.
U0 Secondary open-circuit voltage Peak value.
X% Percentage duty cycle.
The duty cycle expresses the percentage of 10 minutes for
which the machine may work at a certain current I2 and
voltage U2 without overheating.
I2 Cutting current.
U2 Secondary voltage at cutting current I2.
This voltage in measured when cutting with the gas nozzle
in contact with the work piece.If this distance increases,
the cutting voltage also increases and the duty cycle X%
may drop.
U1 Main supply voltage
1~50/60Hz Single phase 50/60 Hz power supply
I1 Primary supply current at the correspondingcutting current
I2 and cutting voltage U2 .
IP21S Housing protection rating.
PAGE 4
On. light for 4-6 sec..
,cuntinue to press the
When pilot arc is end
ON

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4.2 Cutting start-up
Read the standards CEI 26/9 – CENELEC HD 407 and CEI 26.11 – CENELEC HD
433 carefully before using the equipment, and make sure the cable insulation is
fully intact. Make sure the trigger has not been pressed.
Turn the machine on using the switch B. The warning lamp D will light and thermal
lamp E will blink for 5 sec. to indicate that the machine is on.
Press the torch trigger briey to open the ow of compressed air ; for rst start the-
re isn’t pilot arc but only air ow to clean the air hose from . Since the arc is
not lit, air leaves the torch for 20-25 sec.
Connect the grounding clamp to the workpiece. The cutting circuit must not be
deliberately placed in direct or indirect contact with the protective wire except in the
workpiece. If the workpiece is deliberately grounded using the protective conductor,
the connection must be as direct as possible and use a wire of at least the same
size as the cutting current return wire, and connected to the workpiece at the same
point as the return wire clamp or a second grounding clamp placed in the immedia-
te vicinity. Every precaution must be taken to avoid stray currents. Use the knob C to
select the cutting current.
Make sure that the grounding clamp and workpiece have a good electrical contact,
especially with painted, oxidized or insulated sheet metal.
Do not connect the grounding clamp to the part of the material that is to be remo-
ved. Press the torch trigger to strike the pilot arc.
Begin cutting as shown in g. 5a, avoid starting as shown in g. 5b. Further during
cutting operation the torch have to keep in contact with workpiece in order to avoid
torch overheating
(Picture 5c).
Picture 5a Picture 5b Picture 5c
3.4Technicalspecicationstable(table2)
Technical data Site Cut 10
Main supply (-15%/+15%) VAC 1ph x 230V
Frequency Hz 50/60
Main power (60%) KVA 2,6
Open circut voltage V0 V 250
Current range I2 A 13-25
Arc pilotcurrent I2 A 11-13
Cutting current I2 (X%) A 25
I2 (60%) A 25
I2 (100%) A 20
Recommended cutting capacity mm 6
Maximum cutting capacity mm
8
Severence cutting capacity mm
10
Gas ow bar Air compressor.
Insulation class F
Protection degree IP 21S
Dimensions mm 425x210x415
Weight Kg 19,0
4. Start-up and use
The machine must be installed by qualied personnel. All connections must be
made in compliance with current safety standards and full observance of safety
regulations.
4.1 Main supply connection
Connect the power cord A: the yellow-green cable wire must be connected to an
efcient grounding socket on the system. The remaining wires must be connected
to the power supply line by means of a switch placed as close as possible to the
cutting area, to allow it to be shut off quickly in case of emergency.
The capacity of the cut-out switch or fuses installed in series with the switch must
be equal to the current I1 absorbed by the machine.
The absorbed current I1 may be determined by reading the technical specications
shown on the machine under the available supply voltage U1 .
Any extension cords must be sized appropriately for the absorbed current I1.
PAGE 5
pump

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Hold the torch upright while cutting.
When you have nished cutting and released the trigger, air will continue to leave
the torch for approximately 20-25 seconds to allow the torch to cool down.
The standard tip have hole 0,8 mm. , suggested from 18 to 25 A . Below is sugge-
sted to use tip 0,65 mm.
( upon request )
It is best not to turn the machine off until this cool-down period is complete.
For best cutting performances, see Tab. 4: spare parts
To cut perforated or grid metal, after any cutting cycle, pilot arc swicth on for next
cutting cycle. After 4-6 sec. without cutting the arc pilot will switch off .
Use this function only if necessary to avoid unnecessary wear on the electrode and
nozzle.
Picture 6: begin cutting from the center of the workpiece.
On Picture 3 we can see a plot concerning cutting speed vs cutting thickness with
cutting current
Thickness(mm)
Material
Current(Amp)
Speed (m/min)
Note:Theabovetablehastoconsideronlyanexampleforsettingthebest
parameters. The data was collected using automatic cuttin system.
Fortheoverlappedsteel(1,0-1,5mm.)issuggestedtousethenozzlewith
hole 0,65 mm. with 13-18 A ; automatically the generator inverter supplies a
low air quantity to execute such operation .
Picture 3: cutting data
Should you need to make holes or begin cutting from the center of the workpiece, you
must hold the torch at an angle and slowly straighten it so that the nozzle does not
spray molten metal (see Picture 6).this must be done when making holes in pieces
more than 3 mm thick.
Turn the machine off when the task is completed.
PAGE 6
cutting width
air-pressure
Electrode, nozzle
86
25 25
carbon steel carbon steel
1.2 0.9
Built-in airpump Built-in airpump
original electrode and
nozzle of the cutting
torch (0.8)
original electrode and
nozzle of the cutting
torch (0.8)
250 500

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5. Replacing consumer parts
Always shut off the machine before replacing consumer parts.
The electrode must be replaced when it has a crater in the center approximately 1
mm deep.
The diffuser must be replaced when some areas are blackened. Due to its small
size, is very important to position it correctly during assembly (see g. 4).
The gas nozzle or tip cutting must be replaced when the hole is no longer smooth
and the cutting capacity is diminished.
The nozzle holder must be replaced when the insulating part is deteriorated.
For the best cutting performances, use the following tip cutting-nozzle holder com-
bination ( for order code see Spare part section)
Table 4: spare parts
Current/Model From 13 to 18 Amp From 18 to 25 Amp
Site Cut 10 Tip diameter 0,65 mmnoz-
zle holder with 2 holes
Tip diameter 0,8 mmnozzle
holder with 2 holes
Makesurethattheelectrode,thediffuseranthegasnozzlearemounted
correctly,andthatthenozzleholderisrmlytightened
If any of this parts are missing, this will interfere with smooth operation of
themachineand,especially,jeopardizeoperatorsafety.
Picture 8 : mouting schematic
6. Cutting errors
6.1Insufcientpenetration
This error may be caused by the following:
High speed. Always make sure that the arc fully penetrates the workpiece
and is never held at a forward angle of more than 10-15°. This will avoid
incorrect consumption of the nozzle and burns to the nozzle holder.
Excessively thick workpiece This inverter cut 8mm. Max and 10mm.
severance .
Grounding clamp not in good electrical contact with the workpiece.
Worn nozzle and electrode.
Cutting current too low.
NOTE: when the arc does not penetrate, the molten metal scraps obstruct
the nozzle.
6.2 The cutting arc goes off
This error may be caused by:
Worn nozzle, electrode or swirl ring.
Air pressure too high.
Supply voltage too low.
6.3 Shorter life of consumer parts
This error may be caused by:
Oil or dirt in the arc intake.
Unnecessarily long pilot arc.
Low air pressure.
Make sure that the new electrode and nozzle to be mounted are thoroughly clean
and degreased.
Always use original spare parts to avoid damaging the torch.
•
•
•
•
•
•
•
•
•
•
•
•
PAGE 7

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1
7. Maintenance
Always cut off the power supply to the machine before any operation, which must
always carried out by qualied personnel.
7.1 Generator maintenance
In the case of maintenance inside the machine, make sure that the switch B is in
position “O” and that the power cord is disconnected from the mains.
Site Cut 10 power source
Periodically open the cover panel and clean the interior of the machine from the
accumulated metal dust, using low pressure compressed air.
The air compressor is equipped with an air lter ( Pos. 1 – Picture 10 ); periodical-
ly, remove this lter and clean it with low ow air compressed.
7.2 Precautions after repairs
After making repairs, take care to organize the wiring so that there is secure insu-
lation. Do not allow the wires to come into contact with moving parts or those that
heat up during operation. Reassemble all clamps as they were on the original ma-
chine, to prevent a connection from a wire accidentally break or be disconnected.
To ensure earth connection, also mount the screws with geared washers as on the
original machine.
8. Spare parts
8.1 Site Cut 10 power source
Figura 10: Viste generali Site Cut 10
Ref.
Description
5
Main power switch 230 VAC
7
Plasma torch 4 mt (see torch spare parts)
4Regulation current knob
Potentiometer 1 Kohm
1
Green Led 3 mm
3
Red Led 3 mm
2
Yellow Led 3 mm
Led holder
6
Earth clamp
PAGE 8

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8.2 Plasma torch
T3981120 Hand torch 4 m. - Compressor
1 R4919102 Torch head
1a R4929101 O-Ring
2 R4924109 Electrode Hf - back arc stricking
3 R4622101 Air diffuser
4 R4913130 Tip 0,65 ( 10-20 A ) back arc stricking
R4913131 Tip 0,8 ( 20-30A ) back arc stricking
R4913132 Tip 0,9 ( 40A ) back arc stricking
5 R4612102 Outside nozzle , 2 holes
6 R4930117 Handle complete
7 R4932102 Trigger
PAGE 9

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PAGE 10

Partita Iva 03377580240
Telefono [phone]
Telefax [phone]
Ter s.r.l Via Madonna delle Grazie 27
Costabissara 36030 Vicenza
Internet: http//www.terwelding.com
e-mail: [email protected]