Unitor UPC 1041 User manual

Revision date: 14-11-30 Page 1 of 42
Instruction manual
UPC 1041
Air Plasma Cutter

Revision date: 14-11-30 Page 2 of 42
CONTENTS
1. TECHNICAL DATA
2. INSTALLATION
3. OPERATING INSTRUCTIONS
4. TORCH PARTS
5. MAINTENANCE
6. TROUBLE SHOOTING
7. SAFETY INSTRUCTIONS
8. SERVICE SECTION
UPC-1041 Air Plasma Cutter 192-404100 delivery consist of :
Remarks :
Plug for primary cable and air hose is not supplied as this will depend on the connections
available onboard.

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1 TECHNICAL DATA
Power supply
440 V *, 3~50/60 Hz
Mains fuse min
20 A slow blow
Maximum power
14,7 kVA
Process power
120 V, 20-100 A
Duty cycle @ 40°C
35% @ 100 A
60% @ 80A
100% @ 60A
Power factor
0,95
Open circuit voltage
240 VDC
Protection class
IP 23
Cooling
Forced
Temperature class
F
Dimensions L x W x H
560x190x320
Weight
16 kg
Maximum cutting capacity
40 mm
Quality cut
25 mm
Air pressure
5,0 bar
Air flow PTA 120
190 l/min
Standard torch length
6 m
* May be set for 400(380)V see below, higher fuse size is then required
2 INSTALLATION
After connecting electric power and compressed air, the machine is ready for use.
Power supply
Connect the machine to 3-Phase, 50/60 Hz, 440 V. The machine may be reset to 400 (380) V as follows:
Disconnect the power source from 440V outlet.
Open the machine by removing the handle and cover.
Remove cable no. 22 from 440V on the control transformer and connect it to 400V.
Reassemble the cover and handle.
Connect the power supply to 400V outlet.
NOTE: at least 30 kVA should be available from the generators exclusively for the plasma cutting system. If
available power is lower it may result in major damage to the power source.
If running the machine on 440V while set to 400V and vice versa may result in damage to the power source.
Air supply
Connect dry, clean and oil free compressed air with minimum pressure 6bar, maximum pressure 7 bar to
the filter regulator on the rear of the machine.
Note that the pressure gauge on the front of the UPC-1041 will not show any pressure until the air is
flowing, see Operating instructions.

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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 return clamp directly onto the work piece, ensuring that a good contact is obtained.
If necessary, clean the surface from paint, rust, dirt, etc.
Switch the machine’s main power switch on. The READY lamp will light and the fan will start working.
Choose process power, 20-100 Ampere.
Press trigger shortly to start air pre-flow and check air pressure: 4,5 –5,0 bar.
When cutting at lower amperage than 70 A it may be necessary to lower the air pressure to 4,5 bar in
order to get the best cutting capability.
Do not forget to raise the pressure again to 5 bar if returning to amperage above 70 A.
Cutting
Place the torch in position for cutting or gouging. For most cutting
operations the contact cutting shield should be used. It is placed
directly on the work piece at the edge where cutting should start
Lift the trigger protection and press the trigger-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 obtained within this time, the pilot
arc goes out.
Reposition the torch to ensure that the pilot arc will reach the work-
piece and make a new try.
When the cutting arc is established, pull the torch slowly across the
surface that is to be cut. At correct speed the sparks goes straight
through the metal with only a slight bending towards the beginning of
the cut
Pause briefly at the end of cut before releasing the trigger.
The plasma arc goes out immediately. Air will continue to flow for
about 30 seconds. When removing the finger from the trigger the
trigger protection will close over the button.

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Piercing
Rest the contact drag shield on the
work piece at 45° angle
Press the trigger-switch on the torch handle.
Air will flow for one second before the pilot arc strikes.
After cutting arc starts, slowly and in one smooth movement,
straighten torch back up until 90° angle to plate.
Start moving torch across plate when observing that the arc
penetrates.
Circle cutting guide (optional accessory)
The wheeled wagon in the circle cutting set should be used when
cutting on uneven surfaces where it is difficult to use the drag
shield.
1. Pull off the drag shield
2. Insert the torch to a position where the distance from nozzle
tip to work piece is 3-4mm
3. Tighten the allen screw on the inner ring.
4. Tighten the allen screw on the outer ring with the wheels
axis at 90° to the torch handle
For cutting circles the allen screw in point 4 must be loosened to
allow the torch to rotate in the wagon.
The circle cutting bar is screwed into the wheel centre, and the
centre tap is fastened at the correct radius.
Gouging
1 Pull off the drag shield and shield cup
2 Mount the gouging nozzle and replace the shield cup
3 Contact gouging cannot be done. Start the arc with the nozzle at 45° angle, slightly off the work
piece.
4 When gouging arc is established, move the torch forward, blowing the molten metal out of the
groove.
5 Groove depth and width is adjusted by weaving and torch angle.
NOTE!

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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
accidental firing the pilot arc.
4 TORCH PARTS

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Pos.no
Description
Product no
-
UPC-1041 Plasma cutter complete with 6m cable
192 - 404100
-
Torch PTA 121 with 6m cable and drag shield for UPC-
1041 (incl. w. machine)
192 - 404114
-
Torch PTA 121 with 15 m cable and drag shield for
UPC-1041 (optional)
192 –404115
1 (not
shown)
Hose assembly for PTA 121 torch 6m, excl. torch head
and handle.
On request
1 (not
shown)
Hose assembly for PTA 121 torch 15m, excl. torch head
and handle
On request
2
Trigger button for UPC-1041 w. PTA 121
On request
3
Handle for UPC-1041 w. PTA 121
On request
4
Torch head for UPC-1041 w. PTA 121
On request
5
Electrode for UPC-1041 w. PTA 121 5 pcs
192 - 404005
6
Tool for electrode change
-
7
Swirl ring for UPC-1041 w. PTA 121 2 pcs
192 - 404006
8
Nozzle 1,0mm 20-50 Amps for UPC-1041 w. PTA 121
5 pcs
192 - 404007
8
Nozzle 1,2mm 50-100 Amps for UPC-1041 w. PTA 121
5 pcs
192 - 404008
8
Nozzle gouging 2,5mm for UPC-1041 w. PTA 121 5
pcs
192 - 404009
9
Shield cup for UPC-1041 w. PTA 121 2 pcs
192 - 404010
10
Spatter shield for UPC-1041 w. PTA 121 2 pcs
192 - 404111
11
Drag shield for UPC-1041 w. PTA 121 2 pcs
192 - 404112
-
Consumables kit complete (included with machine)
The kit includes
3 electrodes ( pos 5)
1 tool for electrodes ( pos 6)
3 nozzles 1,2 ( pos 8)
1 spatter shield ( pos 11)
1 drag shield ( pos 12)
1 gouging nozzle 2,5 ( pos 9)
192 - 404013
12
Wheeled cutting guide with circle cutting attachment
(Optional accessory)
192 –404016

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5. MAINTENANCE
DAILY
Inspect and, if necessary, change the torch consumable parts.
Note:
Electrode and nozzle must be changed at regular intervals, as a general guideline after 2
hours continues use, or after 200 starts.
Always replace the electrode if the center has a pit more than 2 mm (1/16” deep). Replace the nozzle if
the opening is deformed or clearly oversized.
Failure to replace worn nozzle or electrode in time will dramatically reduce the cutting capacity and
eventually ruin the torch.
The moisture trap on the backside of the machine is self relieving by pressure drop, this means that
every time you start and stop a cutting cycle it will drain the moisture in the trap. If cleaning or manual
emptying of 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 THREE TO 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 especially dirty environments this procedure should be carried out more often.

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6. TROUBLE SHOOTING.
Thermal overload.
If the air pressure is correct but the green ready lamp is not lit the power source is overheated and
needs to cool down before it can be used again. Let the machine cool down while switched on until the
ready lamp lights up.
Please note that the UPC-1041 plasma cutter is equipped with an active fan control which will run the
fan until the machine is cooled down to a safe level.
Here is a small description how it works:
The Active fan control will switch on the fan when the operator switches on the machine in order for the
operator to hear that the machine starts up, if the operator doesn’t start a cutting cycle within 5min the
machine will switch off the fan.
When the operator activates the torch the Active fan control will start the fan and keep it running during
the whole cutting cycle and 5min after in order to cool the machine, if the operator doesn’t reactivate
the torch during these 5min the fan switches off.
If the operator activates the torch within the 5min the Active fan control will reset the timing and when
the operator stops the cutting cycle the fan will again run for 5min.
As an added protection the Active fan control senses the temperature on the main transformer via a
thermistor, if the transformer is still warm after the 5min time cycle the fan will keep running until the
transformer has reached a preset temperature.
Torch malfunction.
If the pilot arc does not strike:
-Change nozzle, electrode and electrode insulator.
-Check, and if necessary, adjust inlet air pressure on the rear of the machine to 5
bar.
-If possible, measure gas flow through the nozzle while the post flow function is
active. The flow should be approx. 20-28 l/min.
If the pilot arc is not stable:
-Too high gas flow. Adjust inlet pressure to 5 bar.
If possible measure the flow through the nozzle.
-The machine is working two-phase. Check mains fuses.
Inferior performance or cutting quality:
-Check consumables.
-Inspect the torch body and hose assembly for damage.
-Check the return clamp connection.

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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
• EN 50199 electromagnetic compatibility
Before starting the Plasma Cutting Machine carefully read this Instruction Manual. Only advised
personnel are allowed to operate the plasma installation!
Endangerment due to high contact voltage
Warning! Before opening the plasma cutting machine 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 return lead clamp onto and earth the workplace before starting the
machine!
Important precautions:
Connect power source only to correctly earthed mains socket with proper connected protective earth
conductor.
Wear insulating protective clothing (safety shoes, leather apron, gloves), place torch on a surface
insulated from machine earth during breaks,
Keep and cutting area and plasma machine components dry and clean and follow the maintenance
recommendations strictly.
Working under elevated electrical endangerment
This plasma cutting machine in conformity with valid standards (EN 60974-1) can be used for
operation under elevated electrical endangerment. The design of the torch prevents electrical danger
when the torch is disassembled. Therefore the power source is marked with the S-sign and operation
under enhanced electrical endangerment is allowed.
Attention! Always follow the local safety rules!
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 and 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 and must
follow strictly these instructions.. If electromagnetic interferences are noticed the user is to contact the
producer to solve the problem.

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Recommendations to classify the environment (EN 60974-10):
Before the installation takes place the user has to evaluate 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 must be compatible with electromagnetic
interferences. Special measures may be required.
Recommendations to minimize interferences:
Apply filter for mains connection.
Screening of mains cable of the plasma installation (safe contact between screen and housing
required)
Constant maintenance
Always keep cover plates and doors of the plasma machines closed
Avoid excessive length of cutting cables
Arrange potential equalization between metallic parts around the installation (the operator has to be
insulated from those parts)
Proper return clamp connection onto 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, if necessary
use 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 galvanized materials
Ensure that toxic limits are not exceeded
Endangerment through noise
Be aware that during plasma cutting a high noise level arises, and can reach levels above 100 decibel.
Adequate ear protection must be used.
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
Cool down freshly cut material before handling
Make fire extinguisher available in the cutting area

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8. SERVICE SECTION
Fault finding:
8.1 Check overvoltage varistors
Disconnect the machine from mains power supply.
1. Disconnect the incoming leads from the E5 EMC-filter.
Make a visual inspection of the three varistors if any looks damaged then the machine has been
connected to a voltage exceeding the approved 440VAC.
Check the incoming voltage and replace the varistors.
2. If the varistors are undamaged then measure between the three phases with a resistance test.
Correct value is OL or unlimited, if the value is low then replace the varistors.
V1.
V2.
V3.

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8.2 Check the E5 EMC-Filter PCB.
Verify that the machine is disconnected from the mains power supply.
1. Reconnect the incoming leads to the E5 EMC-Filter.
2. Measure the three phases in the incoming socket with resistance measurement.
Correct value is approx. 240 k ohm, if the value is low or a short is measured then replace the E5
EMC-Filter.
1.
2.
3.

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Cont. 8.2 Check the EMC-Filter
3. Measure between W, V, and U, on the incoming and outgoing side on the E5 EMC-Filter with a
buzzer or resistance measurement.
If no connection, then replace the E5 EMC-Filter.
Note that the placement of V and W is shifted on the outgoing side.
W
V
V
W
U
U
1.
W-W
2.
V-V
3.
U-U

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8.3 Check the B1 Main switch.
Verify that the machine is disconnected from the mains supply.
1. Turn on B1 main switch. Remove the fuse from the T1 Control transformer.
2. Measure between the cables 11, 21 and 31 and the three phases on the incoming side on the main
switch with a resistance or summer measurement.
Correct value is 0 Ohm, if resistance is high then replace the B1 main switch
Replace the fuse on the T1 control transformer and switch off B1 main switch.
1.
2.
3.

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8.4 Check the D5 main rectifier.
Verify that the machine is disconnected from the mains supply.
1. Measure with instrument set to diode test, place the positive probe on cable 74 and the negative
probe on cable 11, 21 and 31. Correct value is approx 0.5V this can differ slightly between
instruments. If a short is measured then replace the D5 main rectifier.
2. Measure with instrument set to diode test, place the negative probe on cable 73 and the positive
probe on cable 11, 21 and 31. Correct value is approx 0.5V this can differ slightly between
instruments. If a short is measured then replace the D5 main rectifier.
1.
2.
3.
1.
2.
3.

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8.5 Check the E1 Primary switching PCB.
Verify that the machine is disconnected from the mains supply.
Note. These measurement are all made at room temperature 20°C, if the machine is used recently the values may differ.
1. Disconnect cable 73 and 74 from the D5 main rectifier.
2. Disconnect the pulse leads from the E2 PWM PCB connector A4.
3. Measure between cables no 73 and 74 with diode test, positive probe on 74.
Correct value is approx. 0.7V. This value may differ between different instruments but if very low or a
short is measured then replace the E1 primary PCB.

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Cont. 8.5 Check the E1 Primary switching PCB.
4. Measure between pin 1-2 and 7-8 with the meter set to diode test and the positive probe on the
red lead. Correct value is approx. 1.15. This value may differ a bit between different instruments but if
very low or a short is measured on one pair then replace the E1 primary PCB.
5. Measure between pin 1-2 and 7-8 with the meter set to diode test and the negative probe on the
red lead. Correct value is approx. 1.10, this value may differ between different instruments but if very
low or a short is measured on one pair then replace the E1 primary PCB.
6. Measure between cable no. 74 and the Out (+) on the E1 primary pcb with the meter set to diode
test and positive probe on cable 74. Correct value is approx. 0.35. This value may differ a bit
between different instruments but if very low or a short is measured then replace the E1 primary PCB.
7. Measure between cable no. 73 and the Out (+) on the E1 primary pcb with the meter set to diode
test and negative probe on cable 73. Correct value is approx. 0.35. This value may differ a bit
between different instruments but if very low or a short is measured then replace the E1 primary PCB.
Reconnect cable 73, 74 to the D5 main rectifier and pulse leads to E2 PWM PCB connector A4.
1.
2.
1.
2.

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8.6 Check the E4 Secondary PCB.
Note. These measurement are all made at room temperature 20°C, if the machine is used recently the values may differ.
1. Disconnect one of the main transformer leads and one of the choke leads.
2. Measure between D3A and D3B with diode test and the red probe on D3B.
Correct value is approx. 0.35. If a low value or a short is measured replace the diode module D3/D4.
3. Measure between D2D and D2C with diode test and the red probe on D2C.
Correct value is approx. 0.35. If a low value or a short is measured replace the diode module D1/D2.
Cont. 8.6 Check the E4 Secondary PCB.
4. Measure between TS1_B and TS1_C, with diode test and the positive probe on TS1_B.
Correct value is approx. 0.35. If a low value or a short is measured replace the transistor module TS1.

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Cont. 8.6 Check the E4 Secondary PCB.
5. Measure between TS1_B and TS1_C, with diode test and the positive probe on TS1_C.
Correct value is OL or unlimited. If a low value or a short is measured replace the transistor module
TS1.
6. Measure between TS1_A and TS1_D with resistance measurement.
Correct value is approx. 2.2 k ohm. If a low value or a short is measured replace the transistor module
TS1 and the E4 Secondary PCB.
7. Measure resistor R12, 23. Correct value is approx. 14 ohms.
8. Reconnect the leads from the main transformer and choke.