Unitor UPC-310 TP User manual

Revision date: 15-08-10 Page 1 of 28
Instruction manual
UPC-310 TP
Air Plasma Cutter

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CONTENTS
1. TECHNICAL DATA
2. INSTALLATION
3. OPERATING INSTRUCTIONS
4. TORCH PARTS
5. MAINTENANCE
6. TROUBLE SHOOTING
7. SAFETY INSTRUCTIONS
8. SERVICE SECTION
UPC-310 TP Air Plasma Cutter 192-310310 delivery consist of:
1
Machine supply complete with 3.5m primary cable 3Gx2.5mm
2
Torch with 4m cable package
3
Return clamp with 3.5m cable and Dix cable connector
4
Starter kit with initial supply of torch spares and consumables
5
Air regulator with filter and water separator mounted on the machine
6
User instruction manual
Remarks:
Air hose is not supplied as this will depend on the connections available on board.

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1 TECHNICAL DATA
Power supply
230 (110 V),1~50/60 Hz
Mains fuse min
16 (32) A slow blow
Maximum power
2,85 kVA
Process power
95 V, 5-30 A
Duty cycle @ 40°C @ 230V
35% @ 30 A
60% @ 25A
100% @ 20A
Power factor
0,95
Open circuit voltage
424 VDC
Protection class
IP 23S
Cooling
Forced
Temperature class
F
Dimensions L x W x H
440x190x320
Weight
9.5 kg
Maximum cutting capacity
10 mm
Quality cut
8 mm
Air pressure
3.5 bar
Air flow PTA 120
115 l/min
Standard torch length
4 m
* For 110V, higher fuse size is then required

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2 INSTALLATION
After connecting electric power and compressed air, the machine is ready for use.
If installing machine on 110V supply the required fuse size is 32A.
NOTE: at least 7.5 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.
Air supply
Connect dry, clean and oil free compressed air with minimum pressure 4 bar, maximum pressure 9 bar to
the filter regulator on the rear of the machine.

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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 power switch on. The green power led will light and the fan will start working.
Choose process power, 5-30 Ampere.
Press trigger shortly to start the pilot arc, release the trigger and adjust during post flow: 3.5 bar.
Cutting
Place the torch in position for cutting with the nozzle in direct contact
with the material to be cut.
Lift the trigger protection and press the trigger-switch on the torch
handle.
The pilot arc strikes immediately.
The pilot arc will burn for about 5 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 15 seconds. When removing the finger from the trigger the
trigger protection will close over the button.

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Piercing
Rest the nozzle on the
work piece at 45° angle
Press the trigger-switch on the torch handle.
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 distance cutting guide (if mounted)
2. Insert the torch into the cutting wagon.
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.
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
accidental firing the pilot arc.

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4 TORCH PARTS

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Pos.no
Description
Product no
-
UPC-310 TP Plasma cutter complete with 3.5m cable
192-310310
-
Torch PTA 25 with 4m cable (incl. w. machine)
192-310328
1
Hose assembly for PTA 25 torch 4m, excl. torch head
and handle.
On request
2
Trigger button for UPC-310 TP w. PTA 25
On request
3
Handle for UPC-310 TP w. PTA 25
On request
4
Torch head for UPC-310 TP w. PTA 25
On request
5
Electrode for UPC-310 TP w. PTA 25 10 pcs
192-310312
6
Swirl ring for UPC-310 TP w. PTA 25 2 pcs
192-310316
7
Nozzle 0.8mm for UPC-310 TP w. PTA 25 10 pcs
192-310314
8
Shield cup for UPC-310 TP w. PTA 25 2 pcs
192-310318
9
Distance guide for UPC-310 TP w. PTA25 5 pcs
192-310320
-
Consumables kit complete (Optional accessories)
The kit includes
3 electrodes ( pos 5)
1 tool for electrodes
3 nozzles 0.8 ( pos 7)
1 shield cup ( pos 8)
1 distance guide ( pos 9)
192-310314
10
Wheeled cutting guide with circle cutting attachment
(Optional accessory)
192-310326
11
Consumable tool PTA 25
192-310322

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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
continuous use, or after 200 starts.
Always replace the electrode if the centre 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.
The machine delivers no power.
The green working indicator is
on. The thermal protection
indicator is continuously on.
The thermal protection of the
welding unit is on.
Wait until the end of the cooling
phase.
The machine delivers no power.
The green working indicator is
on.
The yellow thermal protection
indicator blinks 2 times then
lights off.
The input voltage is outside the
limits. 85-265V.
Check electrical connection,
switch off and on machine to
reset.
The machine delivers no power.
The green working indicator is
on.
The yellow thermal protection
indicator blinks quickly.
Torch consumables not in
place. Torch defect.
Check your torch and
consumables. Switch off and on
machine to reset.
Air pressure to low.
Check your inlet pressure.
Switch off and on machine to
reset.
No pilot arc when pressing the
trigger, the air flows.
Consumables damaged.
Change the consumables.
The arc goes out after approx. 5
seconds.
Ground clamp problem.
Check the electrical connection
on the ground clamp.
After switching OFF the
machine the fan and
compressed air continues.
Torch cooling phase.
Normal behavior. Wait for the
end of the torch cooling phase.
Torch malfunction.
If the pilot arc does not strike:
-Change nozzle, electrode and swirl ring.
-Check, and if necessary, adjust inlet air pressure on the rear of the machine to 3.5
bar.
If the pilot arc is not stable:
-Too high gas flow. Adjust inlet pressure to 3.5 bar.
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 60974-7 Arc welding equipment – Torches.
• EN 60974-10 Arc welding equipment – Electromagnetic compatibility (EMC) requirements.
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 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 60974-10 “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
8.1 Torch Check.
Check that the consumables are in working order and correctly mounted in the torch.
Check the parts in place pins on the torch head, check that the pins springs are OK by pushing them
inwards they should feather easily. If not replace the pins. Check the condition of the brass ring on the
shield cup, if dirty or worn clean or replace the shield cup.
Check the electrode seat on the torch head by pushing the electrode inwards, if the seat sticks or
doesn’t move easily replace the torch head.

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Disconnect the power source from mains power supply.
Remove the handle and cover plate from the power source
8.2 Torch connection test.
1. Torch trigger.
2. Parts in place connection (PIP).
3. Negative lead (Electrode).
4. Pilot lead (Nozzle).
5. Air connection.
Check torch trigger by measuring on the torch trigger connections with summer or resistance
measurement and press the start trigger on the torch. If no connection repair or replace torch.
Check parts in place protection by measuring on the torch (PIP) connections with summer or
resistance measurement. Make sure that the consumables are correctly mounted. If no connection
repair or replace torch.
1
2
3
4
5

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Cont. 8.2 Torch connection test.
Check the pilot lead (nozzle) by measuring between the pilot lead connection and the nozzle with
summer or resistance measurement. Make sure the consumables are correctly mounted. If no
connection repair or replace the torch.
Check the negative (electrode) lead by measuring between the negative lead connection and the
electrode with summer or resistance measurement. If no connection repair or replace the torch.
8.3 Torch function test.
1. Connect the power source to mains power supply.
2. Connect air and adjust to 3.5-4 Bar.
3. Switch on the machine with the potentiometer and set to approx. 15A.
4. Connect the return lead.
Push the trigger with the torch in the air. You should get an arc that lasts about 5sec.
Put one side of the nozzle in contact with the return clamp and press the torch trigger. You should get
a continuous arc that lasts more than 5sec.

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8.4 Replacing the torch.
Disconnect the power source from mains power supply.
Disconnect procedure
Remove the straps.
Disconnect the air hose by pushing down on the push in coupling and pulling the hose out.
Disconnect the trigger leads, PIP leads, pilot lead and negative lead.
Please note that the negative lead is run through the blue LEM module on the PCB.
Loosen the cable gland and pull out the torch cables one at a time.
Connect procedure.
Pull the torch leads through the cable gland one at a time starting with the Trigger/PIP leads.

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Cont. 8.4 replacing the torch.
Run the negative lead through the blue LEM module on the PCB and connect to the connector.
Connect the pilot lead and trigger/PIP leads.
Connect the air hose, shorten it if necessary.
Put some straps on the cables to keep them in place and tighten the cable gland.
Perform the torch function test as described in 8.3

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8.5 PCB Schematics.

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8.6 Board diagnostic.
Disconnect the power source from mains power supply.
Discharge the capacitors by connection a resistor 1kΩ 7W between the screws shown on the
picture, or wait at least 5min before proceeding.
Insulation check.
Measure the resistance between the screws marked in red and earth (PE) the resistance should have
a high value in the mega ohm range, if a value is low or short is measured replace the board.

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Cont. 8.6 Board diagnostic.
Check the start resistor.
Measure the start resistor it should have a value of 47ohms. If the resistor is broken you can try to
replace it. Be careful the resistor might be damaged as a consequence, there might be damages on
the board or power module.
Diode bridge control.
Check the diode bridge by measuring each diode as described below with a diode test.
Correct value is approx. 0.530V