Unitor UPC-310 TP User manual

Revision date: 15-08-10 Page 1 of 28

Instruction manual

UPC-310 TP

Air Plasma Cutter

Revision date: 15-08-10 Page 2 of 28

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:

Machine supply complete with 3.5m primary cable 3Gx2.5mm

Torch with 4m cable package

Return clamp with 3.5m cable and Dix cable connector

Starter kit with initial supply of torch spares and consumables

Air regulator with filter and water separator mounted on the machine

User instruction manual

Remarks:

Air hose is not supplied as this will depend on the connections available on board.

Revision date: 15-08-10 Page 3 of 28

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

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

Revision date: 15-08-10 Page 4 of 28

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.

Revision date: 15-08-10 Page 5 of 28

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.

Revision date: 15-08-10 Page 6 of 28

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.

Revision date: 15-08-10 Page 7 of 28

4 TORCH PARTS

Revision date: 15-08-10 Page 8 of 28

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

Hose assembly for PTA 25 torch 4m, excl. torch head

and handle.

On request

Trigger button for UPC-310 TP w. PTA 25

On request

Handle for UPC-310 TP w. PTA 25

On request

Torch head for UPC-310 TP w. PTA 25

On request

Electrode for UPC-310 TP w. PTA 25 10 pcs

192-310312

Swirl ring for UPC-310 TP w. PTA 25 2 pcs

192-310316

Nozzle 0.8mm for UPC-310 TP w. PTA 25 10 pcs

192-310314

Shield cup for UPC-310 TP w. PTA 25 2 pcs

192-310318

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

Wheeled cutting guide with circle cutting attachment

(Optional accessory)

192-310326

Consumable tool PTA 25

192-310322

Revision date: 15-08-10 Page 9 of 28

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.

Revision date: 15-08-10 Page 10 of 28

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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