SPT SPARCIN 9, SPARCIN 9C Instructions For Use Manual

INSTRUCTIONS FOR USE

SPARCIN 9

SPARCIN 9C

TO THE OPERATOR: PLEASE READ AND UNDERSTAND THIS MANUAL

BEFORE USING THE SPARCIN 9/9C. IT IS ABSOLUTELY VITAL TO KNOW THE
INFORMATION PRESENTED IN THIS MANUAL IN ORDER TO USE THE
SPARCIN 9/9C IN THE BEST WAY.
WITH THIS KNOWLEDGE AND A PROFESSIONAL APPROACH, YOU WILL BE
ABLE TO SOLVE MANY COMPLICATED CUTTING APPLICATIONS WITH THE
SPARCIN 9/9C.

Rev. 3.2. 2017-07-19

STATE OF THE ARC PLASMA CUTTING TECHNOLOGY

SPT Plasmateknik AB

Visiting address:

Telephone

046-18 48 00

Box 4137

Höstbruksvägen 14

Telefax

046-18 48 09

SE-227 22 LUND

SE-226 60 LUND

Email

[e-mail]

Sweden

Sweden

Internet

www.spt.se

SPARCIN 9 / SPARCIN 9C

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CONTENTS

Page

1. TECHNICAL DATA 3

2. INSTALLATION 4

3. OPERATING INSTRUCTIONS 5

4. GENERAL INFORMATION ON PLASMA CUTTING 7

5. ACCESSORIES FOR MANUAL CUTTING 11

6. CHANGING CONSUMABLES 12

7. MAINTENANCE 13

8. TROUBLE SHOOTING 14

9. PERSONAL PROTECTION 15

10. WARRANTY 16

11. SPARE PARTS LIST 18

12. TORCH/TORCH PARTS LISTS 19

13. WIRING DIAGRAM - POWER SOURCE 31

SPARCIN 9 / SPARCIN 9C

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1. TECHNICAL DATA

Power supply: 3~50Hz, 400V (standard)

3~50Hz, 415V on request

Main fuse: 16A slow blow

Process power: 120V, 20-80A

Duty cycle: 60%

Maximum power: 12 kVA

Power factor: 0,95

Open circuit voltage: 200V

Gas pre-flow: 1 sec

Gas post-flow: 5 sec

Dimensions: SPARCIN 9 SPARCIN 9C

Length 550mm 550mm
Width 300mm 300mm
Height 310mm 460mm

Weight: 22kg 28kg

SPARCIN 9 / SPARCIN 9C

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2. INSTALLATION

SPARCIN 9 is ready for use after connection to electric power and compressed air or some
technical gas for plasma cutting.

SPARCIN 9C (with built-in compressor) is ready for use after connection to electric power.

Power supply:

3~50Hz, 400V
Fuse: 16A slow blow

Important!

If the machine is to be connected to a power generator it is absolutely vital that the machine be
fitted with generator filter. If the machine is not fitted with generator filter, serious damage to
the machine and costly repair can be the result. Such damage is NOT covered by the warranty.
The generator must supply minimum 15 kVA exclusively for the SPARCIN 9/9C.

Gas supply ( SPARCIN 9 only )

Air plasma cutting:

Connect the compressed air to the filter regulator and adjust to 3,5-4 bar.

Gas plasma cutting;

Connect the constant flow regulator of the gas cylinder to the filter regulator and
adjust to 3,5-4 bar.

The gas flow should be approx. 18 l/min.

IMPORTANT! The quantity of plasma generating air/gas flowing is decided by a gas

injector situated in the connection between the gas hose and the torch body, and this is
unique for SPARCIN 9. PLEASE NOTE, the torch for SPARCIN 9C has a unique gas
injector.
The use of incorrect hose assembly may result in damage to the torch body as well as the
power source.

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3. OPERATI NG INSTRUCTIONS

Check that the machine has been properly connected to the power supply and gas, see
chapter 2, installation.

NOTE! The machine may only be used with 400V power supply!

Connect the earth-lead to the front of the machine. Connect the earth clamp directly to the
work piece. If necessary, clean the surface from paint, rust, dirt, etc.

Cutting

Place the POWER switch in position ON.

The power lamp READY will light.
The pump, fan (and built-in compressor) will start.

Choose process power (cutting current 20-80A)

Place the torch in position for contact cutting or distance cutting and press the START button
on the torch handle.

Contact cutting

Slide the nozzle against the work piece.
As an accessory, there are special contact cutting nozzles, part no. 199 108, made for
profile cutting.
Contact cutting is suitable for cutting up to 4 mm plate thickness.

Distance cutting

Keep a distance of a few millimetres between the nozzle and the work piece.
The accessories for distance cutting are the distance cutting guide, part no.
199107/199124, the distance roller, part no. 299028/299030 and the circle cutting
bar, part no. 299079/299082.

After activating cutting start the air/gas will flow for a short while before the plasma arc (pilot
arc) strikes. If the cutting process does not start, the pilot arc will go out. Then make another
try.

To stop the cutting process, release the START button on the torch handle. The plasma arc
will go out instantaneously. Gas/air will flow for a few more seconds.

PLEASE NOTE! When the machine is not in use or is only used at long intervals, please
switch off the machine. It contains mechanical components like fan, pump, (and built-in
compressor), which should not be exposed to unnecessary wear.

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SPARCIN 9 / SPARCIN 9C

Air plasma cutting

Use the electrode for air as plasma generating gas.

Gas plasma cutting

Use the electrode for technical gas; nitrogen (N2), argon/hydrogen mix (Ar/H2) or
nitrogen/hydrogen mix (N2/H2)

Use the nozzle marked 0,9, part no. 199060 for cutting plate thickness up to 6 mm, for thicker
plates, use the nozzle marked 1,1, part no. 199001.

PLEASE NOTE! The plasma cutting torch is a component designed for high power

outputs. Please handle the torch body and hose assembly with care.
With the proper handling, by an operator with the proper knowledge, the lifetime of the
cutting torch will be very long, and the low wear on nozzles and electrodes will give good
cutting economy. A damaged hose assembly, e.g. with air or water leakage, will infallibly
damage the torch body.
NEVER USE A DAMAGED PLASMA CUTTING TORCH!

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SPARCIN 9 / SPARCIN 9C

4. GENERAL INFORMATION ON PLASMA CUTTING

With exception of the systems that have built-in compressors (SPARCIN 9C), all SPT
Plasmateknik AB manufactured plasma cutting systems with water cooled torch have full
multi-gas capability.
When using technical gases, a pressure regulator as opposed to a flow regulator must be fitted
to the gas cylinder. The use of flow regulators may lead to ignition problems and torch
malfunction.
This chapter also describes in general how to optimise cutting quality and consumable
lifetime.

When to use technical gas

Mild steel

Mild steel is cut with good quality using a ir a s plasma generating gas. In some applications
however, when better cut quality is desired, pure oxygen can be used as plasma generating
gas.
When cutting with oxygen the consumable lifetime is shorter than with air.

Stainless steel

Most types of stainless steel are cut with good result with air as plasma generating gas. The
weldability of the kerf however may be improved by using a technical gas.
Using pure nitrogen as plasma generating gas you can reduce the amount of chrome-oxide in
the kerf. When cutting with nitrogen, the gas electrode as well as the air electrode may be
used.
To further improve the kerf quality, a mixture of 10% hydrogen in nitrogen (NH10) may be
used. Since this mixture contains hydrogen a tendency to develop dross may occur. This can
be minimised if not eliminated by very precisely adjusting cutting parameters as speed,
distance, gas flow, nozzle size, process power etc. When cutting with NH10 the gas electrode
as well as the air electrode may be used.

Aluminium

There are a great number of different aluminium alloys available. Most of them are cut
without dross and with high speed using air as plasma generating gas. The aluminium-oxide in
the kerf may reduce the weldability of the cut.
To reduce the aluminium-oxide a gas mixture of 10% hydrogen in nitrogen (NH10) may be
used. When cutting with NH10 the gas electrode as well as the air electrode may be used. To
further reduce the aluminium oxide a mixture of 35% hydrogen in argon (AH35) may be used.
When cutting with AH35 the gas electrode must be used.
Note that when cutting with AH35 it may be necessary to use a nozzle with a bigger orifice to
prevent double arcing.

SPARCIN 9 / SPARCIN 9C

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Copper/brass

Copper and brass can depending on alloy be cut with air, nitrogen or a mixture of 10%
hydrogen in nitrogen (NH10). When cutting with air, air electrode must be used. When cutting
with nitrogen or NH10 air electrode as well as gas electrode may be used.

Titanium

Titanium is best cut with a mix of 70% helium in argon. When using this mixture, gas
electrode must be used. Some titanium alloys are better cut with air or oxygen.

Piercing

Piercing is not recommended above 15 mm material thickness at >80A and 12 mm at <80A.
When firing the pilot arc the nozzle must be protected from molten metal spattering back by
keeping an adequate distance to the work piece. The piercing standoff distance must be at
least double the cutting distance.
The piercing capacity is highly material dependant.

How to improve cutting quality

To reach the best possible results the first step is to assure that the plasma cutting system is
properly installed an adjusted.
The cut quality is primarily determined from angle deviation, dross formation and the surface
of the kerf.

Angle deviation

The angle deviation is either positive or negative. A positive angle deviation (V-shaped)
occurs as a result of more material being removed in the upper part than the lower part of the
cut. A negative angle deviation occurs as a result of the reversed conditions.
Problems with angle deviation consists either of the cut having too much angle deviation or
inconsistent angle deviation, i.e. positive on one side, negative on the other.

Too much angle deviation

• Incorrect distance between nozzle and work piece. Adjust the distance.
Too much distance > positive angle deviation
To little distance > negative angle deviation

• Worn or damaged consumables. Check the parts and change if necessary.

• Wrong cutting direction. The left side of the cut seen from the cutting direction of the

torch has less angle deviation than the opposite side. Check the direction and change if
necessary.

SPARCIN 9 / SPARCIN 9C

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• Too high cutting speed. By slowing the cutting speed the angle deviation can be
minimised.

Inconsistent angle deviation

• Worn or damaged consumables. Check the consumables and change if necessary.

• The torch is not fitted straight in relation to the work piece. Check the torch position

and adjust if necessary.

• Magnetic remanence in the work piece. Parts that are handled with electro-magnetic
lift tools may become magnetic. Make sure that the material is handled without using
magnetic lift tools.

Dross formation

Dross free cutting requires that all parameters for each job are optimised.

Dross formation as a result of too low cutting speed

• This type of dross formation occurs when the cutting speed is too low. The dross is
extensive and porous. It is easy to remove. Reduce the dross formation by increasing
cutting speed.

Dross formation as a result of too high cutting speed

• This type of dross formation occurs when the cutting speed is too high. The dross
looks like drops of molten metal and is hard to remove.
By lowering the cutting speed the dross formation can be reduced. If reducing the
speed does not solve the problem it may help to lower the distance between nozzle and
work piece.

Sporadic dross formation

• Worn or damaged consumables. Check and change if necessary.

• This type of dross formation may be material dependant. Some materials cause more

dross than others.

• Work piece temperature. When cutting the first parts from a work piece the dross
formation can be lass than when the material has become heated.

The surface of the kerf

The kerf may be convex or concave. An accurate adjustment of the cutting speed and distance
can help in obtaining a straight cut.

Concave kerf

• Too little distance between nozzle and work piece. Increase the distance in order to
straighten the kerf.

SPARCIN 9 / SPARCIN 9C

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Convex kerf

• Too much distance between nozzle and work piece, or too high cutting current. By
first lowering the torch and then if necessary lowering the current the kerf can be
straightened.
Some combinations of plasma generating gas and material can more than others cause
convex kerfs.

Optimising consumable lifetime

The consumable parts of the water cooled torch guarantee the best possible consumable
lifetime and optimum cutting economy. To optimise the consumable lifetime the following
instructions must be followed.

Optimising electrode lifetime

• When piercing the torch must not be too close to the work piece

• Program the sequence so that the plasma arc goes out before the torch goes over the

edge of the work piece. If the pilot arc re-ignites the electrode lifetime is reduced.

• The electrode lifetime can be increased by programming the sequence so that several
parts are cut in one sequence, thereby reducing the number of starts.

• When changing plasma generating gas the gas system must be flushed.

Optimising nozzle lifetime

• When piercing, the torch must not be too close to the work piece. The piercing
distance should be at least double the cutting distance.

• The distance between nozzle and work piece must be kept constant so that the nozzle
does not touch the work piece.