Unitor UPC 85 ML Instruction Manual

Air Plasma Cutter

Instruction manual

UPC 85 ML

01

Rev. No. Version

Date issued

02

Revision summary

00 6938800000 April 24, 2018

01 6938800000 September 23, 2019

Primary Voltage

Cord size

Len

gth 230 V

1P

6mm

(10 AWG)

Up to

40 m (

131

feet) 400 V 3P

6mm² (

10 AWG)

Up to

200 m (

656 feet) 44

0 V 3P

6mm² (

10 AWG)

Up to

200 m (

656 feet)

03

CONTENTS

1.Safety instructions

2.Technical data

3.Installation

4.Operating instructions

5.Torch parts

6.Maintenance

7.Trouble shooting

8.Cutting/thickness characteristics

9.Wiring diagram

10.Parts list

DELIVERY

UPC-85 ML Air Plasma Cutter 404185 delivery consist of:

1 Machine supply complete with 3,5m primary cable 3+G x 4mm2
2 Torch with 6m cable (connected directly to the machine)
3 Return clamp with 6m cable with Dix25
4 Initial supply consumables kit of 2 x Electrode, 2 x Tip Cutting, 1 x Cartridge, 1 x Shield Cup
5 Air regulator with filter and water separator mounted on the machine
6 User instruction manual

Remarks:
Air hose is not supplied.
Minimum diameter of the air hose should be 9mm – 3/8”.
In case you use an extension cord, be sure that it is of an appropriate wire gauge for the cord length and
system voltage.

2

04

1 SAFETY INSTRUCTIONS

ELECTRIC SHOCK CAN KILL

- Disconnect the power supply before working on the plasma
machine.

- Do not work with deteriorated cable sheaths.

- Do not touch bare electrical parts.

- Ensure that all the panels covering the plasma machine are firmly
secured in place when the machine is connected to the mains
supply.

- Insulate yourself from the work bench and from the floor (ground):
use insulating footwear and gloves.

- Keep gloves, footwear, clothes, the work area and this equipment
clean and dry.

PRESSURISED CONTAINERS CAN EXPLODE IF WELDED.

When working with a plasma machine:

- do not cut pressurised container.

- do not cut in environments containing explosive powders or
vapours.

THE RADIATIONS GENERATED BY THE WELDING ARC CAN
DAMAGE THE EYES AND CAUSE BURNING OF THE SKIN.

- Provide suitable protection for the eyes and body.

- It is indispensable for contact lens wearers to protect
themselves with suitable lenses and masks.

NOISE CAN DAMAGE YOUR HEARING.

- Protect yourself suitably to avoid hearing damage.

FUMES AND GASES CAN DAMAGE YOUR HEALTH.

- Keep your head out of the reach of fumes.

- Provide suitable ventilation of the work area.

- If the ventilation is not sufficient, use an exhaust system that sucks from the bottom.

HEAT, SPLASHES OF MOLTEN METAL AND SPARKS CAN CAUSE FIRES.

- Do not cut near inflammable materials.

- Avoid having any type of fuel with you such as cigarette lighters or matches.

- The cutting sparks can cause burns. Keep the tip of the electrode far from your body and from other
persons.

PREVENTION OF ELECTRIC SHOCKS

Take the following precautions when working with a plasma machine:

- keep yourself and your clothes clean.

- do not be in contact with damp or wet parts when working with the plasma machine.

- maintain suitable insulation against electric shock. If the operator has to work in a damp environment, he
must take extreme care and wear insulating footwear and gloves.

- check the machine power cable frequently: it must be free from damage to the insulation. BARE CABLES
ARE DANGEROUS. Do not use the machine if the power cable is damaged; it must be replaced
immediately.

- if it is necessary to open the machine, first disconnect the power supply. Wait 5 minutes to allow the
capacitors to discharge. Failure to take this precaution may expose the operator to dangerous risks of
electric shock.

- never work with the plasma machine if the protective cover is not in place.

- ensure that the earth connection of the power supply cable is perfectly efficient.
This machine has been designed for use in a professional and industrial environment. For other types of
application contact the manufacturer. If electromagnetic disturbances are found it is the responsibility of
the machine user to solve the problem with the technical assistance of the manufacturer.

It is forbidden for people with PACEMAKERS to use or come near the machine.

PREVENTION OF BURNS

To protect your eyes and skin from burns and ultraviolet rays:

- wear dark glasses. Wear suitable clothing, gloves and footwear.

- use masks with closed sides, having lenses and protective glass according to standards (degree of
protection DIN 10).

- warn people in the vicinity not to look directly at the arc.

PREVENTION OF FIRE

Plasma cutting produces splashes of molten metal.
Take the following precautions to prevent fire:

- ensure that there is a fire extinguisher in the welding area.

- remove all inflammable material from the immediate vicinity of the welding area.

- cool the cut material or let it cool before touching it or putting it in contact with combustible material

- never use the machine for cutting containers of potentially inflammable material. These containers must be
completely cleaned before they are cut.

- ventilate the potentially inflammable area before using the machine.

- do not use the machine in atmospheres containing high concentrations of powders, inflammable gases or
combustible vapours.

LIFTING

WARNING! The UPC-85 ML weights 45kg / 100 lb.

Lifting by hand:

Lift the machine using the two handles provided.

Lifting with hoist and strap

Lift the machine by using ONLY both handles as shown on the picture.
Keep the machine as horizontal as possible

05

INSTRUCTION FOR INSECURE POSITIONING

Failure to properly secure the machine can cause personal injury. If machine is in an insecure position do not
attempt to switch on. Do not put the machine on an unlevelled surface greater than 10°.

2 TECHNICAL DATA

Power supply 230V ±10% 1~50/60 Hz

Mains fuse minimum (Slow
blow)
Maximum power 230V 1F: 7,45 KVA

Process power 88V – 20A

Air supply
NB! Dry and oil free
Duty cycle @ 40° 25% @60A 20% @85A

Power factor 0,99 0,99
Open circuit voltage 280V 280V
Protection class IP 44 IP 44
Environmental conditions Cutting: -10°C + 40°C Cutting: -10°C + 40°C

Transport and storage: -20°C + 55°C Transport and storage: -20°C + 55°C
Cooling Forced Forced
Temperature class H H
Dimensions L x W x H 495x280x720 mm 495x280x720 mm
Weight 45 kg 45 kg
Severance cut 18 mm

Quality cut 16 mm

Recommended cut 12 mm

230V 1P: 25A

104V – 60A

5-5,5 bar
150 l/min

60% @ 45A 60% @ 55A

100% @ 40A 100% @ 50A

400-440V ±15% 3~50/60 Hz

400-440V 3P: 20A

400-440V 3F: 12,10 KVA

88V – 20A

114V – 85A

5-5,5 bar
150 l/min

40 mm

25 mm

20 mm

06

07

3 INSTALLATION

WARNING: This Class A equipment is not intended for use in residential locations where the electrical
power is provided by the public low-voltage supply system. There may be potential difficulties in ensuring
electromagnetic compatibility in those locations, due to conducted as well as radiated disturbances. This
equipment is complying with IEC 61000-3-12 and It can be connected to a public and private low voltage
system. The good operation of the machine is ensured by correct installation; you must therefore proceed as
follows:

- Position the machine in such a way that there is no obstacle to the air circulation ensured by the internal fan
since the internal components require suitable cooling.

- Ensure that the fan does not send deposits or dust into the machine.

- Avoid impacts, rubbing, and – absolutely no exposure to dripping water, excessive heat sources, or any
abnormal situations.

CONNECTION

- Before making the electrical connections between the Inverter and the line switch, ensure that the switch is
turned off.

- The distribution panel must comply with the regulations in force in the country of use.

- The mains system must be of the industrial type.

- When using long extension cables, the core diameter section is increased as required for optimum performance.

- The power input supply socket must have a suitable switch provided with slow burning' type fuse(s).

- In the event of damage to the power cable, replacement or repair must be performed by a qualified person at an
approved service centre.

1-PHASE CONNECTION

This unit can be connected to input power 230 VAC 1
Phase without removing cover to relink the power
source.

The Multi-link in this unit automatically adapts the power
source to the primary voltage being applied.
Check input voltage available at site. This machine can
be connected to any input power between 230 and 500
VAC 3-Phase.

3-PHASE CONNECTION

EARTHING

- To ensure user protection the Inverter must by law be correctly connected to the earth system
(INTERNATIONAL SAFETY REGULATIONS).

- It is necessary to provide good earthing by means of the yellow-green wire in the power cable, in order to
avoid discharges due to accidental contacts with earthed objects.

- The chassis (which is conductive) is electrically connected with the earth wire; if the equipment is not
suitably connected to earth it may cause electric shocks which are dangerous to the user and those nearby.

PNEUMATIC CIRCUIT CONNECTION:

The machine uses compressed air for plasma cutting. Any cylinder of compressed air may therefore be
used, or air from a compressor. The air must be free from polluting particles, such as oil or other
contaminating agents. A pressure regulator is provided to ensure the correct air flow rate on the torch.

KEY:

1– Air filter
2– Reducer (pressure regulator)
3– Pressure gauge
4– Pressure switch
5– Solenoid valves

A pressure between 5 bar and 5.5 bar must be applied to the air filter located on the rear panel of the
machine (150l/min). The pressure must not exceed 6 bar. The pressure regulator 1 is set by the
manufacturer at 4.8 bar. Check the pressure by pressing the Air Test button on the front panel and check
that the pressure gauge gives a reading of 4.8 bar. If necessary to the correct pressure by turning the knob
on the pressure regulator.

A pressure switch (4) in the machine will stop operation if the pressure at output of the reducer (2) is below 3
bar, which is minimum to guarantee operation.

08

4 OPERATING INSTRUCTIONS

Place machine as far away from where cutting takes place as possible. Use all of the 6m torch length. This is
to prevent the fumes produced by cutting from being sucked into machine by the cooling fans through the
front and side ventilation openings.

BEFORE CUTTING

The operator may start up the machine only after having read and understood all parts of this manual.
Depending on the type of cut to be performed he must follow the work phases described below.

WARNING! A preflow of 2 seconds after pressing the torch button to alert the operator of the

imminent start of the pilot arc.

1. Ensure that the work environment and your clothing satisfy the safety requirements described.

2. Position the unit in a place where there is no obstruction to air circulation.

3. Connect the unit to a suitable power socket (an earthed socket is obligatory).

4. Connect the compressed air pipe to the air filter on the rear panel.

5. Ensure that there is no water in the air filter. If necessary, empty the filter.

NOTE! Air filter is a semi-automatic drain. Semi-automatic drain operates when the air line is
depressurised. When the filter is pressurised, the drain can still operate manually by pushing the
tube in the filter, which then protrudes outside the filter bowl.

6. Return clamp must be clamped into the work piece or cutting table. The area must be free from oil, paint

and rust. Connect only to the main part of the work piece; do not connect to the part to be cut off.