Most MasterCut 120 CNC Manuale utente
Operaon Manual
MasterCut 120 CNC
Operaon Manual
rev. 1.1 of 19.11.2018
MasterCut 120 CNC MOST
Before starting work every person using or responsible for maintenance work on
this device should familiarize with the entire content of these operating manual.
is will optimize the use of device potential.
Attention! Prior commencing work, familiarize yourself with the user manual.
Operaon Manual
rev. 1.0 of 19.11.2018
-2-
MasterCut 120 CNC MOST
Plasma Cuer
Table of contents:
1. Introducon 3
2. Health and Safety Manual 3
3. Installaon and use 7
4. Technical data and accessories 8
5. Requirements for compressed air supply 9
6. The main parts of the device 10
7. Torches 11
8. Starng work 17
9. Cung (ps) 17
10. Problems occurring during work resulng in poor cung quality 19
11. Electrical scheme 20
12. Spare parts 21
CE Declaraon Of Conformity 23
Operaon Manual
rev. 1.0 of 19.11.2018
-3-
MasterCut 120 CNC MOST
Plasma Cuer
1. Introducon
Thank you for buying the Inverter Plasma Cuer MasterCut 120 CNC MOST. Prior commencing work please
familiarize yourself with the user manual. MasterCut 120 CNC is designed for quality plasma jet cung of
metal sheets of up to 20 mm thick (for black steel). We do believe that this product will meet your require-
ments. This manual may be supplemented with a training conducted by our qualied personnel. If you are
interested, please contact the nearest branch of the RYWAL-RHC Group.
Recykling
In accordance with Direcve 2012/19 / EU WEEE 11 (WEEE - Waste Electrical and Elec-
tronic Equipment), aer decommissioning, the device must be recycled by a specialized
company.
Do not dispose of worn-out equipment with domesc waste!
2. Health and Safety Manual
Use and maintenance of plasma cuer may be dangerous. To avoid accidents user must
observe health and safety regulaons. Cung machines may be used only by qualied
personnel. Keep up to date with the naonal regulaons regarding the device operaon
and accident prevenon.
Remove all combusble materials from the cung zone before starng work. Do not cut
in tanks where ammable liquids (fuel) were stored previously. Place all combusble ma-
terials away from cung spaer. Cung may be carried out in properly venlated rooms
equipped with permanent or mobile ltering devices.
Electricity. Correct operaon of the device is possible only aer a correct installaon.
Disconnect the device before longer breaks in its usage. Do not leave the equipment unat-
tended. Always make sure that the installaon is grounded.
Operaon Manual
rev. 1.0 of 19.11.2018
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MasterCut 120 CNC MOST
Plasma Cuer
Operator’s skin is exposed to a risk of contact with plasma arc radiaon and aggressive
substances. Wear suitable protecve clothing. Pay aenon to the protecon of bystan-
ders against UV radiaon emied by the plasma arc. During the cung process, harmful
gases and fumes are generated. Use respiratory protecon. Noise generated during cut-
ng may damage your hearing. Use personal hearing protecon.
Persons with a pacemaker are not allowed to work with this device.
Danger of burns. Never touch the materials while cung or shortly aer nishing witho-
ut protecve (welding) gloves. Avoid skin contact with parcles oang in the air. Do not
direct the plasma torch against other persons.
Keep a re exnguisher close to the cung locaon. Aer nishing cung check work
staon against re hazard.
Do not cut without proper eye protecon. Pay aenon for providing safety for bystan-
ders against welding radiaon. Applied eye protecon should have minimum 10 DIN safe-
ty glasses. Do not direct the plasma torch against faces of other persons.
Electromagnec interference
The device may inuence other devices sensive to electro-magnec interference (ro-
bots, computers, etc.) Always ensure that the devices within the cung work staon are
resistant to interference. For the purpose of liming interference, it is recommended to
use cables as possible and arranged in parallel. Always work in a distance at least 100 m
from other sensive devices. Always make sure that the installaon is grounded. In case
of interference issues with other devices, properly shield the cables oruse appropriate
lters.
Operaon Manual
rev. 1.0 of 19.11.2018
-5-
MasterCut 120 CNC MOST
Plasma Cuer
ATTENTION!
The following user manual should be read prior installing and starng the device. Manual
OSH manual should be known to every operator and employee responsible for equipment maintenance.
Aenon!
Commissioning and normal operaon are possible only aer reading the carefully reading following manual.
Cung with plasma arc requires fullment of condions resulng from re regulaons. The operator of se-
mi-automac cuer should be supplied with protecve clothing and equipment in accordance with current
regulaons. It is necessary to use a set of personal protecve equipment (PPE) in accordance with according
to provisions of the Council Direcve 89/686/EEC. Personal protecve equipment (PPE) includes: welding
mask, welding glasses, welding gloves, welding apron, leather shoes, hearing protectors. Despite the high
technical standard of the device, the personnel should represent considerable discipline in approach to
health and safety requirements to protect against harmful and health hazardous factors developed from
cung technology.
OPERATING CONDITIONS
This device can operate under severe condions. It is however important to apply simple prevenve measu-
res to ensure long and reliable work:
• do not place or use this device on an inclined surface (of more than 15°),
• do not use the device for pipe defrosng,
• the device needs to be located in a place with free clean air circulaon free clean air circulaon (to and
• from the fan without obstacles). When connected to electrical network
• the device must not be covered e.g. with a lt,
• minimize the amount of dirt and dust that can get into the device,
• device has an IP23S protecon rang of housing, keep it dry and not locate
• on wet surfaces or in a puddle.
• do not use the device for cung tanks previously used for ammable substances storing, as there is a
• risk of explosion,
• device is designed to work in industrial condions and is marked as class A according to PN-EN 60974-10
GASES AND FUMES
Plasma cung techniques produce harmful gases and fumes containing ozone and hydrogen as well as oxi-
des or metal parcles. Therefore, the cung work staon should be ed with very good venlaon (dust
and smoke extracon or airy locaon) Metal surfaces intended for cung should be free from chemical
contaminaon, especially degreasers (solvents) that decompose during welding process and produce toxic
gases. Cung of galvanized, cadmium-coated or chromium-plated parts is permied only when a sucon
and ltering device is ed, and with introducon of fresh air to the cung work staon.
RADIATION
Ultraviolet emission radiated when cung is harmful to eyesight and skin. Therefore a welding mask with
protecve lters is required.
Operaon Manual
rev. 1.0 of 19.11.2018
-6-
MasterCut 120 CNC MOST
Plasma Cuer
Cung work staon should meet certain requirements and include:
• adequate lighng system,
• xed or movable protecon screens, governing bystanders (depending on requirements),
• against radiaon eects
• locaon with wall colour providing appropriate for radiaon absorpon.
FIRE PROTECTION
Cung work staon should be located at a safe distance from ammable materials placed especially on the
oor or walls. All ammable materials need re protecon against hot metal drops. It is recommended to t
the work staon with re blankets and re exnguishers eg powder or snow type.
PROTECTION AGAINST ELECTRIC SHOCK
It is unacceptable to connect the device to an improper installaon or to an installaon with unveried zero-
ing eciency. It is prohibited to use of device with shields removed or remove the external shields while the
device is connected to electric network. It is not allowed to work on a suspended device (e.g. using a crane or
a gantry). Only authorized persons should perform maintenance and repair works keeping it in compliance
with the safety condions applicable to renovaon equipment. The device is marked with the [S] sign which
means the possibility of working in an environment with an increased risk of electric shock.
ATTENTION!
Device idling voltage U0 = 380 V, which complies with PN-EN 60974-1 for plasma cuers. Be especially care-
ful when replacing spare parts or the welding torch.
MAINTENANCE
ATTENTION!
In order to carry out any repair or maintenance acvity, it is recommended to contact your nearest technical
support of RYWAL-RHC - a list of authorized service shops is located on the last page of this manual. Any
signs of damage should be reported immediately.
The most important issue is the maintenance of the plasma torch. Regularly remove splashes that sck to
the cover and the nozzle. Worn parts should be replaced immediately with new ones (electrodes, nozzles,
swirl ring - diuser, covers). Regularly check the patency of channels in the swirl ring. If clogged - should be
cleaned (e.g. with compressed air), if it does not bring any improvement, the diuser should be replaced
with a new one. Poor condion of the diuser aects the cung quality and may cause damage to the
device.
In case the torch cables are damaged, it should be replaced immediately with new ones, as there is a risk
of electric shock (high voltage of idling).
Operaon Manual
rev. 1.0 of 19.11.2018
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MasterCut 120 CNC MOST
Plasma Cuer
General maintenance (daily):
• check the condion of cables and connecons, replace if necessary,
• check the condion of high-speed torch parts. If necessary, replace it with new ones. It is recommen-
ded that simultaneous replacement of used nozzles and electrodes is performed.
• check condion of plasma torch, replace if necessary,
• check condion and operaon of the cooling fan; keep the cooling air inlet and outlet openings clean,
• keep the device clean.
Periodic maintenance (every 3 months at least)
Periodic maintenance frequency can be increased depending on the environment condions
of the device locaon:
• using the vacuum cleaner to remove dust from the outside of the housing and from the inside of the
cuer - do not use compressed air cuer for cleaning,
• check and ghten all the screws,
• check the state of all electrical contacts and correct if necessary.
Mandatory device checks
According to the Labour Code provisions: „All responsibility for the safe use of machinery and equipment
shall be borne by the owner.”
This results in the obligaon to perform periodic and post-repair checks and inspecons of equipment. The
scope of these tests is dened by PN-EN 60974- standard.
Periodic tests are carried out at least once a year (legal basis PN-EN ISO 17662 clause
4.2), and post-repair tests aer each repair that restored welding funconality (legal basis: PN-EN 60974-4
clause 4.6).
All above services re performed by the technical support of RYWAL-RHC.
UWAGA!
Sieć zasilająca i sprężone powietrze musi być odłączona od urządzenia przed każdą czynnością konserwacyj-
ną i serwisową. Po każdej naprawie wykonać odpowiednie sprawdzenie w celu zapewnienia bezpieczeństwa
użytkowania.
3. Installaon and use
The user is responsible for connecng the cuer in accordance with the operang instrucons. In the event
of electromagnec interference, the user should recfy the cause. In the event of repeated problems, con-
tact the manufacturer.
Before using the equipment, operator should esmate the possible impact of disturbances on the environ-
ment, in parcular the presence of persons with pacemakers or hearing aids.
Work with a plasma generator is acceptable, but it must meet certain requirements. It is recommended to
use a unit with an asynchronous generator. If the aggregate does not provide adequate power, this results in
lowering the arc parameters or turning o the cuer.
Ground cable
It is recommended to use wires as short as possible, placed close to each other, preferably on the oor level
or as close to it as possible.
Operaon Manual
rev. 1.0 of 19.11.2018
-8-
MasterCut 120 CNC MOST
Plasma Cuer
Locaon of plasma cuer
Observe the following rules:
• ensure easy access to connecons, wires and switches.
• do not place the cuer in small, conned spaces.
• do not place the cuer on surfaces with an inclinaon greater than 15 degrees.
Device installaon:
• connecon or repair of the device may only be carried out by trained personnel,
• connecon of several cuers (in series or in parallel) is forbidden,
• before removing the covers of the device, always disconnect the charger from the power supply,
• periodically carry out the necessary cleaning and maintenance,
• ensure that power and ground are sucient and adequate.
• before cung starts, check the condion of the cables and repair or replace them
• in case of damage.
• make sure to use correct spare parts for your plasma torch,
4. Technical data and accessories
Technical parameters Unit
Electrical power supply [V/Hz] 3x400/50-60
Network security [A] 32 A
Max current I1[A] 34,7
Max eecve current I1e [A] 27,8
Idling gear voltage U0[V] 380
Cung current (DC=100%) 12[A] 100
Cung current (DC=60%li) 12[A] 120
Cung current (DC=60%) 1.10[A] 120
Maximum thickness of qualitave cung for black
steel
[mm] 20
Air work pressure [bar] 5,5
Max air pressure [bar] 8,5
Air consumpon [l/min] 295
Arc ignion pneumac-contact
Current adjustment steeples
Housing protecon class IP23S
Class according to standard EN 60974-1; -10 Class A
Dimensions (H x W x L) [mm] 240x440x675
Weight [kg] 32,4
Table 1: MasterCut 120 CNC MOST. Technical parameters
Operaon Manual
rev. 1.0 of 19.11.2018
-9-
MasterCut 120 CNC MOST
Plasma Cuer
5. Requirements for compressed air supply
• recommended compressed air pressure 5.0 to 8.5 bar.
• approx. air consumpon <300 l/min.
• compressed air must be dry and clean.
• compressed air minimum temperature: 3°C.
• maximum oil content is 0.1 mg/m3.
• maximum parcle size in the air: 15 microns.
• compressor tank minimum size: 100 litres.
• do not use oil-lubricated air. It may damage the plasma torch.
ATTENTION!
It is recommended to use an addional air dryer at the device inlet, e.g. AT-1000. Complaints on quick
parts wears or short circuit in plasma cuer torch, where no addional air dryer was installed will be
considered negavely.
Accessories available:
Figure 1: AT-1000 lter and the way of xing it to the device gas quick coupling.
1AT-1000 air lter with xing 617610 5302
2 Paper insert for AT-100 617610 5303
3 AT-1000 lter adaptor (Inlet-outlet ngs) 617610 5304
Accessories available for ordering in each RYWAL-RHC branch (see page 24)
Table 2: MasterCut 120 CNC MOST. Accessories available.
ATTENTION!
Using of improperly cleaned or moist air will result in shorter service life of parts or may damage the torch.
Operaon Manual
rev. 1.0 of 19.11.2018
-10-
MasterCut 120 CNC MOST
Plasma Cuer
6. The main parts of the device.
Panel przedni i tylni
Figure 2: Main parts
Pos. Descripon
A1 Mass wire socket
A2 Remote control connector (on request)
A3 Plasma torch socket
A4 Cung current knob (A)
A5 Power ON LED - ON
lights up when device is connected to the network
A6 Cung current values display
A7 LED indicates overheang of the device. In this case - leave the device turned ON to
cool down
A8
Error LED:
1. Flashing - no nozzle cover or cover ed incorrectly
2. Lit - low compressed air pressure
A9 Manometer
A10 Acvity LED of the plasma torch Lights up when buon is pressed, the torch is energized
A11
Work mode switch
Seng the compressed air pressure
Cung
A12 Air connecon
A13 Pressure regulator with lter
A14 Power cord mounng
A15 ON/OFF switch
Table 3: MasterCut 120 CNC MOST. Device construcon
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