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INSTRUCTION MANUAL FOR CEBORA CP-161 PLASMA TORCHES
Before using this welding torch, read carefully this man-
ual.
This welding torch is made in accordance with IEC
60974-7 standard safety requirements. According to
the above standard
declares that this welding torch must be used solely
with CEBORA power sources. Spare parts and con-
sumables are integral part to this
therefore CEBORA considers the use of parts that are
not CEBORA genuine parts as a tampering action
and consequently, in accordance with the spirit of
this same standard CEBORA assumes no responsi-
bility including those provided for in the guarantee
contract.
Any use which is not described has to be considered as
NOT ALLOWED.
Starting up, operation and maintenance must be carried
out by skilled personnel.
Accident
prevention regulations in force should be
respected.
1 - GENERAL
This welding torch, designed for plasma arc cutting of
electro-conducting materials (metals and alloys) uses air
as plasma gas and cooling agent.
The "PLASMA ARC" cutting is the result of the high tem-
perature generated by a concentrated electric arc and
therefore highly hazardous situations may occur. It is
essential to pay especially close attention to the chapter
on SAFETY PRECAUTIONS in the manual of the power
source to which the welding torch is connected.
These welding torches should not be used under rain or
snow or equivalent condition.
This manual must be stored carefully in a place familiar to
the operator using the welding torch. It must be consult-
ed whenever doubts arise and be kept for the entire
welding torch life-span; it will also be used for ordering
replacement parts.
2 TECHNICAL SPECIFICATIONS
Maximum cutting current I2 = 160A D.C.
Duty cycle X = 60% with I2= 160A.
Duty cycle X = 100% with I2= 120A.
Working voltage U2. = 140V (nozzle-piece distance:
4mm).
Working voltage U2 = 100V (nozzle contacts the piece).
Working pressure with a 6m = 5.0 bar (0.5 MPa) cable.
Working pressure with a 12m = 5.4 bar (0.54 MPa) cable.
Total air capacity = 210 litres/minute.
3 ACCESSORIES AND CONSUMABLES (fig .1)
4 SAFETY
This welding torch is equipped with an electric safety
devise located on the welding torch body to avoid any
dangerous voltage when the nozzle, the electrode, the
swirl ring or the nozzle holder are replaced. It is in accor-
dance with IEC 60974-7 Standard which requires that
when a live nozzle is vertically located on a flat surface
it should not be touched with the conventional test finger
requirements
CEBORA SPA
welding torch,
whose characteristics are specified in the standard.
5 WELDING TORCH MAINTENANCE
Always shut off the unit before any maintenance
operation
5.1 REPLACING THE CONSUMABLES
Making reference to Fig. 2 , parts subject to wear are as
follows: electrode C, swirl ring B, nozzle E and nozzle
protection F. These should be replaced after unscrewing
the nozzle holder D. Electrode C must be replaced when
it shows an approx 1.5 mm deep crater at the centre.
WARNING: When unscrew-
ing the electrode do not
force it but apply a progres-
sive strength until the thread
is disengaged. The new
electrode must be screwed
in its seat and locked with-
out tightening all the way
down.
Nozzle E is to be replaced
when its central hole is
damaged or enlarged as
compared to a new one.
Delayed replacements of
electrode and nozzle cause
overheating , which can
reduce swirl ring
B life.
After these replacements,
check that the nozzle holder
D is accurately tightened.
WARNING: screw the nozzle holder D onto the welding
torch body only when electrode C, swirl ring B and noz-
zle E are assembled. If these elements are not assem-
bled the equipment operation is jeopardized as well as
the operator's safety.
5.2 REPLACEMENT OF THE WELDING TORCH
The units with S mark, designed to operate in highly haz-
ardous ambient are equipped with a protection device
which requires the use of a tool to assemble and disas-
semble the welding torch.
Unscrew the screws that fasten the protection device to
the unit, unscrew the ring nut of the central adapter,
remove the protection device.
Replace the welding torch and follow the previous
instructions in reverse direction.
Connect the yellow/green cable to terminal (
power source (CP 161 DAR only).
Note 1:
• Do not dent the contact tip, do not bend the welding
torch fitting pins.
Note 2:
• With welding torch CP 161 DAR, used on units with no
interface circuit, operation start is obtained with cable
wires AB. In this case when cutting operation is com-
pleted, the start contact must be positioned in open
position (OFF).
C
B
E
D
F
fig. 2
) on the
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