ESAB M3 Plasma A6 Standard Lift Assembly m3 CAN Plasma System Instruction manual

®

A6 Standard Lift Assembly m3 CAN Plasma System

Instruction Manual

Form Number 0560946014 REV04

Date: 01 /0 5 / 11

BE SURE THIS INFORMATION REACHES THE OPERATOR.

YOU CAN GET EXTRA COPIES THROUGH YOUR SUPPLIER.

CAUTION

These INSTRUCTIONS are for experienced operators; if you are not fully familiar with the principles of operation and safe practices for arc welding and cutting equipment, we urge you to read booklet “Precautions and Safe Practices for Arc Welding, Cutting, and Gouging” (Form 52-529). Do NOT permit untrained persons to install, operate, or maintain this equipment. Do NOT attempt to install or operate this equipment until you have read and fully understand these instructions. If you do not fully understand these instructions, contact your supplier for further information. Be sure to read Safety Precautions before installing or operating this equipment.

USER RESPONSIBILITY

This equipment will perform in conformity with the description thereof contained in this manual and accompanying labels and/or inserts when installed, operated, maintained and repaired in accordance with the instructions provided. This equipment must be checked periodically. Malfunctioning or poorly maintained equipment should not be used. Parts that are broken, missing, worn, distorted or contaminated should be replaced immediately. Should such repair or replacement become necessary, the manufacturer recommends that a telephone or written request for service advice be made to the Authorized Distributor from whom it was purchased.

This equipment or any of its parts should not be altered without the prior written approval of the manufacturer. The user of this equipment shall have the sole responsibility for any malfunction which results from improper use, faulty maintenance, damage, improper repair or alteration by anyone other than the manufacturer or a service facility designated by the manufacturer.

READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.

PROTECT YOURSELF AND OTHERS!

A6 Plasma Lift Assembly

Safety

Precautions

Users of ESAB welding and plasma cutting equipment have ultimate responsibility for ensuring that anyone who works on or near the equipment observes all relevant safety precautions� Safety precautions must meet requirements that apply to this type of welding or plasma cutting equipment�

All work must be carried out by trained personnel well acquainted with operation of welding or plasma cutting equipment� Incorrect operation of equipment may lead to hazardous situations which can result in injury to the operator and damage to equipment� The following recommendations should be observed in addition to standard regulations that apply to the workplace�

1�

Anyone who uses welding or plasma cutting equipment must be familiar with:

…

Proper operation�

Location of emergency stops� … Designed function� … Relevant safety precautions� … Welding and/or plasma cutting� …

Operators must ensure that:2�

No unauthorized person within the working …

area of equipment when it is started up�

…

No one is unprotected when plasma arc is

struck�

3�

The workplace must be:

Suitable and … Free from drafts� …

Personal safety equipment:4�

Always wear recommended personal safety …

equipment, such as safety glasses, ame proof clothing, and safety gloves�

…

Do not wear loose tting items, such as scarves, bracelets, rings, etc�, which could become trapped or cause burns�

3

A6 Plasma Lift Assembly

General precautions:5�

Make sure return cable is connected securely� … Work performed on high voltage equipment …

may only be carried out by a qualied electrician�

…

Appropriate re extinguishing equipment

must be clearly marked and close at hand�

… must not be

Lubrication and maintenance

carried out on equipment during operation�

Enclosure Class

Maximum

Tilt Allowed

15°

CAUTION

The IP code indicates the enclosure class, i�e� the degree of protection against penetration by solid objects or water� Protection is provided against touch with a nger, penetration of solid objects greater than 12mm and against spraying water up to 60 degrees from vertical� Equipment marked IP23S may be stored, but is not intended to be used outside during precipitation unless sheltered�

If equipment is placed on a surface that slopes more than 15°, toppling over may occur. Personal injury and/or signicant damage to equipment is possible.

WARNING

4

WELDING AND PLASMA CUTTING CAN CAUSE INJURY TO YOURSELF AND OTHERS. TAKE PRECAUTIONS WHEN WELDING OR CUTTING. ASK FOR YOUR EMPLOYER’S SAFETY PRACTICES WHICH SHOULD BE BASED ON MANUFACTURERS’ HAZARD DATA.

A6 Plasma Lift Assembly

General Safety Recommendations

ELECTRIC SHOCK - Can kill�

Ground welding or plasma cutting units in

•

accordance with applicable standards�

•

Do not touch live electrical parts or electrodes with bare skin, wet gloves, or wet clothing�

•

Insulate yourself from earth ground and the workpiece�

•

Ensure your working stance is safe�

FUMES AND GASES - Can be dangerous to health�

•

Keep your head out of the fumes�

Use ventilation, extraction at the arc, or both, to •

take fumes and gases away from your breathing zone and the general area�

CAUTION

ARC RAYS - Can injure eyes and burn skin�

•

Protect your eyes and body, using correct welding/plasma cutting screens and lter lens�

•

Wear protective clothing�

Protect bystanders with suitable screens or •

curtains�

FIRE HAZARD - Sparks (spatter) can cause re� Make sure that there are no ammable materials nearby�

NOISE - Excessive noise can damage hearing�

Protect your ears, using ear protection�

•

Warn bystanders of the risk�•

MALFUNCTION - Call for expert assistance in the event of malfunction�

READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.

PROTECT YOURSELF AND OTHERS!

5

A6 Plasma Lift Assembly

CAUTION

To avoid personal injury and/or equipment damage, lift using method and attachment points shown below.

6

A6 Plasma Lift Assembly

Description

Introduction

The A6 lift assembly provides vertical motion for the PT-36 plasma torch, using a typical motor, screw, and slide conguration� The motor turns an enclosed spindle screw, which in turn raises/lowers the lifting plate along linear rails� Directional commands given from CNC determines direction of lift travel� Fixed limit switches are included to prevent upper and lower over travel�

The lift assembly also contains components necessary to control height over work surfaces; initial, piercing, and cornering heights are encodercontrolled during the plasma cycle through use of SDP les� During part production, stando is automatically controlled by taking voltage measurements between torch nozzle and work surface�

Finally, A6 lifts include Omni Soft Touch® assemblies to protect the system during station crashes� Proximity switches monitor torch position in mounting� If the torch is jarred in any direction, process movement will stop and an error report will be sent to CNC� Illustrations on following pages will detail major lift components and their location� For illustrated part breakdown, see end section of this manual�

7

A6 Plasma Lift Assembly

1 2 3 4 5 6 7 8

9 10 11

Major Components

Lift electrical enclosure and adaptor plate

Electrical soft touch box (option)

INA precision slide assembly

Lift motor

Limit switch assembies (upper/lower)

Torch bundle guide ring

OMNI mounting bracket

Plasma warning label

Electrical soft touch wire (option)

OMNI soft touch® assembly

Plasma splatter shield

8

A6 Plasma Lift Assembly

1 2 3 4 5 6 7 8 9

10

A6 Lift/Cable Block Diagram

Input Power

ACON (CAN)

Motor

Encoder

Switch Interface

Crash Protection

Soft Touch Interconnection

Electrical Soft Touch

Torch Touch Wire

VDR

NOTE - gray dashed line denotes optional electric soft touch components.

9

A6 Plasma Lift Assembly

Technical Specications

Lift Speed:• 450 IPM [11�43m per minute]

•

Approximate Vertical Travel: 8�1” [205�5 mm]

Approximate Weight of Lift Assembly: 36 lbs� •

[16�3 kg]

•

Torch Barrel Size: 85�7 mm

Component Tolerances•

IHS Accuracy: ± 0�5 mm … Encoder Accuracy: ± 0�25 mm … Voltage Accuracy: ± 1 volt …

10

A6 Plasma Lift Assembly

O 0.33

[8.38 mm]

4.25

[107.95 mm]

4.25

[107.95 mm]

x6 HOLES

4.41

[112.01 mm]

8.10 [205.50 mm]

(VERTICAL TORCH TRAVEL)

3.21

[81.64 mm]

26.44

[671.58 mm]

9.98

[253.54 mm]

1.57

[40.00 mm]

2.68

[68.00 mm]

Installation

Mounting

Both the A6 lift and electronics enclosure come complete with adaptor plates that enable mounting to almost any vertical surface. See illustrations below for spacing requirements and hole pattern dimensions.

NOTE - Lift adaptor plate can be positioned over entire length of slide assembly.

A6 Lift Assembly dimensions

11

A6 Plasma Lift Assembly

11.00

[279.4 mm]

12.00

[304.8 mm]

0.34 THRU x4 HOLES

5.87

[149.1 mm]

4.87

[123.7 mm]

NOTICE

Torpedo Level

Ensure lift assembly is mounted plumb; use a torpedo level and adjust mounting bolts as needed.

A6 electrical enclosure w/ adaptor plate

NOTE - electrical enclosure can be mounted in any manner; just ensure cables are not under any strain or twisted.

12

A6 Plasma Lift Assembly

m3 CAN OEM Interface Box

Electrical Interfacing

After lift assembly and electrical enclosure have been mounted, make the following electrical connections:

Lift Input Power1� (4 pin, male_female): connection is from control interface box AHC Power to lift electrical enclosure SB2�

2� (M12, 8 pin, male_male):

ACON cable connection is from control interface box CAN # connector to lift electrical enclosure SB1�

NOTICE

CAN # connection used will vary depending on your system conguration. See System Interconnection manual (PN

0558008527) to determine your system conguration.

Junma Motor cable3� : connection is from lift motor to Yaskawa® amplier connector CNB (inside lift electrical enclosure)�

4� : connection is from

Junma Encoder cable lift encoder to encoder splice cable open connection (inside lift electrical enclosure)�

5� (M12, 5 pin male_

Switch Interface cable female): connection is from lift electrical enclosure SB4 to lift assembly limit switches�

6� (M12, 8 pin male_

Crash Protection cable female): connection is from lift electrical enclosure SB3 to Omni® Soft Touch proximity sensor�

13

Lift Electrical Enclosure

1 2 3 4 5 6 7

A

2

1

A

5

3

4

6

7

OR

connection guide

A6 Plasma Lift Assembly

SB2 - Input Power

SB1 - ACON

Motor Cable clamp

Encoder Cable clamp

SB4 - Switch Interface

SB3 - Crash Protection OR

SB3 - Soft Touch Interconnection

SB5 - VDR cable from RAS box

14

A6 Plasma Lift Assembly

9

7

8

NOTICE

The following connections will need to be made if your plasma station has electrical soft touch option installed:

7� (M12, 8 pin

Soft Touch Interconnection cable female-female): connection is from lift electrical enclosure SB3 to soft touch enclosure ST1�

The Soft Touch Proximity cable (#7) will replace the Crash Protection cable (#6) on plasma stations utilizing electrical soft touch option.

See block diagram on page 9 above for details.

Soft Touch Proximity cable8� (M8 female socket_ free wire end): connection is from X3 (inside soft touch electrical enclosure) to Omni® Soft Touch proximity sensor�

Electrical Soft Touch Enclosure Connection Guide

9� (14-16AWG, in-line terminal_

Torch Touch wire torch clamp): connection is from soft touch board X4 to torch clamping ring� Attach this clamping ring to metal portion of PT-36 torch body�

Soft touch enclosure lid was made transparent to show box detail.

15

A6 Plasma Lift Assembly

CAUTION

DO NOT cut under water if electrical soft touch option is installed on your plasma station!

Station Grounding

Before placing the plasma station into operation, ensure that the following grounding points are established:

CAUTION

•

Lift Electrical Enclosure

Soft Touch Electrical Enclosure•

Grounding points should be fastened to bare, unpainted metal and should measure less than 2Ω (ohms) on a digital multimeter�

Do not use star washers to establish grounding points!

Star washers do not cut painted surfaces adequately enough to establish ground potential; ground surfaces should be against bare metal.

16

A6 Plasma Lift Assembly

Maintenance

CAUTION

Preventative Maintenance Schedule

Time periods suggested below are based on average plasma station usage� If station is employed in a heavy usage cycle, used outdoors, or used on a multi-torch cutting machine, suggested time intervals should be shortened� Regularly scheduled maintenance will signicantly increase the life and performance of your equipment�

Read all instruction manual’s safety and maintenance procedures before beginning any preventative maintenance!

Daily

Wipe dust and fume buildup from lift assembly •

and components�

•

Check for worn or damaged cables on all lift subassemblies�

•

Ensure all mechanical fasteners and electrical connections are correct; no stripping of hardware, connections are tight, exposed wires, etc�

•

Check that both upper and lower limit switches are functioning correctly�

•

Use your CNC’s station travel buttons to ensure lift assembly has proper, smooth movement�

•

Replace worn PT-36 torch consumables�

Test Omni® crash protection function; ensure •

that when plasma torch is jarred in any direction that a crash signal appears at the CNC�

17

A6 Plasma Lift Assembly

Weekly

Check alignment of lift assembly�• Check Omni® proximity sensor position and •

adjust, if required�

•

Check encoder IHS height�

Clean and lubricate INA slide assembly (see •

procedure on page 14)�

Monthly

Check alignment, clean and lubricate Omni® •

crash assembly (see procedure on page 19)�

Semi-Annually

Inspect guide strip cover on INA slide assembly; •

if cracks are present or surface begins to curl, replace it and both endplates�

CAUTION

NOTICE

This guide strip is an integral part for ensuring inside of the slide assembly remains free of contaminants.

•

Repeat all previous maintenance procedures�

Consider calling your ESAB Service •

Representative to schedule an semi-annual station inspection�

Many replacement parts subject to wear or used in preventative maintenance schedules are available directly through ESAB Cutting Systems.

See “Consumables and Spare Parts” section in Replacement Parts portion of this manual before ordering.

18

A6 Plasma Lift Assembly

Maintenance Procedures

The following section contains maintenance procedures for the lift assembly and components� This section will provide some basic troubleshooting methods to return your station to correct operation� Only qualied maintenance personnel should utilize these procedures�

19

A6 Plasma Lift Assembly

1

2

3

1

2

3

1 2 3 4 5

2

3

4

5

1

Torch support bracket

Slide strip seal (magnetic surfaces lie underneath)

INA Slide Cleaning and Lubrication

In order for the INA slide assembly to perform at optimum levels, it will need to be inspected, cleaned and lubricated on a weekly basis� The following procedure will detail steps necessary to correctly disassemble, clean and lubricate your slide assembly:

1�

Disconnect motor cable, crash proximity cable and touch wire, if installed�

2�

Remove (4) cap screws attaching height control/crash assembly Support Bracket to INA slide�

3�

Wipe the outside surface of the slide strip seal with a clean dry cloth��

Slide carriage

CAUTION

Wiper with teon

End Plate

Cover Strip

End Plate Rollers

Magnetic Strip (Reference)

Do not attempt to disassemble slide in order to clean ball screw nut. This will not be necessary for cleaning or lubrication.

20

Step 4

A6 Plasma Lift Assembly

Dis-assemble end plate and wiper assembly, 4� both top and bottom (shown)�

Remove the cover strip (both screws) from the mount bar

Step 5

Remove the two screws holding the cover strip

5�

mount bar, top and bottom�

Remove the strip seal from the mount bar on 6� top and bottom� Bottom mount bar is shown at the left�

21

Pull seal strip from station mount slide

A6 Plasma Lift Assembly

7�

Magnetic Strips

9�

Remove end plate from the cover strip by sliding it o the end of the cover strip, top and bottom�

Remove the strip seal by lifting the seal above 8� the station mount slide� The seal will pull out of a slot in the station mount slide as shown�

Wipe magnetic surfaces clean of debris, carefully not allowing any dust or debris to transfer to the ball screw or linear rails�

Move slide carriage to downward travel limit

10�

and wipe ball screw with clean, dry cloth� Repeat process with carriage in upward travel limit�

Repeat process for linear rails, located under

11�

the ball screw�

12�

Apply lithium based NGLI 2 grease to entire ball screw / linear rail surface�

22

A6 Plasma Lift Assembly

Linear rail surface (hidden in this view

Ball Screw

Linear Bearing

Linear Rail

Ball Screw Nut

Ball Screw

Inspect the end plate rollers for wear or 13� damage� Replace if wear is detected�

14�

Inspect the end plate wipers for wear or damage� Damage may occur if lift limit switches are not set properly�

Front

A-6 Lift Top View

CAUTION

Damaged Wiper

Slide cover wipers will likely be damaged if lift limit switches are not set properly.

Dysfunctional cover wipers will shorten component life and add service cost.

Replace if damaged.

Follow the limit switch setting instructions specied in this maintenance section.

23

A6 Plasma Lift Assembly

1 2 3 4 5

1

2

3

4

5

Reassemble INA Slide

Place the cover strip through the end plate as 1� shown in the path at the left�

Wiper with teon

End Plate

Cover Strip

End Plate Rollers

Magnetic Strip (Reference)

Push cover strip through the slot in the slide plate.

Push the cover strip through the slot of the

2�

slide plate�

Reassemble wiper and end plate to the slide 3� plate with the 2 cap screws�

24

4�

Repeat steps 1 and 3 for the other end plate�

Lower slide limit

A6 Plasma Lift Assembly

Re-assemble the cover strip mount bars to the 5� cover strip� DO NOT tighten these screws yet� The cover strip will not be taut resulting in a poor seal� This slack will be eliminated later�

Screw mount bars to the slide, top and bottom� 6� Tighten these screws�

Slide Cover Mount Screws

Upper slide limit

Eliminate cover slack by rst driving the slide 7� until the bottom limit switch is activated�

8�

Tighten the cover mount screws on the bottom mount�

9�

Raise the lift slide to the upper limit�

Tighten the upper cover mount screws�10�

Reassemble torch mount and sensor 11� connections�

25

A6 Plasma Lift Assembly

1

2

3

4

1

2

3

4

NOTICE

INA Slide Flange Bearing Replacement Procedure

Under normal operating conditions, replacement of this bearing should not be necessary; this lift was designed to provide many years of dependable service with proper preventative maintenance performed on a monthly basis� Symptoms of a failing ange bearing include chatter and increased vibration - should it be necessary to change the ange bearing, a procedure is provided below:

Many replacement parts subject to wear or used in preventative maintenance schedules are available directly through ESAB Cutting Systems.

Motor / Encoder

See “Consumables and Spare Parts” section in Replacement Parts portion of this manual before ordering.

Repeat steps #1-3 of cleaning/lubrication

1�

procedure from previous page�

Remove cap screws attaching lift motor

2� (1) to

motor adaptor plate (2)�

Remove cap screws attaching motor adaptor 3� plate (2) to upper actuator mount (3)�

Remove both cap screws from 4� upper actuator

front cover (4)�

Motor adaptor plate

Upper actuator mount

Upper actuator front cover

26

A6 Plasma Lift Assembly

1

2

3

4

5

6

7

1

2

3

4

5

6

7

CAUTION

DO NOT loosen or remove (4) cap screws holding upper actuator mount to slide assembly under any circumstances!

Doing so will cause the slide assembly to be misaligned and nonrepairable.

5� (2) from ball

Remove motor coupling assembly screw shaft�

6�

Motor adaptor plate

Motor coupling

Ball screw locknut

Flange bearing unit

Strip seal cover

Magnetic seals

Upper actuator mount

Remove ball screw locknut by removing two inner setscrews�

Remove four cap screws holding ange 7� bearing unit (4) to upper actuator mount (7)� Pull bearing and ball screw away from actuator�

27

A6 Plasma Lift Assembly

CAUTION

NOTICE

Use a gear puller or similar device to pull 8� bearing o end of ball screw�

Be careful not to "mushroom" end of ball screw when removing bearing.

Push replacement bearing onto ball screw 9� journal�

10�

Apply Loctite® 242 (blue) to four ange bearing cap screws and partially thread into place�

Ensure idler end of ball screw seats itself inside ange bearing unit.

Ball screw alignment xture

Ball screw locknut

Using ange bearing alignment xture (ESAB

11�

PN 0560947817), line up ball screw� Alignment xture will t into grooves present in upper actuator mount (7)�

12�

Finish tightening four ange bearing cap screws:

Torque specication = 11 inlbs [1.24 Nm]�

Apply Loctite® 242 to new locknut 13� (3) and thread it onto ball screw� Tighten locknut so bearing is pushed up against the collar reference surface on ball screw:

Torque specication = 10-12 inlbs [1.13-1.36 Nm].

14�

Reinstall two setscrews into locknut and replace upper actuator front cover�

28

A6 Plasma Lift Assembly

1

2

3

4

1

2

3

4

Reinstall four cap screws into motor adaptor 15� plate (2) and attach to upper actuator mount (3)�

Torque specication = 11 inlbs [1.24 Nm]

16� (1) to adaptor plate (2)

Reinstall motor/encoder using M4 cap screws�

Torque specication = 26 inlbs [2.93 Nm]

17�

Replace strip seal cover�

Reinstall Omni® support bracket and station 18� cables�

Motor / Encoder

Motor adaptor plate

Upper actuator mount

Upper actuator front cover

CAUTION

Ensure strip seal cover is not gathering (or "puckering") at either end. Move carriage assembly back and forth and alternate adjusting the seal’s hardware.

29

A6 Plasma Lift Assembly

7

6

5

4

2

3

8

1

2

3

4

5

6

7

8

Omni Crash Protection

Description

The Soft Touch Omni® unit is a patented crash protection and plate sensing device�

To electrical enclosure

Sensor Cable

Proximity Sensor Body

Torch Handle Clamp (2)

Sensitivity gap

Sensor Contact Stud

Lock Nut

Bellows

30

A6 Plasma Lift Assembly

1

2

3

Function Description

Horizontal movement occurs when the torch runs into the side of the cutting table� The horizontal movement is transferred vertically through a unique patented design using precision bearings� During this vertical movement, the gap (1) between sensor (2) and contact stud (3) widens causing a voltage drop� This 15v drop allows the CNC to recognize an operation fault� If the torch experiences a vertical force such as a part ipping or torch driving into plate, this gap will again widen and voltage drop will occur, stopping all movement�

31

A6 Plasma Lift Assembly

Replacing / Adjusting the Omni® Sensor

Procedure:

1�

Disconnect the cable from sensor by unscrewing connector�

Loosen lock nut�2�

Unscrew sensor and remove�3�

32

A6 Plasma Lift Assembly

1

NOTICE

Omni® Sensor Installation

See your machine schematic set for cable wiring instructions for this equipment.

Thread provided jam nut on new sensor�1�

Thread sensor into brass insert hole until sensor 2� touches contact stud (1)�

NOTICE

Sensor may bottom out on threads before sensor touches contact stud. Lift torch assembly and try to turn the sensor down more to conrm sensor is touching. Adjust stud up if sensor threads are bottoming out and repeat procedure.

Make a reference mark on brass threaded insert 3� in line with a mark on jam nut�

4�

From the position of contact between stud and sensor, rotate sensor barrel out one full turn� One full turn results in a gap of 1mm�

33

lesser

Sensitivity

GREATER Sensitivity

Possibility of equipment

damage when crashed

Possibility of production interuption

due to incidental crash detection

Least sensitive - no gap

Most sensitive -

1.5 mm gap

No Protection Gap greater than 1.5 mm

Effectiveness of OMNI

Proximity Gap Size

NOTICE

A6 Plasma Lift Assembly

The sensitivity range of the proximity sensor is 1.5 mm.

By turning sensor back out one full turn from maximum downward position, crash sensitivity will be approximately 0.5 mm. Crash sensitivity can be adjusted ± from this point by a ¼ turn. A larger gap will result in a more crash sensitive device.

CAUTION

34

Incidental crash detection may result in having the gap between proximity sensor and contact stud too great.

If gap is larger than working range of sensor, protection will not be available.

Conversely, inadequate torch protection may result if gap is set too small. Using a gap that is as large as operationally convenient is recommended (no incidental crashes).

A6 Plasma Lift Assembly

CAUTION

Sensor cable damage may result from twisting.

Disconnect cable before rotating Omni® proximity sensors.

Tighten jam nut�5�

Reattach cable to sensor�6�

35

A6 Plasma Lift Assembly

Omni® Mechanical Alignment

The Soft Touch Omni® Protection Device requires precise mechanical alignment to function properly� Poor mechanical alignment causes false crashes, hard touches and torch/holder damage� Check mechanical alignment monthly and lubricate at that time�

To check for proper alignment:

Move plasma station to a serviceable location,

1�

preferably not over cutting table�

2�

Turn o all machine power and all plasma auxiliary equipment power�

Electric Shock Kills!

DANGER

Always turn power o on the plasma console before doing maintenance on a plasma torch!

Remove both torch clamps and lift torch from 3� holder�

4�

Grasp torch body and twist from side to side� If there is any visible twisting movement in the torch, the Omni will need adjustment�

5�

Hold torch body while trying to move torch laterally in all directions� If there is any visible lateral play in torch holder, it will require adjustment�

36

The Omni device may also need realignment if a crash signal cannot be cleared or the torch has horizontal play in the torch holder�

A6 Plasma Lift Assembly

3

1

5

4

1

2

1

2

3

4

5

152

3

1

4

Disassembly

Remove (2) screws holding upper torch clamp 1� to torch and remove� Repeat for bottom clamp�

2�

Remove front end of plasma torch consumables; torch body/bundle can now be pulled up through torch holder�

3�

Remove (3) screws fastening Omni to support bracket; these are on the underside of support bracket�

Torch clamps

Bellows clamps

Bellows

Torch

Proximity Cable

Remove (3) screws holding the cover on Omni 4�

Omni Cover - Top

device and lift cover o�

5�

Loosen (2) clamps holding baes and lift boot out of way�

37

A6 Plasma Lift Assembly

1

2

1

Lubrication

While unit is disassembled, inspect and lubricate roller bearings�

1�

Remove one of three bearing retainer plates� Do not lose any roller bearings – they can fall out of raceway when retainer plate is removed�

2�

Clean bearings (if necessary) and lubricate well with silicone grease�

3�

Reassemble bearing retainer plate and move to next set of bearings�

Lubricate roller bearings

Bearing retainer plates

38

A6 Plasma Lift Assembly

1

2

3

4

5

1

2

3

4

5

A

B

Limit Switch Positioning and Adjustment

It is critical that A6 lift assemblies have a minimum of 7.87” [200mm] of vertical travel� In order for this to be achieved, both upper and lower travel limit switches should be positioned in the following manner:

A. : distance between upper

Upper Limit Switch

actuator mount (bottom surface) and upper limit switch adaptor plate (top surface) needs to be 2.75” [69.85mm]�

B. : distance between lower

Lower Limit Switch

actuator mount (top surface) and lower limit switch adaptor plate (bottom surface) needs to be 1.50” [38.1mm]�

To adjust either limit switch positions, loosen both M2 screws; adaptor will slide freely along lift slotted surface�

Lift Upper Actuator mount

Upper Limit Switch Adaptor plate (top surface)

Lift Clamping slot

Lower Limit Switch Adaptor plate (shown w/ switch hidden)

Lift Lower Actuator mount (top surface)

39

A6 Plasma Lift Assembly

Initial Height

Piercing

Height

Cutting

Height

Pilot

Arc

Starts

Arc Voltage

Height Control

Turns On

Travel Starts

Encoder Height

HF

Delay

Pierce

Delay

AHC

Delay

Travel

Delay

Technical Descriptions and

Encoder Height Control

Troubleshooting

Introduction

This method for controlling initial height allows faster cycle times when cutting multiple parts with a single torch by eliminating unnecessary vertical movement� Plate thickness is input (�SDP/�TDF le) and is used to calculate precise slow down positions from total available stroke (distance of torch tip in upper travel position to table slat surface)� These constants dene operation of lift for encoder height control, software slow down functions and plate thickness input�

40

A6 Plasma Lift Assembly

Table Slat

Measured Distance from

Torch Tip to Table Slat

Encoder Station Constant (STA.kon) Reference Chart

Constant Number Channel Number Description

43

44

94 Distance: ULS <--> Table Slat (Low 16 Bit)

95 Distance: ULS <--> Table Slat (High 16 Bit)

98

99

100

101

* *

* * * *

*NOTE = these values will be set at factory.

Encoder Pulses / meter (Low 16 Bit)

Encoder Pulses / meter (High 16 Bit)

Distance: Ref Sensor #1 <--> #2 (Low 16 Bit)

Distance: Ref Sensor #1 <--> #2 (High 16 Bit)

Distance: Ref Sensor #1 <--> Nozzle (Low 16 Bit)

Distance: Ref Sensor #1 <--> Nozzle (High 16 Bit)

Setting Station Constants using distance calculations

Due to varying table heights, plate thickness, and lift mounting, the end user will often times need to recongure station constants� In cases where measurements must be taken and aect constant values, use the following method for computation�

Example: Distance between upper limit switch and table slat (STA�kon 94 & 95)�

Measure distance from torch tip when plasma lift is in upper most travel position to table slat surface� Subtract 1 inch to allow for any possible table out of level condition� 9 inches will be used in an example for this calculation�

9” – 1” (safety clearance) =

1� 8”

2�

Convert inches to micrometers = 8” x 25�4 x 1000 = 203200

3� 319C0

Convert value into hexadecimal =

4� word) values =

Split into two 16 bit (or 0003 & 19C0

5�

Convert these two values back into decimal

0003 = 3 19C0 = 6592

6� 3 & STA�kon 94 = 6592

STA�kon 95 =

41

A6 Plasma Lift Assembly

Standoff

Scrap

Part

Lower

Voltage

Lower

Standoff

=

Higher

Voltage

Higher

Standoff

=

Initial

Height

Piercing

Height

Cutting

Height

Pilot

Arc

Starts

Arc Voltage

Height Control

Turns On

Travel Starts

Encoder Height

HF

Delay

Pierce

Delay

AHC

Delay

Travel Delay

AVHC Introduction and Oset Adjustment

The Arc Voltage Height Control system (AVHC) maintains plasma torch height above work piece during cutting�

The AVHC system maintains torch height (“stando”) by measuring arc voltage, comparing this measured voltage to the reference voltage in the selected �SDP / �TDF le, then adjusting torch up or down to maintain that voltage� A longer arc means higher arc voltage; higher arc voltage results in higher stando; and vise versa�

This reference value is predetermined in the �SDP / �TDF le, based on several other cutting parameters, such as amperage, nozzle orice size, and cutting speed� Operators can also change desired arc voltage in parameter window by adjusting Main Arc Voltage parameter� However, it is good practice to rename this modied �SDP / �TDF le - this way the original le is still available for use�

42

NOTICE

The .SDP / .TDF plasma parameters Ignition Height, Pierce Height, and Cutting Height are distances controlled by Encoder Height Control. AVHC is not utilized until AFTER cutting cycle begins.

A6 Plasma Lift Assembly

Basic A6 Lift Assembly Troubleshooting

With proper preventative maintenance performed on the A6 lift assembly, it will provide many years of precision and reliable service� However, issues may arise over time, even with most proactive PM schedules� Information is provided below to correct some common assembly failure modes that may occur and return it to normal operation:

Plasma station attempts to fire in mid-air:

Remove shield cup from PT-36 torch and check for debris adhering to inside surface; it is likely that torch is receiving a false touch signal (shield cup to nozzle)� Vision 50P CNC will deliver an on-screen warning message in this event�

NOTICE

If carriage position is past either slowdown soft limit, no on-screen warning message will be displayed on Vision CNC.

Overload fault indicator on Yaskawa

servopack™ will not clear:

Seen after the station has been "slammed" into either lower or upper hard limit; rst attempt to reset power to plasma station by disconnecting input power cable and reconnect after 10 seconds� If fault persists, physically remove motor from slide assembly and shaft will release� Re-install motor to slide assembly� After fault indicator has been reset, check condition of carriage endplates and wipers; replace if damage is present (see Replacement Parts section, page 12 for part numbers, if required)�

43

A6 Plasma Lift Assembly

Motor turning with brakes attempting to hold:

This failure is characterized by brakes producing large, audible squeaking sound with plasma station activated� Under normal conditions, when lift is commanded to move, coil will energize and brake will release with an audible click� Test the components by:

1�

Open lift electrical enclosure

Locate ACON Junma MCU unit�2�

Remove wires from MCU connector X157-5 and 3� 6�

4�

Turn station on and measure voltage across these wires� If +24VDC is measured, MCU unit is operating correctly�

5�

To discern if brake has failed, turn station o and measure resistance across brake leads (see schematics in back of this manual)� Replace motor if you read a short (less than 2Ω)�

NOTICE

This failure can also be indicated by a pre-lit Overload fault indicator (AL2) on the Yaskawa Servopack™ unit; this entails that brakes are preventing the motor from moving.

No audible sound should be present.

44

1

2

3

Yaskawa JUNMA Servopack

1

2

3

A6 Plasma Lift Assembly

Yaskawa Junma Servopack™ Alarm Indicators

The Yaskawa Junma Servopack unit is responsible for motor speed, direction, and acceleration as well as encoder count and pulse monitoring� It also communicates directly with the Vision CNC, forming a closed-loop monitoring system� Tables on following pages will describe the servopack’s alarm displays, their cause and meaning, and generalized information for corrective action:

Alarm Indicator 1

Alarm Indicator 2

Alarm Indicator 3

45

Alarm

Display

Alarm Name

Condition

Trigger Cause

Corrective

Action

Speed Error

Power was turned ON. A servopack fault occurred. Replace the servopack.

AL1 = On AL2 = O AL3 = O

Servo was turned ON.

Phases U, V, and W in servomotor are wired to wrong terminals.

Correct wiring.

Encoder wiring is incorrect.

Malfunction occurred due to noise in encoder wiring.

Take measures against noise for encoder wiring.

A servopack fault occurred. Replace the servopack.

Phases U, V, and W in servomotor are wired to wrong terminals.

Correct wiring.

Servomotor operation was started or was switched to high speed operation.

Encoder wiring is incorrect.

Malfunction occurred due to noise in encoder wiring.

Take measures against noise for encoder wiring.

Position pulse reference input has exceeded 10,000 pulses per revolution.

Correct reference value input.

A servopack fault occurred. Replace the servopack.

Table 1 - Speed Errors

A6 Plasma Lift Assembly

46

Alarm

Display

Alarm Name

Condition

Trigger Cause

Corrective

Action

AL1 = O AL2 = On AL3 = O

Overload

Power was turned on. A servopack fault occurred. Replace the servopack.

Servo was turned ON or servomotor did not operate for a reference input from the controller.

Servomotor main circuit cable wiring is incorrect or its contact wiring is faulty.

Check and correct servomotor wiring.

Encoder cable wiring is incorrect or its contact wiring is faulty.

A servopack fault occurred. Replace the servopack.

Normal operation

Drop in power supply voltage.

Ensure power supply voltage is within permissible range.

Servomotor coil burned out.

Measure coil resistance. If open, replace servomotor.

Servomotor was operated with holding brake engaged.

Measure voltage of brake terminals and release brake.

Ambient temperature around servomotor exceeded 131°F

(55 °C ).

Take measures to ensure working area is less than 131°F (55 °C ).

A servopack fault occurred. Replace the servopack.

Table 2 - Overload Errors

A6 Plasma Lift Assembly

47

Alarm

Display

Alarm Name

Condition

Trigger Cause

Corrective

Action

AL1 = On AL2 = On AL3 = O

Encoder

Error

Power was turned on or during servomotor operation.

Encoder wiring and contact wiring are incorrect.

Correct wiring.

Noise intererence occurred because encoder cable distance is too long

Ensure encoder is no more than 20 meters.

Disconnected encoder cable.

Replace encoder cable through ESAB Customer Service.

A zero point error occurred. Replace the servopack.

An encoder fault occurred.

Alarm

Display

Alarm Name

Condition

Trigger Cause

Corrective

Action

AL1 = O AL2 = O AL3 = On

Voltage

Error

Power was turned on or normal operation.

Main power was turned ON again before the power supply to servopack was completely OFF.

Wait until servopack's REF indicator is OFF, and turn on main power again.

AC power supply voltage exceeded permissible range.

Ensure AC power voltage is within specied range.

A servopack fault occurred. Replace the servopack.

Table 3 - Encoder Errors

A6 Plasma Lift Assembly

Table 4 - Voltage Errors

48

A6 Plasma Lift Assembly

Alarm

Display

Alarm Name

Condition

Trigger Cause

Corrective

Action

AL1 = O AL2 = On AL3 = On

Built-in

Fan

Stopped

Power was turned on or during motor operation.

Fan motor stopped. Replace cooling fan in Servopack.

Air intake is blocked. Inspect and clear obstruction.

Alarm

Display

Alarm Name

Condition

Trigger Cause

Corrective

Action

ALL On

System

Error

Power was turned on. A servopack fault occurred.

Replace the servopack and contact ESAB customer support.

Alarm

Display

Alarm Name

Condition

Trigger Cause

Corrective

Action

All ash

on to o

at regular

intervals

Reference

changed

Power was turned on or during servomotor operation.

N/A

Turn on main power again (operation of the servomotorcan continue during display of this alarm).

49

A6 Plasma Lift Assembly

50

A6 Plasma Lift Assembly

REPLACEMENT

PARTS

51

Replacement Parts

Table of Contents

Introduction

General Information �� 3

Ordering Information �� 4

A6 INA Lift Assembly, OEM Kit

0560947165 Rev 01 �� 5

A6 Lift Assembly

0560946827 REV 06 �� 9

INA Slide Assembly

0560943744 Rev 01 �� 11

m3 INA Station Box Assembly

0560945596 REV 06 ��13

Omni Soft Touch Assy

0560941537 Rev 00 ��17

Wire Kit, Soft Touch

0560947295 Rev 02 �� 19

Consumable and Spare Part Reference List

Part Numbers Vary �� 21

Replacement Parts

Introduction

General Information

This section provides replacement parts information and will assist during station maintenance� It is arranged by functional groups or assemblies for easy identication of individual parts and replaceable assemblies� The Replacement Parts List consists of a parts list for the main assembly and one for each major assembly and subassembly� Item numbers that identify parts in the illustration are given in the list where applicable, along with part numbers and descriptive information�

Common hardware items or other parts readily available from commercial sources are not included� Parts purchased from vendors by ESAB are listed by ESAB part numbers� Hardware is specied as items in the parts list but normally doesn’t have an ESAB part number�

The end of this manual section has spare parts and consumable reference sheets� Please use these when ordering wear items and consumables, based on your needs�

Replacement Parts

NOTICE

Replacement Parts

Ordering Information

When ordering replacement parts, order by part number and complete part description as given in the description column� Also, give machine model number and serial number� Address all inquiries to your local ESAB Distributor or to ESAB Cutting Systems, P�O� Box 100545, Florence, South Carolina, 29501�

To avoid unnecessary delays, positively identify your correct assembly before ordering replacement parts.

Replacement Parts

REPLACEMENT

PARTS

NOTE:

1. 0560947295 IS SELECTED FOR ELECTRICAL SOFT TOUCH OPTION (QTY 1) AND INCLUDES SOFT TOUCH BOX / BRACKET AND TOUCH WIRE KIT.

2. ELECTRICAL SOFT TOUCH OPTION CANNOT BE USED WITH UNDERWATER CUTTING.

3. THIS DRAWING HAS THE ELECTRICAL SOFT TOUCH OPTION DISPLAYED.

5

2

6

20

17

7

19

16

9

18

13

12

4

1

810111415

3

A6 INA Lift Assembly, OEM Kit

0560947165 Rev 01

5

REPLACEMENT

PARTS

A6 CABLE INTERCONNECTION

BLOCK DIAGRAM

2

ACON

3

MOTOR

4

ENCODER

5

SWITCH INTERFACE

6

CRASH PROTECTION

7

SOFT TOUCH INTERCONNECTION

8

SOFT TOUCH

1

INPUT POWER

9

TORCH TOUCH WIRE

1

2

A6 LIFT / SLIDE

ASSEMBLY

CRASH

SENSOR

6

INTERFACE

OEM

BOX

CNC

PLASMA

TORCH

3 4 5

1

8

9

7

NOTE - GRAY DASHED LINE DENOTES ELECTRIC SOFT TOUCH OPTION COMPONENTS.

A6 LIFT

ELEC ENCL

SOFT

TOUCH

ENCL

10

VDR

RAS

10

Replacement Parts

6

Replacement Parts

REPLACEMENT

PARTS

LENGTH PART NUMBER

4m (13') 0560947087

5m (16') 0560947088

6m (19') 0560947089

7m (23') 0560947090

8m (26') 0560947091

9m (30') 0560947092

10m (33') 0560947093

15m (49') 0560947094

20m (66') 0560947095

LENGTH PART NUMBER

4m (13') 0558008467

5m (16') 0558008468

6m (19') 0558008469

7m (23') 0558008470

8m (26') 0558008471

9m (30') 0558008472

10m (33') 0558008473

15m (49') 0558008478

20m (66') 0558008479

LENGTH PART NUMBER

3m 0560946843

5m 0560946844

10m 0560946845

15m 0560946846

20m 0560946847

LENGTH PART NUMBER

3m 0560946848

5m 0560946849

10m 0560946850

15m 0560946851

20m 0560946852

LENGTH PART NUMBER

3m 0560947825

5m 0560947826

10m 0560947827

15m 0560947828

20m 0560947829

TABLE 1 - INPUT POWER CABLE

TABLE 2 - ACON CABLE

TABLE 3 - MOTOR CABLE

TABLE 4 - ENCODER CABLE

TABLE 5 - SWITCH INTERFACE CABLE

LENGTH PART NUMBER

3m 0560947812

5m 0560947813

10m 0560947814

15m 0560947815

20m 0560947816

LENGTH PART NUMBER

3m 0560944138

5m 0560944139

10m 0560944140

15m 0560947907

20m 0560944141

TABLE 6 - CRASH PROXIMITY CABLE

TABLE 7 - SOFT TOUCH INTER CABLE

LENGTH PART NUMBER

3m 0560947867

5m 0560947868

10m 0560947869

15m 0560947870

20m 0560947871

LENGTH PART NUMBER

4m (13') 0560947068

5m (16') 0560947077

6m (19') 0560947069

7m (23') 0560947070

8m (26') 0560947071

9m (30') 0560947072

10m (33') 0560947078

15m (49') 0560947073

20m (66') 0560947074

TABLE 8 - SOFT TOUCH PROX CABLE

TABLE 10 - VDR CABLE

7

Replacement Parts

REPLACEMENT

PARTS

ITEM QTY PN DESCRIPTION

1 1 0560945596 ELEC ENCLOSURE, INA LIFT

2 1 0560946827 LIFT ASSY, A6 SA

3 1 0560947283 ADPT PLATE, ELEC ENCL

4 1 0560947284 COVER PLATE, ELEC ENCL

5 REF 0560947295 ELECTRIC SOFT TOUCH OPTION KIT

6 1 2081816 PLASMA WARNING LABEL

7 1 2132645 BRKT, PLASMA DANGER

8 4 ANSI B 18.2.4.1 M - M8 x 1.25 Hex Nut

9 4 ANSI B18.3.4M - M6 x 1 x 16 Button SHCS - Metric

10 4 ANSI B18.3.4M - M8 x 1.25 x 25 Button SHCS - Metric

11 10 DIN 125 - A 8.4 Flat Washer

12 4 DIN 126 - 6.6 Flat Washer

13 4 DIN 128 - A6 Spring Washer

14 4 DIN 128 - A8 Spring Washer

15 4 DIN 7991 - M5x12 Countersunk Screw - Metric

16 1 ISO 4014 - M8 x 40 Hex-Head Bolt

17 4 ISO 4032 - M3.5 Hex Nut

18 4 ISO 4032 - M6 Hex Nut

19 1 ISO 4032 - M8 Hex Nut

20 4 ISO 7045 - M3.5 x 6 - 4.8 - Z Pan Head Screw - Metric

21 PICK SEE TABLE 1 CABLE, INPUT POWER

22

PICK

SEE TABLE 2 CABLE, ACON

23 PICK SEE TABLE 3 CABLE, MOTOR

24

PICK

SEE TABLE 4 CABLE, ENCODER

25

PICK

SEE TABLE 5 CABLE, INA SWITCH INTERFACE

26

PICK

SEE TABLE 6 CABLE, CRASH PROTECTION

27

PICK

SEE TABLE 7 CABLE, INTERCONNECT

28

PICK

SEE TABLE 8 CABLE, SOFT TOUCH PROX, SHLD

29

PICK

SEE TABLE 10 CABLE, VDR

PARTS LIST

8

A6 Lift Assembly

22

2

14

1

18

5

9

10

19

1

22

1

15

3

14

26

12

16

17114

8

25

72120613

0560946827 REV 06

REPLACEMENT PARTS

A6 Lift Assembly

REPLACEMENT

PARTS

9

REPLACEMENT PARTS

PARTS LIST

ITEM QTY PART NUMBER DESCRIPTION

1 14 0006101002 HEXAGON SOCKET CAP SCREW M4X16

2 3 0006101008 HEX�S�H�C�SCR�-ISO4762-M4X10

3 4 0 006101014 HEX�S�H�C�SCR�-ISO4762-M5X16-8�8

4 2 000610102 3 HEX�S�H�C�SCR�-ISO4762-M6X10-

5 6 0 0 0 6 10 1112 HEX�S�H�C�SCR�-ISO4762-M8X30-

6 4 0006101120 HEX�S�H�C�SCR�-ISO4762-M3X16-8�8-

7 4 0006102002 SLOT�CH�H�SCR�-ISO1207-M2X6-

8 1 0 0 0 6 118 113 HEX� S� BH SCR-ISO7380-M3X6-A2

9 6 0006130008 HEXAGON NUT GALVANIZED M 8

10 6 0006150006 WASHER GALVANIZED B8

11 2 0006157013 SPR�L�WASHER-DIN128-B6-

12 1 0558008301 PT-36 TORCH CAN VERSION (4�5’)

13 2 0560935261 MICRO SWITCH SR-3-E-SW

14 1 05 60 94153 7 ASSY OMNI SOFT TOUCH M3 PROX

15 1 0560943743 200W JUNMA MOTOR WITH BRAKE

16 1 056 09 4374 4 INA SLIDE, 217MM STROKE, 4MM LEAD

17 1 0560943754 HOSE SUPPORT - SMALL GANTRY

18 1 0 560 943761 SLIDE ADAPTER PLATE

19 1 0560943762 CAM LIMIT SWITCH

20 2 0560943763 SWITCH ADAPTER PLATE

21 2 0560943769 TEE NUT M2

22 1 BRKT SUPPORT OMNI CRASH JUNMA AHC-SA

23 1 0560946828 CONNECTOR M12 FEMALE 5 PIN

24 1 0560947830 OEM A6 LIFT ASSEMBLY SCHEMATIC

25 1 0560948448 NAMEPLATE A6 LIFT

26 1 0560949375 MAGNETIC SHIELD ASSY

27 620 0560950354 HEAT SHRINK 3/8” BLACK

28 220 0560950440 HEAT SHRINK 1/2” BLACK

29 1 0560950514 LABEL WARNING PINCH HAZARD

PARTS

REPLACEMENT

10

A6 Lift Assembly

REPLACEMENT

PARTS

INA Slide Assembly

NOTES:

1. DO NOT LOOSEN OR REMOVE THESE FOUR BOLTS UNDER ANY CIRCUMSTANCES! THIS WILL CAUSE BALLSCREW MISALIGNMENT.

(14.90 [378.40 mm])

(6.47 [164.30 mm])

NOTE 1

0560943744 Rev 01

Replacement Parts

11

Replacement Parts

REPLACEMENT

PARTS

NOTES:

SEE SECTION 5 OF THIS MANUAL FOR PROCEDURE ON FLANGE (SUPPORT) BEARING REPLACEMENT. THE BEARING SHOULD NOT BE CHANGED WITHOUT ALIGNMENT FIXTURE.

ITEM QTY PN DESCRIPTION

1 1 0560942894 ASSY, MOTOR COUPLING

2 1 0560942892 THRUST BEARING PLATE

3 1 0560947294 REPLACEMENT KIT, FLANGE BEARING, INA LIFT

4 1 0560942891 SHAFT ADAPTOR

5 1 0560942893 COVER, GUIDE STRIP

6 1 0560942895 ASSY, CARRIAGE ENDPLATE WIPER

7 1 0560942897 END PLATE ASSY W/ WIPER

REPLACEABLE PARTS LIST - INA LIFT

5

2

6

1

752

6

3

4

1

12

REPLACEMENT PARTS

9

5

61134610

9

5

6

11

34610

31

29

28

25

7

3

15

20

34

21

83414

16

4

34

366103324

2

13

202126

m3 INA Station Box Assembly

0560945596 REV 06

m3 INA Station Box Assembly

REPLACEMENT

PARTS

13

REPLACEMENT PARTS

35

12

32

PARTS

REPLACEMENT

14

m3 INA Station Box Assembly

REPLACEMENT PARTS

PARTS LIST

ITEM QTY GIN DESCRIPTION

1 1 0004654140 END PLATE

2 1 0006100008 HEX� SCREW-ISO4017-M4X12-

3 2 0006101008 HEX�S�H�C�SCR�-ISO4762-M4X10

4 6 0006101318 CHEESE HEAD SCREW ISO7045 M5 X 10

5 4 0 0 0 6 118 111 ISO7380-M6X10-A2 HEXAGON SOCK� BUTTON HEAD SCREW

6 7 0006130035 HEX�NUT-S1-ISO4032-M4-

7 2 0006150003 WASHER GALVANIZED A4

8 4 0006150004 WASHER GALVANIZED A5

9 4 0006150005 WASHER GALVANIZED B6

10 6 0006157017 SPR�L�WASHER-DIN128-B4

11 1 0006159018 TOOTH LOCKED WASHER DIN6797 V4,3

12 1 0558954035 LABEL CE LOGO

13 1 05 60 94143 2 BUS BAR, COPPER

14 1 0560943507 MCU JUNMA INTERFACE

15 1 056 0944331 SE RVO PACK

16 1 0560944343 DIN RAIL MOUNTING 35MM X 7�5MM

17 1 0560944430 A6 M3 PLASMA BOX SCHEMATIC

18 1 0560945363 JUNMA ENCODER SPLICE CABLE

19 1 0560945373 JUNMA I/O SIGNAL CABLE

20 1 0 56 09 45374 CNA CONNECTOR

21 1 0560945375 CNA CONNECTOR

22 1 0560945584 ASSY, STATION CONTROL BOX

23 1 0560945597 FACE PANEL ASSEMBLY, M3, INA

24 1 0560945881 TRANSFORMER, 12/24 VSEC 80 VA

25 8 0560946204 QUICK WIRE TERMINAL CONNECTOR 90°

26 1 05 609 47161 FILTER, EMI, 250VAC 5A

27 1 0 560 948185 PLUG SET MCU JUNMA W/O L�

28 1 0560948408 CONTACT INSERT 12 PIN

29 1 056 09 48 410 PLASTIC SLEEVE HOUSING

30 1 0 5 6 0 9 4 8 411 HALF SCREW CONNECTION (7-14MM)

31 1 0 56 09 48 412 HALF SCREW CONNECTION(4-6�5MM)

32 1 0560950378 NAMEPLATE 2�38 X 3�38

33 4 0560950488 GROUND CLIP

34 4 0560950489 RING TERMINAL LUG

35 1 0560950490 GROUND DECAL

36 9 0560950498 TERMINAL INLINE FEMALE 0�25” X 14-16AWG

REPLACEMENT

PARTS

m3 INA Station Box Assembly

15

Spacer Page

REPLACEMENT PARTS

PARTS

REPLACEMENT

16

m3 INA Station Box Assembly

REPLACEMENT

PARTS

B

SECTION B B

A

SECTION

AA

11

25223332123314

8

9

5

10

6

7

2

14

13

34

17

25

22

18

153119

14

262221

35

23

31

12

Omni Soft Touch Assy

0560941537 Rev 00

Replacement Parts

17

Replacement Parts

REPLACEMENT

PARTS

ITEM

NO.

PART NO. QTY. DESCRIPTION

QUANTITIES ARE IN U/M ESTIMATED BY INVENTORY

BILL OF MATERIALS

1 2238468 1 SLEEVE, TORCH HOLDER 2 2233370 2 CLAMP, TORCH 3 2238469 1 RING, TORCH MOUNTING 4 0560936077 1 COVER OMNI SOFT TOUCH W/PROX 5 2157761 3 SLEEVE, SPRING 6 2238471 1 BEARING HOUSING 7 2238478 1 BRACKET, TOP CLAMP 8 2209090 3 SPRING, COMPRESSION DIE

10 05N00080 3 NUT, HEX ~ M5-0.8

9 2233364 3 STUD, (METRIC)

12 05S24010 4 SCREW, SET,CONE PT. HEX SOC. ~ M5-0.8 X 10 MM LG.

11 - - REF LOCK NUT M8-1.0

13 04S12012 3 SCREW, HEX SOC HD. CAP ~ M4-0.7 X 12 MM LG. 14 0560935243 1 PROX M8 4W PNP QD 15 2238484 1 BLOCK 16 17 57000462 12 PIN, DOWEL ~ .250 DIA X .50 LG 18 23211302 2 SCREW, HEX SOC HD. CAP ~ M3-0.5 X 16 MM LG. 19 - - 1 SCREW,HEX HD. CAP ~ M5-0.8 X 45 MM LG. 20

21 2238473 2 PLATE, BEARING ADJUSTMENT 22 03S12006 7 SCREW, HEX SOC HD. CAP ~ M3-0.5 X 6 MM LG 23 2238472 2 RETAINER, BEARING PLATE 24 25 2238485 1 RETAINER, NON-ADJUSTMENT 26 06S26020 4 SCREW, HEX SOC HD. CAP S.S. ~ M6-1.0 X 20 MM LG.

28 03S12012 2 SCREW, HEX SOC HD. CAP ~ M3-0.5 X 12 MM LG. 29 30

31 05N01080 8 NUT, HEX JAM ~ M5-0.8 32 2231375 2 CLAMP, WORM 5" DIA. 33 2238860 1 BOOT 34 77500101 A/R GREASE, SILICONE 35 03S12008 12 SCREW, HEX SOC HD. CAP ~ M3-0.5 X 8 MM LG

27

18

REPLACEMENT

PARTS

Wire Kit, Soft Touch

213

567

4

ITEM QTY PN DESCRIPTION

1 1 0560946810 ASSY, SOFT TOUCH BOX

2 1 0560947291 SOFT TOUCH BRACKET

3 1 0560947293 WIRE KIT, SOFT TOUCH

4 8 DIN 125 - A 6.4 Flat Washer

5 4 M5x0.8 x 16 SHCS - Metric

6 4 DIN 127 - A 5 Spring Washer

7 4 M - M5 x 0.8 Hex Nut

PARTS LIST

0560947295 Rev 02

Replacement Parts

19

REPLACEMENT

PARTS

Spacer Page

Replacement Parts

20

Replacement Parts

REPLACEMENT

PARTS

ITEM QTY PN DESCRIPTION

1 1 0560935261 MICROSWITCH SR-3-E-SW

2 1 0560942894 MOTOR COUPLING

3 1 0560942891 ADAPTOR

4 1 0560942893 COVER PLATE

5 1 0560942897 ENDPLATE (w/WIPERS)

6 1 0560947294 FLANGE BEARING REPLACEMENT KIT

7 1 0560935243 PROXIMITY SENSOR, M8 PNP

PARTS LIST

BASIC SPARE PARTS, A6 INA LIFT ESAB PN 0560947289

ITEM QTY PN DESCRIPTION

1 1 0560935261 MICROSWITCH SR-3-E-SW

2 1 0560942894 MOTOR COUPLING

3 1 0560942891 ADAPTOR

4 1 0560942893 COVER PLATE

5 1 0560942897 ENDPLATE (w/WIPERS)

6 1 0560947294 FLANGE BEARING REPLACEMENT KIT

7 1 0560935243 PROXIMITY SENSOR, M8 PNP

8 1 0560943743 JUNMA MOTOR

PARTS LIST

EXTENDED SPARE PARTS, A6 INA LIFT ESAB PN 0560947290

Consumable and Spare Part Reference List

Part Numbers Vary

NOTICE

1-800-ESAB-123

The following section was designed to assist operators in identifying and ordering maintenance/ consumable parts� Items listed below are parts that will need replacement at least on a yearly basis, many with smaller maintenance intervals� Quantities suggested are estimated, based on normal machine usage, product lead times and availability; end users will need to best decide what quantities to purchase based on their production schedule�

The parts represented here, at some point, will be necessary to maintain the process tool. Please dial our toll free number for pricing and availability or contact your nearest distributor.

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REPLACEMENT

PARTS

Spacer Page

Replacement Parts

22

Revision History:’

04 - Updated vertical torch travel dimension on Page 11 and updated replacement parts.

•

Customer / Technical Support

(843)-664-4405

(800) ESAB-123 (372-2123)

ESAB Welding and Cutting Products

PO Box 100545 Ebenezer Rd

Florence, SC 29501-0545

http://www.esab.com

http://www.esabcutting.com

ESAB Cutting Systems - Canada

6010 Tomken Road

Mississauga, Ontario Canada L5T 1X9

Phone: (905) 670-0220

Fax: (905) 670-4879

ESAB-Cutting Systems GmbH

Robert-Bosch-Strasse 20

Postfach 1128

D-61184 Karben 1 Phone 011-49-6039-400 Fax 011-49-6039-403-02

http://www.esab.com

Printed in U.S.A.

ESAB M3 Plasma A6 Standard Lift Assembly m3 CAN Plasma System Instruction manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Contents

Safety

Description

Installation

Maintenance

Replacement Parts

General Information

Ordering Information

A6 INA Lift Assembly, OEM Kit

0560947165 Rev 01

A6 Lift Assembly

0560946827 REV 06

INA Slide Assembly

0560943744 Rev 01

m3 INA Station Box Assembly

0560945596 REV 06

Omni Soft Touch Assy

0560941537 Rev 00

Wire Kit, Soft Touch

0560947295 Rev 02

Consumable and Spare Part Reference List

Part Numbers Vary