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

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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

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