ESAB m3 plasma Vision 50P CNC and Interface Box m3 G2 Plasma System Instruction manual

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Vision 50P CNC and Interface Box m3 G2 Plasma System

Operator's Manual (EN)

0558008526 02/2012

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 our 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 the 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!

TABLE OF CONTENTS

Section / Title Page

1.0 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

2.0 Vision 50P CNC with Interface Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

2.1 Vision 50P CNC (0558008253) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

2.2 Vision 50P CNC Interface Box (0558008250). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

2.3 Plasma Process Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

2.4 Vision 50P CNC Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

2.5 Operation without Height Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

2.6 Sequence of Operation without Height Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

2.7 Operation with Height Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52

2.8 Sequence of Operation with Height Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53

2.9 Cutting Holes With Plasma . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55

TABLE OF CONTENTS

SECTION 1 SAFETY PRECAUTIONS

1.0 Safety Precautions

WARNING: These Safety Precautions are

for your protection. They summarize precautionary information from the references

listed in Additional Safety Information section. Before performing any installation or operating procedures, be sure to read and follow the safety precautions listed below as well as all other manuals, material safety data sheets, labels, etc. Failure to observe Safety Precautions can result in injury or death.

PROTECT YOURSELF AND OTHERS -Some welding, cutting, and gouging processes are noisy and require ear protection. The arc, like the sun, emits

ultraviolet (UV) and other radiation and can injure skin and eyes. Hot metal can cause burns. Training in the proper use of the processes and equipment is essential to prevent accidents. Therefore:

1. Always wear safety glasses with side shields in any

work area, even if welding helmets, face shields, and goggles are also required.

2. Use a face shield tted with the correct lter and

cover plates to protect your eyes, face, neck, and ears from sparks and rays of the arc when operating or observing operations. Warn bystanders not to watch the arc and not to expose themselves to the rays of the electric-arc or hot metal.

3. Wear ameproof gauntlet type gloves, heavy long-

sleeve shirt, cuess trousers, high-topped shoes, and a welding helmet or cap for hair protection, to protect against arc rays and hot sparks or hot metal. A ameproof apron may also be desirable as protection against radiated heat and sparks.

4. Hot sparks or metal can lodge in rolled up sleeves,

trouser cus, or pockets. Sleeves and collars should be kept buttoned, and open pockets eliminated from the front of clothing.

5. Protect other personnel from arc rays and hot

sparks with a suitable non-ammable partition or curtains.

6. Use goggles over safety glasses when chipping slag

or grinding. Chipped slag may be hot and can y far. Bystanders should also wear goggles over safety glasses.

1.1 Safety - English

FIRES AND EXPLOSIONS -- Heat from ames and arcs can start res. Hot slag or sparks can also cause res and explosions. Therefore:

1. Remove all combustible materials well away from the work area or cover the materials with a protective non-ammable covering. Combustible materials include wood, cloth, sawdust, liquid and gas fuels, solvents, paints and coatings, paper, etc.

2. Hot sparks or hot metal can fall through cracks or crevices in oors or wall openings and cause a hidden smoldering re or res on the oor below. Make certain that such openings are protected from hot sparks and metal.“

3. Do not weld, cut or perform other hot work until the workpiece has been completely cleaned so that there are no substances on the workpiece which might produce ammable or toxic vapors. Do not do hot work on closed containers. They may explode.

4. Have re extinguishing equipment handy for instant use, such as a garden hose, water pail, sand bucket, or portable re extinguisher. Be sure you are trained in its use.

5. Do not use equipment beyond its ratings. For example, overloaded welding cable can overheat and create a re hazard.

6. After completing operations, inspect the work area to make certain there are no hot sparks or hot metal which could cause a later re. Use re watchers when necessary.

7. For additional information, refer to NFPA Standard 51B, "Fire Prevention in Use of Cutting and Welding Processes", available from the National Fire Protection Association, Batterymarch Park, Quincy, MA

02269.

ELECTRICAL SHOCK -- Contact with live electrical parts and ground can cause severe injury or death. DO NOT use AC welding current in damp areas, if movement is conned, or if there is danger of falling.

SECTION 1 SAFETY PRECAUTIONS

1. Be sure the power source frame (chassis) is connected to the ground system of the input power.

2. Connect the workpiece to a good electrical ground.

3. Connect the work cable to the workpiece. A poor or missing connection can expose you or others to a fatal shock.

4. Use well-maintained equipment. Replace worn or damaged cables.

5. Keep everything dry, including clothing, work area, cables, torch/electrode holder, and power source.

6. Make sure that all parts of your body are insulated from work and from ground.

7. Do not stand directly on metal or the earth while working in tight quarters or a damp area; stand on dry boards or an insulating platform and wear rubber-soled shoes.

8. Put on dry, hole-free gloves before turning on the power.

3. Welders should use the following procedures to minimize exposure to EMF:

A. Route the electrode and work cables together.

Secure them with tape when possible.

B. Never coil the torch or work cable around your

body.

C. Do not place your body between the torch and

work cables. Route cables on the same side of your body.

D. Connect the work cable to the workpiece as close

as possible to the area being welded.

E. Keep welding power source and cables as far

away from your body as possible.

FUMES AND GASES -- Fumes and gases, can cause discomfort or harm, particularly in conned spaces. Do not breathe fumes and gases. Shielding gases can cause asphyxiation.

Therefore:

9. Turn o the power before removing your gloves.

10. Refer to ANSI/ASC Standard Z49.1 (listed on next page) for specic grounding recommendations. Do not mistake the work lead for a ground cable.

ELECTRIC AND MAGNETIC FIELDS — May be dangerous. Electric current owing through any conductor causes localized Electric and

Magnetic Fields (EMF). Welding and cutting current creates EMF around welding cables and welding machines. Therefore:

1. Welders having pacemakers should consult their

physician before welding. EMF may interfere with some pacemakers.

2. Exposure to EMF may have other health eects which

are unknown.

1. Always provide adequate ventilation in the work area by natural or mechanical means. Do not weld, cut, or gouge on materials such as galvanized steel, stainless steel, copper, zinc, lead, beryllium, or cadmium unless positive mechanical ventilation is provided. Do not breathe fumes from these materials.

2. Do not operate near degreasing and spraying operations. The heat or arc rays can react with chlorinated hydrocarbon vapors to form phosgene, a highly toxic gas, and other irritant gases.

3. If you develop momentary eye, nose, or throat irritation while operating, this is an indication that ventilation is not adequate. Stop work and take necessary steps to improve ventilation in the work area. Do not continue to operate if physical discomfort persists.

4. Refer to ANSI/ASC Standard Z49.1 (see listing below) for specic ventilation recommendations.

SECTION 1 SAFETY PRECAUTIONS

5. WARNING: This product, when used for welding or cutting, produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer. (California Health & Safety Code

§25249.5 et seq.)

CYLINDER HANDLING -- Cylinders, if mishandled, can rupture and violently release gas. Sudden rupture of cylinder, valve, or relief device can injure or kill. Therefore:

1. Use the proper gas for the process and use the

proper pressure reducing regulator designed to operate from the compressed gas cylinder. Do not use adaptors. Maintain hoses and ttings in good condition. Follow manufacturer's operating instructions for mounting regulator to a compressed gas cylinder.

1. Always have qualied personnel perform the installation, troubleshooting, and maintenance work. Do not perform any electrical work unless you are qualied to perform such work.

2. Before performing any maintenance work inside a power source, disconnect the power source from the incoming electrical power.

3. Maintain cables, grounding wire, connections, power cord, and power supply in safe working order. Do not operate any equipment in faulty condition.

4. Do not abuse any equipment or accessories. Keep equipment away from heat sources such as furnaces, wet conditions such as water puddles, oil or grease, corrosive atmospheres and inclement weather.

5. Keep all safety devices and cabinet covers in position and in good repair.

6. Use equipment only for its intended purpose. Do not modify it in any manner.

2. Always secure cylinders in an upright position by chain or strap to suitable hand trucks, undercarriages, benches, walls, post, or racks. Never secure cylinders to work tables or xtures where they may become part of an electrical circuit.

3. When not in use, keep cylinder valves closed. Have valve protection cap in place if regulator is not connected. Secure and move cylinders by using suitable hand trucks. Avoid rough handling of cylinders.

4. Locate cylinders away from heat, sparks, and ames. Never strike an arc on a cylinder.

5. For additional information, refer to CGA Standard P-1, "Precautions for Safe Handling of Compressed Gases in Cylinders", which is available from Compressed Gas Association, 1235 Jeerson Davis Highway, Arlington, VA 22202.

EQUIPMENT MAINTENANCE -- Faulty or improperly maintained equipment can cause injury or death. Therefore:

ADDITIONAL SAFETY INFORMATION -- For more information on safe practices for

electric arc welding and cutting equipment, ask your supplier for a copy of "Precautions and Safe Practices for Arc Welding, Cutting and Gouging", Form 52-529.

The following publications, which are available from the American Welding Society, 550 N.W. LeJuene Road, Miami, FL 33126, are recommended to you:

1. ANSI/ASC Z49.1 - "Safety in Welding and Cutting"

2. AWS C5.1 - "Recommended Practices for Plasma Arc Welding"

3. AWS C5.2 - "Recommended Practices for Plasma Arc Cutting"

4. AWS C5.3 - "Recommended Practices for Air Carbon Arc Gouging and Cutting"

SECTION 1 SAFETY PRECAUTIONS

5. AWS C5.5 - "Recommended Practices for Gas Tungsten Arc Welding“

6. AWS C5.6 - "Recommended Practices for Gas Metal Arc Welding"“

7. AWS SP - "Safe Practices" - Reprint, Welding Handbook.

8. ANSI/AWS F4.1, "Recommended Safe Practices for Welding and Cutting of Containers That Have Held Hazardous Substances."

MEANING OF SYMBOLS - As used throughout this manual: Means Attention! Be Alert! Your safety is involved.

Means immediate hazards which, if not avoided, will result in immediate, serious personal injury or loss of life.

Means potential hazards which could result in personal injury or loss of life.

Means hazards which could result in minor personal injury.

SECCION 1 SEGURIDAD

1.2 Safety - Spanish

ADVERTENCIA: Estas Precauciones de Se-

guridad son para su protección. Ellas hacen

resumen de información proveniente de las referencias listadas en la sección "Información Adicional Sobre La Seguridad". Antes de hacer cualquier instalación o procedimiento de operación , asegúrese de leer y seguir las precauciones de seguridad listadas a continuación así como también todo manual, hoja de datos de seguridad del material, calcomanias, etc. El no observar las Precauciones de Seguridad puede resultar en daño a la persona o muerte.

PROTEJASE USTED Y A LOS DEMAS-Algunos procesos de soldadura, corte y ranurado son ruidosos y requiren protección para los oídos. El arco,

como el sol , emite rayos ultravioleta (UV) y otras radiaciones que pueden dañar la piel y los ojos. El metal caliente causa quemaduras. EL entrenamiento en el uso propio de los equipos y sus procesos es esencial para prevenir accidentes. Por lo tanto:

1. Utilice gafas de seguridad con protección a los lados

siempre que esté en el área de trabajo, aún cuando esté usando careta de soldar, protector para su cara u otro tipo de protección.

2. Use una careta que tenga el ltro correcto y lente

para proteger sus ojos, cara, cuello, y oídos de las chispas y rayos del arco cuando se esté operando y observando las operaciones. Alerte a todas las personas cercanas de no mirar el arco y no exponerse a los rayos del arco eléctrico o el metal fundido.

3. Use guantes de cuero a prueba de fuego, camisa

pesada de mangas largas, pantalón de ruedo liso, zapato alto al tobillo, y careta de soldar con capucha para el pelo, para proteger el cuerpo de los rayos y chispas calientes provenientes del metal fundido. En ocaciones un delantal a prueba de fuego es necesario para protegerse del calor radiado y las chispas.

4. Chispas y partículas de metal caliente puede alojarse

en las mangas enrolladas de la camisa , el ruedo del pantalón o los bolsillos. Mangas y cuellos deberán mantenerse abotonados, bolsillos al frente de la camisa deberán ser cerrados o eliminados.

5. Proteja a otras personas de los rayos del arco y chis-

pas calientes con una cortina adecuada no-amable como división.

6. Use careta protectora además de sus gafas de segu-

ridad cuando esté removiendo escoria o puliendo.

La escoria puede estar caliente y desprenderse con velocidad. Personas cercanas deberán usar gafas de seguridad y careta protectora.

FUEGO Y EXPLOSIONES -- El calor de las amas y el arco pueden ocacionar fuegos. Escoria caliente y las chispas pueden causar fuegos y explosiones. Por lo tanto:

1. Remueva todo material combustible lejos del área de trabajo o cubra los materiales con una cobija a prueba de fuego. Materiales combustibles incluyen madera, ropa, líquidos y gases amables, solventes, pinturas, papel, etc.

2. Chispas y partículas de metal pueden introducirse en las grietas y agujeros de pisos y paredes causando fuegos escondidos en otros niveles o espacios. Asegúrese de que toda grieta y agujero esté cubierto para proteger lugares adyacentes contra fuegos.

3. No corte, suelde o haga cualquier otro trabajo relacionado hasta que la pieza de trabajo esté totalmente limpia y libre de substancias que puedan producir gases inamables o vapores tóxicos. No trabaje dentro o fuera de contenedores o tanques cerrados. Estos pueden explotar si contienen vapores inamables.

4. Tenga siempre a la mano equipo extintor de fuego para uso instantáneo, como por ejemplo una manguera con agua, cubeta con agua, cubeta con arena, o extintor portátil. Asegúrese que usted esta entrenado para su uso.

5. No use el equipo fuera de su rango de operación. Por ejemplo, el calor causado por cable sobrecarga en los cables de soldar pueden ocasionar un fuego.

6. Después de termirar la operación del equipo, inspeccione el área de trabajo para cerciorarse de que las chispas o metal caliente ocasionen un fuego más tarde. Tenga personal asignado para vigilar si es necesario.

7. Para información adicional , haga referencia a la publicación NFPA Standard 51B, "Fire Prevention in Use of Cutting and Welding Processes", disponible a través de la National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

CHOQUE ELECTRICO -- El contacto con las partes eléctricas energizadas y tierra puede causar daño severo o muerte. NO use soldadura de corri-

ente alterna (AC) en áreas húmedas, de movimiento connado en lugares estrechos o si hay posibilidad de caer al suelo.

SECCION 1 SEGURIDAD

1. Asegúrese de que el chasis de la fuente de poder esté conectado a tierra através del sistema de electricidad primario.

2. Conecte la pieza de trabajo a un buen sistema de tierra física.

3. Conecte el cable de retorno a la pieza de trabajo. Cables y conductores expuestos o con malas conexiones pueden exponer al operador u otras personas a un choque eléctrico fatal.

4. Use el equipo solamente si está en buenas condiciones. Reemplaze cables rotos, dañados o con conductores expuestos.

5. Mantenga todo seco, incluyendo su ropa, el área de trabajo, los cables, antorchas, pinza del electrodo, y la fuente de poder.

6. Asegúrese que todas las partes de su cuerpo están insuladas de ambos, la pieza de trabajo y tierra.

7. No se pare directamente sobre metal o tierra mientras trabaja en lugares estrechos o áreas húmedas; trabaje sobre un pedazo de madera seco o una plataforma insulada y use zapatos con suela de goma.

8. Use guantes secos y sin agujeros antes de energizar el equipo.

9. Apage el equipo antes de quitarse sus guantes.

10. Use como referencia la publicación ANSI/ASC Standard Z49.1 (listado en la próxima página) para recomendaciones especícas de como conectar el equipo a tierra. No confunda el cable de soldar a la pieza de trabajo con el cable a tierra.

CAMPOS ELECTRICOS Y MAGNETICOS - Son peligrosos. La corriente eléctrica uye através de cualquier conductor causando a nivel local

Campos Eléctricos y Magnéticos (EMF). Las corrientes en el área de corte y soldadura, crean EMF alrrededor de los cables de soldar y las maquinas. Por lo tanto:

1. Soldadores u Operadores que use marca-pasos para

el corazón deberán consultar a su médico antes de soldar. El Campo Electromagnético (EMF) puede interferir con algunos marca-pasos.

2. Exponerse a campos electromagnéticos (EMF) puede

causar otros efectos de salud aún desconocidos.

3. Los soldadores deberán usar los siguientes procedimientos para minimizar exponerse al EMF:

A. Mantenga el electrodo y el cable a la pieza de

trabajo juntos, hasta llegar a la pieza que usted quiere soldar. Asegúrelos uno junto al otro con cinta adhesiva cuando sea posible.

B. Nunca envuelva los cables de soldar alrededor

de su cuerpo.

C. Nunca ubique su cuerpo entre la antorcha y el

cable, a la pieza de trabajo. Mantega los cables a un sólo lado de su cuerpo.

D. Conecte el cable de trabajo a la pieza de trabajo

lo más cercano posible al área de la soldadura.

E. Mantenga la fuente de poder y los cables de soldar

lo más lejos posible de su cuerpo.

HUMO Y GASES -- El humo y los gases, pueden causar malestar o daño, particularmente en espacios

sin ventilación. No inhale el humo

o gases. El gas de protección puede causar falta de oxígeno. Por lo tanto:

1. Siempre provea ventilación adecuada en el área

de trabajo por medio natural o mecánico. No solde, corte, o ranure materiales con hierro galvanizado, acero inoxidable, cobre, zinc, plomo, berílio, o cadmio a menos que provea ventilación mecánica positiva . No respire los gases producidos por estos materiales.

2. No opere cerca de lugares donde se aplique sub-

stancias químicas en aerosol. El calor de los rayos del arco pueden reaccionar con los vapores de hidrocarburo clorinado para formar un fosfógeno, o gas tóxico, y otros irritant es.

3. Si momentáneamente desarrolla inrritación de

ojos, nariz o garganta mientras est á operando, es indicación de que la ventilación no es apropiada. Pare de trabajar y tome las medidas necesarias para mejorar la ventilación en el área de trabajo. No continúe operando si el malestar físico persiste.

4. Haga referencia a la publicación ANSI/ASC Standard

Z49.1 (Vea la lista a continuación) para recomendaciones especícas en la ventilación.

SECCION 1 SEGURIDAD

5. ADVERTENCIA-- Este producto cuando se utiliza para soldaduras o cortes, produce humos o gases, los cuales contienen químicos conocidos por el Estado de California de causar defectos en el nacimiento, o en algunos casos, Cancer. (California Health & Safety Code §25249.5 et seq.)

MANEJO DE CILINDROS-- Los

cilindros, si no son manejados correctamente, pueden romperse y liberar violentamente gases. Rotura repentina del cilindro, válvula, o válvula de escape puede causar daño o muerte. Por lo tanto:

1. Utilize el gas apropiado para el proceso y utilize

un regulador diseñado para operar y reducir la presión del cilindro de gas . No utilice adaptadores. Mantenga las mangueras y las conexiones en buenas condiciones. Observe las instrucciones de operación del manufacturero para montar el regulador en el cilindro de gas comprimido.

2. Asegure siempre los cilindros en posición vertical

y amárrelos con una correa o cadena adecuada para asegurar el cilindro al carro, transportes, tablilleros, paredes, postes, o armazón. Nunca asegure los cilindros a la mesa de trabajo o las piezas que son parte del circuito de soldadura . Este puede ser parte del circuito elélectrico.

3. Cuando el cilindro no está en uso, mantenga la

válvula del cilindro cerrada. Ponga el capote de protección sobre la válvula si el regulador no está conectado. Asegure y mueva los cilindros utilizando un carro o transporte adecuado. Evite el manejo brusco de los

1. Siempre tenga personal cualicado para efectuar l a instalación, diagnóstico, y mantenimiento del equipo. No ejecute ningún trabajo eléctrico a menos que usted esté cualicado para hacer el trabajo.

2. Antes de dar mantenimiento en el interior de la fuente de poder, desconecte la fuente de poder del suministro de electricidad primaria.

3. Mantenga los cables, cable a tierra, conexciones, cable primario, y cualquier otra fuente de poder en buen estado operacional. No opere ningún equipo en malas condiciones.

4. No abuse del equipo y sus accesorios. Mantenga el equipo lejos de cosas que generen calor como hornos, también lugares húmedos como charcos de agua , aceite o grasa, atmósferas corrosivas y las inclemencias del tiempo.

5. Mantenga todos los artículos de seguridad y coverturas del equipo en su posición y en buenas condiciones.

6. Use el equipo sólo para el propósito que fue diseñado. No modique el equipo en ninguna manera.

INFORMACION ADICIONAL DE SEGURIDAD -- Para más información sobre las prácticas de seguridad de los equipos de arco eléctrico para soldar y cortar, pregunte a su suplidor por una copia de "Precautions and Safe Practices for Arc Welding, Cutting and Gouging-Form 52-529.

Las siguientes publicaciones, disponibles através de la American Welding Society, 550 N.W. LeJuene Road, Miami, FL 33126, son recomendadas para usted:

1. ANSI/ASC Z49.1 - "Safety in Welding and Cutting"

2. AWS C5.1 - "Recommended Practices for Plasma Arc Welding"

MANTENIMIENTO DEL EQUIPO -- Equipo defectuoso o mal mantenido puede causar daño o muerte. Por lo tanto:

3. AWS C5.2 - "Recommended Practices for Plasma Arc Cutting"

4. AWS C5.3 - "Recommended Practices for Air Carbon Arc Gouging and Cutting"

SECCION 1 SEGURIDAD

SIGNIFICADO DE LOS SIMBOLOS

-- Según usted avanza en la lectura de este folleto: Los Símbolos Signican ¡Atención! ¡Esté Alerta! Se trata de su seguridad.

Signica riesgo inmediato que, de no ser evadido, puede resultar inmediatamente en serio daño personal o la muerte.

Signica el riesgo de un peligro potencial que puede resultar en serio daño personal o la muerte.

Signica el posible riesgo que puede resultar en menores daños a la persona.

SECTION 1 SÉCURITÉ

1.3 Safety - French

AVERTISSEMENT : Ces règles de sécurité

ont pour but d'assurer votre protection. Ils récapitulent les informations de précaution

provenant des références dans la section des Informations de sécurité supplémentaires. Avant de procéder à l'installation ou d'utiliser l'unité, assurezvous de lire et de suivre les précautions de sécurité cidessous, dans les manuels, les ches d'information sur la sécurité du matériel et sur les étiquettes, etc. Tout défaut d'observer ces précautions de sécurité peut entraîner des blessures graves ou mortelles.

PROTÉGEZ-VOUS -- Les processus de soudage, de coupage et de gougeage

produisent un niveau de bruit élevé et exige l'emploi d'une protection auditive. L'arc, tout comme le soleil, émet des rayons ultraviolets en plus d'autre rayons qui peuvent causer des blessures à la peau et les yeux. Le métal incandescent peut causer des brûlures. Une formation reliée à l'usage des processus et de l'équipement est essentielle pour prévenir les accidents. Par conséquent:

1. Portez des lunettes protectrices munies d'écrans la-

téraux lorsque vous êtes dans l'aire de travail, même si vous devez porter un casque de soudeur, un écran facial ou des lunettes étanches.

2. Portez un écran facial muni de verres ltrants et de

plaques protectrices appropriées an de protéger vos yeux, votre visage, votre cou et vos oreilles des étincelles et des rayons de l'arc lors d'une opération ou lorsque vous observez une opération. Avertissez les personnes se trouvant à proximité de ne pas regarder l'arc et de ne pas s'exposer aux rayons de l'arc électrique ou le métal incandescent.

3. Portez des gants ignifugiés à crispin, une chemise

épaisse à manches longues, des pantalons sans rebord et des chaussures montantes an de vous protéger des rayons de l'arc, des étincelles et du métal incandescent, en plus d'un casque de soudeur ou casquette pour protéger vos cheveux. Il est également recommandé de porter un tablier ininammable an de vous protéger des étincelles et de la chaleur par rayonnement.

4. Les étincelles et les projections de métal incandescent

risquent de se loger dans les manches retroussées, les rebords de pantalons ou les poches. Il est recommandé de garder boutonnés le col et les manches et de porter des vêtements sans poches en avant.

5. Protégez toute personne se trouvant à proximité des

étincelles et des rayons de l'arc à l'aide d'un rideau ou d'une cloison ininammable.

6. Portez des lunettes étanches par dessus vos lunettes

de sécurité lors des opérations d'écaillage ou de meulage du laitier. Les écailles de laitier incandescent peuvent être projetées à des distances considérables. Les personnes se trouvant à proximité doivent également porter des lunettes étanches par dessus leur lunettes de sécurité.

INCENDIES ET EXPLOSIONS -- La chaleur provenant des ammes ou de l'arc peut provoquer un incendie. Le laitier incandescent ou les étincelles

peuvent également provoquer un

incendie ou une explosion. Par conséquent :

1. Éloignez susamment tous les matériaux combustibles de l'aire de travail et recouvrez les matériaux avec un revêtement protecteur ininammable. Les matériaux combustibles incluent le bois, les vêtements, la sciure, le gaz et les liquides combustibles, les solvants, les peintures et les revêtements, le papier, etc.

2. Les étincelles et les projections de métal incandescent peuvent tomber dans les ssures dans les planchers ou dans les ouvertures des murs et déclencher un incendie couvant à l'étage inférieur Assurez-vous que ces ouvertures sont bien protégées des étincelles et du métal incandescent.

3. N'exécutez pas de soudure, de coupe ou autre travail à chaud avant d'avoir complètement nettoyé la surface de la pièce à traiter de façon à ce qu'il n'ait aucune substance présente qui pourrait produire des vapeurs inammables ou toxiques. N'exécutez pas de travail à chaud sur des contenants fermés car ces derniers pourraient exploser.

4. Assurez-vous qu'un équipement d'extinction d'incendie est disponible et prêt à servir, tel qu'un tuyau d'arrosage, un seau d'eau, un seau de sable ou un extincteur portatif. Assurez-vous d'être bien instruit par rapport à l'usage de cet équipement.

5. Assurez-vous de ne pas excéder la capacité de l'équipement. Par exemple, un câble de soudage surchargé peut surchauer et provoquer un incendie.

6. Une fois les opérations terminées, inspectez l'aire de travail pour assurer qu'aucune étincelle ou projection de métal incandescent ne risque de provoquer un incendie ultérieurement. Employez des guetteurs d'incendie au besoin.

7. Pour obtenir des informations supplémentaires, consultez le NFPA Standard 51B, "Fire Prevention in Use of Cutting and Welding Processes", disponible au National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

CHOC ÉLECTRIQUE -- Le contact avec des pièces électriques ou les pièces de mise à la terre sous tension peut causer des blessures graves ou mor-

telles. NE PAS utiliser un courant de soudage c.a. dans un endroit humide, en espace restreint ou si un danger de chute se pose.

SECTION 1 SÉCURITÉ

1. Assurez-vous que le châssis de la source d'alimentation est branché au système de mise à la terre de l'alimentation d'entrée.

2. Branchez la pièce à traiter à une bonne mise de terre électrique.

3. Branchez le câble de masse à la pièce à traiter et assurez une bonne connexion an d'éviter le risque de choc électrique mortel.

4. Utilisez toujours un équipement correctement entretenu. Remplacez les câbles usés ou endommagés.

5. Veillez à garder votre environnement sec, incluant les vêtements, l'aire de travail, les câbles, le porteélectrode/torche et la source d'alimentation.

6. Assurez-vous que tout votre corps est bien isolé de la pièce à traiter et des pièces de la mise à la terre.

7. Si vous devez eectuer votre travail dans un espace restreint ou humide, ne tenez vous pas directement sur le métal ou sur la terre; tenez-vous sur des planches sèches ou une plate-forme isolée et portez des chaussures à semelles de caoutchouc.

8. Avant de mettre l'équipement sous tension, isolez vos mains avec des gants secs et sans trous.

9. Mettez l'équipement hors tension avant d'enlever vos gants.

10. Consultez ANSI/ASC Standard Z49.1 (listé à la page suivante) pour des recommandations spéciques concernant les procédures de mise à la terre. Ne pas confondre le câble de masse avec le câble de mise à la terre.

CHAMPS ÉLECTRIQUES ET MAGNÉTIQUES — comportent un risque de danger. Le courant électrique qui passe dans n'importe quel conduc-

teur produit des champs électriques et magnétiques localisés. Le soudage et le courant de coupage créent des champs électriques et magnétiques autour des câbles de soudage et l'équipement. Par conséquent :

1. Un soudeur ayant un stimulateur cardiaque doit

consulter son médecin avant d'entreprendre une opération de soudage. Les champs électriques et magnétiques peuvent causer des ennuis pour certains stimulateurs cardiaques.

2. L'exposition à des champs électriques et magné-

tiques peut avoir des eets néfastes inconnus pour la santé.

3. Les soudeurs doivent suivre les procédures suivantes pour minimiser l'exposition aux champs électriques et magnétiques :

A. Acheminez l'électrode et les câbles de masse

ensemble. Fixez-les à l'aide d'une bande adhésive lorsque possible.

B. Ne jamais enrouler la torche ou le câble de masse

autour de votre corps.

C. Ne jamais vous placer entre la torche et les câbles

de masse. Acheminez tous les câbles sur le même côté de votre corps.

D. Branchez le câble de masse à la pièce à traiter le

plus près possible de la section à souder.

E. Veillez à garder la source d'alimentation pour le

soudage et les câbles à une distance appropriée de votre corps.

LES VAPEURS ET LES GAZ -- peuvent causer un malaise ou des dommages

corporels, plus particulièrement dans les espaces restreints. Ne respirez pas les vapeurs et les gaz. Le gaz de protection risque de causer l'asphyxie. Par conséquent :

1. Assurez en permanence une ventilation adéquate dans l'aire de travail en maintenant une ventilation naturelle ou à l'aide de moyens mécanique. N'effectuez jamais de travaux de soudage, de coupage ou de gougeage sur des matériaux tels que l'acier galvanisé, l'acier inoxydable, le cuivre, le zinc, le plomb, le berylliym ou le cadmium en l'absence de moyens mécaniques de ventilation ecaces. Ne respirez pas les vapeurs de ces matériaux.

2. N'eectuez jamais de travaux à proximité d'une opération de dégraissage ou de pulvérisation. Lorsque la chaleur

ou le rayonnement de l'arc entre en contact avec les

vapeurs d'hydrocarbure chloré, ceci peut déclencher la formation de phosgène ou d'autres gaz irritants, tous extrêmement toxiques.

3. Une irritation momentanée des yeux, du nez ou de la gorge au cours d'une opération indique que la ventilation n'est pas adéquate. Cessez votre travail an de prendre les mesures nécessaires pour améliorer la ventilation dans l'aire de travail. Ne poursuivez pas l'opération si le malaise persiste.

4. Consultez ANSI/ASC Standard Z49.1 (à la page suivante) pour des recommandations spéciques concernant la ventilation.

SECTION 1 SÉCURITÉ

5. AVERTISSEMENT : Ce produit, lorsqu'il est utilisé dans une opération de soudage ou de coupage, dégage des vapeurs ou des gaz contenant des chimiques considéres par l'état de la Californie comme étant une cause des malformations congénitales et dans certains cas, du cancer. (California Health & Safety Code §25249.5 et seq.)

MANIPULATION DES CYLINDRES -La manipulation d'un cylindre, sans observer les précautions nécessaires, peut produire des fissures et un

échappement dangereux des gaz. Une brisure soudaine du cylindre, de la soupape ou du dispositif de surpression peut causer des blessures graves ou mortelles. Par conséquent :

1. Utilisez toujours le gaz prévu pour une opération

et le détendeur approprié conçu pour utilisation sur les cylindres de gaz comprimé. N'utilisez jamais d'adaptateur. Maintenez en bon état les tuyaux et les raccords. Observez les instructions d'opération du fabricant pour assembler le détendeur sur un cylindre de gaz comprimé.

2. Fixez les cylindres dans une position verticale, à

l'aide d'une chaîne ou une sangle, sur un chariot manuel, un châssis de roulement, un banc, un mur, une colonne ou un support convenable. Ne xez jamais un cylindre à un poste de travail ou toute autre dispositif faisant partie d'un circuit électrique.

3. Lorsque les cylindres ne servent pas, gardez les

soupapes fermées. Si le détendeur n'est pas branché, assurez-vous que le bouchon de protection de la soupape est bien en place. Fixez et déplacez les cylindres à l'aide d'un chariot manuel approprié. Toujours manipuler les cylindres avec soin.

4. Placez les cylindres à une distance appropriée

de toute source de chaleur, des étincelles et des ammes. Ne jamais amorcer l'arc sur un cylindre.

5. Pour de l'information supplémentaire, consultez

CGA Standard P-1, "Precautions for Safe Handling of Compressed Gases in Cylinders", mis à votre disposition par le Compressed Gas Association, 1235 Jeerson Davis Highway, Arlington, VA 22202.

ENTRETIEN DE L'ÉQUIPEMENT -- Un équipement entretenu de façon défectueuse ou inadéquate peut causer des blessures graves ou mortelles. Par conséquent :

1. Efforcez-vous de toujours confier les tâches d'installation, de dépannage et d'entretien à un personnel qualié. N'eectuez aucune réparation électrique à moins d'être qualié à cet eet.

2. Avant de procéder à une tâche d'entretien à l'intérieur de la source d'alimentation, débranchez l'alimentation électrique.

3. Maintenez les câbles, les ls de mise à la terre, les branchements, le cordon d'alimentation et la source d'alimentation en bon état. N'utilisez jamais un équipement s'il présente une défectuosité quelconque.

4. N'utilisez pas l'équipement de façon abusive. Gardez l'équipement à l'écart de toute source de chaleur, notamment des fours, de l'humidité, des aques d'eau, de l'huile ou de la graisse, des atmosphères corrosives et des intempéries.

5. Laissez en place tous les dispositifs de sécurité et tous les panneaux de la console et maintenez-les en bon état.

6. Utilisez l'équipement conformément à son usage prévu et n'eectuez aucune modication.

INFORMATIONS SUPPLÉMENTAIRES RELATIVES À LA SÉCURITÉ -- Pour obtenir de l'information supplémentaire sur les règles de sécurité à observer pour l'équipement de soudage à l'arc électrique et le coupage, demandez un exemplaire du livret "Precautions and Safe Practices for Arc Welding, Cutting and Gouging", Form 52-529.

Les publications suivantes sont également recommandées et mises à votre disposition par l'American Welding Society, 550 N.W. LeJuene Road, Miami, FL 33126 :

1. ANSI/ASC Z49.1 - "Safety in Welding and Cutting"

2. AWS C5.1 - "Recommended Practices for Plasma Arc Welding"

3. AWS C5.2 - "Recommended Practices for Plasma Arc Cutting"

4. AWS C5.3 - "Recommended Practices for Air Carbon Arc Gouging and Cutting"

SECTION 1 SÉCURITÉ

SIGNIFICATION DES SYMBOLES Ce symbole, utilisé partout dans ce manuel, signie "Attention" ! Soyez vigilant ! Votre sécurité est en jeu.

DANGER

Signie un danger immédiat. La situation peut entraîner des blessures graves ou mortelles.

AVERTISSEMENT

Signie un danger potentiel qui peut entraîner des blessures graves ou mortelles.

ATTENTION

Signie un danger qui peut entraîner des blessures corporelles mineures.

SECTION 2 VISION 50P CNC WITH INTERFACE BOX

2.0 Vision 50P CNC with Interface Box

The m3-CAN Plasma System consists of several components: Vision 50P, Interface Box (or CAN Hub), Shield Gas Box, Plasma Gas Box, Remote Arc Starter (RAS), Power Supply, Coolant Circulator, Torch, Lifter (optional), and customer CNC.

External CNC

( Digital I/O )

Vision 50P

Control

Interface

CAN

Component Locator Designation

(See following pages for component illustrations)

Remote

Arc

Starter

Gas Controls Power Cable

AHC/Lift Power Cable

CAN

Shield Gas

Control

CAN

(RAS)

AHC / Lift

( Optional )

Plasma

Gas Control

External Power

120V / 3A without AHC

230V / 3A with AHC

Vision 50P CNC and Interface Box Component Locator Designations

Vision 50P

CNC

SECTION 2 VISION 50P CNC WITH INTERFACE BOX

2.1 Vision 50P CNC (0558008253)

Vision 50P is a touch-screen based CNC used to control plasma cutting and marking process, gas control, current control and sequence control. However it has no function related to machine movement. Vision 50P is a PC-based operating panel for controlling peripheral components with ACON protocol. Vision 50P has a 8,4” VGA TFT-Display with touch control and a incremental potentiometer with push button for navigation and acknowledgement and a key switch for authorization management. The CAN-Bus and power supply is connected via a 8 pin CAN connector. Vision 50P provides an additional Ethernet and USB interface for communication and maintenance.

9.25”

(235.0 mm)

Weight:

10 lbs. (4.5 kg)

12.75”

(323.9 mm)

Vision 50P case is 4.62” (117.5 mm) wide. It is

5.12” (130.2 mm) wide if you include knob on the front panel

Vision 50P can run under two dierent modes: Operation Mode or Service Mode. The default mode is Operation Mode and allows the operator to conduct all necessary operations. Service Mode is needed for service, such as update station constant, diagnosis, etc. Some process parameters are displayed only under Service Mode. Service Mode can be activated if a USB keyboard is plugged in or the key is turned to ‘0’ position.

In the front panel, there is a incremental potentiometer. If the operator does not have a keyboard, the two input devices for Vision 50P are the incremental potentiometer and the touch screen. With this incremental potentiometer, the operator can scroll down/up to another parameter. While pressing it down, the operator can also change the value of that parameter.

MAINTENANCE

PCU: Process Control unit • ACU: Axis Control Unit • SCU: Serial Control Unit•

The Motor Control Unit (MCU) primarily replaces the lift functionality of the ATHC and ATAS Servo cards.

The Process Control Unit (PCU) controls all process- related functions of the station, whether a tooled or central station (i.e. Solenoid valve action, automatic ignition, ow controls, etc).

The Axis Control Unit (ACU) takes over controlling movements of a multi-axis device. This unit replaces the functionality of the AT2PE positioning card.

The Serial Control Unit (SCU) has been designed as a general purpose controller, typically to control third party peripherals, such as an ink jet marker or pin stamp unit.

Unit Select Switches

ACON units are designated through use of select switches. These will be set correctly at the factory - if a unit needs to be replaced, locate the dual address rotary switches and set them to corresponding station(s), using chart below:

SECTION 2 VISION 50P CNC WITH INTERFACE BOX

2.1 Vision 50P CNC (0558008253) (con’t.)

Vision 50 has three ports on the back panel: CAN+Power, USB and Internet Port. CAN is always used for communication and also 24VDC power to 50P. USB is used for keyboard, USB stick, etc. Internet Port is used only for service.

USB

LAN

POWER +

CAN

CAN-Bus and Power Supply

Pin # Name

1 (White) Not Used

2 (Brown) Not Used

3 (Pink) CAN GND

4 (Yellow) CAN-H Out

5 (Grey) CAN-L Out

6 (Green) CAN GND

7 (Blue) +24VDC

8 (Red) DC COM

Each device contains two address switches. The combination of these switches identify the station and substations on the CAN Bus. Switch 1 designates the station number. Switch 2 designates the substations.

S1 S2 Device

1 - 12 0 MCU – B4 / A6 Lift Assembly 1 - 12 1 Shield Gas Box 1 - 12 2 Plasma Gas Box 1 - 12 3 Remote Arc Starter (RAS) Box 1 - 12 4 Interface Box 1 - 12 5 Water Injection Box

m3 CAN Plasma System

SECTION 2 VISION 50P CNC WITH INTERFACE BOX

2.1 Vision 50P CNC (0558008253) (con’t.)

Operating Conditions:

Operating Temperature: 5 - 50°C Max. Humidity: 95% Enclosure Degree of Protection: IP54 Power Supply: 24V +/- 20%

CAUTION

Hole in mounting plate allows proper cooling air circulation through Vision 50P. Do not block opening or heat related damage may occur.

Replacement Parts

It is recommended that customers contact Technical

Support before attempting repairs on these units.

Item

No.

2 Potentiometer 0558008729

Description ESAB PN

Complete control with all

components excluding

cabinet

0558008728

3.74”

(95mm)

1.87”

(47.5mm)

0.274”

(6.96mm)

1.69”

(43mm)

0.79”

(20mm)

1.57”

(40mm)

Vision 50P CNC Mounting Hole Locations

(Bottom View)

SECTION 2 VISION 50P CNC WITH INTERFACE BOX

2.2 Vision 50P CNC Interface Box (0558008250)

I G

D JEFH

( One Plasma Station with AHC shown )

Weight:

10.1 lbs. (4.6 kg)

Interface Box case is 6.00” (152.4 mm) wide. It is

8.50” (215.9 mm) wide if you include the ttings on front and back

ID Switch

14-Pin

Power

Switch

CAN Cable

( P1 )

B ( J3 ) 19-Pin

PIN Function

A Fault B Motion Enable C CNC COM D Mark Mode E Cycle Start

F Corner / IHS G ENC_0 / ARC_1 H Station On

J +24 VDC K Station Down

L Station Up

M Digital Out 9

N Digital Out 11 P 24 DC COM R Gas Error

S AHC Error T Up Limit SW U Down Limit SW V Digital Out 8

Note:

Chassis must be connected to the machine ground.

GND

7.50”

(190.5 mm)

10.75”

(273.1 mm)

12.75”

(323.9 mm)

SECTION 2 VISION 50P CNC WITH INTERFACE BOX

2.2 Vision 50P CNC Interface Box Mounting Holes

11.50”

(292.1 mm)

3.00”

(76.2 mm)

 0.281”

(7.14 mm)

SECTION 2 VISION 50P CNC WITH INTERFACE BOX

2.2 Vision 50P CNC Interface Box (0558008250) (con’t.)

One Plasma with AHC

CAN # Function

1 Not used 2 Plasma Control Unit 3 * AHC / Lift 4 * Shield Gas Control 5 * Plasma Gas Control 6 * Arc Starter 7 * Interface

Two Plasma with AHC

CAN # Function

1 Plasma Control Unit 2 * AHC / Lift 3 * Shield Gas Control 4 * Plasma Gas Control 5 * Arc Starter 6 * Interface 7 Crossover

One Plasma no AHC

CAN # Function

1 Not used 2 Not used 3 Plasma Control Unit 4 * Shield Gas Control 5 * Plasma Gas Control 6 * Arc Starter 7 * Interface

Two Plasma no AHC

CAN # Function

1 Not used 2 Plasma Control Unit 3 * Shield Gas Control 4 * Plasma Gas Control 5 * Arc Starter 6 * Interface 7 Crossover

Two Plasma with AHC

CAN # Function

1 Not used 2 Crossover 3 * AHC / Lift #2 4 * Shield Gas Control #2 5 * Plasma Gas Control #2 6 * Arc Starter #2 7 * Interface #2

* These components can be connected in any order. Refer to enclosed diagrams.

CAN # Function

Two Plasma no AHC

1 Not used 2 Not used 3 Crossover 4 * Shield Gas Control #2 5 * Plasma Gas Control #2 6 * Arc Starter #2 7 * Interface #2

SECTION 2 VISION 50P CNC WITH INTERFACE BOX

2.2 Vision 50P CNC Interface Box (0558008250) (con’t.)

One Plasma Station with AHC

ID Switch: S1 = 1, S2 = 4

INTERFACE BOX

Two Plasma Stations with AHC

ID Switch: S1 = 1, S2 = 4 ID Switch: S1 = 2, S2 = 4

INTERFACE BOX

CROSS-OVER CABLE

NOTE:

This cable is only used with a Vision 50P to connect the

second Interface Box.

INTERFACE BOX

SECTION 2 VISION 50P CNC WITH INTERFACE BOX

2.2 Vision 50P CNC Interface Box (0558008250) (con’t.)

One Plasma Station without AHC

ID Switch: S1 = 1, S2 = 4

INTERFACE BOX

Two Plasma Stations without AHC

ID Switch: S1 = 1, S2 = 4 ID Switch: S1 = 2, S2 = 4

INTERFACE BOX

CROSS-OVER CABLE

NOTE:

This cable is only used with

a Vision 50P to connect the

second Interface Box.

INTERFACE BOX

SECTION 2 VISION 50P CNC WITH INTERFACE BOX

Connector J3 on Interface Box (0558008250)

PIN (Wire# ) Signal Function

1. Signal output from Interface Box.

2. Errors, such as gas error, power supply error, and coolant error, will

(# 1)

(# 2)

(# 3)

(# 4)

(# 5)

(# 6)

(# 7)

(PCUA X63-1 and X62-1)

Cycle Start (PCUA X61-1)

Fault

(PCUA X63-2)

Motion Allowed

(PCUA X62-2)

CNC COM

Mark Mode

(PCUA X61-4)

Corner / IHS

(PCUA X60-4)

ENC_0 / VOLT_1

(PCUA X60-1)

activate (high) this Fault signal.

3. Once Fault signal is high, Vision 50P will stop the plasma, and remove ‘Motion Enable’, then the customer CNC needs to remove ‘Cycle Start’ signal.

1. Signal output from Interface Box to Customer CNC.

2. This signal is selectable among “Motion Enable”, “Arc On”, or “Arc On After Piercing Delay” depending on the station constant # 214 in SPS.KON.

3. “Motion Enable” becomes activated after the piercing delay. Customer CNC can move the torch when ‘Motion Enable’ is TRUE after the cycle starts. Be sure to check this signal during cutting and marking. Once it turns FALSE, “Cycle Start” must be removed.

4. “Arc On": becomes activated immediately after the main arc is ON.

5. “Arc On After Piercing Delay” become activated after the piercing delay is done and the arc must be ON.

1. Provided by customer CNC. This will aect the signal level of “Fault” and “Motion Enable”.

2. Depending on the signal level of Customer CNC, it can be AC or DC. Max 130VAC/3A or 30VDC/3A.

1. Selects marking (1) or cutting (0) mode.

2. Signal level is 24VDC.

1. Activates the plasma system.

2. Remove ‘Cycle Start’ signal at the end of geometric motion during normal marking/cutting.

3. During hole-cutting, CNC should remove ‘Cycle Start’ before the end of geometry in order to improve the roundness and overall quality.

1. During cutting this signal acts as "corner" signal; before cutting it acts as "IHS".

2. Corner prevents torch from diving down when the machine slows down in the geometry corner or at the start/end of line if arc voltage mode is selected.

3. A False Corner signal (0) means CNC is moving at a constant cutting speed. A True Corner Signal (1) means CNC is approaching corner, and AHC will be blocked.

4. When a constant speed is reached, remove the ‘Corner’ signal to activate automatic height control. At corner or anytime the machine slows down, the ‘Corner’ signal must be ON to prevent torch from diving inside corners.

5. Customer CNC must provide this signal if AHC function from Vision 50P is used.

6. "IHS" signal will turn on / o gas pre-ow if AHC from Vision 50P is not used.

1. Selects height control mode: Encoder (FALSE) or Arc Voltage (True).

2. Encoder height control is useful during hole-cutting.

SECTION 2 VISION 50P CNC WITH INTERFACE BOX

2.2 Vision 50P CNC Interface Box (0558008250) (con’t.)

Connector J3 on Interface Box (0558008250)

PIN (Wire# ) Signal Function

1. Turns ON/OFF the station.

(# 8)

(# 9)

(# 10)

(# 11)

(# 12)

(# 13)

(# 14)

(# 15)

(# 16)

(# 17)

(# 18)

(# 19)

Station Select

(PCUA X48-1)

+24VDC

(PCUA X48-2)

Station Down

(PCUA X48-4)

Station Up

(PCUA X49-1)

Digital Out 9

(PCUA X66-2)

Digital Out 11

(PCUA X66-5)

24VDC COM

(PCUA X40-2)

Gas Error

(PCUA X62-5)

AHC Error

(PCUA X63-5)

Up Limit SW

(PCUA X65-2)

Down Limit SW

(PCUA X64-5)

Digital Out 8

(PCUA X65-5)

2. Customer can also turn ON/OFF the station from Vision 50P. The last action, either from Customer CNC or Vision 50P, will control the status ON/OFF.

3. It is not time sensitive.

1. 24VDC supplied to Customer CNC.

2. Customer CNC will use this signal to provide Digital Inputs for Interface Box.

1. Moves down the torch.

2. It is not time sensitive.

1. Moves up the torch.

2. It is not time sensitive.

1. Digital Out 9

1. Digital Out 11

1. 24VDC COM.

2. For production testing only.

1. Indicates fault in gas / water ow.

2. Fault (Pin A) must be high.

1. Indicates fault from AHC.

2. Fault (Pin A) must be high.

1. Lifter is in up limit position

1. Lifter is in down limit position

1. Digital Out 8

For underwater cutting without air curtain, customer can enable additional pre-ow by setting the station constant #213 in SPS.KON.

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2.3 Plasma Process Parameters

The following parameters are used in the m3 CAN plasma system. Some of them are displayed only in Service Mode but hidden in Operation Mode.

Parameters Description Hidden

Gas Selection

Pilot Arc

Main Arc Voltage

Kerf

Travel Speed

Plate Thickness Used in calculating the slowdown height. Ignition Height Distance from torch to plate during pilot start sequence.

Piercing Height

Cutting Height

Piercing Time

Lead-in Time

THC Delay After Corner Time before the voltage height control reactivates after corner.

Raise Torch When Finished Time before raising the torch after cutting nished.

PG1 Start Pressure

(ARG, H35, N2/O2/AIR)

PG1 Cut Pressure

(ARG, H35, N2/O2/AIR)

PG2 Start Pressure (O2/N2/AIR) Plasma Gas 2 Start pressure.

PG2 Cut Pressure (O2/N2/AIR) Plasma Gas 2 Cut pressure.

SG1 Start Flow (AIR/N2) Shield Gas 1 Start ow.

SG1 Cut Flow (AIR/N2) Shield Gas 1 Cut ow.

SG2 Start Flow (O2/CH4) Shield Gas 2 Start ow.

SG2 Cut Flow (O2/CH4) Shield Gas 2 Cut ow.

Species gas type for plasma start, cut, and shield gases. See table below for details for gas selection.

Sets appropriate Pilot Arc Current. ONLY FOR EPP-201 AND EPP-

360. Species arc voltage used during plasma cutting and marking. This

setting is important because it controls the torch height if there is no encoder height control.

Predicted measurement of material removed during cutting process. It is the gap between production part and plate. Cutting speed, torch stando (arc voltage), and cutting current will aect kerf.

Recommended travel speed for requested cutting condition. Usually reduced for small holes.

Distance from torch to plate during piercing sequence. Enough piercing height to avoid torch contact with the molten spatter which can damage the shield and/or nozzle which will in turn, diminish hole quality.

Distance from torch to plate during cutting. Used during encoder height control with ESAB lifts; otherwise, it is a reference height for OEM lifters. Maintaining this height during the cutting cycle is very important.

Time for the plasma torch to stay at piercing height. Optimized to ensure the torch is at the correct height and the arc is stable before the lead in starts.

Time delay of height control activation to allow torch to enter part pattern. Optimized to ensure the torch is at the correct height and the arc is stable before the lead in starts.

Plasma Gas 1 Start pressure.

Plasma Gas 1 Cut pressure.

Yes

No No

Yes

Yes Yes

Yes

Yes Yes Yes Yes Yes Yes

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Current Value Current used for cutting. No

Current Off Value Current used when cutting is done. No

Current Ramp Up Time

Time needs for cutting current to ramp up from Current Start Value to Current Value.

Yes

Current Ramp Down Time

Time needs for cutting current to ramp down from Current Value to Current Off Value.

Yes

Gas Off Delay

Time delay to shut down gases after the cutting current starts ramping down.

Yes

Plasma Station Number

Plasma station number from 1 to 12. Used to diagnose and monitor the process.

Yes

Quality Type or Marking Yes

Material Type Carbon Steel, Stainless, or Aluminum. Yes

Nozzle Code Code to identify different nozzle. Yes

Water Flow Cut water flow for waterinjection only. Yes

2.3 Plasma Process Parameters (con't.)

Plasma Process Parameters

Parameters Description Hidden

Current used after an arc is established with a pilot. This value is typi-

Current Start Value

Current Value

Current O Value

Current Ramp Up Time

Current Ramp Down Time

Gas O Delay

Plasma Station Number

Nozzle Code Code to identify dierent nozzle. Yes

Water Flow Cut water ow for water injection only. Yes

cally as low as half the actual cutting current, so be sure to allow for enough time to get to full cutting current before starting motion.

Current used for cutting. Sometimes this value can be reduced to enhance the hole quality further.

Current before the arc is turned o. This setting inuences the lead out of the hole. The higher the value, the more gouging occurs. A lower setting can help enhance lead out quality.

Time needs for cutting current to ramp up from Current Start Value to Current Value. On very thin material this time must be minimized or the arc will go out due to lack of material

Time needs for cutting current to ramp down from Current Value to Current O Value.

Time delay to shut down gases after the cutting current starts ramping down.

Plasma station number from 1 to 12. Used for process diagnosis and monitoring.

Current

Value

Yes

AMPERES

TIME

Current

Start Value

Current Ramp

Up Time

Graph is for illustration only. Values are not

Gas

Pressure

Gas O

Delay

necessarily in proportion.

Current

O Value

Current Ramp

Down Time

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2.3 Plasma Process Parameters (con't.)

Gas Selection, m3 CAN Plasma

GS GAS TYPE SG-SG1 SG-SG2 SG-PG1 SG-PG2 PG-PG1 PG-PG2

GS_N2_O2_N2O2 1 2 2 1 3 1

(PG1 START, PG2 CUT) N2 O2 N2 O2 N2/O2/AIR O2

GS_AIR_O2_AIRO2 2 2 3 1 3 1

(PG1 START, PG2 CUT) AIR O2 AIR O2 N2/O2/AIR O2

GS_N2_N2_N2CH4 1 1 2 2 3 2

(N2-PG2 START, N2-PG2 CUT) N2 CH4 N2 N2 N2/O2/AIR N2

GS_N2_H35_AIR 2 - 2 2 2 2

(PG2 START, PG1 CUT) AIR N2 N2 H35 N2

GS_N2_H35_N2CH4 1 1 2 2 2 2

(PG2 START, PG1 CUT) N2 CH4 N2 N2 H35 N2

GS_ARG_ARG_AIR 2 - 2 1 1 1

(PG1 START, PG1 CUT) AIR N2 O2 ARG O2

GS_ARG_ARG_N2 1 - 2 1 1 1

(PG1 START, PG1 CUT) N2 N2 O2 ARG O2

GS_AIR_AIR_AIR 2 - 3 3 3 3

(PG2 START, PG2 CUT) N2 N2 O2 N2/O2/AIR O2

GS_N2_O2_AIR 1 - 2 1 3 1

(PG1 START, PG2 CUT) AIR N2 O2 N2/O2/AIR O2

GS_N2_N2_AIR 2 - 2 2 3 2

(PG2 START, PG2 CUT) AIR N2 N2 N2/O2/AIR N2

GS_ARG_O2_N2O2 1 2 2 1 1 1

(PG1 START, PG2 CUT) N2 O2 N2 O2 ARG O2

GS_ARG_O2_AIRO2 2 - 2 1 1 1

(PG1 START, PG2 CUT) AIR N2 O2 ARG O2

GS_ARG_ARG_H2O 1 1

(PG1 START, PG2 CUT) ARG ARG

GS_N2_N2_H2O 2 2 3 2

(PG1 START, PG2 CUT) N2 N2 N2 N2

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2.4 Vision 50P CNC Operation

Each time the Vision 50P is powered on, the process screen will be loaded as Figure 2.1.

NOTE:

All of the screen shots that follow were taken under "Service" mode.

Figure 2.1 Process Screen

Before pressing the "START" button or F7, the operator needs to make sure the right TDF le is being used. The TDF le contains important cutting data and parameters. Cutting processes and Marking processes have separate TDF les. To select the right TDF le, press the button or F8 to switch to the technology data screen shown in Figure 2.2.

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On the top of technology data screen, the current TDF selected will be displayed. Press F5 or to change the TDF le. As shown in Figure 2.3, the customer can choose Quality, Materials, Current, Thickness, and Gas Type. ESAB’s TDF lename has a predened format. If needed, the customer can have user-dened extensions for TDF les. At the lower part of the screen, the needed consumables for the selected TDF or process are listed and illuminated with pictures.

Figure 2.2 Technology Data Screen

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To select the TDF le for plasma marking, press F2 or . The “Plasma Marking” will be high lighted in green as shown in Figure 2.4. Press F2 again to switch back to "Plasma Cutting". For marking, the customer can select Materials, Current, Thickness, Gas Type, etc. Again, the consumables necessary to perform the selected marking process will be displayed. This can help the customer select the right consumables.

Figure 2.3 Cutting TDF File Selection

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Figure 2.4 Marking TDF Selection

Press F1 or to conrm the selection. Press F8 or to cancel the selection. Then Vision 50P will go back to technology data screen again as Figure 2.5.

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Figure 2.5 Technology Data Screen

Press ESC button , it will switch to Process Screen as in Figure 2.6. If everything is setup, pressing but ton or F7 will start cutting or marking. Process status will be displayed on the screen, such as En-

coder Height, Lift Position, Arc Voltage, Cutting Current, PG Output Pressure, PG2 Flow, SG1 Flow, SG2 Flow, PG1 Pressure, PG2 Pressure, SG Mix Pressure, Required PG Flow and cut water ow, cut water pressure. All the above statuses can be viewed by pressing button or F1. If the button is not shown, press F9 or

and scroll down to next page as in Figure 2.7.

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Figure 2.6 Process Screen

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Figure 2.7 Process Screen

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Below are some advanced features available to the service engineer, but rarely used by the customer. These features can only be accessed in Service Mode.

2.4.1 Change and Save TDF File

If the standard TDF les do not work for a special case, the customer can modify and save TDF les. In the technology data screen (Figure 2.5), change the parameters as needed, press F7 or . A window will pop

up and let you save the changes (F1 or ) or cancel the changes (F8 or ) (Figure 2.8). Then it will switch back to the technology data screen.

Figure 2.8 Save Changes to TDF

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In the technology data screen (Figure 2.5), press but- ton or F6 to see the large view of consumables. (Figure 2.9). Press “X” in the top right corner to close this window.

Figure 2.9 Large View of Consumables

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2.4.2 Change Process from Cutting to Marking

Press the “ESC” Button or ESC on the keyboard to go back to the process screen. Then press the “F1” key to switch between “Cutting” and “Marking" Process. The process number should change from 1 (cutting) to 5 (marking). (see Figure 2.10) This can be veried from the TDF lename shown on the top of the screen.

Figure 2.10 Process Changed to Marking

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2.4.3 Gas Test

In the process screen, press the “MORE” button or to get the buttons for gas testing commands (see Figure 2.11).

Figure 2.11 Gas Test

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Press the “F1” or to view dierent parameters: Encoder Height, Arc Voltage, Lift Position, Cutting Current, PG Output Pressure, SG1 Flow, PG2 Flow, SG2 Flow, PG1 In Pressure, SG Mix Pressure, PG2 In Pressure,

and Required PG Flow. Press the “Start Gas Test” button to test the start gas without cutting. Flow values are only shown when using PG2 as the start gas. Press “Start Gas” button again to stop the start gas test. Press “Cut Gas Test” button to test the cut gas. It will display the output cut pressure during cutting, but the ow will be larger without the arc. Press “Cut Gas Test” button to stop testing.

Press “Shield Gas Test” button and “Start Gas Test” button to display the actual Shield Gas Flow during the start of plasma (see Figure 2.12). Press “Start Gas Test” button again to stop testing.

Figure 2.12 Test Shield Gas During Plasma Start

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While the “Shield Gas Test” button is selected, press the “Cut Gas Test” button to display shield gas ows during cutting. The plasma arc does not inuence shield gas ow.

Figure 2.12a Test Shield Gas During Cutting

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2.4.4 Troubleshooting of Remote CNC Interface Box

For troubleshooting, with a keyboard press “Alt+3” or click the top menu on the touch-screen directly to display the pull down menu (see Figure 2.13), and then select “Shift P5-Diagnosis” (see Figure 2.14) on this screen. It will display the PLC version.

Figure 2.13 Menu

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Figure 2.14 Diagnosis Window

Press the “More” button or (see Figure 2.15), then F3 or (see Figure 2.16), expand Stations and Substations and select Substation 1.4 (see Figure 2.17). The version numbers for the hardware, rmware and PC can be found in the diagnostics screen.

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Figure 2.15. Additional Buttons for Diagnosis

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Figure 2.16. Stations and Substations

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Figure 2.17. Select Substation 1-4

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Press “F2” or to check the signals for the CNC Interface Box (Figure 2.18). You can use “F6” and “F7” to switch between digital output/input and analog output/input screens. Figure 2.18

displays the digital output screen.

Those output signals can be forced to a specic value. For example, in Figure 2.19, the signal Rem_Motion_Enable is forced. From customer CNC, one can check if the motion enable is received as “1”.

Figure 2.18. Signals on CNC Interface Box

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Figure 2.19 Digital Output is Forced

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2.5 Operation without Height Control

The following signals are required between the remote/customer CNC to Vision 50P Control.

2.5.1 Signals from Remote CNC to M3-CAN plasma system

The signal from Pin “E” (Wire#5), ‘Cycle Start’, activates the plasma system. And the signal from Pin “D” (Wire#4), ‘Mark Mode’, selects marking or cutting mode. The ‘Mark Mode’ signal must be ENABLED in order to select marking mode. If parameters or TDF les are chosen properly, Vision 50P can automatically switch between the selected marking and cutting les.

2.5.2 Signals from M3-CAN plasma system to Remote CNC

The signal from Pin “B” (Wire#2), ‘Motion Enable’ will be passed over to Remote CNC after piercing delay is completed. Remote CNC should start cutting motion when ‘Motion Enable’ signal is true after the cycle starts. The signal from Pin “A” (Wire#1) is Fault. Any gas error, power supply error, and CC-11 error can activate this signal (becoming high). When Fault is high, the plasma system will be turned o, and ‘Motion Enable’ will be removed so that the Remote CNC can remove the ‘cycle start’.

2.6 Sequence of Operation without Height Control

1. Select Cutting and Marking le from Vision 50P. Information will be saved in Vision 50P’s ash memory, after Vision 50P is powered on, those information will be loaded again. You don’t need to change les again until you change nozzle, material, or material thickness.

2. Make sure No Height Control ( ) is ON (touch the screen or press ‘F2’). This informs Vision 50P that there is No Height Control used.

3. The default mode is Cutting. Turn on Marking Mode if desired.

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4. Turn on and hold ‘Cycle Start’ signal from customer CNC. After the piercing delay (about 100 msec), check for ‘Motion Enable’ signal. If ‘Motion Enable’ signal is true, customer CNC can start motion.

5. Always check ‘Motion Enable’ signal during cutting/marking. If ‘Motion Enable’ signal turns OFF, arc has been lost and CNC must remove ‘Cycle Start’. Vision 50P will automatically turn the plasma o if arc is not detected after a delay time.

6. Remove ‘Cycle Start’ signal at the end of geometric motion during normal marking/cutting. During hole-cutting, CNC should remove ‘Cycle Start’ before the end of geometry in order to improve the roundness and overall quality. The pre-stop time depends upon the type of material, thickness, and current.

7. Repeat (1)-(6) for the second part.

2.7 Operation with Height Control

Make sure ‘No Height Control’ is OFF (press or press F2) to informs Vision 50P that operation needs height control. This needs to be done only once because this information is saved in ash memory after Vision 50P is powered o. The following signals are required between the Remote CNC and Vision 50P.

2.7.1 Signals from Remote CNC to M3-CAN Plasma System

1. Pin “E” (Wire#5), ‘Cycle Start’, activates the plasma system.

2. Pin “D” (Wire#4), ‘Mark Mode’, selects marking or cutting mode. The ‘Mark Mode’ signal must be ENABLED in order to select marking mode. If parameters or TDF les are chosen properly, Vision 50P can automatically switch between the selected marking and cutting les.

3. Pin “H” (Wire#8), ‘Station On’ switches ON/OFF the station. Vision 50P can also switch ON/OFF stations. The last ON / OFF command from Vision 50P and remote CNC will be eective.

4. Pin “K” (Wire#10), ‘Station Down’, moves down torches. This signal is not time sensitive.

5. Pin “L” (Wire#11), ‘Station Up’, moves up torches. This signal is not time sensitive.

6. Pin “F” (Wire#5), ‘Corner’: This signal prevents torch from diving down when the machine slows down in the geometry corner or at the start/end of line. A False Corner Signal (0) means CNC is moving at a constant cutting speed. A True Corner Signal (1) means CNC is approaching corner and AHC will be blocked. Customer CNC must provide this signal if the height control is used.

7. Pin “G” (Wire#7), ‘Enc/ArcVolt’, selects Encoder height control or Arc Voltage height control. True or ‘1’ means ArcVolt; false or ‘0’ means Encoder. Encoder height control is useful during hole-cutting. In Process Screen, button or F4 can do the same function. When is ON, ArcVolt is selected; otherwise, Encoder is selected. This signal is also saved on ash memory and will be automatically loaded when Vision 50P is powered on.

2.7.2 Signal From M3-CAN Plasma System To Remote CNC:

1. Pin “B” (Wire#2): This signal will be dierent depending on station constant #214 in SPS.KON. "Motion Enable" will be passed over to Remote CNC after piercing delay is completed. Remote CNC

should start cutting motion when "Motion Enable" signal is true after the cycle starts. “Arc On": becomes activated immediately after the main arc is ON. “Arc On After Piercing Delay” become activated after the piercing delay is done and the arc must be ON.

2. Pin “A” (Wire#1) is Fault. Any gas error, power supply error, and CC-11 error can activate this signal (becoming high). When Fault is high, the plasma system will be turned o, and ‘Motion Enable’ will be removed so that the Remote CNC can remove the ‘cycle start’.

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2.8 Sequence of Operation with Height Control

2. Make sure No Height Control is OFF. This informs Vision 50P that there is Height Control used.

3. The default mode is Cutting. Turn on Marking Mode if desired.

4. Turn on and hold ‘Cycle Start’ signal from customer CNC. After a short delay (about 100 msec), check for ‘Motion Enable’ signal. If ‘Motion Enable’ signal is true, customer CNC can start motion. When a constant speed is reached, remove the ‘Corner’ signal to activate automatic height control if arc voltage mode is selected. During corner or anytime the machine slows down, the ‘Corner’ signal must be ON to prevent torch from diving inside corners.

5. Always check ‘Motion Enable’ signal during cutting/marking. If ‘Motion Enable’ signal turns OFF, arc has been lost and CNC must remove ‘Cycle Start’. Vision 50P will automatically turn plasma o if arc is not detected after a delay time.

7. Repeat (1)-(6) for the second part.

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During cutting small holes, parts are falling down before the geometry cutting is completed, the arc may not be

detected. Button or ‘F8’ in Process Screen can turn the cut loss signal on or o. If this button is ON, it will ignore any cut loss after the arc is established; but for normal cutting, this button should be OFF.

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2.9 Cutting Holes With Plasma

2.9.1 Introduction

The intent of this section is to provide the information necessary to produce good hole quality when using the plasma process. This capability is becoming more of a necessity as customers begin to expect more and more from the plasma process. There are several dierent areas which have to be addressed to obtain the required results. These areas are height control, good speed regulation via the motion device, a power supply capable of providing stable current output at all amperages, and a good programming package which allows you to program the needed arc lead in and lead out segments. Each one of these areas will be discussed individually.

2.9.2 Encoder Height Control

Height control can be broken down into three separate areas. It is very important to understand how each of these areas aect the overall hole quality.

The rst area is the encoder height control. This control sets three separate heights that are critical to the operation.

The rst area is initial height. This is the height above the work piece, in inches, the torch is set to establish the correct height for the pilot arc to transfer to main cutting height.

The second area that the encoder height control is set to is the pierce height, which is the height the torch rises to after the main arc transfer. This setting is used to protect the nozzle and shield from any material blow back as a result of the main arc transfer.

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A6 Plasma Lift Assembly

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 encoder- controlled 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, the A6 lift includes Omni Soft Touch® to protect the system during station crashes. Proximity switches monitor torch position in the mounting. If the torch is jarred in any direction, machine/ station movement will stop and an error report will be sent to CNC. Illustrations on the following page

2.9.2 Encoder Height Control (con't.)

The third area is the actual cutting height at which to cut the required part. When cutting holes, this feature directly controls the side wall straightness of the hole. Do not use arc voltage control to maintain torch height when cutting holes. Usually the diameter of these holes is so small that the arc voltage never activates. Instead, use the encoder height control. Increasing this cutting height raises the torch to a higher position above the work piece. This increases the arc voltage (stand o) thus increasing the taper to the side walls of the hole. This causes what is referred to as a positive cut angle. Decreasing the stand o physically lowers the torch, causing the voltage to be lower, thus producing a negative cut angle. The denition of a positive cut angle is one where the top of the hole is a wider diameter than the bottom diameter. The denition of a negative cut angle is one in which the top diameter of the hole is smaller than the diameter of the bottom of the hole

The encoder cutting height controls the straightness of the side wall, which helps make the top and bottom diameter of the hole the same dimension. If cutting holes with diameters 2.00" (50.8mm) and smaller, the encoder height control is to be used. Holes with diameters greater than 2.00" (50.8mm) should be cut using the arc voltage control.

B4 Lift

A6 Lift

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2.9.3 Cutting Speed Regulation

The cutting machine must have good speed regulation. For years, it has been assumed that when you are cutting small holes, it was necessary to reduce the cutting speed from the normal speed when cutting a larger part. The general rule is to reduce the cutting speed by 50% of normal travel speed. An example would be if cutting

0.50” (12.7mm) thick carbon steel at 100ipm (2540mmpm), then a 0.50” (12.7mm) diameter hole would be 50ipm (1270mmpm). This is just a starting point. It may be necessary to reduce the cutting speed even lower.

When attempting to cut small holes it is necessary to reduce the cutting speed. This reduction in speed helps control the roundness of the hole. Most machines have diculty in trying to cut holes at high speed. This is because of the mass and weight of the machine. The inertia of the machine wants to sling the torch around thus producing an oblong or an oval hole. In addition, slowing the machine down also helps improve the wall straightness.

It is very important that the machine design has minimum backlash. Any unwanted movement will show up in the cut quality.

To summarize: The speed at which the hole is cut contributes to the roundness of the hole.

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2.9.4 Power Supply

All of the power supplies ESAB manufactures today are referred to constant current devices. Unlike the power supplies of yesterday, these units are capable of sustaining a constant current output at any cutting voltage, providing they are within the design specication of that unit. The CNC controls of today interact with these power supplies and are capable of remotely controlling current output from these units. In addition, because of the remote capability, the control can regulate current output in the beginning, during the cut, and at the end. In many cases when cutting small diameter holes, complete current control is required to control hole quality, especially at the completion of the cut. In addition, all of ESAB power supplies for mechanized plasma applications are designed for 100% duty cycles. This means continuous operation 60 minutes per hour.

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Part Programming Techniques

2.9.5 Part Programming Techniques

Although there are several techniques to programming small holes (diameter of 1.5 x plate thickness and lower), we will look at two techniques in depth.

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2.9.6 Codes That Can Aect Hole Quality

The M57 command will do two things. First, if there is no encoder height control, it will simply

M57

F The “F” can be inserted to call a dierent feedrate (e.g F50.0) that will enhance hole quality.

M174

freeze the voltage height control. Second, it can be used to enable the encoder height control by placing the M57 before the M65 (plasma on command).

“Flying O” - This code will shut o the plasma at the point it is inserted in the program without stopping machine motion. This function will not utilize the current ramp down, current o value and gas o delay parameters.

2.9.7 Selection Of Lead-In Type

This depends on the size of the hole. A straight lead in works well in most cases versus a radius lead in which works well on mostly larger holes. This can be seen in the illustrations below. The green path is the programmed path and the red path is the torch path. Look at where paths intersect on the radius lead in illustration. This area usually leaves a at spot or hump. This can be attributed to the arc expanding as it travels into the previous cut path. The straight lead in has a much smaller previous cut path therefore reducing the at spot.

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2.9.7 Selection Of Lead-In Type (con't.)

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In the graphic below, notice we led in from the center of the hole at 90 degrees. (Refer to point 1 and red code). The M57 inserted before the M65 tells the controller that we are going to use the encoder for height control. The encoder height value can be optimized to give us the best cutting height for the hole which may be different from standard contour cutting. After the piercing routing completes, the machine will lead into the contour at 90 degrees and continue in a counter-clockwise direction to cut the hole. As the machine approaches the lead in kerf, there are a couple of different things we can do. One is to use the M174. This will turn the plasma off at the entry point of the lead in or shortly after it. This code should not be limited to either before or after. Material type, amperage, hole size and gas selection all influence on where this code should be placed to optimize the hole quality. (Refer to point 2 and blue code). Remember that the M174 is a “Flying Off” command and will shut off the plasma on the fly. We use an over burn (refer to point 3 and green code) to keep the machine moving beyond the intersection of the lead in and the end of the hole contour as the plasma goes out.

2.9.7 Selection Of Lead-In Type (con't.)

In the graphic below, notice we led in from the center of the hole at 90°. (Refer to point 1 and red code).

The M57 inserted before the M65 tells the controller to use the encoder for height control. The encoder height value can be optimized to give the best cutting height for the hole which may be dierent from standard contour cutting. After the piercing routing completes, the machine will lead into the contour at 90° and continue in a counter-clockwise direction to cut the hole. As the machine approaches the lead in kerf, there are a couple of dierent things that can be done. One is to use the M174. This will turn the plasma o at the entry point of the lead in or shortly after it. This code should not be limited to either before or after. Material type, amperage, hole size and gas selection all inuence where this code should be placed to optimize the hole quality. (Refer to point 2 and blue code). Remember that the M174 is a “Flying O” command and will shut o the plasma on the y. We use an over burn (refer to point 3 and green code) to keep the machine moving beyond the intersection of the lead in and the end of the hole contour as the plasma goes out.

N0031 G41 N0032 M57 N0033 M65 N0034 G01 X1.442 Y-1.231

N0035 G03 X1.548 Y-1.014 I1.718 J-1.231 N0036 G03 X1.442 Y-1.231 I1.718 J-1.231 N0037 M174

N0038 G03 X1.447 Y-1.281 I1.718 J-1.231 N0039 M66

N0040 G40

SECTION 2 VISION 50P CNC WITH INTERFACE BOX

Another way to program the hole is to follow the example below. Here we still use the encoder for height control, still lead in at 90 degrees but do not use the M174 at the end of the cut. Instead, we use the parameter “Current Off Value” to turn the current down after the over burn move. You see that the M66 code comes after the over burn which turns the plasma off. When the controller sees this code, the current goes to the current off value which can be optimized in conjunction with the ramp down time and the over burn distance for the hole and material you are cutting. If the Current Off Value is at the same value as the cutting current value, then the plasma will gouge the contour of the hole instead of leaving a smooth area at the lead out point.

2.9.7 Selection Of Lead-In Type (con't.)

Another way to program the hole is to follow the example below. Here we use the encoder for height control, still lead in at 90° but do not use the M174 at the end of the cut. Instead, use the parameter “Current O Value” to turn the current down after the over burn move. The M66 code comes after the over burn which turns the plasma o. When the controller sees this code, the current goes to the current o value which can be optimized in conjunction with the ramp down time and the over burn distance for the hole and material being cut. If the Current O Value is at the same value as the cutting current value, then the plasma will gouge the contour of the hole instead of leaving a smooth area at the lead out point.

SECTION 2 VISION 50P CNC WITH INTERFACE BOX

One should be careful also to check for the kerf offset when cutting very small holes. The angle of the straight lead in will have to be modified to allow the start position to remain in the center of the hole. Ignoring this offset can lead to the plasma starting on the edge or outside the edge of the hole.

2.9.7 Selection Of Lead-In Type (con't.)

Always check for the kerf oset when cutting very small holes. The angle of the straight lead in will have to be modied to allow the start position to remain in the center of the hole. Ignoring this oset can lead to the plasma starting on the edge or outside the edge of the hole.

• Make sure the plasma starts in the center of the hole.

• Make sure the plasma torch is at the correct height before it reaches the edge of the contour.

• Make sure the feed rate is correct.

• Follow either of the previous two examples to end the cut with minimal deformation to the hole.

SECTION 2 VISION 50P CNC WITH INTERFACE BOX

Error List for Vision 50P SPS

ID Description Possible Solutions

11002 IHS Timeout

11003 Ignition Fault

11004 Cut Loss

11005

11006 Torch Collision

11007

11012

11014 Process Is Not Available 1. Please select available process. 11016 No Valid Station Selected 1. Please select a valid station.

11019 Coolant Error

11024 SG1 Flow Is Low

11025 SG2 Flow Is Low

11026 Gas O Delay Is Too Long

11027 Arc Voltage Is Too Low

11028 Arc Voltage Is Too High

Error When

Reading SPS.Kon

No Supply Voltage

On Substation

Lower Limit

Switch Activated

1. Touch signal is already closed.

2. Check for short on reference sensor #1 or #2.

1. If no spark from torch, the gas pressure is high, or the open circuit voltage is low.

2. If there is spark from torch but not transfer, the initial height is too high, or the start current is too low.

3. Pilot arc relay is not energized.

4. Pilot arc relay contact is bad.

5. Pilot arc resistor is open.

1. Pierce height is too high during start.

2. No plate under torch during cutting.

3. Pierce time is too long.

1. SPS.KON is not readable.

2. Make sure SPS.KON exist and is not used by other program.

1. Reset torch holder.

2. Arc voltage is too low.

3. Crossing large Kerf without AHC blocked.

4. Machine is moving too slow.

1. Check 24VDC power supply to substation.

2. Check CAN cable connections.

1. Lift is at lower limit switch. Machine should not be able to move.

1. Coolant through torch is less than 1.0 GPM (4.5 l/Min.). The minimum ow through torch is 1.3 GPM (5.9 l/Min.) @175PSI (12.1 bars).

2.Check the water pump output pressure (175PSI / 12.1 bars).

3. EPP-360 is in slave mode.

1. Shield cup too small.

2. Ensure correct consumables.

3. Check hoses for blockages.

4. Check input pressures of SG box.

1. Shield cup too small.

2. Ensure correct consumables.

3. Check hoses for blockages.

4. Check input pressures of SG box.

1. Gas o delay must be shorter than the current ramp down time.

2. Gas o delay will be set equal to the current ramp down time.

1. Arc voltage is 10volts lower than required.

2. Please decrease VDR ratio in SPS.KON.

1. Arc voltage is 10volts higher than required.

2. Please increase VDR ratio in SPS.KON.

SECTION 2 VISION 50P CNC WITH INTERFACE BOX

Error List for Vision 50P SPS

ID Description Possible Solutions

11029

11030 Not Used 11031 PG2 Output Pressure Is High 1. Nozzle too small. 11032 PG1 Output Pressure Is High 1. Nozzle too small.

11049 Coolant Level Low

11062 High Speed Touch

11063 PG2 Input Pressure Is High 1.PG2 input pressure (PG box inlet) is high.

11064 PG2 Flow Is Low

11065 PG1 Output Pressure Is Low 1.Nozzle too large. 11066 PG2 Output Pressure Is Low 1.Nozzle too large.

11067 SG1 Flow Is High

11068 SG2 Flow Is High

11069 PG1 Input Pressure Is Low 1.PG1 input pressure (PG box inlet) is too low.

11070 PG2 Input Pressure Is Low 1.PG2 input pressure (PG box inlet) is too low.

11071 PG2 Flow Is High

11072 Sensor Short

11073

11074

11075 Cut Water Flow Is Blocked.

11076

Current Ramp Down

Time Is Too Short

Proportional Valve Power

Fault

Power Supply Can Not Output The Requested Current

Arc Current Is lower Than

Requested

1. Current ramp down time must be longer than the gas o delay.

2. Current ramp down time will be set equal to the gas o delay.

1. Please add more coolant.

2. Check switch for activation when cooler is full.

1.Please set correct slow down distance in station constant and correct plate thickness in TDF le.

1.Nozzle too small.

2.Hose is blocked between PG box and torch.

1.Shield cup too large.

2.Ensure correct consumables.

3.Check hoses for leakages.

4.Check input pressures of SG box.

1.Shield cup too large.

2.Ensure correct consumables.

3.Check hoses for leakages.

4.Check input pressures of SG box.

1.Nozzle too large.

2.Leak between PG box and torch.

1.Short between nozzle and shield cup.

2.Clean trash inside torch.

1.Proportional valve (water injection only) has no power.

2.Check 24VDC power inside the water injection box.

1.The requested output current is not available for the selected power supply.

2.Check SPS.Kon to make sure the right power supply is selected.

1.Cut water hose is blocked.

2.Cut water valve is not ON.

3.Smaller nozzle.

4.Proportional valve does not work.

1.The actual current is less than the requested current.

2.Check the control cable between RAS box and power supply.

SECTION 2 VISION 50P CNC WITH INTERFACE BOX

Error List for Vision 50P SPS

ID Description Possible Solutions

11077

11078 PG1 Input Pressure Is High 1. PG1 input pressure (PG box inlet) is too high.

11079

11080

11081

11082 Cut Water Flow Is Too Low 1. Check water valve. 11083 Cut Water Flow Is Too High 1. Check proportional valve.

11084

11085

11086

11087

11088

11089

11090

11091

11092

Arc Current Is higher Than

Requested

Plasma Power Supply

Failed.

Cut Water Pressure Is Too

Low

Cut Water Pressure Is Too

High

Marking le is manually

selected while Auto Mark

Selection is enabled

Marking is not available for

current over 400A

Plate Thickness for this

nozzle is not valid

Marking for selected nozzle

is not available

Marking for Aluminum is

not available

No cut data for the selected

thickness

No cut data for the selected

current

No cut data for the selected

nozzle code

Cut Water Pressure out of

range

1. The actual current is higher than the requested current.

1. Check the front panel for error code. Look for solution in the manual for plasma power supply.

1. Check water pump.

1. Check proportional valve.

1. Disable Auto Mark Selection (SPS.KON#220).

2. Select the right marking le manually.

3. Select any other cutting le, and then remotely select the cutting le needed.

1. Choose another marking le.

1. Please select correct thickness for this nozzle.

1. Please select less than 450amp nozzle for marking.

1. Please select MS or SS for marking.

1. Please load or create cut data for this thickness

2. You are using auto selection, but you manually select TDF le; please remotely select any other cutting le, then select the cutting le needed.

1. Please load or create cut data for this current.

2. You are using auto selection, but you manually select TDF le; please remotely select any other cutting le, then select the cutting le needed.

1. Please load or create cut data for this nozzle code.

2. You are using auto selection, but you manually select TDF le; please remotely select any other cutting le, then select the cutting le needed.

1. Please check the cut water pressure.

SECTION 2 VISION 50P CNC WITH INTERFACE BOX

Error Codes for SG and PG Boxes

Error ID Description

89 CRC error during downloading station constants

90 Module carried out a reset 200 Value range of CAN reference setting has been exceeded 201 Inlet pressure for PG1 is too low 202 Inlet pressure for PG1 is too high 203 Inlet pressure for PG2 is too low 204 Inlet pressure for PG2 is too high

REVISION HISTORY

1. Initial release - 04 / 2009

2. Revision 04/2010 - added vision 50P mounting diagram.

3. Revision 02/2012 - updates per K. Li.

ESAB Welding & Cutting Products, Florence, SC

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