ESAB ULTRAREX UXB Blow Torch Cutting Machine, ULTRAREX UXB blow torch cutting Instruction manual

Warning: Oxyfuel plasma and laser cutting units together with the power sources, switch cabinets, coolers, etc., that are part of the installation, must never and under no circumstances be run in explosion-prone areas.

In accordance with DIN-EN-1127-1 and DIN-EN-13463-1, cutting units and their power sources, switch cabinets, coolers, etc. are potential ignition sources.

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Instruction manual

This instruction manual is intended to enable safe operation of the ULTRAREX UXB blow torch cutting machine in accordance with its intended purpose. Reading and observing the instruction manual will help to avoid hazards, reduce down times and increase the reliability and useful life of the machine.

The instruction manual must be available at all times on the machine. It must be read and applied by all persons entrusted with work on the machine. In addition to the instruction manual and the binding accident prevention regulations applicable in the country of use, the specialised standards applicable to safety and expert working must also be observed.

Before you switch on the machine for the first time, please read through all chapters of this instruction manual attentively and acquaint yourself thoroughly with all details.

This instruction manual only contains general information on operation of the ULTRAREX UXB blow torch cutting machine. Actual operation is realised via the connected CNC controller. This is why you will find exact details of operation in the separate instruction manual of the CNC controller.

Instruction manual

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For more in-depth information, ESAB CUTTING SYSTEMS after-sales service personnel will be pleased to advise you at all times.

ESAB Cutting SYSTEMS GmbH Postfach 11 28 § D-61174 Karben Robert-Bosch-Straße 20 § D-61184 Karben

Phone: (060 39) 40 - 0 Extension, after-sales service: - 333 Fax, after-sales service: - 266

Karben,

This document is intended only for purchasers of our machines and must neither be duplicated nor communicated to third parties nor made available without written consent (Law governing copyright and related proprietary rights, copyright law dated 09.09.1965).

Instruction manual

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Contents

General 6 For your safety 7

General 8 Hazards from the machine 10 Use in accordance with the intended

purpose 13 Safety rules 15 Permitted users 17 Personal protective equipment 18 Workplace 19 Safety measures 20 Emergency behaviour 21

Electrical and gas safety facilities

General 23 Safety facilities prior to

the machine 25 Safety facilities on the machine 26 Checklist for checking

safety facilities 28 Warning information on

the machine 29

Operation 30

General 31 Possibilities of adjusting the burner

holders 32 Flush cutting 36 Preparing work 37 Preparing and switching on the

machine 39 Switching off the machine 42

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Contents

Switching off in an emergency 43 Commissioning after

Emergency Stop 44 Work sequences with the CNC

controller 45 Work sequences with the

photoelectronic controller 49 Work sequences for machines

without solenoid valves 53

Cleaning and maintenance 56

Cleaning 57 Cleaning the nozzles 58 Checking the safety facilities 60 Lubricating machine parts 61

Readjustments 62

General 63 Readjusting the track 64 Readjusting the trolley 65 Readjusting the height adjustments 66

Remedying malfunctions 67 Repair 69

Annexes

Introduction to flame cutting techniques B-1

Technical data D-1 Overview of the machine M-1 Cutting and consumption tables T-1 Specifications, standards, guidelines

and laws V-1 Tools and options W-1 Electromagnetic compatibility Y-1 Verzeichnis der gültigen Seiten Z-1

Instruction manual

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General

The ULTRAREX UXB blow torch cutting machine is manufactured in accordance with the applicable technical regulations and the state of the art. Nevertheless, machines pose risks that cannot be prevented by design measures. Additional safety notes are given here to ensure the operator’s adequate safety. Sufficient safety when handling the machine is guaranteed only when observing these notes.

From time to time it is necessary to highlight certain parts of the text. Highlighted text has different meanings depending on its importance:

Note: Represents a note which, if observed, will facilitate working with the machine.

Caution: Represents a note drawing attention to the fact that material and the machine could become damaged.

Warning: Represents a note drawing attention to a risk of personal injury or mortal danger.

All figures and sketches in this instruction manual consist of non-binding depictions.

Instruction manual

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For your safety

Overview

General Hazards from the machine

Emissions 10 Electromagnetic compatibility 10 Blow torch nozzles 11 Heating flame 11 Hazards from accessories 12

Use in accordance with the intended purpose

Safety rules

Regulations for electrical connection work 16 Regulations for work on the gas supply 16

Permitted users Personal protective equipment

13 15

17 18

Workplace Safety measures Emergency behaviour

19 20 21

Instruction manual

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For your safety

General

Handling of blow torch cutting machines, fuel gases and oxygen requires specialised knowledge. Training and instruction of operating personnel in safety matters are necessary.

You will find general notes on safety and accident prevention in the national accident prevention regulations. regulations applies. These are listed below. It is imperative to obey all regulations listed.

In addition to the instruction manual, the user must provide instruction with regard to

A whole further series of safety

• general legal regulations,

• binding accident prevention regulations,

• binding environmental regulations,

• supervisory and reporting obligations with regard

to special plant situations (e.g. in relation to work organisation, work sequences and deployed personnel etc.)

and to make them public in a suitable location.

1 Please refer to Annex V for further information.

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For your safety

Prior to commencing work, personnel entrusted with work on the machine must have attentively read the instruction manual and, in particular, the chapter entitled ‘For your safety’. This applies particularly to personnel who work only occasionally on the machine (e.g. tooling or maintenance).

Note:

It is imperative to use workshop equipment ap propriate to the work when carrying out maintenance work.

Instruction manual

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For your safety

Hazards from the machine

The ULTRAREX UXB blow torch cutting machine features protective equipment. Nevertheless, the following hazards may arise when using it:

hazards to the life and limb of the operator or third

•

parties, hazards to the machine and other assets of the

•

user, hazards to efficient operation of the machine.

•

Emissions

The following emissions can be expected when carrying out blow torch cutting work:

• sparks,

• slag splashes,

• smoke,

• dust,

• toxic gases (e.g. nitrogen oxides NO

• noise,

• heat radiation, light radiation, UV radiation.

Therefore, adequate ventilation of the workplace and suitable personal protection of operators must be ensured.

Noise emission value

On average, the workplace-related emission value of the blow torch cutting machine at the workplace of operating personnel is 85 ±2 dB(A).

, ozone O3),

Electromagnetic compatibility

Please refer to Annex Y for information on electromagnetic compatibility.

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For your safety

Blow torch nozzles

The blow torch nozzles get hot during operation. If work has to be done on the nozzles, wait until they have cooled down or wear protective gloves.

Heating flame

Warning: Never look into the burner flames without wearing welder’s protective goggles. Otherwise, your eyes will be permanently damaged!

Figure 1: Mandatory sign ‘Wear protective goggles’

The mandatory sign ‘Wear protective goggles’ is attached to the blow torch cutting machine as a reminder of this warning.

Help to make work on the machine safe:

•

Observe all safety and hazard information on the machine.

•

Keep all safety and hazard information on the machine completely in a legible state.

1 Please refer to Annex V for further information.

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For your safety

Hazards from accessories

The torches have been manufactured and tested in accordance with the state of the art. Changes or conversions must not be implemented on the burners without the manufacturer’s permission. Inexpert handling and use that does not conform to the intended purpose may produce hazards for the operator and for other persons. The burner and the machine may also become damaged.

Instruction manual

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For your safety

Use in accordance with the intended purpose

The ULTRAREX UXB blow torch cutting machine is intended exclusively for cutting metallic plate workpieces. Any other use, or use exceeding this scope, e.g. machining of several workpieces located one on top of the other, is deemed to not be in conformity with the intended purpose of the machine.

The following are prerequisites for oxy-fuel blow torch cutting of metallic plate workpieces:

The ignition temperature of the metal must be

•

lower than its melting temperature.

• The melting temperature of combustion products must be lower than the melting temperature of the metal.

Note: You will find an overview of blow torch cutting techniques in Annex B ‘Introduction to blow torch cutting techniques’.

Use in accordance with the intended purpose also includes observance of the instruction manual and conformity with the inspection and maintenance conditions.

Use the machine only in a technically perfect condition and being conscious of safety and hazards.

All malfunctions, in particular those that might have a detrimental influence on safety, must be remedied immediately. In the event of changes that have a bearing on safety or changes in operating behaviour, the machine must be shut down immediately. Malfunctions must be reported immediately to the responsible department or person.

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For your safety

Changes, attachments and conversions that might have a detrimental influence on safety must not be implemented on the machine. This also applies to the installation and the settings of safety equipment and repairs to these.

Spheres of competence with regard to the different activities carried out on the machine must be clearly defined and kept to. There must be no uncertainties in respect of spheres of competence as these may endanger the safety of users.

The user must also make sure that only authorised persons work on the system. The operator is responsible to third parties within the operating zone of the system.

The blow torch nozzles must only be used for the fuel gas stated in the abbreviation on the nozzle. Improper use of the nozzle will destroy the nozzle and burner.

Attention must always be paid to ensuring that the burner does not knock on anything that could push it out of the vertical position.

Flashback protection of burners and nozzles will be diminished if use is made of highly soiled or damaged nozzles.

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For your safety

Safety rules

When working on the blow torch cutting machine, the national regulations, specifications and laws applicable to this machine must be observed.

The user of the blow torch cutting machine is responsible for conformity with the national regulations, specifications and laws during operation of the machine.

Different accident prevention regulations apply in Germany. Please refer to Annex V for further information.

Caution: Work on the gas supply and on the electrical system must only be carried out by specialists trained for the purpose.

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For your safety

Regulations for electrical connection work

The national regulations, specifications and laws applicable to electrical connection work must be observed.

Regulations for work on the gas supply

The national regulations, specifications and laws applicable to work on the gas supply must be observed.

1 Please refer to Annex V for further information.

Instruction manual

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For your safety

Permitted users

Only persons who have reached the age of 18 and who are acquainted with the equipment and processes may be entrusted with the task of blow torch cutting. Youths older than 16 years of age may operate the blow torch cutting machine provided this is necessary for them to achieve their training goal and if their protection is guaranteed by a supervisor.

Only persons who have read and understood the instruction manual are permitted as operators.

Work on the machine may only be carried out by reliable personnel.

Only persons trained or instructed by the manufacturer may be deployed. Personnel’s spheres of competence with regard to operation, tooling, maintenance and repairs must be defined clearly.

It has to be assured that only authorised personel will work on the machine.

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For your safety

Personal protective equipment

Operating personnel must wear protective personal equipment when operating the ULTRAREX UXB blow torch cutting machine.

Operating personnel’s protective personal equipment must consist of the following items:

protective helmet,

•

hearing protection,

•

welder’s protective goggles,

•

protective gloves,

•

protective shoes,

•

protective clothing.

•

Wear a protective helmet Wear hearing protection Wear welder’s protectivegoggles

Wear protective gloves

Figure 2: Standard mandatory signs relating to wearing of protective personal equipment

Wear protective shoes

Wear protective clothing

Standard mandatory signs are affixed to the machine.

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For your safety

Workplace

The workplace is located on the side of the machine in front of the control panel.

Warning: Do not step onto the moving machine. There is a risk of injury from getting stuck on moving parts of the machine.

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For your safety

Safety measures

Caution: All locations required for operation, maintenance and repair must always be freely accessible.

The machine must be set up so that a clearance of at least 500 mm is left on all sides.

Corresponding inner-company instructions and checks must ensure that the workplace environment is always kept clean and neat.

Switch off the machine and interrupt the power and media supplies

• before leaving the machine.

• before carrying out maintenance and cleaning

work.

Warning: Never remove safety facilities. Never alter safety facilities. Never render safety facilities inoperable. You will otherwise put yourself and others at risk!

Personnel entrusted with work on the system must not leave long hair untied, nor wear loose clothing or jewellery including rings and bracelets. There is a risk of injury, e.g. from getting caught in moving parts of the machine.

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For your safety

Emergency behaviour

In an emergency, press the red Emergency Stop pushbutton immediately. Apart from the CNC controller, the machine is deenergised. Close the main valves of the gas tap leading to the machine.

Malfunctions must be reported immediately to the responsible department or person.

Note: There is one Emergency Stop pushbutton each in the control panel and on the opposite side of the machine.

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Electrical and gas safety facilities

Overview

General Safety facilities prior to the

machine

Safety facilities for acetylene 25 Safety facilities for other fuel gases 25

Safety facilities on the machine Checklist for checking safety

facilities Warning information on the

machine

23 25

Instruction manual

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Electrical and gas safety facilities

General

The main switch upstream of the machine must be lockable so as to render operation by unauthorised persons impossible.

The following pages show the blow torch cutting machine’s safety facilities.

Check safety facilities

at the beginning of every work shift (single-shift

•

operation). once every week (continuous operation).

•

after every maintenance or repair.

•

In doing so, check the following:

• prescribed condition.

• prescribed position.

• firm securing.

• prescribed operability.

Warning: If a single safety facility is defective, there is a risk of gas return flow

when the corresponding burner touches down on the sheet. if a tilted sheet seals off the burner opening.

To carry out these checks, use the checklist (copiable) on page 28. Remedy defects before operating the machine!

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Electrical and gas safety facilities

If defects should become apparent during operation, shut down the machine immediately and remedy them.

Do not alter or remove any safety facilities. Do not eliminate any safety facilities by making changes on the machine.

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Electrical and gas safety facilities

Safety facilities prior to the machine

Caution: A tapping point is absolutely necessary. Regulations, specifications and laws govern which further items of safety equipment have to be available. Please refer to Annex V for further information.

Safety facilities for acetylene

Caution: Back-pressure valves for acetylene and single bottle safeguards must bear a design approval mark.

Back-pressure valves for acetylene and single bottle safeguards must be designed so as to prevent return gas flow and flame flashback.

Safety facilities for other fuel gases

Tapping points for other fuel gases (e.g. propane and butane) must feature a design-approved back-pressure valve that safeguards against return gas flow and flame flashback.

Note:

For further information, please refer to the

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operating instructions of the safety facility and Annex V.

1 This requirement is fulfilled by ESAB tapping points.

Instruction manual

Electrical and gas safety facilities

Safety facilities on the machine

Note: All listed safety facilities are not necessarily

Safety facility Location Purpose

included in the scope of delivery.

1 Emergency Stop pushbutton on the CNC controller’s

control panel on the face side of the beam,

opposite the control panel

Single safeguards for protection against gas return flow and flashback are installed for

• fuel gas,

• heating oxygen and

• cutting oxygen

in all supply lines from the solenoid valves to the ESAB machine cutting burners.

in an emergency, stop all machine movements

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Electrical and gas safety facilities

A Work area of the machine 1 Emergency Stop pushbutton B Operator control area C Area for which the operator is responsible E Setting up area

Figure 3: Lage der Sicherheitseinrichtungen an der Maschine (linke Ausführung)

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Electrical and gas safety facilities

Checklist for checking safety facilities

Caution: Pay attention to the safety rules on page 15 of this manual.

Date Name Testing location

Work done

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Electrical and gas safety facilities

Warning information on the machine

12 3

Figure 4: Positions of warning information on the machine (left-handed version)

Type of warning information Location

1 on the door of the

control cabinet

3 depending on the equipment on the respective

No oil and grease on

oxygen valves and lines!

Explosion risk!

fire hazard inkjet unit

Laser beam

UV radiation plasma marking unit

at the inlet of the gas supply

carriage

projection laser (laser class 3A)

Work on the plasma burner only

after deactivating the power

source

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plasma burners

Operation

Overview

General Possibilities of adjusting the burner

holders

Burner carriage A0: adjusting the height manually 32 Burner carriage A0: adjusting the height by motor 34

Flush cutting Preparing work

Necessary operating pressures 38

Preparing and switching on the machine

Preparing for cutting 39 Starting, interrupting, continuing and ending a cut 41

Switching off the machine

36 37

Switching off in an emergency

Shutting down the burners manually 43

Commissioning after Emergency Stop Work sequences with the CNC

controller

Manually controlled edge cut 45 Program-controlled edge cut 46 Program-controlled hole piercing 47

Work sequences with the photoelectronic controller

Strip cut 49 Contour cut with initial edge cutting 50 Hole piercing 51

Work sequences for machines without solenoid valves

Work sequences for machines without solenoid valves 53 Photoelectronically controlled contour cut with initial edge cutting 54 Photoelectronically controlled hole piercing 55

Instruction manual

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Operation

General

This instruction manual only contains general information on operation of the ULTRAREX UXB blow torch cutting machine. The machine is operated with coordinate drive via photoelectronic scanning and is controlled by a microprocessor. Photoelectronic scanning control automatically follows, without physical contact, the line of a drawing or the edge of a silhouette. The burners are moved according to the contour of the scanning source. The feed rate is constant in all directions of movement.

The ULTRAREX UXB blow torch cutting machine can be optionally operated via CNC controller (option). When using this method of control, a measuring rack is also fitted on the track in the longitudinal direction (guide side). One sensor each for transversal and longitudinal movement complete the CNC controller.

You will find information on how to operate the controller in the separate instruction manual for the controller.

Caution: Have you read and understood the safety information? You must not operate the machine beforehand!

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Possibilities of adjusting the burner holders

Burner carriage A0: adjusting the height manually

Operation

1 Burner 2 Star handle (height) 3 Hexagon socket head cap screw

(inclined/longitudinal)

4 Hexagon socket head cap screw

(inclined/transversal)

5 Star handle (shifting/longitudinal)

Manual height adjustment

The height of the burners (1) in the burner holder can be adjusted by app. 200 mm. To do this, undo the star handle (2), shift the burner to the required height and then tighten the star handle again.

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Operation

Inclining in longitudinal direction

The burner holders can be adjusted by ±10° about the y-axis in the longitudinal direction. To do this, undo the cap screw (3) on the burner bearing, adjust the required inclination and retighten the cap screw.

Inclining in transversal direction

The burner holders can be adjusted by ±45° about the x-axis in the transversal direction. To do this, undo the cap screw (4) on the burner bearing, adjust the required inclination and retighten the cap screw.

There is a graduated scale on the bearing to help you to do this.

Shifting in the longitudinal direction

The burner holders can be shifted by ±25 mm in the longitudinal direction (x-axis). To do this, undo the star handle (5) on the burner bearing, adjust the required position and tighten the handle again.

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Burner carriage A0: adjusting the height by motor

Operation

1 Burner 2 Motor (height) 3 Hexagon socket head cap screw

(inclined/longitudinal)

4 Hexagon socket head cap screw

(inclined/transversal)

5 Star handle (shifting/longitudinal)

Height adjustment by motor

The height of the burners (1) in the burner holder can be adjusted by app. 200 mm using a motor. The height of the burners is adjusted by the two pushbuttons ‘burner up’ and ‘burner down’ via the control panel. When reaching the end position a current limiter is triggered which stops the motor.

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Operation

Inclining in longitudinal direction

Inclining in transversal direction

There is a graduated scale on the bearing to help you to do this.

Shifting in the longitudinal direction

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Operation

Flush cutting

Flush (congruent) cutting means that at least two interconnected burner carriages move in the same direction.

To do this, the trailing carriages of the applicable burners concerned must be linked to the drive carriage (3) by means of a clamping unit (1) and a driving rod (2).

If the mechanical link between driving rod and trailing carriage has to be done by a steel strip, the the trailing carriages of the burners concerned must be clamped to the steel strip in the same way.

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Operation

Preparing work

Check all safety facilities before commissioning (see section entitled ‘Checklist for checking safety facilities’, page 28).

You must only operate the machine if

it is in a safe and operable state.

•

all protective facilities are present and are

•

operable.

You must

check the machine at least once every shift for

•

externally recognisable damage and defects. shut down and safeguard the machine

•

immediately in the event of malfunctions.

• report occurring changes immediately to the responsible person.

• remedy malfunctions immediately yourself or have them remedied.

• before switching on the machine, make sure that no-one can be endangered by the machine starting up.

•

before switching on the machine, make sure that all parts coming into contact with oxygen are devoid of oil and grease, as otherwise there is a risk of explosions.

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Operation

Necessary operating pressures

The necessary values for the operating pressures are listed in cutting and consumption tables (see Annex T). The gas supply system must provide corresponding pressures. Cutting capacity will be reduced if the available pressure is less than specified in the corresponding table.

Note: Set pressures for the burners with the burner valves open (flowing pressure measurement).

Caution: It is imperative to keep to specified gas and oxygen pressure values. Otherwise, the burner and nozzle may become damaged.

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Operation

Preparing and switching on the machine

Switch on the main switch of the power supply.

Open the manually-operated valves of the gas tapping point.

Switch on the machine’s main switch.

Release the Emergency Stop switches.

Activate the machine on the CNC controller.

Undo the coupling via the Bowden cable and slide the trolley to the required position. Engage again.

Preparing for cutting

Place the workpiece on the cutting table.

Align the plate parallel to the track. Use the fixed plate stops (if available) on the cutting table. To check the position, you can move with the machine and a burner along the plate in the x direction.

Make sure that the plate lies flat.

Firmly clamp the burner carriage on the driving rod. Undo the coupling via the Bowden cable and slide the carriage to the required position. Engage again.

Move the burners to the required position, making use of the adjustment possibilities on the burner holders.

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Operation

Warning: Never allow gas to flow out of a burner without a heating flame burning. There is a risk of poisoning and explosion.

Make sure that

you have chosen the right combinations of

•

burners, flame cutting nozzles and fuel gas for the cutting task.

all nozzles are clean and fully operable.

•

no-one is in the area of the flame when igniting

•

there are no fire-hazard materials in the proximity

•

of the cutting flame.

Specify the cut either manually or by recalling a program.

Select the cutting speed. You will find guide values for the speed in the cutting and consumption tables.

If you want to carry out program-controlled cuts, you must first move to the reference points in the x and y directions.

Warning: Never look into the flame when not wearing welder’s protective goggles. Otherwise, your eyes will be damaged permanently!!

Adjust the heating flame according to the values in the cutting table, paying attention to the cutting thickness.

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Operation

Make sure that the cutting flame is correctly set.

Establish the correct distance between the nozzle and workpiece.

Note: When working with the automatic height control facility:

Preselect the burner carriages with which you

•

intend to work. Activate automatic height control.

•

The preselected burners move down to the

•

plate. The distances are controlled automatically.

•

Starting, interrupting, continuing and ending a cut

Please refer to the CNC controller’s instruction manual for details of how to start, interrupt, continue and end a cut.

Note: If you switch off the blow torch cutting machine by way of the CNC controller, the burner valves are automatically closed in the correct order:

•

Cutting oxygen,

•

Fuel gas,

•

Heating oxygen.

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Switching off the machine

Switch off the machine on the CNC controller.

Close the manually-operated valves of the gas tapping point.

Switch off the machine’s main switch..

Operation

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Operation

Switching off in an emergency

Press the Emergency Stop pushbutton to switch off the machine. All machine motions are stopped immediately. Apart from the CNC controller, the machined is deenergised. Close the manually operated valves of the gas tapping point.

Note: There is one Emergency Stop pushbutton on the front of the trolley.

Shutting down the burners manually

It is imperative to keep to the following sequence when shutting down the burners: First shut down the cutting oxygen, then the fuel gas and finally the heating oxygen.

This sequence is the result of safety considerations. The gas with the highest pressure must be shut down first. When the fuel gas is then shut down, the heating oxygen blows any remainders of the fuel gas out of the burner and the nozzle. The heating oxygen is then shut down.

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Operation

Commissioning after Emergency Stop

Rectify the reason for actuating the Emergency Stop function.

Release the Emergency Stop pushbutton in order to resume work.

Proceed as described in the sections entitled

‘Preparing work’ (page 37)

•

and ‘Preparing and switching on the machine’

•

(page 39)

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Operation

Work sequences with the CNC controller

Manually controlled edge cut

Note: You can prematurely activate the cutting oxygen by hand once the ignition temperature of the material has been reached. As long as the preheating time is running, you can prolong it by selecting the ‘Heating flame ON’ function a second time.

By means of the CNC controller, position the

•

burner on the initial cutting position.

• Select the required burner carriage.

• Select the cutting process (Autogenous).

• Select edge cutting.

• Activate burner height control.

• Activate the heating flame.

Note: If not all burners ignite, they can be post-ignited by repeatedly activating the heating flame.

•

Select the cutting direction.

•

Start the machine.

After expiry of the preheating time, the machine activate the cutting oxygen and starts to move.

Following completion of cutting:

•

Stop the machine.

•

Deactivate the heating flame.

•

Deactivate burner height control.

•

Raise the burner carriages.

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Operation

Program-controlled edge cut

Load the NC program.

•

Enter the cutting speed and the joint, unless this is

•

already specified in the program. Select the edge start, either manually or by means

•

of modal functions in the program.

• Adjust the preheating time.

• Select the required burner carriages, either

manually or by means of modal functions in the program.

• Start the program.

The selected burners are positioned on the initial cutting point. The height control system switches itself on. The burners move down to the plate and ignite. The preheating time with high pressure starts to run. At the end of the preheating time, the cutting oxygen is activated. Feed begins.

The following take place automatically at the end of cutting or of the program:

•

feed is stopped,

•

the heating flame is switched off,

•

automatic height control is switched off,

•

the burners are raised.

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Operation

Program-controlled hole piercing

Load the NC program.

•

Enter the cutting speed and joint, unless these are

•

specified in the program. Select hole piercing, either manually or by means

•

of a modal function in the program.

• Set the preheating time.

• Set the burner raising time.

• Set the cycle for the cutting oxygen.

• Select the required burner carriages, either

manually or by means of a modal function in the program.

• Start the program.

The selected burners are positioned on the initial cutting point. The height control system switches itself on. The burners move down to the plate and ignite.

The central gas and oxygen supply is opened at an increased pressure (for a boosted warming flame). The prewarming time begins to run. At the end of the prewarming time, the burners are raised briefly, if required. Automatic height control is switched off. The distance between the nozzle and plate is now app. 15 - 20 mm. The pressure of the cutting oxygen is activated and increased. At the same time, feed is activated.

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Operation

Once the maximum oxygen pressure has been reached, automatic height control is activated again.

After expiry of a predefinable high-pressure extension time, the high pressure heating flame is switched back to the normal heating flame.

At the end of cutting or at the end of the program, the following take place automatically:

feed is deactivated,

•

the heating flame is deactivated,

•

automatic height control is deactivated,

•

the burners are raised.

•

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Operation

Work sequences with the photoelectronic controller

Strip cut

Disengage the drives.

•

• Adjust the burner manually according to the width

of the strip and position it on the initial cutting position.

• Select the required burner carriage.

• Engaged the drives.

• Select the cutting process (autogenous).

• Select edge cutting.

• Activate burner height control.

•

Activate the heating flame.

Note: If not all burners ignite, they can be re-ignited by activating the heating flame again.

•

Select the cutting direction.

•

Start the machine.

After expiry of the preheating time, the machine activates the cutting oxygen and sets itself in motion.

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Operation

After cutting:

Stop the machine.

•

Deactivate the heating flame.

•

Deactivate burner height control.

•

Move up the burner carriage.

•

Contour cut with initial edge cutting

• Make sure that the scanning head is adjusted in such a way that it can move along the entire contour.

• In the case of complicated contours: move the machine manually over the sheet metal panel with the drives disengaged.

•

Check the positions of the burners at important points on the contours.

•

Set the burner to initial edge cutting.

•

Select the required burner carriage.

•

Engage the drives.

•

Select the cutting process (autogenous).

•

Activate burner height control.

•

Activate the heating flame.

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Operation

Note: If not all burners ignite, they can be re-ignited by activating the heating flame again.

Select the cutting direction.

•

Start the machine.

•

After expiry of the preheating time, the machine activates the cutting oxygen and sets itself in motion.

After cutting:

Stop the machine.

•

Deactivate the heating flame.

•

Deactivate burner height control.

•

Move up the burner carriage.

•

Hole piercing

•

Enter the cutting speed and the cut joint.

•

Select hole piercing.

•

Adjust the preheating time.

•

Adjust the burner lifting time.

•

Adjust the cycle for the cutting oxygen.

•

Select the required burner carriages.

•

Start the machine.

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Operation

The selected burners are positioned on the initial cut ting point. Height control switches on. The burners move down to the plate and ignite.

The central gas and oxygen supply is opened with increased pressure (for a boosted heating flame). The preheating time elapses. If required, the burners are raised briefly after expiry of the preheating time. Automatic height control is switched off. The distance between the nozzle and the plate is now approximately 15 - 20 mm. The cutting oxygen pressure is activated and increased. The feed function is simultaneously activated.

Automatic burner height control is activated again once the maximum oxygen pressure has been reached.

After expiry of an adjustable high pressure prolongation time, the system switches back from the high pressure heating flame to the normal heating flame.

Once the ‘hole piercing’ function sequence has ended,

•

feed is deactivated.

•

the heating flame is deactivated.

•

automatic height control is deactivated.

•

the burners are raised.

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Operation

Work sequences for machines without solenoid valves

Disengage drives.

•

Manually adjust the burners according to the strip

•

width and position them on the initial cutting point. Select the required burner carriages.

•

Select the burner height.

•

Engage drives.

•

Open the central valves for heating gas and

•

heating oxygen. Ignite the heating flame and individually adjust it

•

with the aid of the adjustment valves.

• Select the cutting speed.

• Select the cutting direction.

• Open the central valve for cutting oxygen.

• Start the machine.

After completing the cut:

• Immediately close the central valve for cutting

oxygen.

•

Close the central valves for heating gas and heating oxygen.

•

Switch off the machine.

•

Disengage drives.

•

Move the machine back.

Instruction manual

Change index: 0 ULTRAREX UXB (GB)

Operation

Photoelectronically controlled contour cut with initial edge cutting

Make sure that the scanning head is adjusted in

•

such a way that it can move along all the contours. In the case of complicated contours: manually

•

move the machine over the sheet metal panel with disengaged drives.

Check the positions of the burners at the important

•

points on the contours. Position the burners to initial edge cutting.

•

Select the required burner carriages.

•

Select the burner height.

•

Engage the drives.

•

Open the central valves for heating gas and

•

heating oxygen.

• Ignite the heating flame and individually regulate it

with the aid of the adjustment valves.

• Select the cutting speed.

• Select the cutting direction.

• Preheat the material to be cut.

• Open the central valve for cutting oxygen.

•

Start the machine.

After completing the cut:

•

Immediately open the central valve for cutting oxygen.

•

Close the central valves for heating gas and heating oxygen.

•

Switch off the machine.

•

Disengage the drives.

•

Move the machine back.

Instruction manual

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Operation

Photoelectronically controlled hole piercing

Make sure that the scanning head is adjusted in

•

such a way that it can move along all the contours. In the case of complicated contours: manually

•

move the machine over the sheet metal panel with disengaged drives.

Check the positions of the burners at the important

•

points on the contours. Position the burners to initial edge cutting.

•

Select the required burner carriages.

•

Select the burner height.

•

Engage the drives.

•

Open the central valves for heating gas and

•

heating oxygen.

• Ignite the heating flame and individually regulate it

with the aid of the adjustment valves.

• Select the cutting speed.

• Select the cutting direction.

• Preheat the material to be cut.

• Slowly open the central valve for cutting oxygen.

•

Start the machine.

•

Once the sheet has been pierced, open the central valve for cutting oxygen fully.

After completing the cut:

•

Immediately open the central valve for cutting oxygen, heating gas and heating oxygen.

•

Switch off the machine.

•

Disengage the drives.

•

Move the machine back.

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Cleaning and maintenance

Overview

Cleaning Cleaning the nozzles

Cleaning using a cleaning needle 59

Checking the safety facilities

Single safeguards at the burner inlet 60

Lubricating machine parts

57 58

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Cleaning and maintenance

Cleaning

To arrive at perfect cutting results with the ULTRAREX UXB blow torch cutting machine, it must be thoroughly cleaned once every week.

Wipe the track and guide rail with a clean, lint-free cloth. Then rub the rails with an oily cloth. Carry out the same procedure for all load-bearing and guide rollers and with frictional wheel of the longitudinal drive.

If this is not done, these parts can become damaged in a very short time as the result of the oxide dust occurring during cutting. In turn, this will cause unsettled running of the machine, thus producing poor cutting results.

The rack of the transversal drive on the trolley must be kept extremely clean. This is best done by blowing on the rack at least once every week with compressed air. Proceed in the same way with the measuring rack on the guide rail of CNC-controlled drives.

Clean the rails of the cable hose suspension in the longitudinal and transversal directions at least once every quarter to remove oxide dust.

Instruction manual

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Cleaning and maintenance

Cleaning the nozzles

Warning: The flame cutting nozzles get hot during operation. If work has to be done on the nozzles, wait until they have cooled down or wear protective gloves.

Clogged or soiled nozzles can be cleaned carefully using the affiliated cleaning needle or by means of the corresponding nozzle cleaning solution.

Caution: Incorrect or incorrectly used cleaning agents will destroy the nozzles.

Damaged nozzles must be replaced immediately. The nozzles must always be screwed into the burners without applying force.

Instruction manual

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Cleaning and maintenance

Cleaning using a cleaning needle

Warning: Improper handling of nozzle cleaning needles may damage the nozzle hole.

Note: You can clean the nozzles more simply and safely by using cleaning solution.

Proceed as follows:

• Switch off the preheating cycle and heating flames

• Switch off all burner carriages not affected.

• Extract the ignition cables of all burner carriages

not affected.

• Switch on the cutting oxygen.

• Close burner valves on the burner to be able to

insert the cleaning needle in the nozzle.

•

Carefully move the cleaning needle in the hole.

•

Remove the cleaning needle from the hole.

•

Slowly open the valve for cutting oxygen on the burner to blow out soiling.

Instruction manual

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Cleaning and maintenance

Checking the safety facilities

All safety facilities for oxygen and fuel gases must be checked once annually for protection against gas return flow and must be replaced if necessary (see section entitled ‘Checklist for checking safety facilities’, page 28).

Single safeguards at the burner inlet

All ESAB machine cutting burners are equipped with single safeguards at all three gas inlets.

After a flashback, the corresponding single safeguard must be replaced by a new one.

Caution: All safety facilities must always be checked by experts.

Note: All safety facilities can be checked by ESAB CUTTING Systems specialists.

Instruction manual

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Cleaning and maintenance

Lubricating machine parts

The slides and guideways must be maintained in accordance with the lubrication chart.

A film of grease must be applied to the spindles of the height adjustments after every 500 hours of operation. The hardened guide rods must be oiled at the same time (see lubrication chart in Annex M).

Note: All load-bearing and guide rollers are equipped with ball bearings featuring permanent lubrication. The gears are also permanently lubricated with a special grease.

Instruction manual

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Readjustments

Overview

General Readjusting the track Readjusting the trolley Readjusting the height

adjustments

Height adjustment A0 - adjusting the height manually 66 Height adjustment A0 - adjusting the height by motor 66

63 64 65

Instruction manual

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Readjustments

General

All guide and support rollers on the trolley and on the transversal carriages can adjusted by means of eccentric bolts.

Instruction manual

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Readjustments

Readjusting the track

Approximately every six months, the track must be checked with regard to its rectilinearity, parallelism (track width), its horizontal plane and its stability.

The track can be readjusted with reference to the layout diagram and available adjustment possibilities.

Note: Standardised measuiring instructions for checking the positions of the tracks are available. Please refer to Annex V for further information.

Instruction manual

Change index: 1 ULTRAREX UXB (GB)

Readjustments

Readjusting the trolley

The trolley is guided by lateral guide rollers on the rail head. The two inner lateral guide rollers are eccentric and must be turned in. Adjust the rollers so that they can still just be turned by hand. The rollers prevent the gantry from moving out of its rectangular position with respect to the track.

The drives are simultaneously engaged or disengaged via a Bowden cable coupling. Transversal motion is transmitted by a drive pinion to the rack. Longitudinal motion is transmitted to the guide rail by a friction wheel.

1 fixed roller 2 eccentric roller 3 track rail

213

If the coupling is engaged via the coupling lever (1), the transversal drive is moved against the rack with its drive pinion via a rocker. Parallel to this, the

longitudinal drive is positioned with its friction wheel on the guide rail via a rocker.

By adjusting the adjustment nut (2) on the Bowden cable,

•

correct engagement of the drive pinion in the rack

•

correct positioning of the friction wheel on the guide rail

are guaranteed.

Instruction manual

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Readjustments

Readjusting the height adjustments

Height adjustment A0 - adjusting the height manually

The height of the vertical adjuster A0 can be

adjusted manually by approximately 200 mm.

The lift rack (3, burner shaft) is guided by a circular guide (2). The height is altered by undoing the clamping screw (1) and by turning the star handle (4).

Height adjustment A0 - adjusting the height by motor

The height of the vertical adjuster A0 can be

adjusted by motor by approximately 200 mm.

The lift rack (1, burner shaft) is guided by five vertical rollers (2, 3). The roller (2) can be adjusted with an eccentric screw (4) so as to achieve exact guidance

of the lift rod (1).

Instruction manual

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Remedying malfunctions

Fault Effect Remedy Burner detonation

Cause: nozzle soiling (e.g. when the burner is lowered onto the material) or by operating errors.

Burner backfires

Burner backfiring can generally only be caused by incorrect operating pressures or damaged equipment.

Burner damage

Do not operate burner if there are leaks on screwed joints of burners and nozzles or damage as the result of burner backfiring or a clogged injector nozzle etc.

Outflow speed is reduced. The flame penetrates into the burner and is extinguished with a bang.

The flame penetrates far into the burner and continues burning in the area of the mixing point. This causes a whistling noise. If the burner is not shut down immediately, its mixing chamber melts in a short time, thus destroying its protection against backfiring, which destroys the burner.

The heating flame goes out despite perfect nozzles, frequently causing a bang during cutting. Such burners must be replaced immediately.

Shut down the burner, readjust it and ignite.

Immediately close burner gas and oxygen valves. The heating flame can be reignited once the burner has cooled down. In doing so, open the valve for heating oxygen first. Use undamaged nozzles only, paying attention to perfect sealing surfaces on nozzles and the burner.

Replace the defective burner by a perfectly operating burner. In the event of repair, please contact ESAB after-sales service.

Flame cutting faults

Poor cutting quality, material melts onto the top of the cut

Cutting breaks off

The cutting jet no longer produces a cut joint. The heating flame may continue to burn or may go off.

Instruction manual

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Check cutting speed, nozzle distance, heating flame, nozzles, height adjustment.

Stop the machine and move back to where cutting broke off. Select initial edge cutting, set the corresponding preheating time and activate it. The machine continues the cut after expiry of the preheating time.

Remedying malfunctions

Fault Effect Remedy Automatic burner height

control slow, unsettled, does not keep to the right height

Flame cutting faults Have the control loop

readjusted by an electronics specialist.

HF cable pulled off

HF cable torn off

Automatic burner height control moves up the burner holder.

The burner moves out of the nominal position.

Fit the HF cable again.

Replace HF cable.

Instruction manual

Change index: 1 ULTRAREX UXB (GB)

Repair

Warning: The manufacturer cannot be held liable for unauthorised repairs or changes on the part of the user or third parties carried out without the permission of the manufacturer.

Repairs should only be carried out by authorised ESAB specialists. Perfect functioning and safety are guaranteed only if use is made of original spares. For safety reasons, the user must not carry out any repairs on burners and nozzles. Have burner repairs carried out by ESAB CUTTING Systems only.

Caution: Never combine burners and nozzles from different manufacturers. Such combinations pose a risk of explosion.

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Repair

Only combine the burners and nozzles that are intended for each other. The burners and nozzles bear corresponding abbreviated designations.

Burner Gas-mixing nozzle

Figure 5: Example of matching symbols on the burner and a gas-mixing nozzle

Instruction manual

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Annex B: Introduction to flame cutting techniques

Note: Only general information on flame cutting techniques is given here. For exact information on the working sequences on the machines, please refer to the respective instruction manual.

Overview

General About safety

Hazards and emissions B-4 Notes on the safety of operating personnel B-5

What materials are suitable for flame cutting?

About gases and burners

Fuel gas types B-8 Necessary operating pressures B-8 The gas distributor in the cutting process Significance of the cutting and consumption tables B-10 Burner types B-11 Blow torch nozzles B-14

About work preparation

Adjusting the heating flame B-15 Adjusting the cutting jet B-17

B-3 B-4

B-7 B-8

B-9

B-15

Working with flame cutters

Shutting down the burners manually B-18 Distance of the nozzle from the workpiece B-18 Start of the cut B-19 Preheating times B-19 Behaviour in the event of flashbacks B-21

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B-18

B-1

Annex B: Introduction to flame cutting techniques

After cutting

Cutting quality B-22 Flame cutting flaws B-22

B-22

Instruction manual

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B-2

Annex B: Introduction to flame cutting techniques

General

Oxy-acetylene flame cutting is a thermal separation method.

Prerequisites for flame cutting are:

The material heated to the ignition temperature

•

must burn in the oxygen jet. The combustion products must form a

•

low-viscosity slag. Only in this way can they be driven out of the joint.

Sequence of oxy-acetylene flame cutting:

1. The part to be separated is brought to ignition

temperature by the heating flame on the

workpiece surface.

2. The material at the separation point is

combusted in the jet of the cutting oxygen.

3. The resulting combustion products (slag) are

driven out of the joint by the cutting oxygen.

Note: Process guidelines, definitions and quality classes for autogenous flame cutting are standardised. Please refer to Annex V for further information.

Instruction manual

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B-3

Annex B: Introduction to flame cutting techniques

About safety

Hazards and emissions

Caution: When operating blow torch cutting machines, observe the safety information given in the corresponding instruction manual and your establishment’s directives.

The following emissions must be expected when carrying out flame cutting work:

sparks,

•

slag splashes,

•

• smoke,

• dust,

• toxic gases (e.g. nitric oxides NO

• noise,

• heat radiation, light and UV radiation.

Therefore, adequate ventilation of the workplace and suitable personal protection of operators must be ensured by the user.

To some extent, national regulations apply to operation of blow torch cutting machines. Please refer to Annex V for further information.

When operating flame cutting machines, effective suction extraction facilities may reduce the pollutant

, ozone O3),

burden (e.g. ESAB cutting table with suction extraction).

Instruction manual

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B-4

Annex B: Introduction to flame cutting techniques

Notes on the safety of operating personnel

You may only carry out flame cutting work when wearing your personal protective equipment. Please refer to the respective instruction manual or your plant instructions for details of the items of which the protective equipment consists.

When igniting the flame, make sure nobody is within the range of the flame.

Never allow gas to flow out of a burner without a heating flame burning.

Never combine burners and nozzle from different manufacturers. Such combinations pose an explosion risk.

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B-5

Annex B: Introduction to flame cutting techniques

Burner Gas-mixing nozzle

Figure B-1: Example of matching symbols on the burner and a gas-mixing nozzle

Only ever combine burners and nozzles that are intended for each other. Burners and nozzles are identified by corresponding abbreviated designations of the type and fuel gas.

Make sure that there are no fire-hazard materials in the area of the cutting flame.

Never leave flame cutting nozzles lying around loosely. Store nozzles in the corresponding receptacles.

Instruction manual

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B-6

Annex B: Introduction to flame cutting techniques

What materials are suitable for flame cutting?

For a material to be suitable for flame cutting,

its ignition temperature must be lower than its

•

melting temperature. the melting temperature of combustion products

•

must be lower than the melting temperature of the metal. Only in this way is it possible to drive combustion products out of the joint.

the ignition temperature at the cutting location

•

must be maintained constantly. This is done by the heating flame, which compensates for heat losses.

Figure B-2: Ignition curve

Unalloyed steels with a low carbon content (< 0.3 % carbon content) are suitable for flame cutting. Unalloyed steels with a higher carbon content (0.3%-2%)aresuitable for flame cutting after preheating.

Low alloy steels are suitable for flame cutting after preheating if their carbon content equivalent is no greater than 2 %. Cast iron, aluminium, copper and CrNi steels are not suitable for autogenous flame cutting.

Note: The carbon equivalent K is calculated in accordance with the formula:

=+ + + + +

1 Meanings:

Instruction manual

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Mn6Ni15Cr5Mo4V

C = carbon, Mn = manganese, Ni = nickel, Cr = chrome, Mo = molybdenum än, V = vanadium All components in %.

B-7

Annex B: Introduction to flame cutting techniques

About gases and burners

Fuel gas types

Fuel gases are

acetylene,

•

natural gas,

•

propane,

•

mixed gases.

•

Fuel gas and heating oxygen are mixed to get the heating gas.

The oxygen should be as pure as possible, at least

99.5 %.

Necessary operating pressures

The required operating pressure values are listed in cutting and consumption tables (see example on page B-10). The gas supply system must provide corresponding pressures. Cutting capacity is reduced if available pressure is less than specified in the corresponding table.

The pressures for the burners are set with the burner valves open (flowing pressure measurement).

Instruction manual

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B-8

1 Cutting oxygen supply line 2 Heating oxygen supply line 3 Fuel gas supply line 4 Fuel gas prop valve 5 Heating oxygen prop valve 6 Electronic pressure control

for cutting oxygen

7 Fuel gas pressure sensor

Annex B: Introduction to flame cutting techniques

The gas distributor in the cutting process

The cutting process is selected by way of the CNC controller. The program is started.

8 Heating oxygen pressure

sensor

9 Outlets to the burners

Figure B-3: Gas distributor

The proportional valves for the fuel gas (4) and heating oxygen (5) open according to the pressure setting on the CNC controller. The pressure setting is reported back to the CNC controller by the pressure sensors for fuel gas (7) and heating oxygen (8).

The pressure of the cutting oxygen is controlled via the CNC controller. Depending on the setting, the pressure of the cutting oxygen is raised or lowered by way of the electronic pressure control (6).

The cutting oxygen is deactivated after completion of the cutting operation. The lines between the burners and the electronic pressure control (6) are drained. The proportional valves for fuel gas (4) and heating oxygen (5) are closed.

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B-9

Annex B: Introduction to flame cutting techniques

Table B-1: Excerpt from a cutting and consumption table

Significance of the cutting and consumption tables

The cutting and consumption tables should help the operator

• to choose the right flame cutting nozzle according

to sheet thickness.

• to set the necessary gas pressures for the heating

flame and the cutting oxygen.

•

to choose the right cutting speed.

•

to enter the right joint.

Table B-1 gives an example of cutting and consumption tables.

The tables differ depending on nozzle types and fuel gas type.

Most tables specify two different speeds for cuts. The lower speed is used for high-grade cuts, while the higher speed is used for simple parting cuts. Please refer to Annex V for information about cutting qualities.

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B-10

Annex B: Introduction to flame cutting techniques

If the material to be cut is rusty, soiled or has a protective coating, the speed should be reduced in comparison with the specified values. Only in this way can a high cutting quality be achieved.

Depending on the actual condition of the gas, the purity of the oxygen and the material to be cut, it may also be necessary to select a different cutting speed to the one given in the table. If necessary, determine the right speed by trial and error.

All specified values (cutting speed, gas consumption, cutting joint width etc.) merely represent average values. In practice it is not uncommon to deviate from them and, in the case of the cutting speed, this might even be called for.

Burner types

A distinction is made between four types of burners:

• injector burner (fig. B-4),

• injector burner with COOLJET nozzle (fig. B-5),

• burner for gas-mixing nozzles (fig. B-6),

•

injektor burner with automatic internal ignition, Multijet BIF.

Instruction manual

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B-11

Figure B-4:Structure of an injector burner

Annex B: Introduction to flame cutting techniques

Injector burner

In the case of the injector burner, fuel gas (3) and heating oxygen (2) are mixed prior to entry into the cutting nozzle. The cutting oxygen (1) is fed separately. A burner matching the type of fuel gas must be used.

Injector burner with COOLJET nozzle

In the case of the injector burner with COOLJET

nozzle, a small quantity of oxygen (1) flows through cooling flow valve (6) and cutting duct (12) during

5 6

7 8

11 12

preheating. This prevents hot gases from rising into the nozzle (11) and the burner. At the same time, efficient cooling of the nozzle and burner is achieved.

1 Cutting oxygen 7 Injector (t max. 40 °C) 2 Heating oxygen 8 Cooling oxygen 3 Fuel gas 9 Aluminium body 4 Shut-off valves 10 Fuel gas-oxygen mixture

Figure B-5: Structure of an injector burner with COOLJET nozzle

Change index: 0 ULTRAREX UXB (GB)

5 Flame locks 11 Cutting nozzle 6 Cooling flow valve 12 Cutting oxygen duct

Instruction manual

B-12

Annex B: Introduction to flame cutting techniques

Burner for gas-mixing nozzles

Figure B-6: Structure of a gas-mixing nozzle

In the case of the machine cutting burner for gas-mi xing nozzles, the fuel gas (1) and heating oxygen (2) do not mix until they reach the cutting nozzle at the mixing point (4) to the heating gas. The cutting oxygen (3) is fed separately.

Burners with gas-mixing nozzles are

safeguarded against flashback.

•

identical for all fuel gas types; merely the nozzles

•

have to be chosen according to the type of fuel gas.

Injektor burner with automatic internal ignition, Multijet BIF

With this burner, the fuel gas and the heating oxygen are mixed before entering the cutting nozzle. The corresponding burner must be used depending on the type of gas (acetylene, propane or natural gas).

There is no need for conventional external ignition because this type of burner is equipped with an automatic internal ignition facility.

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B-13

Annex B: Introduction to flame cutting techniques

Blow torch nozzles

Blow torch nozzles get hot during operation.

If work has to be done on the nozzles, you must

take care.

•

take adequate preventive measures.

•

The blow torch nozzles must only be used for the fuel gas specified in the abbreviated designation on the nozzle. The nozzle and burner will be destroyed if the wrong blow torch nozzle is used.

Clogged or soiled nozzles can be cleaned cautiously with the affiliated cleaning needle or with the corresponding nozzle cleaning solution. Wrong or wrongly used cleaning agents will destroy the nozzles.

Damaged nozzles must be replaced immediately.

Caution: Nozzles must always be screwed into the burner without applying force. It is imperative to use two spanners.

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B-14

Annex B: Introduction to flame cutting techniques

About work preparation

Adjusting the heating flame

Warning: Never look into the burner flames without wearing welder’s protective goggles. Otherwise, your eyes will be permanently damaged!

The mandatory sign ‘Wear protective goggles’ is attached to the blow torch cutting machine as a reminder of this warning.

Figure B-7. Mandatory sign ‘Wear protective goggles’

Handling sequence overview:

•

Open the burner valves for heating oxygen and fuel gas completely.

•

Ignite the gas mixture.

1 Please refer to Annex V for further information.

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B-15

1 Primärflamme 2 Sekundärflamme

Annex B: Introduction to flame cutting techniques

3 Gasüberschuss

Brenngasüberschussflamme neutral eingestellte Flamme

Figure B-8: Flammenbilder der Brennerflammen

A fuel gas surplus flame is produced if the pressure is set properly. The flame must then be neutrally set. By means of the fuel gas valve, the quantity of fuel gas flowing in is reduced until the primary flame (1) becomes clearly visible.

Thin sheet is cut with a weak (‘soft’) heating flame, while thicker sheet is cut with a stronger (‘hard’) cutting flame.

When the heating flame is set correctly, the admixed cutting oxygen stands out clearly and sharply as a jet. The heating flame is too strong if cut edges start to melt, overhang or show molten beads. Too weak a heating flame detonates during cutting. This may lead to cutting breaking off or even to flashbacks.

Figure B-9: Correctly set cutting jet

1 Primary flame 2 Secondary flame 3 Cutting oxygen jet

Change index: 1 ULTRAREX UXB (GB)

Too weak a heating flame produces substantial los ses in cutting performance. The cut exhibits extreme traces of scoring and irregularities.

Instruction manual

B-16

Annex B: Introduction to flame cutting techniques

Adjusting the cutting jet

The quality of the cutting jet is crucially important to achieving a perfect cut. The cutting jet is good if it lies precisely in the middle of the heating flame and has a clearly recognisable almost cylindrical shape.

The cutting jet is disturbed when

the cutting jet widens in the downward direction in

•

the shape of a broom shortly after emerging. the cutting jet is scarcely visible.

•

Clogged or soiled nozzles can be cleaned cautiously with the affiliated cleaning needle or with the corresponding nozzle cleaning solution. Wrong or

Figure B-10: Burner flame with disturbed cutting jet

1 Primary flame 2 Secondary flame 3 Disturbed cutting jet

wrongly used cleaning agents will destroy the nozzles.

Damaged nozzles must be replaced immediately.

Caution: Nozzles must always be screwed into the burner without applying force. It is imperative to use two spanners.

Instruction manual

Change index: 1 ULTRAREX UXB (GB)

B-17

Annex B: Introduction to flame cutting techniques

Working with flame cutters

Shutting down the burners manually

When closing the burner valves manually, pay attention to the correct sequence: Shut down the cutting oxygen first, then the fuel gas and, finally, the heating oxygen.

Figure B-11: Correct distance between nozzle and workpiece

Distance of the nozzle from the workpiece

The correct distance between the flame cutting nozzle and the workpiece is also important when it comes to producing a good cut. The distance is correct when the tip of the primary flame (with the cutting jet deactivated) is approximately 1 mm above the workpiece. Depending on nozzle size, for acetylene, this is the case at a nozzle distance of 3 10 mm. In the case of other fuel gases, the correct distance is approximately between 6 and 12 mm.

Cutting thickness in mm Nozzle distance in mm

<10

10-25

3 5

25-50

50 - 100

> 100

Table B-2: Approximate nozzle distance for acetylene

Instruction manual

Change index: 1 ULTRAREX UXB (GB)

6 8

B-18

Annex B: Introduction to flame cutting techniques

When using propane, natural gas or mixing gases as the fuel gas, owing to the geometry of the heating flame the chosen distances must be slightly larger.

The correct nozzle distance must be monitored during cutting and adjusted if necessary.

Start of the cut

The cut can be started in two different ways, either by an initial cut on the edged of the sheet (edge cut) or somewhere on the sheet (hole piercing). When piercing a hole, the workpiece must be preheated for longer because more material has to be heated up.

Preheating times

The time during which the heating flame brings the sheet to ignition temperature is referred to as the preheating time.

The required preheating time

• the initial cutting point (edge or in the sheet).

• the type of fuel gas.

•

the sheet surface (the preheating time must be prolonged if it is soiled).

•

the set heating flame.

•

the cutting nozzle.

depends on

1 Here and below, the preheating time stands for the heating time

of blow torch cutting machines.

Instruction manual

Change index: 1 ULTRAREX UXB (GB)

B-19

Annex B: Introduction to flame cutting techniques

The following tables provide an overview of typical preheating times.

Fuel gas types

Acetylene Propane Natural gas

Cutting

thickness in

mm <20 5 8 10 < 50 8 10 13

< 100 10 14 18

Table B-3: Average preheating times for initial cutting on a sheet edge

Acetylene Propane Natural gas

Cutting

thickness in

mm <20303440

Preheating time in secods

Fuel gas types

Preheating time in seconds

<50505360

< 100 78 80 85

Table B-4: Average preheating times for hole piercing

When piercing holes with blow torch cutting machines, after preheating the pressure of the cutting oxygen is continuously increased until the sheet has been pierced.

1 Data refers to the cutting and consumption tables issued by us.

Instruction manual

Change index: 0 ULTRAREX UXB (GB)

B-20

Annex B: Introduction to flame cutting techniques

Behaviour in the event of flashbacks

If highly soiled or damaged nozzles are used for cutting, it may occur that the flame will flash back into the interior of the burner. This is immediately recognisable by the sudden disappearance of the heating flame and simultaneous whistling or hissing in the burner. In such cases, the fuel gas valve must be closed immediately, followed by the heating and cutting oxygen valves. The heating flame can then be ignited again once the burner has cooled down. Pay attention to opening the valve for the heating oxygen first. If the burner is not shut down immediately in the event of such flashback occurring, its mixing system will be destroyed and the burner can therefore no longer be used.

A burner that has become useless is recognisable by the fact that, among other things, its heating flame will frequently go off with a bang despite the use of nozzles that are in perfect condition. Such a burner must be replaced immediately.

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B-21

Annex B: Introduction to flame cutting techniques

After cutting

Cutting quality

Cutting qualities are described in standards. Please refer to Annex V for further information.

Flame cutting flaws

Irregularities (flame cutting defects) on autogenous flame cuts, laser and plasma cuts are generally assessed with reference to standards. Please refer to Annex V for further information.

Instruction manual

Change index: 1 ULTRAREX UXB (GB)

B-22

Annex D: Technical data

Overview

Nameplate and CE plate Dimensions, weight, energy

supply

D-2

D-3

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D-1

Annex D: Technical data

Nameplate and CE plate

Figure D-1: Position of the nameplate (1) and CE plate (2) on the machine

ESAB CUTTING SYSTEMS GmbH

ESAB

Typ

Masch. Nr.

Baujahr

Figure D-2: Nameplate of the ULTRAREX UXB blow torch cutting machine

Robert-Bosch-Str. 20 D-61184 Karben

Tel. 06039/40-0 Fax 06039/40-266

KVA

Figure D-3: CE plate (for EU states only)

Instruction manual

Change index: 3 ULTRAREX UXB (GB)

D-2

Annex D: Technical data

Dimensions, weight, energy supply

Track height

Track length

Cutting length

Cutting thickness

Machine height

Machine length

Height of cutting table mm

Machine width

Cutting width

Maximum machine speed mm/min

Machine weight

Maximum number of single burners

Fuel gas

Voltage

Power consumption

≈

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Change index: 1 ULTRAREX UXB (GB)

D-3

Annex M: Overview of the machine

Overview

General view of the machine Machine description

Track M-3 Trolley M-3 Transversal carriage M-4 Burner carriages M-4 Burners and nozzles M-6 Autogenous equipment M-8 Hose and cable guidance on the machine M-9 Electrical equipment M-9 CNC controller M-10 Photoelectronic control M-10

Lubrication chart

Technical data ESSO Nuto H32 M-13

M-2 M-3

M-11

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M-1

Annex M: Overview of the machine

General view of the machine

Figure M-1: General view of the machine (left-hand version)

1 Track 5 Transversal carriage 2 Trolley 6 Trailing carriage with vertical adjustment and

torch

3 Photoelectronic controller 7 Coupling lever with Bowden cable for trolley

and transversal carriage freewheeling

4 CNC controller Emergency Stop pushbutton

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M-2

Annex M: Overview of the machine

Machine description

The ULTRAREX UXB blow torch cutting machine is a photoelectronically or CNC-controlled blow torch cutting machine that is designed for continuous industrial use.

Track

The track consists of machined flat rails.

In the case of the CNC-controlled blow torch cutting machine, a measuring rack is fitted on the guiding side. In the case of the photoelectronically controlled blow torch cutting machine, a corresponding sensor is installed for the longitudinal movement.

Trolley

The trolley is driven by a dynamic servo drive on machined flat rails (x-axis). The drive operates with a proven friction wheel drive system. The welded construction of the trolley featuring a very sturdy and low-vibration design ensures high surface quality of cut workpieces.

DeFreewheeling is achieved via a Bowden cable

coupling (1).

The Bowden cable coupling is fitted on the trolley.

Instruction manual

Change index: 0 ULTRAREX UXB (GB)

M-3

Annex M: Overview of the machine

Transversal carriage

Transversal movement (y-axis) is realised by a motor-driven carriage via a rack drive. Freewheeling is achieved by means of the same Bowden cable coupling as in the case of the trolley.

The trailing carriages (burner carriages) and the optical carriage are fitted on the driver rod of the transversal carriage.

Burner carriages

The burner carriages consist of trailing carriages (1), vertical adjustment (2), burner holders (3) and burners (4) and, if applicable, further tools.

Optical and trailing carriages

The optical and trailing carriages feature readjustable running, guiding and counter rollers. Therefore, the carriages can be moved easily along the guide.

2 1

Optical carriage

The carriages are clamped onto the driver rod (1) by means of a clamping unit (2).

Instruction manual

Change index: 0 ULTRAREX UXB (GB)

Trailing carriage

M-4

Annex M: Overview of the machine

Height adjustment

The trailing carriages of the ULTRAREX UXB blow torch cutting machine can be equipped with two different height adjustments:

Height adjustment Lift in mm A0 - motor-driven 200 A0 - manual 200

Burner holders

Diverse burner holders are available for the height adjustments:

Height adjustment Burner holder for A0 - motor-driven one tool A0 - manual one tool

Table M-1: Overview of height adjustments and affiliated burner holders

Possibilities of adjusting burners:

•

burner up and down in the burner holder depending on the free burner length,

•

burner holder parallel to the x-axis ±25 mm,

•

±45° swivel about the x-axis,

•

±10° swivel about the y-axis.

Instruction manual

Change index: 3 ULTRAREX UXB (GB)

M-5

ESAB ULTRAREX UXB Blow Torch Cutting Machine, ULTRAREX UXB blow torch cutting Instruction manual

Specifications and Main Features

Frequently Asked Questions

User Manual