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.
Change index: 0 Safety note (GB)
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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).
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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
22
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
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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:
F
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.
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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
8
10
13
15
17
18
Workplace
Safety measures
Emergency behaviour
19
20
21
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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
1
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:
F
It is imperative to use workshop equipment ap
propriate to the work when carrying out
maintenance work.
-
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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),
x
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.
1
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.
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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
•
F
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.
1
Regulations for work on the gas supply
The national regulations, specifications and laws
applicable to work on the gas supply must be
observed.
1
1 Please refer to Annex V for further information.
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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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F
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
26
28
29
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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.
1
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:
1
For further information, please refer to the
F
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operating instructions of the safety facility and
Annex V.
1 This requirement is fulfilled by ESAB tapping points.
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Electrical and gas safety facilities
Safety facilities on the machine
Note:
All listed safety facilities are not necessarily
F
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
E
A
B
C
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
2
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
29
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
31
32
36
37
39
42
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
43
44
45
49
53
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