English Plasma Manual HPR 260 BPLH

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USER MANUAL

PLASMA CUTTING MACHINE

MODEL BPL-H 3006

No part of this Users Manual may be reproduced or transmitted by any without Prior permission of Baykal Makine Sanayi ve Ticaret A..

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TABLE OF CONTENTS

A. GENERAL MACHINE INFORMATION ................................................................................................. 5

1. Safety Features of Your Plasma Machine ....................................................................................................... 6

2. Important Safety Information and Instructions ............................................................................................. 8

3. Overall Drawing of the Machine .................................................................................................................. 14

4. Lifting and Transportation ........................................................................................................................... 14

5. Unpacking and Installation .......................................................................................................................... 16

B. OPERATING AND MAINTENANCE INSTRUCTIONS ..................................................................... 20

1. Technical Data .............................................................................................................................................. 20

2. Main Part ..................................................................................................................................................... 20

3. PC DT12 Control Unit .................................................................................................................................... 21

4. Hypertherm HPR_260 Plasma Power Supply ............................................................................................... 22

5. Filtering System (Optional) ........................................................................................................................... 26

6. CAD Software (Lantek Expert II Cut Plus) ..................................................................................................... 27

C. OPERATING THE PLAZMA CUTTING MACHINE .......................................................................... 29

1. Electrical Connection .................................................................................................................................... 29 a. Electrical Cabinet ...................................................................................................................................... 29 b. Control Panel ............................................................................................................................................ 32 c. X -axis Limit Switches ............................................................................................................................... 34 d. Z -axis proximity switches ........................................................................................................................ 35 e. Y- axis limit switches ................................................................................................................................ 36

2. Using the Machine and Operating Software ................................................................................................ 36 a. Numeric Control Nc And Cage ........................................................................................................... 37 b. PC DT12 .................................................................................................................................................... 37 c. Cage .......................................................................................................................................................... 38

3. Using the Machine ....................................................................................................................................... 39 a. Start up ..................................................................................................................................................... 39 b. Adjustment (referencing to zero): ............................................................................................................ 42 c. Manual mode: .......................................................................................................................................... 44 d. Plate rotation: .......................................................................................................................................... 47 e. Automatic Mode ...................................................................................................................................... 49 f. Simulation ................................................................................................................................................ 52

4. Control Software .......................................................................................................................................... 54 a. Main Menu ............................................................................................................................................... 55

i. Active Functions ................................................................................................................................... 56 ii. Drop Down Menu ................................................................................................................................. 56 iii. NC Info ............................................................................................................................................. 57 iv. Colors of NC Alarm Board / Plc Alarm Board .................................................................................... 57 v. State Icons ............................................................................................................................................ 57 vi. Exit from the Application Package ................................................................................................... 58

b. Adjustment ................................................................................................................................................... 59

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i. F1 Zero Search .......................................................................................................................................... 59

c. Manual ......................................................................................................................................................... 60 i. F1 I/O ........................................................................................................................................................ 61 ii. F2 Axes ..................................................................................................................................................... 63 iii. F3 Move Axis ........................................................................................................................................ 64 iv. F4 Users Variables ............................................................................................................................... 64 v. F5 Speed ................................................................................................................................................... 65 vi. F6 Manual Cutting ................................................................................................................................ 65 vii. F7 XY Plate Rotation ............................................................................................................................. 66

d. Automatic ..................................................................................................................................................... 68 a. F7 Directory .............................................................................................................................................. 69 b. F2 User Rotation ....................................................................................................................................... 69 c. F3 Graphics ............................................................................................................................................... 70

i. F4 Zoom Area ....................................................................................................................................... 71 ii. F5 Step By Step ..................................................................................................................................... 72

d. Graphic Colors .......................................................................................................................................... 73 e. F1 Execute ................................................................................................................................................ 74

i. F6 Oxy Parameters ............................................................................................................................... 75 ii. F7 Tool Head Change (Drill Parameters) .............................................................................................. 77 iii. F12 Previous ..................................................................................................................................... 77 iv. F1 Go On ........................................................................................................................................... 79 v. F1 Input ................................................................................................................................................ 80 vi. F1 Simulated ..................................................................................................................................... 80 vii. Error Page ......................................................................................................................................... 81 viii. F1 Detail ........................................................................................................................................... 82 ix. F2 Help ............................................................................................................................................. 82 x. F3 CNC log-file ...................................................................................................................................... 83 xi. F4 PLC Historical ............................................................................................................................... 83

5. Program Archive ( Plasma ISO ) .................................................................................................................... 84 a. F1 New ..................................................................................................................................................... 86 b. F2 Open .................................................................................................................................................... 86

F1 Edit........................................................................................................................................................... 86 F6 Editing ...................................................................................................................................................... 87 F7 Find .......................................................................................................................................................... 88

6. Configuration Setting ................................................................................................................................... 88 a. General ..................................................................................................................................................... 89 b. Syncro Files ............................................................................................................................................... 90 c. Serial Port ................................................................................................................................................. 91 d. ISO Parameters ......................................................................................................................................... 92 e. Error Codes of Syncro ............................................................................................................................... 93

7. Maintenance and Inspectation .................................................................................................................... 98 a. Types and Frequency of Inspectations ..................................................................................................... 98 b. Troubleshooting ....................................................................................................................................... 99 c. Conditions of storage, re-utilization and scrapping ............................................................................... 102 d. Lubrication ............................................................................................................................................. 103

D. PRINCIPLES OF PLASMA CUTTING TECHNOLOGIES .............................................................. 106

Cut Charts ....................................................................................................................................................... 109 Consumables .................................................................................................................................................. 110 Recording Consumable Life ............................................................................................................................ 112 Consumable Life ............................................................................................................................................. 112

i. Pierce Height ...................................................................................................................................... 113

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ii. Reducing Errors .................................................................................................................................. 113 Cut Quality ..................................................................................................................................................... 114

Reading the Cut .......................................................................................................................................... 114 Bevel Angle ................................................................................................................................................. 114 Decreasing Dross (Slag) .............................................................................................................................. 115 Appearance of Cut...................................................................................................................................... 116 Reading Lag Lines ....................................................................................................................................... 117 Effects of Cutting Speed on Arc Voltage .................................................................................................... 118 Cutting Direction ........................................................................................................................................ 119 Cutting Holes .............................................................................................................................................. 120

E. ELECTRIC CIRCUIT DIAGRAM ........................................................................................................ 121

F. SPARE PARTS ............................................................................................................................................ 137

G. APPENDIXES .......................................................................................................................................... 144

APPENDIX A: ISO Programming ......................................................................................................................... 144 Structure of Iso Programs .............................................................................................................................. 144 G Functions .................................................................................................................................................. 144 M Functions .................................................................................................................................................. 145 G Codes Programming ................................................................................................................................. 146 Meaning of M Functions ................................................................................................................................ 148 Example of ISO program ................................................................................................................................ 150

APPENDIX B: Cut Charts .................................................................................................................................... 152

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A. GENERAL MACHINE INFORMATION

1 Registered Trademark Baykal Mak. San. ve Tic. A.. 2 Machine Type Plasma BPL-H 3008 3 Serial Number

4 Year Of Manufacture 2009

5 Address Of Manufacturer

Baykal Mak. San. ve Tic. A.. Organize Sanayi Blgesi Yeil Cad. No: 24 16140 Bursa / TURKEY 0090 - 224 - 243 16 10

0090 - 224 - 243 12 86

6 Address Of The Authorized Dealer

, 115114, , . .7, .1, 1- .: (495) 223 02 81 : (495) 223 02 82 www.cf-industry.ru, [email protected]

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1. Safety Features of Your Plasma Machine

Emergency switches operate to stop the machine in emergency and have to be used any time that a dangerous situation advises to stop immediately the machining, or anytime that it is necessary to get in some areas around the machine for inspectation or maintenance. More than one emergency switches has been placed on the machine in the following areas in compliance with the essential requirements of the Machine Directive and the indications of the EN 418 rule.: on the left and right size of the beam (see Figure- 1) and on the control panel (see Figure- 2).

Figure- 1

Figure- 2

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Control lights are placed on the beam. It is equiped with the following lights to indicate what kind of function of the machine is working (see Figure- 3)

The red light lights up when the machine is in emergency stop. The green light lights up when the machine is working. The yellow light lights up when the reset of the machine takes place

Figure- 3

Cable and hose carriers are assembled to protect cables and gas hoses in order to avoid the hose and cable entanglement and their eventual consequent demages, in order to reduce potential dangers.

Push buttons were thought and realized in compliance with the essential requirements of the Machine Directives and with the indications of EN 292 rule.

Main switch (on the cover of electric panel ) for controlling the machine, it has two position;

1. OFF position (0 position): on such position the electric equipment of the machine is completely isolated.

2. ON position (1 position): when the switch is on this position the console is under tension. (machine is energized)

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2. Important Safety Information and Instructions

!!!

Danger Cutting can cause fire or explosion.

Remove all flammables within 10 m of the cutting area. Never cut containers with potentially flammable materials inside - they must be emptied and properly cleaned first

When cutting with oxygen as the plasma gas, an exhaust ventilation system is required

Be sure the area is safe before doing any cutting. Keep a fire extinguisher nearby

Quench hot metal or allow it to cool before handling or before letting it touch combustible materials

Ventilate potentially flammable atmospheres before cutting

Do not use the plasma system if explosive dust or vapors may be present

Do not cut pressurized cylinders, pipes, or any closed container

Do not cut containers that have held combustible materials

Oxygen and methane are flammable gases that present an explosion hazard. Keep flames away from cylinders and hoses that contain methane or hydrogen mixtures. Keep flames and sparks away from the torch when using methane or argon-hydrogen plasma.

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!!!

Danger Electric shock can kill Touching live electrical parts can cause a fatal shock or severe burn.

Operating the plasma system completes an electrical circuit between the torch and the workpiece. The workpiece and anything touching the workpiece are part of the electrical circuit.

Never touch the torch body, workpiece table when the plasma system is operating.

Wear insulated gloves and boots, and keep your body and clothing dry.

Do not stand, sit or lie on - or touch - any wet surface when using the plasma system.

Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground. If you must work in or near a damp area, use extreme caution.

Provide a disconnect switch close to the power supply with properly sized fuses. This switch allows the operator to turn off the power supply quickly in an emergency situation.

Install and ground this equipment according to the instruction manual and in accordance with national and local codes.

Inspect the input power cord frequently for damage or cracking of the cover. Replace a damaged power cord immediately. Bare wiring can kill.

Inspect and replace any worn or damaged torch leads.

Do not pick up the workpiece, including the waste cutoff, while you cut. Leave the workpiece in place or on the workbench with the work cable attached during the cutting process.

Before checking, cleaning or changing torch parts, disconnect the main power or unplug the power supply.

Never bypass or shortcut the safety interlocks.

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Before removing any power supply or system enclosure cover, disconnect electrical input power. Wait 5 minutes after disconnecting the main power to allow capacitors to discharge.

Never operate the plasma system unless the power supply covers are in place. Exposed power supply connections present a severe electrical hazard.

When making input connections, attach proper grounding conductor first.

Each Hypertherm plasma system is designed to be used only with specific Hypertherm torches. Do not substitute other torches which could overheat and present a safety hazard.

!!!

Danger Cutting can produce toxic fumes and gases that deplete oxygen and cause injury or death.

Keep the cutting area well ventilated or use an approved air-supplied respirator.

Do not cut in locations near degreasing, cleaning or spraying operations. The vapors from certain chlorinated solvents decompose to form phosgene gas when exposed to ultraviolet radiation.

Do not cut metal coated or containing toxic materials, such as zinc (galvanized), lead, cadmium or beryllium, unless the area is well ventilated and the operator wears an air-supplied respirator. The coatings and any metals containing these elements can produce toxic fumes when cut.

Never cut containers with potentially toxic materials inside -they must be emptied and properly cleaned first.

!!!

Danger

A plasma arc can cause injury and burns. Plasma arc comes on immediately when the torch switch is activated. The plasma arc will cut quickly through gloves and skin.

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Keep away from the torch tip.

Do not hold metal near the cutting path.

Never point the torch toward yourself or others.

!!!

Danger Arc rays can burn eyes and skin. Eye Protection Plasma arc rays produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin.

Use eye protection in accordance with applicable national or local codes

Wear eye protection (safety glasses or goggles with side shields, and a welding helmet) with appropriate lens shading to protect your eyes from the arc's ultraviolet and infrared rays.

Skin Protection Wear protective clothing to protect against burns caused by ultraviolet light, sparks andhot metal.

Gauntlet gloves, safety shoes and hat

Flame-retardant clothing to cover all exposed areas.

Cuffless trousers to prevent entry of sparks and slag.

Remove any combustibles, such as a butane lighter or matches, from your pockets before cutting.

Cutting Area Prepare the cutting area to reduce reflection and transmission of ultraviolet light:

Paint walls and other surfaces with dark colors to reduce reflection.

Use protective screens or barriers to protect others from flash and glare.

Warn others not to watch the arc. Use placards or signs.

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!!!

Warning Graunding Safety Work Cable : Attach the work cable securely to the workpiece or the work table with good metal-to-metal contact. Do not connect it to the piece that will fall away when the cut is complete. Work Table : Connect the work table to an earth ground, in accordance with appropriate national or local electrical codes

Be sure to connect the power cord ground wire to the ground in the disconnect box.

If installation of the plasma system involves connecting the power cord to the power supply, be sure to connect the power cord ground wire properly.

Place the power cord's ground wire on the stud first, then place any other ground wires on top of the power cord ground. Fasten the retaining nut tightly.

Tighten all electrical connections to avoid excessive heating.

!!!

Danger Gas cylinders can explode if damaged Gas cylinders contain gas under high pressure. If damaged, a cylinder can explode.

Handle and use compressed gas cylinders in accordance with applicable national or local codes.

Never use a cylinder that is not upright and secured in place.

Keep the protective cap in place over valve except when the cylinder is in use or connected for use.

Never allow electrical contact between the plasma arc and a cylinder.

Never expose cylinders to excessive heat, sparks, slag or open flame.

Never use a hammer, wrench or other tool to open a stuck cylinder valve.

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!!!

Warning Noise can damaged hearing. Prolonged exposure to noise from cutting or gouging can damage hearing.

Use approved ear protection when using plasma system.

Warn others nearby about the noise hazard.

!!!

Warning A plasma arc can damaged frozen pipes. Frozen pipes may be damaged or can burst if you attempt to thaw them with a plasma torch.

!!!

Warning Pacemaker and hearing aid operation. Pacemaker and hearing aid operation can be affected by magnetic fields from high currents. Pacemaker and hearing aid wearers should consult a doctor before going near any plasma arc cutting and gouging operations. To reduce magnetic field hazards:

Keep both the work cable and the torch lead to one side, away from your body

Do not wrap or drape the torch lead or work cable around your body.

Keep as far away from the power supply as possible.

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3. Overall Drawing of the Machine

Figure- 4: Overall view of the machine and represantation of the axes

4. Lifting and Transportation

Lifting the bed assembly: The bed assembly must be lifted with proper belts and hook as shown in Figure- 5. The bed assembly is equiped with two eyebolts adequate to ensure the sling works properly.

Figure- 5

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Lifting the bridge: The bridge must be lifted with proper belts and hook as shown in Figure- 6. The bridge is equiped with two belt holes.

Figure- 6

Lifting the exaust ventillation system: The exaust ventilation system must be lifted with proper belts and hook as shown in Figure- 7. The belts must be set under two sides.

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Figure- 7

Transportation of all units: All units are packed, loaded onto a truck with crane, positioned and fatened to avoid damage, transported to their destination and unloaded from the truck.

You must use suitable equipment to move these parts inside the plant such as forklifts, bridge cranes. Make sure that you use approved-type accessories (belts, chains and hooks with maximum load indicated or boards on the forks)

5. Unpacking and Installation

!

Assembly and installation will be done by BAYKAL technicians.

Before the machine is delivered, prepare the electric power, gas and pneumatic supply lines needed to operate the machine.

Air for pneumatic systems must be filtered and dry before it is let into the circuit

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You must first study the layout of the machine to find the most appropriate place for it in the shop so that the various phases of the production cycle can be carried out in the simplest and most ergonomic manner.

The floor where the machine will be placed on, must not present neither holes or juts, that may compromise the stability, duration and noise caused by vibrations because of a wrong positioning; the floor needs to respect some proper constructive characteristics.

Overall dimensions of the machine must be considered when installing

The machine will be levelled and screwed on the floor by BAYKAL technicians.

Machine will stand on the steel washer on the floor shown in Figure- 8

Figure- 8

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All components of the machine, namely Main part, Hypertherm Plasma Power Supply, Filtering System and Control Unit (Electric panel and Control Unit), will be placed by BAYKAL technicians.

For minimum installation dimensions, see Figure- 9 below. Installation dimensions will be determined later in the installation place.

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Figure- 9: Installation Diagram

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B. OPERATING AND MAINTENANCE INSTRUCTIONS

1. Technical Data

Baykal BPLH 3006 Plasma Cutting Machine consists of three parts.

1. Main Part (Work table, Moving parts and Electric cabinet) 2. Hypertherm Hydefinition Plasma Power Supply 3. CAD Software

2. Main Part

Technical Specifications

Machine width : 5200 mm

Machine lenght : 10000 mm

Cutting width : 3000 mm

Cutting lenght : 8000 mm

Cutting range : 400 mm

Working Table height : 745 mm

Supply voltage : 380 V 10 %

Frequency : 50 60 Hz 2 %

Power consuption : 45 kW

Working temperature : Min -10 C ila Max +40 C

Ideal working temperature : +5 C ila +30 C

Y axis driving system : Double sided and two directional longitudinal driving

Y axis guiding

: Lineer rail system

Y axis motors : Brushless AC servomotors

Y axis movement : Rail driving

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X axis driving system : Two directional driving

X axis guiding : Lineer guiding system

X axis motors : Brushless AC servomotors

X axis movement : Pinion on rack rail driving

Positioning speed : Max 30 meter/min

Visual warning devices : Coloured lamps

Control : Windows based CNC unit

Fume exausting system : Pneumatic valves controlled by CNC

3. PC DT12 Control Unit


Processor: EPIA 1000 MHz Operating system: Windows XP Professional Memory: 512 MB HardDisk: 80GB 4 Serial Ports 4 USB Ports 1 PS2 port for Mouse 1 PS2 port for Keyboard Trackballor external keyboard

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Display LCD SVGA800x600 TFT Touchscreen 2 Ethernet Ports Audio Connectors VGA Port

4. Hypertherm HPR_260 Plasma Power Supply

HPR_260 HyPerformance cutting unit consists of six parts. Power supply, gas console, RHF console, Valve assembly and torch assembly. HPR_260 unit can be easily used to cut materials. HPR_260 is designed to cut mild steel, stainless steel and aliminium. By means of Gas control unit, you can cut different materials using different gases and gas combinations.

Power unit: This unit supplies current from 30 up to 260 Amps and have a 311 Volt DC current. By means of PCB microprocessor which controls plasma functions, it automatically performs the start-up sequence, machine interface functions, gas and cutting parameters and the stop time sequence.

The Cutting- and Pearcing-Highs are same following

Material Amper Max. cutting Max. pearcing Mild steel 260 65 38

Stainless steel 260 50 32 Aluminum 260 50 25

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Power unit: Maximum OCV ( U0) : 311 VDC Maximum output current (I2) : 260 Amps Output voltage (U2) : 50-175 VDC Duty cycle rating (X) : 100% at 45.5 KW ,40, (140 F) Cooling : Forced air (F class) Ambient temperature/ Duty cycle

: Power supply will operate between -10 and +40 C. ( + 14 and 104 F )

Supply voltages : 400 VAC CE, 3 Faz, 50-60 Hz, 32 Amp

Air Quality & Pressure

quality pressure +/- 10 % Flow rate O2 oxygen purity 99.5%

clean, dry, il-free 827 kPa / 8.3 bar

120 psi 4250 I/h 150 scfh

N2 Nitrogen purity 99.99% clean, dry, il-free

827 kPa / 8.3 bar 120 psi

7080 I/h 250 scfh

Air clean, dry, il-free 827 kPa / 8.3 bar 120 psi

7080 I/h 250 scfh

H35 Argon-hydrogen Purity 99.995% (H35=65% Argon, 35% Hydrogen)

827 kPa / 8.3 bar 120 psi

4250 I/h 150 scfh

F5 Nitrogen-hydrogen purity 99.98% (F5=95 Nitrojen, 5% Hydrogen)

827 kPa / 8.3 bar 120 psi

4250 I/h 150 scfh

Mild Steel Stainless Steel Aluminium

Gas-Types Plasma Shield Plasma Shield Plasma Shield Cutting 30 to45 A O2 O2 N2 & F5 N2 Air Air Cutting 80 A O2 Air F5 N2 Cutting 130 A O2 Air N2 & H35 N2 H35 & Air N2 & Air

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HPR 260 Consumables

HPR 260 consumables are 7 pieces. You see the details about consumables below

Material Current Plasma Gas Schield

Gas Min. Thickness

(mm) Max.Thickness

(mm)

Mild Steel

Marking (15 A) N2 N2 30 Amp O2 O2 0.5 6 80 Amp O2 Air 2 20 130 Amp O2 Air 3 38 200 Amp O2 Air 6 50 260 Amp O2 Air 6 64

Stainless Steel

Marking (15A) N2 N2 45 Amp N2 N2 0.8 4 45 Amp F5 N2 0.8 6 80 Amp F5 N2 4 10 130 Amp N2 N2 6 20 130 Amp H35 N2 10 25 200 Amp H35 N2 10 20 260 Amp H35 N2 10 50

Aluminum

15 Amp N2 N2 45 Amp Air Air 1.2 6 130 Amp Air Air 6 25 130 Amp H35 N2 10 25 200 Amp H35 N2 10 20 260 Amp H35 N2 6 50

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1.

Electrode life:

Group change: It consists of a nozzle, an electrode and a shield. It is a easy wearing group. Their wearing live depends on piercing number and cutting period. They should be changed always as a set. Change them when the gas holes blocked and erosion in nozzle (nozzle always must be round and not signs of ark in its surface) or when electrode is damaged.

Shield

2. Swirl ring: It is a less wearing part. In case of corrosion, demage or blocked holes, it must be changed.

3. Shield cap: It should be changed once a year or in case of corrosion, demage, missing material, crack or burned.

*** For more information See related manual.***

5. Filtering System (Optional)

The machine has a fume exausting system under the grid bench to exaust the dust and fume existing during cutting process. In order to be sucked out these subtances, a filtering and ventiation system is provided with the machine. This system must be connected to the small openings in the back side of the machine by special pipelines. This unit is optional and if customer decides to purchase it saperately, please contact with Baykal machinery for correct choise.


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6. CAD Software (Lantek Expert II Cut Plus)

Specifications

Powerful database structure and file system

Common use in same database with other computers connected to the same Network

Easy switching among the databases in a system

Improved import and export options

Program structure with modules such as CAD (Computer aided Designing), material, sheet (plate), Language, Configuration, operation center

Easy drawing with parametric shapes

A class, functional drawing interface

Complete control advantage over cutting process with Nesting options

Complete control advantage over cutting process with Machining options

Complete control advantage over cutting process with Lead-in / Lead-out options

Complete control advantage over cutting process with Remnant plate and saving options

Manual, semi-automatic and full automatic nesting and machining options

Complete control over machine with kerf, plate and cutting simulations

Auxiliary functions such as part test, dimensions e.g.

Multi-torch connection support

Improved common cutting options

Computing cutting time and cuting cost accurately

Printing copy for machine operator

Designing proper configurations and taking G codes after defining different machines

Custom settings on User interface

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Supported Operating Systems

Win2K, WindowsXP, Windows Vista, Windows 7.

Options

Tube cutting (Duct): This is a powerful module for calculating HVAC and DUCT figures in which users simply select and enter the dimensions. Thus the figure will be automatically developed, ready for machining.

Expert III: This is a system that provides integrated manegement of the whole production process in sheet metal manufacturing environments.


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C. OPERATING THE PLAZMA CUTTING MACHINE

1. Electrical Connection

a. Electrical Cabinet

Figure- 10:Electrical Cabinet

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Figure- 11: Inside the cabinet

Figure- 12

1 2 3

4 5

6

7 8 9 10 1112 15 13 14

15

16

17

18

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No Description

1. Main Transformer (Electrical diagram label or representation 2T1 )

2. DC Power Supply (Electrical diagram label 2G2 )

3. Laser pointer (Electrical diagram label 6A1 )

4. Input Boards (Electrical diagram label IN1,IN2, IN3 )

5. Output Boards (Electrical diagram label MUS1,MUS3 )

6. Control Fuses (Electrical diagram label from 1F1 to 1F10 )

7. Plug (Electrical diagram label 2E1 )

8. Phase control

9. Smoke absoption system Motor Switch

10. Control Relays (Electrical diagram label 3K1 and 3K3 )

11. Emergency stop module (Electrical diagram label 3A1 )

12. Plasma On Relay (Electrical diagram label 9K2 )

13. Main Switch (Electrical diagram label 2Q1 )

14. Syncro-PLC (Electrical diagram label CNC-X, CNC-Y, CNC-S and CNC-Z )

15. Terminals

16. THC-Cart

17. Noise Filter (Electrical diagram label 2FT1 )

18. X ,Y,S and Z Axis Motor Drivers (Electrical diagram label X,Yand S (Slave) axis )

19. A,B axis Drivers.

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b. Control Panel

Electrical Label Name Description

NC12

Main Control Unit Main control unit is an industrial PC which controls all functions of the machine.

1 NC12 ON/OFF Switch This switch is used for turn on or off the PC *

2 RUN Activates emergency module, servo drivers and I/O module.

3 STOP Halts the axis movement and cutting process.

4 START Starts the axis movement and cutting process.

5 RETRACE After machine is stoped, this button retraces the machine to the begining of the last contour.

6 Reference points The axis move on the refence points

7 JOG Z + It makes Z axis move incrementally in the positive direction.

8 JOG Z - It makes Z axis move incrementally in the negative direction.

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9 VENTILATIN START Starts ventilation system

10 VENTILATION STOP Stops the exaust ventilation system

11 Park position When pressing this button, machine goes to the predefined parking position

12 Emergency Stop Button In case of emergency

13 JOYSTICK It is used for positioning the machine manually.

14 Oxy Torch 1 Up Used to move the Oxy Torch 1 Up

15 Oxy Torch 1 Down Used to move the Oxy Torch 1 Down

16 Oxy Torch 2 Up Used to move the Oxy Torch 2 Up

17 Oxy Torch 2 Down Used to move the Oxy Torch 2 Down

18 Ignition Used to ignite the oxy torch.

19 Preheat On/Off Used to open preheat valves.

20 Cut On/Off Used to open cut valves.

21 Mode Selection Auto / Manual selection.

22 Potansiometre Used to adjust the height of the Oxy Torch.

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c. X -axis Limit Switches

No Electrical Label Name

1 5S1 + limit switch X axis

2 5S3 Zero reference switch (X=0 point)

3 5S2 - limit switch X axis (located on the other corner)

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d. Z -axis proximity switches


1 4S3 Touching sensor

2 4S1 Torch protection

3

4S2 Torch protection

4 5S7 The top limit switch (Under the cover)

5 5S8 The bottom limit switch (Under the cover)

(1)

(2) (3)

4

5

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e. Y- axis limit switches


1 5S6 Zero reference switch (y=0 point)

2 5S5 - limit switch Y axis

3 5S4 + limit switch Y axis (on the back side of the machine)

2. Using the Machine and Operating Software

This section follows the principle to examine the different subjects by starting from the functions which are available in the main menu at the machine starting and then the many submenus as they are available.

The whole is preceded by the introduction and by general topics. After the section concerning the menu functions, there are some additional subjects.

Some functions can be available more than once in the different menus. Unless otherwise established, the functions are described in only one chapter you have to refer to every time that the functions are mentioned again.

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a. Numeric Control Nc And Cage

The Numerical Control PC DT12 is the real industrial PC ("NC") which is subdivided into two parts: the real PC and the external keyboard.

From now on, by NC we'll mean the PC control unit, including the unit based on PC Pentium MMX 233 MHz and its physical interfaces (Screen, Keyboard, Floppy Disk, Serial), while by CAGE we'll mean the cards all together, including the 68000 microprocessor unit that is in charge of the real control of the machine tool.

As a general rule this handbook will refer to the NC as this unit concerns the operator and the application program. Some references to the Cage will be made when required.

b. PC DT12

From the outside the NC looks like the above board.

The handbook refers often to the "cursor shift keys" or to the "function keys" and to the ENTER key.

The monitor is a color TFT 800x600 Touch Screen

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At the back there are the connectors for the four service serial lines (Ex.: Unloading of Files from CAD), the connector of the parallel port and the connector for the keyboard.

The screen output is on a 15-pole standard connector and it is foreseen for VGA monitor.

WINDOWS is the operating system. The supplied version is generally the latest available and anyway the one considered as the most suitable for the characteristics of the Teseo Application Package.

c. Cage

By CAGE we mean the part controlling the axes movements and the management of the digital INPUTS/OUTPUTS. Physically, this structure is able to receive a variable configuration of cards with its own CPU which is able to run the programs and the instructions given by the NC.

The CAGE communicates with the PC DT12 by an external serial cable. There are also the CPU card, the INPUT/OUTPUT cards and those for the Axes Control and the Supply Unit. The supply unit gives also the power supply voltages for the PC part.

In case of bad working, check the fuses of the supply unit (even if leds are on)

The Cage includes also the PLC (CPU card) and it is in the buffer. The buffer of the CPU card can include other important data.

The removal of the CPU card from the cage doesn't imply any loss of data as the buffer is on the CPU itself. For the same reason, never put the CPU card on metal parts if you don't want it to be damaged.

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ATTENTION Pay the greatest attention to the tightening of the cards and the connectors on the Cage.

The operations about the cage (cards and connectors) must be carried out subject to manufacturer's agreement.

3. Using the Machine

Operating of the plasma cutting machine can be explained in five phases.

1. Start up

2. Adjustment (Zero referencing) 3. Manual Mode

4. Automatic Mode

5. Simulation

a. Start up

On starting, the PC DT12 and the Cage execute different initialization phases that end up in their mutual connection and in the machine preparation for the user's operations.

Every unit executes its own initialization phase (or "bootstrap") with different characteristics and times.

In particular, the cage executes a comparatively shorter phase, compared to the PC DT12, where the PLC boots and remains in the wait state. During this phase, some external and internal protections avoid any movement or action not foreseen by the Manufacturer or Teseo.

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The PC DT12 executes a normal bootstrap, peculiar to PCs, composed of the BIOS start with the self-diagnosis of the storage and the peripherals, the installation of the drivers and then the loading of WINDOWS and the application package.

On starting, the Application Package checks the presence of the drivers and the necessary initialization files; in case of anomaly, the execution is aborted and the control is given to WINDOWS. In this case, put in contact with BAYKAL.

After checking the presence of these components, the Application Package starts the connection with the Cage.

If the connection between the units is successful, the home page of the application package is displayed on the screen and the starting phase can be considered as ended.

Prior to starting up the machine, check the emergency stop buttons and limit switches in all axis against any demage or mechanically function lost.

Be sure of nobody to stand on the work table or to access to movement area of the machine axis.

Check the gas hoses to be connected to the gas console properly.

Check rack rails against any demage .

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Do not forget connecting power cable of the machine and the hypertherm unit to the nearest power supply.

1.

Turn on the main switch to position I (Figure- 13:a).

The machine will be energized.

(a)

(b)

(c)

Figure- 13

2.

Turn on the PC DT12 on/off switch on control panel to position on (Figure- 13:b)

PC DT12 unit will be energized and control software will start automatically after windows will have been loaded.

You will see the Main menu in the screen.

3.

Press the Run button (See Figure- 13:c)

Emergency module, servo drivers and I/O modules will be activated.

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b. Adjustment (referencing to zero):

!

1.

The machine always must be referanced to the zero position of the machine XY coordinate system before starting cutting.

Press F1 Adjustment key in Main menu on the PC DT12 unit (See Figure- 14).

You will see adjustment menu in the screen.

Figure- 14

2.

Press F1 Zero search key on the PC DT12 unit (see Figure- 15).

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Figure- 15

3.

Press the start button ( Number 4 ) on the control unit (see Figure- 16).

The machine will move to the origin (0,0) of the machine coordinate system.

NOTE:

The origin of the coordinate system is determined according to the zero switch (X an Y axis electrical connection in section 6.3.1) position in X and Y axis.

The torch will be in upper position in Z axis.

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Figure- 16

c. Manual mode:

Press F2 Manual key in the Main menu on the PC DT12 unit (see Figure- 17).

In manual menu;

a) You can cut plates manually using the manual cutting option b) You can set plate position using the plate rotation option in manual menu c) The machine can be positioned manually using the joystick on the control

panel or entering position value directly . d) You can observe I/O states when the machine starts up. e) You can also determine the reference point of the plate without using plate

rotation option. In order to that, take the torch to any point above the plate and press the zero point button on the control panel.

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Figure- 17

a.

Manual cutting:

You can cut plates manually using the joystick on control panel in this mode.

1. Press F6 Manual cutting key in Manual Menu (see Figure- 18) on PC DT12 unit.

The cutting speed window will pop up.

2. Enter the cutting speed according to the cutting charts in Appendix C. 3. Press F1 to confirm the speed value.

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Figure- 18

4. Keep the Joystick ( Number 13 ) pressed (see Figure- 19).

Torch will descend and touch the plate. Thus it will be referenced and rise to the cutting hight.

After a time setted in CNC parameters, hypherterm unit will open the gas flow and fire up the plasma gas.

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Figure- 19

5. Use the joystick to control the cutting direction.

! REMEMBER: When cutting, keep the joystick pressed.

6. To stop cutting, release the joystick.

d. Plate rotation:

b.

Plate rotation is used for parallelizing the plate sides to the machine X-Y coordinate system. If the plate sides on the work table is not parallel to the machine sides, you should make plate rotation.

1. Press F7 Plate rotation key in manual menu (see Figure- 20).

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Figure- 20

Fig.- 6.3.2.9

2. Select point 1 over the plate using joystick and confirm with F1 (see Figure- 20)

3. Select point 2 over the plate using joystick and confirm with F1. (see Figure- 20)

4. Select point 3 over the plate using joystick and confirm with F1. (see Figure- 20)

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5. Press F7 to confirm all points (see Figure- 20)

You will see pop-up window in the screen showing the plate angle and offset.

6. Press F2 to confirm the values in pop up window.

!

DO NOT forget reseting the plate rotation after cutting the rotated plate. In order to reset plate rotation;

Press F6 Reset key in the plate rotation menu.

e. Automatic Mode

In this mode, you can cut pre-programmed plates with a CAD software.

To select automatic mode, press F3 Automatic key in Main menu (see in Figure- 21).

Figure- 21

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1. Insert a flash disk including CAD produced programs to the USB port.

2. Press F4 Copy Programs key.

System ask which programs you want to copy to the default directory.

Note: If your machine is connected to a network, CAD programs can be sent directly to the program directory of the machine from any local computer connected to the same network.

3. Select program using the up-down arrows in the key pad and press OK

4. After copying the programs to the directory, select a program to be cutcut using up-down arrows.(See in Figure- 22)

Figure- 22

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NOTE : If you want to start cutting from any line in the program;

Press F5 Resume Program key in Automatic menu Select the program line from which you want to start cutting using up- down arrow keys. Press F1 to confirm Press start button. Cutting will start from that line.

5. Press F1 Execute key .(See in Figure- 23).

Figure- 23

!

Torch Parameters

6. Press F4 Torch Parameters key (See in Figure- 24).

Note: If the CAD software is used correctly all the parameters will come automatically from the software.

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Figure- 24

7. Press Start button ( Number 4 ). Cutting will start.

Note : While the cutting is going on, press F2 Torch Blocking key. So the torch hight will NOT change during cutting.

Note : Press F3 Gpraphic key to observe cutting from graphical veiw.

f. Simulation

After pressing F1 Execution key in Automatic menu, press F1 Simulation key (See in Figure- 25. Then press Start button.

The machine will start simulating the cutting process.

Note : In order to make simulation when cutting process is going on, press stop button to halt the cutting process. Then press F1 Simulation key. The machine will start simulating the cutting process.

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Figure- 25

54

4. Control Software

Software Organisation:

Start up

MAIN MENU

ADJUSTMEN MANUAL AUTOMATIC

Zero Search

I/O Axes Move User Variables Speed Manual Cutting XY Plate Rotation

Execute User Rotation Graphics Copy Program Resume Program Tool Radius Directory

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a. Main Menu

The page layout is common to all the pages of the submenus of the NC. Sometimes windows can be displayed in the area called "Working Area" (e.g. Automatic or Graphics), but basically there are always five fixed areas. Namely:

State icons : Diagnosis icons of the machine state Active Menu Board : It displays the currently active menu NC Alarm Board : It displays the alarms generated by the cage PLC Alarm Board : It displays the messages from PLC Function Keys : They allow to see the next submenu or to

enable the associated function

The F12 key is common to all menus and it allows to go back to the previous menu or, in case of Main Menu, to terminate the Application Package

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i. Active Functions

The active functions are

ii. Drop Down Menu

By the ALT key or F10 you can access the drop-down menu with the following functions:

File\Exit (Alt+F4)

Exit from the application package.

Management\Parameters (Ctrl+F1)

It enables the editor of the machine tables

Management\Programs (Ctrl+F2)

It enables the editor of the ISO programs

Page\PLC Errors (F9)

It displays the page of PLC error diagnostics

Page\NC Info (Ctrl+I)

It displays the info page about the cage SW

Preferences\Alarm colors selection (Ctrl+A)

It allows to change the default colours of the alarm messages

Preferences\Graphics colors selection (Ctrl+G)

It allows to change the default colours of the graphics window

Help (Alt+H)

It enables the on-line help of the application package by means of Microsoft Internet Explorer

F1 : Adjustment Setting of axes and tongs reading F2 : Manual Manual shifting operations of the axes

F3 : Automatic Automatic execution/continuation of ISO programs

F6: Shutdown A short cut to shut down the NC

F7: Diagnostic It has not been implemented yet.

F12 : Exit Exit from the application

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iii. NC Info

It displays the information about software (EPROM type and version and PLC name and version) installed on the Cage.

iv. Colors of NC Alarm Board / Plc Alarm Board

When you press the mouse right key near one of the two message boards of the application package, you can change the default colours of the boards by means of a colour interactive window.

v. State Icons

At the right top of the window of the application package there are 4 icons with the following mean:

ICONS OF COMMUNICATION STATE

: They signal the state of the serial

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communication

: Simulated Status (Green = OFF; Yellow = ON)

:They signal the EMERGENCY state of the machine (green = OK; red = EMERGENCY)

:They signal the HOLD state of the machine (green = OK; yellow = HOLD)

vi. Exit from the Application Package

The exit from the application package is not a normal working condition for the machine-tool. You have to exit only if you really know what you want to do and we don't recommend this exit if you haven't a good knowledge of WINDOWS. Wrong operations can damage the Application package or one of its components and consequently the machine can be put out of service until the Manufacturer or Teseo repair the damaged parts.

An unintentional exit doesn't cause any damage and all you have to do is to turn off and then to start again the PC DT12 by executing again the setting phases.

When the NC gives the control to WINDOWS and even if the PLC is still working, it is not possible to execute any operation of axes movement and head movement either.

Always close the WINDOWS session before turning off the PC DT12 so as to avoid any damage to the Application package or to one of its components.

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b. Adjustment

The setting menu allows the operator to execute the axes references

The following function keys are active:

F1 : Zero search It executes the axes reference cycle

F12 : Back Back to the previous page

i. F1 Zero Search

The axes reference is essential to execute movements different from JOGs. By the key 'F1 Zero Search', the PC DT12 gets ready to start the cycle. It is necessary to press START in order to start the reference search of every axis.

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c. Manual

By "manual" we mean a particular condition of the PC DT12 that allows more direct operations of the machine-tool without changing the essential safety conditions. The following function keys are active:

F1 : I/O It displays the input and output list

F2 : Axes It allows to move the axes on target

F3 : Move It moves the axis to the desired distance

F4 : User Variables It shows the value of some variable used also while cutting

F5 : Speed Changes the speed manually by arrow keys

F6: Manual Cutting It allow manual cutting operation.

F7: XY Plate rotation In that case the plate can placed using 3 points.

F12 : Previous Back to the previous page

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i. F1 I/O

By means of F1 key it is possible to display the list of outputs and inputs alternatively.

F1 Inputs

By this window it is possible to check the input state. The input state is represented (for the 4 cards) in the synoptic table on the right bottom. The page shows the first 13 inputs. Any other input can be displayed by means of the keys PAGE/PAGE .

The selected input is red-highlighted in the list and bordered in yellow in the synoptic table. The joined words allow a faster identification of the module concerned. The first field is an input description, the second, third and fourth field define the module, byte and bit corresponding to the selected input respectively.

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F1 Outputs

By this window it is possible to check the output state. The output state is represented (for the 4 cards) in the synoptic table on the right bottom. The page shows the first 13 outputs. Any other output can be displayed by means of the keys PAGE/PAGE .

The selected output is red-highlighted in the list and bordered in yellow in the synoptic table. The joined words allow a faster identification of the module concerned. The first field is an input description, the second, third and fourth field define the module, byte and bit corresponding to the selected input respectively.

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ii. F2 Axes

The keys and of the cursor control pad allow to select the axis to be moved. Axes shifting (JOGGING)

!

In the axes shifting, also called JOGGING, the axes are moved by means of JOYSTICK on the control board. The movement is fast and the speed can be controlled using F5 Speed option. The PC DT12 just displays the positions of the axes, while the movement limits are entrusted to the limit stop of axes over-run.

You always move the axes in manual mode by only using the joystick. That is you dont need any software function or option in manual menu to succeed jogging operation. It is enough to be in manual menu. Simply use the joystick to move the machine.

! An axis on a limit stop of maximum run can be shifted in the opposite direction only

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iii. F3 Move Axis

With the function 'F3 Move', the desired value is requested by an interactive window and it refers to the currently selected axis (highlighted in red and shown in the prevous picture). After entiring the desired position by numerical key, if you press the pushbutton "Move" of the interactive window, the PC DT12 moves the selected axis to the desired value.

It is not necessary to set the axes in order to move them by JOG.

Without setting, the displayed values could be wrong.

iv. F4 Users Variables

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The black left window is upgraded with the list of some user variables that are displayed also in Automatic Menu during cutting. In this page the more important are the ORIGIN variables that mean the virtual zero of the sheet. While entering in Manual menu they are cleared and the user can change them pressing the Button (Zero Point) on the control board. On pressing this button, the NC reads the axis positions and use them as new virtual zero for the sheet.

v. F5 Speed

This window allows to control the speed. By means of the arrow keys it is possible to increase/decrease the speed.

vi. F6 Manual Cutting

This function allows to cut plates manually. When you press Manual Cutting key, a pop up window will open. This window determines axes speed in manual cutting opetration.

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vii. F7 XY Plate Rotation

This function allows the plates settled in wrong way to be parallelized to machine coordinate system.

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The left bottom side of window you can see a representation for this operation. At first you must selects points in the plate by Joystick. Then confirm these one after another points by F1 Confirm point key. After confirming every point by one by, press F6 Confirm all points key. At that moment, a pop up window will appear and shows new parameters for the plate references.

! After completing cutting operation according to the rotated plate, DO NOT FORGET reseting the created reference point. In order to do that press F6 Reset plate rotation key. So the reference point will be set to the initial value adjusted in Adjustment menu.

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d. Automatic

This window includes not only the function keys of the Automatic but also the list of PRG files available in the NC memory storage. These files are called Part Programs and generated by direct writing or imported in the NC memory storage from an external Floppy Disk. By means of the cursor control keys (arrows) it is possible to select one of the available files and to send it for execution or to display it graphically. The following function keys are active:

F1 : Execute Program execution

F2 : User rotation

F3 : Graphics Graphic display of the program

F4 : Copy Programs It copies the Part Programs directly from floppy

F5 : Resume Program It lets to resume a Part Program from the last step worked.

F6 : Tool Radius It shows the table of the tools Radius ( Kerf ) . F7 : Directory Choice of Part Program directories

F12 : Previous Back to the previous page

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a. F7 Directory

By means of the cursor keys it is possible to move in the directory tree (ENTER allows to open the selected directory).

With the Up and Down Arrows Key it is possible to select a directory, then press F1 to enable it as storage directory. The following function keys are active:

F1 OK It enables the selected directory as directory storing Part Program

b. F2 User Rotation

F2

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c. F3 Graphics

It is possible to have a graphic display of the selected Part Program.

The working surface of the machine with the pertaining values and all the workings are displayed. It is not a CAD, but just a graphic aid for the display of the PPs generated.


F1 : Overall view It executes the graphics by displaying the whole working

F2 : Scale up It scales up the zoom

F3 : Scale down It scales down the zoom

F4 : Zoom area It allows to scale up a part of the working

F5 : Step by step It executes the graphics one instruction at a time

F6 : Tool Correction It executes the graphics with tool correction ( kerf ). F7: Show work

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Since to implement the graphics the same functions of program generation/control are enabled, the same geometric errors that would come out during the program execution in Automatic are detected. Therefore the following controls are active: axis limits, space occupied by tongs and, in case of active tool correction, also the figure feasibility. It is a good test for the program feasibility.

Even if some paths can be displayed incorrectly (in particular with the ZOOM) because of numeric truncation, controls are executed with the greatest numerical precision. So, badly displayed situations can be unreal, while the errors signalled are real for the NC.

i. F4 Zoom Area

It allows to zoom in on a selected area of the currently displayed graphics

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ii. F5 Step By Step

It allows the step-by-step execution (an ISO instruction at a time) of the graphics of the selected program.

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d. Graphic Colors

By pressing the Preference Graphic colors on the graphics window it is possible to change the default colours of the graphics window.


Change It allows to change the colour of the graphic element selected by means of a colour interactive window

Preview It implements the graphics with the current colours but doesn't save any modification about them

OK It implements the graphics with the current colours and stores the current layouts on disk

Ondo Resets the last change

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e. F1 Execute

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In this condition, if you press START the machine begins running the program. While cutting the NC shows the line of the Part Program that is active.. After the program execution, if you press START again the execution restarts.

During the program running it is possible to interrupt the axes movement by means of the button STOP on the console. This causes the stop on ramp on the path and the call to the upper dead point of the torch. From this condition it is possible to restart by pressing again the button START or to abort the execution by F8. During the program running, the key F8 causes the exit from the current window by generating an emergency request to the axes checker and the consequent cycle abort. The following function keys are active :

F1 Simulated It enables the simulating function of the machine

F2 Torch Blocking Block the torch hight control

F3 Graphics Graphic display of the program

F6 Oxy Parameters Used for entering oxy cutting parameters.

F7 Tool Head Change Used for entering drill parameters.

F8 Previous It terminates the automatic session and goes back to the previous page

i. F6 Oxy Parameters

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Oxy Preheat (msec)=Preheating time. Propan Preheat(msec)= Time for enabling the preheat valve. Oxy Torch Rise (msec) = This is the time for the oxy torch distance between the parts. Oxy Torch Ignite (msec)= Time for igniting the torch after pressing the start button. Ignite Valve Delay (msec)= Time for the ignition valve.

By pressing F3 go to the next page for additional parameters.

Oxy Torch Pierce (msec)= Time for piercing. Oxy Torch Uptime(msec)= Piercing height. Oxy Torch Regulation Delay (msec)= Time for enabling the capasitive sensor.

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ii. F7 Tool Head Change (Drill Parameters)

Timer clamp down (1=0.1 sec)= Time for the clamps. Timer raise drill ( 1=0.1 sec)= Raising time for the drilling tool. Timer drill down (1=0.1 sec)= Lowering time for the drilling tool. Timer end work drill ( 1=0.1 sec)= Waiting time before raising the drilling head. Timer first mov drill ( 1=0.1 sec)= Time for the first movement of the drilling tool. Timer Quick Mov (1=0.1 sec)= Not used. Timer oil drill (1=0.1 sec)= Not used. Timer no oil (1=0.1 sec)= Not used.

iii. F12 Previous

It allows to terminate the program running.

F12 Previous

If you confirm the termination of the current automatic session, the function of go on program will be enabled.

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iv. F1 Go On

Sometimes, after an EMERGENCY or a RESET that caused the automatic execution of a Part Program to be aborted, it is necessary to restart this execution. This restart is possible, always within the automatic session, by pressing the function key 'F1 Go on'.

The editor will display on the screen the Part Program and the last line executed will be highlighted. So you must look for the previous G00 Instruction, select it and then press F8.

It is possible also to restart from a different piece scrolling up or down the Part Program. You can restart only from a G00 Instruction, otherwise the NC will prompt an error message.


F1 Input It allows to insert additional ISO lines

F2 Reset It reloads the original version of the program (without any additional ISO line)

F8 Back It runs the program from the selected line

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v. F1 Input

vi. F1 Simulated

If this function is enabled, the machine starts to execute the Part Program without cutting. It is useful for testing or jumping a piece already cut.

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vii. Error Page

The error page allows to display any active PLC error. For every active error, the following information can be available:

error description (PLC error number and description) position of component/s involved in the error

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F1 Detail It displays the detail of the component/s involved in the currently selected error

F2 Help It opens the on-line help at the PLC error page and it displays the information about the currently selected error

F3 CNC log-file It displays the NC error historical

F4 PLC log-filel It displays the PLC error historical

F8 Close It closes the error page

viii. F1 Detail

It displays the detail of the component/s involved in the currently selected error.

ix. F2 Help

It opens the on-line help (by means of Microsoft Internet Explorer) at the PLC

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error page and it displays the information about the currently selected error.

x. F3 CNC log-file

It displays the NC error historical.

xi. F4 PLC Historical

It displays the PLC error historical

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5. Program Archive ( Plasma ISO )

Press Ctrl+F2 The Program File application has the functions of generation/replacement/maintenance of Part Program generated by both the NC and the outside (CAD or another source). Part Program, hereinafter called PP, means the programs in ISO language written by the user. Some functions are available in AUTOMATIC (see the pertaining chapter) with the same characteristics, but they will be treated with full particulars in this chapter.

By entering this page, the list of PPs available in the machine and the active function keys are displayed.

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The left windows shows the current directory, the right one shows the list of programs of the current directory; the bottom left window shows the current disk and the bottom right one shows the currently selected file.

It is possible to scroll these lists by means of the vertical arrows and the tabulation keys. From this menu it is possible to access the following functions:

F1 New Generation of a new file by editor

F2 Open Opening of a selected file

F3 Delete Deletion of a selected file

F4 Rename It change name to the selected file

F5 Copy Copy of a selected file

F12 Exit Exit from the Program File application

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a. F1 New

A new empty file with .PRG extension is generated.

b. F2 Open

In this page it is possible to choose whether to edit the previously selected Part Program or to display its graphics.


F1 : Edit It changes the file by editor

F2 : Graphics It displays the file graphics


F1 Edit

In this page it is possible to edit the previously selected Part Program. NB: according to the current terminology of Editors, "Block" means a group of some lines.


F1 Go to It allows to reach the specified line (no. of line) F2 Change It allows the modification of the current line

F3 Delete It deletes the current line

F4 Insert It inserts a new blank line

F5 Graphics It displays the program graphics

F6 Editing It enables the editing operations on text blocks

F7 Find It finds a text string within the program

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F12 Back Back to the previous page

This editor is an easy instrument conceived to create small PPs or to modify existing PPs; in this case, we recommend to keep a copy.

NB: All the operations of line insertion/deletion and Block insertion/deletion modify the progressive numbering that automatically fits into the new situation.

F6 Editing

This page is dedicated to the management of text blocks within the PP.


F1 Select It allows to select a block

F2 Copy It stores the selected block

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F3 Cut It erases the selected block and stores it

F4 Paste It pastes a previously stored block beginning from the current line

F12 Back Back to the previous page

F7 Find

This page is dedicated to the management of text block within the PP

6. Configuration Setting

The configuration setting application package allows to modify the different interface parameters.

89

a. General

This table allows to define all the parameters of the user interface.

90

b. Syncro Files

This category allows to define:

the file of machine parameters to be used for the interface (it is possible to choose among all those available in the CFG subdirectory of the interface directory); the file of machine initialization to be used for the interface (it is possible to

choose among all those available in the CFG subdirectory of the interface directory); the eprom version used (so as to correctly display and manage the above

mentioned parameters).

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c. Serial Port

This category allows to define all the configuration parameters of the PC serial port used to connect to the Syncro.

92

d. ISO Parameters

This category allows to define all the parameters concerning the ISO compiler for the generation of Part Program:

machine configuration (punching machine only); ISO programming system A or B;

insertion of the ISO source instruction number in the compiled program so as to be able to display the ISO instruction under execution during the program execution; insertion of the ISO source instruction in the compiled program for the

program generation control.

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e. Error Codes of Syncro

System errors The Synchro system errors are divided into the following typologies:

Executor's errors Axis handler's errors

Executors errors

The control execution error codes can be displayed during the program execution.

They can be identified by the following format:

00.XX.YYYY

00 = System Errors.

XX = Executor's Number

YYYY = Error coding The Error Coding shows one of the following codes .

1 Unknown instruction

2 Not implemented instruction

3 Instruction not admitted for immediate execution

4 Instruction not admitted in program execution

5 Inexistent program

6 Unavailable axis

7 Repeated axis

8 Axis not reset

9 Out-of-limit Axis Value

10 Moving axis

11 DIGITAL IO number not admitted

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12 DIGITAL IO number repeated

13 Jog analog output value not acceptable

14 Speed value not acceptable

15 Acceleration value not acceptable

16 Instruction not admitted in interpolation

17 Axis not enabled for interpolation

18 Program in receiving phase

19 Program already opened

20 Out-of-limit X value linear interpolation

21 Out-of-limit Y value linear interpolation

22 Out-of-limit Z value linear interpolation

23 Z variation not admitted linear interpolation

24 X radius not admitted circular interpolation

25 Y radius not admitted circular interpolation

26 Too big working angle circular interpolation

27 Out-of-limit X value circular interpolation

28 Out-of-limit Y value circular interpolation

29 Out-of-limit Z value circular interpolation

30 Z variation not admitted circular interpolation

31 Not linear axis in interpolation X,Y,Z

32 Not polar axis in interpolation tangency

33 Too many polar axes in interpolation tangency

34 Out-of-limit polar axis value in interpolation

35 Program with wrong checksum

36 Not erasable program (LNC) 37 Wrong variable name

38 Interpolator already used

39 Interpolator not enabled

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40 Direct control to slave axis

41 Control cannot be executed by master axis

42 Slave axis not admitted

43 Active slave axis

44 Wrong master/slave ratio

45 Missing Master axis

46 Scale factor not acceptable

47 Axis Value on Scale not acceptable

48 Control cannot be executed Axis on Scale

49 Acquisition of flying value not initialized

50 Unavailable flying value

51 Instruction not admitted in Interpolation Search

52 DAC number not admitted (available axis) 53 Synchronous axis

54 Program execution block timeout

55 Number of turned axes not admitted

56 Control cannot be executed on turned axis

57 Axis not turned in interpolation

58 Offset executors not congruent

59 Axis not in maintenance

90 Pressed stop

91 Pressed hold

92 Overtemperature

93 Interpolator error

94 Wrong machine parameters

95 Machine parameters checksum error

99 ALL_AXIS function not implemented

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The following errors can be displayed during the execution preparation:

200 Unknown SBL control

201 Inexistent program

202 Too many programs sent: the maximum limit is 150

203 Insufficient storage for programs

204 Syntax error on SBL control

205 Radius tolerance error on CIR, CIL controls (for circular interpolation only) 206 Interpolation without previous source MOV (see SBL handbook) 207 Wrong program number (from 1 to 30000) 208 Missing executor

209 Executor in motion in program sending

210 Out-of-limit value

211 Variable in interpolation value

212 Control not accepted

213 Too big radius in circular interpolation

214 Program sending with wrong checksum

250 Busy executor for direct control

251 Executor's error during the execution in circular buffer

252 Reset hold by SPR control

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Axis handlers errors

They can be identified by the following format:

01.XX.YYYY

01 = Axis Handler's Errors

XX = Axis Number

YYYY = Error coding The Error Coding can take one of the following values.

1 Driver not ready

2 Axis against upper hardware L.S.

3 Axis against lower hardware L.S.

4 Max. tracking error exceeded

5 DAC ZERO offset max. compensation exceeded

6 Axis against upper emergency limit stop

10 Max. tracking error in interpolation exceeded

11 Timeout axis in tolerance

12 Out-of-limit axis positioning

13 Axis value overflow

14 Master/slave max. disalignment error exceeded

15 Flying value input switching alarm

20 Out-of-limit axis in interpolation

NB: "EXECUTOR" means one of the active tasks on the CAGE.

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7. Maintenance and Inspectation

!

General maintenance and cleaning of the machine requires careful attention. Therefore the machine must be shut-off before starting any maintenance work.

a. Types and Frequency of Inspectations

Inspectation

Period

Responsibility

Grid replacement Four times a year

Operator

X axis rack-rail cleaning (Use iron brush and compressed air)

Once a month

Operator

Y axis rack-rail cleaning (Use iron brush and compressed air)

Once a month Operator

Greasing (Lubrication) of the torch support sliding blocks (Use F type grease FD5, FD10, FD12)


Y axis floating shaft support greasing (Put grease on the bearing lubricators) Once a month Operator

X axis floating shaft support greasing (Put grease on the bearing lubricators) Once a month Operator

Check the Torch (Before starting cutting, check the main body of the torch and spare parts are in a good state. Check that there are no burnings or color change on the torch spare parts or demage)

Daily Operator

Check the Torch and Plasma generator cables. (Against any burn, demage and wear)


Plasma generator cleaning

(see related manual) Once a month -------

99

Check cooling fan in electric panel against functionality Daily Operator

Cleaning Fume and dust filter

(see related manual) Twice a month --------

Cleaning the exusting system

Once a year (It depends on machined sheet and amount of work)

Operator

Safety & limit switches against loosening or damage weekly Operator

Terminal connections of the electrical installation Once a year

Qualified electrician

Gas (hoses) connections against loosening or damage Daily Operator

b. Troubleshooting

This part is organized as follows: 1. Problem is stated 2. List of causes 3. The solutions

Problem

Possible causes

Solution

Machine can NOT be zero- referenced.

1. Torch protection sensor is off.

2. One of the emergency stop buttons is pressed.

1. a. Fix the torch in its place b. Check the proxymities. ( Leds must be lighting)

2. a. Check the emergency

stop buttons. b. See the inputs in Manual menu. All inputs must be active. If

100

not, the buttons would not be working properly

Manual Jogging can not be done.

The first cause above. (in item 1) Note: If a problem occurs in torch protection sensor, the Z axis can be moved upwards manually.

Note1: Check inputs in manual menu. The following inputs must be active.

A TIME OUT error occurs in any axis

Servo drivers error Change parameter Fn00A . If error increases, decrease the valu in that parameter.

Programs can not be copied from floppy driver.

1. Floppy driver does not work

2. Corrupted diskette 3. File extention is

different from PRG.

1. Change floppy driver

2. Change diskette 3. Ckeck file

extentions in diskette.

Using Resume Program options, a problem exists.

You probably start the cutting process from M codes.

Do not start cutting from M codes

Programs can not be seen

Wrong programs directory

Change the directory.

In automatic mode, machine starts moving before completing piercing.

1. Wrong torch parameter 2. The contact in P10

relay in electrical cabinet

1. Increase the OK TO MOVE delay parameter in torch paramaters

2. Change the relay

101

In automatic mode, machine waits too much to move after completing piercing

Wrong torch parameter

Decrease the OK TO MOVE delay parameter in torch paramaters

Torch crashes the plate

1. Wrong torch parameters

2. Torch sensor does not work

1. Increase the Torch adj.delay parameter in torch parameters

2. Check Torch sensor in torch assembly

The plasma ark does not fire See the plasma generator

manual

The cut is interrupted See the plasma generator manual

Excess burns occurs 1. Exausting system problems

2. Filter problem

1. Exausting system may be filled with slags. Clean the system

2. See Filtering system manual

Plasma does not pierce the plate See the plasma generator

manual

Serial communication error in PC DT12 control unit

1. Cable problem between control unit and PLC

2. Parameter error

1. Check the serial connection cable

2. Load default initialize fle (SYS42001.ini)

102

c. Conditions of storage, re-utilization and scrapping

a.

b.

c.

Storage: In cases wh

Date post:	17-Dec-2015
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English Plasma Manual HPR 260 BPLH

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