KOIKE ARONSON, INC. Club/Technical... · cutting galvanized metal and use proper ventilation. 14.Do...

TECHNICAL MANUAL

KOIKE ARONSON, INC.635 W. Main St., Arcade NY, 14009-0307 (585) 492 2400, Fax (585) 457 3517

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PLATE-PRO EXTREME

INSTRUCTION MANUAL MI0560A

May 2010Revision D

CONTENTS

PLATE-PRO EXTREME®®

SECTION 1 SAFETY PRECAUTIONS ............................................................................1

Section 1.1 General Safety, Oxy Fuel Cutting .................................................................4Section 1.2 General Safety.............................................................................................4Section 1.3 General Safety, Plasma Cutting ...................................................................5Section 1.4 General Safety, Miscellaneous .....................................................................8

SECTION 2 General Introduction ................................................................................ 11

Section 2.1 Scope ........................................................................................................ 11Section 2.2 Description................................................................................................. 11Section 2.3 Axis Definition ............................................................................................ 11Section 2.4 Rail Assembly ............................................................................................ 11Section 2.5 Saddle Assembly ....................................................................................... 11Section 2.6 Transverse Beam Assembly (Drive) ........................................................... 12Section 2.7 X-Drive Assembly ...................................................................................... 12Section 2.8 Y-Drive Assembly ...................................................................................... 12Section 2.9 Gas System Assembly ............................................................................... 12Section 2.10 Gas Control Panel...................................................................................... 12Section 2.11 Operator Control Console .......................................................................... 12Section 2.12 Limit Switches............................................................................................ 12Section 2.13 Torch Station (Main)................................................................................... 12Section 2.14 Torch Station (Slave) ................................................................................. 13Section 2.15 Steel Band Assembly ................................................................................. 13

SECTION 3 Pre-installation Requirements ................................................................. 14

Section 3.1 Pre-installation Safety ................................................................................ 14Section 3.2 Site Location .............................................................................................. 14Section 3.3 Site Preparation ......................................................................................... 14Section 3.4 Electrical Requirements ............................................................................. 15Section 3.5 Compressed Air ......................................................................................... 15Section 3.6 Oxy-Fuel Requirements ............................................................................. 15Section 3.7 Burning Table ............................................................................................ 16

SECTION 4 Installation................................................................................................ 18

Section 4.1 Installation Safety Precaution ..................................................................... 18Section 4.2 Handling and Storage ................................................................................ 18Section 4.3 Unpacking and Cleaning ............................................................................ 18Section 4.4 Rail Installation .......................................................................................... 19Section 4.5 Machine Mounting...................................................................................... 19Section 4.6 Motor/Gear Unit Installation........................................................................ 19Section 4.7 Torch Carriages ......................................................................................... 20Section 4.8 Torch Stations............................................................................................ 20Section 4.9 CNC Interface ............................................................................................ 20Section 4.10 Utilities....................................................................................................... 20Section 4.11 General Plasma Connections..................................................................... 20

SECTION 5 Operation.................................................................................................. 22

SECTION 6 Maintenance ............................................................................................. 23

Section 6.1 Safety Precautions..................................................................................... 23Section 6.2 General Information ................................................................................... 23Section 6.3 Preventative Maintenance Schedule .......................................................... 24Section 6.3.1 Each Eight (8) ............................................................................................ 24Section 6.3.2 Each Fifty (50) Operation Hours ................................................................. 24Section 6.3.3 Each Two Hundred Fifty Hours................................................................... 24Section 6.3.4 Each One Thousand (1000) Hours ............................................................. 25Section 6.4 Guide Roller Adjustment ............................................................................ 25Section 6.5 Rail Cleaning ............................................................................................. 25Section 6.6 Roller Cleaning .......................................................................................... 25Section 6.7 Wheel Cleaning.......................................................................................... 25Section 6.8 Gears and Pinions ..................................................................................... 25Section 6.9 Gas Control System................................................................................... 25Section 6.10 Drive Tuning Procedure ............................................................................. 25Section 6.11 Cut Quality Troubleshooting ....................................................................... 25Section 6.12 Synch Error................................................................................................ 26Section 6.13 Check Valve Test....................................................................................... 26

SECTION 7 Replacement Parts ................................................................................... 28

LIST OF ILLUSTRATIONS /TABLES

Figure 1.1 Machine Safety Frame (Working Area)....................................................... 10Figure 3.1 Concrete Floor Composition....................................................................... 16Figure 3.2 Generic Ground Layout .............................................................................. 17Figure 6.1 Check Valve............................................................................................... 26Figure 7.1 Machine Overview Front ............................................................................ 27Figure 7.2 Machine Overview Side.............................................................................. 28Figure 7.3 Y-Axis Carriage.......................................................................................... 29Figure 7.4 X-Axis Carriage.......................................................................................... 30Figure 7.5 Band Assembly.......................................................................................... 31Figure 7.6 KARCNCX................................................................................................. 32

Appendix A List of Terms and Abbreviations .................................................................A1Appendix B Model G Torch Lifter ..................................................................................B1Appendix C Pulse Ignition ............................................................................................ C1Appendix D Hi/Lo Gas Control ..................................................................................... D1Appendix E Plasma Operation ......................................................................................E1Appendix F Rail Installation ..........................................................................................F1Appendix G Air Scribe Marker ...................................................................................... G1Appendix H Slave Carriage .......................................................................................... H1

Safety

1

SECTION 1SAFETY PRECAUTIONS

USER RESPONSIBILITY - This equipment will perform in conformity with thedescription thereof in this manual and accompanying labels and/or inserts wheninstalled, operated, maintained and repaired in accordance with the instructionsprovided. THIS EQUIPMENT MUST BE CHECKED PERIODICALLY. Defectiveequipment should not be used. Parts that are broken, missing, plainly worn, distortedor contaminated should be replaced immediately. Should repair or replacementbecome necessary, KOIKE ARONSON recommends that a request for service bemade to the KOIKE ARONSON Authorized Distributor from whom purchased ordirectly to the KOIKE ARONSON Service Department.

This equipment or any of its parts should not be altered without prior writtenapproval of KOIKE ARONSON. The user of this equipment shall have soleresponsibility for any malfunction, which results from improper use, faultymaintenance, damage, improper repair or alteration by anyone other than KOIKEARONSON or a facility, designated by KOIKE ARONSON, INC.

NOTES, CAUTIONS & WARNINGS

Throughout this manual, notes, cautions, and warnings are used to describesituations that require additional information. The following formats are used foreach:

Notes: A note offers additional information, such as an operating tip, that aids the user inoperating the equipment.

Caution: A caution describes a situation that may cause damage to the machine and offersadvice to avoid or rectify the situation.

A warning describes a situation that presents a physical danger to the operator, andoffers advice to avoid or rectify the situation. Each type of warning displays anapplicable danger symbol, such as fire, explosion, electrical shock and so on.

WARNING

Safety

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KOIKE ARONSONSYMBOL LIBRARY

SYMBOL MEANING

GENERAL INFORMATION

ELECTRICAL SHOCK CAN KILL

POISON/TOXIC

FLAMMABLE/COMBUSTIBLE

EXPLOSION HAZARD

DO NOT WATCH THE ARC

OPEN GEARING

GROUND THIS EQUIPMENT

COMPRESSED GAS

Safety

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SYMBOL MEANING

EYE PROTECTION REQUIRED

USE AN APPROVED RESPIRATOR

WEAR APPROVED EAR PROTECTION

INSULATED GLOVES REQUIRED

INSULATED FOOTWARE REQUIRED

NO OPEN FLAME

HOT SURFACE DO NOT TOUCH

DO NOT REMOVE GUARDS

WEAR PROPER EYE PROTECTION WHEN PLASMA CUTTING

WEAR PROTECTIVE CLOTHING

Safety

4

Before using this equipment and its options each person operating, maintaining orsupervising the use of this equipment must read the following safety instructions.

1.1 GENERAL SAFETY, OXY/FUELCUTTING

Operation of oxy/fuel torches involvesoxygen and flammable gases underpressure, open flames, flying slag and hotmetal, fumes and combustion products.Follow the precautions in this GeneralSafety Section as well as those throughoutthis manual for your personal safety and thesafety of personnel in the area that may beaffected.

1.2 GENERAL SAFETY

Operation of this machine involves variousmoving and rotating parts that could proveto be dangerous. Follow the precautions inthis General Safety Section, as well asthose throughout this manual, for yourpersonal safety and the safety of personnelin the area that may be affected. Failure toobserve these safety practices may causeserious injury or death.

1. Install and operate this machine only in awell-ventilated area.

2. Connect and maintain electrical groundsto the equipment according to localcodes and the National Electrical Code.

3. Check gas and electrical connections fortightness after installation and on aregular basis thereafter.

4. Keep combustibles away from the workarea or protect them from sparks andflames.

5. Check for proper function of check valvesregularly. Do not remove or bypass checkvalves.

6. Always open gas valves slowly.

7. Never use oxygen to ventilate the area orclean off clothing.

8. Keep oil, grease, and combustible dustaway from all oxygen equipment.

9. Purge oxygen and fuel lines individuallywhenever combustible mixtures in thelines are suspected.

10. Never use an oxygen hose for any othergas than oxygen.

11. Replace hoses that are damaged byphysical abuse or by sparks, heat or openflame.

12. Examine hoses at regular intervals forleaks, wear, loose connections or otherhazards.

13. Coil excess hose and place it out of theway to prevent damage and to eliminatetripping danger.

14. Maintain all pressure regulators inproper working condition.

Safety

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15. Never use a regulator for any gas otherthan that for which it is intended.

16. Never use a regulator that leaks, creepsexcessively or is physically damaged inany way.

17. Never attempt to lubricate a regulatorwith oil or grease.

18. Handle and use compressed gascylinders in accordance with safetystandards published by the CompressedGas Association (CGA), and CanadianStandards Association (CSA).

19. Never use a cylinder that leaks or isphysically damaged.

20. Never use a cylinder that is not uprightand secured in place.

21. Never move or transport a cylinderwithout the protective valve cover inplace.

22. Never use a gas cylinder or its contentsfor any purpose other than that for whichit is intended.

23. Never lubricate cylinder valves with oilor grease.

24. Never expose cylinders to excessiveheat, sparks, slag or open flame.

25. Never use hammers, wrenches or othertools to open stuck cylinder valves.

26. Never cover the gas panel withoutventing the bottom of the cover. Fuelgases are heavier than air.

27. Wear filter-lens safety eye protection.Wear gauntlet gloves, safety shoes,flame-retardant clothing, and no-cufftrousers. Do not wear loose clothingaround this machinery because it cancatch on the machine.

28. Shut off power and gas supplieswhenever leaving the machineunattended or before servicing.

29. Keep equipment clean and in goodoperating condition.

30. Read accessory instruction manualssupplied for these items for additionalsafety and operating guidelines beforeoperating this equipment.

31. No repair should ever be undertaken orattempted by anyone other than aKOIKE ARONSON designatedtechnician.

32. Read and understand further detailedsafety precautions throughout thismanual.

1.2 GENERAL SAFETY, PLASMACUTTING

Plasma Arc cutting is a high intensity sourceof visible light emission as well as ultravioletand infrared radiation. It can cause severeeye damage and inflict burns on exposedskin when those portions of the body are notsuitably protected.

Safety

6

Follow the precautions in this GeneralSafety Section and read the suppliedplasma equipment instruction manual foradditional and more detailed safetyprecautions.

1. Facilities should be available for themedical treatment of arc flashes orburns to the eyes.

2. Provide radiation protection for theoperator and for personnel in theadjacent area.

3. Do not, under any circumstances, look ata plasma arc without full eye protection.When near the plasma cutting equipmentalways wear flash goggles with sideshields and containing No. 4 filter lenses.

4. The operator must use, in addition toflash goggles, a suitable helmet for eyeand face protection when cutting. Thehelmet must be equipped with a numberfilter plate as indicated:

Arc Current US Shade No. ISO 4850Up to 100 Amps 8 11100 to 200 Amps 10 11-12200 to 400 Amps 12 13Over 400 Amps 14 14

5. Only use helmet or hand shields that arein good condition. Repair or replacedamaged equipment promptly. Protectcolored filter plates with a clear glasscover plate.

6. Warn other people in the area not to lookdirectly at the arc unless they wearglasses/goggles or a helmet.

7. Never start the plasma arc without makingcertain that nearby personnel are wearingadequate protective equipment.

8. All areas of the body must be covered bydark substantial clothing (preferably flameretardant) to protect against arc burn,sparks and flying hot metal.

9. The plasma operation should be locatedin an area where protection for otherpersonnel may be readily provided.Portable non-combustible reflectingscreens or enclosures with non-reflectingwalls may be used. Screens andenclosures should permit free circulationof air at floor level.

10.Do not cut in the presence ofatmospheres containing even minuteamounts of chlorinated solvents. The heatand ultraviolet radiation can decomposethese vapors to form Phosgene, a highlytoxic gas, and other irritatingdecomposition products.

11.Do not cut in atmospheres containingexplosive dust or vapors.

12.Keep the cutting area well ventilated.

Safety

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13.Wear proper breathing mask whencutting galvanized metal and use properventilation.

14.Do not cut pressurized cylinders or anyclosed container.

15.Make fire extinguishers available in thecutting area.

16.Remove combustible material from theimmediate cutting area.

17.Quench freshly cut metal or allow metalto cool before handling it or bringing it incontact with combustible materials.

18.To prevent electric shock keep yourbody and clothing dry.

19.Do not stand in, sit on or lie on any wetsurface when using the plasma system.

20.Maintain proper insulation againstelectrical shock. If you must work in ornear a damp area, use extreme caution.Wear insulated gloves and boots.

21.Provide a wall mounted disconnectswitch with proper size fuses close tothe power supply. This switch allowsthe operator to turn the power supplyoff quickly in an emergency.

22.Conform to all local codes for primarywiring sizes and types.

23. Inspect the primary power cordfrequently for damage or cracking of thecover. Bare wiring can kill. Do not usethe system with a damaged power cord.If a power cord is damaged, replace itimmediately.

24. Inspect the torch leads. Replace if frayedor damaged.

25.Never operate the plasma system unlessthe power supply unit covers are inplace. Exposed power supplyconnections present a severe electricalhazard.

26.Do not pick up the work piece, includingthe waste cutoff, while you cut. Leave thework piece in place or on the worktablewith the work cable attached at all times.

27.Before changing the torch parts,disconnect the main power supply. Afterchanging the torch parts and returningthe retaining cap to its operating position,plug the power supply in again.

28.Never bypass or shortcut the safetyinterlocks.

29.Before removing a power supply coverfor maintenance, USE APPROVEDLOCKOUT PROCEDURES. Disconnectthe main power at the wall, shut offswitch or unplug the power supply. Toavoid exposure to severe electricalhazard, wait five (5) minutes afterdisconnecting the main power to allowcapacitor discharge to occur. Test forzero volts.

Safety

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30.Be sure the power cord is plugged into aproperly grounded outlet or that thepower cord ground wire is properlyconnected to the ground in thedisconnect box.

31. If installation of the plasma systeminvolves connecting the power cord tothe power supply, ensure that the powercord ground wire is properly connected.Conform to CSA standards by placingthe power cord ground wire on the studfirst; then place the other ground wireson top of the power cord ground. Fastenthe retaining nut tightly.

32.Make sure that all electrical connectionsare tight to avoid excessive heating.

33.Clamp the work cable to the worktable.This is the “star” ground connection.

34.Connect the worktable to a good earthground. Consult the National ElectricalCode, Grounding Electrode System, orother appropriate national or localcodes.

35. Plasma cutting operation noise levelsmay be high enough to require earprotection for the operator and otherpersonnel in the adjacent area.

36.When using a water table to confine slagetc. while plasma arc cutting plate,especially aluminum or magnesium,cutting may cause an accumulation ofexplosive gas below the plate. Do notallow aluminum or magnesium dross toaccumulate in a water table. Prior tocutting, raise and lower the water levelseveral times to dissipate trapped gases.Do not leave plate on the table forextended periods, for example overnightor weekends. When the table is not inuse, keep the water level down. Do notcut these materials under water. Readadditional cautions in the relatedmanuals.

37.No repair should ever be undertaken orattempted by anyone other than a KOIKEARONSON designated technician.

1.3 GENERAL SAFETY, MISCELLANEOUS

1. Keep the working area dry to avoid anelectrical shock.

2. Check that the machine voltage andsupply voltages are the same beforeturning on the power switch.

3. Never operate this machine unless allelectrical box covers are attached.Exposed electrical connections present asevere electrical hazard.

4. When igniting or adjusting torch flame atthe start of cutting, take care not to beburned.

5. Never touch torch tip when lit, or you maybe burned.

Safety

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6. When replacing or cleaning a torch tipduring cutting be sure to give the tipsufficient time to cool. The tip will be veryhot.

7. After cutting never touch the work-pieceor scrap until they cool. You can beburned.

8. During the piercing operation on heavierplate (25mm or larger) there can be agood deal of spatter. Be sure to stayaway from the torch and stay in theoperation zone to prevent exposure toburn from the spatter.

9. During the cutting operation never touchthe torch flame or plasma arc.

10. Do not climb on the cutting table, as it ispossible to slip and cause injury.

11. Take care not to climb on or over the railas it has rack attached to it and cancause injury.

12. There is no pressure relief valve in thegas system; supply pressures should beadjusted at the supply source regulators.

Maximum supply pressures are:

Oxygen 1034 kPA (150psi) (10.3 bar)

Fuel 103 kPA (15psi) (1.3 bar)

WARNING

Protect yourself and others. Read and understand these instructions. FUMES ANDGASES can be dangerous to your health. HEAT RAYS (INFRARED &ULTRAVIOLET) from flame, arc or hot metal can injure eyes. Read and understandthe manufacturers’ instructions and your employer's safety practices. Use enoughventilation/exhaust at the flame/arc, or both, to keep fumes and gases from yourbreathing zone, and the general area. Keep your head out of the fumes.

Safety

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1. The working area shown is required toensure safe operation. To keep otherpersonnel away from the machine and thecutting process, a fence should beinstalled on the circumference of theworking area. The working area should bethe beam width + 2000 mm and themachine length + 2000 mm.

2. Consumables should be changed in theFlame Adjustment Area in front of themachine noted above. Never climb on thecutting table.

3. Machine operation should be performedfrom the working area.

4. Before starting machine motion makesure that there is nobody behind themachine. Do not go behind the controlpanel or main beam while the machine isin motion as you should be at the controlpanel watching the cutting process.

5. Be sure to shut OFF electrical powerbefore taking parts off the table or puttingplate on the table.

6. This machine moves at rapid speeds;no one should be on the cutting table asthis could cause personal injury.Removing cut parts or scrap from thecutting table should be done when themachine is not in motion and parked in theparking area.

Figure 1.1 Machine Safety Frame (working area)

Fence

FlameAdjustment

Rails

CuttingTable

Walkway

Cutting Machine

Machine ParkingArea

Working Area

General Introduction

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SECTION 2GENERAL INTRODUCTION

2.1 SCOPE

This manual provides general installation,operation and service information for the KOIKE

ARONSON PLATE-PRO EXTREME®® series ofcutting machines. This manual includes anillustrated part listing to aid in ordering parts.

2.2 DESCRIPTION

Your PLATE-PRO EXTREME series isdesigned with time proven constructiontechniques. This machine uses the latest inelectronic and mechanical technologies. Speed,accuracy, versatility, and durability have been

engineered into the PLATE-PRO EXTREME®®

for demanding production jobs. The HI/LO gassystem along with the CNC programmablecontrol and selectable features combine forease of operation in cutting of plate steel.Additional accessories are available to furtherenhance the versatility of the PLATE-PRO

EXTREME®®.

The Koike Aronson Inc. PLATE-PRO

EXTREME®® is designed to meet your cuttingand marking requirements for steel plate.Optional equipment available will increaseproduction and reduce production cycle time.

The PLATE-PRO EXTREME®® incorporatesthree AC servo drive systems into its dualmicro-processor CNC. The CNC is equipped tooperate a maximum of two plasma systems andup to three oxy-fuel stations or one plasmasystem and four oxy-fuel stations.

2.3 AXIS DEFINITION

To avoid confusion in determining direction andaid in identifying part locations:

1. The X-axis is parallel to the transverse(main) beam.

2. The Y-axis is parallel to the longitudinalrail system.

2.4 RAIL ASSEMBLY

The PLATE-PRO EXTREME®® rail systemconsists of two main rail weldments with 22kg crane rails with integrated drive rack. Themain support rail weldment is fabricated from3/4 inch thick steel plate for rigidity and easeof installation. The mounting surface foranchoring the rail support weldment to thefloor is factory welded with leveling boltsalready attached. All rail lengths are pre-fabricated and come in 3 meter increments.

Adjuster blocks that allow for up/down andlateral rail alignment are mounted 1 meterapart, center to center for all installations.Mechanical stops at the end of the rail systemprovide machine over-travel protection. Allhardware for rail installation is included withthe rail package.

2.5 SADDLE ASSEMBLY

Two saddle assemblies travel on the Y-axisrail system, driven by dual Y-axis main drivemotors and planetary gearboxes. Two (2)wheel assemblies support the saddles, oneon the forward end and one on the aft end ofeach saddle to provide stability. The mainsaddle (inboard), on the operator control sideof the machine, utilizes two sets of guiderollers to provide guidance down the railsystem. The inboard guide roller is eccentric,allowing adjustment to maintain machinealignment along the entire length of the railsystem.


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2.6 TRANSVERSE BEAM ASSEMBLY(X-drive)

This is a structural steel tube extending in a leftto right direction facing the machine and issupported by the inboard and outboard saddles.The beam is factory squared to both saddles,pinned in position and bolted. A precision,replaceable linear round way is utilized to keepthe master and slave carriages in preciseposition.

2.7 X-AXIS DRIVE ASSEMBLIES

The X-axis drive carriage supports one torchstation and or one or more options. The driveassembly is located on the transverse beammaster carriage. A motor and planetary gearassembly drives the carriage along the X-axis.The X axis pinion engages to a rack assemblymounted to the transverse beam to provideprecise motion. The pinion is engaged to therack using a spring washer assembly to ensurepositive engagement of the pinion to the rack.

2.8 Y-AXIS DRIVE ASSEMBLY

The inboard Y-axis drive assembly is mountedin the center of the main saddle assemblyfacing out. A pivot mount assembly supports themotor and planetary gear unit. The outboard Y-axis drive assembly is mounted in the center ofthe outboard saddle assembly facing out. Apivot mount assembly supports the motor andplanetary gear unit. The two motor assembliesare electronically coupled to keep the machineparalleled for precision cutting. The inboard andoutboard axis gear pinion engages to a rackassembly to provide precise motion. The gearpinions are engaged to the rack using a springwasher assembly to ensure positiveengagement of the pinion to the rack.

2.9 GAS SYSTEM ASSEMBLY

The manifold assembly is located on themachine near the center of the shelf assembly.Connections are made from the manifold to the

torch stations. The cut manifold is located atthe bottom section of the mounting bracket.The preheat oxygen manifold is located justabove the cut manifold. The fuel manifold islocated above the preheat oxygen manifold.The optional ignition manifold is supplied froma tee connection from the preheat fuelmanifold and is located above the fuelmanifold. Five (5) outlet bushings on eachmanifold pipe allow for connection of torchhoses. Individual preheat solenoids areprovided for each oxy-fuel station. Unusedmanifold outlets are capped.

2.10 HI-LO GAS CONTROL PANEL

The gas control panel contains gauges forobserving the gas pressures and solenoidsfor the transition of HI to LO pressure to themanifold assemblies. Machine mountedregulators are provided for oxygen and fuelpressure adjustment. The optional ease onvalve assembly allows for gradual activationof cutting oxygen to prevent blow back orflameouts during thick plate piercing.

2.11 OPERATOR CONTROL CONSOLE

The operator/CNC control is mounted to themachine on the main rail saddle assembly.

2.12 LIMIT SWITCHES

Two (2) limit switches are mounted on thetransverse beam assembly. The limit switchesprevent an over-travel condition of the X-axisdrive unit.A limit switch mounted to the main (inboard)saddle, limits Y-axis travel. Should a limitswitch be tripped, the drive signal isinterrupted, and all cutting operations arestopped. To recover from a limit trip see theoperation section of this manual.

2.13 TORCH STATION (Main)

One torch station is mounted on thetransverse drive carriage. This station could


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be an oxy/fuel or plasma torch station. Theoxy/fuel station consists of the torch, fuel andoxygen hoses, check valves, cut oxygensolenoid, motorized lifter, electrical cable, and aflexible cable carrier assembly. The plasmastation consists of the plasma torch and leads.Optional height controls are also mounted here.

2.14 TORCH STATION (Slave)

Oxy/fuel or tool slave stations include a carriagefor mounting to the transverse beam. Once thecorrect cutting separation is set, there stationsare secured to the steel band and they preciselyfollow the cutting operation of the mastercarriage.

2.15 STEEL BAND ASSEMBLY

The steel band assembly consists of a singlepulley assembly. The assembly is mountedon the extreme left and right of the transversebeam assembly. A 25mm steel band isthreaded around the assembly and is firmlyconnected to the transverse drive carriage.This allows motion for the slave torchstations. The steel band assembly allows theslave station(s) to have “like image cutting” ofthe master station(s).

Pre-installation Requirements

14

SECTION 3PRE-INSTALLATION REQUIREMENTS

3.1 PRE-INSTALLATION SAFETY

All equipment must be installed inaccordance with local requirements and theNational Electrical Code. Connect andmaintain good electrical grounds, as perarticle 250 of the NEC, to the supply groundwire, cutting machine and cutting table. Donot ground to electrical conduit, or pipescarrying gases or flammable liquids. Useonly correct sizes of electrical cable.

Plan to provide ventilation. Properventilation is vital for safety, good visibilityand personal comfort.

Equipment necessary for lifting the machineweight must be available at the time ofinstallation (overhead crane, forklift, etc.).

All normal safety precautions used inworking with flammable gases, electricalequipment and heavy machinery, as well asprocedures listed in your company safetymanual, must be followed to preventpossible injury.

Caution:When welding, DO NOT ground to the

machine, the rail system or to burning table,to avoid damage to electronic components.Evidence of welding to the cutting machine

equipment will void all warranties.

NOTE: The following preparations shouldbe complete before the arrival of theinstalling technician.

3.2 SITE LOCATION

The machine requires a space where floorvibration is at a minimum. Precisionoperation is necessary for accurate part

processing. Avoid areas where vibrationscaused by drop hammers, heavymachinery and punch presses are used.Position the unit close to the productionline, with adequate lighting and ventilation.

Special consideration must be used in theselection of a site for machine operation.Gas supply, electrical power, clean dryshop air and water in the immediate vicinityare essential for economical operation ofthe machine. Material handling equipmentis important for safe loading and unloadingof the parts.

3.3 SITE PREPARATION

The floor area supporting the rails andtable should be specified by a qualified civilengineer after reviewing the appropriatedrawing supplied with this machine. Thefoundation shall be designed to meet localbuilding codes. Koike Aronsonrecommends the concrete to be 3000psiminimum strength. Floor vibration shouldnot exceed 10um. Refer to Figure 3.1.Solid, secure and accurate rail and supportbeam installation is critical to ensuremaximum accuracy for the cuttingprocesses. The floor for the machineinstallation should be level within 3/8in.(9.5mm) over the entire length and width. Ifany possibility of floor settlement exists,separate footing should be provided over afirmly packed base. If a possibility ofequipment vibration exists, the machineshould be provided with an adequateisolation pad.


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3.4 ELECTRICAL REQUIREMENTS

The position of cables is very important forproper operation of the system. Use carewhen routing electrical wires and cables toavoid pinching or chafing against metallic orother abrasive objects.

Local codes as well as the NationalElectrical Standard must be followed for allpower and grounding installations.

Cutting machine electrical requirements are208/230/240 Volts AC (±10%), 50-60 Hz,single phase, 15 Amps. Koike Aronsonprovides the machine main power cable.Koike Aronson recommends all powercables be kept as far as possible fromauxiliary components such as machinecontrol boxes, solenoids, etc. Avoid randomplacement of wiring.Keep all wiring as short as possible, Do Notcoil any cables. Make sure all supply hosesand cable are long enough for the type ofcarrier system used.

This requires careful and proper installationof ground rods and associated wireconnections. Ground wires will connect tothe plasma power supply (if equipped), andthrough a "STAR" ground connection on thecutting table. Ground rod size for plasmasystems of 100 amperes or less should be12mm (1/2”) diameter solid copper, 2.5M (8’)in length. The wire connection to the Starground should be a properly sized strandedwire, and should not exceed 1.2M (4’) inlength. The ground rod for machines with aplasma system of 100 amperes or moreshould be 19mm (3/4”) diameter solid

copper, 4.5M (14’) in length. If you cannotdrive a 4.5M ground rod you may use two(2) 2.5M (8’) ground rods connected toeach other with 4/0 cable and then to theStar ground. The wire to the Star groundconnection will be a minimum of 4/0 cableand should not exceed 1.2M (4’) in length.

Note: Ground rods must be installedaccording to the National ElectricalCode Standards.

All ground connections must make intimatecontact with the components they aregrounding. All rusted or painted surfacesmust be cleaned and the connectionsmade should be tight. Any grounding strapshould be sized to current load per article250 of the NEC.

3.5 COMPRESSED AIR

Compressed air for general blow down andclean up should be dry, clean and oil freewith a 5-micron maximum particle size.

3.6 OXY-FUEL REQUIREMENTS

Oxygen and fuel gas supply systemsshould be recommended and installed byyour local gas supply distributor. For mostmulti-torch production cutting machines, acylinder bank or pipeline system is usuallyrequired.

During an installation of this type, careshould be taken to ensure that oxygenvalves, lines and fittings are cleaned foroxygen service. Station drops, fuel andoxygen should be spaced at least 300 mmapart center-to-center, and identified bycolor. All fuel and oxygen lines should beinstalled according to applicableregulations and safety rules.

CAUTIONThe AC power to the cutting machinemust come from a dedicated source. Noother machinery or equipment should beconnected to this service.

CAUTIONProper grounding of the cutting machineand peripheral equipment is critical tothe reliable operation of the system.


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Station drops should be installed on a wall orcolumn for rigid support. Installation shouldbe at the rear of the rail system for use withthe type of carrier system used for machinesupply.

Oxygen supply requirements must becalculated on the maximum number oftorches to be used and the maximummaterial thickness expected. Your local gassupplier is best suited to assist you indetermining your supply requirements.

A locally supplied pressure booster isnormally required for low-pressure naturalgas.

Compressed air for general blow down andclean up should be dry, clean and oil freewith a 5-micron maximum particle size.

3.7 BURNING TABLE

The burning table, fabricated enclosed oropen frame, is a customer responsibility.Refer to the layout drawing in Section 1figure 1.1, for your cutting machine todetermine clearance available for theburning table before fabrication. Theburning table may be as long as the cuttinglength provided by the rail system less thecutting machine parking space. Tablewidth and the outside dimensions, may beas wide as the designated cutting width ofthe machine plus 12.0in. (300 mm). A tablesurface (bottom of plate) height of 24.0in.(609 mm) is recommended. Do not anchorthe table in place before rail installation.

WARNINGDo not allow oil, grease, or combustiblesto be exposed to oxygen equipment.Use only thread-sealing compoundapproved for oxygen service whenmaking up threaded joints.

Small Stone

Re-enforcing meshConcrete

Vibration dampeningif required

Figure 3.1


17

Figure 3.2

Installation

18

SECTION 4INSTALLATION

4.1 INSTALLATION SAFETYPRECAUTION

Connect and maintain suitable electricalgrounds to the supply ground wire. Do notconnect ground to electrical conduit or topipes carrying gases or flammable liquids.Use only the recommended size of electricalcable, in accordance with article 250 of theNEC.

If it was necessary to install forcedventilation, operate the cutting machine onlywhen such ventilation is running to preventharmful and dangerous accumulations offumes.

Avoid enclosing areas where fuel gas leaksmay occur, or insure that such leaks cannotoccur in lines passing through or ending inconfined spaces.

Use normal precautions when loading oroperating heavy equipment. Follow theprocedures in your company safety manual.

4.2 HANDLING AND STORAGE

When the shipment arrives at your location,accompany the driver in counting all thecartons indicated on the driver's waybill.

Inspect each piece for signs ofmishandling or apparent damage. Ifdiscrepancies exist or any evidence ofdamage exists, note it BOLDLY acrossthe face of the waybill BEFORE YOUSIGN IT. Sign the waybill only after thisinspection. If you note discrepancies onthe delivery ticket, DO NOT open thecartons.

Call the trucker's local office and ask thata claims investigator be sent as soon aspossible to verify the status of theshipment. Also, call your Koike Aronsonrepresentative. Try to arrange the meetingso that the claims investigator and therepresentative will be present when thedamage/shortage is verified. The truckerwill supply you with the necessary claimsforms if required. Freight claims are thereceivers’ responsibility. Please followthese instructions carefully; KoikeAronson and your distributor will supportyou fully in the unlikely event that a freightclaim is necessary.

Handle the packing cartons carefully, rightside up as marked. Store cartons in a drylocation until ready to install.

4.3 UNPACKING AND CLEANING

The equipment has been packaged toprevent damage in transit. Unpackcarefully to prevent accidental damage byuncrating tools. After uncrating, examinethe equipment for signs of damage,particularly to control knobs, switches andelectrical components. Report anydamage to the freight carrier and KoikeAronson immediately.

WARNING

Voltages used with this machine can beinjurious to personnel if improperlyused. All equipment must be installedand maintained in accordance with localrequirements and the National ElectricCode.

Installation

19

Remove preservation coating from allunpainted surfaces with WD-40®, LPS-1® ormineral spirits.

4.4 RAIL INSTALLATION

Proper installation of rails and theirmechanical alignment is CRITICAL toensure cutting accuracy for this machine.Refer to the Appendix titled Rail Installationfor proper installation of the rails.

4.5 MACHINE MOUNTING

The cutting machine can be mounted on therail system from above (vertically) using anoverhead crane or from the front(horizontally) when overhead clearance istoo low.

Suspend the cutting machine assembly bymeans of the two (2) lifting strap assembliesunder the two beams located near the insideof the inboard saddle assembly and onelocated near the inside of the outboardsaddle assembly. Balance the machine bytest lifting.

When the machine is suspended, and theload is secured, clean the fixed guide andmain rollers. This is necessary for themachine to clear the rack when it is placedon the rails. Clean the adjustable guiderollers before placing the machine on therails.

NOTE: Maintain straight and level alignmentof saddles with the rails when makingcontact, to prevent damage to wheels, guiderollers, rails or rack.

Vertical Mounting: Align all four (4) wheelsof both saddles with the rails and gentlylower the full weight of the saddles onto therails. Reposition the machine, if necessary,to a position where the fixed rollers (frontand rear) are against the rail.

Adjust the rollers equally against the railso that when the guide roller is heldbetween the thumb and forefinger, theroller will just slip against the rail. Saddlesshould be level and should roll freely.Install the mechanical end stops to therail.

Horizontal Mounting: With saddlesaligned straight and level with the rails,make contact with the rear guide rollers ofthe main saddles. Roll the saddles slowlyrearward until the rear wheels of thesaddles make contact with the railsfollowed by the front wheels of thesaddles.

Adjust the guide rollers as indicated in thevertical mounting section. Install themechanical end stops to the rails.

4.6 MOTOR/PLANETARY GEAR UNIT

INSTALLATION

The motor and planetary gear units havebeen factory installed on the machine. Toengage the units, remove all the packingand support banding from the unit.Engage the gear pinion to the rack. Installthe spring washer assembly by tension.The tension on the assembly should betight enough so the spring can just beturned with your thumb and forefinger.

Note: For proper engagement and tensionto the rack, pull out on the mountassembly. This should be difficult. Note

This machine has open gearing.Keep hands clear when themachine is being operated.

WARNING

Installation

20

that it will not fully disengage the pinion butshould spring back to fully engage to therack. Improper tension of the springassembly will cause premature wear of thepinion and rack.

4.7 TORCH CARRIAGES

All slave carriages for individualtorches/tools are installed and adjusted atKoike Aronson, Inc. There is no installationrequired. Remove all packing and supportbands from the carriage assembly.

4.8 OXY-FUEL TORCH STATIONS

Torch lifters mount directly to the torchcarriages using the spacer provided and four(4) hex head cap screws. The torch stationclosest to the operator control console isdesignated as station number one (1).

With the torch “free” hanging, connect thecorrect hose(s) to the cutting torch. Loosenthe clamp screw on the motorized lifter.Insert the torch holder stud and tighten inplace. To achieve accurate cutting the torchmust be perpendicular to the surface of theplate. A swivel adjustment between themotorized lifter and the mounting stud clampwill allow for the necessary adjustment.Connect the flexible cable carrier to themounting bracket using the hardwaresupplied. Connect the torch lifter cable to thelifter assembly. Check the tightness of allhardware and hose connections. If theoptional auto ignition is fitted with yourmachine, install the hardware at this time.Refer to the Appendix for Pulse Ignition forproper adjustment.

4.9 CNC INTERFACE

The CNC control has been removed fromthe machine for shipment. Unpack itCAREFULLY and install the CNC in theoperator control. Connect the cableassemblies to the CNC. All cable assemblies

for CNC connection are appropriatelylabeled.

4.10 UTILITIES

The machine is supplied with a flexiblemain power track system. Route all supplyhoses and cables through the carriersystem in a neat and orderly fashion. Tieall cables and hoses to the tie plateslocated at each end of the cable carrierusing provided ty-wraps.

Connect the power cable from a properlyfused dedicated source (review Section 3

Pre-Installation) to the power disconnecton the machine. Check to see that thepower source is off and/or tagged Out ofService to avoid a potential electricalshock.

If an optional oxy-fuel system is installed,connect the fuel and oxygen supply hosesfrom the station drop to the correctconnection on the main valve unit. Agreen 1/2-inch “C” R/H fitting, oxygensupply hose connects to the cuttingoxygen main valve unit. A red 1/2-inch “C”L/H fitting, fuel supply hose connects tothe fuel main valve unit.

Connect the air hose to the main valveunit marked “AIR”.

4.11 GENERAL PLASMA MACHINECONNECTIONS

Plasma system installations differ frominstallation to installation due to the typeof system and height control ordered atthe time of purchase.

Installation

21

Some of the hosing and cables are left onthe machine neatly coiled and packed forshipping. The cables and hoses are labeledas to their connection to the plasma system.The remaining hoses and cables are packedseparately. After the flexible cable carrier isinstalled, locate the remaining hoses andcables, and carefully route through thecarrier. Route the hoses and cables in aneat and orderly fashion. The hoses andcables are labeled for connection. Check allgrounding for the plasma system. Make sureall ground connections are properlytightened. For a more detailed view of theinstallation, refer to Koike Aronson drawingsand the Vendor manual(s) provided withyour machine.

Operation

22

SECTION 5OPERATION

5.1 OPERATIONAL SAFETY

Follow the precautions in theSAFETY section and throughout thismanual for your personal safety andthe safety of personnel near theequipment.

1. Operate cutting equipment only in awell-ventilated area.

2. Check gas connections for tightnessregularly.

3. Keep combustibles away from thework area or protected from sparksand flames.

4. Verify the functionality of all checkvalves regularly.

5. Before connecting a pressure-reducing regulator to an oxygencylinder or manifold, always wipe theoutlet connection with a clean, oil freecloth and slightly open the cylindervalve to remove any dirt orcontaminate particles.

6. Always drain gas from the oxygenregulator before opening cylinder ormanifold valve. Proceed by engagingthe adjusting screw and openingdown-stream valves to allow gas toescape. The adjusting screw may

then be released before opening thecylinder valve.

7. Open cylinder or supply valves slowly.

8. Never use oxygen to ventilate area orclean off clothing.

9. Keep oil, grease and combustiblesaway from oxygen equipment.

10.Before igniting any torch, purge oxygenand fuel lines by briefly opening andclosing each valve.

11.Wear eye protection safety goggleswith appropriate filter lens. See page B-5.

12.Keep equipment clean and in goodoperating condition.

13.WELDING: DO NOT ground to themachine, the rail system or to thecutting table at any time to avoiddamage to electronic components.Failure to follow this warning may voidall manufacturers’ warranties.

5.2 GENERAL OPERATIONS

1. For machine control operations,refer to the KARCNCX OperationManual.

Maintenance

23

SECTION 6MAINTENANCE

6.1 SAFETY PRECAUTIONS

1. Shut OFF main power switch, pull fuses, orlock and red tag switch before attemptingwork on electrical circuits. Do not touchelectrically HOT parts or those with residualvoltage, such as capacitors until they havebeen grounded and their electric chargedissipated.

2. Check gas cylinder valves, regulators, hose,and torch connections regularly for leaks.


4. Always purge oxygen and fuel linesindividually to discharge combustiblemixtures before lighting each torch. Closeeach torch valve before opening the nextone.

5. Do Not purge in the presence of flame, litcigarettes and other sources of ignition.

6. Before attempting to disassemble any part ofthe Gas System, depressurize the System.Do Not disconnect any part of the GasSystem that is under pressure.

7. All parts, repaired, replaced or otherwisehandled, must be cleaned for oxygenservice.

8. Regularly, inspect check valves and keepthem in operating order. They preventreverse flow (from torches to hoses) ofhazardous mixtures of flammable gas andair (or oxygen). Refer to 6.1 on how to test acheck valve.

9. Keep power cables dry, free of oil andgrease, and protected at all times fromdamage by hot metal and sparks. Do Notuse any power cable with worn or damagedinsulation. Repair or replace immediately.

10. Equipment that is not functioning properlyshould Not be used until all repairs havebeen completed and the equipment hasbeen tested to ascertain that it is in properoperating condition.

11. When welding Do Not ground to themachine, the rail system, or to the cuttingtable at any time to avoid damage toelectronic components. Failure to follow thiswarning may void manufacturers'warranties.

12. Except for inspection and maintenancelisted in this manual, it is recommendedthat all other servicing be done by anauthorized Koike Aronson, Inc. servicetechnician.

13. Goggles with correct filter lenses must beworn whenever torches are lit. Suitableprotective clothing must be worn wherenecessary.

Comply with these and other safety procedureslisted in this manual. Refer to appropriatemanuals, furnished by the manufacturer, forsafety procedures for plasma, drive, N/C orother optional equipment.

6.2 GENERAL INFORMATION

This manual provides standard preventativemaintenance procedures required for accurateand proper operation of the PLATE-PROEXTREME® cutting machine. Follow theseprocedures to maintain machine operation atpeak efficiency and to extend the useful life ofthe machine.

The machine has been assembled, properlyadjusted and factory tested before shipment.Factory settings, other than those listed in theinstallation section of this manual, should notbe changed. If machine performance isunsatisfactory, contact a Koike Aronson, Inc.authorized service representative for advice.

Maintenance

24

Keep the machine clean, in good condition andfree of oil, grease and other combustibles. Ifreplacement parts are required, it isrecommended that they be purchased fromKoike Aronson, Inc. through an authorizeddistributor.

The manufacturers for optional items such asplasma systems, microprocessor controls andcertain other components have furnishedseparate manuals listing maintenanceprocedures.

6.3 PREVENTATIVE MAINTENANCESCHEDULE

Although this machine does not requireextensive maintenance, the followingprocedures should be preformed routinelybased on operation hours. The followingmaintenance guidelines are solely theresponsibility of the operator (customer).Failure to comply with these guidelines for yourmachine can result in poor cut quality, a roughrunning machine or service calls at theexpense of the customer that are not coveredunder machine warranty by the Distributor orby Koike Aronson, Inc.

CAUTIONDO NOT allow any grease that has not beenapproved for oxygen use come in contactwith oxygen equipment.

6.3.1 EACH EIGHT (8) OPERATION HOURS

1. Blow off rails, rollers and wheels with low-pressure shop air (Not Oxygen).

2. Spray a clean cloth lightly with WD-40®orLPS-1®, and wipe the wheels, rollers, x-axisway bar, gears, rails and rack.

3. Ensure that the main saddle side guiderollers are tight to the side of the rail. Theoutside rollers are non-adjusting; the insiderollers are adjustable.

4. Check rail scraper pads for wear. Replacewhen the pads are worn or insufficientlycleaning the rails.

5. Clean torches and tips.

6. If the machine is equipped with an air scribe,punch marker, or torch breakaway device,check that the air supply is clean and dry.Moisture free air is important to theoperation of these options.

6.3.2 EACH FIFTY (50) OPERATION HOURS

1. Check gas system for leaks with soap andwater solution.

2. Check for damage to the gear rack. Repairwith a file or replace if damage is excessive.

3. Remove wheel guards located on theoutside of the saddles and clean mainwheels.

4. Clean, readjust and grease torch holders.

5. Check roller bearings on X-axis carriage forsmooth operation. Clean and lube ifnecessary.

6.3.3 EACH TWO HUNDRED FIFTY (250)HOURS

1. Check for backlash in X and Y drive pinionsto the rack. Make sure the pinion is notworn. If backlash exists, check the rack forwear.

2. Check that the steel band that runs the slavecarriages is tight and free of cracks.

3. Check gas system for leaks with soap andwater solution.

Maintenance

25

6.3.4 EACH ONE THOUSAND (1000) HOURS

1. Clean and dust off all electrical equipment.

2. Test cutting oxygen check valves for reverseflow. Refer to Section 6.11 on how to test acheck valve.

6.4 GUIDE ROLLER ADJUSTMENT

After prolonged usage, the main saddleeccentric guide rollers may require adjustment.

Adjust eccentric bolts until rollers can just beturned, using thumb and forefinger, against theside of the rail. Check that all guide rollers turneasily as the machine is moved.

6.5 RAIL CLEANING

Spray a clean cloth lightly with WD-40®or LPS-1®, and wipe the top, sides and rack clean.When cutting spatter settles on the rails, cleanor chip off with a steel flat tool. Be sure not todamage the rail or rack.

File off larger burrs that may appear on therails as they could affect cutting performance.

6.6 ROLLER CLEANINGAt least once each shift, remove dirt buildupfrom small rollers, main carriage side guiderollers and torch carriage rollers as follows:

a. Hold a steel flat bar (1.6 x 25 mm crosssection or a steel pocket rule) flat on railedge against roller surface.

b. Move the carriage in a direction away fromthe bar, holding the bar against the roller forat least one complete revolution to scrapeoff dirt buildup.

6.7 WHEEL CLEANING

At least once each shift, remove dirt buildupfrom wheels on the Y- axis saddle.

Scrape off buildup from wheels with the edgeof a steel flat bar (1.6 x 25 mm, or pocket rule)while rolling carriage through one revolution ofeach wheel.

6.8 GEARS AND PINIONS

At least once each shift remove debris fromgears and pinions using a stiff wire brush.Spray on a light film of LPS-1®.

6.9 GAS CONTROL SYSTEM

Refer to the appropriate appendix on the GasControl System Manual for Set-up andoperation.

6.10 DRIVE TUNING PROCEDURE

The PLATEPRO EXTREME® uses AC servodrives. No electrical adjustments are required.The parameters for each drive are factory setand must not be changed without consultingKoike Aronson, Inc.

6.11 CUT QUALITY TROUBLE-SHOOTING

1. Cut edges distorted or melted - Preheatflame too high.

2. Flame backfiring - Preheat flame too low, tooclose to work piece.

3. Distorted flames - Dirty cutting tip, replace orclean.

4. Dispersed or slanting oxygen jet - Cutting tipis dirty or distorted.

5. Cut edge is cambered toward bottom -Preheat flame too low, cutting oxygen toohigh.

6. Too much drag on the cut surface - cuttingspeed is too fast.

If incoming supply pressures are correct andgas panel pressure setups are correct for thefuel gas, but torch and tip combinationproblems persist, contact your Koike Aronson,Inc. service representative for assistance.

Maintenance

26

6.12 SYNCH ERROR

An out of synch error may be caused byseveral mechanical problems. Check thefollowing before attempting synchronizationadjustment:

a. Check the entire rail system forstraightness.

b. Check Y-axis drive racks for dents,straightness and cleanliness. Usealignment rack to check the joints formovement and wear.

c. Check the planetary gear pinions for wear.Verify that set screws are tight.

d. Check side guide rollers for properadjustment.

e. Refer to the KARCNC operation manual toclear the error.

6.13 CHECK VALVE TEST

Check valves are mechanical devices that canleak when dirty or misused.

a. Turn off gas supplies and depressurizethe gas and oxygen system.

b. Remove suspected bad check valve.c. Using nitrogen, at .07psig, the check

valve will allow flow through followingthe direction of the arrow stamped onthe valve.

d. Reversing the flow of nitrogen, thecheck valve will not allow flow throughthe valve.

If nitrogen flows though, replace the valve.Reference: Figure 6.1

GASFLOWIN

GASFLOWOUT

NormalConditions

REVERSEGASFLOW

GASFLOWSTOPS

ReverseConditions

Figure 6.1Check Valve

WARNINGAlways test and purge in a well-ventilated areafree from open flame or other sources of ignition.

Replacement Parts

27

SECTION 7REPLACEMENT PARTS

To assure minimum down time, it is recommended that spare parts noted by anasterisk * in the Part Number column of the parts list be kept on hand. To assureproper operation, it is recommended that only genuine KOIKE ARONSON parts andproducts be used with this equipment.

To order replacement parts:

a. Contact Koike Aronson Inc. service at 1-800-252-5232.b. Provide Sales Order (SO#), serial number and model of equipment from the Serial

Tag located on the main beam.c. Provide part number, description and quantity of part.d. Be sure to indicate any special shipping instructions.

Figure 7.1 Front View

Y-axis CableCarrier Assembly

3100Rail Gauge 162.75”

2500Rail Gauge 138.75”

2000Rail Gauge 114.75

Measured Between Centers Of 23Kg Rail

X-axis CableCarrier Assembly

CNC

Slave CarriagesIf Equipped

Heat Shield

Replacement Parts

28

Figure 7.2 Side View

Hi-Lo GasConsole

Hi-Lo GasManifold

Y-axis CableCarrier Assembly

CNC

X-Motor and PlanetaryGear Unit

Replacement Parts

29

Figure 7.3 Saddle Assembly

Item Number Part Number Part Description1 1115-1017-00 WHEEL & AXLE ASSEMBLY2 1115-1018-00 SIDE GUIDE ROLLERS

3 1115-1019-00 RAIL SCRAPER ASSEMBLY4 9935-4174-00 LIMIT SWITCH W/ROLLER LEVER5 0868-9228-00 PLANETARY GEARBOX6 0868-8814-00 DRIVE PINION

7 9983-0342-02 MOTOR AC

15

6

4

3

2

7

Replacement Parts

30

Figure 7.4 Master Carriage

Item Number Part Number Part Description1 0868-8807-01 ROLLER2 0868-8814-00 DRIVE PINION3 0868-9228-00 PLANETARY GEARBOX4 9983-0342-02 MOTOR AC5 1138-3133-01 WASHER, BELLEVILLE SPRING

5

3

2

1

4

Replacement Parts

31

Figure 7.5 Steel Band Unit

Item Number Part Number Part Description1 1138-9234-00 LIMIT SWITCH2 0868-6855-00 COLLAR,SET SCR

3 0866-6511-00 BEARING4 1138-9382-00 SNAP RING,

5 0866-9082-00

BAND, STEEL .0118 X 1" SS3100 SERIES - 31.25 FT

2500 SERIES - 27.25 FT2000 SERIES - 23.25 FT

1

2 3 4

5

Replacement Parts

32

Figure 7.6 Hi-Lo Gas Console

Item Number Part Number Part Description1 1138-3005-01 PRES GAUGE SCALE 0-30 PSI/KGCM SQ2 1138-3004-01 PRES GAUGE SCALE 0-200,PSI/KGCM SQ3 201-1106 REGULATOR FUEL4 201-1105 REGULATOR OXYGEN5 1138-5504-00 SOLENOID VALVE, SUPPLY OXYGEN

6 1138-5507-01 SOLENOID VALVE, FUEL7 1138-5505-00 SOLENOID VALVE, BLOW OXYGEN8 0866-8742-00 DOME REGULATOR

Figure 7.7 Hi-Lo Gas Manifold

12 32

645

6

5

8

7

Replacement Parts

APPENDIX A

PLATE-PRO EXTREME®®

List of Terms and Abbreviations

Abbreviation Term

AC Alternating CurrentAmph Aphenolamp(s) Ampere(s)BTU British Thermal Unitsccw Counter-ClockwiseCGA Compressed Gas AssociationCSA Canadian Standards Associationcw Clockwisedia. DiameterDVM Digital Volt MeterE-Stop Emergency Stopetc And so forthHHCS Hex Head Cap ScrewHz Hertzie That is for examplein InchesINC. Incorporatedipm Inches per MinutekPa KilopascalsL/H Left HandM MeterMFD Microfaradmm MillimeterNC Normally ClosedNEC National Electric CodeNG Northrup GrummanNo. NumberNO Normally OpenNPT National Pipe Threadoxy Oxygenoz Ouncespsi Pounds Per Square InchPWM Pulse Width ModulatorRecpt ReceptacleR/H Right HandSO# Sales Order NumberTP Test Pointvdc Volts direct current“ Inches--F Female--M Male

Replacement Parts

APPENDIX B

MODEL G SERIESTORCH LIFTERS

Replacement Parts

B-1

TABLE OF CONTENTS

SECTION 1 SAFETY PRECAUTIONS ...................................................... B-3

Section 1.1 General Safety, Oxy/Fuel Cutting........................................... B-4Section 1.2 General Safety, Plasma Cutting............................................. B-5

SECTION 2 INTRODUCTION.................................................................... B-7

Section 2.1 Scope..................................................................................... B-7Section 2.2 Description ............................................................................. B-7Section 2.3 Specifications......................................................................... B-7

SECTION 3 INSTALLATION..................................................................... B-8

Section 3.1 Installation G6 - G12 .............................................................. B-9

SECTION 4 MAINTENANCE................................................................... B-10

Section 4.1 Safety Precautions ............................................................... B-10Section 4.2 General Information ............................................................. B-10Section 4.3 Daily Routine Maintenance .................................................. B-10Section 4.4 Monthly Routine Maintenance.............................................. B-10Section 4.5 Electrical Maintenance ......................................................... B-14Section 4.6 Mechanical Maintenance ..................................................... B-14

SECTION 5 REPLACEMENT PARTS..................................................... B-18

SECTION 6 OPTIONAL ACCESSORIES................................................ B-20

Replacement Parts

B-2

ILLUSTRATIONS & TABLES

Figure 3.1 Model G Lifter Installation ...................................................... B-9Figure 4.1 Lifter Shaft Extended............................................................ B-11Table 4.1 Troubleshooting Guide......................................................... B-12Figure 4.2 Adjustment Assembly........................................................... B-15Figure 4.3 Motor & Coupling Assembly................................................. B-16Figure 4.4 Wiring Diagram .................................................................... B-16Figure 4.5 Lifter Cable Configuration .................................................... B-17Figure 4.6 Ballscrew Replacement........................................................ B-17Figure 5.1 Model G Parts Breakdown ................................................... B-19Figure 6.1 Short Torch Support............................................................. B-21Figure 6.2 Long Torch Support ............................................................. B-21Figure 6.3 Manual Torch Holder, Small Handle .................................... B-22Figure 6.4 Manual Torch Holder, Large Handle .................................... B-22Figure 6.5 Manual Torch Holder, 1-3/8" Oxy/Fuel or Plasma Torch...... B-23Figure 6.6 Torch Fore-Aft Adjuster........................................................ B-23

B-3


USER RESPONSIBILITY - This equipment will perform in conformity withthe description thereof in this manual and accompanying labels and/orinserts when installed, operated, maintained and repaired in accordancewith the instructions provided. This equipment must be checkedperiodically. Defective equipment should not be used. Parts that arebroken, missing, plainly worn, distorted, or contaminated should bereplaced immediately. Should repair or replacement become necessary,Koike Aronson recommends that a request for service be made to the KARAuthorized Distributor or directly to the Koike Aronson ServiceDepartment.

This equipment or any of its parts should not be altered without priorwritten approval of Koike Aronson. The user of this equipment shall havesole responsibility for any malfunction which results from improper use,faulty maintenance, damage, improper repair or alteration by anyone otherthan Koike Aronson or a facility designated by Koike Aronson.


Throughout this manual, notes, cautions, and warnings are used todescribe situations that require additional information. The followingformats are used for each:

Notes: A note offers additional information, such as an operatingtip, that aids the user in operating the cutting system.

Caution: A caution describes a situation that may cause damage to thelifter and offers advice to avoid or rectify the situation.

WARNING

A warning describes a situation that presents a physical danger to theoperator, and offers advice to avoid or rectify the situation.

B-4


Operation of oxy/fuel torchesinvolves oxygen and flammablegases under pressure, open flames,flying slag and hot metal, fumes andcombustion products.

Follow the precautions in thisGeneral Safety Section as well asthose throughout this manual foryour personal safety and the safetyof personnel in the area that may beaffected.

1. Check gas and electricalconnections for tightness afterinstallation and on a regular basisthereafter.

2. Keep combustibles away from thework area or protect them fromsparks and flames.

3. Check for proper function of checkvalves regularly. Do not remove orbypass check valves.


5. Never use oxygen to ventilate thearea or clean off clothing.

6. Keep oil, grease, and combustibledust away from all oxygenequipment.

7. Purge oxygen and fuel linesindividually whenever combustiblemixtures in the lines are suspected.

8. Never use the oxygen hose forany other gas than oxygen.

9. Replace hose that is damaged byphysical abuse or by sparks, heat oropen flame.

10. Examine hoses at daily intervalsfor leaks, wear, loose connections orother hazards.

11. Coil excess hose and place it outof the way to prevent damage and toeliminate tripping hazard.

12. Maintain all pressure regulatorsin proper working condition.

13. Never use a regulator for anygas other than that for which it isintended.

14. Never use a regulator that leaks,creeps excessively or is physicallydamaged in any way.

15. Never attempt to lubricate aregulator with oil or grease.

16. Wear filter-lens safety eyeprotection. Wear gauntlet gloves,safety shoes, flame retardantclothing, and cuffless trousers. Donot wear loose clothing around thismachinery as it can catch on themachine.

17. Shut off power and gas supplieswhenever leaving machineunattended or before servicing.

18. Keep equipment clean and ingood operating condition.

19. Read and understand furtherdetailed safety precautionsthroughout this manual.

B-5

20. Also, refer to the latest revisionsof the following sources of safepractices in welding and cutting.

A. National Fire ProtectionAssociation Standard 51B CUTTINGAND WELDING PROCESS,obtainable from NFPA, BatterymarchPark, Quincy, MA 06269.

B. NFPA Standard 51, OXY/FUELGAS SYSTEMS FOR WELDINGAND CUTTING, obtainable same asitem A.

C. American Welding Societypublication C4.2-90, OPERATOR'SMANUAL FOR OXY/FUEL GASCUTTING, obtainable from AWS,Box 351040, Miami, FL 33135

1.2 GENERAL SAFETY, PLASMACUTTING

Plasma Arc cutting is a high intensitysource of visible light emission aswell as ultraviolet and infraredradiation. It can cause severe eyedamage and inflict burns on exposedskin when those portions of the bodyare not suitably protected.

Follow the precautions in thisGeneral Safety Section and read thesupplied plasma equipmentinstruction manual for additional andmore detailed safety precautions.

1. Facilities should be available forthe medical treatment of arc flashesor burns to the eyes.

2. Provide radiation protection for theoperator and for personnel in theadjacent area.

3. Do not, under any circumstances,

look at a plasma arc without full eyeprotection. When in the vicinity of theplasma cutting equipment alwayswear flash goggles with side shieldsand containing No. 4 filter lenses.

4. The operator must use in additionto flash goggles, a suitable helmetfor eye and face protection whencutting. The helmet must beequipped with a filter plate asindicated:

Arc Current Up to 100 AmpsShade No. 8Arc Current 100 to 200 AmpsShade No. 10Arc Current 200 to 400 AmpsShade No. 12Arc Current Over 400 Amps ShadeNo. 14

5. Do not use a helmet or handshield that is not in good condition.Repair or replace promptly. Protectcolored filter plates with a clear glasscover plate.

6. Warn other people in the area notto look directly at the arc unless theywear glasses/goggles or a helmet.

7. Never start the plasma arc withoutdetermining that nearby personnelare wearing adequate protectiveequipment.

8. All areas of the body must becovered by dark substantial clothing(preferably flame retardant) toprotect against arc burn, sparks andflying hot metal.

9. The plasma operation should belocated in an area where protectionfor other personnel may be readilyprovided. Portable non-combustible

B-6

reflecting screens or enclosures withnon-reflecting walls may be used.Screens and enclosures shouldpermit free circulation of air at floorlevel.

10. Remove combustible materialfrom the immediate cutting area.

11. Quench freshly cut metal orallow metal to cool before handling itor bringing it in contact withcombustible materials.

12. To prevent electric shock keepyour body and clothing dry.

13. Do not stand in, sit on or lie onany wet surface when using theplasma system.

14. Maintain proper insulationagainst electrical shock. If you mustwork in or near a damp area, useextreme caution. Wear insulatedgloves and boots.

15. Inspect the torch leads.Replace if frayed or damaged.

16. Before changing the torch parts,disconnect the main power supply.

After changing the torch parts andreturning the retaining cap to itsoperating position, plug the powersupply in again.

17. Never bypass or shortcut thesafety interlocks.

18. Plasma cutting operation noiselevels may be high enough to requireear protection for the operator andother personnel in the adjacent area.

19. When using a water table whileplasma arc cutting plate, especiallyaluminum or magnesium may causean accumulation of explosive gasbelow the plate. Do not allowaluminum or magnesium dross toaccumulate in a water table. Beforecutting, raise and lower the waterlevel several times to dissipatetrapped gases. Do not leave plate onthe table for extended periods, i.e.overnight or weekends. When thetable is not in use, keep the waterlevel down. Do not cut thesematerials under water. Readadditional cautions in the relatedmanuals.

B-7

SECTION 2

INTRODUCTION2.1 SCOPE

This manual provides generalinstallation, operation and serviceinformation for the Koike AronsonModels G6, and G12 MotorizedTorch Lifters. This manual includesan illustrated part listing to aid inordering parts.

2.2 DESCRIPTION

The Koike Aronson Model GMotorized Torch Lifter is a compact,rugged accessory for most heavy-duty cutting machines. The lifter maybe mounted by one of two methods,bolt on or pin clamp. The heavy-dutyaluminum casting, stepper motor andball-screw drive provides accuratevertical positioning of the torch inrelationship with the work piece.

2. 3 SPECIFICATIONS

The G6 has 6 in. (152.4mm) ofvertical travel at 37.5ipm(952.5mm/min.), with a liftingcapacity of 50 lbs. (22.68Kg). Themaximum rotational movement at apoint 3 in. (76.2mm) from centerwhen subjected to a 10 lb. (4.54Kg)force acting first in one direction andthen the other is 0.005 in. (.127mm).The lifter weights 17 lbs. (7.71Kg).

The G12 has 12 in. (304.8mm) ofvertical travel at 37.5ipm(952.5mm/min.), with a liftingcapacity of 50 lbs. (22.68Kg). Themaximum rotational movement at apoint 3 in. (76.2mm) from centerwhen subjected to a 10 lb. (4.54Kg)force acting first in one direction andthen the other is 0.005 in. (.127mm).The lifter weights 20 lbs. (9.07Kg).

Lifter style: G6

Lifter style: G12

B-8


3.1 INSTALLATION G6-G12

Installation of the G6 - G12 MotorizedTorch Lifters is accomplished using four(4) M8 Hex Head Capscrews whichfasten the lifter to the torch carriage. A60mm x 64mm M8-1.25 pattern needs tobe drilled and tapped in the torch carriagefor installation. Typically the patternwould be centered on the carriage, beinglevel and plumb, but it can be placed indifferent positions if there is adequate

material for the tapped holes and thebalance of the carriage is notcompromised. Keep in mind the strokelength of the lifter and the height of thecutting table. Connect the lifter cable fromthe control to the cable connection on thetop of the lifter (See Figure 3.1) .

B-9

60mm(2.36”)

64mm(2.51”)

Cable Connection

Figure 3.1 Model GLifter

B-10


4.1 SAFETY PRECAUTIONS

1. Shut OFF main power switch; pull fuses, orlock and red tag switch before attempting workon electrical circuits. Do not touch electricallyHOT parts or those with residual voltage, suchas capacitors until they have been groundedand their electric charge dissipated.

2. Keep lifter cables dry, free of oil and grease,and protected at all times from damage by hotmetal and sparks. Do Not use any power cablewith worn or damaged insulation; repair orreplace immediately.

3. A lifter that is not functioning properly shouldNot be used until all repairs have beencompleted and the lifter has been tested toascertain that it is in proper operatingcondition.

4. Inspection and maintenance of the lifter asindicated in this manual may ordinarily beundertaken by a competent person having atleast general experience in the maintenance ofequipment of this nature.

CAUTION: No maintenance or repair shouldever be undertaken by anyone not having

sufficient qualifications.

4.2 GENERAL INFORMATION

This manual provides standard preventativemaintenance procedures required for accurateand proper operation of the Model G SeriesMotorized Torch Lifters. Follow theseprocedures to maintain lifter operation at peakefficiency and to extend the useful life of thelifter.

The motorized torch lifter has beenassembled, properly adjusted and factorytested before shipment. Factory settingsshould not be changed. If lifter performance isunsatisfactory, contact a Koike Aronsonauthorized service representative for advice.

PREVENTIVE MAINTENANCE means themaintaining of equipment in sound conditionand is a way of avoiding breakdowns andaccidents and the consequent expense ofrepairs and interruption in production flow.

4.3 DAILY ROUTINE MAINTENANCE

1. Fully extend the motorized torch lifter shaft.(See Figure 4.1) Shut OFF the main powerswitch. Ensure that the circuit breaker for thecutting machine is in the OFF position.Uniformly spray a light coat of WD-40® orequivalent on the lifter shaft.

2. Check that lifter cable connections aresecure.

4.4 MONTHLY ROUTINE MAINTENANCE

1. Fully extend the motorized torch lifter shaft.(See Figure 4.1) Shut OFF the main powerswitch. Ensure that the circuit breaker for thecutting machine is in the OFF position. Usinga clean shop cloth, wipe the shaft clean oflubricant and iron oxide dust. Uniformly applya light coat of Never Seez® lubricant orequivalent. Fully retract and extend the liftershaft several times. With the shaft in theretracted position wipe off any excesslubrication.

B-11

Lifter ShaftStroke

Figure 4.1 Extended Lifter Shaft.

B-12

TROUBLESHOOTING GUIDE

PROBLEM PROBABLE CAUSE SOLUTION

Torch Lifter does notmove.

Motor not operating

Ball Screw Clutch not holding

Broken motor coupling

Check for power on lifter cable.

Replace Ball Screw assembly.

Replace motor coupling.

(See Sections 4.5 and 4.6)Excess rotationalmovement.

Improper detent (bronzebushing) adjustment

Adjust detent so the shaft can be turnedapproximately 1/5 of a turn usingmoderate force.

Raise and lower the torch lifter. If thetorch will not raise loosen the tensionadjustment set screw until the liftermoves smoothly (See Section 4.6).

Lifter motor becomeshot and the motor willonly run intermittently.

Defective motor capacitor Replace capacitor.

Torch Lifter runs inone direction only.

Faulty Motor

Open circuit in the electricalassy. wiring

Short in the electrical assy.wiring

Replace Motor.

Troubleshoot the wiring inside the drivecontrol.

Check for 110VAC ±10V at pins C & Dusing pin B for neutral.

Torch Lifter will notrun.

Defective Motor

Defective Capacitor

Defective Resistor

Open Circuit

Loose Connection

Replace defective component.

Troubleshoot the wiring.

Return Lifter to Koike Aronson for repair.

B-13

TROUBLESHOOTING GUIDE (CONT’D)

PROBLEM PROBABLE CAUSE SOLUTIONTorch Lifter blowsfuses.

Defective Motor

Defective Capacitor

Defective Resistor Circuit

Short in Motor Controller

Short in Drive Control or Cable

Unplug lifter cable and operate thedrive control if the fuse blows theproblem is in the drive control and thecontrol must be diagnosed permanufacturer’s recommendations. If theproblem is in the cable check forcontinuity and short circuits.

If the fuse does not blow,troubleshooting must be performed onthe torch lifter (See Section 4.5).

Lifter operates thesame direction (up ordown) regardless ofthe control switchdirection.

Shorted, grounded or brokenconnection in the black or redmotor wiring

Check continuity, connections andshielding on the black and red wires.

B-14

4.5 ELECTRICAL MAINTENANCE

If the torch lifter does not move, it can beeither an electrical or mechanical problem.If it is an electrical the following should bechecked:

The first check is on the lifter cable. Withthe control switch in the up/down positionremove the cable from the torch lifter. Onthe lifter cable plug check for 110VAC ±10Vat pins C (up) & D (down) using pin B forneutral. (See Figure 4.5) If there is nopower the problem is in the drive controllerand you need to use its documentation forcorrective actions. If there is power to thelifter, remove the motor cover by removingthe four (4) M4 retaining capscrewssecuring the cover using a 3 mm allenwrench. Remove the four (4) M5 retainingcapscrews from the motor assembly usinga 4 mm allen wrench. Remove the motorassembly (See Figure 4.3). Using the drivecontroller attempt to raise and lower thelifter. If the motor turns, the problem ismechanical (See Section 4.6). If the motordoes not turn, check for power at eitherblack wire on the capacitor while using thedrive controller switch to move the lifter inthe up and down directions. If there ispower present the motor must be replaced.If power is not present replace the capacitor(See Figure 4.4).

4.6 MECHANICAL MAINTENANCE

Although this lifter does not requireextensive maintenance, if the routinemaintenance is performed, there are acouple of items that may need to bemaintained or adjusted.

If there is excessive rotational movement,the rotational braking tension must beadjusted. Before trying to adjust thetension, the bronze detent bushing shouldbe inspected for damage or uneven wear. Ifeither is found it should be replaced. Tocheck the detent bushing remove the lifterfrom the machine, remove the adjustment

plug (one (1) inch socket head set screw)from the lifter. Remove the tension springand bronze detent bushing. If the bushing isnot damaged reinstall it (See Figure 4.2).

Lower the lifter shaft three (3) inches. Slidea steel bar or screwdriver through the two(2) holes in the bottom of the lifter shaft.Reinstall the tension spring and adjustmentplug turning the plug clockwise until thelifter shaft will only rotate 1/4 of a turn.Without reattaching the lifter to the torchcarriage, operate the lifter up and down tocheck that there is no binding. If bindingoccurs loosen the adjustment plugaccordingly.

Note: The lifter shaft should be adjusted sothat it can be turned NO more than 1/4 turn.

Move the shaft off center in either direction,it should always return to center.

If the lifter will not move and it has beendetermined that it is a mechanical problem:

Remove the four (4) retaining capscrewssecuring the cover using a 3 mm allenwrench. Remove the four (4) retainingcapscrews from the motor assembly usinga 4 mm allen wrench. Remove the motorassembly. If the problem is the motorcoupling it can be replaced by inserting thenew coupling into the slotted shafts in theball screw and motor and reassemble. If thecoupling is not the problem the problem isprobably the ball screw clutch.

To change the ball screw, remove the four(4) M4 retaining capscrews securing thecover using a 3 mm allen wrench. Removethe four (4) M5 retaining capscrews fromthe motor assembly using a 4 mm allenwrench. Remove the motor assembly (SeeFigure 4.3). Remove the motor coupling.

Caution: The bushing should slide in and outsmoothly and turn freely within its housing. Ifit does not, the shaft or lifter may bedamaged.

B-15

Using an appropriate size snap ring pliersremove the snap ring from the bearing andball screw assembly. Remove the bronzedetent bushing, tension spring andadjusting plug from the lifter tube.

Slide the shaft and ball screw assembly outof the torch lifter tube. Heat the uppersection of the shaft to loosen the Loctite®and using a strap wrench, turn the ballclutch nut counter clockwise to remove itfrom the torch lifter shaft.

Reverse the process to install a new ballscrew. There are a couple of added steps.Before inserting the new ball screw, cleanthe lifter tube and the bronze bushings atthe lower end of the tube. Lubricate thelifter shaft with a uniformly applied light coatof Never Seez® lubricant or equivalent.Loctite® Stud Lock Red #7331 must beused where the ball screw attaches to thelifter shaft (See Figure 4.2 & 4.6).

.

Tension Spring

Detent Bushing

Adjustment Plug

Lower Bushings

Figure 4.2 Adjustment Assembly

B-16

Figure 4.3 Motor and Coupling Assembly

B COMMON

C UP

D DOWN

E GROUND

GROUND

SCREW

MOTOR LEADS

50 25W

CAPACITOR

5 MFD 300 VAC

WHITE

CABLE RECP.

GREEN

BLA

CK

RE

D

Figure 4.4 Wiring Diagram

B-17

Figure 4.5 Lifter Cable Configuration

Not used

Ground

DownUp

Neutral

D

A

E

C

B

Use Loctite here

Figure 4.6 Ballscrew Replacement

B-18


To assure minimum down time, it is recommended that spare parts noted by an asterisk * in thePart No. column of the parts list be kept on hand.

To assure proper operation, it is recommended that only genuine Koike Aronson (KAR) parts andproducts be used with this equipment.

To order replacement parts:

a. Provide part number, description and quantity of part.

b. Indicate any special shipping instructions.

B-19

Figure 5.1 Model G Torch Lifter

Item Part No. Description

1 0866801000 Spring2 9938138400 Set Screw, 1-14 x 3/4, Flat Point3 9938228300 Bushing, 7/8 x ½ x 14 9938228400 Bushing, 1-3/4 x 1-3/8 x 15 9938431100* Coupling, 85197-26 9938431400 Ball Screw, 6" Stroke

9938431401 Ball Screw, 12" Stroke7 9968253100 Snap Ring, Internal, 42mm8 9938938000 Motor, Step9 0868612300 Receptacle, Amphenol, MS3102A-14S-5P10 0868642800* Capacitor, 5 MFD11 0868630900* Resistor, 50 OHMS, 25 Watt

B COMMON

C UP

D DOWNE GROUND

GROUNDSCREW

MOTOR LEADS

50 25W

CAPACITOR

5 MFD 300 VAC

WHITE

CABLE RECP.

GREEN

1

23

44 56 7

89

1011

B-20

SECTION 6OPTIONAL ACCESSORIES

The following pages show a variety of different torch holders and adjusters.

To order accessories:

a. Provide part number, description and quantity of the part.

b. Indicate any special shipping instructions.

B-21

50 mm

Figure 6.1 Short Torch Support (ZS61106)

105 mm

Figure 6.2 Long Torch Support (ZS60200)

B-22

Figure 6.3 Manual Torch Holder, Small Handle (ZS61108)

Figure 6.4 Manual Torch Holder, Large Handle (ZS60201)

B-23

Figure 6.6 Torch Fore-Aft Adjuster (ZS61100)

`Figure 6.5 Manual Torch Holder, 1-3/8” Oxy/Fuel Victor, Harris, Oxyweld orPlasma (0866842800)

This page left intentionally blank

APPENDIX C

PULSE IGNITION

October, 1999Revision 0

C-1

TABLE OF CONTENTS

SECTION 1 SAFETY PRECAUTIONS ............................................................... C-3

Section 1.1 General Safety, Oxy/Fuel Cutting ..................................................... C-4

SECTION 2 INTRODUCTION .......................................................................... C-5

Section 2.1 Scope ............................................................................................... C-5Section 2.2 Installation Requirements ................................................................. C-5Section 2.3 Description........................................................................................ C-5

SECTION 3 INSTALLATION ............................................................................... C-6

Section 3.1 Mechanical Installation ..................................................................... C-6Section 3.2 Electrical Installation ......................................................................... C-6Section 3.3 Operation .......................................................................................... C-6Section 3.3.1 Manual .............................................................................................. C-6Section 3.3.2 CNC ............................................................................................... C-6

SECTION 4 MAINTENANCE ............................................................................... C-7

Section 4.1 Daily ............................................................................................... C-7Section 4.2 Monthly ............................................................................................. C-7Section 4.3 Adjustment........................................................................................ C-7Section 4.3.1 Adjust Airflow .................................................................................... C-7Section 4.3.2 Spark Gap Adjustment...................................................................... C-7Section 4.3.3 Fine Tuning....................................................................................... C-7

SECTION 5 REPLACEMENT PARTS ................................................................. C-9

C-2


Figure 4.1 Air Flow/Electrode Adjustment Location......................................... C-7Help Flow Chart Troubleshooting ............................................................................. C-8Figure 5.1 Pulse Ignition.................................................................................. C-9

C-3


USER RESPONSIBILITY - This equipment will perform in conformity with the descriptionthereof in this manual and accompanying labels and/or inserts when installed, operated,maintained and repaired in accordance with the instructions provided. This equipmentmust be checked periodically. Defective equipment should not be used. Parts that arebroken, missing, plainly worn, distorted or contaminated should be replaced immediately.Should repair or replacement become necessary, Koike Aronson recommends that arequest for service be made to the Koike Aronson, Inc. Authorized Distributor from whompurchased or directly to the Koike Aronson, Inc. Service Department.

This equipment or any of its parts should not be altered without prior written approval ofKoike Aronson. The user of this equipment shall have sole responsibility for anymalfunction, which results from improper use, faulty maintenance, damage, improperrepair or alteration by anyone other than Koike Aronson or a facility, designated by KoikeAronson.


Throughout this manual, notes, cautions, and warnings are used to describesituations that require additional information. The following formats are used foreach:

Notes: A note offers additional information, such as an operating tip, that aids the user inoperating the cutting system.

Caution: A caution describes a situation that may cause damage to themachine and offers advice to avoid or rectify the situation.

WARNING


C-4


Operation of oxy/fuel torches involvesoxygen and flammable gases underpressure, open flames, flying slag and hotmetal, fumes and combustion products.

Follow the precautions in this General SafetySection as well as those throughout thismanual for your personal safety and thesafety of personnel in the area that may beaffected.1. Check gas and electrical connections for

tightness after installation and on aregular basis thereafter.


3. Check for proper function of check valvesregularly. Do not remove or bypasscheck-valves.


5. Never use oxygen to ventilate the area orclean off clothing.



8. Never use the oxygen hose for any othergas than oxygen.

9. Replace hose that is damaged by physicalabuse or by sparks, heat or open flame.

10.Examine hoses at daily intervals forleaks, wear, loose connections or otherhazards.

11.Coil excess hose and place it out of theway to prevent damage and to eliminatetripping danger.

12.Maintain all pressure regulators inproper working condition.

13.Never use a regulator for any gasother than that for which it isintended.

14.Never use a regulator that leaks,creeps excessively or is physicallydamaged in any way.

15.Never attempt to lubricate aregulator with oil or grease.

16.Wear filter-lens safety eyeprotection. Wear gauntlet gloves,safety shoes, flame retardantclothing, and no-cuff trousers. Do notwear loose clothing around thismachinery as it can catch on themachine.

17.Shut off power and gas supplieswhenever leaving machineunattended or before servicing.


19.Read and understand furtherdetailed safety precautionsthroughout this manual.

20.Also, refer to the latest revisions ofthe following sources of safepractices in welding and cutting.

A. National Fire Protection AssociationStandard 51B CUTTING ANDWELDING PROCESS, obtainable fromNFPA, Batterymarch Park, Quincy, MA06269.

B. NFPA Standard 51, OXYGEN/FUELGAS SYSTEMS FOR WELDING ANDCUTTING, obtainable same as item A.

C. American Welding Society publicationC4.2-90, OPERATOR'S MANUAL FOROXY/FUEL GAS CUTTING.

C-5

SECTION 2INTRODUCTION

2.1 SCOPE

This appendix provides a systematic guidefor installation, operation, adjustment and atroubleshooting guide for the pulse ignitionsystem. Follow all steps in order and obeyall safety precautions.

2.2 INSTALLATION REQUIREMENTS

Pulse ignition requires a supply pressure of15psi. Propane is used as its primary gas.Natural gas can be used only if adjustmentsare made with the airflow. Acetylene cannotbe used. If you are using acetylene as themachine gas, a separate supply of propanemust be provided for ignition.

2.3 DESCRIPTION

Pulse ignition uses propane as its primaryfuel gas. Do not use acetylene. Inletsupply for the ignition system is suppliedfrom the preheat fuel manifold. A separatemanifold is provided with a supply solenoid.Outlet bushings are located on the manifoldfor each torch station. Caps are installed forunused outlets.

At the torch station, a solenoid, high voltagetransformer, a venturi tube with nozzle andmounting hardware are provided forassembly at the torch. Mounted on the topof the tube is the air flow adjustment andthe spark adjustment. Between the highvoltage transformer and the electrode is anoise suppressor installed with the ignitioncable. The suppressor is used for reducingRF noise generated by the transformer.Once the ignite signal is generated, themanifold supply solenoid opens allowingfuel to flow to the torch station solenoid.The torch station solenoid is pulsed (turnedon and off) at a rate programmed to theterritorial location of the machine. The rateis adjusted for proper airflow. The highvoltage transformer is on steady throughoutthe ignition cycle. The electrode ignites thefuel as it passes through the flow tube.Since the gas is pulsed, the venturi of thetube pulls the gas through the tube and outthe nozzle. A flame about four to six incheslong is produced igniting the selected oxy-fuel torch.

C-6


3.1 MECHANICAL

Move the standard preheat manifolds (fuel,preheat oxygen and cut) to as low on thesupport brackets as possible. Locate theignition manifold towards the top of thesupport brackets, centering the manifoldbetween them. Install the manifold clamps.Remove the caps on the fuel preheat teeand install the hose to connect the twomanifolds. The long red hose is connectedto the outlet bushing and is routed throughthe flexible cable carrier to the oxy-fuelstation. Install the igniter tube with the torchclamps. The tube nozzle must face thetorch tip and be located approximately oneinch above the tip. The tube and solenoidmust also be clear of all other parts andaccessories. Connect the hose to the top ofthe solenoid inlet fitting. Position theadjustment collar so it is convenient tomake airflow and electrode adjustments.Tighten all hardware and hose connections.

3.2 ELECTRICAL

Connect the ignition supply solenoid to themain electrical enclosure. Follow theassociated electrical drawings forreference. Connect the high voltagetransformer and the solenoid wires to theappropriate connector on the J-box. The J-box is located on the back of the slavestation. The ignition wire is connected to thehigh voltage transformer to the noisesuppressor to the electrode. Be sure toplace the insulated sleeve over theconnection at the electrode and the rubberinsulator at the high voltage transformer.

3.3 OPERATION

3.3.1 MANUAL

Pressing the ignite button on the touchpanel will turn on the ignition cycle for four(4) seconds. This allows sufficient time forthe torch to ignite. You must have an oxy-fuel station selected.

3.3.2 CNC

Using CNC programming the ignition cycleis started automatically with the selectedtorch or torches.

WARNINGPurge all oxygen and fuel supply lines.

WARNINGFuel gas is highly flammable.Care must be taken working

with this system.

WARNING

gG

Before performing electricalmaintenance, machine electrical

power must be OFF.

C-7


4.0 MAINTENANCE

This section includes preventative androutine maintenance using the pulseignition system. This section also contains aset-up and troubleshooting guide forproblems that may occur.

4.1 DAILY

Clean the nozzle of blow-back from piercingthe plate. Ensure the clamps holding thetube are tight.

4.2 MONTHLY

Perform a leak test on the hoses andfittings. Before making any correctionsensure the system is purged. Check allhoses for wear and pinch points. Replacethe hose or correct the routing if necessary.

4.3 ADJUSTMENT

Ensure the ignition system is installedproperly. Ensure the gas supply is set to15psi. Select an oxy-fuel station and pressignite. Wait a few seconds to allow the fuelto fill the hose and fittings.

4.3.1 ADJUST AIRFLOW

Locate the adjusting slide assembly. Usinga Phillips screwdriver, adjust the air intakeholes on the slide until they are inline withintake holes on the ignition block.

4.3.2 SPARK GAP ADJUSTMENT

Locate the pilot block and the Phillips screwwith the nut attached to it. Adjust the nut soit touches the head of the screw. Turn thescrew clockwise so it just touches theelectrode. Turn counter-clockwise five (5)complete turns. This sets the spark gap ofthe electrode to the ignition block.

4.3.3 FINE TUNE

The airflow and spark gap may have to beadjusted depending on gas used. The flameshould be bluish in color. If it is not, someadjustment in the air may be necessary.

Figure 4.1

Air Flow Adjustment

Electrode Adjustment

C-8

4.0 HELP FLOW CHART

Select an oxy-fuel station

(Press button)

Close manualvalves on the

torch(Fuel, oxygen

and cut)

Pressignitionbutton

Did ignition takeplace and a blue 4in. flame appear?

Did ignition takeplace and a blue 4in. flame appear?

Lightwith

manualstriker

Check forplugged nozzleassembly, clean

if necessary.

No No

Yes

Yes

Is the solenoidpulsing?

Check gas flowCheck floworifice for

obstructions

Check electricalcircuit. If the

electrical is ok,replace solenoid

No

Adjust the air flowfor the bluest flame

possible.

Adjust the air flowfor the bluest flame

possible.

WARNINGTURN OFF GAS

SUPPLY.Remove igniter

assembly. Press theignition button andcheck for spark. Ifthe spark is not

present check thehigh voltage circuit. If

the spark is weakadjust the gap using

the adjustmentscrew.

The ignition system should now be operational

Check forcorrosion on the

electrode,remove cover,

clean ifnecessary.

WARNINGTURN OFF GAS

SUPPLY.Remove igniter

assembly. Press theignition button andcheck for spark. If

the spark is notpresent check the

high voltage circuit. Ifthe spark is weak

adjust the gap usingthe adjustment

screw.

C-9


Figure 5.1Note: Only Major Components Are Listed.

Item Number Part Number Part Description Quantity1115-7933-00 Pulse Ignition

1 *ZS60287 Ignition Transformer 12 *1138-3078-00 Check Valve, Fuel 13 *1138-5506-00 Solenoid Valve, Fuel 14 *1115-7925-00 Pilot Orifice 15 1115-7931-00 Adjusting Collar 16 1115-7926-00 Mixing Pipe,1/2” Dia. X 2-1/4 1

2

1

3

4

5

8

12

7

10

11

6

9

13

14

15

C-10

Part Listing Continued

7 1115-7927-00 Pilot Block, 3/4Dia. X1.25x1.75 18 1115-5245-01 Clamp 19 1115-7924-00 Tube, Copper 1

10 1115-5246-00 Clamp 111 *1115-7930-00 Pilot Nozzle, 3/4Dia.x1.56 112 *1115-7932-00 Electrode 113 1138-8906-00 Noise Suppressor 114 ZM62972 Glass Fiber Tube, Igniter 115 ZM62973 Teflon Tube, Igniter 1

APPENDIX D

HI/LO GAS PANEL

D-1

TABLE OF CONTENTS

SECTION 1 SAFETY PRECAUTIONS

Section 1.1 General Safety, Oxy/Fuel Cutting......................................................D-3

SECTION 2 INTRODUCTION

Section 2.1 Scope ...............................................................................................D-4Section 2.2 Installation Requirements..................................................................D-4Section 2.3 Specifications....................................................................................D-4Section 2.4 Theory of Operation ..........................................................................D-4Section 2.5 Installation Connections ....................................................................D-5Section 2.6 Optional Ease-On..............................................................................D-5

SECTION 3 OPERATION

Section 3.1 Overview ..........................................................................................D-7

SECTION 4 MAINTENANCE

Section 4.0 40 Hours ...........................................................................................D-8Section 4.1 Help Flow Chart ................................................................................D-8

SECTION 5 REPLACEMENT PARTS..................................................................D-9

Figure 2.1 Connections/Flow Diagram ...............................................................D-6Figure 5.1 HI/LO Panel ......................................................................................D-9

D-2

SECTION 1

SAFETY PRECAUTIONS

USER RESPONSIBILITY - This equipment will perform in conformity with thedescription thereof in this manual and accompanying labels and/or inserts wheninstalled, operated, maintained and repaired in accordance with the instructionsprovided. This equipment must be checked periodically. Defective equipment shouldnot be used. Parts that are broken, missing, plainly worn, distorted or contaminatedshould be replaced immediately. Should repair or replacement become necessary,Koike Aronson recommends that a request for service be made to the Koike Aronson,Inc. Authorized Distributor from whom purchased or directly to the Koike Aronson, Inc.Service Department.

This equipment or any of its parts should not be altered without prior written approvalof Koike Aronson. The user of this equipment shall have sole responsibility for anymalfunction, which results from improper use, faulty maintenance, damage, improperrepair or alteration by anyone other than Koike Aronson or a facility, designated byKoike Aronson.


Throughout this manual, notes, cautions, and warnings are used to describesituations that require additional information. The following formats are used for each:

Notes: A note offers additional information, such as an operating tip, that aids the user inoperating the cutting system.


WARNING


D-3


Operation of oxy/fuel torches involvesoxygen and flammable gases underpressure, open flames, flying slag, hotmetal, fumes, and combustion products.

Follow the precautions in this GeneralSafety Section as well as those throughoutthis manual for your personal safety and thesafety of personnel in the area that may beaffected.

1. Check gas and electrical connections fortightness after installation and on aweekly basis.


3. Check for proper function of checkvalves regularly. Do not remove orbypass check valves.


5. Never use oxygen to ventilate the areaor to clean off clothing.



8. Never use the oxygen hose for anyother gas than oxygen.

9. Replace hose that is damaged byphysical abuse or by sparks, heat oropen flame.

10.Examine hoses at daily intervals forleaks, wear, loose connections or otherhazards.

11.Coil excess hose and place it out of the wayto prevent damage and to eliminate trippingdanger.

12.Maintain all pressure regulators in properworking condition.

13.Never use a regulator for any gas otherthan that for which it is intended.

14.Never use a regulator that leaks, creepsexcessively or is physically damaged in anyway.

15.Never attempt to lubricate a regulator withoil or grease.

16.Wear filter-lens safety eye protection. Weargauntlet gloves, safety shoes, flameretardant clothing, and cuffless trousers. Donot wear loose clothing around thismachinery as it can catch on the machine.

17.Shut off power and gas supplies wheneverleaving machine unattended or beforeservicing.


19.Read and understand further detailedsafety precautions throughout this manual.

20.Also, refer to the latest revisions of thefollowing sources of safe practices inwelding and cutting.

A. National Fire Protection AssociationStandard 51B CUTTING AND WELDINGPROCESS, obtainable from NFPA,Batterymarch Park, Quincy, MA 06269.

B. NFPA Standard 51, OXYGEN/FUEL GASSYSTEMS FOR WELDING ANDCUTTING, obtainable same as item A.

C. American Welding Society publication C4.2-90, OPERATOR'S MANUAL FOROXY/FUEL GAS CUTTING.

D-4


2.1 SCOPE

This appendix provides a step by step guide for operation, adjustment and atroubleshooting guide for the HI/LO gas system. The HI/LO system provides for smoothtransitions between the Hi preheat setting to the low preheat setting during the actual cut.


Two separate oxygen supply lines of three-eighths of an inch inside diameter. One fuel lineof three-eighths of an inch inside diameter. Two short supply lines, one oxygen and onefuel to the manifold assembly.

2.3 SPECIFICATIONS

Maximum input supply pressure: Cutting Oxygen: 100psigPreheat Oxygen: High preheat setting is dependent on the

tip chart setting for selected tip.Preheat Fuel: High preheat setting is dependent on the tip

chart setting for selected tip. Note: DoNot Exceed 15psig for any type of fuelgas.

2.4 THEORY OF OPERATION

Theory of operation:

The gas and oxygen main supply lines connect directly to the gas panel inlet and thecutting oxygen supply is a separate connection directly to the cutting oxygenmanifold inlet.

The preheat pressures set at the supply tanks are referred to as the high preheatpressures and the pressures regulated at the HI/LO manifold are the low preheatpressures. The system allows a very hot flame for preheating the plate quickly whilealso regulating the supply to a lower preheat flame necessary when the actualcutting is taking place.

When the preheat output is turned on through a CNC program or by a manualswitch, the preheat solenoid valves on the inlet of the manifolds and on the HI/LOgas panel energize. All four valves being normally closed valves now open and allowgas to enter into the HI/LO panel around the pilot regulator, out of the gas panelwithout any restriction into the manifold, and then flow to the torch.

Once the cutting oxygen is turned on the preheat valves on the HI/LO panel areturned off. The preheat gases are then forced into the inlet of the pilot regulators,which are used to adjust the desired flow to the torch. This is the low preheat setting.It is important to note that the low preheat cannot be adjusted unless the cut signal isactivated.

D-5

2.5 INSTALLATION CONNECTIONS.

Refer to Figure 2.1 for the connections.

2.6 OPTIONAL EASE-ON ASSEMBLY

The optional ease-on assembly controls the rate at which cutting oxygen is pressurized.This valve allows for smooth starts during piercing.

Note: Turning the valve clockwise slows the rate at which the cut oxygen comes on.Turning the valve counter clockwise increases the rate at which the cut oxygen comes on.

D-6

Figure 2.1 Gas Schematic Hi-Lo System

D-7

SECTION 3OPERATION

3.0 OPERATION

3.1

Note: This procedure must be done before using the CNC operation or the manualcut function of the manual controls.

The following gives a general procedure for using the HI/LO panel. When all connectionsare made and leak tested, select the proper tip for the steel plate to be cut.

a. Place the selected tip in the desired torch for cutting.b. Make sure the tip nut is tight.c. Open the cutting oxygen tank regulator and adjust the pressure for 100psi.d. Open the High Preheat oxygen tank regulator and adjust the pressure for the HI tip

chart setting. Note: This is a coarse setting adjustment. Note: A slight increase inpressure may be required due to the length of the incoming supply hose to the HI/ LOpanel.

e. Open the Fuel tank regulator and adjust the pressure for the tip chart setting. Note:This is a coarse setting adjustment.

f. Place the selected TORCH switch in the ON position.g. Place the PREHEAT switch to the ON position. The switch is located on the CNC.h. At the torch, open the torch fuel preheat valve slightly by turning counter clockwise ¼

turn.i. Ignite the torch and open slightly the preheat oxygen valve.j. At the tank regulators (preheat fuel and oxygen), adjust the flame for the hottest high-

preheat flame setting necessary for the thickness of steel plate you are cutting.k. Place the CUT switch to the ON position. The switch is located on the CNC.l. At the torch, open the torch cut valve all the way by turning counter clockwise.m. At the HI/LO panel adjust the settings for a neutral flame at the torch. Manually open

and close the torch cutting oxygen valve several times, adjusting the fuel valve ifnecessary to achieve: satisfactory preheat flame when cutting oxygen is off; and aneutral flame around the cutting oxygen stream for several inches from the tip facewhen the cutting oxygen is ON. Note: The cutting oxygen stream within the neutralflame should be straight and several inches long.

n. The flame should now be properly adjusted for cutting.

Note: THIS SETUP IS FOR ONE TORCH ONLY. WHEN USING MULTIPLE TORCHES,ADJUSTMENT OF THE TORCH VALVES MAY BE NECESSARY (TRIMMING).

WARNING

ENSURE ALL HOSE FITTINGS ANDTANK FITTINGS ARE TIGHT BEFOREPROCEEDING. PERFORM A LEAKTEST ON ALL FITTINGS.

D-8


4.0 40 HOURS

After 40 hours of operation, perform a leak test on all connections and fittings.

4.1 HELP FLOW CHART

Low preheats donot work

Cannot adjust lowpreheatflame atthe HI/LO Panel

The OFF/BOOST/AUTO switch notplaced in AUTO

Solenoids at theHI/LO panel not

Turning Off

Make sure thesupply lines are

connected properly

Make sure thesupply pressure is

set correctly

HI/LOW GAS PANEL WORKING CORRECTLY

D-9


Hi-Lo Gas ConsoleItem Number Part Number Part Description

1 1138-3005-01 PRES GAUGE SCALE 0-30 PSI/KGCM SQ2 1138-3004-01 PRES GAUGE SCALE 0-200,PSI/KGCM SQ3 201-1106 REGULATOR FUEL4 201-1105 REGULATOR OXYGEN5 1138-5504-00 SOLENOID VALVE, SUPPLY OXYGEN

6 1138-5507-01 SOLENOID VALVE, FUEL7 1138-5505-00 SOLENOID VALVE, BLOW OXYGEN8 0866-8742-00 DOME REGULATOR

Hi-Lo Gas Manifold

12 3 645

6

5

8

7

APPENDIX E

PLASMA OPERATION

GENERAL PLASMA CUTTING INFORMATION

Prior to cutting with plasma, you must have the gas settings for the plate thickness, arc voltage,current, speed settings in the CNC set correctly.

SINGLE PLASMA

Single plasma operation starts by selecting plasma one (1) on the operator’ control unit. Note: Ifyour machine has two systems, select Plasma 1 or Plasma 2. The button selected enables allfunctions for the plasma station. This includes start, torch height control and machine motion.Machine motion is a signal generated from the plasma system when the main arc from the plasmasystem starts. The signals, plasma START and torch height control are signals generated from theCNC and controlled from the parameters for plasma setups. The CNC must be set for plasmacutting with the correct settings for the plasma type and height control used. Selecting start fromthe CNC starts the cutting process.

DUAL PLASMA: SAME TYPE OF PLASMA

Selecting Plasma 1 and Plasma 2 will enable dual plasma operation. Pressing the START on theCNC will initiate IHS for both plasma systems. The start signal will wait until both IHS completesignals are present. When the plasma starts the height controls are independent allowing for partaccuracy for both plasma systems.If optional safety mounts (torch breakaway) are mounted to the lifters, when one of the safetymounts trips, both plasmas will shut down. You must clear the obstruction and reset the mount.Once reset, lost cut recovery using the CNC will resume the cut.

WARNING

Ensure all safety precautions and warnings are adhered to. All plasma cuttingradiates high levels of light and noise.

APPENDIX F

RAIL INSTALLATION AND SPECIFICATIONS

F-1

TABLE OF CONTENTS

SECTION 1 SAFETY PRECAUTIONS ................................................................F-2

SECTION 2 INTRODUCTION ..........................................................................F-3

Section 2.1 Scope ................................................................................................F-3Section 2.2 Installation Requirements ..................................................................F-3Section 2.3 Specifications.....................................................................................F-3

SECTION 3 BASIC RAIL INSTALLATION ...........................................................F-4

Section 3.1 Koike Aronson Rail Installation ..........................................................F-5Section 3.2 Fine Rail Alignment............................................................................F-5Section 3.4 Suggested Tool Listing for Rail Installation........................................F-6

Figure I.1 Recommended Foundation Support ..................................................F-5

F-2


USER RESPONSIBILITY - This equipment will perform in conformity with thedescription thereof in this manual and accompanying labels and/or inserts wheninstalled, operated, maintained and repaired in accordance with the instructionsprovided. This equipment must be checked periodically. Defective equipment shouldnot be used. Parts that are broken, missing, plainly worn, distorted or contaminatedshould be replaced immediately. Should repair or replacement become necessary,Koike Aronson recommends that a request for service be made to the Koike Aronson,Inc. Authorized Distributor from whom purchased or directly to the Koike Aronson,Inc. Service Department.

This equipment or any of its parts should not be altered without prior written approvalof Koike Aronson. The user of this equipment shall have sole responsibility for anymalfunction, which results from improper use, faulty maintenance, damage, improperrepair or alteration by anyone other than Koike Aronson or a facility, designated byKoike Aronson.



Notes: A note offers additional information, such as an operating tip, that aidsthe user in operating the cutting system.


WARNING


F-3


2.1 SCOPE

This appendix provides a step-by-stepguide for the floor mounted rail systemsused with the PLATE-PRO EXTREMEseries or cutting machines approved byKoike Aronson, Inc.


NOTE: The following preparationsshould be complete before the arrival ofthe installing technician.

SITE LOCATIONSpecial consideration must be used in theselection of a site for cutting machineoperation. Fuel, oxygen, electrical outlets,clean dry shop air and water in theimmediate vicinity are essential foreconomical operation of any oxy-fuel/plasma cutting machine. Materialhandling is also important and space forstockpiling plate and parts as well asmaterial movement by hoist, truck or othermeans must be considered.

The machine requires a space where floorvibration is at a minimum. Precisionoperation is necessary for accurate partprocessing. Avoid areas where vibrationscaused by drop hammers, heavy machineryand punch presses are used. Position theunit close to the production line, withadequate lighting and ventilation

Review the dimensional machine layout inorder to determine correct working arearequirements, allowing adequate aislespace to provide for operator safety, trafficflow and overhead clearance.

SITE PREPARATIONThe floor area supporting the rails and tableshould be specified by a qualified civilengineer after reviewing the appropriate

drawing supplied with this machine. Thefoundation shall be designed to meet localbuilding codes. Koike Aronsonrecommends the concrete to be 3000psiminimum strength. Floor vibration shouldnot exceed 10um. Reference Figure I.1.

Solid, secure and accurate rail and supportbeam installation is critical to ensuremaximum accuracy for the cutting, oxy-fueland plasma processes. The floor for themachine installation should be level within3/8in. (9.5mm) over the entire length andwidth.

If any possibility of floor settlement exists,separate footing should be provided over afirmly packed base. If a possibility ofequipment vibration exists, the machineshould be provided with an adequateisolation pad.

SPECIFICATIONS

The PLATE-PRO EXTREME®® rail systemconsists of two main rail weldments with 22kg crane rails with integrated drive rack.The main support rail weldment isfabricated from 3/4 inch thick steel plate forrigidity and ease of installation. Themounting surface for anchoring the railsupport weldment to the floor is factorywelded with leveling bolts already attached.All rail lengths are pre-fabricated and comein 3 meter increments. Adjuster blocks thatallow for up/down and lateral rail alignmentare mounted 1 meter apart, center to centerfor all installations. Mechanical stops at theend of the rail system provide machineover-travel protection. All hardware for railinstallation is included with the rail package.

F-4

SECTION 3BASIC RAIL INSTALL

3.0 BASIC RAIL WELDMENT INSTALLATIONNOTE: THIS SECTION COVERS THEBASIC FLOOR MOUNTED WELDMENTRAIL SYSTEM ENSURE THE RACKFACES OUT.

1. Locate the rail gauge of your machine.(This is found on the drawing of yourmachine.)

2. Snap a chalk line the entire raildistance.

3. Using the rail gauge, measure thedistance and snap another line parallelto the first line.

NOTE: Check this measurement severaltimes before continuing. This measurementis critical to the rest of the installation.

4. Locate the center of the rail weldmentand mark the bottom of both ends.

5. Place the rail weldment on the chalkline aligning the center of the railweldment to the chalk line. Set outboardH-beam and verify equal diagonals.

Note: The thickness of the support pad mayvary due to floor flatness. Do Not use longerbolts for leveling the rail weldment. Use ashim pad if required.

6. Using a manometer (water level), locatethe highest point of the rail weldmentusing the main rail and outboard rail.Note: Take a reading at each rail jointadjuster. This is the four-hole adjuster.

7. At each anchor pad, level the railweldment at the top, side to side andat the same height as possible to thepoint found in step 6. Note: The railweldment cannot be perfectlyleveled but the closer it is to levelthe easier the rail installation will be.If required, two rail weldments canbe fitted end to end. Ensure theseare as tight together as possible.

8. Anchor the rail weldment to the floorat the mounting pads using a roto-hammer and a one-half inchconcrete bit. Ensure the holes madeare cleaned.

9. Weld the rail weldment together atthe seams.

10.Thoroughly clean the protectivecoating on the rails using LPS-1 orWD-40. Ensure the ends of the railare also cleaned.

11. Check rail gauge.

FINAL INSTALLATION NOTE: WHEN THERAILS ARE INSTALLED AND CHECKEDFOR LOCATION AND ALL FASTENERSARE CHECKED FOR TIGHTNESS, THEENTIRE RAIL SYSTEM MUST BEGROUTED. THE GROUT MUST MEETTHE ASTM C-109 6000PSI/24 HOURSARMY CORPS OF ENGINEERS SPECCRD-C 621. 0% SHRINKAGE, 0%EXPANSION

F-5

3.1 KOIKE ARONSON RAILINSTALLATION

NOTE: The rail is attached to the railweldment at Koike Aronson. The railsmust be cleaned. When placing theweldment on the floor ensure the rackfaces out.

1. Make sure steps 1-11 of the Basic H-Beam install is complete and allhardware is secure.

2. Center the main rail on the pads,side-to-side and repeat for theoutboard side.

3. Measure the diagonals on the firstsection of rails. Ensure thismeasurement is within 1mm(.039”).

4. Level the main and outboard rails inboth directions. Level the length ofthe rail with the water level andacross the top with a small precisionlevel.

5. Place the piano wire (.020) on thetop inside edge of the main rail.Tighten and secure both ends of therail. Note: Ensure that the piano wireis drawn tight and secure in placeusing C- clamps.

6. By observing the distance betweenthe wire and the rail by roughestimations, you can adjust the railso it is close to being straight.

7. Perform steps 5 and 6 for theoutboard rail.

8. Check the rail gauge. It should bewithin 1mm (.039”).

Note: Ensure that both end sections aretightened completely.

3.2 Fine Rail Alignment

1. Using the electronic micrometer,adjust the main rail straightness towithin .1mm (.004”) over the entirelength. You must adjust at each railweldment.

2. Check rail gauge. It should be within +1mm (.039”).

3. Perform step 1 on the outboard rail. Itshould be within .1mm (.004”) overthe entire length.

4. Ensure all rail mounting hardware istight. Note: If you have to tighten anyhardware at this point, you must checkfor straightness.

Note: Tightness of rail hardware ensuresthe integrity of the installation. Make surethe hardware is tight.

12

Small Stone

Re-enforcing meshConcrete

Vibration dampeningif required

Figure I.1

F-6

3.4 SUGGESTED TOOL LISTING FOR RAIL INSTALLATION

Part Number1. Water Level 0866-5181-00

2. Micrometer Kit K115-9060-00

3. Tracing Pen ZS62725 for Oxy-fuel torch

4. Tracing Pen ZS6272501 for Plasma torch

5. Tap M12x1.75 for adjusting pads and rail level

6. Tap M6x1 for mounting the rack

APPENDIX G

AIR SCRIBE MARKER

December, 2001Revision 0

G-1

TABLE OF CONTENTS

SECTION 1 SAFETY PRECAUTIONS ...............................................................G-2

SECTION 2 INTRODUCTION ................................................................................

Section 2.1 Scope ...............................................................................................G-3Section 2.2 Installation Requirements .................................................................G-3

SECTION 3 OPERATION ..........................................................................................

Section 3.1 Manual .............................................................................................G-4Section 3.2 CNC /Automatic Operation ...............................................................G-4

SECTION 4 MAINTENANCE .....................................................................................

Section 4.1 Changing the stylus ..........................................................................G-6

SECTION 5 REPLACEMENT PARTS .................................................................G-7


Figure G-1 Scribe.............................................................................................. G-5Table G-1 Troubleshooting .............................................................................. G-6Figure G-2 Parts................................................................................................ G-7

G-2


USER RESPONSIBILITY - This equipment will perform in conformity with the descriptionthereof in this manual and accompanying labels and/or inserts when installed, operated,maintained and repaired in accordance with the instructions provided. This equipmentmust be checked periodically. Defective equipment should not be used. Parts that arebroken, missing, plainly worn, distorted or contaminated should be replaced immediately.Should repair or replacement become necessary, Koike Aronson recommends that arequest for service be made to the Koike Aronson, Inc. Authorized Distributor from whompurchased or directly to the Koike Aronson, Inc Service Department.






WARNING


G-3


2.1 SCOPE

This appendix provides a step-by-step guidefor operation, adjustment and atroubleshooting guide for the scribe markingstation. The station consists of a model Gtorch lifter (a six or twelve inch lifter) with afour-inch stroke air cylinder. Air solenoidscontrol the up and down movement of thecylinder while another controls the on and offoperation. A coarse adjustment to the plateis made by the Model “G” torch lifter.


There are no requirements for this stationwhen ordered at the time of machinepurchase. When the situation arises that atorch station be added to the existingmachine, Koike Aronson must be notified asto how many existing stations are currentlyon the machine. The electrical assemblyconsists of the cables and software for theoptions ordered with the station. A Filter-Lubricator-Regulator with good qualityspindle oil is recommended. The FLR shouldbe adjusted so there is a slight oil mist in theexhaust.

G-4

SECTION 3OPERATION

3.0 OPERATION

Refer to KARCNC X Operation Manual For CNC setup and operation.

3.1 CNC/AUTOMATIC OPERATION

The codes for marker on/off and offset on/off must be in the program to be marked and / orcut.At the operator’s panel, lower the scribe assembly to within the marking distance. Enter theprogram for marking. The marking process will automatically be selected and perform theup/down of the scribe cylinder and the scribe on/off processes of the program.

G-5

Model G Torch Lifter

Stylus

Scribe Assembly

Air Cylinder, 4”stroke


Figure G-1Scribe

G-6

4.1 CHANGING THE STYLUS

a. Carefully, place the housing in copper-covered or leather-covered vise jaws, inlet sidedown.

b. Using a wrench on the flats of the nosepiece unscrew (turn counterclockwise) andremove the nosepiece.

c. Remove the stylus spring and the stylus.

d. Install the stylus spring onto the new stylus and insert the stylus into the housing.

e. Screw the nosepiece into the housing and tighten securely. (Turn clockwise to install)

Reference: Figure G-2

TROUBLESHOOTING GUIDE

Trouble Probable Cause SolutionLow power Low pressure at the inlet Check the air supply. For top performance,

the air pressure must be 90 psig (6.2bar/62OkPa) at the inlet.

Internal dirt accumulation Pour about 3 cc of a clean, suitable cleaningsolution into the air inlet and operate the toolfor a few seconds. Immediately, pour a fewdrops of the recommended oil into the airinlet and operate the tool for about 30seconds to lubricate the internal parts.

Worn Piston and/or Cylinder Replace the Piston and/or Cylinder.Lack of adequate lubrication Check the lubricator to make sure it is

working properly. If a lubricator is not used,pour a few drops of the recommended oil intothe air inlet after every two hours ofoperation.

Leaky Throttle Sleeve Worn Housing Seals Replace the Housing Seals.

Air cylinder will not raise orlower

Check the I/O to ensure theoutput for the solenoids iscoming on.

Ensure CNC program iscorrect.

Check the I/O fuses.

Correct the posted program.

Table G-1

WARNING

Disconnect the air supply before performing any maintenance on the scribe assembly.

G-7


Nosepiece

Stylus Spring

1138417904 Stylus

Cylinder Spacer

O-Ring

Cylinder

Piston

Piston Stop

Housing

Housing Seal

Throttle Sleeve

Inlet

Figure G-2 Scribe Assembly

APPENDIX H

SLAVE STATION

MARCH 2009Revision 0

H-1

TABLE OF CONTENTS

SECTION 1 SAFETY PRECAUTIONS .............................................................. H-1

SECTION 2 INTRODUCTION

Section 2.1 Scope ............................................................................................... H-3Section 2.2 Installation Requirements ................................................................. H-3

SECTION 3 MAINTENANCE ............................................................................... H-4

H-2


USER RESPONSIBILITY - This equipment will perform in conformity with the descriptionthereof in this manual and accompanying labels and/or inserts when installed, operated,maintained and repaired in accordance with the instructions provided. This equipmentmust be checked periodically. Defective equipment should not be used. Parts that arebroken, missing, plainly worn, distorted or contaminated should be replaced immediately.Should repair or replacement become necessary, Koike Aronson recommends that arequest for service be made to the Koike Aronson, Inc. Authorized Distributor from whompurchased or directly to the Koike Aronson, Inc Service Department.






WARNING


H-3


2.1 SCOPE

This appendix provides a step-by-step guide for operation, adjustment and atroubleshooting guide for the slave torch station. The station consists of the carriage withadjustable rollers, a model G torch lifter (a six or twelve inch lifter) with cable carrier, andoptional equipment such as a cutting torch, automatic ignition, water spray, capacitiveheight sensing or a scribe marker.


There are no requirements for this station when ordered at the time of machine purchase.When the situation arises that a torch station be added to the existing machine, KoikeAronson must be notified as to how many existing stations are currently on the machine.The electrical assembly consists of the cables and software for the options ordered with thestation.

H-4


Refer to the appropriate appendix for the required maintenance on existing options.

Required maintenance on the station: the support rollers must be cleaned at least onceevery eight hours of operation with a clean cloth, lightly oiled with LPS-1® .

Cutting oxygen solenoid valve

Station parking clamp

Not Shown: Cable Carrier

Torch Support

Torch Holder

Torch Tip

Model “G” torch lifter 6” or 12” stroke

Check Valves

Steel Band Clamp

Rollers

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