KOIKE ARONSON, INC. 635 W. Main St., Arcade NY, (585) , Fax (585) Visit us at

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1 ARONSON TECHNICAL MANUAL KOIKE ARONSON, INC. 635 W. Main St., Arcade NY, (585) , Fax (585) Visit us at VERSAGRAPH MILLENNIUM INSTRUCTION MANUAL MI0548A Subject to change without notice September, 2012 Revision J

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3 Safety MI0548A CONTENTS VERASAGRAPH MILLENNIUM SECTION 1 SAFETY PRECAUTIONS...6 Section 1.1 Section 1.2 Section 1.3 SECTION 2 General Safety...6 General Safety, Plasma Cutting...10 General, Miscellaneous...13 General Introduction...16 Section 2.1 Scope...16 Section 2.2 Description...16 Section 2.3 Axis Definition...16 Section 2.4 Rail Assembly...17 Section 2.5 Saddle Assembly...17 Section 2.6 Transverse Beam Assembly (Drive)...17 Section 2.7 X-Drive Assembly...17 Section 2.8 Y-Drive Assembly...17 Section 2.9 Gas System Assembly...17 Section 2.10 Gas Control Panel...18 Section 2.11 Operator Control Console...18 Section 2.12 Limit Switches...18 Section 2.13 Torch Station (Main)...18 Section 2.14 Torch Station (Slave)...18 Section 2.15 Steel Band Assembly...18 Section 2.16 Electrical Features...18 SECTION 3 Pre-installation Requirements...19 Section 3.1 Pre-installation Safety...19 Section 3.2 Sight Location...19 Section 3.3 Sight Preparation...20 Section 3.4 Electrical Requirements...20 Section 3.5 Oxy-Fuel Requirements...21 Section 3.6 Burning Table...21 SECTION 4 Installation...22 Section 4.1 Installation Safety Precaution...22 Section 4.2 Handling and Storage...22 Section 4.3 Unpacking and Cleaning...22 Section 4.4 Rail Installation...23 Section 4.5 Rack Installation...23 Section 4.6 Machine Mounting

4 Safety MI0548A Section 4.7 Motor/Planetary Gear Unit Installation...24 Section 4.8 Torch Carriages...24 Section 4.9 Torch Stations...24 Section 4.10 CNC Interface...24 Section 4.11 Utilities...24 Section 4.12 General Plasma Connections...24 SECTION 5 Operation...26 Section 5.1 Operational Safety...26 Section 5.2 General Operation...27 Section 5.3 Control Button Functions...30 Section Control On...30 Section Control Off...30 Section Power On...30 Section E-Stop...30 Section 5.4 Touch Screen Functions...30 Section Plasma Section Plasma Section Plasma Section Plasma Section Arc Writer Current...31 Section Go To Panel Information...31 Section Arc Marker Section Arc Marker Section Arc Marker Section Arc Marker Section Cycle Drill...32 Section Stop Drill...32 Section Scribe Marker...32 Section Punch Marker...32 Section Zinc Marker...32 Section Zinc Marker Preheat...32 Section Laser Spot...32 Section Ignite...32 Section Low Preheat...33 Section High Preheat...33 Section Boost...33 Section Cut...33 Section Select Section All Up...33 Section All Down...34 Section 5.5 Error Messages...34 Section X FWD Limit...34 Section X Reverse Limit...34 Section Y FWD Limit

5 Safety MI0548A Section Y Reverse Limit...34 Section Oxy-1 Parked...34 Section Tool Error...35 Section Out of Sync...35 Section X Servo Alarm...35 Section Y1 Servo Alarm...35 Section Y2 Servo Alarm...35 Section 5.6 Manual Gas Operation...35 Section Servo Gas Control System...35 Section Purging...35 Section Ignition Procedure...36 Section 5.7 Operational Considerations...37 Section 5.8 Set-up For Manual Oxy-fuel Cut...37 SECTION 6 Maintenance...39 Section 6.1 Safety Precautions...39 Section 6.2 General Information...39 Section 6.3 Preventative Maintenance Schedule...40 Section Each Shift...40 Section Each Forty (40) Operation Hours...41 Section Each Two Hundred Fifty Hours...41 Section Each One Thousand (1000) Hours...41 Section Each Two Thousand (2000) Hours...41 Section 6.4 Guide Roller Adjustment...41 Section 6.5 Drive Tuning Procedure...41 Section 6.6 Gas Control...41 Section 6.7 Cut Quality Troubleshooting...41 Section 6.8 Battery Replacement...43 SECTION 7 Replacement Parts...77 LIST OF ILLUSTRATIONS /TABLES Figure 1.1 Machine Safety Frame...15 Figure 2.1 Machine...16 Table 4.1 Plasma Systems/KAR Manuals...25 Figure 5.1 Touch Panel Power up Screen...27 Figure 5.2 Extended Oxy-Fuel Screen...28 Figure 5.3 Information and Diagnostics...29 Figure 6.1 Ball Slide Lubrication...42 Figure 6.2 Machine Hardware Options Screen...44 Figure 6.3 Programmable Controller Communication Screen...45 Figure 6.4 I/O Select Screen...46 Figure 6.5 Local Machine Diagnostics Screen...48 Figure 6.6 Servo Communications Diagnostics Screen

6 Safety MI0548A Figure 6.7 CNC 1 Diagnostics I/O Screen...50 Figure 6.8 CNC 2 Diagnostics I/O Screen...51 Figure 6.9 Tool 16 Plasma 1 I/O Screen...52 Figure 6.10 Tool 17 Plasma 1 I/O Screen...54 Figure 6.11 Tool 18 Plasma 1 I/O Screen...55 Figure 6.12 Tool 19 Plasma 1 I/O Screen...56 Figure 6.13 Tool 32 Scribe I/O Diagnostics Screen...57 Figure 6.14 Tool 36 Arcwriter w/thc I/O Diagnostics Screen...58 Figure 6.15 Tool 40 Oxy-fuel 1 w/thc I/O Diagnostics Screen...60 Figure 6.16 Tool 41 Oxy-fuel 2 w/thc I/O Diagnostics Screen...62 Figure 6.17 Tool 48 Oxy-fuel 1 No/THC I/O Diagnostics Screen...63 Figure 6.18 Tool 49 Oxy-fuel 2 No/THC I/O Diagnostics Screen...65 Figure 6.19 Tool 50 Oxy-fuel 3 No/THC I/O Diagnostics Screen...66 Figure 6.20 Tool 51 Oxy-fuel 4 No/THC I/O Diagnostics Screen...67 Figure 6.21 Tool 52 Oxy-fuel 5 No/THC I/O Diagnostics Screen...68 Figure 6.22 Tool 53 Oxy-fuel 6 No/THC I/O Diagnostics Screen...69 Figure 6.23 Tool 54 Oxy-fuel 7 No/THC I/O Diagnostics Screen...70 Figure 6.24 Tool 55 Oxy-fuel 8 No/THC I/O Diagnostics Screen...71 Figure 6.25 Tool 56 Oxy-fuel 9 No/THC I/O Diagnostics Screen...72 Figure 6.26 Tool 57 Oxy-fuel 10 No/THC I/O Diagnostics Screen...73 Figure 6.27 Tool 59 Arcwriter 1 No/THC I/O Diagnostics Screen...74 Figure 6.28 Tool 64 Drill I/O Diagnostics Screen...76 Figure 7.1 Machine Overview...77 Figure 7.2a Front of Servo Gas Panel...78 Figure 7.2b Approximate Solenoid Location...79 Figure 7.2c Cut /Ease on Section...80 Figure 7.2d High Preheat Oxygen...81 Figure 7.2e Low Preheat Oxygen Section...82 Figure 7.2f High Preheat Fuel Section...83 Figure 7.2g Low Preheat Fuel Section...84 Figure 7.3 Main Valve Assembly...85 Figure 7.4 Manifold Assembly...86 Figure 7.5 Drive Assembly...87 Figure 7.6 Main Wheel and Guide Assembly...88 Figure 7.7 Transverse Carriage Assembly...89 Figure 7.8 Steel Belt Unit...90 Figure 7.9 Typical Slave Station...91 Figure 7.10a Front Panel Electrical...92 Figure 7.10b Front Panel Electrical (continued)...93 Figure 7.11 Station Gas Control...95 Figure 7.12 Rail Blower Assembly...96 Figure 7.13 Typical Air Supply Panel...97 Figure 7.14a Rail Assembly...98 Figure 7.14b Machine Stopper...99 Figure 7.14c Rail Adjuster, Mid...99 Figure 7.14d Rail Adjuster, Joint

7 Safety MI0548A Figure 7.15 Main Control Unit Main Control Unit (continued) Appendix A Appendix B Appendix C Appendix D Appendix E Appendix F Appendix G Appendix H Appendix I Appendix J Appendix K List of Terms and Abbreviations... A1 Model G Torch Lifter... B1 Pulse Ignition... C1 Drill Station... D1 Servo Gas System... E1 Plasma Operation...F1 Capacitance Sensing... G1 Drive Parameter Settings... H1 SP I1 Rail Installation and Specification... J1 Air Scribe Marker... K1 5

8 Safety SECTION 1 SAFETY PRECAUTIONS USER RESPONSIBILITY - This equipment will perform in conformity with the description thereof in this manual and accompanying labels and/or inserts when installed, operated, maintained and repaired in accordance with the instructions provided. This equipment must be checked periodically. Defective equipment should not be used. Parts that are broken, missing, plainly worn, distorted or contaminated should be replaced immediately. Should repair or replacement become necessary, KOIKE ARONSON recommends that a request for service be made to the KOIKE ARONSON Authorized Distributor from whom purchased or directly to the KOIKE ARONSON Service Department. This equipment or any of its parts should not be altered without prior written approval of KOIKE ARONSON. The user of this equipment shall have sole responsibility for any malfunction, which results from improper use, faulty maintenance, damage, improper repair or alteration by anyone other than KOIKE ARONSON or a facility, designated by KOIKE ARONSON. NOTES, CAUTIONS & WARNINGS Throughout this manual, notes, cautions, and warnings are used to describe situations 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 in operating the cutting system. Caution: A caution describes a situation that may cause damage to the machine and offers advice to avoid or rectify the situation. WARNING A warning describes a situation that presents a physical danger to the operator, and offers advice to avoid or rectify the situation. Each type of warning displays an applicable danger symbol, ie. fire, explosion, electrical shock, etc. 1.1 GENERAL SAFETY, OXY/FUEL CUTTING Operation of oxy/fuel torches involves oxygen and flammable gases under pressure, open flames, flying slag and hot metal, fumes and combustion products. Follow the precautions in this General Safety Section as well as those throughout this manual for your personal safety and the safety of people in the area that may be affected. 6

9 Safety KOIKE ARONSON SYMBOL 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 SYMBOL MEANING 7

10 Safety 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 Before using the cutting machine and its options each person operating, maintaining 8

11 Safety or supervising the use of this equipment must read the following safety instructions. 1. Install and operate this machine only in a well-ventilated area. 2. Connect line cord ground wire and machine to good electrical grounds according to local codes and the National Electrical Code. 3. Check gas and electrical connections for tightness after installation and on a regular basis thereafter. 4. Keep combustibles away from the work area or protect them from sparks and flames. 5. Check for proper function of check valves regularly. Do not remove or bypass check valves. 6. Always open gas valves slowly. leaks, wear, loose connections or other hazards. 13. Coil excess hose and place it out of the way to prevent damage and to eliminate tripping danger. 14. Maintain all pressure regulators in proper working condition. 15. Never use a regulator for any gas other than that for which it is intended. 16. Never use a regulator that leaks, creeps excessively or is physically damaged in any way. 17. Never attempt to lubricate a regulator with oil or grease. 18. Handle and use compressed gas 7. Never use oxygen to ventilate the area or clean off clothing. 8. Keep oil, grease, and combustible dust away from all oxygen equipment. 9. Purge oxygen and fuel lines individually whenever combustible mixtures in the lines are suspected. 10. Never use the oxygen hose for any other gas than oxygen. 11. Replace hoses that are damaged by physical abuse or by sparks, heat or open flame. 12. Examine hoses at regular intervals for cylinders in accordance with safety standards published by the Compressed Gas Association (CGA), and Canadian Standards Association (CSA). 19. Never use a cylinder that leaks or is physically damaged. 20. Never use a cylinder that is not upright and secured in place. 21. Never move or transport a cylinder without the protective valve cover in place. 22. Never use a gas cylinder or its contents for any purpose other than that for which it is intended. 9

12 Safety 23. Never lubricate cylinder valves with oil or grease. 24. Never expose cylinders to excessive heat, sparks, slag or open flame. 25. Never use hammers, wrenches or other tools to open stuck cylinder valves. 1.2 GENERAL SAFETY, PLASMA CUTTING Plasma Arc cutting is a high intensity source of visible light emission as well as ultraviolet and infrared radiation. It can cause severe eye damage and inflict burns on exposed skin when those portions of the body are not suitably protected. 26. Never cover the gas panel without venting the bottom of the cover. Fuel gases are heavier than air. 27. Wear filter-lens safety eye protection. Wear gauntlet gloves, safety shoes, flameretardant clothing, and no-cuff trousers. Do not wear loose clothing around this machinery as they can catch on the machine. 28. Shut off power and gas supplies whenever leaving the machine unattended or before servicing. Follow the precautions in this General Safety Section and read the supplied plasma equipment instruction manual for additional and more detailed safety precautions. 1. Facilities should be available for the medical treatment of arc flashes or burns to the eyes. 2. Provide radiation protection for the operator and for personnel in the adjacent area. 29. Keep equipment clean and in good operating condition. 30. Read accessory instruction manuals supplied for these items for additional safety and operating guidelines before operating this equipment. 31. No repair should ever be undertaken or attempted by anyone other than a KOIKE ARONSON designated technician. 3. Do not, under any circumstances, look at a plasma arc without full eye protection. When near plasma cutting equipment, always wear flash goggles with side shields and containing No. 4 filter lenses. 32. Read and understand further detailed safety precautions throughout this manual. 10

13 Safety 4. The operator must use in addition to flash goggles, a suitable helmet for eye and face protection when cutting. The helmet must be equipped with a number filter plate as indicated: Arc Current Up to 100 Amps Shade No. 8 Arc Current 100 to 200 Amps Shade No. 10 Arc Current 200 to 400 Amps Shade No. 12 Arc Current Over 400 Amps Shade No Do not use helmet or hand shields that are not in good condition. Repair or replace promptly. Protect colored filter plates with a clear glass cover plate. 6. Warn other people in the area not to look directly at the arc unless they wear glasses/goggles or a helmet. 7. Never start the plasma arc without determining that nearby personnel are wearing adequate protective equipment. 10. Do not cut in the presence of atmospheres containing even minute amounts of chlorinated solvents such as Trichloroethylene and Perchloroethylene since the heat and ultraviolet radiation can decompose these vapors to form Phosgene, a highly toxic gas, and other irritating decomposition products. 11. Do not cut in atmospheres containing explosive dust or vapors. 12. Keep the cutting area well ventilated. 13. Wear proper breathing mask when cutting galvanized metal and use proper ventilation. 14. Do not cut pressurized cylinders or any closed container. 15. Make fire extinguishers available in the cutting area. 8. All areas of the body must be covered by dark substantial clothing (preferably flame retardant) to protect against arc burn, sparks and flying hot metal. 9. The plasma operation should be located in an area where protection for other personal may be readily provided. Portable non-combustible reflecting screens or enclosures with non-reflecting walls may be used. Screens and enclosures should permit free circulation of air at floor level. 16. Remove combustible material from the immediate cutting area. 17. Quench freshly cut metal or allow metal to cool before handling it or bringing it in contact with combustible materials. 11

14 Safety 18. To prevent electric shock keep your body and clothing dry. 19. Do not stand in, sit on or lie on any wet surface when using the plasma system. 20. Maintain proper insulation against electrical shock. If you must work in or near a damp area, use extreme caution. Wear insulated gloves and boots. 21. Provide a wall mounted disconnect switch with proper size fuses close to the power supply. This switch allows the operator to turn the power supply off quickly in an emergency situation. 22. Conform to all local codes for primary wiring sizes and types. 23. Inspect the primary power cord frequently for damage or cracking of the cover. Bare wiring can kill. Do not use the system with a damaged power cord. If a power cord is damaged, replace it immediately. 24. Inspect the torch leads. Replace if frayed or damaged. 25. Never operate the plasma system unless the power supply unit covers are in place. Exposed power supply connections present a severe electrical hazard. 26. Do not pick up the work piece, including the waste cutoff, while you cut. Leave the work-piece in place or on the worktable with the work cable attached at all times. 28. Never bypass or shortcut the safety interlocks. 29. Before removing a power supply cover for maintenance use approved lockout procedures, disconnect the main power at the wall, shut off switch or unplug the power supply. To avoid exposure to sever electrical hazard, wait five (5) minutes after disconnecting the main power to allow capacitor discharge to occur. Test for zero energy. 30. Be sure the power cord is plugged into a properly grounded outlet or that the power cord ground wire is properly connected to the ground in the disconnect box. 31. If installation of the plasma system involves connecting the power cord to the power supply, ensure that the power cord ground wire is properly connected. Conform to CSA standards by placing the power cord ground wire on the stud first; then place the other ground wires on top of the power cord ground. Fasten the retaining nut tightly. 32. Make sure that all electrical connections are tight to avoid excessive heating. 33. Clamp the work cable with good metalto-metal contact to the work-piece (not the portion that will fall away) or to the worktable. 34. Connect the worktable to a good earth ground. Consult the National Electrical Code, Grounding Electrode System, or other appropriate national or local codes. 27. Before changing the torch parts, disconnect the main power supply. After changing the torch parts and returning the retaining cap to its operating position, plug the power supply in again. 12

15 Safety 35. Plasma cutting operation noise levels may be high enough to require ear protection for the operator and other personnel in the adjacent area. 36. When using a water table to confine slag etc. while plasma arc cutting plate, especially aluminum or magnesium, cutting may cause an accumulation of explosive gas below the plate. Do not allow aluminum or magnesium dross to accumulate in a water table. Prior to cutting, raise and lower the water level several times to dissipate trapped gases. Do not leave plate on the table for extended periods of time, ie. overnight or weekends. When the table is not in use, keep the water level down. Do not cut these materials under water. Read additional cautions in the related manuals. 37. No repair should ever be under taken or attempted by anyone other than a KOIKE ARONSON designated technician. 1.3 GENERAL SAFETY, MISCELLANEOUS 4. When igniting or adjusting torch flame at the start of cutting take care not be burned. 5. Never touch torch tip when lit, or you may be burned. 6. When replacing or cleaning a torch tip during cutting be sure to give the tip sufficient time to cool. The tip will be very hot. 7. After cutting never touch the work-piece or scrap until they cool. You can be burned. 8. During the piercing operation on heavier plate (25mm or larger) there can be a good deal of spatter. Be sure to stay away from the torch and stay in the operation zone to prevent exposure to burn from the spatter. 9. During the cutting operation never touch the torch flame or plasma arc. 10. Do not climb on the cutting table, as it is possible to slip and cause injury. 11. Take care not to climb on or over the rail as it has rack attached to it and can cause injury. 1. Keep the working area dry to avoid an electrical shock. 2. Check that the machine voltage and supply voltages are the same before turning on the power switch. 12. There is no pressure relief valve in the gas system therefore supply pressures should be adjusted at the supply source regulators. Maximum supply pressures are: Oxygen 1034 kpa (150 psi)(10.3 bar) 3. Never operate this machine unless all electrical box covers are attached. Exposed electrical connections present a severe electrical hazard. Fuel 103 kpa (15 psi)(1.3 bar) 13

16 Safety WARNING Protect yourself and others. Read and understand these instructions. FUMES AND GASES can be dangerous to your health. HEAT RAYS (INFRARED & ULTRAVIOLET) from flame, arc or hot metal can injure eyes. Read and understand the manufacturers instructions and your employer's safety practices. Use enough ventilation/exhaust at the flame/arc, or both, to keep fumes and gases from your breathing zone, the general area. Keep your head out of the fumes. 14

17 Safety Walkway Rails Cutting Table Cutting Machine Fence Flame Adjustment Figure The working area shown Figure 1.1 is required to ensure safe operation. This area should have fireproof floor, must provide adequate clearance around the machine for proper operation and personal safety per local code and should be clearly marked with appropriate warnings. 2. This machine moves in multiple directions and at various speeds. All personal, materials and equipment not involved in the production process must be kept clear of the work area. 3. Only qualified personal should operate or service this equipment. The work area must be checked for personnel and obstructions prior to starting machine or initiating machine motion. 4. Machine operation and monitoring of the cutting process should be performed from the operator station, at the control console. 5. Consumables should be changed in the Flame Adjustment Area in front of the machine noted above. 15

18 General Introduction MI0548A SECTION 2 GENERAL INTRODUCTION 2.1 SCOPE This manual provides general installation, operation and service information for the KOIKE ARONSON VERSAGRAPH MILLENNIUM series of cutting machines. This manual includes an illustrated part listing to aid in ordering parts. 2.2 DESCRIPTION Your VERSAGRAPH MILLENNIUM series is designed with time proven construction techniques. This machine uses the latest in electronic and mechanical technologies. Speed, accuracy, versatility and durability have been engineered into the MILLENNIUM for demanding production jobs. The sophisticated Servogas system along with the CNC programmable control and touch screen selectable features combine for ease of operation and precision cutting of plate steel. In addition, accessories for specific purposes are available to further enhance the versatility of the VERSAGRAPH MILLENNIUM. The Koike Aronson Inc. MILLENNIUM is designed to meet your cutting and marking requirements of steel plate. Optional equipment Figure.2.1 available will increase production and reduce production cycle time. The VERSAGRAPH MILLENNIUM features a touch screen interface to a programmable controller for ease of operation. The MILLENNIUM features an AC servo drive unit. The drive incorporates a synchronized axis control for rail axis movement. This feature increases position and part accuracy. 2.3 AXIS DEFINITION To avoid confusion in determining direction and aid in identifying part locations: 1. The X-axis is parallel to the transverse (main) beam. (See Section 7, Figure 1 for more information). 2. The Y-axis is parallel to the longitudinal rail system. (See Section 7, Figure 1 for more information). 16

19 General Introduction MI0548A 2.4 RAIL ASSEMBLY The VERSAGRAPH MILLENNIUM has two rail installation options and additional rail extensions available in 3-M increments. The most used option is KOIKE ARONSON supplied wide flange W12-58# beam. The other option is customer supplied beams fabricated to KOIKE ARONSON drawing specifications. All required hardware is included with the rail package. A 3 M rail package consist of two (2) heavy-duty crane type rails, drive rack, mid and joint rail adjuster blocks and required mounting hardware. Adjuster blocks which allow for up/down and lateral rail alignment are mounted 1000mm apart center to center for all installations. Mechanical stops at the end of the rail system provide machine over travel protection. 2.5 SADDLE ASSEMBLIES Two saddle assemblies travel on the Y-axis rail system, driven by an Y-axis main drive motor mounted on the outboard side of the main carriage. The outboard saddle also has a drive motor assembly mounted to it. Two (2) wheel assemblies support each saddle, one on the forward end and one on the aft end of the saddle to provide stability. The main saddle (inboard), on the operators control side of the machine utilizes two sets of rollers to provide guidance down the rail system. The inboard roller, facing the front of the machine, is eccentric to adjust to the guide rail and maintain positive machine alignment. 2.6 TRANSVERSE BEAM ASSEMBLY (X-drive) This is twin beam structural tubing extending in a left to right direction facing the machine and supported by the inboard and outboard saddles. The beam is factory squared to both saddles, pinned in position and bolted. Precision, replaceable linear ways have been mounted to keep the master and slave mounted carriages in precise position. 2.7 X-AXIS DRIVE ASSEMBLY The X-axis drive carriage supports one torch station and or one or more options. The drive is located on the transverse beam master carriage. A motor and planetary gear assembly drives the carriage along the X-axis. The X axis gear pinion engages to a rack assembly mounted to the transverse beam to provide precise motion. The gear pinion is engaged to the rack using a precision air tension assembly. 2.8 Y-AXIS DRIVE ASSEMBLY (INBOARD AND OUTBOARD) The inboard Y-axis drive assembly is mounted in the center of the main saddle assembly facing out. A pivot mount assembly supports the motor and planetary gear unit. The outboard Y-axis drive assembly is mounted in the center of the outboard saddle assembly facing out. A pivot mount assembly supports the motor and planetary gear unit. The two motor assemblies are electronically coupled to keep the machine paralleled for precision cutting. The inboard and outboard axis gear pinion engages to a rack assembly to provide precise motion. The gear pinions are engaged to the rack using a precision air tension assembly. 2.9 GAS SYSTEM ASSEMBLY The manifold assembly is located on the machine, inside the middle, vented enclosure assembly. Attached to each manifold pipe inlet are pressure regulators, and filters. Connections are made from the manifold to the main valve assembly located on the outboard side of the transverse beam assembly. The cut manifold is located in the front section of the mounting brackets. The preheat oxygen is supplied with a teed hose connection from the cut manifold. It is located next to the cut 17

20 General Introduction MI0548A manifold. The fuel manifold is supplied from the main valve assembly and is located next to the preheat manifold. The ignition manifold is supplied from a teed connection from the preheat fuel manifold and is located in the rear of the manifold mounting brackets. Eight (8) outlet bushings on each manifold pipe allow for connection of torch hoses. Individual preheat solenoids are provided for each oxy-fuel station. Caps for unused manifold outlets are provided GAS CONTROL PANEL The gas control panel is mounted in an enclosure next to the operators control station. The gas control panel contains gauges for observing the gas pressures to the manifold assemblies. Regulators are provided for oxygen and fuel pressure adjustment. The ease on valve allows for gradual activation of cutting oxygen to prevent blow back during thick plate piercing. The system provides Dual Hi-Low flame adjustment and precise independent balancing of preheat flames. It also provides an adjustment for the ignition manifold OPERATOR CONTROL CONSOLE The operator control console is mounted to the machine on the rail main saddle assembly. A dual pivot arm assembly supports the console and allows the operator a full view of torch stations in use. This also allows for a more controlled walkway for the operator. The control console encloses the CNC and operator interface controls LIMIT SWITCHES Two (2) limit switches are mounted on the transverse beam assembly. The limit switches cause an over-travel condition of the X-axis drive unit. A limit switch mounted to the slave (outboard) saddle limits Y-axis travel. Should a limit switch be tripped, the drive signal is interrupted, and all cutting operations are stopped. To recover from a limit trip see the operation section of this manual TORCH STATION (Main) One torch station is mounted on the transverse drive carriage. An oxy/fuel or plasma torch station mounted on the drive carriage. The oxy/fuel station consists of the torch, fuel and oxygen hoses, check valves, motorized lifter and electrical cable, and a flexible, enclosed cable carrier assembly TORCH STATION (Slave) Oxy/fuel or tool slave stations include a carriage for mounting to the transverse beam. These stations are manually locked to the steel band assembly for securing the carriage to the beam once the correct cutting distance is set. An electrical proximity switch is mounted on the slave station. This allows the interface to disable all functions of the station STEEL BAND ASSEMBLY The steel band assembly consists of double pulley sheave assemblies. The sheave assemblies are mounted on the extreme left and right of the transverse beam assembly. A 50mm steel band is threaded around the assembly and is firmly connected to the transverse drive carriage. This allows motion for the slave torch stations. The steel band assembly allows for image or mirror cutting depending on how the clamp assembly is locked to it ELECTRICAL FEATURES The VERSAGRAPH MILLENNIUM uses a brush-less AC drive system. This machine features an industrial grade touch screen operator interface. The MILLENNIUM incorporates an easy to understand and troubleshoot programmable interface. This type of interface makes the field added options easier to install with less down time. The MILLENNIUM comes standard with customer optioned CNC. 18

21 Pre-Installation Requirements MI0548A SECTION 3 PRE-INSTALLATION REQUIREMENTS 3.1 PRE-INSTALLATION SAFETY All equipment must be installed in accordance with local requirements and the National Electrical Code. Connect and maintain good electrical grounds, as per article 250 of the NEC, to the supply ground wire, cutting machine and cutting table. Do not ground to electrical conduit, or pipes carrying gases or flammable liquids. Use only correct sizes of electrical cable. Plan to provide ventilation. Proper ventilation is vital for safety, good visibility and personal comfort. If necessary, in a fixed cutting area use an exhaust hood of required capacity. An additional exhaust line located below the work-piece level in a boxed in cutting table can remove fumes that are heavier than air. Adequate equipment necessary for lifting the cutting machine weight must be available at the time of installation, such as an overhead crane, forklift, etc. All normal safety precautions used in working with flammable gases, electrical equipment and heavy machinery, as well as procedures listed in your company safety manual must be followed to prevent possible 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 ground to the cutting machine equipment will void warranties. NOTE: The following preparations should be complete before the arrival of the installing technician. 3.2 SITE LOCATION Special consideration must be used in the selection of a site for cutting machine operation. Fuel, oxygen, electrical outlets, clean dry shop air and water in the immediate vicinity are essential for economical operation of any oxyfuel/plasma cutting machine. Material handling is also important and space for stockpiling plate and parts as well as material movement by hoist, truck or other means must be considered. The cutting machine requires a space where floor vibration is at a minimum. Precision operation is necessary for accurate part cutting. An area where transmission of vibration (caused by drop hammers, heavy machinery, trucks or rail sidings) must be avoided. Positioning of the unit close to a production line, adequate lighting and ventilation should also be considered. Review the dimensional machine layout in Table 2.1 in order to determine correct working area requirements, allowing adequate aisle space to provide for operator safety, traffic flow and overhead clearance. 19

22 Pre-Installation Requirements MI0548A 3.3 SITE PREPARATION Solid, secure and accurate rail installation is critical to insure maximum accuracy for any oxy-fuel/plasma cutting machine. The floor for the machine installation should be level within 9.5 mm over the entire rail length and width. The floor area supporting the rails should be a minimum of 200 mm thick reinforced concrete free from cracks or other imperfections. If any possibility of floor settlement exists, separate footing should be provided over a firmly packed base. If a possibility of equipment vibration exists, the cutting machine rail system should be provided with an adequate isolation pad. 3.4 ELECTRICAL REQUIREMENTS The position of cables on a cutting machine is very important for proper operation of the system. Use care when routing electrical wires to avoid pinching or chafing against metallic or other abrasive objects. Local codes as well as the National Electrical Standard must be followed for all power and grounding installations. Caution: The AC power to the cutting machine must come from a dedicated source. No other machinery or equipment should be connected to this line. Cutting machine electrical requirements are 230 Volts AC (±10%), Hz, single phase, 25 Amps. Koike Aronson provides the machine main power cable. Koike Aronson recommends all power cables be kept as far as possible from auxiliary components such as machine control boxes, solenoids, etc. Avoid random placement of wiring. Keep all wiring as short as possible, Do Not coil any cables. Make sure all supply hoses and cable are long enough for the type of carrier system used. Caution: Proper grounding of the cutting machine and peripheral equipment is critical to the reliable operation of the system. This requires careful and proper installation of ground rods and associated wire connections. Ground wires will connect to the cutting table; through a "STAR" ground connection. The ground rod for oxy-fuel systems and plasma systems of 100 Amps or less should be 12 mm diameter solid copper, 2.5 M in length. The wire connection to the Star ground should be a proper sized stranded wire, and should not exceed 1.2 M in length. The ground rod for machines with plasma system of 100 Amps or more should be 20 mm diameter solid copper, 4.5 M in length. If you cannot drive a 4.5 M ground rod, you may use two (2) 2.4 M ground rods connected to each other with 4/0 cable and then to the Star ground. The wire to the Star ground connection will be a minimum of 4/0 cable and should not exceed 1.2 M in length. Note: Ground rods must be installed according to the National Electrical Code Standards. All ground connections must make intimate contact with the components they are grounding. All rusted or painted surfaces must be cleaned and the connections made should be tight. Any grounding strap should be sized to current load per article 250 of the NEC. 20

23 Pre-Installation Requirements MI0548A 3.5 OXY-FUEL REQUIREMENTS Oxygen and fuel gas supply systems should be recommended and installed by your local gas supply distributor. For most multi-torch production cutting machines, a cylinder bank or pipeline system is usually required. During an installation of this type, care should be taken to ensure that oxygen valves, lines and fittings are cleaned for oxygen service. Station drops, fuel and oxygen should be spaced at least 300 mm apart center to center, and identified by color. All fuel and oxygen lines should be installed according to applicable regulations and safety rules. Station drops should be installed on a wall or column for rigid support. Installation should be at the rear of the rail system for use with the type of carrier system used for machine supply. WARNING Do not allow oil, grease, or combustibles to be exposed to oxygen equipment. Use only threadsealing compound approved for oxygen service when making up threaded joints. Oxygen supply requirements must be calculated on the maximum number of torches to be used and the maximum material thickness expected. Your local gas supplier is best suited to assist you in determining your supply requirements. A locally supplied pressure booster is normally required for low-pressure natural gas. Compressed air for general blow down and clean up should be dry, clean and oil free with a 5-micron maximum particle size. 3.6 BURNING TABLE The burning table, fabricated enclosed or open frame, is a customer responsibility. Refer to the layout drawing in Section 2 figure 2.1, for your cutting machine to determine clearance available for the burning table before fabrication. The burning table may be as long as the cutting length provided by the rail system less the cutting machine parking space. Table width and the outside dimensions, may be as wide as the designated cutting width of the machine plus 305 mm. A table surface (bottom of plate) height of 585 mm is recommended. Do not anchor the table in place before rail installation. 21

24 SECTION 4 INSTALLATION 4.1 INSTALLATION SAFETY PRECAUTION WARNING Voltages used with this machine can be injurious to personnel if improperly used. All equipment must be installed and maintained in accordance with local requirements and the National Electric Code. Connect and maintain suitable electrical grounds to the supply ground wire. Do not connect ground to electrical conduit or to pipes carrying gases or flammable liquids. Use only the recommended size of electrical cable, in accordance with article 250 of the NEC. If it was necessary to install forced ventilation, operate the cutting machine only when such ventilation is running to prevent harmful and dangerous accumulations of fumes. Avoid enclosing areas where fuel gas leaks may occur, or insure that such leaks can not occur in lines passing through or ending in confined spaces. Use normal precautions when loading or operating heavy equipment. Follow the procedures in your company safety manual. 4.2 HANDLING AND STORAGE evidence of damage exists, note it BOLDLY across the face of the way bill BEFORE YOU SIGN IT. Sign the way bill only after this inspection. If you note discrepancies on the delivery ticket, DO NOT open the cartons. Call the trucker's local office and ask that a claims investigator be sent as soon as possible to verify the status of the shipment. Also, call your Koike Aronson representative. Try to arrange the meeting so that the claims investigator and the representative will be present when the damage/shortage is verified. The trucker will supply you with the necessary claims forms if required. Freight claims are the receivers responsibility. Please follow these instructions carefully, Koike Aronson and your distributor will support you fully in the unlikely event that a freight claim is necessary. Handle the packing cartons carefully, right side up as marked. Store cartons in a dry location until ready to install. 4.3 UNPACKING AND CLEANING The equipment has been packaged to prevent damage in transit. Unpack carefully to prevent accidental damage by uncrating tools. After uncrating, examine the equipment for signs of damage, particularly to control knobs, switches and electrical components. Report any damage to the freight carrier and Koike Aronson immediately. Remove preservation coating from all unpainted surfaces, as components are needed for installation, with WD-40, LPS-1 or mineral spirits. When the shipment arrives at your location, accompany the driver in counting all the cartons indicated on the driver's waybill. Inspect each piece for signs of mishandling or apparent damage. If discrepancies exist or any 22

25 Installation MI0548A 4.4 RAIL INSTALLATION Proper installation of rails and their mechanical alignment is CRITICAL to insure cutting accuracy with coordinate drive cutting machines. The guide rail must be straight within 0.1 mm over the entire length. It must be level within ± 1mm over the entire length. The outboard rail must be straight within 0.1 mm over the entire length. It must be level within 1mm over the entire length. The rail gauge between the guide rail and the outboard rail must be parallel within 1 mm the entire length. The levelness between the guide rail and outboard rail must be maintained within 1 mm the entire length. If W12-58# WIDE FLANGE BEAM is being used the beam's top center must be straight within ± 1.5 mm over the entire length. The beam must be shimmed with solid shim to prevent rocking under the anchors and properly grouted. 4.5 RACK INSTALLATION Lay out the guide and outboard rack, positioned as shown on the rail assembly drawing. Start from the center of the rail system working to each end. Fasten into place with provided capscrews using the short piece of alignment rack supplied for tooth to tooth positioning at joints. Tighten all capscrews. Reference the appropriate drawing for exact rack layout. 4.6 MACHINE MOUNTING The cutting machine can be mounted on the rail system from above (vertically) using an overhead crane or from the front (horizontally) when overhead clearance is too low. near the inside of the outboard saddle assembly. Balance the machine by test lifting. When the machine is suspended, and the load is secured, remove and clean the fixed guide rollers. This is necessary for the machine to clear the rack when it is placed on the rails. Clean the adjustable guide rollers before placing the machine on the rails. NOTE: Maintain straight and level alignment of carriages with the rails when making contact, to prevent damage to wheels, guide rollers, rails or rack. Vertical Mounting: Align all four (4) wheels of both carriages with the rails and gently lower the full weight of the carriages onto the rails. Reposition the machine, if necessary, to a position where the fixed rollers (front and rear) are against the rail. Adjust the rollers equally against the rail so that when the guide roller is held between the thumb and forefinger, the roller will just slip against the rail. Carriages should be level and roll freely. Install the mechanical end stops to the rail. Horizontal Mounting: With carriages aligned straight and level with the rails, make contact with the rear guide rollers of the main carriage. Roll the carriage slowly rearward until the rear wheels of the carriage make contact with the rails followed by the front carriage wheels. Adjust the guide rollers as indicated in the vertical mounting section. Install the mechanical end stops to the rails. Suspend the cutting machine assembly by means of the two (2) lifting strap assemblies under the two beams located near the inside of the inboard saddle assembly and one located 23

26 Installation MI0548A 4.7 MOTOR/PLANETARY GEAR UNIT INSTALLATION The motor and planetary gear units have been factory installed on the machine. To engage the units, remove all the packing and support banding from the unit. Align the gear pinion to the rack. NOTE: When the machine main air supply is applied, the precision air cylinders will engage the pinion to the rack. These cylinders are factory set for proper air tension. 4.8 TORCH CARRIAGES All slave carriages for individual torches/tools are installed and adjusted at Koike Aronson, Inc. There is no installation required. Remove all packing and support bands from the carriage assembly. 4.9 TORCH STATIONS Torch lifters mount directly to the torch carriages using the spacer provided and four (4) hex head capscrews. The torch station closest to the operator control console is designated as station number one (1). With the torch free hanging, connect the correct hose(s) to the cutting torch. Loosen the clamp screw on the motorized lifter. Insert the torch holder stud and tighten in place. To achieve accurate cutting the torch must be perpendicular to the surface of the plate. A swivel adjustment on the motorized lifter and the mounting stud clamp will allow for the necessary adjustment. Connect the flexible cable carrier to the mounting bracket using the hardware supplied. Connect the torch lifter cable to the lifter assembly. Check the tightness of all hardware and hose connections CNC INTERFACE The CNC control has been removed from the machine for shipment. Unpack it CAREFULLY and install the CNC in the operator control. Connect the proper cable assembly to the CNC. All cable assemblies are labeled at Koike Aronson, Inc. as to where they connect to the CNC UTILITIES The machine is supplied with a flexible main power track system. Route all supply hoses and cables through the carrier system in a neat and orderly fashion. Connect the power cable from a properly fused dedicated source (review Section 3 Pre- Installation) to the power disconnect on the machine. Check to see that the power source is off and/or tagged Out of Service to avoid a potential electrical shock. Connect the fuel and oxygen supply hoses from the station drop to the correct connection on the main valve unit. A green 1/2 inch C R/H fitting, oxygen supply hose connects to the cutting oxygen main valve unit. A red 1/2 inch C L/H fitting, fuel supply hose connects to the fuel main valve unit. Connect the air hose to the main valve unit marked air. WARNING This machine has open gearing. Keep hands clear when the machine is being operated GENERAL PLASMA MACHINE CONNECTIONS 24

27 Installation MI0548A Plasma system installations differ from installation to installation due to the type of system and height control ordered at the time of purchase. Some of the hosing and cables are left on the machine neatly coiled and packed for shipping. These are labeled as to where their connection is to the plasma system. The remaining hoses and cables are packed separately. After the flexible cable carrier is installed, locate the remaining hoses, cables, and route through the carrier, paying close attention as to connectors and fittings. Routing of the hoses and cables has to be accomplished in a neat and orderly fashion. The hoses and cables are labeled to where they connect. Check all grounding for the plasma system. Make sure all ground connections are properly tightened. For a more detailed view of the installation, refer to KAR drawing and the vendor manual. Table 4.1 includes a listing of the manuals used by KAR for plasma systems. Table 4.1 KAR/VENDOR PLASMA MANUAL Vendor Vendor Manual w/ Part Number KAR Manual Part Number Hypertherm Power Max 800 IM-227 MI0043V227 Hypertherm Power Max 900 IM-308 MI0043V308 Hypertherm Power Max 1100 IM-273 MI0043V223 Hypertherm Power Max 1100 Interface IM-284 MI0043V284 Hypertherm HD3070 IM346 MI0043V346 Hypertherm HT2000 IM207 MI0043V207 Hypertherm HT4000 Installation IM147 MI0043V147 Hypertherm HT4000 Operation IM148 MI0043V148 Hypertherm HT4000 Parts List IM149 MI0043V149 Hypertherm HT4100 Installation IM165 MI0043V165 Hypertherm HT4100 Operation IM166 MI0043V166 Hypertherm HT4100 Maintenance IM167 MI0043V167 Hypertherm HT4100 Instruction IM200 MI0043V200 Hypertherm Command Torch Height Control IM278 MI0043V278 Hypertherm Arc Writer IM252 MI0043V252 Thermal Dynamics Merlin MI0227V Thermal Dynamics Merlin GC-3000 Gas Control MI0228V Thermal Dynamics Merlin 6000 Operation MI0236V Thermal Dynamics RC6010 Remote Control MI0241V2478 Thermal Dynamics Merlin 6000GST Operation MI0241V2652 Thermal Dynamics Merlin 6000GST Gas Control MI0241V2641 Thermal Dynamics Merlin 6000GST Arc Starter MI0241V2654 Thermal Dynamics Merlin 1000 Operation MI0241V2708 Thermal Dynamics Standoff Control SC MI0241V

28 Operation MI0548A SECTION 5 OPERATION 5.1 OPERATIONAL SAFETY Follow the precautions in the SAFETY section and throughout this manual for your personal safety and the safety of people near the equipment. 1. Operate cutting equipment only in a wellventilated area. 2. Check gas connections for tightness regularly. 3. Keep combustibles away from the work area or protected from sparks and flames. 4. Verify the functionality of all check valves regularly. 5. Before connecting pressure reducing regulator to a oxygen cylinder or manifold, always wipe outlet connection with a clean, oil free cloth and "crack" the cylinder valve to remove any dirt or contaminate particles. 6. Always drain gas from the oxygen regulator before opening cylinder or manifold valve. Proceed by engaging the adjusting screw and opening down-stream valves to allow gas to escape. The adjusting screw may then be released before opening the cylinder valve. 7. Open cylinder or supply valves slowly. 8. Never use oxygen to ventilate area or clean off clothing. 9. Keep oil, grease and combustibles away from oxygen equipment. 10. Purge oxygen and fuel lines before igniting each torch, by briefly opening and closing each valve in turn. 11. Wear appropriate eye protection safety goggles with filter lens. 12. Keep equipment clean and in good operating condition. 13. When welding DO NOT ground to the machine, the rail system or to the cutting table at any time to avoid damage to electronic components. Not following this warning may void all manufacturers warranty. 26

29 Operation MI0548A 5.2 GENERAL OPERATION The control switches and the touch panel button functions of the VERSAGRAPH MILLENNIUM are described below. This section is reserved for error messages that may occur during operation. See Section 5.5 Figure 5.1 (Main Operator Display Screen) Pressing this button enables the information and diagnostic screen. Figure 5.3 is displayed. Pressing this button enables the extended oxy-fuel screen for up to 10 torches. Figure 5.2 is displayed. 27

30 Operation MI0548A Figure 5.2 (Extended Oxy-fuel Screen) Pressing this button returns to the main operator display screen. Figure 5.1 is displayed. 28

31 Operation MI0548A Figure 5.3 (Information and Diagnostic Selection Pressing this button returns to the main operator display screen. See Figure 5.1. For a detailed description of the following buttons, see Section 6, Maintenance. Pressing this button allows an on-line view of the available hardware options and which ones are used on the machine. See Figure 6.2. Pressing this button allows an on-line view of the available programmable control modules associated with the hardware options used on the machine and if they are communicating properly. See Figure 6.3. Pressing this button enables the screen for SELECT TOOL I/O TO VIEW. See Figure

32 Operation 5.3 CONTROL BUTTON FUNCTIONS CONTROL ON NOTE: ALL E-STOP BUTTONS NEED TO BE DE-SELECTED. With main machine power applied to the machine, press the control on pushbutton. This applies power to all control circuits. The push-button illuminates green indicating that control power is on CONTROL OFF Pressing this button turns off DC control power. The power is used for control circuits, I/O, the programmable controller and other control circuits POWER ON Pressing this button with the E- STOP button pushed in causes no action. With main machine power applied to the machine, press the power on push-button. This applies AC power. The push-button illuminates green indicating that power is on to the drives and AC control circuits E-STOP This button when pressed removes all power from the servo drives causing motion to stop. It also removes all power from the Interface and all gas solenoids. To recover from an E-Stop condition, pull the E- Stop button (towards you). Press the control power on button. 5.4 TOUCH SCREEN FUNCTIONS PLASMA 1 (OPTION) MI0548A Pressing this button once will enable all plasma 1 torch functions. The button will illuminate indicating that selected torch is active. Pressing this button again will disable all plasma 1 functions and turn the light off. Note: The Plasma and oxy-fuel select switches cannot be selected at the same time. The option last selected will override the prior selection. Note: If using the safety mount feature for the plasma torch and a trip occurs, a warning will appear (Tool Error) and the cut process stops. To start the cut process again, correct the cause of the trip and press the selected plasma torch button. The CNC cut re-start process has to be started PLASMA 2 (OPTION) Pressing this button once will enable all plasma 2 torch functions. The button will illuminate indicating that the selected torch is active. Pressing this button again will disable all plasma 2 functions and turn the light off PLASMA 3 (OPTION) Pressing this button once will enable all plasma 3 torch functions. The button will illuminate indicating that the selected torch is active. Pressing this button again will disable all plasma 3 functions and turn the light off PLASMA 4 (OPTION) Pressing this button once will enable all plasma 4 torch functions. The button will illuminate indicating that the selected torch is active. Pressing this button again will disable all plasma 4 functions and turn the light off. 30

33 Operation ARC WRITER CURRENT (OPTION) Pressing this button allows for current setting of the Arc Writer. A number pad will appear. Type in the desired current, press enter, press done. Note: 19 amps is the maximum current setting GO TO PANEL INFORMATION Pressing this button allows a view of the power up screen to appear ARC MARKER 1 (OPTION) ARC MARKER 2 (OPTION) MI0548A Pressing this button once will enable all arc marker 2 torch functions. The button will illuminate indicating that the selected torch is active. The up arrow button allows the torch to raise to the full up position. The down arrow button allows torch to lower to the down position. The up and down buttons are used for manual operation. The arc marker will raise and lower automatically under CNC operation. Pressing this button again will disable all arc marker 2 functions and turn the light off ARC MARKER 3 (OPTION) Pressing this button once will enable all arc marker 1 torch functions. The button will illuminate indicating that the selected torch is active. The up arrow button allows the torch to raise to the full up position. The down arrow button allows torch to lower to the down position. The up and down buttons are used for manual operation. The arc marker will raise and lower automatically under CNC operation. Pressing this button again will disable all arc marker 1 functions and turn the light off. Pressing this button once will enable all arc marker 3 torch functions. The button will illuminate indicating that the selected torch is active. The up arrow button allows the torch to raise to the full up position. The down arrow button allows torch to lower to the down position. The up and down buttons are used for manual operation. The arc marker will raise and lower automatically under CNC operation. Pressing this button again will disable all arc marker 3 functions and turn the light off. Note: When using a CNC program for Arc writing and Plasma or Oxy-fuel cutting, the button will illuminate automatically. The next cut operation button will flash. After the marking process is complete, the cut operation light will illuminate steady and will extinguish when complete. Note: If using the safety mount feature for the plasma torch and a trip occurs, a warning will appear (Tool Error) and the cut process stops. To start the cut process again, correct the cause of the trip and press the selected plasma torch button. The CNC cut re-start process has to be started ARC MARKER 4 (OPTION) Pressing this button once will enable all arc marker 4 torch functions. The button will illuminate indicating that the selected torch is active. The up arrow button allows the torch to raise to the full up position. The down arrow button allows torch to lower to the down position. The up and down buttons are use for manual operation. The arc marker will raise and lower automatically under CNC operation. Pressing this button again will disable all arc marker 4 functions and turn the light off. 31

34 Operation MI0548A CYCLE DRILL (OPTION) Pressing this button once will manually start the drill cycle. No other buttons need to be pressed since the drill cycle has a pneumatic auto feature. The button will illuminate throughout the drill cycle STOP DRILL (OPTION) Pressing this button during the drill cycle will stop the drill and retract to the up proximity switch. The button will illuminate momentarily indicating that the drill cycle has stopped SCRIBE MARKER (OPTION) Pressing this button once will enable scribe marker functions. The button will illuminate indicating that the selected torch is active. The up arrow button allows the marker to raise to the full up position. The down arrow button allows the marker to lower to the down position. The up and down buttons are used for manual operation. The scribe operation will automatically lower the scribe, turn the scribe on and raise the scribe with the correct CNC program PUNCH MARKER (OPTION) Pressing this button once will enable punch marker functions. The button will illuminate indicating that the selected torch is active. The up arrow button allows the marker to raise to the full up position. The down arrow button allows the marker to lower to the down position. The up and down buttons are used for manual operation. The punch operation will automatically lower the punch, turn the punch on and raise the punch with the correct CNC program ZINC MARKER (OPTION) Pressing this button once will enable Zinc marker functions. The button will illuminate indicating that the selected marker is active. The up arrow button allows the marker to raise to the full up position. The down arrow button allows the marker to lower to the down position. The up and down buttons are used for manual and CNC operation. The marking process is semi-automatic with the correct CNC program ZINC MARKER PREHEAT (OPTION) Pressing this button once illuminates the button indicating the option is enabled. This button starts the circulating oxygen and powder to dry out and prepare for marking. The preheat solenoids will also enable allowing for the gas and oxygen to flow through the torch for ignition and preheat. If automatic ignition is fitted on your machine, the torch will automatically ignite. After 4 seconds, the ignition solenoid will turn off. The preheat solenoids will stay on. This button is used mainly for torch set-up. Under CNC operation, the above description will occur automatically LASER SPOT (OPTION) Pressing this button once illuminates the button and turns the laser spot on. This indicates that the option is enabled. This option allows for alignment of the tool to the plate. Pressing the button again extinguishes the light and turns the laser spot off IGNITE (OPTION) Ignition is the process of igniting an oxy-fuel torch. It is used during manual operation of the oxy-fuel torches. Its function is to energize the pilot gas solenoid and the ignition transformer. This button is a momentary button, pressing and holding will cause the pilot gas solenoid to energize allowing the flow of gas to the ignition tube on the torch. 32

35 Operation This will energize the ignition transformer generating a spark, igniting the pilot gas. The button will illuminate when pressed. Releasing the button will de-energize the pilot gas solenoid and the ignition transformer. The selected torch(es) will not actually ignite unless the low preheat button is also pressed LOW PREHEAT (OPTION) Low preheat gas is used to heat the metal to a temperature where the metal will react with the cutting oxygen. The button will illuminate when pressed. Pressing this button will energize and latch the solenoids corresponding to the low preheat function on the gas panel to become active. It also turns the ignition on for the selected torches for three and a half seconds. This also allows low preheat gas to flow from the manifold to the torch. This button is used mainly for set-ups for the low preheat pressures before cutting the plate. Pressing the button a second time will de-energize the low preheat solenoids and extinguish the torch and button HIGH PREHEAT (OPTION) High preheat is used to rapidly heat the plate to piercing temperature. The button will illuminate when pressed. Pressing this button will energize the solenoids corresponding to high preheat function on the gas panel to become active. This allows high preheat gas to flow from the manifold to the torch. This button can also be used for set-ups for the high preheat pressures and before cutting the plate. Pressing the button a second time, or entering cut mode will deenergize the high preheat solenoids and extinguish the button BOOST (OPTION) MI0548A allows high preheat gas to flow from the manifold to the torch. Releasing the button will de-energize the high preheat solenoids and extinguish the button CUT (OPTION) Cut oxygen is used in the cutting process to rapidly oxidize a narrow section of metal to make the cut. This button is used for set-up operation of the oxy-fuel torches and actual part cutting. The button will illuminate when pressed. Its function is to energize the cut oxygen solenoids on the gas manifold and the selected torches. Pressing the button one time will cause the cut oxygen solenoids to energize allowing cut oxygen to flow to the torch. Pressing the button a second time or pressing stop will cause the cut solenoids to deenergize and extinguish the button SELECT 1-8 (OPTION) Individual oxy-fuel torch selects torches1 to 8 for oxy-fuel cutting. Pressing the torch select button once enables all torch station functions for the selected torch. The button will illuminate when pressed. Pressing the button again will disable the torch functionality ALL UP (OPTION) Pressing and holding this button allows all the selected torches to move in the upward direction. The button will illuminate when pressed. The torch will begin moving upward at approximately 40 in/min, it will continue going up until the button is released or the maximum up position is reached. Tap- pressing the button will allow for incremental movement of the torch approximately 1/32. Also known as momentary high preheat. This button is only active during the cutting mode. In cutting mode, it is used to generate more heat (Boost) to power through slag or other debris that may be on the plate. Pressing, and holding the button causes the solenoids corresponding to high preheat function on the gas panel to become active and the light to illuminate. This 33

36 Operation ALL DOWN (OPTION) Pressing and holding this button allows all the selected torches to move in the downward direction. The button will illuminate when pressed. The torch will begin moving downward at approximately 40 in/min, it will continue going down until the button is released or the maximum down position is reached. Tappressing the button will allow for incremental movement of the torch approximately 1/ ERROR MESSAGES Error messages will appear on the touch panel screen when a particular problem exists. A limit switch trip, servo alarm and oxy-station parked are some of the errors that may blink on the screen X FWD. LIMIT This error message will flash when the transverse axis moving in the plus direction reaches the travel limit. Note: Axis direction is dependent on the CNC encoder direction. To clear the error message, jog the machine in the opposite direction. Once off the limit the message will go away. Note: Refer to the CNC manual on how to jog the machine X REVERSE LIMIT This error message will flash when the transverse axis moving in the minus direction reaches the travel limit. Note: Axis direction is dependent on the CNC encoder direction. To clear the error message, jog the machine in the opposite direction. Once off the limit the message will go away Y FORWARD LIMIT This error message will flash when the rail axis moving in the plus direction reaches the travel limit. MI0548A Note: Axis direction is dependent on the CNC encoder direction. To clear the error message, jog the machine in the opposite direction. Once off the limit the message will go away Y REVERSE LIMIT This error message will flash when the rail axis moving in the minus direction reaches the travel limit. Note: Axis direction is dependent on the CNC encoder direction. To clear the error message, jog the machine in the opposite direction. Once off the limit the message will go away OXY-1 PARKED This error message will appear when on oxy-fuel torch station is selected and it is located off the main cut area; not over the transverse drive rack. To clear the error, move the parked station over the rack then select the torch. Note: This error is true for all oxy-fuel stations on machines with tool parking. 34

37 Operation MI0548A TOOL ERROR This error message will appear when the safety mount for the plasma torch or the marking tool trips. The CNC will pause causing the all cut functions or movement to stop. To clear the message, correct the cause of the trip and reset the air holder. You must restart the CNC OUT OF SYNC This error message will appear when the rail drives exceed the maximum amount of preset error in the synchronization circuit. To clear the error, check the rails and pinions for any obstructions and clear. Turn off power, disengage the drives from the rack press the drive power on and engage the drives X SERVO ALARM The X servo alarm will turn on when a problem with the associated drive occurs Y1 SERVO ALARM The Y1 servo alarm will turn on when a problem with the associated drive occurs Y2 SERVO ALARM The Y2 servo alarm will turn on when a problem with the associated drive occurs. NOTE: TO REMOVE A SERVO ALARM, YOU MUST PRESS THE E-STOP. WAIT TEN (10) SECONDS BEFORE RESETTING POWER ON. 5.6 MANUAL GAS OPERATION SERVO GAS CONTROL SYSTEM The Servo Gas Control System consists of the gas control panel and various other components which provide Dual HI-LO flame adjustment, precise independent balancing of preheat flames and an Ease-on cutting oxygen control. The gas control system set-up is the first step in preparing to oxy/fuel cut plate. Your machine has a Servo Gas Control System, follow the Servo Gas Control Section PURGING When all gas supply connections to the machine are complete or when the machine is idle for extended periods with torch valves open, the system must be purged to remove any mixture of air-fuel or oxygen-fuel that may cause a fire and/or explosion in torch hoses and manifold. Hazardous oxygen-fuel mixtures may also be caused by clogged tips and other equipment malfunction, or by improper operating and ignition procedures. To Purge: You must select an oxy-fuel torch station. a. Close all manual torch valves and check that the same size tips are installed on all torches. b. Press Cut. c. Set Low Preheat Oxygen regulator at normal pressure. d. Set Low Fuel regulator at 3 to 4 psi. e. Set the Cutting Oxygen regulator at normal pressure. f. Open preheat oxygen valve on the first torch a full turn for 3 seconds and close it. Repeat this step on each torch in turn. Note: Use 3 second purge for machine equipped with four (4) or more torches. For fewer torches, purge 4 to 5 seconds for each torch valve. 35

38 Operation g. Open the fuel valve on the first torch a full turn for 3 seconds and close it. Repeat this step on each torch in turn. h. Open cutting oxygen valve on the first torch for 3 seconds and close it. Repeat this step on each torch in turn. i. Depressurizing the system: 1. Turn off all gas function buttons. 2. Back off all regulator-adjusting screws. 3. On one torch only, open preheat oxygen, then the fuel valve until the respective gauge pointers reach zero (0). 4. Close valves IGNITION PROCEDURE 1. Start: MI0548A 5. IGNITE and Adjust Low Preheat Flame (One Torch): a. Open the fuel valve slightly, ignite the torch, and then slightly open the preheat oxygen valve. b. Adjust both valves for correct preheat flame. c. Open and close torch cutting oxygen valve several times, readjusting the fuel valve if necessary to achieve satisfactory preheat flame when cutting oxygen is off. A preheat envelope around the cutting oxygen stream should be formed for several inches from the tip face when cutting oxygen is on. The cutting oxygen within this envelope should be straight and several inches long. a. Back off adjusting screws of all five (5) pilot regulators. b. Close all torch valves. c. Press the Low Preheat button. 2. Set Up Fuel Pressures: a. Open fuel valve on one torch 1/2 turn. b. Adjust Low (Preheat) Fuel pilot regulator for operating pressure. c. Press the High Preheat button. d. Adjust High Fuel regulator for operating pressure. e. Press the Low Preheat button. f. Close fuel valve. 3. Setup Preheat Oxygen Pressure: a. Open preheat oxygen valve on one torch a full turn. b. Adjust Low Preheat Oxygen pilot regulator for operating pressure. c. Press the High Preheat button and adjust the High Preheat Oxygen regulator for operating pressure. d. Turn on the Cut switch and close the torch valve. 4. Setup Cutting Oxygen Pressure: a. Open the cutting oxygen valve on one torch. b. Adjust Cutting Oxygen pilot regulator for cutting pressure. c. Close valve Adjust High Preheat Flame (One Torch): a. Press the High preheat button and trim the flame if necessary by adjusting the high FUEL pilot regulator for higher or lower pressure. DO NOT touch valve settings. b. Press the cut button. c. Close the torch cutting oxygen valve. 7. IGNITE Other Torches: a. With Cut switch still ON, ignite the other torches one at a time as described in step 5. b. After lighting each torch, close its cutting oxygen valve. 8. Check HIGH to LOW Transition and Set Cutting Oxygen EASE-ON: a. Press the High Preheat button, then press the Low. Open all torch cutting oxygen valves. Press the Preheat switch from Low to High and press Cut. Turn Cut OFF and Low ON two (2) or three (3) times to check that there are no flame outs or flames going seriously off-ratio in these transitions. b. If a problem occurs the Gas System must be re-tuned. During the switching process, while the cutting oxygen goes on and off, set the EASE-ON valve for desired rate of cutting oxygen pressure rise (normally 2 to 3 seconds).

39 Operation 9. Cut: a. Press the low preheat button. b. The Gas System is ready for cutting. Shut the gas system off. (Make sure all preheat and cut button lights are off.) Re-light the torches. Regulators and torch valves need not be adjusted. 5.7 OPERATIONAL CONSIDERATIONS 1. For cutting a plate of a given thickness, various tip manufacturers will recommend larger or smaller oxygen bore sizes, higher or lower operating pressures, and higher or lower speeds. These recommendations will yield varying results, depending upon whether the objective is high quality, faster speed, or minimum consumption of cutting oxygen and/or preheat gases. 2. The cutting speed achieved in practice with multi-torch cutting machines is usually lower than the speed that can be quoted in tables, primarily because steel has varying degrees of rust and scale which requires reduced speeds to maintain the cut. The boost button will help overcome this situation. It is also more difficult for the operator to maintain the proper distance from the tip to the work with several torches than it is with one (1) torch. 3. The data, in general, applies to all of the noted fuel gases if the steel is clean. Where varying degrees of rust and scale are present, reduced speed is required, and in general the hotter fuel gases will prove more effective in removing rust and scale than the cooler fuel gases. In particular, natural gas with subnormal BTU content will require substantially reduced speeds. 4. In shape cutting, it may be necessary to reduce speeds on small radii (because of draglines) in order to obtain the desired shape. 5. Tips with larger bore sizes may be used to obtain higher speeds where cutting speed is of greater importance than the cutting quality and where the larger kerf can be tolerated. 6. When bevel cutting, select the tip for actual cut depth instead of plate thickness. As the angle of the torch from perpendicular is increased, the preheat flow must also be MI0548A increased to maintain reasonable cutting speed. This applies in particular to material up to 60 to 80 mm. The thicker materials present fewer problems. 5.8 SET-UP FOR MANUAL OXY-FUEL CUT (I-CUT) The operator must know the following information. Plate thickness must be known. A customer chart should be set-up once the plate thickness, cut speeds. Tip size is also useful information. Set the I-torch(es) cutting width distance by measuring the tip to tip distance. Use the torches that are convenient for the cut. Manually lock into place using the torch carriage clamp to the steel band of the sheave assembly. Prepare the CNC for a square or rip cut, setting the direction of travel and cut speed. Press the required torch select button(s). Press the low preheat button and adjust the flame for the tip being used. Press the cut button, and adjust for proper flame and pressure for the size of the tip being used. Turn off the gases. Line up the machine to the desired pierce point. Press low preheat, the selected torches will ignite, press high preheat, set the torch distance off the top of the plate for quick preheating for piercing. When the plate is ready for piercing, press the all up to piercing height. Press cut, (high preheats will turn off). After the molten blow is through, lower the torches by pressing the all down, with the CNC, press the direction of travel. The machine will move at the set speed. Continue with the cut until you have passed the desired length. To stop the cut, press the cut button, press the low preheat button. The torch will extinguish. Stop the movement of the CNC. 37

40 Maintenance MI0548A This Page Left Intentionally Blank 38

41 Maintenance SECTION 6 MAINTENANCE MI0548A 6.1 SAFETY PRECAUTIONS 1. Shut OFF main power switch, pull fuses, or lock and red tag switch before attempting work on electrical circuits. Do not touch electrically HOT parts or those with residual voltage, wait approximately five (5) minutes before touching any electrical component. Their electric charge will be dissipated. 2. Check gas cylinder valves, regulators, hose, and torch connections regularly for leaks with a solution of 1/4 oz. liquid soap per gallon of water. 3. Always open gas valves slowly. 4. Always purge oxygen and fuel lines individually to discharge combustible mixtures before lighting each torch. Close each torch valve before opening the next one. 5. Do Not purge in the presence of flame, lit cigarettes and other sources of ignition, nor towards persons or clothing. 6. Before attempting to disassemble any part of the System, depressurize the System. Do Not disconnect any part of the System that is under pressure. 7. All parts, repaired, replaced or otherwise handled, must be cleaned for oxygen service. 8. Regularly inspect check valves and keep them in operating order. They prevent reverse flow (from torches to hoses) of hazardous mixtures of flammable gas and air (or oxygen). 9. Keep power cables dry, free of oil and grease, and protected at all times from damage by hot metal and sparks. Do Not use any power cable with worn or damaged insulation, repair or replace immediately. 10. Equipment, which is not functioning properly, should Not be used until all repairs have been completed and the equipment has been tested to ascertain that it is in proper operating condition. 11. An experienced maintenance technician must perform inspection and maintenance of equipment as indicated in this manual. 12. Warning: When welding Do Not ground to the machine, the rail system, or to the cutting table at any time to avoid damage to electronic components. Failure to follow this warning may void manufacturer's warranty. 13. Except for inspection and maintenance listed in this manual, it is recommended that all other servicing be done by an authorized Koike Aronson service technician. 14. Goggles with correct filter lenses must be worn whenever torches are lit. Suitable protective clothing must be worn where necessary. Comply with these and other safety procedures listed in this manual. Refer to appropriate manuals, furnished by the manufacturer for optional equipment. 6.2 GENERAL INFORMATION This section of the manual provides preventative maintenance procedures required for accurate and proper operation of the Versagraph MILLENNIUM cutting machine. Follow these procedures to maintain machine operation at peak efficiency and to extend the useful life of the machine. 39

42 Maintenance The machine has been assembled, properly adjusted and factory tested before shipment. Factory settings, other than those listed in the Installation section of this manual, should not be changed. If machine performance is unsatisfactory, contact a Koike Aronson authorized service representative for advice. Keep the machine clean, in good condition and free of oil, grease and other combustibles. If replacement parts are required, it is recommended that they be purchased from Koike Aronson through an authorized distributor. The manufacturer has furnished separate manuals, listing maintenance procedures. 6.3 PREVENTATIVE MAINTENANCE SCHEDULE Although this machine does not require a great deal of maintenance, the following procedures should be preformed routinely based on the section description. (Shift or Operation Hours). The following maintenance guidelines are solely the responsibility of the operator (customer) and are not covered under machine warranty neither by the Distributor nor by Koike Aronson. Failure to comply with these guidelines for your machine can result in poor cut quality, a rough running machine or service calls at the expense of the customer. CAUTION DO NOT allow any grease, which has not been approved for oxygen use come in contact with oxygen equipment EACH SHIFT 1. Blow surfaces clean with low pressure (below 30 psi) shop air. Clean or scrape off any hardened surface. Blow off rails, rollers and wheels with low pressure shop air. DO NOT USE OXYGEN. MI0548A 2. Wipe rails clean with lint free cloth. Spray LPS-1 on cloth or on rails after cleaning to leave a LIGHT FILM of LPS-1 for protective lubrication. A heavier coating will attract dust. Do Not use a petroleum base oil as it will cause dirt build up. Using a lightly lubricated cloth, such as WD-40 or LPS-1, wipe the wheels, rollers, gears and rack clean. 3. At least once each shift, remove dirt buildup from wheels on both Y- axis saddles. Scrape off buildup from wheels with the edge of steel flat bar (2mmx25mm, or pocket rule) while rolling carriage through one revolution of each wheel Remove dirt buildups from the guide rollers as follows: a. Hold a steel flat bar (2mm x 25mm, crosssection or a steel pocket rule) flat on rail edge against roller surface. b. Move the carriage in a direction away from the bar, holding the bar against the roller for at least one complete revolution to scrape off dirt build up. Ensure that the main saddle side guide rollers are adjusted properly to the side of the rail. The outside rollers are non-adjusting, the inside rollers are adjustable. See Section 6.4 for proper adjustment. 5. At least once each shift remove debris from gears and pinions using a stiff wire brush. 6. Check rail scraper pads for wear. Replace when they are worn and no longer clean the rails. 7. Smooth rail axis rail with a file removing all burrs and splatter. This may be necessary more often depending on how often you pierce thick plate with oxy/fuel. Burrs that may appear on the rails could affect cutting performance. 40

43 Maintenance 8. Wipe the torches clean and check the rack for steel splatter. Clean or replace the rack if necessary. 9. Clean and adjust igniter electrode. Replace it if point is worn flat or if the ceramic is cracked. Clean the igniter orifice (remove it to clean) EACH FORTY (40) OPERATION HOURS 1. Check gas system for leaks with soap and water solution. 2. Check for damage to the gear rack. Repair with a file or replace if damage is excessive. 3. Remove the access covers for the saddle wheels. Wipe the main wheels clean. 4. Clean, and readjust the torch holders. 5. Clean the transverse rack and planetary gear pinion EACH TWO HUNDRED FIFTY (250) HOURS 1. Grease NSK linear ball slides, on both axis with NSK approved #2 lithium grease. Fill until grease can be seem coming out of the ball slide. The grease fitting is located for accessibility to apply the grease. See Figure 6.1. NSK grease is recommended for use: Part # NSKGRSAV2 Grease Gun # NOTE: To grease the linear guides it will be necessary to use a grease fitting extension adapter such as Lincoln model number Check gas system for leaks with soap and water solution EACH ONE THOUSAND (1000) HOURS 1. With power off, ensure all exposed electrical equipment is clean and dust free. 2. Check all cutting oxygen check valves for reverse flow. MI0548A EACH TWO THOUSAND (2000) HOURS 1. Check that the Y axis motor mounts do not move in an up/down motion. If the motor mount needs adjustment, use a spanner wrench to tighten the spanner nut on the bottom of the pivot shaft until there is no up/down motion but that the motor mount can still pivot side to side. 2. Check that backlash from the motor to the gearbox is a minimum of 0.05mm. To adjust backlash, ensure the proper air pressure is applied to the cylinders for each axis. 6.4 GUIDE ROLLER ADJUSTMENT After prolonged usage, the main saddle eccentric guide rollers may require adjustment. Adjust eccentric bolts until rollers can just be turned, using thumb and forefinger, against the side of the rail. Check that all guide rollers turn easily as the machine is moved and have no vibration. 6.5 DRIVE TUNING PROCEDURE The MILLENNIUM uses an AC servo drive unit. No electrical adjustments are required. The parameters for each drive are factory set and must not be changed without consulting Koike Aronson, Inc. 6.6 GAS CONTROL SYSTEM Refer to Appendix E 6.7 CUT QUALITY TROUBLE-SHOOTING 1.Cut edges distorted or melted, the preheat may be flame too high. 2. Flame backfiring - Preheat flame too low, too close to work piece. 3. Distorted flames - Dirty cutting tip, replace or clean. 41

44 Maintenance 4. Dispersed or slanting oxygen jet - Cutting tip is dirty or distorted. 5. Cut edge is cambered toward bottom - Preheat flame too low, cutting oxygen too high. 6. Too much drag on the cut surface - cutting speed is too fast. If incoming supply pressures are correct and gas panel pressure setups are correct for the fuel gas, but torch and tip combination problems persist, contact your Koike Aronson service representative for assistance. MI0548A 7. An out of synch error may be caused by several mechanical problems. Check the following before attempting synchronization adjustment: a. Check the entire rail system for straightness. b. Check Y-axis drive racks for dents, straightness and cleanliness. Use alignment rack to check the joints for movement and wear. c. Check the planetary gear pinions for wear. d. Check side guide rollers for proper adjustment. Figure

45 Maintenance MI0548A 6.8 Battery replacement The batteries for the PLC must be replaced every two years. Replacement batteries are size AAA alkaline. a. Turn main power OFF at the Electrical enclosure at the back of the machine. (Red handle disconnect). b. Remove the enclosure door panel. WARNING: Removal and Replacement may require two people. c. Using a small adjustable wrench, turn main machine power ON. WARNING: Avoid Electrical shock. Be careful where the hands and fingers are placed. d. Follow normal machine power on procedures. e. Locate the CPU assembly for the PLC. (This is located at the lower left side of the electrical enclosure). f. A spring clip retains the CPU module to the mounting rail assembly. g. Place a small common screwdriver inside the clip and pull down. WARNING: The electrical circuit is energized. h. Grasp the module carefully and swing to the side as shown. i. Unclip the side snapped cover. This exposes the batteries. j. Replace the batteries following the polarity marked on the cover. k. Install the cover in place. Make sure the cover snaps in place. l. Place the module back to the rail assembly and clip in place. m. Turn main power OFF. n. Install the main electrical enclosure cover. o. Resume normal machine operations. 43

46 Maintenance MI0548A HELP DIAGNOSTICS TROUBLESHOOTING USINGTHE OPERATOR INTERFACE PANEL Figure 6.2 (Machine Hardware Options Screen) Pressing this button returns to the main operator screen. This screen allows the viewer to observe the hardware-configured options of the machine. An example of how to read this screen is as follows: The machine has a D80, one HT2000 with a Torch Height Control, and two oxy-fuel stations with No THC. The light for the D80 CNC PRESENT will be illuminated green, the light for T16 PLASMA 1 W/THC will be illuminated green, the light for T48 OXY-1 NO THC and T49 OXY-2 NO THC will also be illuminated green. If for some reason one of the lights is not illuminated, check the drawing for that particular option and check for the jumper. If the jumper is present, check the softwaretroubleshooting screen (HEALTH Figure 6.3) for that option. 44

47 Maintenance MI0548A Figure 6.3 (Programmable Controller Communication Screen) Pressing this button returns to the main operator screen. NOTE: Read notes 1 and 2 on this screen before resuming. To understand how to read this screen, the programmable controller and added modules are numbered Number 1 refers to the main programmable controller processor and it s light should always be illuminated yellow are the actual tools configured and should only be on if the address matches the machines configured options. Using the machine configured with, a D80, one HT2000 with a Torch Height Control, and two oxy-fuel stations with no THC. Light 1 will be illuminated, light13 (option for the D80), 16 (plasma 1 w/thc), 48 (oxy-1 no THC) and (49 oxy-2 no THC) will also be illuminated yellow. 45

48 Figure 6.4 (I/O Select Screen) This screen allows a view of all the configured options that the Millennium uses. The crimson colored keys are the currently configured I/O options. The following list of buttons represents the actual tool I/O, figure number and page number for the pressed button. Pressing this button returns to the main operator screen. Pressing this button goes to the Local Machine I/O diagnostics screen such as limit switches, beacon light etc. See Figure 6.5, page 44. Pressing this button goes to the Servo Motor Control I/O diagnostics screen such as drive inhibit, X alarm etc. See Figure 6.6, page 45. Pressing this button goes to the Promotion 2000 and the D80 CNC I/O diagnostics screen. See Figure 6.7, page 46. Pressing this button goes to the Burny 5 and Burny 10 CNC I/O diagnostics screen. See Figure 6.8, page

49 Maintenance Pressing this button goes to the T16 I/O diagnostics screen (Plasma1 w/thc). See Figure 6.9, page 48. Pressing this button goes to the T17 I/O diagnostics screen (Plasma2 w/thc). See Figure 6.10, page 50. Pressing this button goes to the T18 I/O diagnostics screen (Plasma3 w/thc). See Figure 6.11, page 51. Pressing this button goes to the T19 I/O diagnostics screen (Plasma3 w/thc). page 52. See Figure 6.12, Pressing this button goes to the T32 I/O diagnostics screen (Air Scribe). See Figure 6.13, page 53. Pressing this button goes to the T36 I/O diagnostics screen (Arc Writer 1 w/thc). See Figure 6.14, page 54. Pressing this button goes to the T40 I/O diagnostics screen (Oxy-Fuel 1 w/thc). See Figure 6.15, page 56. Pressing this button goes to the T41 I/O diagnostics screen (Oxy- Fuel 1 w/thc). See Figure 6.16, page 58. Pressing this button goes to the T48 I/O diagnostics screen (Oxy- Fuel 1 no/thc). See Figure 6.17, page 58. Pressing this button goes to the T49 I/O diagnostics screen (Oxy- Fuel 2 no/thc). See Figure 20, page MI0548A Pressing this button goes to the T50 I/O diagnostics screen (Oxy- Fuel 3 no/thc). See Figure 6.19, page 62. Pressing this button goes to the T51 I/O diagnostics screen (Oxy-Fuel 4 no/thc). See Figure 6.20, page 63. Pressing this button goes to the T52 I/O diagnostics screen (Oxy- Fuel 5 no/thc). See Figure 6.21, page 64. Pressing this button goes to the T53 I/O diagnostics screen (Oxy-Fuel 6 no/thc). See Figure 6.22, page 65. Pressing this button goes to the T54 I/O diagnostics screen (Oxy- Fuel 7 no/thc). See Figure 6.23, page 66. Pressing this button goes to the T55 I/O diagnostics screen (Oxy-Fuel 8 no/thc). See Figure 6.24, page 67. Pressing this button goes to the T56 I/O diagnostics screen (Oxy-Fuel 9 no/thc). See Figure 6.25, page 68. Pressing this button goes to the T57 I/O diagnostics screen (Oxy-Fuel 10 no/thc). See Figure 6.26, page 69. Pressing this button goes to the T59 I/O diagnostics screen (Arc Writer 1 no/thc). See Figure 6.27, page 70. Pressing this button goes to the T64 I/O diagnostics screen (Drill). See Figure 6.28, page 72.

50 Figure 6.5 (Local Machine Diagnostics I/O Screen) Pressing this button returns to the main operator screen. Pressing this button returns to the I/O Select screen. To understand how to read this screen, the Machine requires discrete inputs and outputs to run. These are listed on Figure 6.5. Under the Input side, the MCR, +X LIMIT, -X LIMIT, +Y LIMIT and -Y LIMIT lights should all be illuminated green. If the light is not illuminated, check the physical status of each, then I/O module one, reference drawing for the location of the module. Under the output side the MACH READY LT (GREEN) on the light tower indicates that there are no problems with the machine and is ready for operation. The MACH IN CYCLE LT (AMBER) indicates the machine may be waiting for the main arc signal from the plasma system. The MACH STOPPED LT (RED) indicates that a problem exists. Reference drawing for more information. 48

51 Maintenance MI0548A Figure 6.6 (Servo Communication Diagnostics I/O Screen) Pressing this button returns to the main operator screen. Pressing this button returns to the I/O Select screen. To understand how to read this screen, the main programmable controller module communicates with AC servo drives with discrete inputs and outputs. The inputs are wired from the drives to the programmable controller. For example if the drive senses a fault, the alarm signals the programmable controller. The programmable controller will then turn on an output for the tower to illuminate the RED light. A message will also appear on the main operator s screen. The outputs are wired from the programmable controller to the drives. The GREEN light illuminated on the tower indicates that all is well with the machine and is ready for a drive command from the CNC. The INTROLOC RUN MODE (SYNCH) indicates that a third axis inhibit for synchronization is required. The signal is used with Burny CNC controls. 49

52 Maintenance MI0548A Figure 6.7 (CNC 1 Diagnostics I/O Screen) Pressing this button returns to the main operator screen. Pressing this button returns to the I/O Select screen. This screen, is divided into two sections one side is for the Promotion 2000 and the other side is for the D80. These are options T10 and T13. With the programmable controller hardwired for the T13 option, the D80 PRESENT and the CNC SINK I/O lights will be illuminated. Remember these are the inputs and outputs to the programmable controller. The inputs correspond to the outputs of the D80, so that an output cut signal from the D80 will turn on the input of the Module for CUT CMD. Likewise, the outputs viewed from the programmable controller on this screen are connected to the inputs of the D80 or other CNC. 50

53 Figure 6.8 (CNC 2 Diagnostics I/O Screen) Pressing this button returns to the main operator screen. Pressing this button returns to the I/O Select screen. This screen is divided into two sections, one side is for the Burny 5 and the other side is for the Burny 10. These are options T15 and T10. With the programmable controller hardwired for the T15 option, the Burny 5 PRESENT and the CNC SINK I/O lights will be illuminated. Remember these are the inputs and outputs to the programmable controller. The inputs correspond to the outputs of the Burny 5, so that an output cut signal from the Burny 5 will turn on the input of the Module for CUT CMD. Likewise, the outputs viewed from the programmable controller on this screen are connected to the inputs of the Burny 5 or other CNC. 51

54 Figure 6.9 (Tool 16 Plasma 1 Diagnostics I/O Screen) Pressing this button returns to the main operator screen. Pressing this button returns to the I/O Select screen. To understand how to read this screen, reference drawing The following is brief description of what the I/O indicates. 52

55 INPUTS Indicates that tool 16 is present and enabled. Indicates that the plasma system requires a pulse start/stop. Indicates that the safety mount is present and enabled or the jumper is installed. Indicates that the tool is not over the burn table and cannot be enabled. This signal is used for a pulse start/stop plasma system such as the KPS 200. The maintained signal from the CNC is sent to the programmable controller to the height control. The height controls plasma start is then sent back to the programmable controller for a pulse start out to the plasma system. With the light illuminated, indicates the programmable controller has received the main arc signal (CSR) from the plasma system. Torch IHS is used with multiple plasma systems. The programmable controller holds the start to the plasma systems until all the height controls complete IHS. Proximity switch input for torch up. Normally used in systems with no IHS. OUTPUTS Output to the height control to start the plasma. Output to height control to disable the plate tracking. Normally used in corners, sharp angles or in small diameter holes. Used with multiple Hypertherm power supplies with multiple height controls. This signal comes on when the height controls have all completed IHS and are ready to ignite. Output for pulse start plasma systems such as the KPS 200. Output for pulse stop plasma systems such as the KPS 200. Used with Thermal Dynamics power supplies that have no IHS. Note: The descriptions above are good for the T17, T18 and T19 Plasma I/O screens. 53

56 Figure 6.10 (Tool 17 Plasma 2 Diagnostics I/O Screen) Pressing this button returns to the main operator screen. Pressing this button returns to the I/O Select screen. 54

57 Figure 6.11 (Tool 18 Plasma 3 Diagnostics I/O Screen) Pressing this button returns to the main operator screen. Pressing this button returns to the I/O Select screen. 55

58 Figure 6.12 (Tool 19 Plasma 4 Diagnostics I/O Screen) Pressing this button returns to the main operator screen. Pressing this button returns to the I/O Select screen. 56

59 Figure 6.13 (Tool 32 Air Scribe Diagnostics I/O Screen) Pressing this button returns to the main operator screen. Pressing this button returns to the I/O Select screen. Inputs Indicates that tool 32 is present and enabled. Indicates that the tool is enabled. not over the burn table and cannot be Outputs Indicates that the output to lower the scribe solenoid is on. Indicates that the output to turn the scribe marking solenoid is on. 57

60 Figure 6.14 (Tool 36 Arcwriter w/thc Diagnostics I/O Screen) Pressing this button returns to the main operator screen. Pressing this button returns to the I/O Select screen. Inputs Indicates that tool 36 is present and enabled. Indicates that the jumper is present and to start and stop the plasma requires a pulse. Indicates that the safety mount is present or the jumper is present. Indicates that the tool is not over the burn table and cannot be enabled. Note: If the tool is mounted on the master carriage this error should never occur. 58

61 Indicates the arc from the power supply has been received. Indicates that the IHS signal from the height control has been received. Indicates the torch has raised to the full up position. Usually a proximity switch input. Outputs Indicates that the output to start the arcwriter. Indicates that the output for corner disable is on. Indicates that this output binary code control bit for the arcwriter current setting is on. Indicates that this output binary code control bit for the arcwriter current setting is on. Indicates that this output binary code control bit for the arcwriter current setting is on. Indicates that this output binary code control bit for the arcwriter current setting is on. Indicates that this output binary code control bit for the arcwriter current setting is on. 59

62 Figure 6.15 (Tool 40 Oxy-fuel 1w/THC Diagnostics I/O Screen) Pressing this button returns to the main operator screen. Pressing this button returns to the I/O Select screen. Inputs Indicates that tool 40 is present and enabled. Indicates that option for pulse ignition is in place. Indicates that the safety mount is present or the jumper is in place. Indicates that the tool is not over the burn table and cannot be enabled. Note: If the tool is mounted on the master carriage this error should never occur. 60

63 Maintenance MI0548A Indicates that the flame at the torch station has been detected and that if the flame should extinguish during the cut the individual solenoids for cut and preheat will shut off. Indicates that a proximity switch input was sensed for torch down. Indicates that a proximity switch input was sensed for torch up. Indicates that the input from the capacitive height sensor control unit was sensed. The ring for that station was touched. Using the auto height sensor this input indicates that the torch has reached the cutting height set at the amplifier unit. Outputs Indicates that the switch input was sensed from the torch control unit indicating that auto plate sensing is enabled. Output indicating that the cut oxygen for the torch station is on. Output indicating that the preheat fuel and oxygen for the torch station is on. Output indicating that the water spray for the torch station is on. The output should only come on when oxy-fuel cut is on. Output to the torch station for ignition. Output to the torch station for the high voltage transformer. Output to enable the automatic height control for the oxy-fuel station. Output to raise the torch. Output to lower the torch. 61

64 Maintenance MI0548A Figure 6.16 (Tool 41 Oxy-fuel 1w/THC Diagnostics I/O Screen) Pressing this button returns to the main operator screen. Pressing this button returns to the I/O Select screen. 62

65 Maintenance MI0548A Figure 6.17 (Tool 48 Oxy-fuel 1 NO THC Diagnostics I/O Screen) Pressing this button returns to the main operator screen. Pressing this button returns to the I/O Select screen. Inputs Indicates that tool 48 is present and enabled. Indicates that option for pulse ignition is in place. Indicates that the safety mount is present or the jumper for this option is in place Indicates that the tool is not over the burn table and cannot be enabled. Note: If the tool is mounted on the master carriage this error should never occur. 63

66 Indicates that the flame at the torch station has been detected and that if the flame should extinguish during the cut the individual solenoids for cut and preheat will shut off. Indicates that a proximity switch input was sensed for torch down. Indicates that a proximity switch input was sensed for torch up. Outputs Output indicating that the cut oxygen for the torch station is on. Output indicating that the preheat fuel and oxygen for the torch station is on. Output indicating that the water spray for the torch station is on. The output should only come on when oxy-fuel cut is on. Output to the torch station for ignition. Output to the torch station for the igniters high voltage transformer. Output to raise the torch. Output to lower the torch. NOTE: For tools 49 through 57 the above description is the same. 64

67 Maintenance MI0548A Figure 6.18 (Tool 49 Oxy-fuel 2 NO THC Diagnostics I/O Screen) Pressing this button returns to the main operator screen. Pressing this button returns to the I/O Select screen. 65

68 Figure 6.19 (Tool 50 Oxy-fuel 3 NO THC Diagnostics I/O Screen) Pressing this button returns to the main operator screen. Pressing this button returns to the I/O Select screen. 66

69 Figure 6.20 (Tool 51 Oxy-fuel 4 NO THC Diagnostics I/O Screen) Pressing this button returns to the main operator screen. Pressing this button returns to the I/O Select screen. 67

70 Figure 6.21 (Tool 52 Oxy-fuel 5 NO THC Diagnostics I/O Screen) Pressing this button returns to the main operator screen. Pressing this button returns to the I/O Select screen. 68

71 Figure 6.22 (Tool 53 Oxy-fuel 6 NO THC Diagnostics I/O Screen) Pressing this button returns to the main operator screen. Pressing this button returns to the I/O Select screen. 69

72 Figure 6.23 (Tool 54 Oxy-fuel 7 NO THC Diagnostics I/O Screen) Pressing this button returns to the main operator screen. Pressing this button returns to the I/O Select screen. 70

73 Figure 6.24 (Tool 55 Oxy-fuel 8 NO THC Diagnostics I/O Screen) Pressing this button returns to the main operator screen. Pressing this button returns to the I/O Select screen. 71

74 Figure 6.25 (Tool 56 Oxy-fuel 9 NO THC Diagnostics I/O Screen) Pressing this button returns to the main operator screen. Pressing this button returns to the I/O Select screen. 72

75 Figure 6.26 (Tool 57 Oxy-fuel 10 NO THC Diagnostics I/O Screen) Pressing this button returns to the main operator screen. Pressing this button returns to the I/O Select screen. 73

76 Figure 6.27 (Tool 59 Arcwriter 1NO THC Diagnostics I/O Screen) Pressing this button returns to the main operator screen. Pressing this button returns to the I/O Select screen. Inputs Indicates that tool 59 is present and enabled. Indicates that the tool is not over the burn table and cannot be enabled. Note: If the tool is mounted on the master carriage this error should never occur. Indicates that a proximity switch input was sensed for torch down. Indicates that a proximity switch input was sensed for torch up. 74

77 Indicates the arc from the power supply has been received. Outputs Indicates the output to the solenoid for lowering the arcwriter is on. Indicates that this output binary code control bit for the arcwriter current setting is on. Indicates that this output binary code control bit for the arcwriter current setting is on. Indicates that this output binary code control bit for the arcwriter current setting is on. Indicates that the output to start the arcwriter is on. Indicates that this output binary code control bit for the arcwriter current setting is on. Indicates that this output binary code control bit for the arcwriter current setting is on. 75

78 Replacement parts MI0548A Figure 6.28 (Tool 64 Drill Diagnostics I/O Screen) Pressing this button returns to the main operator screen. Pressing this button returns to the I/O Select screen. Indicates that tool 64 is present and enabled. Indicates that the drill up proximity switch is enabled. Outputs Indicates that the tool is not over the cutting area and cannot be enabled. Indicates that the drill output is on and to start the drill cycle. Indicates that the drill cycle stop output is on and retract the drill to the up proximity switch. 76

79 Replacement parts MI0548A SECTION 7 REPLACEMENT PARTS To assure minimum down time, it is recommended that spare parts noted by an asterisk * in the Part No. column of the parts list be kept on hand. To assure proper operation, it is recommended that only genuine KOIKE ARONSON parts and products be used with this equipment. Please Note: Koike Aronson / Ransome has manufactured many different revisions of all machines over the past 60 years. All part numbers and descriptions in this manual are subject to change without notice; they are provided for reference only. All replacement part numbers should be verified by the Koike Aronson / Ransome Service Department at , Extension 470 prior to order. The Sales Order Number and Serial Number of your machine will be required when the Service Department is contacted. This will ensure that the correct replacement parts are provided for your particular machine. To order replacement parts: a. Provide Sales Order (SO#), serial number and model of equipment from the Serial Tag located on the main beam. b. Provide part number, description and quantity of part. c. Indicate any special shipping instructions. Air Regulator Enclosure Servo Gas Panel Main Electrical Enclosure Manifold Assembly Enclosure X-axis Drive Assembly Transverse Nylatrac Assembly Plasma/High Frequency Enclosure I- Torch Station w/g lifter Slave Carriage Main Valve Enclosure Plasma Control Options Transverse Beam Operators Control Console Y2-axis Y1-axis or Rail axis H-Beam Assembly CNC w/operator Touch Panel Cutting Table Rail Axis Cable Carrier (Optional Location) Figure 7.1 Typical Machine Component Locations 77

80 Replacement parts MI0548A Front of Servo Gas Panel Figure 7.2 a Note: Only Major Components are listed. Item Number Part Number Part Description Quantity Servo Gas Panel w/o Ignition Pressure Gauge, 4, 0-30psi Pressure Gauge,4, 0-200psi Regulator, Fuel Regulator, Oxygen 3 78

81 Replacement parts MI0548A Approximate Solenoid L HI 6 8 L 7 HI Ease -on CUT Figure 7.2 b Note: Only Major Components are listed. Item Number Part Number Part Description Quantity 6 * Solenoid Valve, Oxygen, NC 5 7 * Solenoid Valve, Oxygen, 3-way 1 8 * Solenoid Valve, Oxygen, NO 4 79

82 Replacement parts MI0548A Cut/Ease-on Oxygen Section Panel Face Gauge Figure 7.2 c Note: Only Major Components are listed. Item Number Part Number Part Description Quantity Adapter, 1/2 F-1/4 M Street Ell,1/ Snubber Gauge,1/ Tee, 1/ Outlet Bushing, 1/4x A L/H Nipple Hex, 1/4 Short Strainer, Asco, 8600A Check Valve,1/4 NPT Flow Control Valve, 1/8 NPT Street Ell 1/4, F-1/8 M Street Tee, 1/ Pipe Plug, 1/4 Hex 1 80

83 Replacement parts MI0548A High Preheat Gauge Panel Face Figure 7.2 d Note: Only Major Components are listed. Item Number Part Number Part Description Quantity Outlet Bushing, 1/4"x A L/H Street Tee, 1/ Pipe Plug, 1/4 Hex Adapter, 1/2 F-1/4 M Cross,1/4 1 81

84 Replacement parts MI0548A Low Preheat Oxygen Section 24 Panel Face 23 Figure 7.2 e Note: Only Major Components are listed. Item Number Part Number Part Description Quantity Nipple, Hex, 1/4 x Valve, Metering, 1/4 Globe 2 82

85 Replacement parts MI0548A High Preheat Fuel Section Panel Face Gauge Figure 7.2 f Note: Only Major Components are listed. Item Number Part Number Part Description Quantity Adapter, 1/2 F-1/4 M Strainer, Asco, 8600A Outlet Bushing, 1/4 x A L/H 6 83

86 Replacement parts MI0548A Low Preheat Fuel Section 24 Panel Face Figure 7.2 g Note: Only Major Components are listed. Item Number Part Number Part Description Quantity Check Valve,1/4 NPT Street Tee, 1/ Valve, Metering, 1/4 Globe Outlet Bushing, 1/4 x A L/H Adapter, 1/2 F-1/4 M 1 84

87 Replacement parts MI0548A Main Valve Assembly (Located on the side of the main valve enclosure) 1 Oxygen Fuel 3 Air Figure 7.3 Note: Only Major Components are listed. Item Number Part Number Part Description Quantity MAIN VALVE ASSEMBLY Ball Valve, 1/2NPT 2 3 * Solenoid Valve, 1//2NPT 1 4 * Solenoid Valve, 1//2NPT Outlet Bushing 1/2C R/H Outlet Bushing 1/2C L/H Ball Valve, 1/4NPT Needle Valve, 1/4NPT Branch Tee, 1/4NPT x6mm 1 85

88 Replacement parts MI0548A Manifold Assembly Ignition (Option) Figure 7.4 Note: Only Major Components are listed. Item Number Part Number Part Description Quantity MANIFOLD ASSEMBLY Muffler, 1/2 1 2 * Solenoid Valve, 1/2 Oxygen Outlet Bushing, 1/4 B R/H Outlet Bushing, 1/4 A R/H 5 5 * Dome Regulator, 1/ Outlet Bushing, 1/2 x C R/H Strainer Outlet Bushing, 1/4 B L/H 18 9 * Solenoid Valve, 1/2 Fuel Outlet Bushing, 1/2 x C L/H Outlet Bushing, 1/4 A L/H (a) Igniter Manifold Assembly 86

89 Replacement parts MI0548A Drive Assembly 1 Rail1, 2 Drive Assembly 2 Transverse Drive Assembly 4 3 Figure 7.5 Note: Only Major Components are listed. Item Number Part Number Part Description Quantity DRIVE UNIT 1 1 CONSULT FACTORY Motor/Gear unit 3 2 *CONSULT FACTORY Pinion (Gear unit) 3 3 CONSULT FACTORY Air Cylinder 2 stroke 3 4 CONSULT FACTORY 90 Deg. Elbow, 1/8NPT 12 87

90 Replacement parts MI0548A Main Wheel and Guide Assembly Reference: 22Kg rail Figure 7.6 Note: Only Major Components are listed. Two assemblies are required for the main saddle assembly. Outboard saddle assembly does not require guide rollers. Quantities for parts listed are for both assemblies. Item Number Part Number Part Description Quantity Main Roller Assy., 10 Dia Roller, 10 x Axle Shaft, 50mmx Clamp Collar, MCL-50F Bearing, Ball, #6304DD Eccentric Shaft, Side Roller Bearing, Ball, # Washer, Shim, 2.25 Diameter x 1/ Bolt, Shoulder, M20x

91 Replacement parts MI0548A Transverse Carriage Assembly 1 Figure 7.7 Note: Only Major Components are listed. Item Number Part Number Part Description Quantity Transverse Carriage Ball Slide w/scraper 4 89

92 Replacement parts MI0548A Steel Belt Unit Figure 7.8 Note: Only Major Components are listed. Item Number Part Number Part Description Quantity XX Steel Belt Unit Pulley Bearing, Ball 6006ZZ Felt,.25x2.12x XX Steel Belt ** Pulley Unit 2 ** The part number varies for the length of the steel band depending on the beam width. 90

93 Replacement parts MI0548A Typical Slave Station Figure 7.9 Note: Only Major Components are listed. Item Number Part Number Part Description Quantity Slave Station (#1) ** Torch Lifter G Junction Box, Molded Cord Set 6CKT, 10Meter Cable Prox Switch, N.O. Turck Bi2- M12-AD4X-H Steel Band Clamp Assy Ball Slide, NSK LAS20ALZ- K2+Scraper 4 6 ZS60200 Torch Support 1 7 ZS61108 Torch Holder 1 8 ZA L Oxy-Torch Solenoid Valve, Cut Oxygen 1 10 ZA Check Valve, Fuel Check Valve, Oxygen Flow Orifice, #56 1 ** Part number for the slave station will change depending on the number of torches on the machine. 91

94 Replacement parts Section 1.01 F ront Panel MI0548A QUICKPANEL III Figure 7.10a Note: Only Major Components are listed. Item Number Part Number Part Description Quantity Front Panel Electrical 1 CONSULT FACTURY Smart Screen Operator Interface, Color, CONSULT FACTURY Contact Block N.O. 2 3 CONSULT FACTURY Contact Block w/lamp 120vac 2 4 CONSULT FACTURY Push Button, Green 2 5 CONSULT FACTURY Contact Block N.C. 2 6 CONSULT FACTURY Push Button, Red 1 7 CONSULT FACTURY E-Stop Push Button, Red Mushroom Head 1 92

95 Replacement parts MI0548A Front Electrical Panel (continued) 8 9 Figure 10B Note: Only Major Components are listed. Item Number Part Number Part Description Quantity 8 CONSULT FACTURY Cable Connector 10 9 CONSULT FACTURY Terminal Block 12 Not Shown CONSULT FACTURY Modbus+ Network Cluster Tee Adapter 1 Not Shown CONSULT FACTURY Communications adapter, Modbus+ 1 Not Shown CONSULT FACTURY Adapter, Modbus RJ45 to 9pinD 1 93

96 Replacement parts MI0548A This Page Left Intentionally Blank 94

97 Replacement parts MI0548A Station Gas Control Figure 7.11 Note: Only Major Components are listed. Item Number Part Number Part Description Quantity Station Gas Control 1 * Solenoid Valve, Fuel 1 2 * Solenoid Valve, Oxygen Cable, 18/3 (Alpha2423C) 25 95

98 Replacement parts MI0548A Rail Blower Assembly Figure 7.12 Note: Only Major Components are listed. Item Number Part Number Part Description Quantity Rail Air Blower Assembly Manifold Block,3/4X1X Elbow, Tube 1/4tube-1/8NPT Nozzle,Air,1/4 Copper Tube 8 96

99 Replacement parts MI0548A Typical Air Supply Panel 1 Air Supply For Safety Mount Plasma 2 2 Air Supply For Safety Mount Plasma 1 Air Supply From Main Valve 3 Air Supply For Drives Engage/Disengage Figure 7.13 Note: Only Major Components are listed. Item Number Part Number Part Description Quantity Transformer,1phase,2Kva 1 2 K Filter Regulator Kit ** Regulator/Filter,1/4NPT *** Solenoid Valve 3 97

100 Replacement parts MI0548A Section 1.02 ail See Figure 7.14a See Figure 7.14b NOTE: IF USING KAR SUPPLIED H BEAMS, ITEMS 3 AND 4 ARE NOT REQUIRED. 4 See Figure 7.14c Figure 7.14a Note: Only Major Components are listed. Item Number Part Number Part Description Quantity XX Rail Assembly Rail Rack, 1000mm 3 K Rail Adjuster Kit, Mid 4 K Rail Adjuster Kit, Joint 98

101 Replacement parts MI0548A Machine Stopper Figure 7.14 b Note: Only Major Components are listed. Item Number Part Number Part Description Quantity 1 ZM Stopper Flat Washer, M Lock Washer, M Nut, Hex, M HHCS,M16x60 4 Rail Adjuster, Mid Note: Only Major Components are listed Figure 7.14 c Item Number Part Number Part Description Quantity K Rail Adjuster, Mid Rail Adjuster, Mid, Machine 1 2 ZM60236 Retaining Dog 2 3 ZM60235 Retaining Washer HHCS, M12x60 Full Thread Nut, Hex, M HHCS, M12x HHCS, M12x Flat Washer, M

102 Replacement parts MI0548A Rail Adjuster, Joint Figure 7.14 d Note: Only Major Components are listed. Item Number Part Number Part Description Quantity K Rail Adjuster, Joint Rail Adjuster, Joint, Machine 1 2 ZM60236 Retaining Dog 4 3 ZM60235 Retaining Washer HHCS, M12x60 Full Thread Nut, Hex, M HHCS, M12x HHCS, M12x Flat Washer, M Joint Fitting, A Joint Fitting, B HHCS, M10x

103 Replacement parts MI0548A Item Number Part Number Part Description Quantity PLC Processor, Momentum, 256K Memory Option Adapter I/O Base, 10 Input, 24VDC 8outputs I/O /Connector to Terminal Converter Servo Amplifier 3 6 CONSULT Encoder Feedback Cable,10M FACTURY 3 7 CONSULT Inductive Reactive Filter, 3Phase, FACTURY 45Amp,.3mH Fuse, 250VAC, 30Amp Class J (FU1,FU2) 2 101

104 Replacement parts MI0548A Parts Continued Item Number Part Number Part Description Quantity Fuse, 250VAC, 10Amp, Slowblow (FU3,FU4) Fuse, 120VAC, 375 ma, 3/8 2 (FU403,FUxx3) (See Note 1) Fuse, 120VAC, 2 AMP, (FU5) Fuse, 120VAC, 1AMP, 2 (FU404,FUxx4) (See Note 1) Power Supply, 24VDC, 2AMP Relay, 24VDC, 1 Pole (See Note 3) Relay, 24VDC, 4 Pole Idec #RH4B-UDC Circuit Breaker, 20AMP, 1Pole Circuit Breaker, 8AMP, 2Pole, 250VAC Circuit Breaker, 6AMP, 1Pole, 240VAC Circuit Breaker, 10AMP, 1Pole, 240VAC Circuit Breaker, 2AMP, 1Pole, 240VAC 2 Note1: Note2: Note3: The number of fuses will vary depending on the number of options for the machine. The number of I/O bases will vary depending on the number of options for the machine. The number of relays to the machine will vary depending on the type of options for the machine. 102

105 MI0548A APPENDIX A VERSAGRAPH MILLENNIUM List of Terms and Abbreviations Abbreviation Term ie That is for example etc And so forth oxy Oxygen CGA Compressed Gas Association CSA Canadian Standards Association No. Number amp(s) Ampere(s) mm Millimeter kpa Kilopascals psi Pounds Per Square Inch M Meter NEC National Electric Code AC Alternating Current Hz Hertz R/H Right Hand L/H Left Hand INC. Incorporated E-Stop Emergency Stop in Inches Inches BTU British Thermal Units oz Ounces vdc Volts direct current PWM Pulse Width Modulator cw Clockwise ccw Counter-Clockwise DVM Digital Volt Meter TP Test Point ipm Inches per Minute SO# Sales Order Number NG Northrup Grumman NC Normally Closed NO Normally Open --F Female --M Male NPT National Pipe Thread dia. Diameter MFD Microfirad Recpt Receptacle Amph Aphenol HHCS Hex Head Cap Screw A-1

106 A-2 MI0548A

107 This Page Left Intentionally Blank MI0548A

108 MI0548A APPENDIX B MODEL G SERIES TORCH LIFTERS B-1

109 MI0548A TABLE OF CONTENTS SECTION 1 SAFETY PRECAUTIONS... B-4 Section 1.1 General Safety, Oxy/Fuel Cutting... B-4 Section 1.2 General Safety, Plasma Cutting... B-5 SECTION 2 INTRODUCTION... B-7 Section 2.1 Scope... B-7 Section 2.2 Description... B-7 Section 2.3 Specifications... B-7 SECTION 3 INSTALLATION... B-8 Section 3.1 Installation G6 - G12... B-8 Section 3.2 Installation GP6 - GP12... B-8 SECTION 4 MAINTENANCE... B-11 Section 4.1 Safety Precautions... B-11 Section 4.2 General Information... B-11 Section 4.3 Daily Routine Maintenance... B-11 Section 4.4 Monthly Routine Maintenance... B-11 Section 4.5 Electrical Maintenance... B-15 Section 4.6 Mechanical Maintenance... B-15 SECTION 5 REPLACEMENT PARTS... B-19 SECTION 6 OPTIONAL ACCESSORIES... B-22 B-2

110 MI0548A ILLUSTRATIONS & TABLES Figure 3.1 Model G Lifter Installation... B-9 Figure 3.2 Model GP Lifter Installation... B-10 Figure 4.1 Lifter Shaft Extended... B-12 Table 4.1 Troubleshooting Guide... B-13 Figure 4.2 Adjustment Assembly... B-16 Figure 4.3 Motor & Coupling Assembly... B-17 Figure 4.4 Wiring Diagram... B-17 Figure 4.5 Lifter Cable Configuration... B-18 Figure 4.6 Ball screw Replacement... B-18 Figure 5.1 Model G Parts Breakdown... B-20 Figure 5.2 Model GP Parts Breakdown... B-21 Figure 6.1 Short Torch Support... B-23 Figure 6.2 Long Torch Support... B-23 Figure 6.3 Manual Torch Holder, Small Handle... B-24 Figure 6.4 Manual Torch Holder, Large Handle... B-24 Figure 6.5 Manual Torch Holder, 1-3/8" Oxy/Fuel or Plasma Torch... B-25 Figure 6.6 Torch Fore-Aft Adjuster... B-25 B-3

111 MI0548A SECTION 1 SAFETY PRECAUTIONS USER RESPONSIBILITY - This equipment will perform in conformity with the description thereof in this manual and accompanying labels and/or inserts when installed, operated, maintained and repaired in accordance with the instructions provided. This equipment must be checked periodically. Defective equipment should not be used. Parts that are broken, missing, plainly worn, distorted or contaminated should be replaced immediately. Should repair or replacement become necessary, Koike Aronson recommends that a request for service be made to a Koike Aronson Inc. Authorized Distributor from purchased or directly to the Koike Aronson Inc. Service Department. This equipment or any of its parts should not be altered without prior written approval of Koike Aronson. The user of this equipment shall have sole responsibility for any malfunction which results from improper use, faulty maintenance, damage, improper repair or alteration by anyone other than Koike Aronson or a facility designated by Koike Aronson. NOTES, CAUTIONS & WARNINGS Throughout this manual, notes, cautions, and warnings are used to describe situations 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 in operating the cutting system. Caution: A caution describes a situation that may cause damage to the lifter and offers advice to avoid or rectify the situation. WARNING A warning describes a situation that presents a physical danger to the operator, and offers advice to avoid or rectify the situation. 1.1 GENERAL SAFETY, OXY/FUEL CUTTING Operation of oxy/fuel torches involves oxygen and flammable gases under pressure, open flames, flying slag and hot metal, fumes and combustion products. Follow the precautions in this General Safety Section as well as those throughout this manual for your personal safety and the safety of personnel in the area that may be affected. 1. Check gas and electrical connections for tightness after installation and on a regular basis thereafter. 2. Keep combustibles away from the work area or protect them from sparks and flames. 3. Check for proper function of check valves regularly. Do not remove or bypass check valves. B-4

112 4. Always open gas valves slowly. 5. Never, use oxygen to ventilate the area or to clean off clothing. 6. Keep oil, grease, and combustible dust away from all oxygen equipment. 7. Purge oxygen and fuel lines individually whenever combustible mixtures in the lines are suspected. 8. Never, use the oxygen hose for any other gas than oxygen. 9. Replace hose that is damaged by physical abuse or by sparks, heat or open flame. 10. Examine hoses at regular intervals for leaks, wear, loose connections or other hazards. 11. Examine hoses at daily intervals for leaks, wear, loose connections or other hazards. 12. Coil excess hose and place it out of the way to prevent damage and to eliminate tripping danger. 13. Maintain all pressure regulators in proper working condition. 14. Never, use a regulator for any gas other than that for which it is intended. 15. Never, use a regulator that leaks, creeps excessively or is physically damaged in any way. 16. Never, attempt to lubricate a regulator with oil or grease. 17. Wear filter-lens safety eye protection. Wear gauntlet gloves, safety shoes, flame retardant clothing, and no-cuff trousers. Do not wear loose clothing around this machinery as they can catch on the machine. 18. Shut off power and gas supplies whenever leaving machine unattended or before servicing. MI0548A 19. Keep equipment clean and in good operating condition. 20. Read and understand further detailed safety precautions throughout this manual. 21. Also, refer to the latest revisions of the following sources of safe practices in welding and cutting. A. National Fire Protection Association Standard 51B CUTTING AND WELDING PROCESS, obtainable from NFPA, Batterymarch Park, Quincy, MA B. NFPA Standard 51, OXYGEN/FUEL GAS SYSTEMS FOR WELDING AND CUTTING, obtainable same as item A. C. American Welding Society publication C4.2-90, OPERATOR'S MANUAL FOR OXY/FUEL GAS CUTTING, obtainable from AWS, Box , Miami, FL GENERAL SAFETY, PLASMA CUTTING Plasma Arc cutting is a high intensity source of visible light emission as well as ultraviolet and infrared radiation. It can cause severe eye damage and inflict burns on exposed skin when suitably protected. Follow the precautions in this General Safety Section and read the supplied plasma equipment instruction manual for additional and more detailed safety precautions. 1. Facilities should be available for the medical treatment of arc flashes or burns to the eyes. 2. Provide radiation protection for the operator and for personnel in the adjacent area. 3. Do not, under any circumstances, look at a plasma arc without full eye protection. When near plasma cutting equipment always wear flash goggles with side shields and containing suitable filter lenses. B-5

113 4. The operator must use in addition to flash goggles, a suitable helmet for eye and face protection when cutting. The helmet must be equipped with a filter plate as indicated: Arc Current Up to 100 Amps Shade No. 8 Arc Current 100 to 200 Amps Shade No. 10 Arc Current 200 to 400 Amps Shade No. 12 Arc Current Over 400 Amps Shade No Do not use a helmet or hand shield that is not in good condition. Repair or replace promptly. Protect colored filter plates with a clear glass cover plate. 6. Warn other people in the area not to look directly at the arc unless they wear glasses/goggles or a helmet. 7. Never, start the plasma arc without determining that nearby personnel are wearing adequate protective equipment. 8. All areas of the body must be covered by dark substantial clothing (preferably flame retardant) to protect against arc burn, sparks and flying hot metal. 9. The plasma operation should be located in an area where protection for other personnel may be readily provided. Portable non-combustible reflecting screens or enclosures with nonreflecting walls may be used. Screens and enclosures should permit free circulation of air at floor level. 10. Remove combustible material from the immediate cutting area. 11. Quench freshly cut metal or allow metal to cool before handling it or bringing it in contact with combustible materials. MI0548A 12. To prevent electric shock keep your body and clothing dry. 13. Do not stand in, sit on or lie on any wet surface when using the plasma system. 14. Maintain proper insulation against electrical shock. If you must work in or near a damp area, use extreme caution. wear insulated gloves 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 and returning the retaining cap to its operating position, plug the power supply in again. 17. Never, bypass or shortcut the safety interlocks. 18. Plasma cutting operation noise levels may be high enough to require ear protection for the operator and other personnel in the adjacent area. 19. When using a water table while plasma arc cutting plate, especially aluminum or magnesium may cause an accumulation of explosive gas below the plate. Do not allow aluminum or magnesium dross to accumulate in a water table. Before cutting, raise and lower the water level several times to dissipate trapped gases. Do not leave plate on the table for extended periods, i.e. overnight or weekends. When the table is not in use, keep the water level down. Do not cut these materials under water. Read additional cautions in the related manuals. B-6

114 SECTION 2 INTRODUCTION MI0548A 2.1 SCOPE This manual provides general installation, operation and service information for the Koike Aronson Models G6, GP6, G12 and GP12 Motorized Torch Lifters. This manual includes an illustrated part listing to aid in ordering parts. 2.2 DESCRIPTION The Koike Aronson Model G Motorized Torch Lifter is a compact, rugged accessory for most heavy-duty cutting machines. The lifter may be mounted by one of two methods, bolt on or pin clamp, on most two axis cutting machines. The heavy-duty aluminum casting, stepper motor and ball screw drive provides accurate vertical placement of the torch in relationship with the work piece SPECIFICATIONS The G6 and GP6 have 6 in. (152.4mm) of vertical travel at 37.5ipm (952.5mm/min). Their lifting capacity is 50 lbs. (22.68Kg). The maximum rotational movement at a point 3 in. (76.2mm) from center when subjected to a 10 lb. (4.54Kg) force acting first in one direction and then the other is in. (.127mm). The lifter weights 17 lbs. (7.71Kg). The G12 and GP12 have 12 in. (304.8mm) of vertical travel at 37.5ipm (952.5mm/min). Their lifting capacity is 50 lbs. (22.68Kg). The maximum rotational movement at a point 3 in. (76.2mm) from center when subjected to a 10 lb. (4.54Kg) force acting first in one direction and then the other is in. (.127mm). The lifter weights 20 lbs. (9.07Kg). Lifter style: G6 Lifter style: GP6 Lifter style: G12 Lifter style: B-7

115 MI0548A SECTION 3 INSTALLATION 3.1 INSTALLATION G6-G12 Installation of the G6 - G12 Motorized Torch Lifters is accomplished using four (4) M8 Hex Head Cap screws that fasten the lifter to a torch carriage. A 60mm x 64mm M pattern needs to be drilled and tapped in the torch carriage for installation. Typically, the pattern would be centered on the carriage, being level and plumb, but it can be placed in different positions if there is adequate material for the tapped holes and the balance of the carriage is not compromised. Keep in mind the stroke length of the lifter and the height of the cutting table. Connect the lifter cable from the control to the cable connection on the top of the lifter (See Figure 3.1). 3.2 INSTALLATION GP6-GP12 Installation of the GP6 - GP12 Motorized Torch Lifter is a simple matter of loosening the cap screw on the torch carriage support collar and inserting the torch lifter mounting 1-1/4 inch diameter pin into the support collar. Plumb the lifter and tighten the cap screw on the support collar. Keep in mind the stroke length of the lifter and the height of the cutting table. Connect the lifter cable from the control to the cable connection on the top of the lifter (See Figure 3.2). B-8

116 MI0548A Cable Connection 64mm (2.51 ) 60mm (2.36 ) Figure 3.1 Model G Lifter B-9

117 MI0548A Cable Connection 31.75mm (1.250") Figure 3.2 Model GP Lifter B-10

118 MI0548A SECTION 4 MAINTENANCE 4.1 SAFETY PRECAUTIONS 1. Shut OFF main power switch; pull fuses, or lock and red tag switch before attempting work on electrical circuits. Do not touch electrically HOT parts or those with residual voltage, such as capacitors until they have been grounded and their electric charge dissipated. 2. Keep lifter cables dry, free of oil and grease, and protected at all times from damage by hot metal and sparks. Do Not use any power cable with worn or damaged insulation. Repair or replace immediately. 3. A lifter that is not functioning properly should Not be used until all repairs have been completed and the lifter has been tested to ascertain that it is in proper operating condition. 4. Inspection and maintenance of the lifter as indicated in this manual may ordinarily be undertaken by a competent person having at least general experience in the maintenance of equipment of this nature. CAUTION: No such maintenance or repair should ever be undertaken by anyone not having such qualifications. 4.2 GENERAL INFORMATION This manual provides standard preventive maintenance procedures required for accurate and proper operation of the Model G Series Motorized Torch Lifters. Follow these procedures to maintain lifter operation at peak efficiency and to extend the useful life of the lifter. The motorized torch lifter has been assembled, properly adjusted and factory tested before shipment. Factory settings should not be changed. If lifter performance is unsatisfactory, contact a Koike Aronson authorized service representative for advice. PREVENTIVE MAINTENANCE means the maintaining of equipment in sound condition and is a way of avoiding breakdowns and accidents and the consequent expense of repairs 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 power switch. Ensure that the circuit breaker for the cutting machine is in the OFF position. Uniformly spray a light coat of WD-40 or equivalent on the lifter shaft. 2. Verify Check that lifter cable connections are secure. 4.4 MONTHLY ROUTINE MAINTENANCE 1. Fully extend the motorized torch lifter shaft (See Figure 4.1). Shut OFF the main power switch. Ensure that the circuit breaker for the cutting machine is in the Off position. Using a clean shop cloth wipe the shaft clean of lubricant and iron oxide dust. Uniformly apply a light coat of Never Seez lubricant or equivalent. Fully retract and extend the lifter shaft several times. With the shaft in the retracted position wipe off any excess lubrication. B-11

119 MI0548A Lifter Shaft Fully Figure 4.1 Extended Lifter Shaft. B-12

120 TROUBLESHOOTING GUIDE MI0548A PROBLEM PROBABLE CAUSE SOLUTION Torch Lifter does not move. Motor not operating Check for power on lifter cable. Ball Screw Clutch not holding Replace Ball Screw assembly. Excess rotational movement. Broken motor coupling Improper detent (bronze bushing) adjustment Replace motor coupling. (See Sections 4.5 and 4.6) Adjust detent so the shaft can be turned approximately 1/5 of a turn using moderate force. Lifter motor becomes hot and the motor will only run intermittently. Torch Lifter runs in one direction only. Defective motor capacitor Faulty Motor Open circuit in the electrical assy wiring Raise and lower the torch lifter. If the torch will not raise loosen the tension adjustment set screw until the lifter moves smoothly (See Section 4.6). Replace capacitor Replace Motor Troubleshoot the wiring inside the drive control. Torch Lifter will not run. Short in the electrical assy wiring Defective Motor Defective Capacitor Defective Resistor Open Circuit Loose Connection Check for 110VAC ±10V at pins C & D using pin B for neutral. Replace defective component. Troubleshoot the wiring. Return Lifter to Koike Aronson Service Center for repair. B-13

121 MI0548A TROUBLESHOOTING GUIDE (CONT D) PROBLEM PROBABLE CAUSE SOLUTION Defective Motor Torch Lifter blows fuses. Defective Capacitor Defective Resistor Circuit Short in Motor Controller Short in Drive Control or Cable Unplug lifter cable and operate the drive control. If the fuse blows the problem is in the drive control and the control must be diagnosed per manufacturer s recommendations. If the problem is in the cable, check continuity. If the fuse does not blow, troubleshooting must be performed on the torch lifter (See Section 4.5). Lifter operates the same direction (up or down) regardless of the control switch direction. Shorted, grounded or broken connection in the black or red motor wiring. Check continuity, connections and shielding on the black and red wires. B-14

122 4.5 ELECTRICAL MAINTENANCE If the torch lifter does not move it can be either an electrical or mechanical problem. If it is electrical, the following should be checked: The first check is on the lifter cable. With the control switch in the up/down position, remove the cable from the torch lifter. On the lifter cable plug check for 110VAC ±10V at pins C (up) & D (down) using pin B for neutral (See Figure 4.5). If there is no power, the problem is in the drive controller and you need to use its documentation for corrective actions. If there is power to the lifter, remove the motor cover by removing the four (4) M4 retaining cap screws securing the cover using a 3 mm allen wrench. Remove the four (4) M5 retaining cap screws from the motor assembly using a 4 mm allen wrench. Remove the motor assembly (See Figure 4.3). Using the drive controller attempt to raise and lower the lifter. If the motor turns, the problem is mechanical (See Section 4.6). If the motor does not turn check for power at either black wire on the capacitor while using the drive controller switch to move the lifter in the up and down directions. If there is power 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 require a great deal of maintenance (if the routine maintenance is preformed), there are a couple of items that may need to be maintained or adjusted. If there is excessive rotational movement, the rotational braking, tension must be adjusted. Before trying to adjust the tension, the bronze detent, bushing should be inspected for damage or uneven wear. If either is found, it should be replaced. To check the detent-bushing, remove the lifter from the machine. Remove the adjustment plug (one inch socket head set screw) from the lifter. Remove the tension spring and bronze detent bushing. If the bushing is not damaged, reinstall it (See Figure 4.2). MI0548A Caution: The bushing should slide in and out smoothly and turn freely within its housing. If it does not the shaft or lifter may be damaged. Lower the lifter shaft three (3) inches. Slide a steel bar or screwdriver through the two (2) holes in the bottom of the lifter shaft. Reinstall the tension spring and adjustment plug by turning the plug clockwise until the lifter shaft will only rotate 1/5 of a turn. Without reattaching the lifter to the torch carriage, operate the lifter up and down to check that there is no binding. If binding occurs, loosen the adjustment plug accordingly. Note: The lifter shaft should be adjusted so that 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 been determined that it is a mechanical problem: Remove the four (4) retaining cap screws securing the cover using a 3mm allen wrench. Remove the four (4) retaining cap screws from the motor assembly using a 4 mm allen wrench. Remove the motor assembly. If the problem is the motor coupling, it can be replaced by inserting the new coupling into the slotted shafts in the ball screw and motor and reassemble. If the coupling is not the problem, the problem is probably the ball screw clutch. To change the ball screw, remove the four (4) M4 retaining capscrews securing the cover using a 3 mm allen wrench. Remove the four (4) M5 retaining cap screws from the motor assembly using a 4 mm allen wrench. Remove the motor assembly (See Figure 4.3). Remove the motor coupling. Using an appropriate size snap ring pliers, remove the snap ring from the bearing and ball screw assembly. Remove the bronze detent bushing, tension spring and adjusting plug from the lifter tube. B-15

123 Slide the shaft and balls crew assembly out of the torch lifter tube. Heat the upper section of the shaft to loosen the Loctite and using a strap wrench turn the ball clutch nut counter clockwise removing it from the torch lifter shaft. MI0548A Reverse the process to install a new ball screw. There are a couple of added steps. Before inserting the new ball screw, clean the lifter tube, especially the bronze bushings at the lower end of the tube. Lubricate the lifter shaft with a uniformly applied light coat of Never Seez lubricant or equivalent. Loctite Stud Lock Red #7331 must be used where the ball screw attaches to the lifter shaft (See Figure 4.2 and 4.6) Detent Bushing Tension Spring Lower Bushings Adjustment Plug Figure 4.2 Adjustment Assembly B-16

124 MI0548A Figure 4.3 Motor and Coupling Assembly MOTOR LEADS CABLE RECP. RED 50 25W WHITE B COMMON C UP D DOWN E GROUND BLACK GREEN GROUND SCREW CAPACITOR 5 MFD 300 VAC Figure 4.4 Wiring Diagram B-17

125 Not used MI0548A Neutral Ground B A E C D Up Down Figure 4.5 Lifter Cable Use Loctite here Figure 4.6 Ball screw Replacement SECTION 5 REPLACEMENT PARTS To assure minimum down time, it is recommended that spare parts noted by an asterisk * in the Part No. column of the parts list be kept on hand. To assure proper operation, it is recommended that only genuine Koike Aronson (KAR) parts and B-18

126 products be used with this equipment. MI0548A To order replacement parts: a. Provide part number, description and quantity of part. b. Indicate any special shipping instructions. B-18

127 MI0548A MOTOR LEADS WHITE 50 25W CAPACITOR 5 MFD 300 VAC GREEN 11 CABLE RECP. B COMMON C UP D DOWN E GROUND GROUND SCREW 8 9 Figure 5.1 Model G Torch Lifter Item Part No. Description Spring Set Screw, 1-14 x 3/4, Flat Point Bushing, 7/8 x ½ x Bushing, 1-3/4 x 1-3/8 x * Coupling, Ball Screw, 6" Stroke Ball Screw, 12" Stroke Snap Ring, Internal, 42mm Motor, Step Receptacle * Capacitor, 5 MFD * Resistor, 50 OHMS, 25 Watt B-20

128 MI0548A MOTOR LEADS WHITE 50 25W CABLE RECP. B COMMON C UP D DOWN E GROUND 8 9 GREEN GROUND SCREW 10 CAPACITOR 5 MFD 300 VAC 11 Figure 5.2 Model GP Torch Lifter Item Part No. Description Spring Set Screw, 1-14 x 3/4, Flat Point Bushing, 7/8 x ½ x Bushing, 1-3/4 x 1-3/8 x * Coupling, Ball Screw, 6" Stroke Ball Screw, 12" Stroke Snap Ring, Internal, 42mm Motor, Step Receptacle * Capacitor, 5 MFD * Resistor, 50 OHMS, 25 Watt 12 ZS61106 Torch Support Adapter Hub B-21

129 MI0548A SECTION 6 OPTIONAL 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-22

130 MI0548A 50 mm Figure 6.1 Short Torch Support (ZS61106) 105 mm Figure 6.2 Long Torch Support (ZS60200) B-23

131 MI0548A Figure 6.3 Manual Torch Holder, Small Handle (ZS61108) Figure 6.4 Manual Torch Holder, Large Handle (ZS60201) B-24

132 MI0548A Figure 6.5 Manual Torch Holder, 1-3/8 Oxy/Fuel or Plasma ( ) Figure 6.6 Torch Fore-Aft Adjuster (ZS61100) B-25

133 MI0548A APPENDIX C PULSE IGNITION October, 1999 Revision 1 C-1

134 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-5 Section 2.2 Installation Requirements... C-5 Section 2.3 Description... C-5 SECTION 3 INSTALLATION... C-6 Section 3.1 Mechanical Installation... C-6 Section 3.2 Electrical Installation... C-6 Section 3.3 Operation... C-6 Section Manual... C-6 Section CNC... C-6 SECTION 4 MAINTENANCE... C-7 Section 4.1 Daily... C-7 Section 4.2 Monthly... C-7 Section 4.3 Adjustment... C-7 Section Adjust Airflow... C-7 Section Spark Gap Adjustment... C-7 Section Fine Tuning... C-7 SECTION 5 REPLACEMENT PARTS... C-9 ILLUSTRATIONS & TABLES Figure 4.1 Air Flow/Electrode Adjustment Location C-7 Help Flow Chart C-8 Figure 5.1 Pulse Ignition C-9 C-2

135 SECTION 1 SAFETY PRECAUTIONS USER RESPONSIBILITY - This equipment will perform in conformity with the description thereof in this manual and accompanying labels and/or inserts when installed, operated, maintained and repaired in accordance with the instructions provided. This equipment must be checked periodically. Defective equipment should not be used. Parts that are broken, missing, plainly worn, distorted or contaminated should be replaced immediately. Should repair or replacement become necessary, Koike Aronson recommends that a request for service be made to a Koike Aronson, Inc. Authorized Distributor or directly to the Koike Aronson, Inc. Service Department. This equipment or any of its parts should not be altered without prior written approval of Koike Aronson. The user of this equipment shall have sole responsibility for any malfunction, which results from improper use, faulty maintenance, damage, improper repair or alteration by anyone other than Koike Aronson or a facility, designated by Koike Aronson. NOTES, CAUTIONS & WARNINGS Throughout this manual, notes, cautions, and warnings are used to describe situations 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 in operating the cutting system. Caution: A caution describes a situation that may cause damage to the machine and offers advice to avoid or rectify the situation. WARNING A warning describes a situation that presents a physical danger to the operator, and offers advice to avoid or rectify the situation. C-3

136 1.1 GENERAL SAFETY, OXY/FUEL CUTTING Operation of oxy/fuel torches involves oxygen and flammable gases under pressure, open flames, flying slag and hot metal, fumes and combustion products. Follow the precautions in this General Safety Section as well as those throughout this manual for your personal safety and the safety of people in the area that may be affected. 1. Check gas and electrical connections for tightness after installation and on a regular basis thereafter. 2. Keep combustibles away from the work area or protect them from sparks and flames. 3. Check for proper function of check valves regularly. Do not remove or bypass check valves. 4. Always open gas valves slowly. 5. Never use oxygen to ventilate the area or clean off clothing. 6. Keep oil, grease, and combustible dust away from all oxygen equipment. 7. Purge oxygen and fuel lines individually whenever combustible mixtures in the lines are suspected. 8. Never use the oxygen hose for any other gas than oxygen. 9. Replace hose that is damaged by physical abuse or by sparks, heat or open flame. 10. Examine hoses at regular intervals for leaks, wear, loose connections or other hazards. 11. Examine hoses at daily intervals for leaks, wear, loose connections or other hazards. MI0548A 12. Coil excess hose and place it out of the way to prevent damage and to eliminate tripping danger. 13. Maintain all pressure regulators in proper working condition. 14. Never, use a regulator for any gas other than that for which it is intended. 15. Never, use a regulator that leaks, creeps excessively or is physically damaged in any way. 16. Never, attempt to lubricate a regulator with oil or grease. 17. Wear filter-lens safety eye protection. Wear gauntlet gloves, safety shoes, flame retardant clothing, and no-cuff trousers. Do not wear loose clothing around this machinery as they can catch on the machine. 18. Shut off power and gas supplies whenever leaving machine unattended or before servicing. 19. Keep equipment clean and in good operating condition. 20. Read and understand further detailed safety precautions throughout this manual. 21. Also, refer to the latest revisions of the following sources of safe practices in welding and cutting. A. National Fire Protection Association Standard 51B CUTTING AND WELDING PROCESS, obtainable from NFPA, Batterymarch Park, Quincy, MA B. NFPA Standard 51, OXYGEN/FUEL GAS SYSTEMS FOR WELDING AND CUTTING, obtainable same as item A. C. American Welding Society publication C4.2-90, OPERATOR'S MANUAL FOR OXY/FUEL GAS CUTTING. C-4

137 MI0548A SECTION 2 INTRODUCTION 2.1 SCOPE This appendix provides a step by step guide for installation, operation, adjustment and a troubleshooting guide for the pulse ignition system. Follow all steps in order and obey all safety precautions. 2.2 INSTALLATION REQUIREMENTS Pulse ignition requires a supply pressure of 15psi. Propane is used as its primary gas. Acetylene can not be used. If you are using acetylene as the machine gas, a separate supply of propane must be provided for ignition. 2.3 DESCRIPTION Pulse ignition uses propane as its primary fuel gas. Do not use acetylene. Inlet supply for the ignition system is supplied from the preheat fuel manifold. A separate manifold is provided with a supply solenoid. Outlet bushings are located on the manifold for each torch station. Caps are installed for unused outlets. At the torch station, a solenoid, high voltage transformer, a venturi tube with nozzle and mounting hardware are provided for assembly at the torch. Mounted on the top of the tube is the air flow adjustment and the spark adjustment. Between the high voltage transformer and the electrode is a noise suppressor installed with the ignition cable. The suppressor is used for reducing RF noise generated by the transformer. Once the ignite signal is generated, the manifold supply solenoid opens allowing fuel to flow to the torch station solenoid. The torch station solenoid is pulsed (turned on and off) at a rate programmed to the territorial location of the machine. The rate is adjusted for proper airflow. The high voltage transformer is on steady throughout the ignition cycle. The electrode ignites the fuel as it passes through the flow tube. Since the gas is pulsed, the venturi of the tube pulls the gas through the tube and out the nozzle. A flame about four to six inches long is produced igniting the selected oxyfuel torch. C-5

138 MI0548A SECTION 3 INSTALLATION 3.1 MECHANICAL 3.2 ELECTRICAL (i) WARNING Fuel gas is highly flammable. Care must be taken working with this system. Before performing electrical maintenance, machine electrical power must be OFF. WARNING Purge all oxygen and fuel supply lines. Move the standard preheat manifolds (fuel, preheat oxygen and cut) to as low on the support brackets as possible. Locate the ignition manifold towards the top of the support brackets, centering the manifold between them. Install the manifold clamps. Remove the cap on the fuel preheat tee and install the hose to connect the two manifolds. The long red hose is connected to the outlet bushing and is routed through the flexible cable carrier to the oxy-fuel station. Install the igniter tube with the torch clamps. The tube nozzle must face the torch tip and be located approximately one inch above the tip. The tube and solenoid must also be clear of all other parts and accessories. Connect the hose to the top of the solenoid inlet fitting. Position the adjustment collar so it is convenient to make airflow and electrode adjustments. Tighten all hardware and hose connections. Connect the ignition supply solenoid to the main electrical enclosure. Follow the associated electrical drawings for reference. Connect the high voltage transformer and the solenoid wires to the appropriate connector on the J-box. The J- box is located on the back of the slave station. The ignition wire is connected to the high voltage transformer to the noise suppressor to the electrode. Be sure to place the insulated sleeve over the connection at the electrode and the rubber insulator at the high voltage transformer. 3.3 OPERATION MANUAL Pressing the ignite button on the touch panel will turn on the ignition cycle for four (4) seconds. This allows sufficient time for the torch to ignite. You must have an oxyfuel station selected CNC Using CNC programming the ignition cycle is started automatically with the selected torch or torches. C-6

139 MI0548A SECTION 4 MAINTENANCE 4.0 MAINTENANCE This section includes preventative and routine maintenance using the pulse ignition system. This section also contains a set-up and troubleshooting guide for problems that may occur. 4.1 DAILY Clean the nozzle from the blow back from piercing the plate. Ensure the clamps holding the tube are tight. 4.2 Monthly Perform a leak test on the hoses and fittings. Before making any corrections ensure the system is purged. Check all hoses for wear and pinch points. If there are any, replace the hose or correct the routing SPARK GAP ADJUSTMENT. Locate the pilot block and the Phillips screw with the nut attached to it. Adjust the nut so it touches the head of the screw. Turn the screw clockwise so it just touches the electrode. Turn counter-clockwise five (5) complete turns. This sets the spark gap of the electrode to the ignition block FINE TUNE. The airflow and spark gap may have to be adjusted depending on gas being used. The flame should be bluish in color. If it is not some adjustment in the air may be necessary. 4.3 ADJUSTMENT Ensure the ignition system is installed properly. Ensure the gas supply is set to 15psi. Select an oxy-fuel station and press ignite. Wait a few seconds to allow the fuel to fill the hose and fittings. Air Flow Adjustment ADJUST AIRFLOW. Locate the adjusting slide assembly, using a Phillips screwdriver; adjust the air intake holes on the slide until they are inline with intake holes on the ignition block. Electrode Adjustment Figure 4.1 C-7

140 MI0548A HELP FLOW CHART Select an oxyfuel station (Press button) Close manual valves on the torch (Fuel, oxygen and cut) Press ignition button Did ignition take place and a blue 4 in. flame appear? No Light with manual striker Check electrical circuit. If the electrical is ok, replace solenoid Did ignition take place and a blue 4 in. flame appear? No No Check gas flow Check flow orifice for obstructions Is the solenoid pulsing? Check for plugged nozzle assembly, clean if necessary. WARNING TURN OFF GAS SUPPLY. Remove igniter assembly. Press the ignition button and check for spark. If the spark is not present check the high voltage circuit. If the spark is weak adjust the gap using the adjustment screw. Yes Yes WARNING TURN OFF GAS SUPPLY. Remove igniter assembly. Press the ignition button and check for spark. If the spark is not present check the high voltage circuit. If the spark is weak adjust the gap using the adjustment screw. Check for corrosion on the electrode, remove cover, clean if necessary. Adjust the air flow for the bluest flame possible. Adjust the air flow for the bluest flame possible. The ignition system should now be operational C-8

141 MI0548A SECTION 5 REPLACEMENT PARTS Figure 5.1 Note: Only Major Components Are Listed. Item Number Part Number Part Description Quantity Pulse Ignition 1 *ZS60287 Ignition Transformer 1 2 * Check Valve, Fuel 1 3 * Solenoid Valve, Fuel 1 4 * Pilot Orifice Adjusting Collar Mixing Pipe,1/2 Dia. X 2-1/4 1 C-9

142 MI0548A Part Listing Continued Pilot Block, 3/4Dia. X1.25x Clamp Tube, Copper Clamp 1 11 * Pilot Nozzle, 3/4Dia.x * Electrode Noise Suppressor 1 14 ZM62972 Glass Fiber Tube, Igniter 1 15 ZM62973 Teflon Tube, Igniter 1 C-10

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144 APPENDIX D MI0548A DRILL STATION October, 1999 Revision 0 D-1

145 MI0548A TABLE OF CONTENTS SECTION 1 Section 1.1 SAFETY PRECAUTIONS...D-3 General Safety, Drill Station...D-4 SECTION 2 INTRODUCTION...D-4 Section 2.1 Scope...D-4 Section 2.2 Installation Requirements...D-4 Section 2.3 Specifications...D-4 SECTION 3 Section 3.1 Section 3.2 SECTION 4 Section 4.0 Section 4.1 Section 4.2 Section 4.3 SECTION 5 Figure 5.1a Figure 5.1b Figure 5.2 OPERATION...D-5 Rough Height Setting...D-5 CNC Operation...D-5 MAINTENANCE...D-6 8 Hours...D Hours...D-6 Help Flow Chart...D-6 Sample EIA Test Drill Program...D-7 REPLACEMENT PARTS...D-8 Drill Station...D-8 Drill Station...D-9 Drill Station Main Valve Assembly...D-9 D-2

146 MI0548A SECTION 1 SAFETY PRECAUTIONS USER RESPONSIBILITY - This equipment will perform in conformity with the description thereof in this manual and accompanying labels and/or inserts when installed, operated, maintained and repaired in accordance with the instructions provided. This equipment must be checked periodically. Defective equipment should not be used. Parts that are broken, missing, plainly worn, distorted or contaminated should 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 approval of Koike Aronson. The user of this equipment shall have sole responsibility for any malfunction, which results from improper use, faulty maintenance, damage, improper repair or alteration by anyone other than Koike Aronson or a facility, designated by Koike Aronson. NOTES, CAUTIONS & WARNINGS Throughout this manual, notes, cautions, and warnings are used to describe situations 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 in operating the cutting system. Caution: A caution describes a situation that may cause damage to the machine and offers advice to avoid or rectify the situation. WARNING A warning describes a situation that presents a physical danger to the operator, and offers advice to avoid or rectify the situation. D-3

147 MI0548A 1.1 GENERAL SAFETY, DRILL STATION 1. Keep equipment clean and in good operating condition. 2. Read and understand further detailed safety precautions throughout this manual. 3. Keep hands and clothing away from rotating end of tool. 4. Wear suitable eye protection while operating tool. 5. Disconnect the air supply from the tool before removing or installing bit or performing maintenance. SECTION 2 INTRODUCTION 2.1 SCOPE This appendix provides a step by step guide for operation, adjustment and a troubleshooting guide for the drilling station. Follow all steps in order and obey all safety precautions. 2.2 INSTALLATION REQUIREMENTS The drill station requires air supply pressure of 90 psi (6 bar). The air supply is connected to the machine by a separate input of the main valve assembly. An air-filter lubricator is provided. The setting on the F.R.L is 5 to 6 drops of oil per free flow cycle. KAR supplies a minimum 3/8 I.D. hoses for the assembly. Solenoids and control hoses are provided for remote operation. 2.3 SPECIFICATIONS (Model # ) 2,800 RPM maximum rotation head speed 3/8 maximum bit capacity Manual feed-rate adjustment Manual rough height setting Emergency retract Automatic operation via CNC program Air Consumption 1800 CFM (Cubic Feet per Hour) per stroke D-4

148 MI0548A SECTION 3 OPERATION 3.0 OPERATION a) WARNING Before changing or replacing tool, ensure the air supply to the drill station is turned off. Keep hands and clothing clear of housing and adjustment screws. Operation of the drilling station is accomplished by using the correct formatted CNC program. The offset for the tool must correct for the part to be drilled. Since the drill is located on the slave station it is not set in a fixed location, the offset between the drill and the plasma and or oxy-fuel station must be set before the program is started. The rough height setting must also be set. 3.1 ROUGH HEIGHT SETTING To set the rough height setting, remove the T-handle lock pin. Note: DO NOT LOOSE OR MISPLACE THIS PIN. Raise or lower the G-lifter by using the spring-loaded switch mounted on the lifter motor housing. The slide assembly will raise and lower with the lifter. Locate the desired height and insert the pin in the nearest alignment hole. 3.2 CNC b) WARNING Make sure the locking pin is removed before raising or lowering the lifter. The drill cycle is started when the START is pressed on the CNC. The solenoid for the tool opens and the head will begin to rotate. The auto feed for the drill is internally controlled. The stroke distance is set. When the stroke distance is reached the drill will retract up and enable the up proximity switch. The input lets the CNC know the cycle is complete and the machine is ready to perform the next function. In case of an emergency the STOP DRILL button on the operator screen should be pressed. This will stop the head rotation and retract the drill. If the STOP DRILL is pressed, you must press STOP on the CNC. Correct the problem and manually finish the drill hole or continue with program using the cut recovery for the CNC. D-5

149 MI0548A SECTION 4 MAINTENANCE HOURS After 8 hours of operation, ensure the lubricator reservoir is filled HOURS Perform a leak test on the hoses and fittings. Check all hoses for wear and pinch points. If there are any, replace the hose or correct the routing. Ensure the grease fittings are properly filled. Make sure the spindle is extended before filling with grease. 4.2 HELP FLOW CHART Drill cycle fails to start in a program Failure to feed or erratic feed Low motor speed or motor does not operate Motor continues to run after retraction Failure to retract Ensure the up proximity switch is funtioning Check air supply Check air supply Piston is not fully retracted Improper alignment of adjustment sscrew and bleed off Program is correct Feedrate control valves need adjusting Clogged or damaged airway Feed control valves dirty or improperly adjusted Air supply is set at the proper setting D80 enter diagnostics and check input 7 Check for air leaks Check for air leaks Make sure solenoid is not dirty Clogged air passage in valve housing Input to PLC is correct Drill station working properly D-6

150 MI0548A 4.3 SAMPLE EIA TEST DRILL PROGRAM (Four corner drill holes 5 inches square) G20 (Select English Units) G91 (Incremental Programming Mode) G99 X1 Y0 I0 J0 (Part Options) G00 X0 Y5 (Rapid Traverse + Y direction) M22 (Drill On) M26 (Wait for Input 7 off, drill moves off proximity switch) M23 (Drill Off) M24 (Wait for Input 7 on, drill up proximity switch) G00 X5 Y0 (Rapid Traverse + X direction) M22 (Drill On) M26 (Wait for Input 7 off, drill moves off proximity switch) M23 (Drill Off) M24 (Wait for Input 7 on, drill up proximity switch) G00 X0 Y-5 (Rapid Traverse - Y direction) M22 (Drill On) M26 (Wait for Input 7 off, drill moves off proximity switch) M23 (Drill Off) M24 (Wait for Input 7 on, drill up proximity switch) G00 X-5 Y0 (Rapid Traverse - X direction) M22 (Drill On) M26 (Wait for Input 7 off, drill moves off proximity switch) M23 (Drill Off) M24 (Wait for Input 7 on, drill up proximity switch) M02 (End of Program) First drill hole Second drill hole Y Last drill hole Third drill hole Note: This program has no drill offset. This means the drill station is mounted on a slave. When mounted on the master, use offset 3 and above. If using a cut program with a drill program, perform all drill functions first. The cut program can then be added. D-7

151 MI0548A SECTION 5 REPLACEMENT PARTS 3 4 Location of drill and retract solenoids Location of retract and stroke adjustment Figure 5.1a Note: Only Major Components Are Listed. Item Number Part Number Part Description Quantity Drill Station Assembly w/g Air Drill, 3 Stroke, 600 RPM T-Handle Lock-pin, 1 /2 Dia Switch, Toggle MOM-OFF-MOM Cutler Hammer #8812-K ZWk0905A1B01 Boot, Rubber, For Toggle Switch Solenoid Valve, 3-Way 1/ Model G12 Lifter, 12 Stroke 1 D-8

152 MI0548A REPLACEMENT PARTS Continued Part of Main Valve Enclosure Figure 5.1b 10 Inside Main Air Enclosure To Drill Retract Solenoid To Air Supply 11 Figure 5.2 To Drill Note: Only Major Components Are Listed. Item Number Part Number Part Description Quantity Prox Switch, N.O. Turk Bi2-M12- AD4X-H Steel Band Clamp Assy Ball Slide, NSK LAS20ALZ-K2 +Scraper Ball Valve,1 / 2 NPT F.R.L. w/gauge 1 /2 NPT 1 D-9

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154 MI0548A APPENDIX E SERVO GAS CONTROL SYSTEM November 1999 Revision 0 E-1

155 MI0548A CONTENTS SECTION 1 SAFETY PRECAUTIONS Section 1.1 General Safety... E-5 SECTION 2 GENERAL INTRODUCTION Section 2.1 Scope... E-6 Section 2.2 Use... E-6 SECTION 3 SETUP AND SERVICE Section 3.1 Operating Principles... E-7 Section 3.2 Pressure Regulation and Control... E-7 Section 3.3 Cut Oxygen Section... E-7 Section 3.4 HI-LOW Preheat Oxygen Section... E-8 Section 3.5 HI-LOW Fuel Section... E-8 Section 3.6 Manifolds (CUT, Preheat Oxygen, Preheat Fuel)... E-9 Section 3.7 Principles of Tune-Up... E-14 Section 3.8 General Service Procedure... E-18 Section 3.9 Check Out Procedure... E-18 Section 3.10 Trouble Shooting Guide... E-24 SECTION 4 GAS SYSTEM START-UP & TUNE-UP Section 4.1 Acetylene... E-27 Section 4.2 Propane... E-29 Section 4.3 Natural Gas... E-31 SECTION 5 OPERATION Section 5.1 Purging... E-33 Section 5.2 Light Up Procedure... E-34 SECTION 6 OPERATING DATA FOR PREHEAT SYSTEM Section 6.1 Acetylene... E-37 Section 6.2 Propane/Propylene... E-39 Section 6.3 Natural Gas... E-41 E-2

156 MI0548A FOR REPLACEMENT PARTS SEE SECTION SEVEN (7) OF THE MAIN MANUAL ILLUSTRATIONS AND TABLES Figure 3.1 Figure 3.2 Figure 3.3 Figure 3.4 Table 3.1 Figure 3.5 Table 3.2 Table 3.3 Table 3.4 Table 6.1 Table 6.2 Table 6.3 Flow Diagram...E-10 Interconnection Hose Diagram...E-11 Front Panel Component Locations...E-12 Rear Panel Component Locations...E-13 Front Panel Control Functions...E-15 Gas Manifold Part Locations...E-15 Solenoid Valve Functions...E-16 Symbol Nomenclature...E-17 Troubleshooting...E-24 Pressure Settings Acetylene...E-37 Pressure Settings Propane/Propylene...E-39 Pressure Settings Natural Gas...E-41 E-3

157 MI0548A SECTION 1 SAFETY PRECAUTIONS USER RESPONSIBILITY - This equipment will perform in conformity with the description thereof in this manual and accompanying labels and/or inserts when installed, operated, maintained and repaired in accordance with the instructions provided. This equipment must be checked periodically. Defective equipment should not be used. Parts that are broken, missing, plainly worn, distorted or contaminated should 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 approval of Koike Aronson. The user of this equipment shall have sole responsibility for any malfunction, which results from improper use, faulty maintenance, damage, improper repair or alteration by anyone other than Koike Aronson or a facility, designated by Koike Aronson. NOTES, CAUTIONS & WARNINGS Throughout this manual, notes, cautions, and warnings are used to describe situations 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 in operating the cutting system. Caution: A caution describes a situation that may cause damage to the machine and offers advice to avoid or rectify the situation. WARNING A warning describes a situation that presents a physical danger to the operator, and offers advice to avoid or rectify the situation. E-4

158 MI0548A 1.1 GENERAL SAFETY, OXY/FUEL CUTTING Operation of oxy/fuel torches involves oxygen and flammable gases under pressure, open flames, flying slag and hot metal, fumes and combustion products. Follow the precautions in this General Safety Section as well as those throughout this manual for your personal safety and the safety of people in the area that may be affected. 1. Check gas and electrical connections for tightness after installation and on a weekly basis. 2. Keep combustibles away from the work area or protect them from sparks and flames. 3. Check for proper function of check valves regularly. Do not remove or bypass check valves. 4. Always open gas valves slowly. 5. Never use oxygen to ventilate the area or clean off clothing. 6. Keep oil, grease, and combustible dust away from all oxygen equipment. 7. Purge oxygen and fuel lines individually whenever combustible mixtures in the lines are suspected. 8. Never use the oxygen hose for any other gas than oxygen. 9. Replace hose that is damaged by physical abuse or by sparks, heat or open flame. 10. Examine hoses at daily intervals for leaks, wear, loose connections or other hazards. 11. Coil excess hose and place it out of the way to prevent damage and to eliminate tripping danger. 12. Maintain all pressure regulators in proper working condition. 13. Never use a regulator for any gas other than that for which it is intended. 14. Never use a regulator that leaks, creeps excessively or is physically damaged in any way. 15. Never attempt to lubricate a regulator with oil or grease. 16. Wear filter-lens safety eye protection. Wear gauntlet gloves, safety shoes, flame retardant clothing, and cuffless trousers. Do not wear loose clothing around this machinery as they can catch on the machine. 17. Shut off power and gas supplies whenever leaving machine unattended or before servicing. 18. Keep equipment clean and in good operating condition. 19. Read and understand further detailed safety precautions throughout this manual. 20. Also, refer to the latest revisions of the following sources of safe practices in welding and cutting. A. National Fire Protection Association Standard 51B CUTTING AND WELDING PROCESS, obtainable from NFPA, Batterymarch Park, Quincy, MA B. NFPA Standard 51, OXYGEN/FUEL GAS SYSTEMS FOR WELDING AND CUTTING, obtainable same as item A. C. American Welding Society publication C4.2-90, OPERATOR'S MANUAL FOR OXY/FUEL GAS CUTTING. E-5

159 SECTION 2 GENERAL INTRODUCTION MI0548A 2.1 SCOPE This appendix provides operating instructions for the Koike Aronson Servo Gas Control System installed on Koike Aronson, Inc. Cutting Machines. For Setup and Service see Section 3 of this manual, for Operating Instructions see Section USE The Servo Gas Control System can be used with the following gases: acetylene, natural gas or propane/propylene with applicable torches and tips. The System provides a dual HI-LOW flame adjustment, precise independent balancing of preheat flames, and an ease-on cutting oxygen control. Special feedback pilot regulators in the system sense the pressure in the manifolds and eliminate the pressure drops between pressure regulator and manifolds, common to conventional regulators. This capability provides precise control of the oxy-fuel ratio of the flames. Maximum supply pressures are: Oxygen Fuel 150 psig (1034 kpa)(10.3 bar) 15 psig (103 kpa)(1.3 bar) E-6

160 MI0548A SECTION 3 SETUP AND SERVICE 3.1 OPERATING PRINCIPLES The servo gas panel has three major components (sections) for the operation of supplying constant pressure to the torch or torches. The three sections are HI-LOW Preheat Oxygen, HI-LOW Preheat Fuel, and Cut. A detailed control principle follows describing what function each section performs. Sub components are the manifolds, for distribution of oxygen and fuel to the torch or torches, individual solenoid control to the torch, the main valve assembly and the supply to the machine. A brief description of each sub component is also listed. 3.2 PRESSURE REGULATION AND CONTROL A dome-loaded regulator at the inlet of each of the three manifolds accomplishes gas pressure regulation, common to all three sections. A pilot regulator on the gas panel, which senses pressure at the manifold, controls the pressure at each manifold. The pilot regulator increases or decreases the dome pressure on the domeloaded regulator to maintain precise control of the manifold pressure over wide ranges of flow rates. This eliminates problems of balancing flames from torch to torch and makes the preheat flame of each torch independent from any of the others. Pressure gauges on the gas panel indicate pressure clearly and accurately at the control point of the manifold. On-off flow of cutting oxygen, HI and LO preheat oxygen, and HI and LO preheat fuel is controlled by normally closed solenoid valves at the inlet of each of the five (5) pilot regulators. Normally open solenoid valves are provided in the cutting oxygen, preheat oxygen, and fuel subsystems to insure quick shutdown of the dome loaded regulators by unloading the dome control pressurization lines. Note: For the following descriptions, follow figure CUT OXYGEN SECTION Oxygen is supplied to the machine from the main supply line through a manual on-off valve and safety solenoid to the filter (F1) and is branched to supply the cutting oxygen and preheat oxygen pilot control systems. SV1 is the cut oxygen select solenoid. The cutting oxygen pressure is set at pilot regulator (R1). A flow orifice (snubber) is installed at the gauge to prevent damage due to the inrush of oxygen pressure. Cutting oxygen flow is controlled for piercing by an adjustable ease on valve (V1) located on the gas panel. The ease-on valve controls the rate at which the cutting oxygen dome loaded regulator (R6) is pressurized. This results in the smooth pressurization of the cutting oxygen manifold at a rate desired by the operator to achieve smooth starts in piercing. A normally open blow off solenoid valve (SV9), through a muffler (M1), dumps the cutting oxygen from the manifold when the cutting oxygen is turned off. This provides for a quick shut down of the cutting oxygen flow. Check valves are provided: CV1 at solenoid valve SV6; CV2 at solenoid valve SV9; and separately at the cutting oxygen inlets of each torch. These check valves have two (2) functions: a. They prevent air (nitrogen) from diffusing into the manifold during the off cycle to contaminate the oxygen and yield poor cuts. b. Torch inlet check valves also prevent preheat flames at the tips, with cutting oxygen off, from pushing combustion gases up into the cutting oxygen manifold. If the flames are rich, combustible fuel gas may enter and may cause an explosion in the cutting oxygen manifold. If the flames E-7

161 MI0548A are lean, water vapor may enter the manifold, condense and reappear as water that squirts on the hot spot, and causes failure in starting a pierce. CAUTION DO NOT USE TORCHES WITHOUT CHECK VALVES INSTALLED AT THE CUTTING OXYGEN INLETS. Because these check valves are necessary to maintain a pure oxygen atmosphere in the cutting oxygen manifold, their action must be checked frequently and maintained in good operating condition. See Section page E- 12 on how to test. 3.4 HI-LOW PREHEAT OXYGEN SECTION This subsection operates in accordance with the general principles given in subsection 3.2 and as follows: HI-LOW preheat oxygen is divided into two sections supplied with oxygen by one common line. Two pilot regulators R2 for HI and R3 for LO control the preheat oxygen pressure settings. The subsystem operates on one or the other of these two pilot regulators by energizing or deenergizing the respective solenoid valve SV2 or SV3. The pilot regulators share one gauge, G2, which also shares one sensing line from the manifold. The sensing line is located on the preheat oxygen manifold just after the domeloaded regulator (R7). Two pilot regulators, R2 for HI and R3 for LO, control the preheat oxygen pressure settings. The subsystem operates on one or the other of these two pilot regulators by energizing or deenergizing the respective solenoid valve SV2 or SV3. Both these regulators and the preheat oxygen pressure gauge G2 have a common pressure sensing line which is connected to the manifold at the pressure sensing point. valves V2 and V3 is selected by a 3-way solenoid valve, SV10: V2 controls the rate of pressurization and V3 controls the rate of depressurization, of the dome of the preheat oxygen regulator R7 on the manifold. These two valves are used to synchronize the pressurization and de-pressurization of the preheat oxygen manifold with that of the fuel manifold to avoid flameouts while switching from LO to HI or HI to LO. A flow orifice (FO1) is connected to a common blow-off solenoid (SV7) to allow a slow rate of de-pressurization when the Preheats are deselected. This allows for an oxygen rich flameout to prevent a carbonizing effect around the torch during shut down. 3.5 HI-LOW FUEL SECTION This subsection operates in accordance with the general principles given in subsection 3.2 and as follows: Fuel is supplied from the main supply line through a filter F2 to the pilot control system. Two pilot regulators, R4 for HI and R5 for LO, control the preheat fuel pressure settings. The subsystem operates on one or the other of these two pilot regulators by energizing or deenergizing the respective solenoid valve SV4 or SV5. Both these pilot regulators and the fuel gauge are connected to the fuel manifold at the pressure sensing point. An adjustable needle valve V4 is installed in the control pressure line to the dome of the fuel regulator R8 on the manifold. The valve is set to a desired rate of de-pressurization of the fuel manifold while switching from HI to LO. As a result of this setting, the valve also controls the rate of pressurization during the switching from LO to HI. It also serves as a pressure gauge snubber when the system is turned on. Flow through either one of two adjustable needle E-8

162 MI0548A A check valve (CV3) is located at outlet of the fuel blow-off solenoid SV8. The check valve is required to prevent contaminates from entering the fuel system when SV8 is open. 3.6 MANIFOLDS (CUTTTING OXYGEN, PREHEAT OXYGEN, PREHEAT FUEL) CUTTING OXYGEN The cutting manifold is supplied with oxygen from the main valve assembly. A four-way fitting is installed at the connecting point. This supplies oxygen to the preheat oxygen manifold and for the servo gas panel. A filter (F3) is installed after the branch connection. The dome loaded regulator (R6) is next in line. An outlet bushing is installed on the dome port for the pilot line from the gas panel. This regulator works on the principle of supply and demand. The more pressure required at the torch, the more flow allowed through the regulator. If less demand is at the torch the regulator will reduce the flow. This prevents the need to adjust the manual valves at the torch when cutting with multiple torches and one or more have a flameout. Mounted next to the regulator is the outlet bushing for the sensing line to the gas panel. Mounted after the outlet are the outlet bushings for connections to the torches. Located at the end of the cutting manifold is a blow-off solenoid (SV9). Mounted on the blow-off solenoid are a check valve (CV2) and a muffler (M1). The muffler allows the oxygen to be dissipated into the atmosphere quietly and quickly PREHEAT FUEL The fuel manifold is supplied with fuel from the main valve assembly. A filter (F4) is installed next. A fuel supply solenoid (SV11) is installed next. The main purpose of the solenoid is safety. A branch connection is installed to supply to the servo gas panel and if the option of ignition is on the machine. The dome loaded regulator (R8) is next in line. An outlet bushing is installed on the dome port for the pilot line from the gas panel. Mounted next to the regulator is the outlet bushing to the gas panel. Mounted after the outlet are the outlet bushings for connections to the torches. NOTE: The outlet bushings of the preheat (oxygen and fuel) manifolds have solenoids mounted on them. This is to provide individual control to each torch station PREHEAT OXYGEN The preheat oxygen manifold is supplied from the cutting oxygen manifold. A filter (F4) is installed after this connection. The dome loaded regulator (R7) is next in line. An outlet bushing is installed on the dome port for the pilot line from the gas panel. Mounted next to the regulator is the outlet bushing to the gas panel. Mounted after the outlet are the outlet bushings for connections to the torches. E-9

163 FIGURE 3.1 MI0548A SV7 SV8 V2 V3 CV3 V4 CV1 SV6 SV10 V1 R1 R2 G2 R3 R4 G3 R5 G1 SV1 SV2 SV3 SV4 SV5 F1 F2 F5 SV1 Preheat fuel manifold R8 F4 R7 Individual solenoid control Preheat oxygen manifold F3 R6 Cutting oxygen manifold CV2 M1 SV9 Cutting oxygen solenoid (part of individual gas control) CV CV CV Main Valve Assembly Oxygen Supply Fuel Supply E-10

164 MI0548A Figure 3.2 Interconnecting Hose Diagram Rear View of Gas Control Panel Preheat Fuel Preheat Oxygen Cutting Oxygen Hose Legend Sensing Hose Pilot Hose Supply Hose Fuel Pilot Out Fuel Sensing In Fuel Supply In Preheat Oxygen Pilot Out Preheat Oxygen Sensing In Cutting Oxygen Pilot Out Cut Oxygen Sensing In Oxygen Supply In E-11

165 MI0548A Figure 3.3 Servo Gas Panel Front View R5 Pilot Regulator G3 Fuel Gauge R4 Pilot Regulator R3 Pilot Regulator G2 Preheat Oxygen R2 Pilot Regulator V1 Cutting Oxygen Flow Valve R1 Pilot Regulator G1 Cutting Oxygen E-12

166 MI0548A Figure 3.4 Servo Gas Panel Side View SV8 Fuel Blow Off V4 Fuel Flow Needle Valve SV5 LO Fuel SV4 HI Fuel F1 Fuel Supply Filter SV7 Preheat Oxygen Blow Off SV3 LO Preheat Oxygen V3 HI to LO V2 LO to HI SV2 HI Preheat Oxygen SV10 Preheat Flow Select SV6 Cut Oxygen Blow Off F2 Oxygen Supply Filter SV1 Cut Oxygen E-13

167 MI0548A 3.7 PRINCIPLES OF TUNE-UP Tuning pertains to adjusting the three needle valves. V2 and V3 for preheat oxygen and V4 for preheat fuel. a. Adjust V4 to transition from HI to LO fuel pressure for 3 to 6 seconds. Note: Turning the valve clockwise, increases the time, turning the valve counterclockwise will decrease the amount of time. This setting is dependant on the fuel supply pressure and the difference between the HI preheat fuel pressure setting and the LO preheat fuel pressure setting. The time should be equal for the HI to LO and LO to HI transition. b. Adjust V2 (preheat oxygen) for the transition of LO to HI, this time should synchronize with the time set for preheat fuel LO to HI. Adjust the HI to LO transition with V3, ensuring the transition is equal to the time the fuel pressure drops from HI to LO. c. Observe the preheat oxygen and fuel gauges, both at the same time, during pressure rise in switching form LO to HI. If transfer time is properly synchronized, both gauge pointers will start rising at the same time and stop when HI pressure is reached, at the same time. If they do not, readjust valve V2 and look for switchover synchronization again, repeating if necessary until they do synchronize. d. During pressure fall in switching from HI to LO, both gauge pointers should start dropping at the same time, and stop at the same time, when the LO pressure setting is reached. If not, readjust valve V3 (for HI to LO) and repeat if necessary until synchronized. e. Further check by observing the flames at the torch, that they stay in near correct ratio (oxygen to fuel) to avoid fuel rich or oxygen rich transition that may cause flameouts. Note: Tune-up adjustments vary with machine fuel supply and the choice in low and high preheat pressure settings. Note: Retuning is necessary: if any other gas or injection system is used; or if flameouts or serious off ratio conditions occur during transition from LO to HI and HI to LO, or if the fuel is changed. Once tuned, the system will operate through the entire range of pressures. E-14

168 MI0548A Table 3.1 Front of Gas Panel Section /Description Control Title Function Top/ Gauge-G3 PREHEAT FUEL Indicates fuel pressure at the manifold, HI and LO. Pilot Regulator-R5 Pilot Regulator-R4 Center/ Gauge-G2 Pilot Regulator-R3 Pilot Regulator-R2 Bottom/ Flow Control Valve-V1 Gauge-G1 Pilot Regulator-R1 LO HI PREHEAT OXYGEN LO HI EASE-ON CUTTING OXYGEN CUTTING OXYGEN Sets LO fuel pressure for cutting. Sets HI fuel pressure for preheating. Indicates preheat oxygen pressure at the manifold, HI and LO. Sets LO preheat oxygen pressure for cutting. Sets HI preheat oxygen pressure for preheating. Controls the rate of rise in cutting oxygen pressure for piercing. Indicates cutting oxygen pressure at the manifold. Sets cutting oxygen pressure. Figure 3.5 Gas Manifold typical Part Locations. Fuel Filter F5 Fuel Supply In 15 psig Maximum Fuel Supply Solenoid SV11 R8 Fuel Dome Loaded Regulators R7 Preheat Oxygen R6 Cutting Oxygen Oxygen Supply In 150 psig Maximum Oxygen Filter F4 Oxygen Filter F3 Muffler M1 Check Valve CV2 Cutting Oxygen Blow-off Solenoid SV9 Part of Cutting Oxygen Manifold E-15

169 MI0548A Solenoid Valve Symbol Function Normal* SV1 SV3 SV2 SV5 SV4 SV6 SV7 SV8 SV9 SV10+ SV11 Cut,O 2 inlet PH,O 2 LO inlet PH,O 2 HI, inlet Fuel LO inlet Fuel HI inlet Cut O 2 Pilot Blow-off PH O 2 Pilot Blow-off Fuel Pilot Blow-off Cut O 2 Manifold Blow-off PH O 2 Flow Selector Fuel Shut-off Table 3.2 Solenoid Valve Functions Gas Mode OFF IGNITION LO HI CUT on/off o/c on/off o/c on/off o/c on/off o/c on/off o/c N.C. off C off C off C off C on O N.C. off C on O on O off C on O N.C. off C off C Off C on O off C N.C. off C on O on O off C on O N.C. off C off C off C on O off C N.O. off O off O off O off O on C N.O. off O on C on C on C on C N.O. off O on C on C on C on C N.O. off O off O off O off O on C *3-O. off 3-O. off 3-O. off 3-O. on 2-O. off 3-O. N.C. off C on O on O on O on O Legend: * Normal (de-energized) position: N.O. - normally open; N.C.-normally closed. 3-O. - No.3 outlet open (HI to LO) Electrical position of solenoid valve coil. Flow position of solenoid valve: O-open; C-closed. + SV10 flow positions: 2-O. - No.2 outlet open (LO to HI) 3-O. - No.3 outlet open (HI to LO) O 2 - Oxygen PH - Preheat E-16

170 MI0548A Table 3.3 Symbol Filters: F1 F2 F3 F4 F5 Dome Loaded Regulators: R6 R7 R8 Valves: V1 V2 V3 V4 Check Valves: CV1 CV2 CV3 Others: FO1 M1 S1 Function Panel Oxygen Supply Panel Fuel Supply Cutting Oxygen Manifold Preheat Oxygen Manifold Fuel Manifold Cut. O 2 Pressure PH O 2 Pressure Fuel Pressure Cut O 2 Ease-On PH O 2 LO to HI tuning PH O 2 HI to LO tuning Fuel transition tuning Cut O 2 pilot line blow-off Cut O 2 manifold blow-off Fuel pilot line blow-off Fuel pilot blow-off orifice Cut O 2 manifold blow-off Cut O 2 gauge snubber E-17

171 MI0548A 3.8 GENERAL SERVICE PROCEDURE A system that is not functioning properly should not be used until all necessary repairs have been made. The system has to be re-tested to ensure it is functioning properly. Inspection, troubleshooting, and repair should only be performed by qualified personnel having knowledge of equipment of this nature. Defective parts should be replaced only with factory (Koike Aronson, Inc.) sold or approved parts. If so advised, return the servo gas panel, manifolds, or other components for factory repair. The repair will be made at current list prices for replacement parts and a reasonable labor charge. This excludes warranty repair. The gas system is thoroughly tested on the cutting machine before it ships. Tuning takes place at actual machine installation. If any problems arise, use the following check out procedure. WARNING Throughout the following procedure, remove all sources of ignition, sparks, open flames, when it is necessary to discharge fuel or check for fuel leaks CHECK VALVE TEST a. Turn off gas supplies and depressurize the gas and oxygen. b. Remove suspected bad check valve. c. Using nitrogen, at.07psig, the check will allow flow through following the flow of the arrow stamped on the valve. d. Reversing the flow of nitrogen, the check valve will not all flow through the valve. e. If nitrogen flows though, replace the valve. 3.9 CHECKOUT PROCEDURE Visual Using Figure 3.1, check that the following are correctly and tightly connected as shown: a. All pilot and sensing hoses. b. All components and interconnections behind the gas panel. c. Supply hoses, components and interconnections at the manifold. d. Hoses from the torches to the respective manifold. e. Ensure the supply pressure for the gas and oxygen is correct Electrical Check each solenoid valve for proper operation from the table 3.2. a. Turn off gas supplies and depressurize the gas and oxygen. b. Turn electrical power on. c. Using the touch panel, select each mode for the oxy-fuel system. Using table 3.2, and a metallic screwdriver, touch the top of the solenoid to ensure the proper solenoid or solenoids energized for each function. Test by selecting on and off. Note: This test is to check that the magnetic coil is energizing and or de-energizing. You will feel the magnetic coil energize. This test does not check the mechanical portion of the solenoid. E-18

172 MI0548A GAS LEAKS Cutting Oxygen a. Close all torch valves. b. Turn off all pilot regulators (R1, R2, R3, R4, R5) by turning the handle counterclockwise c. Turn on the oxygen supply to the machine. (150psig. maximum) d. Enable electrical power for the gas system. e. Press the CUT button on the operators panel and open (turn counterclockwise) the EASE-ON valve a quarter turn. f. Set the cutting oxygen pilot regulator (R1) for a pressure of 100psig. g. Test all cutting oxygen connections for leaks, with a soap and water solution. h. When finished testing, turn R1 counterclockwise and turn off the cut button. i. Tighten any leaky connection found, repair or replace any leaky components. Retest the system Preheat Oxygen a. Close all torch valves. b. Select one oxy-fuel station. c. Turn off all pilot regulators (R1, R2, R3, R4, R5) by turning the handle counterclockwise d. Turn on the oxygen supply to the machine. (150psig. maximum) e. Enable electrical power for the gas system. g. If the system is to be tuned, turn needle valves V2 and V3 slightly counterclockwise. If the system is tuned, Do Not touch the valves. h. Set the LO preheat oxygen regulator (R3) for 100psig and turn the HI preheat regulator (R2) all the way in. i. Test all LO preheat oxygen connections for leaks, with a soap and water solution. j. Turn both pilot regulators counterclockwise and open one torch preheat oxygen valve to depressurize the system. k. Turn off the LO PRHT button. l. Tighten any leaky connection found, repair or replace any leaky components. Retest the system Fuel a. Close all torch valves. b. Select one oxy-fuel station. c. Turn off all pilot regulators (R1, R2, R3, R4, R5) by tuning the handle counterclockwise d. Turn on the fuel supply to the machine. (15psig. maximum) e. Enable electrical power for the gas system. f. Press the LO PRHT button. g. If the system is to be tuned, turn needle valve V4 slightly counter-clockwise. If the system is tuned, Do Not touch the valve. f. Press the LO PRHT button. E-19

173 MI0548A h. Set the LO preheat fuel regulator (R5) for 15psig and turn the HI preheat fuel regulator (R4) all the way in. i. Test all LO preheat fuel connections for leaks, with a soap and water solution. j. Turn both pilot regulators counterclockwise and open one torch preheat fuel valve to depressurize the system. k. Turn off the LO PRHT button. l. Tighten any leaky connection found, repair or replace any leaky components. Retest the system Zero Leak Test for Dome Loaded Regulators (R6, R7, and R8) Fuel, R8 a. Make sure oxy-fuel is not selected on the operators control panel. b. Turn counterclockwise the fuel pilot regulators. ( R4, R5) c. Close all torch fuel valves. (Turn clockwise) d. Disconnect the sensing line from the fuel manifold. e. Open the main fuel gas supply and apply soapy solution to the manifold sensing port. f. If bubbles appear, this is an indication that the dome-loaded regulator is leaking and must be repaired or replaced. g. Reconnect the sensing hose to the manifold. Preheat Oxygen, R7 a. Make sure oxy-fuel is not selected on the operators control panel. b. Turn counter-clockwise the HI and LO preheat oxygen pilot regulators. (R2, R3) c. Close all torch preheat oxygen valves. (Turn clockwise) d. Disconnect the sensing line from the preheat oxygen manifold. e. Open the main oxygen supply (150psig) maximum and apply soapy solution to the preheat oxygen manifold sensing port. f. If bubbles appear, this is an indication that the dome-loaded regulator is leaking and must be repaired or replaced. g. Reconnect the sensing hose to the manifold. Cutting Oxygen, R6 a. Press the CUT button on the operators panel. b. Turn counterclockwise the cutting oxygen pilot regulator. (R1) c. Close all torch cutting oxygen valves. (Turn clockwise) d. Disconnect the sensing line from the cutting oxygen manifold. e. Open the main oxygen supply (150psig) maximum and apply soapy solution to the cutting oxygen manifold sensing port. E-20

174 MI0548A f. If bubbles appear, this is an indication that the dome-loaded regulator is leaking and must be repaired or replaced. g. Reconnect the sensing hose to the manifold. h. Disable the gas mode. (Switch to Plasma mode.) ZERO LEAK TEST FOR INLET SOLENOID VALVES (SV1 thru SV5) a. Ensure the main gas supply is on and the oxy-fuel system is off. b. Turn clockwise all pilot regulators. (R1, R2, R3, R4, R5) c. Attach an identifying label to the three pilot hoses and the three sensing hoses and disconnect them at the manifold. d. Immerse the open ends of the cutting oxygen pilot and sensing hoses in water and cover the exit of the cutting oxygen blow-off solenoid valve (SV6) with your thumb. e. Bubbles in the water indicate a leak in the inlet solenoid valve (SV1). f. Repair or replace the solenoid valve. g. Test the preheat oxygen pilot and sensing hose ends as in the steps a-f covering the exit of preheat oxygen blow-off solenoid (SV7) with your thumb. h. If bubbles appear, one of the two preheat oxygen solenoid valves (SV2) HI or (SV3) has a leak. i. To determine which has a leak, turn counter-clockwise pilot regulator R2. If bubbles continue, SV3 is leaking, if the bubbles stop, SV2 has a leak. j. Test the preheat fuel pilot and sensing hose ends as in the steps a-f covering the exit of preheat fuel blow-off solenoid (SV8) with your thumb. k. If bubbles appear, one of the two preheat oxygen solenoid valves (SV4) HI or (SV5) has a leak. l. To determine which has a leak, turn counter-clockwise pilot regulator R4. If bubbles continue, SV5 is leaking, if the bubbles stop, SV4 has a leak. m. Turn counter-clockwise all pilot regulators. (R1, R2, R3, R4, R5) n. Leave the pilot and sensing hoses disconnected for the next test ZERO LEAK TEST FOR PILOT REGULATORS (R1thru R5) a. Turn fully counterclockwise all five pilot regulators. b. Ensure the main gas supply is on. c. Press the LOW PRHT button on the operators panel. d. Immerse the four ends of the preheat pilot and sensing hoses (fuel and oxygen) in the water. If bubbles appear the respective LO pilot regulator is leaking and must be repaired or replaced. e. Press the HI PRHT button. f. Immerse the four ends of the preheat pilot and sensing hoses (fuel and oxygen) in the water. If bubbles appear the respective HI pilot regulator is leaking and must be repaired or replaced. g. Turn off the HI preheat. h. Press the CUT button on the operators panel. E-21

175 MI0548A i. Check the two cutting oxygen pilot and sensing hoses for a cutting oxygen pilot regulator leak. If a leak appears the pilot regulator (R1) must be repaired or replaced. j. Disable the gas functions and reconnect all the hoses to their respective connecting point ZERO LEAK TEST FOR PILOT BLOW- OFF SOLENOID VALVES (SV6, SV7and SV8) a. Ensure the gas supply fuel and oxygen are on. All torch valves are closed. All the pilot regulators are fully counterclockwise. Press the CUT button. b. Set the LO fuel pilot regulator for 10 psig, LO preheat oxygen for 50 psig, and the cutting oxygen for 100 psig. c. Apply a soapy solution to the exit of all three blow-off valves SV6, SV7 and SV8. d. If bubbles appear, the valve is leaking and must be repaired or replaced. e. Disable the gas and turn fully counterclockwise all pilot regulators. f. Open the preheat valves on one torch to depressurize the system FLOW REGULATOR TEST Note: In order to perform this test multiple torch stations must be installed on your machine. (More than one.) This test will expose a faulty pilot regulator or any other system malfunction. It measures the manifold pressure drop due to the flow increases that occur as each torch is turned on. Conventional machine gas systems usually suffer a drop in delivery pressure between each pressure regulator and its manifold. The pilot regulators with feedback capabilities in this gas system minimize this drop. Should a pilot regulator exceed the permissible drop in the following tests, it is faulty and must be replaced. Preheat Oxygen Regulators a. Ensure that more than one oxy-fuel torch station is available. b. On torch number one, install a number 1 tip for the fuel gas being used and the torch preheat oxygen inlet a number.56 flow orifice; no tips or orifices on the other torches. c. Select oxy-fuel TORCH 1. d. Press the LO PRHT button on the operators panel. e. Turn on the main oxygen supply. f. Turn fully counterclockwise the preheat oxygen valve of torch 1, the one with the tip and orifice installed, keeping all other torch valves closed. g. Turn the adjusting screw of the LO preheat oxygen regulator until the gauge reads 10 psig. E-22

176 MI0548A h. Open the preheat oxygen valves of the other two torches (if available), select the torches and check gauge for any pressure drop; pressure drop should be no more than 0.5 psig. i. Close the torch valves leaving the first one, with the tip and orifice valve open. j. Reset the pressure to exactly 40 psig. k. Open the torch valves of the next torch, and another. Pressure drop should be no more than 2.5 psig. l. Close the torch valves leaving torch 1 open. m. Turn fully counter-clockwise the LO preheat oxygen pilot regulator. n. Press the HI PRHT button on the operators panel. o. Repeat steps f-m for the HI preheat pilot regulator. p. Shut off all torches and oxy-fuel functions. Preheat Fuel Pilot Regulators a. Using the same torch set-up as for the preheat oxygen, Press the LO PRHT button on the operators panel. b. Select oxy-fuel torch station 1. c. Turn on gas supply to the machine. d. Open the fuel valve on the torch (with the orifice and tip installed) keeping all other valves closed. e. Turn clockwise the adjusting screw of the LO preheat fuel pilot regulator and set the pressure at 4 psig. f. Open the fuel valves of the other two torches (if available), select the torches and check gauge for any pressure drop; pressure drop should be no more than 0.25 psig. g. Close the torch valves leaving the first one, with the tip and orifice valve open. h. Reset the LO fuel pressure to 10 psig and repeat step f; pressure drop should be no more than 0.5 psig. i. Press the HIGH PRHT button and check the HI preheat fuel pilot regulator using steps f-h. E-23

177 MI0548A 3.10 TROUBLESHOOTING This table lists possible problems with probable solutions and suggested remedies. Follow the figures listed previously for component location. Gauge creeps when all torch valves are closed. The system is off and all pilot regulators are set to the required pressures. Table 3.4 PROBLEM PROBABLE CAUSE REMEDY a. A leak in the respective dome loaded regulator (R6, R7 or R8) a. Shut off main gas supply and depressurize the supply line to the machine. Unscrew seat from the bottom of the regulator. Remove and clean thoroughly or replace. Cutting oxygen pressure does not rise when the system is turned on; supply pressure is correct and the cutting oxygen pilot regulator is set to the desired pressure. Fuel pressure does not rise when the system is turned on, supply pressure is correct and the pilot regulators (Hi and LO) are set to the desired pressure. b. A leak in respective inlet solenoid valve (SV1, SV2, SV3, SV4 or SV5) a. Ease-on valve (V1) is closed. (Turned fully clockwise) b. Normally open solenoid valve SV6 is not closing or has a leak. c. Pilot line from pilot regulator to dome regulator is loose or is leaking. d. Normally open solenoid valve SV9 on the cutting oxygen manifold is not operating correctly. e. Inlet solenoid valve SV1 is not opening. a. Normally open solenoid valve SV8 is not closing or has a leak. b. Pilot line from pilot regulator to dome regulator loose or leaking. c. Inlet solenoid valves SV4 or SV5 is not opening. d. Needle valve V4 is closed. b. Repair solenoid valve seat or replace. a. Open V1 slightly. b. Close valve outlet with thumb; if pressure rise, solenoid is faulty and should be repaired or replaced. c. Tighten hose and/or repair leak. d. Check electrical function and/or clean the seat. e. Check SV1 for a loose connection; repair if necessary. a. Check electrical function and/or clean the seat. b. Tighten hose and/or repair leak. c. Check SV4 or SV5 for loose a connection; repair if necessary. d. If the system is tuned it is not necessary to touch V4. If the system is not tuned, turn V4 counter-clockwise at least three turns. E-24

178 MI0548A Preheat oxygen pressure does not rise when the system is turned on, supply pressures are correct and pilot regulators (HI and LO) are set to the desired pressures. Preheat gauge (Oxygen or Fuel) pointer fluctuates around set pressure. Fuel pressure rises as the preheat oxygen pressure is increased. Flames flutter and make a vibrating noise. Table 3.4 continued a. Normally open solenoid valve SV7 is not closing or has a leak. b. Pilot line from pilot regulator to dome regulator loose or leaking. c. Pilot solenoid valve SV2 or SV3 is not opening. d. Needle valve V2 is closed. System is unstable One or more faulty check valves on the torches. Fuel check valves are faulty. a. Check electrical function and/or clean the seat. b. Tighten hose and/or repair leak. c. Check SV2 or SV3 for loose a connection; repair if necessary. d. If the system is tuned it is not necessary to touch V2. If the system is not tuned, turn V2 counter-clockwise at least three turns. Slightly adjust the appropriate needle valve (V2, V3 or V4) to dampen the oscillation. Replace the faulty check valve. Replace the faulty check valve. E-25

179 MI0548A SECTION 4 GAS SYSTEM START-UP & TUNE-UP The following pages cover individual procedures for each of the fuel gas categories listed below: Fuel Gas and System Page Section 4.1 Acetylene with Positive Pressure System E-27 Section 4.2 Propane/Propylene with Positive Pressure System E-29 Section 4.3 Natural Gas with Positive Pressure System E-31 NOTE SELECT ONLY THE SECTION FOR THE FUEL GAS AND THE SYSTEM [POSITIVE PRESSURE] BEING USED. FOLLOW THE INSTRUCTIONS FOR THAT PARTICULAR SYSTEM ONLY. E-26

180 MI0548A SECTION 4.1 GAS: Acetylene (Positive Pressure System) GAS SYSTEM START-UP AND TUNE-UP: (At Machine Installation) Torch-Tip Combination: Koike Style 500L torch with No. 56 orifice at the inlet of preheat oxygen valve and a No. 4, Koike 102 tip. Recommended Supply Pressure: Oxygen pisg; Acetylene pisg 1. Start: a. Open needle valves V2, V3 and V4 three (3) turns. b. Purge the system (manifold and hoses) as described in Section 5.1. c. Use four (4) torches on the machine for the tuning procedure. Note: If four torches are not available, tune the system with the largest tip size that you are to use with the machine. 2. Set-up Fuel Pressures: a. Back off adjusting screws of all five (5) pilot regulators. b. Close all torch valves. c. Press the LOW PRHT button on the operators panel. d. Open the main valve supplies of oxygen and fuel. Caution: To prevent fire when setting fuel pressure, keep sources of ignition away from torch area. When unlighted gas is flowing, keep duration as short as possible to minimize gas accumulation. e. Select one of the oxy/fuel stations. Make sure the torch is over the cutting area. f. Open the fuel valve on one torch 1/2 turn. g. Adjust LO (Preheat) Fuel pilot regulator to three (3) pisg. h. Press the High PRHT button for Hi Preheat. i. Adjust Hi Fuel regulator to about 8 pisg. j. Press the LOW PRHT button for LO Preheat. k. Close Fuel valve. 3. Set-up Preheat Oxygen Pressures: a. Open Preheat Oxygen valve on the selected torch one full turn. b. Adjust LO Preheat Oxygen pilot regulator to 10 pisg. c. Press the HIGH PRHT button on the operators panel and adjust the Hi Preheat Oxygen regulator to 25 pisg. d. Press the Cut button on the operators panel and close the manual cut valve at the selected torch. E-27

181 MI0548A 4. Set-up Cutting Oxygen Pressure: a. Open the cutting oxygen valve on the selected torch. b. Adjust Cutting Oxygen pilot regulator to 50 pisg. c. Close the valve. 5. Light and Adjust The Low Preheat Flame: (Selected Torch) a. Press the Cut button, open the fuel valve slightly, light torch, and just open the preheat oxygen valve. b. Gradually open preheat oxygen valve wide, simultaneously trimming the flame with the fuel valve to obtain a neutral flame. c. Manually open and close the torch cutting oxygen valve several times, adjusting the fuel valve if necessary to achieve: satisfactory preheat flame when cutting oxygen is off; and a neutral flame around the cutting oxygen stream for several inches from the tip face when the cutting oxygen is on. Note: The cutting oxygen stream within the neutral flame should be straight and several inches long. 7. Light Other Torches: With Cut still ON, light the other torches available up to four (4) total. Note: The cutting tips installed in the other torches must be the same as the first torch adjusted. 8. Tuning Details: a. Adjust needle valve V4 to give Hi to Low transition time of about 5 seconds by timing pointer movement on the fuel gauge; as a result LO to Hi will be about 2.5 seconds. b. Adjust the needle valves V3 and V2 until transition times noted on preheat oxygen gauge exactly match respective Hi to LO and LO to Hi transition times of the fuel gauge. c. Adjust Ease-On valve for smooth rise on the cutting oxygen gauge. d. Check for any flameouts or serious off ratio situations by alternately switching from LO to Hi, Hi to Cut and back. 6. Adjust High Preheat Flame: (Selected Torch): a. Press the HIGH PRHT button. Trim the flame if necessary, by adjusting Hi Fuel pilot regulator for higher or lower pressure. Do not touch the torch valve settings. (Note: Flames may tend to go off while changing from LO to Hi and vice versa, as the system is not yet tuned-up.) b. Press the Cut button. c. Close torch cutting oxygen valve. E-28

182 MI0548A SECTION 4.2 GAS: Propane/Proylene (Positive Pressure System) GAS SYSTEM START-UP AND TUNE-UP: (At Machine Installation) Torch-Tip Combination: Koike Style 500L torch with No. 56 orifice at the inlet of preheat oxygen valve and a No. 2, Koike 106 tip. Recommended Supply Pressure: Oxygen pisg; Propane pisg 1. Start: a. Open needle valves V2, V3 and V4 three (3) turns. b. Purge the system (manifold and hoses) as described in Section 5.1. c. Use four (4) torches on the machine for the tuning procedure. Note: If four torches are not available, tune the system with the largest tip size that you are to use with the machine. 2. Set-up Fuel Pressures: a. Back off adjusting screws of all five (5) pilot regulators. b. Close all torch valves. c. Press the LOW PRHT button on the operators panel. d. Open the main valve supplies of oxygen and fuel. Caution: To prevent fire when setting fuel pressure, keep sources of ignition away from torch area. When unlighted gas is flowing, keep duration as short as possible to minimize gas accumulation. e. Select one of the oxy/fuel stations. Make sure the torch is over the cutting area. f. Open fuel valve on one torch 1/2 turn. g. Adjust LO (Preheat) Fuel pilot regulator to four (4) pisg. h. Press the High PRHT button for Hi Preheat. i. Adjust Hi Fuel regulator to about 6 pisg. j. Press the LOW PRHT button for LO Preheat. k. Close Fuel valve. 3. Set-up Preheat Oxygen Pressures: a. Open Preheat Oxygen valve on one torch a full turn. b. Adjust LO Preheat Oxygen pilot regulator to 20 pisg. c. Press the HIGH PRHT button on the operators panel and adjust the Hi Preheat Oxygen regulator to 40 pisg. d. Press the Cut button on the operators panel and close the manual cut valve at the selected torch. E-29

183 MI0548A 4. Set-up Cutting Oxygen Pressure: a. Open cutting oxygen valve on the selected torch. b. Adjust Cutting Oxygen pilot regulator to 50 pisg. c. Close the valve. 5. Light and Adjust the Low Preheat Flame: (Selected Torch) a. Press the Cut button, open the fuel valve slightly, light torch, and just open the preheat oxygen valve. b. Gradually open preheat oxygen valve wide, simultaneously trimming the flame with the fuel valve to obtain a neutral flame. c. Manually open and close the torch cutting oxygen valve several times, adjusting the fuel valve if necessary to achieve: satisfactory preheat flame when cutting oxygen is off; and a neutral flame around the cutting oxygen stream for several inches from the tip face when the cutting oxygen is on. Note: The cutting oxygen stream within the neutral flame should be straight and several inches long. 7. Light Other Torches: With Cut still ON, light the other torches available up to four (4) total. Note: The cutting tips installed in the other torches must be the same as the first torch adjusted. 8. Tuning Details: a. Adjust needle valve V4 to give Hi to Low transition time of about 6 seconds by timing pointer movement on the fuel gauge; as a result LO to Hi will be about 4 seconds. b. Adjust the needle valves V3 and V2 until transition times noted on preheat oxygen gauge exactly match respective Hi to LO and LO to Hi transition times of the fuel gauge. c. Adjust Ease-On valve for smooth rise on the cutting oxygen gauge. d. Check for any flameouts or serious off ratio situations by alternately switching from LO to Hi, Hi to Cut and back. 6. Adjust High Preheat Flame: (Selected Torch): a. Press the HIGH PRHT button. Trim the flame if necessary, by adjusting Hi Fuel pilot regulator for higher or lower pressure. Do not touch the torch valve settings. (Note: Flames may tend to go off while changing from LO to Hi and vice versa, as the system is not yet tuned-up.) b. Press the Cut button. c. Close torch cutting oxygen valve. E-30

184 Section 4.3 MI0548A GAS: Natural Gas (Positive Pressure System) GAS SYSTEM START-UP AND TUNE-UP: (At Machine Installation) Torch-Tip Combination: Koike Style 500L torch with No. 56 orifice at the inlet of preheat oxygen valve and a No. 2, Koike 107 tip. Recommended Supply Pressure: Oxygen pisg; Natural Gas pisg 1. Start: a. Open needle valves V2, V3 and V4 three (3) turns. b. Purge the system (manifold and hoses) as described in Section 5.1. c. Use four (4) torches on the machine for the tuning procedure. Note: If four torches are not available, tune the system with the largest tip size that you are to use with the machine. 2. Set-up Fuel Pressures: a. Back off adjusting screws of all five (5) pilot regulators. b. Close all torch valves. c. Press the LOW PRHT button on the operators panel. d. Open the main valve supplies of oxygen and fuel. Caution: To prevent fire when setting fuel pressure, keep sources of ignition away from torch area. When unlighted gas is flowing, keep duration as short as possible to minimize gas accumulation. e. Select one of the oxy/fuel stations. Make sure the torch is over the cutting area. f. Open fuel valve on one torch 1/2 turn. g. Adjust LO (Preheat) Fuel pilot regulator to four (4) pisg. h. Press the High PRHT button for Hi Preheat. i. Adjust Hi Fuel regulator to about 6.5 pisg. j. Press the LOW PRHT button for LO Preheat. k. Close Fuel valve. 3. Set-up Preheat Oxygen Pressures: a. Open Preheat Oxygen valve on one torch a full turn while in LO Preheat. b. Adjust LO Preheat Oxygen pilot regulator to 25 pisg. c. Press the HIGH PRHT button on the operators panel and adjust the Hi Preheat Oxygen regulator to 50 pisg. d. Press the Cut button on the operators panel and close the manual cut valve at the selected torch. E-31

185 MI0548A 4. Set-up Cutting Oxygen Pressure: a. Open cutting oxygen valve on one torch. b. Adjust Cutting Oxygen pilot regulator to 50 pisg. c. Close valve. 5. Light and Adjust Low Preheat Flame (Selected Torch) a. Press the Cut button, open the fuel valve slightly, light torch, and just open the preheat oxygen valve. b. Gradually open preheat oxygen valve wide and simultaneously trimming the flame with the fuel valve to obtain a neutral flame. c. Manually open and close the torch cutting oxygen valve several times, adjusting the fuel valve if necessary to achieve: satisfactory preheat flame when cutting oxygen is off; and a neutral flame around the cutting oxygen stream for several inches from the tip face when the cutting oxygen is on. Note: The cutting oxygen stream within the neutral flame should be straight and several inches long. 7. Light Other Torches: With Cut still ON, light the other torches available up to four (4) total. Note: The cutting tips installed in the other torches must be the same as the first torch adjusted. 8. Tuning Details: a. Adjust needle valve V4 to give Hi to LO transition time of about 5 seconds by timing pointer movement on the fuel gauge; as a result LO to Hi will be about 3 seconds. b. Adjust the needle valves V3 and V2 until transition times noted on preheat oxygen gauge exactly match respective Hi to LO and LO to Hi transition times of the fuel gauge. c. Adjust Ease-On valve for smooth rise on the cutting oxygen gauge. d. Check for any flameouts or serious off ratio situations by alternately switching from LO to Hi, Hi to Cut and back. 6. Adjust High Preheat Flame (One Torch): a. Press the HIGH PRHT button. Trim the flame if necessary, by adjusting Hi Fuel pilot regulator for higher or lower pressure. Do not touch the torch valve settings. (Note: Flames may tend to go off while changing from LO to Hi and vice versa, as the system is not yet tuned-up.) b. Press the Cut button. c. Close torch cutting oxygen valve. E-32

186 MI0548A SECTION 5 OPERATION 5.1 PURGING When all gas supply connections to the machine are completed, the system must be purged. This is required to remove any mixture of air-fuel or oxygen-fuel that may cause a fire and/or explosion in the torch hoses and manifold. If the machine is idle for an extended period of time with the torch valves open you must perform a purge. Hazardous oxygen-fuel mixtures may be caused by clogged tips and other equipment malfunction, or by improper operating and lightup procedures. To Purge: a. Close all torch valves and check that correct tips are installed on all torches. b. Press the LOW PRHT button on the operators panel. c. Select torch station by pressing the selected torch button. Note: Torch Select will not enable if over the parking area. d. Set LO Preheat Oxygen regulator at 10 psig. e. Set LO Fuel regulator at 3 psig. f. Press the CUT button on the operators panel. g. Set Cutting Oxygen regulator at 50 psig. h. Open preheat oxygen valve on the first torch a full turn for 3 seconds and close it. Repeat this step on each torch in turn. Note: Use a 3 second purge for machines equipped with four (4) or more torches. For fewer torches, purge for 5 seconds for each torch valve. i. Open the fuel valve on the first torch a full turn for 3 seconds and close it. Repeat this step on each torch in turn. j. Open cutting oxygen valve on the first torch for 3 seconds and close it. Repeat this step on each torch in turn. k. Depressurize system: 1. Disable all oxy-fuel functions. 2. Back off all regulator-adjusting screws. 3. On one torch only, open preheat oxygen, then the fuel valve until the respective gauge pointers reach zero (0). 4. Close all torch valves. WARNING Extinguish all sources of ignition near torches during the following steps and ventilate area to remove the discharged gases. E-33

187 5.2 LIGHT UP PROCEDURE 3. Setup Preheat Oxygen Pressure: MI0548A 1. Start: a. Back off adjusting screws of all five (5) pilot regulators. b. Close all torch valves. c. Select torch station by pressing the selected torch button. Note: Torch Select will not enable if over the parking area. d. Place the Preheat switch in the center position for LO Preheat. 2. Set Up Fuel Pressures: a. Open fuel valve on one torch 1/2 turn. WARNING To prevent fire, when setting fuel pressure, keep sources of ignition away from torch areas. When unlighted gas is flowing, keep duration as short as possible to minimize gas accumulation. b. Adjust LO (Preheat) Fuel pilot regulator for operating pressure (See Section 3). c. Press the HIGH PRHT button. d. Adjust Hi Fuel regulator for operating pressure. e. Press the LOW Preheat button. f. Close fuel valve. a. Open preheat oxygen valve on one torch a full turn. b. Adjust LO Preheat Oxygen pilot regulator for operating pressure. (See Section 4) c. Press the HIGH PRHT button. and adjust the Hi Preheat Oxygen regulator for operating pressure. d. Press the Cut button and close the torch valve. 4. Setup Cutting Oxygen Pressure: a. Open the cutting oxygen valve on one torch. b. Adjust Cutting Oxygen pilot regulator for cutting pressure (See Section 4). c. Close the torch valve. 5. Light and Adjust Low Preheat Flame (One Torch): a. With Cut ON, open fuel valve slightly, light torch, and just open the preheat oxygen valve. b. Adjust both valves for correct preheat flame (If pressures given in Section 6 Operating Data For Preheat System are correctly used, with No.56 orifice installed at preheat oxygen valve inlet for positive pressure system, preheat oxygen valve should be wide open.) c. Manually open and close the torch cutting oxygen valve several times, adjusting the fuel valve if necessary to achieve: satisfactory preheat flame when cutting oxygen is off; and a neutral flame around the cutting oxygen stream for several inches from the tip face when the cutting oxygen is on. Note: The cutting oxygen stream within the neutral flame should be straight and several inches long. E-34

188 6. Adjust High Preheat Flame (One Torch): a. Press the HIGH PRHT button and trim flame if necessary, by adjusting the Hi FUEL pilot regulator for higher or lower pressure. DO NOT touch valve settings. b. Press the CUT button. c. Close torch cutting oxygen valve. 7. Light Other Torches: a. With Cut still ON, light up other torches one at a time as described in step 5. b. After lighting each torch, close its cutting oxygen valve. MI0548A 8. Check HI to LO Transition and Set Cutting Oxygen EASE-ON: a. With all torches lit, alternate between HI and LO. Open all torches cutting oxygen valves, press CUT on, and press CUT OFF. Cycle (2) or three (3) times to check that there are no flameouts, or flames going seriously off ratio, in these transitions. b. If a problem occurs, the system must be re-tuned (See Section 4). During the switching process, while the cutting oxygen goes on and off, set the EASE-ON valve for desired rate of rise of cutting oxygen pressure (normally 2 to 3 seconds). Cut: The System is ready for cutting. Regulators and torch valves need not be disturbed. 9 E-35

189 SECTION 6 OPERATING DATA FOR PREHEAT/CUTTING MI0548A The following pages cover individual procedures for each of the fuel gas categories listed below: Fuel Gas and System Page Acetylene E-37 Propane/Propylene E-39 Natural Gas E-41 NOTE SELECT ONLY THE PREHEAT DATA SHEET FOR THE FUEL GAS AND THE SYSTEM USED. E-36

190 6.1 MI0548A OPERATING DATA FOR PREHEAT / CUTTING NOTE: SYSTEM MUST BE PURGED AND TUNED BEFORE CUTTING ANY STEEL. GAS: Acetylene Torch-Tip Combination: Koike Style 500L torch with No. 56 orifice at the inlet of preheat oxygen valve and Koike 102- D7 style tips. Recommended Supply Pressure: Oxygen psig; Acetylene psig NOTE: THE SETTINGS LISTED BELOW MAY NOT ALWAYS BE ACHIEVED DUE TO THE TYPE OF STEEL, RUST AND SCALE. Article II. Table 6.1 Pressure Settings Acetylene Appx. Manifold Pressure (psig) Tip Cutting Kerf Steel Thickness HI Preheat LO Preheat Cut Size Speed In. In. In/min. Oxygen Fuel Oxygen Fuel Oxygen 1/ /4-3/ / / / / SETTING UP PREHEAT FLAMES: The following provides brief highlight information for lighting and setting the preheat flames using the Servo Gas Control System. NOTE: Refer to Section 5, Subsection 5.2 for the proper detailed light up procedure. a. For the thickness of the plate to be cut, select LO and HI preheat oxygen and fuel pressures from the Pressure Setting table above. b. Set Gas System at pressures selected above. panel. Manually open and close the torch cutting oxygen valve several times, adjusting the fuel valve if necessary to achieve: satisfactory preheat flame when cutting oxygen is off; and a neutral flame around the cutting oxygen stream for several inches from the tip face when the cutting oxygen is on. Note: The cutting oxygen stream within the neutral flame should be straight and several inches long. d. If higher or lower preheat level is desired, increase or decrease LO preheat pressure. DO NOT throttle preheat oxygen valve on the torch. Leave it wide open. c. Press the CUT button on the operators E-37

191 e. If greater LO fuel pressure is required, open fuel valve farther. Trim flame with LO Fuel regulator. Raise this pressure by 1/2 to 1 psig higher and again trim the fuel valve. MI0548A f. With HIGH Preheat on, trim the HI preheat flame by adjusting the HI Fuel regulator pressure higher or lower as required. DO NOT touch the fuel valve on torch. This level of preheat is suitable for piercing or starting cut. E-38

192 6.2 MI0548A OPERATING DATA FOR PREHEAT SYSTEM NOTE: SYSTEM MUST BE PURGED AND TUNED BEFORE CUTTING ANY STEEL. GAS: Propane/Propylene Torch-Tip Combination: Koike Style 500L torch with No. 56 orifice at the inlet of preheat oxygen valve and Koike Style106-D7 tip. Recommended Supply Pressure: Oxygen psig; Propane psig NOTE: THE SETTINGS LISTED BELOW MAY NOT ALWAYS BE ACHIEVED DUE TO THE TYPE OF STEEL, RUST AND SCALE. Article III. Table 6.2 Pressure Settings Propane/Propylene Appx. Manifold Pressure (psig) Tip Cutting Kerf Steel Thickness HI Preheat LO Preheat Cut Size Speed In. In. In/min. Oxygen Fuel Oxygen Fuel Oxygen 1/ /4-3/ / / / / SETTING UP PREHEAT FLAMES: The following provides brief highlight information for lighting and setting the preheat flames using the Servo Gas Control System. NOTE: Refer to Section 5, Subsection 5.2 for the proper detailed light up procedure. a. For the thickness of the plate to be cut, select LO and HI preheat oxygen and fuel pressures from the Pressure Setting table above. b. Set Gas System at pressures selected above. panel. Manually open and close the torch cutting oxygen valve several times, adjusting the fuel valve if necessary to achieve: satisfactory preheat flame when cutting oxygen is off; and a neutral flame around the cutting oxygen stream for several inches from the tip face when the cutting oxygen is on. Note: The cutting oxygen stream within the neutral flame should be straight and several inches long. d. If higher or lower preheat level is desired, increase or decrease LO preheat pressure. DO NOT throttle preheat oxygen valve on the torch. Leave it wide open. c. Press the CUT button on the operators E-39

193 e. If greater LO fuel pressure is required, open fuel valve farther. Trim flame with LO Fuel regulator. Raise this pressure by 1/2 to 1 psig higher and again trim the fuel valve. MI0548A f. With HIGH Preheat on, trim the HI preheat flame by adjusting the HI Fuel regulator pressure higher or lower as required. DO NOT touch the fuel valve on torch. This level of preheat is suitable for piercing or starting cut. E-40

194 6.3 MI0548A OPERATING DATA FOR PREHEAT SYSTEM NOTE: SYSTEM MUST BE PURGED AND TUNED BEFORE CUTTING ANY STEEL. GAS: Natural Gas Torch-Tip Combination: Koike Style 500L torch with No. 56 orifice at the inlet of preheat oxygen valve and Koike Style107-D7 tip. Recommended Supply Pressure: Oxygen psig; Natural Gas-- 15 psig (5 psig minimum) NOTE: THE SETTINGS LISTED BELOW MAY NOT ALWAYS BE ACHIEVED DUE TO THE TYPE OF STEEL, RUST AND SCALE. Article IV. Table 6.3 Pressure Settings NATURAL GAS Appx. Manifold Pressure (psig) Tip Cutting Kerf Steel Thickness HI Preheat LO Preheat Cut Size Speed In. In. In/min. Oxygen Fuel Oxygen Fuel Oxygen 1/ /4-3/ / / / / SETTING UP PREHEAT FLAMES: The following provides brief highlight information for lighting and setting the preheat flames using the Servo Gas Control System. NOTE: Refer to Section 5, Subsection 5.2 for the proper detailed light up procedure. a. For the thickness of the plate to be cut, select LO and HI preheat oxygen and fuel pressures from the Pressure Setting table above. b. Set Gas System at pressures selected above. c. Press the CUT button on the operators panel. Manually open and close the torch cutting oxygen valve several times, adjusting the fuel valve if necessary to achieve: satisfactory preheat flame when cutting oxygen is off; and a neutral flame around the cutting oxygen stream for several inches from the tip face when the cutting oxygen is on. Note: The cutting oxygen stream within the neutral flame should be straight and several inches long. d. If higher or lower preheat level is desired, increase or decrease LO preheat pressure. DO NOT throttle preheat oxygen valve on the torch. Leave it wide open. E-41

195 e. If greater LO fuel pressure is required, open fuel valve farther. Trim flame with LO Fuel regulator. Raise this pressure by 1/2 to 1 psig higher and again trim the fuel valve. MI0548A f. With HIGH Preheat on, trim the HI preheat flame by adjusting the HI Fuel regulator pressure higher or lower as required. DO NOT touch the fuel valve on torch. This level of preheat is suitable for piercing or starting cut. E-42

196 APPENDIX F MI0548A 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. WARNING Ensure all safety precautions and warnings are adhered to. All plasma cutting radiates high levels of light and noise. SINGLE PLASMA Single plasma operation starts by selecting plasma one (1) on the pushbutton keypad. Note: If your machine has two systems, select Plasma 1 or Plasma 2 When the button is selected all functions for the plasma 1 station are enabled. 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 plasma system is started. The signals, plasma start and torch height control are signals generated from the CNC and are programmable outputs controlled from the parameters for plasma setups. The CNC must be set for plasma cutting with the correct settings for the plasma type and height control used. The signals to the plasma start and height control and from the plasma to the machine go through the programmable logic controller for the tool select. Selecting start from the 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 the CNC will initiate IHS for both plasma systems. The start signal will wait until both IHS complete signals are present. When the plasma starts the height control is independent allowing for part accuracy for both pieces cut. If the optional safety mount is mounted to the lifter, when one of the safety mounts trip, both plasmas will shut down. You must clear the obstruction and reset the mount. The touch panel and the red light located on the three tower will signal an error. Once reset, lost cut recovery using the CNC will resume the cut. F-1

197 MI0548A

198 APPENDIX G MI0548A DIGITAL HEIGHT CAPACITANCE SENSING October 1999 Revision 0 G-1

199 TABLE OF CONTENTS SECTION 1 Section 1.1 SAFETY PRECAUTIONS...G-3 General Safety, Oxy-fuel Cutting...G-4 SECTION 2 INTRODUCTION...G-5 Section 2.1 Section 2.2 Section 2.3 SECTION 3 Section 3.1 Section 3.2 Section 3.3 SECTION 4 Section 4.0 Section 4.1 SECTION 5 Scope...G-5 Installation Requirements...G-5 Specifications...G-5 OPERATION...G-6 Rough Height Setting...G-6 CNC Operation...G-6 Thick Plate Piercing...G-6 MAINTENANCE...G-7 8 Hours...G-7 Adjustment Procedure...G-7 REPLACEMENT PARTS...G-9 ILLUSTRATIONS & TABLES Figure 4.1 Zero Balance Adjustment... G-8 Figure 4.2 Height Setting... G-8 G-2

200 MI0548A SECTION 1 SAFETY PRECAUTIONS USER RESPONSIBILITY - This equipment will perform in conformity with the description thereof in this manual and accompanying labels and/or inserts when installed, operated, maintained and repaired in accordance with the instructions provided. This equipment must be checked periodically. Defective equipment should not be used. Parts that are broken, missing, plainly worn, distorted or contaminated should 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 approval of Koike Aronson. The user of this equipment shall have sole responsibility for any malfunction, which results from improper use, faulty maintenance, damage, improper repair or alteration by anyone other than Koike Aronson or a facility, designated by Koike Aronson. NOTES, CAUTIONS & WARNINGS Throughout this manual, notes, cautions, and warnings are used to describe situations 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 in operating the cutting system. Caution: A caution describes a situation that may cause damage to the machine and offers advice to avoid or rectify the situation. WARNING A warning describes a situation that presents a physical danger to the operator, and offers advice to avoid or rectify the situation. G-3

201 MI0548A 1.1 GENERAL SAFETY, OXY/FUEL CUTTING Operation of oxy/fuel torches involves oxygen and flammable gases under pressure, open flames, flying slag and hot metal, fumes and combustion products. Follow the precautions in this General Safety Section as well as those throughout this manual for your personal safety and the safety of people in the area that may be affected. 1. Check gas and electrical connections for tightness after installation and on a regular basis thereafter. 2. Keep combustibles away from the work area or protect them from sparks and flames. 3. Check for proper function of check valves regularly. Do not remove or bypass check valves. 4. Always open gas valves slowly. 5. Never use oxygen to ventilate the area or clean off clothing. 6. Keep oil, grease, and combustible dust away from all oxygen equipment. 7. Purge oxygen and fuel lines individually whenever combustible mixtures in the lines are suspected. 8. Never use the oxygen hose for any other gas than oxygen. 9. Replace hose that is damaged by physical abuse or by sparks, heat or open flame. 10. Examine hoses at regular intervals for leaks, wear, loose connections or other hazards. 11. Examine hoses at daily intervals for leaks, wear, loose connections or other hazards. 12. Coil excess hose and place it out of the way to prevent damage and to eliminate tripping danger. 13. Maintain all pressure regulators in proper working condition. 14. Never use a regulator for any gas other than that for which it is intended. 15. Never use a regulator that leaks, creeps excessively or is physically damaged in any way. 16. Never attempt to lubricate a regulator with oil or grease. 17. Wear filter-lens safety eye protection. Wear gauntlet gloves, safety shoes, flame retardant clothing, and cuffless trousers. Do not wear loose clothing around this machinery as they can catch on the machine. 18. Shut off power and gas supplies whenever leaving machine unattended or before servicing. 19. Keep equipment clean and in good operating condition. 20. Read and understand further detailed safety precautions throughout this manual. 21. Also, refer to the latest revisions of the following sources of safe practices in welding and cutting. A. National Fire Protection Association Standard 51B CUTTING AND WELDING PROCESS, obtainable from NFPA, Batterymarch Park, Quincy, MA B. NFPA Standard 51, OXYGEN/FUEL GAS SYSTEMS FOR WELDING AND CUTTING, obtainable same as item A. C. American Welding Society publication C4.2-90, OPERATOR'S MANUAL FOR OXY/FUEL GAS CUTTING. G-4

202 MI0548A SECTION 2 INTRODUCTION 2.1 SCOPE This appendix provides a step by step guide for operation, adjustment and a troubleshooting guide for the digital capacitance height sensing unit. This unit maintains the distance between the torch tip and the steel plate. This option utilizes the change between the electrostatic sensing ring and the steel plate. 2.2 INSTALLATION REQUIREMENTS An oxy-fuel station with a Model G motorized lifter is required. 2.3 SPECIFICATIONS A minimum of 100 VAC, 50/60 Hz, 40 VA/set. Tracking accuracy +/ inches (2 mm). Note: Speed 24 IPM (600mm/min.) Tracking height.500in. (15mm) Note: This has an adjustable range of -.2in(5mm) to.39in. (10mm). Can be used with automatic ignition and water spray. +. 2in. (5mm). Tracking method is on and off controlled by CNC or the enable/disable toggle switch. This option must be used with an AC type, up and down lifter. This unit cannot be used with a plasma torch. Cannot be used for thick plate piercing. Note: Above 1in. (25mm). G-5

203 MI0548A SECTION 3 OPERATION 3.0 OPERATION c) WARNING Before attempting any adjustment make sure all gases are turned off to the torch station. Operation of the digital capacitance sense begins by selecting an oxy-fuel torch station.you must also have the CNC setups for oxy-fuel cutting. Pressing the start on the CNC will start the torch lifter motion towards the steel plate. When Zero balance is reached, the torch lifter will stop. This setting is approximately.59in. (15mm) above the plate. At this time, the cutting cycle will begin. The digital capacity height sensing option is equipped with a touch sense. Any time the option is enabled and the sensing ring is touched, all lifter motion will stop and the torch will go up for 1(one) second. NOTE: Zero balance will be explained in the alignment and adjustment section. 3.1 MANUAL Manual operation is used for checking the adjustments, sensitivity and height setting. Note: TURN OFF MANUAL GAS VALVES AT THE SELECTED TORCH. Select the SELECT ON toggle switch located at the pre-amp and drive box mounted on the top of the G lifter at the selected oxy-fuel torch station. At the touch screen panel, select the desired oxy-fuel torch. At the CNC, enter the diagnostic screen, I/O and manually toggle the torch down output. This combination will allow for the adjustment of the sensing box to the ring, plate distance. When the adjustment and alignment is completed, reverse the order of the above steps. 3.2 CNC Select the SELECT ON toggle switch located at the pre-amp and drive box mounted on the top of the G lifter at the selected oxy-fuel torch station. At the touch screen panel, select the desired oxy-fuel torch. With the CNC, select oxy-fuel mode and with the proper cutting parameters, select START, when the cut on signal is received to the programmable controller, starts the process of finding the correct cutting height. 3.3 THICK PLATE PIERCING When piercing thick plate, components of the sensing unit must be removed and disabled. Remove the sensing bar and antenna from the torch. Place these parts where they will not be damaged or lost. Turn off the toggle switch at the pre-amp and drive box. WARNING Failure to perform the above step will damage the G-6

204 MI0548A SECTION 4 MAINTENANCE HOURS After each 8(eight) hours of operation clean the sensor ring and the epoxy where the ring connects to the sensor bar. Inspect the sensing ring for damage and warping. 4.1 ADJUSTMENT PROCEDURE 1. Before adjustment takes place, ensure all cables are connected and no damage to the sensing ring, sensor bar or the sensor box has occurred. 2. Wait 10 (ten) minutes for warm-up stability to take place. Note: Do not have the system enabled at this time. 3. Adjustment of the pre-amp and drive unit. 3.1 Disconnect the FV cable at the pre-amp and drive unit. 3.2 Remove the cover to expose the printed circuit board. 3.3 Apply power to the unit. 3.4 Locate the TP5 and 0v; place a temporary jumper wire across these terminals. 3.5 Locate TP2 and measure the voltage between TP2 and 0v. The voltage measured should be 0VDC. Make sure the trim potentiometer on the sensor box is at the middle position. 3.6 Remove the jumper installed across TP5 and 0v. 3.7 Check up and down movement by manual operation. 3.8 Reconnect the FV cable. 3.9 Measure the voltage at TP7 and adjust VR2 to obtain a reading between 0.1v to 0.3VDC Enable the auto function so the torch begins to move toward the plate. Measure the voltage at TP2 make sure this voltage is negative. Place your hand close to the ring sensor monitoring the voltage at TP2, this should now read a positive voltage and the lifter should be driving the torch up. Note: Do not touch the ring, touch sense is enabled. 4. Adjustment of the height sensor. (Zero Balance) 4.1 Set the height setting potentiometer on the height sensor box for the middle position. 4.2 With a cutting tip installed in the torch, enable the auto mode and let the sensing unit find the height. 4.3 Remove the cover on the sensor box. Do not lose the hardware. 4.4 Turn the enable switch to off. 4.5 Measure the height of the bottom of the sensor ring to the plate. This measurement should be.59in. (15mm).See Figure If the measured distance is not correct, adjust the TCI potentiometer located on the printed circuit card. Note: Use plastic or insulated screwdriver. A metallic tool will change the sensitivity of the adjustment. 4.7 Once Zero Balance is achieved, the covers can be replaced and operation of the system is normal. G-7

205 MI0548A Cover Removed, location of TC1 Figure mm Maximum Distance Plate Surface Figure 4.2 G-8

206 MI0548A SECTION 5 REPLACEMENT PARTS Figure 5.1 Note: Only Major Components Are Listed. Item Number Part Number Part Description Quantity Digital Capacitance Sensing Unit 1 * Sensor w/antenna Cable Support w/screws 2 3 * Sensor Ring (100mm Dia.) Preamp and Drive Unit Preamp and Drive PCB 6 * Capacitance Sensing Unit 1 G-9

207 MI0548A APPENDIX H DRIVE SETTING PARAMETERS October, 1999 Revision 0 H-1

208 MI0548A MILLENNIUM YASKAWA AC SERVO PARAMETER SETTINGS MODEL NUMBER: 08AS Category Gain Related Constants Torque Related Constants Sequence Related Constants Pulse Related Constants User Constant No. Cn-00 Article V. ode Name Unit Lower Limit Upper Limit Factory Setting KAR Factory Settings Not a user constant (Cn-00 is used to select special mode for digital operator.) Cn-01 Memory Switch (see page 404) Cn-02 Memory Switch (see page 405) Cn-03 VREFGN Speed Reference (r/min)/ gain V Cn-04 LOOPHZ Cn-05 PITIME Speed Loop gain Hz Speed Loop integration time constant ms Cn-1A POSGN Position loop gain 1/s Torque reference gain Emergency stop (0.1 V/rated Cn-13 TCRFGN torque) Maximum Cn-06 EMGTRQ torque % 0 torque Forward rotation Maximum Cn-08 TLMTF torque limit % 0 torque Reverse rotation Maximum Cn-09 TLMTR torque limit % 0 torque Speed limit for Maximum Cn-14 TCRLMT torque control I r/min 0 Speed Torque reference Cn-17 TRQFIL filter time constant Forward external Maximum Cn-18 CLMIF torque limit % 0 torque Reverse external Maximum Cn-19 CLMIR torque limit % 0 torque Soft start time Cn-07 SFSACC (acceleration) ms Soft start time Cn-23 SFSDEC (deceleration) ms Maximum Cn-0B TGONLV Zero-speed level r/min 1 speed Cn-0F ZCLVL Zero-clamp level r/min Cn-12 BRKTIM Cn-15 Cn-16 Cn-22 Cn-0A Cn-11 BRKSPD BRKWAI VCMPLV PGRAT PULSNO Time delay from brake reference until servo OFF Speed level for brake reference output during motor operation Output timing of brake reference during motor operation Speed coincidence signal output range Dividing ratio Maximum torque 30 Maximum torque 316 Maximum torque 316 Maximum Speed ms r/min 0 Maximum speed ms r/min setting P/R Number of encoder pulses P/R KAR Installed Settings H-2

209 MI0548A MILLENNIUM YASKAWA AC SERVO PARAMETER SETTINGS (continued) Category Other Constants User Constant No. Article VI. ode Cn-0C TRQMSW Cn-0D REFMSW Cn-0E ACCMSW Name Mode switch Unit Lower Limit (torque reference) % 0 Mode switch (speed reference) r/min 0 Mode switch 10 (acceleration (r/min)/ reference) s Cn-10 JOGSPD Jog speed r/min 0 Cn-1F SPEED1 1 st speed (contact input speed control) Cn-20 SPEED2 2nd speed (contact input speed control) Cn-21 SPEED3 3rd speed (contact input speed Cn-28 NFBCC control) Speed loop compensation constant r/min 0 r/min 0 r/min 0 Upper Limit Maximum Factory Setting KAR Factory Settings torque Maximum speed Maximum speed Maximum speed Maximum speed Maximum speed Cn-29 AXISNO Axis address KAR Installed Settings Note: After changing the setting, always turn the power OFF and then On after changing the setting. This makes the new setting valid. H-3

210 MILLENNIUM YASKAWA AC SERVO PARAMETER SETTINGS (continued) MI0548A List of user constants (memory switch setting 1) User Bit Constant Setting No. No. Input Signal enable/ disable TGON signal switching Operation performed at recovery from power loss Sequence selection at alarm condition Control Mode selection Mode switch selection Cn B A D C 0 1 Does not use servo ON input Use servo ON input (S-ON). (S-ON). Servo is always ON. 0 1 Does not use SEN signal input (SEN) when absolute encoder is Uses SEN signal input (SEN) used. Servopack automatically when absolute encoder is used. treats signal voltage as high level. 0 1 Uses forward rotation prohibited input (P-OT). Does not use forward rotation prohibited input (P-OT). Forward rotation is always possible. 0 1 Uses reverse rotation-prohibited input (N-OT). Does not use reverse rotation prohibited input (N-OT). Reverse rotation is always possible. 0 1 Uses TGON signal (TGON) as running output. Uses TGON signal (TGON) as torque limit output. 0 1 Remains in servo alarm status at recovery from power loss. Automatically resets servo alarm status at recovery from power loss. 0 1 Stops the motor by applying dynamic brake when an alarm arises. Causes the motor to coast to a stop when an alarm arises. 0 1 When an alarm arises, stops the motor by applying dynamic brake and then releases dynamic brake. When an alarm arises, stops the motor by applying dynamic brake but does not release dynamic brake. 0 1 Stops the motor according to bit 6 setting when overtravel is detected (P-OT, N-OT). Decelerates the motor to a stop by applying the torque specified in Cn-06 when overtravel is detected (P-OT, N-OT). 0 1 When an overtravel is detected (P-OT, N-OT), decelerates the motor to a stop by applying the torque specified in Cn-06 and then turns the servo OFF. When an overtravel is detected (P-OT, N-OT), decelerates the motor to a stop by applying the torque specified in Cn-06 and then performs zero-clamp Speed control Speed control Torque control Torque control with zeroclamp function I II Uses internal torque reference as a condition. (Level setting: Cn-0C) Uses speed reference as a condition. (Level setting: Cn-0D) Uses acceleration as a condition. (Level setting: Cn-0E) Does not use mode switch function. Factory Setting KAR Factory Settings KAR Installed Settings H-4

211 MILLENNIUM YASKAWA AC SERVO PARAMETER SETTINGS (continued) MI0548A Encoder selection Torque feed-forward function Rotation direction selection Home position error processing selection Contact input speed User Constant No. Cn-01 Cn-02 Bit No. E F Setting Factory setting KAR Factory Setting Uses incremental encoder Uses absolute encoder Does not use torque feedforward function function 0 0 Uses torque feed-forward 0 1 X-1 Defines Motor CCW Direction Defines Motor CW Direction 0 1 Detects home position error (when absolute encoder is used). Does not detect home position error. 0 1 Does not use contact input speed control. Uses contact input speed control control Note: For the Cn-01 and Cn-02 memory switches, always turn the power OFF and then On after changing the setting. This makes the new setting valid. List of user constants (memory switch setting 2) Reserved Motor selection User Constant No. Cn-02 Bit No Setting Factory setting Y-0 Y1-0 KAR Factory Setting For X, Y1,Y2 Reserve d (not to b e set) SGM motor SGMP motor 0 1 Reserved A-9 Reserved (not to be set) 0 0 Integration time constant setting unit Torque reference filter type B C ms 0.01 ms 0 1 Primary Secondary Reserved E-D Reserved (not to be set) 0 0 Torque reference input selection F 0 1 Uses torque reference or torque feed-forward reference Servopack Type Factory Setting KAR Setting SGDA- S 0 0 SGDA- SP 1 Uses analog voltage reference as torque limit input 0 0 Note: For the Cn-01 and Cn-02 memory switches, always turn the power OFF and then On after changing the setting. This makes the new setting valid. KAR Installed Setting KAR Installed Setting For X, Y1,Y2 H-5

212 APPENDIX I SP400 MI0548A December, 1999 Revision 0 I-1

213 MI0548A TABLE OF CONTENTS SECTION 1 SAFETY PRECAUTIONS... I-3 Section 1.1 General Safety, Oxy/Fuel Cutting... I-4 SECTION 2 Overview... I-5 Section 2.1 I-Cut... I-5 Section 2.2 V-Cut... I-6 Section 2.3 Y-Cut... I-6 Section 2.4 X-Cut... I-7 Section 2.5 K-Cut... I-7 SECTION 3 REPLACEMENT PARTS... I-9 ILLUSTRATIONS & TABLES Figure 2.1 General Torch Layout... I-8 Figure 2.2 Torch Cut... I-8 Figure 3.1 Bevel Assembly... I-9 Figure 3.2 Optional Igniter For Bevel Assembly... I-11 I-2

214 MI0548A SECTION 1 SAFETY PRECAUTIONS USER RESPONSIBILITY - This equipment will perform in conformity with the description thereof in this manual and accompanying labels and/or inserts when installed, operated, maintained and repaired in accordance with the instructions provided. This equipment must be checked periodically. Defective equipment should not be used. Parts that are broken, missing, plainly worn, distorted or contaminated should 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 approval of Koike Aronson. The user of this equipment shall have sole responsibility for any malfunction, which results from improper use, faulty maintenance, damage, improper repair or alteration by anyone other than Koike Aronson or a facility, designated by Koike Aronson. NOTES, CAUTIONS & WARNINGS Throughout this manual, notes, cautions, and warnings are used to describe situations 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 in operating the cutting system. Caution: A caution describes a situation that may cause damage to the machine and offers advice to avoid or rectify the situation. WARNING A warning describes a situation that presents a physical danger to the operator, and offers advice to avoid or rectify the situation. 1.1 GENERAL SAFETY, OXY/FUEL CUTTING I-3

215 MI0548A Operation of oxy/fuel torches involves oxygen and flammable gases under pressure, open flames, flying slag and hot metal, fumes and combustion products. that for which it is intended. 15. Never use a regulator that leaks, creeps excessively or is physically damaged in any way. Follow the precautions in this General Safety Section as well as those throughout this manual for your personal safety and the safety of people in the area that may be affected. 1. Check gas and electrical connections for tightness after installation and on a regular basis thereafter. 16. Never attempt to lubricate a regulator with oil or grease. 17. Wear filter-lens safety eye protection. Wear gauntlet gloves, safety shoes, flameretardant clothing, and cuffless trousers. Do not wear loose clothing around this machinery as they can catch on the machine. 2. Keep combustibles away from the work area or protect them from sparks and flames. 18. Shut off power and gas supplies whenever leaving machine unattended or before servicing. 3. Check for proper function of check valves regularly. Do not remove or bypass check valves. 4. Always open gas valves slowly. 19. Keep equipment clean and in good operating condition. 5. Never use oxygen to ventilate the area or clean off clothing. 20. Read and understand further detailed safety precautions throughout this manual. 6. Keep oil, grease, and combustible dust away from all oxygen equipment. 21. Also, refer to the latest revisions of the following sources of safe practices in welding and cutting. 7. Purge oxygen and fuel lines individually whenever combustible mixtures in the lines are suspected. A. National Fire Protection Association Standard 51B CUTTING AND WELDING PROCESS, obtainable from NFPA, Batterymarch Park, Quincy, MA Never use the oxygen hose for any other gas than oxygen. B. NFPA Standard 51, OXYGEN/FUEL GAS SYSTEMS FOR WELDING AND CUTTING, obtainable same as item A. 9. Replace hose that is damaged by physical abuse or by sparks, heat or open flame. 10.Examine hoses at regular intervals for leaks, wear, loose connections or other hazards. C. American Welding Society publication C4.2-90, OPERATOR'S MANUAL FOR OXY/FUEL GAS CUTTING. 11. Examine hoses at daily intervals for leaks, wear, loose connections or other hazards. 12. Coil excess hose and place it out of the way to prevent damage and to eliminate tripping danger. 13. Maintain all pressure regulators in proper working condition. 14. Never use a regulator for any gas other than I-4

216 MI0548A SECTION 2 OVERVIEW 2.0 GENERAL OVERVIEW The SP400 cutting option can be used in several optional ways to optimize your cutting needs and reduce extra cutting operations. Torch numbers are as follows. The SP-400 has three torches mounted on its station, with one ignition assembly. Depending on the desired cut, the manual needle valves on the manifold for the SP-400 torch station have to be opened for the correct torch. Note that the center torch will ignite the two bevel torches. The torch arrangement depends on the direction of travel. Depending on the plate thickness, preheating the cut path could result in improved cut surface quality. The cutting types are demonstrated in the following figures. The SP400 assembly consists of a model G12 torch lifter that supports the SP400 torch assembly. A gas distributor with manual valves is mounted on the torch arm support bracket. The gas distributor has individual hoses connected to them for gas control to each torch. Mounted on the guide bar assembly is a swivel-mounting bracket for holding the guide bar that supports the three cutting torches. An adjustable counter-weight is attached to the guide bar for the correct tension of the guide rollers to the plate. This arrangement allows the assembly to float on the plate while cutting. The guide rollers are tightened to the support arm. The torch assembly allows for I- cutting, (square), V-cutting (one side bevel), Y- cutting (one side bevel with a land dimension) and X-cutting (the top and bottom of the part are angled). 2.1 I-CUT 2 1 # 5 tip a. Select the desired torch station at the operators control panel. b. Lower the SP400 torch assembly to about three inches from the top of the plate. c. Loosen the wing nut that holds the counter weight assembly and adjust the counter weight so that the guide rollers are just floating on the plate. d. Lock into position and square the I- PART torch to the plate. e. Using a precision square, adjust the I- torch for perpendicularity. f. Once the I-torch is perpendicular, the station is ready to square cut. g. Ensure the correct tip is installed for the thickness of plate you are cutting. h. Loosen the wing nut on the counter weight assembly and ensure the just floating on the plate is still adjusted properly. i. Prepare for normal cutting functions using the CNC. 2 SCRAP 3 # 3 tip # 3 tip I-5 Cut direction

217 MI0548A b. Lower the SP400 torch assembly to about three inches from the top of the plate. 2.2 V-CUT a. Select the desired torch station at the operators control panel. c. Loosen the wing nut that holds the counter weight assembly and adjust the counter weight so that the guide rollers are just floating on the plate. b. Lower the SP400 torch assembly to about three inches from the top of the plate. d. Select torches two and one or three. Adjust torch two for an I-cut. Adjust for the desired cutting angle with torch one or torch three. Note: Using the graduations on the torch holder is a rough angle setting. Take into consideration the torch kerf, scrap side, and torch height to plate. c. Loosen the wing nut that holds the counter weight assembly and adjust the counter weight so that the guide rollers are just floating on the plate. d. Select either torches one or three, and adjust for the desired cutting angle. Note: Using the graduations on the torch holder is a rough angle setting. Take into consideration the torch kerf, scrap side, and torch height to plate. e. To adjust for the land size, take into consideration the kerf of the I-cut and the kerf of the angle cut. Adjust the in/out distance using the adjustment handle for either torch one or torch three PART SCRAP e. Once the torch angle is set, the station is ready to V-cut. PART f. Ensure the correct tip is installed for the thickness of plate you are cutting. SCRAP Land Dimension g. Loosen the wing nut on the counter weight assembly and ensure the just floating on the plate is still adjusted properly. f. Once the torch angles are set, the station is ready to Y-cut. h. Prepare for normal cutting functions using the CNC. h. Loosen the wing nut on the counter weight assembly and ensure the just floating on the plate is still adjusted properly. g. Ensure the correct tips are installed for the thickness of plate you are cutting. 2.3 Y-CUT a. Select the desired torch station at the operators control panel. i. I-6 Prepare for normal cutting functions using the CNC.

218 MI0548A 2.4 X-CUT 2.5 K-CUT a. Select the desired torch station at the operators control panel. a. Select the desired torch station at the operators control panel. b. Lower the SP400 torch assembly to about three inches from the top of the plate. b. Lower the SP400 torch assembly to about three inches from the top of the plate. c. Loosen the wing nut that holds the counter weight assembly and adjust the counter weight so that the guide rollers are just floating on the plate. c. Loosen the wing nut that holds the counter weight assembly and adjust the counter weight so that the guide rollers are just floating on the plate. d. Select torches one and three. Adjust for the desired cutting angle with torch one or torch three. Adjust the desired cutting angle with the torch not previously d. Select torches one, two and three. Adjust torch two for an I-cut. Adjust for the desired cutting angle with torch one or torch three. Adjust the desired cutting angle with the torch not previously selected. Note: Using the graduations on the torch holder is a rough angle setting. Take into consideration the torch kerf, scrap side, and torch height to plate. 3 1 PART SCRAP e. To adjust for the land size, take into consideration the kerf of the I-cut and the kerf of the angle cut. Adjust the in/out distance using the adjustment handle for either torch one or torch three. selected. Note: Using the graduations on the torch holder is a rough angle setting. Take into consideration the torch kerf, scrap side, and torch height to plate. e. 2 Once the torch angles are set, the station is ready to X-cut. 1 3 f. Ensure the correct tips are installed for the thickness of plate you are cutting. PART g. Loosen the wing nut on the counter weight assembly and ensure the just floating on the plate is still adjusted properly. Land Dimension h. Prepare for normal cutting functions using the CNC. I-7 SCRAP

219 MI0548A SP400 Manifold Assembly Model G12 Torch Riser Torch Direction Swivel Assembly Counter Weight Assembly Torch In/Out Adjustment Guide Roller Assembly SP400 Ignitor Assembly Figure 2.1 Bevel Torch Layout Figure 2.2 Torch Cut I-8

220 MI0548A SECTION 3 REPLACEMENT PARTS Front view of Bevel Assembly Figure 3.1 Bevel Assembly I

221 MI0548A Note: Only Major Components Are Listed. Item Number Part Number ZS ZS ZS30223 ZS30248 ZS30351 Part Description TRIPLE BEVEL STATION, SLAVE Torch Lifter Cable Assembly G Torch Riser, 12 Proximity Switch, N.O. 1065VDC Turk, Bi2-M12-AD4X H1141 Distributor Slave Carriage Steel Band Clamp Assembly VG, DX Counter Weight, 6 Dia.x2 Torch Holder, C Type w/guide Roller Wheel, Caster Shoulder Bolt, 6mm Dia. X 20mm Flange Bearing, PAF06070P10 Hand Wheel Threaded Rod, 3/8-16x2.5 Handle Screw Torch Slide Base ZS30353 *NOTE ZS10652 ZS30352 Torch Holder Use Standard KSK Tips Torch Torch Holder Bracket *NOTE: Do Not Use High Speed Tips. I-10 Quantity

222 MI0548A Mounted on support arm next to bevel manifold Center Torch Reference Figure 3.2 Optional Igniter Unit for Bevel Assembly Note: Only Major Components Are Listed. Item Number Part Number ** ZS62971 ZS60991 * ZM *ZM62973 *ZM62972 *ZS60290 ZS60282 ZS60611 ZS Part Description Igniter Unit Solenoid Valve Noise Suppressor Rubber Boot Ignition Transformer, Sig-100-KO Fuel Check Valve Pilot Tube Teflon Tube Glass Fiber Tube Electrode Pilot Tip, Acetylene Pilot Tip, Natural Gas Pilot Tip, Propane Short Clamp Assembly Quantity ** Note: The last two digits of this Part number will change depending on the type of gas used. Order the correct tip for the gas used. I-11

223 MI0548A APPENDIX J RAIL INSTALLATION AND SPECIFICATIONS December 1999 Revision 0 J-1

224 TABLE OF CONTENTS SECTION 1 SAFETY PRECAUTIONS... J-3 SECTION 2 INTRODUCTION Section 2.1 Section 2.2 Section 2.3 Scope... J-4 Installation Requirements... J-4 Specifications... J-4 SECTION 3 BASIC RAIL INSTALLATION... J-5 Section 3.1 Section 3.2 Section 3.3 Section 3.4 Koike Aronson Supplied H-beams/ Rails... J-5 Fine Rail Alignment... J-6 Customer Supplied H-beams... J-6 Suggested Tool Listing for Rail Installation... J-8... J-4 J-2

225 SECTION 1 SAFETY PRECAUTIONS USER RESPONSIBILITY - This equipment will perform in conformity with the description thereof in this manual and accompanying labels and/or inserts when installed, operated, maintained and repaired in accordance with the instructions provided. This equipment must be checked periodically. Defective equipment should not be used. Parts that are broken, missing, plainly worn, distorted or contaminated should be replaced immediately. Should repair or replacement become necessary, Koike Aronson recommends that a request for service be made to Koike Aronson, Inc. Authorized Distributor or directly to the Koike Aronson, Inc. Service Department. This equipment or any of its parts should not be altered without prior written approval of Koike Aronson. The user of this equipment shall have sole responsibility for any malfunction, which results from improper use, faulty maintenance, damage, improper repair or alteration by anyone other than Koike Aronson or a facility, designated by Koike Aronson. NOTES, CAUTIONS & WARNINGS Throughout this manual, notes, cautions, and warnings are used to describe situations 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 in operating the cutting system. Caution: A caution describes a situation that may cause damage to the machine and offers advice to avoid or rectify the situation. WARNING A warning describes a situation that presents a physical danger to the operator, and offers advice to avoid or rectify the situation. J-3

226 MI0548A SECTION 2 INTRODUCTION 2.1 SCOPE SITE PREPARATION This appendix provides a step by step guide for three types of rail installations approved by Koike Aronson, Inc. They are customer supplied H-beam, Koike Aronson, Inc. supplied H-beam and floor mount, pad type. The floor area supporting the rails and table should be specified by a qualified civil engineer after reviewing the appropriate drawing supplied with this machine. The foundation shall be designed to meet local conditions. Koike Aronson recommends the concrete to be 3000psi minimum strength. Floor vibration should not exceed 10um INSTALLATION REQUIREMENTS NOTE: The following preparations should be complete before the arrival of the installing technician. SITE LOCATION Special consideration must be used in the selection of a site for cutting machine operation. Fuel, oxygen, electrical outlets, clean dry shop air and water in the immediate vicinity are essential for economical operation of any oxy-fuel/plasma cutting machine. Material handling is also important and space for stockpiling plate and parts as well as material movement by hoist, truck or other means must be considered. The cutting machine requires a space where floor vibration is at a minimum. Precision operation is necessary for accurate part cutting. An area where transmission of vibration (caused by drop hammers, heavy machinery, trucks or rail sidings) must be avoided. Positioning of the unit close to a production line, adequate lighting and ventilation should also be considered. Review the dimensional machine layout in order to determine correct working area requirements, allowing adequate aisle space to provide for operator safety, traffic flow and overhead clearance. J-4 Solid, secure and accurate rail and support beam installation is critical to insure maximum accuracy for the cutting, oxy-fuel and plasma processes. The floor for the machine installation should be level within 3/8in. (9.5mm) over the entire length and width. If any possibility of floor settlement exists, separate footing should be provided over a firmly packed base. If a possibility of equipment vibration exists, the machine should be provided with an adequate isolation pad. 2.3 SPECIFICATIONS H-beam specifications are W12 72# for the Millennium. H-beam specifications are W16 72# for the Mastergraph.

227 MI0548A SECTION 3 BASIC RAIL INSTALL 3.0 BASIC RAIL INSTALLATION NOTE: THIS SECTION COVERS THE BASIC RAIL OF ALL THREE TYPES OF RAIL INSTALLATIONS. EACH SECTION WILL BE IN DETAIL PERTAINING TO THE TYPE OF RAIL INSTALLATION. 1. Locate the rail gauge of your machine. (This is found on the 888****** drawing of your machine.) 7. At each anchor pad, level the H-beam at the top, side to side and at the same height as possible to the point found in step 6. Note: The H-beam cannot be perfectly leveled but the closer it is to level the easier the rail installation will be. If required, two Hbeams can be fitted end to end. Ensure these are as tight together as possible. 2. Snap a chalk line the entire rail distance. 3. Using the rail gauge, measure the distance and snap another line parallel to the first line. NOTE: Check this measurement several times before continuing. This measurement is critical to the rest of the installation. 8. Anchor the H-beam to the floor at the mounting pads using a roto-hammer and a one-half inch concrete bit. Ensure the holes made are cleaned. 9. Weld the H-beam together at the seams. 4. Locate the center of the H- beam and mark the bottom of both ends. 10. Thoroughly clean the protective coating on the rails using LPS-1 or WD-40. Ensure the ends of the rail are also cleaned. 5. Place the H- beam on the chalk line aligning the center of the H-beam to the chalk line. Set outboard H-beam and check diagonals. 11. Check rail gauge. Note: The thickness of the support pad may vary due to floor flatness. Do Not use longer bolts for leveling the H-beam. Use a shim pad if required. 6. Using a (water level), locate the highest point of the H-beam using the main rail and outboard rail. Note: Take a reading at each rail joint adjuster. This is the fourhole adjuster. J KOIKE ARONSON SUPPLIED HBEAMS/RAILS NOTE: When the H-beams are supplied by Koike Aronson, Inc., the joint rail adjusters and the mid rail adjusters are not required. NOTE: The rail is attached to the H-beam at Koike Aronson with weldments. The rails must be cleaned. When placing the Hbeam on the floor ensure the rack faces out. 1. Make sure steps 1-11 of the Basic HBeam install is complete and all hardware is secure.

228 MI0548A 2. Center the main rail on the pads, side to side and repeat for the outboard side. 3. Perform step 1 on the outboard rail. To be within.1mm (.004 ) over the entire length. 3. Measure the diagonals on the first section of rails. Ensure this measurement is within 1mm (.039 ). 4. Ensure all rail mounting hardware is tight. Note: If you have to tighten any hardware at this point, you must check for straightness. 4. Level the main and outboard rails in both directions. The length with the water level and across the top with a small precision level. Note: Tightness of rail hardware ensures the integrity of the installation. Make sure the hardware is tight. 3.3 CUSTOMER SUPPLIED H-BEAMS NOTE: The customer is responsible for fabrication of the H-BEAM per Koike Aronson, Inc. drawing number CMD or CMD Place the piano wire (.020) on the top inside edge of the main rail. Tighten and secure both ends of the rail. Note: Ensure that the piano wire is drawn tight and secure in place using Cclamps. NOTE: Koike Aronson, Inc. will provide the joint rail adjuster and the mid rail adjuster along with associated mounting hardware for the rail. 6. By observing the distance between the wire and the rail by rough estimations, you can adjust the rail so it is close to being straight. 1. Ensure the H- beam is prepared for the rail installation. 7. Perform steps 5 and 6 for the outboard rail. 2. Make sure steps 1-11 of the Basic HBeam install is complete and all hardware is secure. 8. Check the rail gauge. To be within 1mm (.039 ). 3. Thoroughly clean the protective coating on the rails using LPS-1 or WD-40. Ensure the ends of the rail are also cleaned. Note: Ensure that both end sections are tightened completely. 3.2 Fine Rail Alignment 4. Place the joint rail adjuster and mid rail adjuster in their respective places on the H-beam noting the four and two hole positions for installing the adjusters. 1. Using the electronic micrometer, adjust the main rail straightness to within.1mm (.004 ) over the entire length. You must adjust at each rail weldment. 5. Place the first rail section on the Hbeam. Make sure rack the mounting holes face out. 2. Check rail gauge. To be within + 1mm (.039 ). Note: Never -. J-6

229 6. Place the first rail section on the outboard H-beam. Ensure the rack mounting holes face out. 7. Check the rail gauge. To be within 1mm (.039 ). 8. Ensure the rails are parallel to each other. Inboard and outboard using the first section of rail. Measure the diagonals they have to be within 1mm (.039 ). Floor Pad W12-72 Check the rail gauge. To be within + 1mm (.039 ). Place the remaining main rails on the H-beams and snug all mounting hardware MI0548A 10. At the rail joints, install rail joint fasteners and snug the rails together. 11. Place the piano wire on the top inside edge of the main rail. Tighten and secure both ends of the rail. Note: Ensure that the piano wire is drawn tight and secure in place using C- clamps. Floor Pad W By observing the distance between the wire and the rail by rough estimations, you can adjust the rail so it is close to being straight. 13. Perform steps eleven and twelve for the outboard rail. 14. Check the rail gauge. It should be within + 1mm (.039 ). 15. Perform section 3.2, steps 1 through 4. J-7

230 MI0548A 3.4 SUGGESTED TOOL LISTING FOR RAIL INSTALLATION 1. Water Level Part Number Micrometer Kit K Tracing Pen ZS Tracing Pen ZS for Plasma torch for Oxy-fuel torch 5. Tap M12x1.75 for adjusting pads and rail level 6. Tap M6x1 for mounting the rack J-8

231 MI0548A APPENDIX K AIR SCRIBE MARKER December, 2001 Revision 0 K- 1

232 MI0548A TABLE OF CONTENTS SECTION 1 SAFETY PRECAUTIONS... K-3 SECTION 2 INTRODUCTION Section 2.1 Section 2.2 Scope... K-4 Installation Requirements... K-4 SECTION 3 OPERATION Section 3.1 Section 3.2 Manual... K-5 CNC /Automatic Operation...k-5 SECTION 4 MAINTENANCE Section 4.1 Changing the stylus... K-7 SECTION 5 REPLACEMENT PARTS... K-8 ILLUSTRATIONS & TABLES Figure K.1 Table K-1 Figure K.2 Scribe... K-6 Troubleshooting... K-7 Parts... K-8 K- 2

233 MI0548A SECTION 1 SAFETY PRECAUTIONS USER RESPONSIBILITY - This equipment will perform in conformity with the description thereof in this manual and accompanying labels and/or inserts when installed, operated, maintained and repaired in accordance with the instructions provided. This equipment must be checked periodically. Defective equipment should not be used. Parts that are broken, missing, plainly worn, distorted or contaminated should be replaced immediately. Should repair or replacement become necessary, Koike Aronson recommends that a request for service be made to a Koike Aronson, Inc. Authorized Distributor or directly to the Koike Aronson, Inc Service Department. This equipment or any of its parts should not be altered without prior written approval of Koike Aronson. The user of this equipment shall have sole responsibility for any malfunction, which results from improper use, faulty maintenance, damage, improper repair or alteration by anyone other than Koike Aronson or a facility, designated by Koike Aronson. NOTES, CAUTIONS & WARNINGS Throughout this manual, notes, cautions, and warnings are used to describe situations 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 in operating the cutting system. Caution: A caution describes a situation that may cause damage to the machine and offers advice to avoid or rectify the situation. WARNING A warning describes a situation that presents a physical danger to the operator, and offers advice to avoid or rectify the situation. K- 3

234 MI0548A SECTION 2 INTRODUCTION 2.1 SCOPE This appendix provides a step-by-step guide for operation, adjustment and a troubleshooting guide for the scribe marking station. The station consists of a model G torch lifter (a six or twelve inch lifter) with a four-inch stroke air cylinder. Air solenoids control the up and down movement of the cylinder while another controls the on and off operation. A course adjustment to the plate is made by the Model G torch lifter. 2.2 INSTALLATION REQUIREMENTS 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, Koike Aronson 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 the station. A Filter-LubricatorRegulator with good quality spindle oil is recommended. The FLR should be adjusted so there is a slight oil mist in the exhaust. K- 4

235 MI0548A SECTION 3 OPERATION 3.0 OPERATION 3.1 MANUAL Manual operation begins by selecting the SCRBE MKR push button. Press the ALL DOWN button; the model G lifter will lower the scribe assembly to the plate. When the assembly is within four inches of the plate, press the SCRBE MKR down arrow. The air cylinder will lower the scribe to the plate and turn the scribe on. To turn the scribe off, press the up arrow button. Note the cylinder will retract. Press the ALL UP button to raise the model G lifter. 3.2 CNC/AUTOMATIC OPERATION The codes for marker on/off and offset on/off must be in the program to be marked and or cut. At the operator s panel, lower the scribe assembly to within the marking distance. Enter the program for marking. The marking process will automatically be selected and perform the up/down of the scribe cylinder and the scribe on/off processes of the program. K-5

236 MI0548A SECTION 4 MAINTENANCE Model G Torch Lifter Air Cylinder, 4 stroke Scribe Assembly Stylus Figure K-1Scribe K-6

237 MI0548A WARNING Disconnect the air supply before performing any maintenance on the scribe assembly. Trouble Low power TROUBLESHOOTING GUIDE Probable Cause Solution Low pressure at the inlet Check the air supply. For top performance, the air pressure must be 90 psig (6.2 bar/62okpa) at the inlet. Internal dirt accumulation Pour about 3 cc of a clean, suitable cleaning solution into the air inlet and operate the tool for a few seconds. Immediately, pour a few drops of the recommended oil into the air inlet and operate the tool for about 30 seconds to lubricate the internal parts. Worn Piston and/or Cylinder Lack of adequate lubrication Replace the Piston and/or Cylinder. Check the lubricator to make sure it is working properly. If a lubricator is not used, pour a few drops of the recommended oil into the air inlet after every two hours of operation. Leaky Throttle Sleeve Warn Housing Seals Replace the Housing Seals. Air cylinder will not raise or Check the I/O to ensure the Check the I/O fuses for integrity. lower output for the solenoids is coming on. Ensure CNC correct. program is Correct the posted program. 4.1 CHANGING THE STYLUS Table K-1 a. Carefully, place the housing in copper-covered or leather-covered vise jaws, inlet side down. b. Using a wrench on the flats of the nosepiece unscrew (turn counterclockwise) and remove 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 K-2 K-7

238 MI0548A SECTION 5 REPLACEMENT PARTS Inlet Throttle Sleeve Housing Housing Seal Piston Stop Piston Cylinder O-Ring Cylinder Spacer Stylus Stylus Spring Nosepiece Figure K-2 Scribe Assembly K-8

239 MI0514A APPENDIX L MANUAL BEVEL PLASMA TORCH IMPORTANT THIS MANUAL IS DESIGNED TO DESCRIBE THE MANUAL BEVEL CUTTING PROCESS. A CUSTOMER SUPPLIED CUTTING CHART MUST BE DEVELOPED AND MAINTAINED. DESCRIPTION The manual bevel torch station is designed to place a bevel on the edge of square plate or part. There are no provisions for contour beveling a part. An automatic height control maintains the distance of the torch to the plate by using the arc voltage of the plasma. Located on the bevel block is an air operated safety mount that prevents torch damage by stopping the machine when tripped. Angle adjustment is made by slightly loosening the thumbscrew lock and turning the adjustment knob clockwise or counter-clockwise. A protractor located on the block allows for approximate setting of angles. A laser spot indicator located at the top of the plasma block allows for viewing the offset of the torch. Note the spot will turn off during the cut. When the cut is completed, and after a two second delay the spot will automatically turn on. A swivel assembly allows the torch block to be set at 0, plus 90 and minus 90 degrees. These positions are indicated with a detent using the thumbscrew. INSTALLATION For ease of installation, a few parts are removed for shipping. 1. Install the laser pointer and bracket with the supplied screws to the top mount. Connect the electrical cable to the pointer. 2. Fasten the bevel block assembly to the mounting extension located on the main carriage with the provided hardware. 3. Place the plasma torch body in the clamp so it is approximately centered in the holder and tighten. 4. Level the following components in order a. Extension bracket b. Pivot arm assembly c. Lifter d. Torch mounting bracket 5. Ensure the lifter is parallel to the main beam. Measure from the lifter mount to the faceplate of the main carriage. Measure from both sides of the lifter. 6. Make all electrical connections L-1

240 MI0514A Laser pointer a. Level - Extension bracket b. Level d. Level c. Level L-2 Pivot arm

241 MI0514A SETUP MEASURING CUT OFFSET Three offsets should be measured between the laser pointer and the center of the plasma torch. The offset dimensions are references only. 0, +90 and -90. Enter the measured offsets in the CNC setup screen as offsets 1, 2 and 3 respectively. Note: The offsets are used as a guide only and do not reflect where the cut angle reference to part size occurs. The 0 measurement is recorded with the torch block parallel to the beam assembly. This setting allows cutting bevels in the longitudinal (Y) axis. 0 Degree offset measurement The plus 90 measurement is recorded by loosening the pivot stop clamp and swinging the pivot assembly to the left until the detent sets. The setting allows cutting bevels in the transverse (X) axis. +90 Degree offset measurement The minus 90 measurement is recorded by loosening the pivot stop clamp and swinging the pivot assembly to the right until the detent sets. The setting allows cutting bevels in the transverse (X) axis. -90 Degree offset measurement L-3

242 MI0514A UNDERSTANDING PART SIZE Part size is always determined by the longest measured side. OPERATIONAL NOTES 1. Always use a CW swirl ring for cutting bevel angled parts. A CCW type consumable will drastically change the arc voltage, and cut-face. Damage to the torch may occur. 2. Always cut in a CW direction. 3. The arc voltage and cutting speed must be set to the actual part thickness. This means that a 9mm plate cut on a 45-degree angle is actually 12.72mm. An example of the settings would be: THICKNESS 9mm 12.72mm ANGLE SETTING 0 45 CUTTING SPEED ARC VOLTAGE There is an arc voltage difference between a positive and negative bevel cut. An example of this would be a 9mm, positive 22 cut with an arc voltage setting of 140. The negative 22 cut would have an arc voltage setting of Too low of an arc voltage setting will cause the height control to oscillate. Increase the voltage setting 5 volts with each test cut until the oscillation is minimized. Zero degree, positive and negative angle cutting. L-4

243 MI0514A SETTING THE HEIGHT CONTROL 1. The bevel angle is set manually before initiating a start command. Only nozzle contact sense may be used for setting the pierce height factor. This method uses a wire attached to the shield cap. Do not use the stall force parameter setting. Stall force will cause alignment problems and damage the lifter slide assembly. 2. Angles greater than 15 degrees use larger amperage consumables in the torch, than the cutting charts indicate. 3. Piercing is not recommended. The height control performs three steps when commanded to start the cutting process. Three factors that greatly influence bevel-cutting operations are as follows. 1. Pierce height factor: Pierce height will depend upon the bevel angle. Since the bevel angle is set prior to cutting, the plate must be sensed by nozzle contact. As the torch angle increases, the distance at which the pilot arc must extend to contact the material increases. The arc will only extend so far. If the arc cannot extend long enough to contact the material at the desired angle, main arc will not transfer and the cut will be terminated. In order to establish a main arc of angles above 30, pierce height must be altered. This is accomplished by pressing the A key on the THC remote pendent and lowering the pierce height factor parameter. The standoff height at which the pierce will occur is a percentage of the set cut height. The actual pierce height is set using a combination of the two parameters, pierce height factor and cut height. 2. Cut Height: This parameter sets the height that the torch standoff is immediately adjusted to once main arc transfer has occurred. When performing manual bevel cutting operations, the key to minimizing scrap at the start of the cut is the proper setting of this parameter in relation with the actual set arc voltage. As soon as the pierce completes, the torch must immediately rise to an equal standoff height, as represented by the actual arc voltage setting. This will prevent the height variation at the beginning of the cut, which changes the part size. This parameter setting is located on the main screen of the THC pendant. The combination of the settings 1 and 2 will be set so the height difference between the two processes will be equal. Example Problem: If the cut height is set for.15 inch and the pierce height factor is set at 200 %, the pierce will occur at.3 inches (7.6mm), 200% of.15 inches (3.8mm). This may be too high for a 45-degree angle. Lower the pierce height factor until the pierce is consistent at desired set angle. Example Problem: If the cut height is set for.15 inches (3.8mm) and the pierce height factor is set to 100%, the pierce is consistent (1 and 2 are equal), but the torch standoff adjusts to the set arc voltage as soon as machine motion begins. A delay caused by the accel delay parameter and the distance required to adjust for the set arc voltage could be the problem. L-5

244 MI0514A The accel delay parameter is under the A key parameters on the THC remote. The parameter delays the standoff adjustment to the actual arc voltage setting after machine motion has started. This ensures that the machine has accelerated to speed before turning on the arc voltage control. To minimize this effect on the cut, the set cut height needs to be set as close as possible to the standoff distance represented by the arc voltage parameter. Incorrect adjustment of PIERCE HEIGHT, CUT HEIGHT and ARC VOLTAGE parameters Correct adjustment of PIERCE HEIGHT, CUT HEIGHT and ARC VOLTAGE parameters 3. Arc Voltage: This parameter represents the actual standoff from the material during the cutting process. The voltage setting translates to distance between the material and the center divot of the electrode within the torch body. As the electrode wears, divot becomes deeper; the standoff becomes less for the same arc voltage setting. (The torch will be lower during the cut.) Example: To allow the standoff to increase to the arc voltage standoff distance immediately after the pierce is complete, set cut height parameter to equal the arc voltage distance. Then set pierce height factor below 100 % to allow the pierce to take place. This will minimize the starting scrap distance. Note: ALL THREE PROCESSES MUST WORK TOGETHER FOR A CLEAN, SMOOTH CUT. PROCESS: 1. Start cutting Process: 2. Torch down, material is sensed by ohmic nozzle contact. 3. Torch retracts to distance set by the cut height and pierce height factor. 4. The torch starts, an arc transfer occurs when the standoff height is correctly set. 5. The torch will immediately rise to set cut height. 6. Machine motion will occur and immediately after the acceleration delay, the arc voltage control begins tracking the plate. At this time, no large adjustments for the torch to work standoff distance would be required. L-6