SUAG SCICHAU-CODIMAT-U

GAS CUTTING MACHINE

CNC SYSTEM : BURNY PHATOM CUSTOMER : M/s. GODREJ & BOYCE MFG. CO. LTD, MUMBAI

REFURBISHED BY:

BALAJI AUTOTECH Pvt. Ltd.,

216, NEETHI MARGA, SIDDARTHA NAGARA MYSORE-570 011, PH.: 0821-2474102

e-mail: balaji_autotech@yahoo.com

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MECHANICAL MANUAL 1. ASSEMBLY DRAWINGS 1.1 GAS REG. AND DISTRIBUTION (MO7061) 1.2 MOTOR MTG. ASSY. 1.3 GEN ARRANGEMENT 1.4 RAIL ASSEMBLY 2. SPARE PARTS LIST ASSEMBLY DRAWINGS 3. DESCRIPTION OF PROCESS AND EQUIPMENT 3.1 Process 3.2 Gas supply to the machine 3.3 Hoses and connection 3.4 Pressure regulators 3.5 Nonreturn valves 4. INSTRUCTIONS FOR SAFETY 5. STARTING-UP AND MAINTANANCE

5.1 Selecting the Nozzles 5.2 Setting the gas pressure 5.3 Igniting and adjusting the flame 5.4 Maintenance of torches, nozzles & non return valves 5.5 Starting the cut and hole-piercing 5.6 Hole-piercing 5.7 Cutting by means of multi-bevel heads 5.8 Cutting speed 6. MACHINE CUTTING NOZZLES 6.1 Maintenance instructions for flame cutting nozzles 7. TYPICAL OPERATING DATA FOR FLAME CUTTING NOZZLE

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8. GAS REGULATOR AND CONTROLS 9. OPERATING INSTRUCTIONS FOR ESAB PRESSURE REGULATORS

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2. SPARE PART LIST SL. DESCRIPTION NO. 1 PINION 22T/1.5M 2 RACK-1 3 RACK-2 DEEP GROVE BALL 4 BEARING 5 AIR CONDITIONER 6 7 8 9 10 11 12 13 14 15 16 CABLE DRAG CHAIN GAS REGULATOR GAS REGULATOR GAS REGULATOR PRESSURE GAUGE PRESSURE GAUGE SILENCER HTD PULLEY 22-8M-27 HTD PULLEY 44-8M-30 CLAMPING BUSH HTD BELT DRG/TYPE M06498 M06496 M06497 6305-2RS1 TURBO-450M2 (ADVANCE) 055.30.75.100-46 LINKS IDA4B IOX14 IOX13B 0-14 KG/CM2, 1/4 BSP 0-4 KG/CM2, 1/4 BSP 1/2" BSP M06511 M06512 RCK13, 20x47 480-8M-20 20mm ID, BLACK COLOR 8mm ID 8mm ID FD204NCFBRV3LDBSP, 220VAC WITH LED FS204NCFBRV3LDBSP WITH 220VAC WITH LED QTY UOM 3 NO 46 NO 5 NO 6 NO 1 NO 4 2 1 2 2 1 1 3 3 3 3 NO NO NO NO NO NO NO NO NO NO NO AXIS / TYPE X/Y X/Y X/Y X/Y PANEL Y GAS GAS GAS OXYGEN ACETYLENE OXY BO BO BO BO GAS ACETYLENE OXYGEN ACETYLENE OXYGEN

17 ROCK DRILL HOSE 18 RED HOSE 19 BLUE HOSE 2 WAY SOLENOID 20 VALVE 2 WAY SOLENOID 21 VALVE

40 MT 30 MT 60 MT 4 NO 8 NO

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3. Description of processes and equipment

3.1 Process

Oxy-fuel flame cutting is that thermal cutting process which is executed with a fuel gas/oxygen flame and cutting oxygen. The material is heated locally to ignition temperature and combusted at this point in the stream of cutting oxygen. The heat which is produced by the heating flame and on combustion of the material permits a continuous process of combustion in the stream of cutting oxygen. The reaction is propagating in the depth and upon movement in the feed direction. The oxides produced mixed with weld metal also called cutting slag are ejected by the cutting oxygen jet, thereby producing the cutting kerf. Flame cutting of materials is only possible of they meet the following requirements: 1. The material which is heated to ignition temperature must combust in the oxygen stream production fluid oxides, which can be ejected. 2. The ignition temperature of the material must be below its melting point. 3. The combustion heat of material must be as great as possible and its thermal conductivity as low as possible. 4. These requirements are met by all structural steels, many low alloy steels and steel castings a well as titanium. 3.2 Attention! Please observe the following regulations: Accident prevention regulations for oxygen (VBG 62) Technical regulations for acetylene plants and calcium carbide stores (TRAC) Safety devices for sewer gas, long distance gas (e.g. propane, butane)DVGM, memorandum G 606. Gas supply to the machine

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Oxygen According to requirements, it is possible to use batteries or bundles of cylinders, or cold vaporisers. Depending on the facilities available, the flame cutting machine can be supplied via the works system or direct from the gas supply source. Fuel gas -Acetylene Depending on the consumption level, batteries or bundles of cylinders, or generator, may be used for supplying acetylene. -fuel gas mixtures * dependent on the consumption level, map gas is supplied by single cylinders, cylinder batteries or tanks. -propane Generally speaking, a liquid gas tank with a vaporizing station is installed for supplying propane. -Natural gas Natural gas is provided via pipelines. The minimum pressure at the torch inlet must be observe (see cutting tables). Extraction points The extraction points should be selected on the basis of the minimum quantities of gas required and the types of fuel gas to be used. Literature Storage and distribution stations (cylinder batteries, bundles, vaporizer stations) for technical gases Pipework fittings for technical gases Gas supply equipment (extraction point fittings ) for flame cutting machines Determining the nominal bores of pipe work and fittings for gases

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3.3

Hoses and connections : : : : Blue Red Orange Black

Oxygen Fuel gas (except liquid gas) Propane/butane/fuel gas mixtures * Compressed air

Hoses must be secured with suitable hose clips or hose joints. The length of the hoses should be such that it does not impede the travel of the cross-carriage. Do not confuse the hoses for heating and cutting oxygen. Connections comply with DIN 8542 3.4 Pressure regulators

Depending on the type of machine, the pressure regulators are located at the extraction point or at the central control of the machine. All regulators are of the directly controlled, proportional type. The valve cone is controlled, proportional type. The valve cone is controlled via a diaphragm by means of the interaction of gas pressure and spring pressure or control pressure. The outlet pressure remains constant even in the event of fluctuating inlet pressures. The gas throughput of the pressure regulators incorporated in the machine corresponds with the performance range of the machine. If no pressure regulators are incorporated in the machine, it is necessary to select extraction point pressure regulators which correspond with the maximum gas throughput. 3.5 Nonreturn valves

In order to secure the hoses and the gas supply lines in the flame cutting machine, nonreturn valves with flame arresters are mounted between hoses and torch adjustment valves. On flame cutting machines whish are equipped with ignition devices, the fuel gas outlet for the ignition torch must be located between the Nonreturn valves and the torch adjustment valve.

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For arrangement of the nonreturn valve see fig.1. For flame cutting machines which are equipped with machine cutting torches MS 3450 with integrated ignition refer to the Instruction Manual.

Fig.1 Arrangement of the nonreturn valves 1. 2. 3. 4. 5. 6. Solenoid valve for ignition device Adjustment Valve for ignition torch Ignition torch Machine cutting torch Torch adjustment valves Installation possibility for test pressure gauge (T irons and pressure gauge, see page No.--) 7. Nonreturn valves 8. Fuel gas supply line 9. Heating oxygen supply line 10. Cutting oxygen supply line

4. Instructions for safety

1. The machine must not be started without the prescribed safety device mounted at the ex-action point of the central fuel gas supply line. 2. The user has to use the fuel gas specified for the machine.

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3. The machine cutting torches should be operated exclusively with the fuel gas for which they are marked. The messer griesheim machine cutting torches are to be combined only with the corresponding cutting nozzles from messer griesheim of the same type of gas. 4. When switched on the machine must be under the supervision of the operating personnel. 5. Within the working range of the machine, sufficient clearance is to be kept to rotating units, oppositely directed torch carriages or similar equipment. 6. Before work is started (change of shift ) the operating personnel must make sure that the machine, in particular the cutting torches, is ready for operation. The screw connections of the gas pipings and at the torch must be tightened firmly and gas-tight. 7. All adjustment valves on non-used machine cutting torches are to be closed by hand. 8. Ignition, adjustment and extinguishing of the flame are to be carried out in accordance with the instruction manual. 9. To avoid fire and explosion hazards gases or gas mixtures should by no means escape uncontrolled, especially where water or suction tables are used. 10. For manual ignition of the torches only suitable gas igniters should be used. 11. Check after electrical ignition that all pre-selected torches have been ignited. 12. In case of clogged flame cutting nozzles, after flame flashback or backfiring, immediately close the adjustment valves for fuel gas, heating oxygen by hand in the given order. 13. On exchangeable units, e.g. single torches, triple torch units, the individual gas connections are to be made work-like. When the units are not connected, the supply lines for exchangeable units are to be closed gas-tight.

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14. During flame cutting, the following personal protective means are to be used. The operating personnel should not keep easily inflammable goods in their clothing. The operator must wear: an another for the protection of the truck (leather) protective glasses with lateral protection and standardized protective filters In addition, the operator shall be equipped with: gloves safety shoes leggings (as far as necessary) protective helmet personal acoustic protection (Capsular or in form of wad or plugs)

15. Inflammable materials are to be stored out of the sparking area only. 16. Oxygen must not come into contact with parts contaminated with oil or greases (also clothing). 17. It is prohibited to use oxygen for cleaning, cooling or venting. 18. In case of longer interruptions of work, e.g. end of shift, weekend or repairs, close the shutoff valves at the extraction points (fuel gas, heating oxygen, cutting oxygen, compressed air, water). 19. Defective torches, nozzles, valves, hoses, nonreturn valves, pressure regulators, pressure gauges etc. are to be replaced or repaired by qualified personnel only. 20. The flame cutting machine and its torch units are to be serviced according to the instruction manual. 21. The machine must not be operated during the execution of maintenance, repair, adjustment and inspection works. The same applies to the exchange of torch units, torches, nozzles and similar parts. 22. Apart from the afore-mentioned change of torch units, cutting torches and nozzles and, no structural changes or modifications must be made to the machine.

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5.

Starting-up and maintenance

5.1 Selection the nozzles Select the appropriate type of nozzle for the torch according to the workpiece thickness that is to be cut and screw it into the torch head of the machine cutting torch making sure that no gas is leaking. For this job use suitable tools and apply a counter grip at the flat faces of the faces of the torch head. The cutting range, required cutting oxygen pressure and type of gas are as per make of nozzle head. Attention: Combine nozzles only with torches of the same type of gas A P M C Y = Acetylene = Propane = methane (natural gas ) = Town gas = Fuel gas mixtures (methyl-acetylene propadiene mixtures: Mapp gas etc.)

5.2 Setting the gas pressures For cutting oxygen, heating oxygen and fuel gas. With the valves open (central control and torch valves) set the pressure in accordance with the adjusting screw on the pressure regulator. For measuring the pressure at the torch inlet, test pressure gauges are available which are to be installed between the machine cutting torches and the torch adjustment valves. Close the central control and torch valves again. When the cutting operation has been completed or interrupted for a longer period of time, relive the pressure regulators by turning back the adjusting screws and close the extraction point valves.

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5.3 Igniting and adjusting the flames When the gas pressures have been set at the pressure regulators, open all central control valves. At each individual torch : fully open the heating oxygen valves, open the fuel gas valve slightly, allow the issuing gas mixture to flow uncombusted for a few seconds, then ignite and set a neutral flame. Attention ! During ignition, the torches must be at least 100 mm above the workpiece surface. Setting the heating flame 1. Acetylene/oxygen With the heating oxygen valve open, first set surplus acetylene with the fuel gas valve on the cutting torch (idientified by the licking, undefined, luminous flame cone, see figure - 2A). Then reduce the acetylene supply until the longest, sharply defined cone is obtained, see figure- 2B. Since the hearing flame has to provide only a certain proportion of the thermal requirements for the cutting process, it must be adjusted accordingly i.e. it is uneconomical if the heating flame is too large, especially as the desired sharpness of the cut edge is also adversely affected. The size of the heating flame is set with the heating oxygen valve of the torch, the volume of fuel gas for the neutral flame being proportioned at the same time using the fuel gas valve. Check the cutting oxygen jet. It must flow in a straight, cylindrical form the nozzle and must not flutter. The heating flame must surround the oxygen jet concentrically (See Figure 2 C). When each torch has been set individually as described above, it is necessary to operate the central control valves. The corresponding cutting oxygen valves for the individual torches remain open at all times, whilst the individual heating oxygen and fuel gas valves are used only as adjustment valves.

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If it is necessary to turn off an individual torch, first close the cutting oxygen valve, then the fuel gas valve and, finally, heating oxygen valve.

A
Fig. 2 setting the heating flame A B C

heating flame with surplus acetylene Neutral heating flame Correct form and position of the oxygen jet in relation to the heating flame

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2. Propane/ oxygen, map gas/ oxygen, Methane / oxygen, town gas/ oxygen In the case of slow-combusting gases such as propane, map gas, methane and town gas, it is not quite as easy to recognize the correct flame setting for flame cutting as with acetylene. With some practice, however, it is possible to identify the most economic setting for these gases, too, by the size and color of the flame 5.4 Maintenance of torches, nozzles and nonreturn valves Protect torches from damage. Keep the nozzles clean at all times and, if dirty, use only suitable nozzle cleaners, wire brushes or nozzles cleaning powder. Please pay attention to the detailed Maintenance instructions for flame cutting nozzles Soiled and damaged nozzles impair the cutting quality and flashback safety of the torch. ( see also maintendvce instructions foThheavyduty flame cutting nozzles art. No. 0.810.996.) The flame arresters of the non return valves are made of sintered metal and are soiled in the course of time by carbon deposits resulting from flashbacks or dirt from the supply lines. This increases the pressure loss and impairs the function of the torch. Therefore, the nonreturn valves are to be replaced dependent on the dirt produced. In the event of flashback, the flame penetrates into the torch where it continues to burn in the mixing zone, producing whistling, hissing noises. In order to prevent damage to, or even destruction of the torch, immediately close Fuel gas valve Heating oxygen valve Cutting oxygen valve In the given order. Then allow the torch to cool down and remedy the defect. Should flashback recur, we recommend that the torch is passed to an authorized workshop for inspection and repair. at the corresponding torch

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5.5

Starting the cut and hole-piercing

Set clearance between nozzle and surface of work-piece in accordance with the cutting table. Position the torch suspension in the direction of the cut so that the cutting jet does not grub up the workpiece surface. When the ignition temperature of the material is reached, open the cutting oxygen and switch on the machine drive. The cutting jet must produce sharp edges when starting the cut. 5.6 Hole-piercing If the cut is to be started at a hole within the workpiece, the starting hole can be pierced in the following ways: 5.61 By means of hand cutting torch: preheat the piercing point well. When the material has been heated up to its ignition temperature, slightly incline the torch and, at the same time, gradually open the cutting oxygen valve. Then swivel the torch until the torch head is in a vertical position.

Fig. 3 Hole-piercing with the machine cutting torch 5.62 With the machine cutting torch (Figure 3): Ignite the fuel gases, set nozzle clearance according to table and heat the material to ignition temperature. Then switch on the machine drive and slowly open the cutting oxygen valve (proportioning valve ) so that the molten material does not damage the nozzles.

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5.43 5.6 5.71

With the automatic hole-piercing system: Cutting by means of multi-bevel heads : Torch sequence with endlessly rotating multibevel heads

For K-cuts (type of kerf DHY according to DIN 8551) by means of endlessy rotating multibevel heads, the torches are to be arranged s shown in Fig., observe the sense of travel.

1 Torch I 2 Torch II 3 Torch III 4 Work piece 5 Scrap 6 scanning feeler 7 scanning feeler

Fig. 4a Sequence of torches with endlessly rotating multi-bevel heads For sequence of torches with non-rotating multibevel heads, see the following page, section 5.72.

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5.72 Torch sequence with endlessly rotating multibevel heads For K-cuts (type of kerf DHY according to DIN 8551), the torches are to be arranged as shown in fig. the clearance between the individual torches is bigger than in case of the multibevel head of Fig., because sharp cuts cannot be executed by this unit.

1 2 3 4 5 6

Torch I Torch II Torch III Work piece Scrap Cutting direction

Fig.4b

Sequence of torches with non-rotating multibevel heads,

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5.8 Cutting speed experienced operators can tell from the way the sparks fly and from the noise produced by the cutting process whether the cutting speed is right figure 10 shows the pattern of sparks that is produced by the correct, inadequate and excessive cutting speeds.

Cutting direction Cutting speed correct

Cutting direction Cutting speed too high

Cutting direction Cutting speed too low

Fig. 5 Cutting speed

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Note : Sharp, satisfactory cut edges can be obtained only if the heating flame is correctly set! The cutting speed can be infinitely varied during cutting. 6. 6.1 Machine cutting nozzles Maintenance instructions for flame cutting nozzles

Heavy-duty flame cutting nozzles are of high cutting performance and a long service life. They are manufactured with great precision, carefully checked and packed so that damages during transport are being excluded. Corrosion protective agents, rust and scale on the surface of the sheets to be cut as well as spattering of slag are the reasons for deposits, contamination or damage to the nozzles. The nozzles must be cleaned. 6.1.1 Wet cleaning A simple and protective way of nozzles cleaning is wet cleaning. For this purpose, usually 50 grs. Of nozzles cleaning powder are dissolved in 1l of water. The cutting nozzles to be cleaned are put into solution for 8-12 hours (according to the degree of contamination). Then they are rinsed with flowing water and dried. 6.1.2 Mechanical cleaning Cleaning the nozzle faces Slight contamination on the face of the cutting nozzles and within the direct vicinity of the mouth of the preheat flues of the cutting oxygen conduit can be removed by means of a soft brass brush Cleaning the cutting oxygen conduit The tightest orifice (Fig. 6, section1) of the cutting oxygen conduit is cleaned with a orifice cleaning needle

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Contamination of the conic or conic/cylindrical widening are effectively removed by means of wet cleaning (item 6.1.1)

Fig. 6 Small contaminations and slight burring deposits at the nozzle exit edge (fig. 7) can be removed with the WRF 6358 tapered orifice cleaning needle.

Fig. 7

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Cleaning attempts with unsuitable tools with sharp edges (twist drills, triangular scraper, reamer etc.,) lead to the destruction of wall and form of conduit.

Fig. 8 6.1.3 Cleaning the preheat flues Cleaning the preheat slots Contaminations of the preheat slots can only be removed by means of a suitable slot cleaner which must follow the guide motion from A to B

Fig. 9

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Cleaning the preheat orifice Small contaminations of the preheat orifice can be removed with an orifice cleaning needle or a cleaning drill.

Fig. 10 Important hint for the use of gas mixing nozzles Because of their high operating reliability, gasmixing nozzles are used preferably in sites where high thermal stress has to be reckoned with. When nozzles are changed or especially when new nozzles are used, it is important to strongly tighten the thumbscrew so that the sealing surface of the nozzles may adjust to the sealing surface of the torch head(Fig. 11). In case of extreme heating of cutting nozzle and torch head and subsequent cooling down, it may happen that the nozzle in the torch head loosens and gets leaky. Therefore the thumbscrew must be tightened again after the first thermal stress. Thereby it is necessary to use the torch spanner and to apply a counter grip on the torch head. Damaged sealing surface in the torch head or on the nozzle must be reconditioned by means of suitable milling tools (Fig. 12+13) Only unobjectionable torches and nozzles guarantee: good sealing, reliable work, long service life and the highest cutting results.

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Fig. 11

Fig. 12 Torch head with milling tool WSF 7019

Fig. 13 Nozzle with milling tool WSF 7022

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7. TYPICAL OPERATING DATA FOR FLAME CUTTING NOZZLE

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8. GAS REGULATORS AND CONTROLS The preheat gas and oxygen regulators and the cutting oxygen control regulator and their respective gages are located on the gas regulator panel conveniently located above CNC pendent. These controls function as follows : The HIGH PREHEAT FUEL GAS pressure regulator is used for setting the high pressure of pre-heat fuel used to provide a hot flame for fast starts. The LOW PREHEAT FUEL GAS pressure regulator is used for setting the lower pressure used for normal operation. With the preheat switch in the on position the gage reads the pressure set by the low pressure regulator and preheat fuel gas at this pressure is available to all torches. When high preheat switch is selected the gage reads the pressure set by the high pressure regulator, and preheat fuel gas at this pressure is available to all torches. NOTE In setting high and low pressures, it is best to set the high pressure setting first to avoid the possibility of a low pressure that is actually above the high pressure setting. The high preheat oxygen pressure regulator is used for setting the high pressure of preheat oxygen used to provide a hot flame for fast starts. The low pressure regulator is used for setting the lower pressure used for normal operation. With the preheat switch in the on position the gage reads the pressure set by the low pressure regulator and preheat fuel gas at this pressure is available to all torches. When high preheat switch is selected the gage reads the pressure set by the high pressure regulator, and preheat fuel gas at this pressure is available to all torches. The pressure set on the cutting oxygen control regulator is the cutting oxygen pressure made available to all torches during normal operation by the main oxygen flow regulator. This is the pressure registered on the gage.

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Fig. 14 Gas regulator panel 1. 2. 3. 4. 5. 6. 7. 8. Preheat oxygen pressure gauge Preheat oxygen regulator - high Preheat oxygen regulator Low Cutting oxygen pressure gauge Acetylene pressure gauge Acetylene regulator - low Acetylene regulator - High Cutting oxygen regulator

9. OPERATING INSTRUCTIONS FOR ESAB PRESSURE REGULATORS CHECK BEFORE USE 1. Use correct regulator for gas and pressure rating. 2. 3. The regulator if stored for a long time in ON position may have caused permanent deformation of diaphragh, spring and valve. All gauge pointer at zero process adjusting knob screwed fully out and down stream valve or closed.

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4. 5. 6. 7.

Ensure that no grease oil or foreign substance as entered to the regulator become dangerous during operation. Ensure that the regulator as not be stored in low ambient temperature causing freeze. Ensure that all dirt dust moisture and foreign substance are blown out from the hose pipe. Ensure sufficient gas is available for the job in hand once the gauge pointer has steadied, open the cylinder valve one future turn. Ensure the regulator inlet & nut are compatable with the seating and thread of the cylinder or pipeline outlet.

8.

INSTRUCTION FOR SAFE OPERATION 1. Cylinder should be located where they not be knocked or contaminated with oil or greases and be securely supported in a vertical position. All cylinder or pipelines key operated valve should have a key fitted or adjacent to them to ensure rapid closure in case of emergency. 2. Prior to fitting a regulator, the valve seating and regulator inlet, should be examined for signs of damage or contamination with oil, greases or paint. If present regulator should be removed form service. 3. Oxygen and inert gas regulators have connection with right hand threads to tighten turn clockwise, while fuel gas regulator have lefthanded thread to tighten anti-clockwise. 4. Never change a regulator inlet to enable it to be used with another gas. 5. Regulator should be fitted using the correct size of spanner should not be used as they will tend to turn the hexagon nut. Excess force should not be required or used as it could damage the threads. 6. Position the regulator so that there is minimum obstruction of the cylinder valve spindle key. In an emergency it may be necessary to stop the exit of gas in the shortest time possible. OPERATING THE REGULATOR DURING USE 1. Slowly open the cylinder or pipeline valve one full turn, using cylinder key or the hand wheel. Key operated valves should require

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no addition leverage. If excessive force is required to open, then the cylinder should be removed from service after closing the valve. 2. Ensure contents pressure is resistering on the contents gauge or indicator if fitted. Propane regulator do not have any indicating contents as the pressure within the cylinder is dependent on the ambient temperature. 3. Test the valve/regulator inlet joint detergent in water solution, with a paint brush that there is no leakage. 4. The safety relief valve in the regulator automatically controls the system. The safety valve will give vent pressure above 1.5 times of delivered working pressure. 5. In regulator the inlet and outlet bonnets have relief holes as preventive measures in case of accidental failure. 6. Screw the pressure adjusting knob in a clockwise direction to increase pressure and in an anticlock direction to decrease pressue until the required working pressure in recorded on the outlet pressure gauge. 7. Shielding gas regulator are fitted with a flow gauge instead of an outlet pressure gauge. Flow is recorded in L/min & ft. / hr . operation of the pressure adjusting knob will control flow of gas through a minute orifice in the outlet and ensure an even delivery of gas which can be monitored on the flow gauge. CLOSING DOWN THE REGULATOR AFTER USE 1. Release the pressure adjusting knob immediately after use avoid damage of the diaphagram. If in ON position, it may give permanent deform to the diaphagram, thereby stopping the function of regulator. 2. clean the surface and store it properly in the package to ensure that dirt, dust do not enter the regulators.

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ESAB REGULATORS COMPLY WITH ISI & ISO STANDARDS

SINGLE STAGE REGULATOR
Gas Acetylene Oxygen Oxygen Application Pre-heat cutting Pre-heat cutting Heavy cutting & heating Max. Outlet Pressure(Bar) 1.0 10.0 14.0 Max Flow (L/Min.) 250 1000 3300 Model IDA-4B IOX-13B IOX-14

DO
Keep the pressure regulators in neat and clean place free from any dust, grease or oily substance.

DO NOT
Do not use oily or greasy substance to the regulators or the pipe lines otherwise there may be excessive heat in the regulator and may even Cause Explosion. Do not open the cylinder valves suddenly and fully otherwise a sudden surge may cause damage to the internal component. Do not remove or tamper with the safety valve.

Ensure that the cylinder valve is slowly opened.

Use the control valve for flow of gas and open it slowly according to the requirement of gas for use. Safety valve is provided for venting out any excess pressure of gas. In two stage regulator first stage is present. The gas pressure regulation Sophisticated equipment.

Do not remove or tamper with the safety valve. So not adjust the first stage.

Do not cause rough handling.

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ELECTRICAL SAFETY 1. All electrical/electronic trouble shooting and repair should be undertaken only by personnel who are properly trained and have adequate knowledge and skill. 2. It must be assumed at all times that POWER in ON so all conditions must be treated as live. This practice develops a caution that may prevent an accident. 3. REMOVE LOAD from circuit or equipment. 4. OPEN disconnect or breaker and (a) lock in open position or (b) remove fuses or (c) install Hold-Off tag or (d) have someone stand by. A switch in the open position with a lock that you only have a key for is positive protection from someone accidentally turning power on while you are working. 5. MAKE CERTAIN you have opened the circuit by using the proper test equipment. NOTE: Test equipment must be checked at regular intervals. 6. Capacitors MUST be given time to discharge, otherwise it should be done manually with CARE. 7. When trouble shooting LIVE equipment, the necessary precautions must be taken as follows: a) MAKE CERTAIN your tools and body are clear of ground. b) Use extra PRECAUTION in DAMP areas. c) BE ALERT and work without any outside distraction. 8. BEFORE applying POWER to any equipment, it must be established without a DOUBT that all persons are CLEAR. 9. The CONTROL PANEL DOORS shall necessary to check out the electrical CLOSING the door, make certain that operating properly with the MECHANISM. be open ONLY when it is equipment or wiring. After the disconnecting means is DISCONNECT HANDLE

10. ALL COVERS on junction boxes must be CLOSED before leaving any job 11. BEFORE STARTING, markings and notices. read and understand all WARNING

12. READ all marking such as nameplates and identification plates.

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13. DO NOT alter circuits unless authorized to do so by the manufacturer. 14. DO NOT alter or by-pass protective interlocks. 15. DO NOT place jumper wires across fuses. 16. DO NOT alter over current protective devices. 17. WHEN conductors are REPLACED, they shall conform to the manufacturers SPECIFICATIONS, including PROPER COLOR CODING. 18. GROUND connections cause fault currents to flow directly into the ground instead of following through the body into the ground. ALL ELECTRICAL APPARATUS MUST BE PROPERLY GROUNDED. 19. Use CAUTION when connecting test equipment probes to test points. SHOCK HAZARDS could exist at the test points or in the test point area and/ or TRANIENTS induced by the probes could cause a MACHINE ACTION. 20. AVOID wearing glasses that have a METAL FRAME. 21. AVOID wearing a necklace or chain that is made of METALLIC substance.

ELECTRICAL AND MAINTENANCE TRAINING 1. Burny phantom system package a) PC based CNC unit with LCD display b) Hard drive c) Floppy drive with USB port d) AC Servo drive for 3 Axis ( X-axis, XX-axis and Y-axis) e) AC Servo motors (3 nos.) with 1:25 inbuilt gearbox) 2. System related cards in the cabinet & test points. a) Front panel PCB for oxy process control front panel switches like Igniter ON/OFF Input/Output, Preheat gases ON/OFF, Cutting oxygen Input/Output, Water spray I/O, Auto height ON/OFF, Station selection Input/Outputs, Lifter Up/Down Input/Output and Emergency logic interface In this PCB there are ISO test points i.e., (+5V, Gnd.) (+15V, Gnd.) (+24V, Gnd.)

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3. Encoder Interface cards: This is used for Encoder feedback from X, XX and Y- axis Interface between CNC and drive. Test points: +5V, Gnd. 4. Back panel: Back panel consisting of 15 connectors, they are 10 Recp, 11 Recp, 12 Recp, 14 Recp, 15 Recp, 16 Recp. Encoder connector (X, Y and XX-axis), RS232-1, RS232-2 connecters, 49 Recp, Motor power connector-3Nos, and CNC input power supply connector. 10 RECP: This connector is Interfaced from Burny to Electrical panel for plasma operation (optional) only we used External E-STOP contact, Crash Sensor contact both shorted in the panel for reset the machine (see circuit diagram). 11 RECP: This connector also used for plasma application we are not connected any pins to oxy process logics 12 RECP: This connector is used for Igniter sol ON/OFF, Igniter spark plug ON/OFF, and Vent logic, vent sol ON/OFF (optional) see circuit diagram. 14 RECP: This connector is used for Station1 and 2 preheat gas and oxy solenoid ON/OFF, Cutting oxy sol ON/OFF and station 1 & 2 torch lifter up/down (see circuit diagram) 15 RECP: This connector is used for Station3 and 4 preheat gas and oxy solenoid ON/OFF, Cutting oxy sol ON/OFF and station 3 & 4 torch lifter up/down. But in this connector we are not used any pins to up/down No.3 torch lifter. Because there is no drive only hardware relay logics has been made (see circuit diagram). 5. DC power supply board: This card is used for feed DC supply to all 3 axis drives. Input 230V AC, output 360V DC. 6. SMPS: This is used for +24V DC logics.

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7. Relay card: This card is used to get the solenoid supply for oxy process logics. 8. Electrical I/F panel: This consisting of Relay cards for solenoid ON/OFF, SMPS2Nos. One smps for clutches ( 24V DC operated), another for Relay logics, MCBs and bridge rectifier for torch-3 up/down (input 230V AC, output 230V DC) 9. Drive tuning (X-axis, Y-axis and XX-axis): Procedure:- Before connecting communication cable switch off CNC connect communication cable from drive to CNC.

a) b) c) d) e)

Switch on CNC Select personal computer setting Click start Move arrow keys to program Select Burny Phantom BL Drive tuning then

Communication screen will come, Select COMMUNICATION, click OK. Now screen is ready to drive communication Press TOOLS Click RESTORE BACKUP, in this file select required motor ID for example 3102A A230GS-3000RPM Press OK or SAVE Note: Please check Motor ID No. and note down. Select SETUP Click Servo tuning, press OK. Select SETUP Click Analog I/O And Calculate the required motor RPM DesiredTableSpeed Required Motor rpm= PinionCircumference * GearRatio Where Pinion Circumference= Piniondiameter *

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What we entered in the system is 6000 ( RapidMovementOfTable ) * 50 32 mm * 3.14 =304.54 This value to be entered in the setup Analog I/O screen. This value obtained from RPM 3000 304 .54 Required motor rpm= Voltage 9.5V Go to SETUP Click Save to NVM Press yes Go to TOOLS Click Backup Amp Save the file by Entering X axis tuning This is used to communicate Same procedure to be followed for other two axis. Close the communication screen and shutdown the CNC system and switch off and switch on. Press menu on CNC screen Click Utilities Select system setup Select motion configuration Select required axis eg (x or y) Now calculate the Required Encoder pulses/mtr EncoderLines * GearRatio Ticks meter *K *4 PinionDiameter *
Ticks meter 2000 * 50 *1000 * 4 32 * 3.14

3.1415927

Ticks/meter= 3892700 Enter this value into X axis Ticks/meter parameter Then move the axis by starting the graph and adjust Aff, Vff, D Gain and P Gain. Up to graph should be straight line without any variations. This procedure to be followed for all 3 axis and the press save and save to file

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Encoder connector 3Nos.: These connectors are I/F from Burny CNC I/F card to motor encoder. RS232-1 and RS232-2 connector: These two are COM 1 and COM2 communication connectors for program Transmit and Receive from PC to CNC. Pin configuration Burny 2 3 7 9 8 Computer 9 Pin D connector 3 2 5 7 8 1 4 6 RD TD Gnd Com RTS CTS DSR

RECP 49 Connector: This Connector is used for limit switch functions X+ hard limit, X-hard limit, Y+ hard limit and Y- hard limit (see circuit diagram). CNC I/P power supply connector: 230V 3 pin. Trouble shooting, diagnostic function tracing conducted. Measurement of table has been conducted.

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FAULT AND TROUBLE SHOOTING: 1. External stop error: Release emergency stop PB and check error message goes OFF, if not check external emergency and cross sensor contacts on Recp 10 on back panel or check interphase panel TB contacts as per circuit is closed. 2. Drive fault: This fault occurs due to encoder pulses missing or encoder cable removed or motor over loaded due to mechanical jam like clutch problem, rack and pinion mismatch , motor power cable fault. For encoder checking: First remove corresponding axis motor assembly and remove gear box on motor and rotate encoder for one rotation CW and check the feed back on system screen, if OK rotate in CCW direction check again. If the encoder counting is alright, continue checking next step. In case of mechanical jam, check rack and pinion for correct meshing, check for blockage of teeth due to presence of foreign objects and if yes, clean thoroughly. 3. System software related fault: System is not initializing properly system will gives the error message on the screen. Note down the error message please refer manual for trouble shooting the system software related problems

Check to be done daily, weekly monthly Daily clean the rack and rails Clean air conditioner filter weekly Check spring tension of X, XX and Y axis motor assembly every 12 months

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BURNY SYSTEM PARAMETERS

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SLNO 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

AXIS TRAJECTORY DESCRIPTION JOG ACCELERATION MAX ACCELERATION MAX JOG VELACITY MAX VELOCITY S CURVE ACCELERATION GAIN USE S CURVE DESABLE RAIL SLAVE GOAL POINT TOLERENCE CORNER SPEED AXIS JERK FILTER BACK UP VELOCITY MINIMUM CORNER ANGLE MAXIMUM CORNER ANGLE RAPID STOP ACCELERATION W_ ARC ACCE/DERATE

UNIT 0.2 m/s/s 0.2 m/s/s 0.1 m/s 0.1 m/s 10 FALSE FALSE 0.1 0.0008 0.1 0.12 m/s 11 22 0.5 m/s/s 70%

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SLNO 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25

MACHINE PARAMETERS DESCRIPTION MIN. OFF TIME BLEED OFF DELAY SW SENCE TIME PLASMA ARC ON DELAY PLASMA ARC OFF DELAY PLASMA START DELAY PLASMA ARC ON SENCE TIME MARKER VELOCITY MARKER DELAY TEACHABLE PREHEAT DEFAULT DWELL PUNCH MARK1 DELAY PUNCH MARK2 DELAY RAPID PIERCE RADIOUS RAPID PIERCE VELOCITY PRESSURE BLEED DOWN TIME OXY RAISE TIMER PLASMA RAISE TIMER ENABLE PLASMA 1 DOWN PLATE ENABLE PLASMA 2 DOWN PLATE IGNITOR ON TIMER IGNITOR ON GAS TIMER PLASMA 2 START DELAY PLASMA 2 ARC ON DELAY SWITCH LIMIT WARNING

UNIT 0 (S) 0 (S) 0.01 (S) 0 (S) 2.0 (S) 3.0 (S) 0.01 (S) 0.1 m/s 4 (S) FALSE 0 (S) 0 (S) 0 (S) 0.0032 (m) 0.01 (m/s) 0.5 (S) 5 (S) 2 (S) FALSE FALSE 3 (S) 5 (S) 2 (S) 2 (S) FALSE

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SLNO 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

I/O CONFIGARATION DESCRIPTION INVERT HEIGHT DISABLE USE RS 422 FEEDRATE THRESH FEEDRATE THRESH HYST SPEED POT MINIMUM SPEED POT MAXIMUM SPD POT MAX PERCENTAGE PLASMA HEIGHT DISTANCE USE FRONT PANEL SPEED POT OK TO RUN TYPE ENABLE RAPID STOP ENABLE C AXIS LOCK BACK PANEL MO SPECIAL OP #1 SPEED DAC CHANEL SPEED TYPE SPEED VOLTS CUT SPEED ZERO VOLTS OXY PIERCE TYPE HEIGHT DISABLE START

UNIT FALSE FALSE 95% 2% 0V DC 4.046V DC 120% 0.01 (m) TRUE 1 FALSE FALSE 0 BOARD # 0#1 0% 0 0 0 0 FALSE

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SLNO 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

AXIS X AND Y DESCRIPTION AXIS MINUS LIMIT SOFTWARE AXIS PLUS LIMIT SOFTWARE ZERO VOLT OFF DB FACTOR DB THRSHOLD DEFAULT AFF DEFAULT D GAIN DEFAULT I GAIN DEFAULT P GAIN DEFAULT VFF INVERT ENCODER FOLLOWING ERROR LIMIT STOP FOLLOWING ERROR INVERT PWR AMPLIFIER TICKS PER METER BACKLASH

UNIT 100 (m) 100 (m) 0V 0 UNITLESS 0 (m/s) 0.1 Vcy cy/m 0 V cy/m 35 V/m/cy 2720 V/m 99 Vcy/m FALSE 100 m 100 m FALSE 3861700 0

NOTE: DONT CHANGE ANY PARAMETERS

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