ESAB CUTTING SYSTEMS

Operator Training

Arya, Garry Wong, June 2017

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OPERATOR TRAINING CMB

Key Focus
- Operational safety
- Introduction to machine modules
- Operation training
- Maintenance training
- Question & Answer
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OPERATOR TRAINING CMB
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MACHINE SAFETY SYSTEMS CMB

Safety System Location Task

Emergency Power Off
Track Limit Switches
Torch Anti-collision Device
On the T5 Controller Panel
And
On the right side of gantry
Software limit switches set in
T5 Controller
And
Hardware limit switches
mounted on tracks
Plasma Station
When activated, stops all
machine movement.
When activated, stops all
machine movement.
When activated, stops all
machine movement.
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PLASMA STATION CMB
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CUTTING MACHINE LAYOUT CMB
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DESCRIPTION OF CUTTING MACHINE CMB

2.Carriage - Oxyfuel
1.Motor Carriage -Plasma

3. Carriage Oxyfuel Triple-Torch

Vision T5
Controller
Steel band SUPRAREX SXE - P

Cutting Table

400 Effective Cutting Width 400

Track Width

FRONT VIEW
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DESCRIPTION OF CUTTING MACHINE CMB

X x 1000 mm Railway tracks

Basic Machine

Rail Pads Slave Carriage Oxyfuel Triple-Torch

Effective Cutting Length in mm

Cutting Area Steel band

2000 mm Effective
Cutting Width
Parking Area
in mm
Gas manifold
Slave Carriage Oxyfuel
Motor Carriage Plasma

Power Track
Vision T5 Controller
Bracket Arm
Plasma Power Source TOP VIEW
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AXIS OF CUTTING MACHINE CMB
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OPERATION TRAINING CMB

Introduction
Objective of training is to train CNC Cutting Machine Operator
to effectively and safely operate and maintain cutting
machine.

Training will cover cutting machine safety features, operation

of Vision controller, gantry & subsystems such as plasma
system, marking devices and fume extraction system.
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OPERATION TRAINING CMB

General Training Content

Day 01
Orientation to CNC cutting machine and subsystems, if any.
Controller training
Controller panel overview.
Controller safety features and operations¹.
Backup / Restore of Controller setup².
Subsystem training – Plasma System³.
Subsystem training – Oxyfuel System⁴.

Day 02
Refresher of Day 01 training.
Continue Controller and subsystem(s) training.
Independent operation under supervision of ESAB trainer⁵.

Day 03
Revision of Day 01 & 02 training.
Individual Operator test by ESAB trainer⁶.
Basic maintenance of CNC cutting machine & subsystems⁷.
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OPERATION TRAINING CMB

Training focus
(1) Controller safety features and operations.
Activate and deactivate Emergency Stop button
Turn on 24V
Perform machine reference
Control gantry movements
Control station(s) movements
Perform manual plate alignment
Use standard shape library
Adjust and edit gantry / plasma / oxyfuel parameters
Download and save NC file from thumb drive
Recognition of machine data plate
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OPERATION TRAINING CMB

Training focus
(2) Backup / Restore of Controller setup.
Perform backup of complete system
Perform restore of complete system

(3) Training of Plasma System.

Activate and deactivate Emergency Stop button
Switch on system
Top up of coolant
Activate and reset anti-collision device
Identification of PT-36 torch and consumables
Identification of Plasma cut data
Recognition of plasma modules and data plates
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OPERATION TRAINING CMB

Training focus
(4) Training of Oxyfuel System.
Control and adjust gas valves
Identification of Oxyfuel torch and consumables
Identification of Oxyfuel cut data
(5) Independent operation under supervision of ESAB trainer.
Prepare 2 simple NC files on thumb drive. 1 for plasma process and another for oxyfuel
process.
Prepare scrap plate for plasma and oxyfuel cutting.
Perform Training Focus 1 – 4
Use plasma process to cut NC file on thumb drive and standard shape library
Use oxyfuel process to cut NC file on thumb drive and standard shape library
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OPERATION TRAINING CMB

Training focus

(6) Individual Operator test by ESAB trainer.

Prepare 2 simple NC files on thumb drive. 1 for plasma process and another for
oxyfuel process.
Prepare scrap plate for plasma and oxyfuel cutting.
ESAB trainer to select 1 cut shape and dimension from standard shape library.
ESAB trainer to determine readiness of trainee(s)
Conduct test for Training Focus 1 – 4
Use plasma process to cut NC file on thumb drive and standard shape library
Use oxyfuel process to cut NC file on thumb drive and standard shape library
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OPERATION TRAINING CMB

Training focus

(7) Basic maintenance of CNC cutting machine & subsystems.

Introduction of maintenance tasks and schedules
Walkthrough of maintenance tasks
Walkthrough of spare parts manual
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MAINTENANCE TRAINING CMB
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MAINTENANCE TRAINING CMB
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MAINTENANCE TRAINING CMB
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MAINTENANCE TRAINING CMB
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MAINTENANCE TRAINING CMB
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MAINTENANCE TRAINING CMB
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MAINTENANCE TRAINING CMB
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MAINTENANCE TRAINING CMB
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MAINTENANCE TRAINING CMB
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MAINTENANCE TRAINING CMB

ESAB Coolant
Part Number 0558004297
25% Propanediol & 75% Distilled Water
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MAINTENANCE TRAINING CMB

PT-36 Plasma Torch

What are the common wear parts?
Shield
Nozzle
Nozzle Electrode
Electrode

Shield
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MAINTENANCE TRAINING CMB
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MAINTENANCE TRAINING CMB

Heating cap Cutting nozzle

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Question & Answer

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Thank you

TELEREX 33m
The biggest Panel line machine in the world
Myer Shipyard Germany
Arya, Garry Wong, Jun 2017