ESAB ESAB DMX Automated Beveler User manual

Brand: ESAB

Model: ESAB DMX Automated Beveler

Category: Power tools

Type: User manual

This manual is also suitable for

DMX Automated Beveler

OWNERS

MANUAL

DMX Automated Beveler

Article Number: 0560956471

Revision Date: August 3, 2018

Revision Number: AB

Language: EN

esab.com

Art # A-13398

WE APPRECIATE YOUR BUSINESS!

Congratulations on your new ESAB product. We are proud to have you as our customer and will

strive to provide you with the best service and reliability in the industry. This product is backed

by our extensive warranty and world-wide service network. To locate your nearest distributor or

service agency, visit us on the web at www.esab.com

This Operating Manual has been designed to instruct you on the correct use and operation of your

ESAB product. Your satisfaction with this product and its safe operation is our ultimate concern.

Therefore please take the time to read the entire manual, especially the Safety Precautions. They

will help you to avoid potential hazards that may exist when working with this product.

YOU ARE IN GOOD COMPANY!

The Brand of Choice for Contractors and Fabricators Worldwide.

ESAB is a Global Brand of manual and automation Plasma Cutting Products.

We distinguish ourselves from our competition through market-leading, dependable products

that have stood the test of time. We pride ourselves on technical innovation, competitive prices,

excellent delivery, superior customer service and technical support, together with excellence in

sales and marketing expertise.

Above all, we are committed to developing technologically advanced products to achieve a safer

working environment within the welding industry.

Revision History

AA 12/17 Original Release

AB 8/18 Added head leveling procedure; Updated parts for leveling; Corrected Cable

assembly part numbers; Added i-Series Cable numbers; Added note about DMX lubrication

Plasma Cutting Accessory

DMX™ Automated Beveler

Owners Manual Number 0560956471

Published by:

ESAB Group Incorporated

2800 Airport Rd.

Denton, Texas 76207

www.esab.com

ESAB B rand.

Reproduction of this work, in whole or in part, without written permission of the

publisher is prohibited.

The publisher does not assume and hereby disclaims any liability to any party for any

loss or damage caused by any error or omission in this Manual, whether such error

results from negligence, accident, or any other cause.

For Material Print Specications, refer to document ?

Original Publication Date: December 7, 2017

Revision Date:

Record the following information for Warranty purposes:

Where Purchased:_______________________________

Purchase Date:__________________________________

Serial #:___________________________

WARNING

Read and understand this entire Manual

and your employer’s safety practices

before installing, operating, or servicing

the equipment.

While the information contained in this

Manual represents the Manufacturer’s

best judgement, the Manufacturer

assumes no liability for its use.

CAUTION

Be sure this information reaches the operator.

You can get extra copies through your supplier.

These INSTRUCTIONS are for experienced operators. If you are not fully familiar with

the principles of operation and safe practices for arc welding and cutting equipment, we

urge you to read our booklet, “Precautions and Safe Practices for Arc Welding, Cutting,

and Gouging,” Booklet 0-5407. Do NOT permit untrained persons to install, operate, or

maintain this equipment. Do NOT attempt to install or operate this equipment until you

have read and fully understand these instructions. If you do not fully understand these

instructions, contact your supplier for further information. Be sure to read the Safety

Precautions before installing or operating this equipment.

USER RESPONSIBILITY

This equipment will perform in conformity with the description thereof contained 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.

Malfunctioning or poorly maintained equipment should not be used. Parts that are broken,

missing, worn, distorted or contaminated should be replaced immediately. Should such repair

or replacement become necessary, the manufacturer recommends that a telephone or written

request for service advice be made to the Authorized Distributor from whom it was purchased.

This equipment or any of its parts should not be altered without the prior written approval of the

manufacturer. The user of this equipment shall have the sole responsibility for any malfunction

which results from improper use, faulty maintenance, damage, improper repair or alteration by

anyone other than the manufacturer or a service facility designated by the manufacturer.

READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.

PROTECT YOURSELF AND OTHERS!

Table of Contents

TOC

Contents

SAFETY

Introduction ............................................................................................................................................................. 3

General Safety ......................................................................................................................................................... 4

Working with Plasma Cutting Equipment ..................................................................................................... 5

Working with Gas Control and Supply Systems .......................................................................................... 12

Recommended Safety References ................................................................................................................... 15

International ...................................................................................................................................................... 15

Germany .............................................................................................................................................................. 16

United States ..................................................................................................................................................... 17

Canada ................................................................................................................................................................. 18

Additional Sources .......................................................................................................................................... 18

Description

General Information .............................................................................................................................................. 21

Parts of the DMX VBA Station ...................................................................................................................... 22

3 Axis Servo Control ........................................................................................................................................ 22

Smartbevel™ Technology .................................................................................................................................... 23

Automatic Compensation of Tilt Angle and Kerf Oset .................................................................... 23

Automatic Height Oset ............................................................................................................................... 23

Bevel Land Compensation ............................................................................................................................ 23

High Accuracy Angle Control ...................................................................................................................... 24

Automatic Speed Reduction ........................................................................................................................ 24

Process Variables Programming ................................................................................................................. 24

Positional Osets in Bevel Cutting ............................................................................................................. 25

Features ............................................................................................................................................................... 26

Table of Contents

TOC Table of Contents

Specications ........................................................................................................................................................... 26

Introduction ....................................................................................................................................................... 26

Capabilities ............................................................................................................................................................... 27

Single Bevels ...................................................................................................................................................... 27

Double Bevels ................................................................................................................................................... 27

Triple Bevels ....................................................................................................................................................... 28

Denitions for Top and Bottom Bevels .................................................................................................... 28

Top Bevels ........................................................................................................................................................... 28

Bottom Bevels ................................................................................................................................................... 29

Maximum Bevel Angle ................................................................................................................................... 29

Smart Bevel Technology ................................................................................................................................ 30

Initial Height Sensing ............................................................................................................................................ 31

Dimensional Limitations ...................................................................................................................................... 32

Water Table Dimensional Limitations ....................................................................................................... 32

Operation

Introduction ............................................................................................................................................................. 35

Basic Motion Controls ........................................................................................................................................... 36

Jogging the Bevel Axes ........................................................................................................................................ 37

Crash Recovery Process ....................................................................................................................................... 41

Smart Align Kit ........................................................................................................................................................ 42

Torch alignment Tool ...................................................................................................................................... 42

One Touch Alignment ......................................................................................................................................... 43

Summary Description..................................................................................................................................... 43

Alignment Procedure ..................................................................................................................................... 43

Table of Contents

TOC

Maintenance

Introduction ............................................................................................................................................................. 57

Routine Maintenance ........................................................................................................................................... 58

Routine Maintenance Frequency ..................................................................................................................... 58

Routine Maintenance Checks ............................................................................................................................ 59

Daily ...................................................................................................................................................................... 61

Weekly ................................................................................................................................................................. 61

Monthly ............................................................................................................................................................... 62

Semi-Annually ................................................................................................................................................... 63

Annually .............................................................................................................................................................. 63

Additional .......................................................................................................................................................... 63

Cleaning..................................................................................................................................................................... 64

Station Cleaning ............................................................................................................................................... 64

Electrical Enclosures ........................................................................................................................................ 65

Lubrication................................................................................................................................................................ 66

Lubrication ......................................................................................................................................................... 66

Lift Linear Bearings .......................................................................................................................................... 67

Lift Lead Screw/Nut ......................................................................................................................................... 67

Carriage Linear Bearings ................................................................................................................................ 67

Bevel Station Mechanical Alignment and Calibration ............................................................................... 68

Introduction ....................................................................................................................................................... 68

DMX Bevel Calibration .......................................................................................................................................... 70

A and B Motor replacement ......................................................................................................................... 75

Setting the Initial Height ..................................................................................................................................... 76

Setting Station Vertical (Plumb) ........................................................................................................................ 79

Table of Contents

TOC

Replacement Parts

General Information .............................................................................................................................................. 83

Ordering Information ........................................................................................................................................... 84

DMX Plasma Bevel

0560954600 Rev 3 .................................................................................................................................................. 85

BOM ...................................................................................................................................................................... 94

Electrical Enclosure DMX

0560956085 Rev 3 .................................................................................................................................................. 97

BOM ............................................................................................................................................................................ 99

Smart Align Calibration Unit DMX

0004686176 Rev 1 .................................................................................................................................................. 101

Grease Gun Coupler Alemite

0560957495 Rev 1 .................................................................................................................................................. 102

Torch Leveling Tool

0558004936 Rev 1 .................................................................................................................................................. 103

Alignment Nozzle DMX

0004471607 Rev 1 .................................................................................................................................................. 104

Alignment Cable

0558008466 Rev 1 .................................................................................................................................................. 105

Cables DMX

Part Numbers ........................................................................................................................................................... 106

Table of Contents

TOC

Torch Bundles

PT-36 ........................................................................................................................................................................... 107

BOM ............................................................................................................................................................................ 108

Torch Bundles

i-Series Torch Bundles ........................................................................................................................................... 109

BOM ............................................................................................................................................................................ 109

Table of Contents

TOC

Spacer Page

Table of Contents

SAFETY

MAINTENANCE

OPERATION

REPLACEMENT PARTS

DESCRIPTION

SAFETY

Spacer Page

SAFETY

Introduction

Used to call attention to medium risk

hazards, which if not avoided, could result

in death or serious injury.

WARNING

Introduction

ESAB cutting machines are designed to operate

both safely and eectively. Sensible attention

to operating procedures, precautions, and safe

practices is required to achieve a full measure of

usefulness. Whether an individual is involved with

operation, servicing, or as an observer, compliance

with established precautions is mandatory. Failure

to observe precautions could result in equipment

damage, serious injury, or death. The following

precautions are guidelines when working with

cutting machines and associated equipment. More

explicit precautions are found within the instruction

literature. For specic safety and industry-related

information, obtain and read publications listed in

Recommended References.

The following words and symbols are used

throughout this manual to indicate dierent levels of

required safety involvement:

Used to call attention to important

information not directly related to

safety hazards or could potentially cause

equipment damage.

Used to call attention to high risk hazards,

which if not avoided, will result in death or

serious injury.

DANGER

Used to call attention to low risk hazards,

which if not avoided, could result in minor

or moderate injury.

CAUTION

SAFETY

General Safety

SAFETY

READ AND UNDERSTAND THIS

INSTRUCTION MANUAL BEFORE

USING MACHINE.

Failure to follow safety instructions

could result in death or serious injury.

• Read entire procedure before

operating or performing any

equipment maintenance.

• Special attention must be given to

all hazard warnings that provide

essential information regarding

personnel safety and/or possible

equipment damage.

• Read all safety publications made

available by your company.

WARNING

READ AND UNDERSTAND ALL

SAFETY LABELS ON MACHINE.

Failure to follow safety label

instructions could result in death or

serious injury.

Refer to instruction manual content for

specic safety information.

WARNING

General Safety

SAFETY

Working with Plasma Cutting Equipment

Working with Plasma Cutting

Equipment

ELECTRICAL SHOCK HAZARD.

Electrical shock can cause serious injury

or death.

• Do NOT touch plasma torch, cutting

table, or cable connections during

plasma operation.

• Turn ALL power before touching or

servicing plasma system components

(i.e. plasma torch, ow controls, arc

starters, power supplies, coolant

circulators, or electronic enclosures).

• Do not touch live electrical

components.

• Keep all panels and covers in place

when machine is connected to power

source.

• Insulate yourself from workpiece

and electrical ground by wearing

insulated gloves, shoes, and

clothing.

• Keep gloves, shoes, clothing, work

area, and equipment dry at all times.

WARNING

SAFETY

Working with Plasma Cutting Equipment

SAFETY

WARNING

SPARK HAZARD.

Heat, weld spatter, and sparks can cause

re and burns.

• Do not cut near combustible

material. Do not cut containers that

have held combustibles.

• Do not have combustibles (e.g.

lighters or matches) on your person

at any time.

• Wear correct eye protection, gloves

and ame-retardant clothing that

covers all exposed areas.

BURN HAZARD.

The plasma process can cause severe

burns during the cutting sequence.

• Keep hands clear of plasma torches

during and after operation. Allow

torch ample time to cool.

• Do not touch plate or cut parts

immediately after cutting. Allow

metal time to cool or douse with

water. Wear gauntlet style gloves

when picking up cut parts.

• Plasma arcs can cause burns. Keep

yourself and others away from the

plasma process during operation.

WARNING

SAFETY

Working with Plasma Cutting Equipment

EXPLOSION HAZARD.

The plasma process can create hydrogen

gas pockets in water tables. These

pockets will explode when ignited by

sparks or plasma arc. Explosions can

cause serious personal injury or death.

• If cutting underwater, aerate

water under the plate surface with

compressed air.

• If cutting above water, use fans to

circulate air between plate and water

surface.

• If water table has not been used for

several hours, vibrate or jolt it to

break up hydrogen pockets.

• Do not leave plate on table

overnight.

• Change water in table often to break

up hydrogen pockets.

• Maintain water pH level near 7

(neutral).

• Clean slag (especially ne particles)

from bottom of water table

frequently.

• Programmed part spacing should be

a minimum of twice the kerf width to

ensure material is always under the

kerf.

WARNING

SAFETY

Working with Plasma Cutting Equipment

SAFETY

EXPLOSION HAZARD.

Certain molten aluminum lithium (AlLi)

alloys can cause explosions when plasma

cut in the presence of water.

• Do NOT plasma cut AlLi alloys with or

near water. These alloys should only

be dry cut on a dry table.

• Do NOT dry cut over water.

• Do NOT use water injection plasma

torches.

• Contact your aluminum supplier

for additional safety information

regarding hazards associated with

these alloys.

WARNING

ROTATING STATION ASSEMBLIES

CAN CAUSE SERIOUS INJURY.

Unit rotation will occur suddenly and

travel swiftly.

Keep all personnel away from the

immediate area during setup, testing,

maintenance, and automatic operation.

WARNING

SAFETY

Working with Plasma Cutting Equipment

WARNING

RADIATION HAZARD.

Plasma arc rays can injure eyes and burn

skin.

• Wear correct eye and body protection.

• Wear dark safety glasses or goggles

with side shields. Replace glasses/

goggles when lenses are pitted or

broken.

• Warn others not to look directly at the

arc unless wearing appropriate safety

glasses.

• Prepare cutting area to reduce

reection and transmission of

ultraviolet light.

• Paint walls and other surfaces with

dark colors to reduce reections.

• Install protective screens or curtains to

reduce ultraviolet transmission.

WARNING

NOISE HAZARD.

Noise from plasma arc can damage

your hearing. Wear proper hearing

protection.

SAFETY

Working with Plasma Cutting Equipment

SAFETY

TOXIC FUME HAZARD.

The plasma cutting process can produce

poisonous fumes and toxic gases. Certain

chlorinated solvents decompose and

form phosgene gas when exposed to

ultraviolet radiation.

• Do NOT breathe in fumes.

• Keep cutting area well ventilated.

• Wear proper breathing apparatus

when ventilation is not adequate.

• If the cutting process is active for

extended periods of time, a fume

removal system is recommended.

Ensure it is installed and maintained

properly.

• Do not cut metal or painted metals

containing zinc, lead, cadmium

or beryllium unless fume removal

equipment is installed and operating

properly.

WARNING

SAFETY

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ESAB ESAB DMX Automated Beveler User manual

Brand: ESAB

Model: ESAB DMX Automated Beveler

Category: Power tools

Type: User manual

This manual is also suitable for

DMX Automated Beveler

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