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ESAB ESAB DMX Automated Beveler, DMX Automated Beveler User manual

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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
© Copyright 2017 by
ESAB B rand.
All rights reserved.
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
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
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
Table of Contents
TOC
Torch Bundles
PT-36 ........................................................................................................................................................................... 107
BOM ............................................................................................................................................................................ 108
Torch Bundles
i-Series Torch Bundles ........................................................................................................................................... 109
BOM ............................................................................................................................................................................ 109
Table of Contents
Table of Contents
TOC
Spacer Page
Table of Contents
SAFETY
SAFETY
MAINTENANCE
OPERATION
REPLACEMENT PARTS
DESCRIPTION
SAFETY
2
Spacer Page
SAFETY
SAFETY
3
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
SAFETY
General Safety
SAFETY
4
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
WARNING
General Safety
SAFETY
SAFETY
5
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
6
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
SAFETY
7
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
8
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
SAFETY
9
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
10
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
/