ESAB M3® Plasma B4 Heavy Duty Lift Assembly m3 CAN Plasma System User manual

Form Number 0560946015 REV04

Date: 02 / 2 5/ 11

®

B4 Heavy Duty Lift Assembly

m3 CAN Plasma System

Instruction Manual

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 booklet “Precautions and Safe Practices for Arc Welding, Cutting, and

Gouging” (Form 52-529). 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 Safety Precautions before

installing or operating this equipment.

CAUTION

This equipment will perform in conformity with the description thereof contained in this manual and accompa-

nying labels and/or inserts when installed, operated, maintained and repaired in accordance with the instruc-

tions 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 imme-

diately. 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 ser-

vice facility designated by the manufacturer.

USER RESPONSIBILITY

READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.

PROTECT YOURSELF AND OTHERS!

1

B4-200 Plasma Lift Assembly

Contents

Safety

Precautions �� 3

Enclosure Class �� 4

General Safety Recommendations �� 5

Description

Introduction �� 7

Major Components - B4 Lift �� 8

Installation

Mounting �� 9

Electrical Interfacing �� 10

Station Grounding �� 13

Maintenance

Preventative Maintenance Schedule �� 14

Daily �� 14

Weekly �� 15

Monthly �� 15

Semi-Annually �� 15

Maintenance Procedures

B4-200 Lift �� 17

Introduction �� 17

Lift Cleaning and Lubrication �� 17

B4 Lift Part Removal and Replacement �� 19

2

B4-200 Plasma Lift Assembly

Omni Crash Protection �� 26

Description �� 26

Function Description ��27

Replacing / Adjusting the Omni® Sensor ��28

Omni® Sensor Installation ��29

Omni® Mechanical Alignment ��32

Disassembly �� 33

Lubrication ��34

Technical Descriptions and Troubleshooting

Encoder Height Control �� 35

Introduction ��35

Encoder Station Constant (STA�kon) Reference Chart ��36

Setting Station Constants using distance calculations ��36

AVHC Introduction and Oset Adjustment �� 37

Basic B4 Lift Assembly Troubleshooting �� 38

Yaskawa Junma Servopack™ Alarm Indicators �� 39

3

B4-200 Plasma Lift Assembly

Precautions

Users of ESAB welding and plasma cutting

equipment have ultimate responsibility for ensuring

that anyone who works on or near the equipment

observes all relevant safety precautions� Safety

precautions must meet requirements that apply to

this type of welding or plasma cutting equipment�

All work must be carried out by trained personnel

well acquainted with operation of welding or

plasma cutting equipment� Incorrect operation of

equipment may lead to hazardous situations which

can result in injury to the operator and damage to

equipment� The following recommendations should

be observed in addition to standard regulations that

apply to the workplace�

Anyone who uses welding or plasma cutting

1�

equipment must be familiar with:

Proper operation�

…

Location of emergency stops� …

Designed function� …

Relevant safety precautions� …

Welding and/or plasma cutting� …

Operators must ensure that:2�

No unauthorized person within the working …

area of equipment when it is started up�

No one is unprotected when plasma arc is

…

struck�

The workplace must be:

3�

Suitable and …

Free from drafts� …

Personal safety equipment:4�

Always wear recommended personal safety …

equipment, such as safety glasses, ame proof

clothing, and safety gloves�

Do not wear loose tting items, such as

…

scarves, bracelets, rings, etc�, which could become

trapped or cause burns�

Safety

4

B4-200 Plasma Lift Assembly

General precautions:5�

Make sure return cable is connected securely� …

Work performed on high voltage equipment …

may only be carried out by a qualied

electrician�

Appropriate re extinguishing equipment

…

must be clearly marked and close at hand�

Lubrication and maintenance

… must not be

carried out on equipment during operation�

The IP code indicates the enclosure class, i�e� the

degree of protection against penetration by solid

objects or water� Protection is provided against

touch with a nger, penetration of solid objects

greater than 12mm and against spraying water up to

60 degrees from vertical� Equipment marked IP23S

may be stored, but is not intended to be used out-

side during precipitation unless sheltered�

Enclosure Class

Maximum

Tilt Allowed

15°

If equipment is placed on a surface that slopes

more than 15°, toppling over may occur.

Personal injury and/or signicant damage to

equipment is possible.

CAUTION

WELDING AND PLASMA CUTTING CAN

CAUSE INJURY TO YOURSELF AND

OTHERS. TAKE PRECAUTIONS WHEN

WELDING OR CUTTING. ASK FOR YOUR

EMPLOYER’S SAFETY PRACTICES WHICH

SHOULD BE BASED ON MANUFACTURERS’

HAZARD DATA.

WARNING

5

B4-200 Plasma Lift Assembly

ELECTRIC SHOCK - Can kill�

Ground welding or plasma cutting units in

•

accordance with applicable standards�

Do not touch live electrical parts or electrodes

•

with bare skin, wet gloves, or wet clothing�

Insulate yourself from earth ground and the

•

workpiece�

Ensure your working stance is safe�

•

FUMES AND GASES - Can be dangerous to health�

Keep your head out of the fumes�

•

Use ventilation, extraction at the arc, or both, to •

take fumes and gases away from your breathing

zone and the general area�

ARC RAYS - Can injure eyes and burn skin�

Protect your eyes and body, using correct

•

welding/plasma cutting screens and lter lens�

Wear protective clothing�

•

Protect bystanders with suitable screens or •

curtains�

FIRE HAZARD - Sparks (spatter) can cause re� Make

sure that there are no ammable materials nearby�

NOISE - Excessive noise can damage hearing�

Protect your ears, using ear protection�

•

Warn bystanders of the risk�•

MALFUNCTION - Call for expert assistance in the

event of malfunction�

General Safety

Recommendations

READ AND UNDERSTAND THE INSTRUCTION

MANUAL BEFORE INSTALLING OR OPERATING.

PROTECT YOURSELF AND OTHERS!

CAUTION

6

B4-200 Plasma Lift Assembly

To avoid personal injury and/or equipment dam-

age, lift using method and attachment points

shown below.

CAUTION

7

B4-200 Plasma Lift Assembly

Introduction

The B4-200 lift assembly provides vertical motion for

the PT-36 plasma torch, using a typical motor, screw,

and slide conguration� The motor turns an enclosed

spindle screw, which in turn raises/lowers the lifting

plate along linear rails� Directional commands given

from CNC determines direction of lift travel� Fixed

limit switches are included to prevent upper and

lower over travel�

The lift assembly also contains components

necessary to control height over work surfaces;

initial, piercing, and cornering heights are encoder-

controlled during the plasma cycle through use

of SDP/TDF les� During part production, stando

is automatically controlled by taking voltage

measurements between torch nozzle and work

surface�

Finally, the B4 lifts include an Omni Soft Touch®

assembly to protect the system during station

crashes� Proximity switches monitor torch position in

the torch holder� If the torch is jarred in any direction,

process movement will stop and an error report will

be sent to CNC� The Illustration on following page

will detail major lift components and their location�

For illustrated part breakdowns, see end section of

this manual�

Description

8

B4-200 Plasma Lift Assembly

Major Components - B4 Lift

Remote Arc Starter box

Torch Bundle Guide ring

B4 Lift Mounting bracket (option)

Electrical Soft Touch box

B4 Lift Electronics Enclosure

Plasma Gas box

B4 Lift Assembly

OMNI Mounting bracket

Electrical Soft Touch wire (option)

OMNI Soft Touch® assembly

PT-36 m3C Torch

1

2

3

4

5

6

7

8

9

10

11

Technical Specications

Lift Speed:• 315 IPM [8.0m per minute]

Vertical Travel: 8.00” [200.0 mm]

•

Approximate Weight of Lift Assembly •

including torch holder: 85 lbs. [38.5 kg]

Torch Barrel Size: 85.7 mm

•

Component Tolerances•

IHS Accuracy: ± 0.5 mm …

Encoder Accuracy: ± 0.25 mm …

Voltage Accuracy: ± 1 volt …

9

B4-200 Plasma Lift Assembly

Installation

Mounting

B4 lift hole patterns are provided below to aid end

users in mounting the plasma station. An optional

plasma bracket/nut plate are available as an option;

part numbers are included in Replacement Parts

section of this manual.

B4-200 Lift Assembly dimensions

(6) M8 x 1.25 x 40

Socket Head Cap Screws

5.00”

[127.0mm]

4.13” [104.9mm]

0.49” [12.4mm]

3.64” [92.4mm]

4.47”

[113.5mm]

x6 M8x1.25 - 6H

THRU HOLES

0.53”

[13.5mm]

2.50”

[63.5mm]

10

B4-200 Plasma Lift Assembly

NOTICE

Ensure lift assembly is mounted

plumb; use a torpedo level and

adjust mounting bolts as needed.

Torpedo Level

Electrical Interfacing

After lift assembly and electrical enclosure have

been mounted, make the following electrical

connections:

Lift Input Power1� (4 pin, male_female):

connection is from control interface box AHC

Power to lift electrical enclosure SB2�

ACON cable

2� (M12, 8 pin, male_male):

connection is from control interface box CAN #

connector to lift electrical enclosure SB1�

Crash Protection cable3� (M12, 8 pin male_

female): connection is from lift electrical

enclosure SB3 to Omni® Soft Touch proximity

sensor�

NOTICE

CAN # connection used will vary

depending on your system conguration.

See System Interconnection manual (PN

0558008527) to determine your system

conguration.

m3 CAN OEM Interface Box

11

B4-200 Plasma Lift Assembly

Lift Electrical Enclosure

connection guide

SB2 - Input Power

SB1 - ACON

SB3 - Crash Protection OR

Soft Touch Interconnection

SB5 - VDR (RAS)

1

2

3

A

3

A

2

1

12

B4-200 Plasma Lift Assembly

The following connections will need to be made if

your plasma station has electrical soft touch option

installed:

Soft Touch Interconnection cable

4� (M12, 8 pin

female-female): connection is from lift electrical

enclosure SB3 to soft touch enclosure ST1�

Soft Touch Proximity cable5� (M8 female socket_

free wire end): connection is from X3 (inside

soft touch electrical enclosure) to Omni® Soft

Touch proximity sensor�

Torch Touch wire

6� (14-16AWG, in-line terminal_

torch clamp): connection is from soft touch

board X4 to torch clamping ring� Attach this

clamping ring to metal portion of PT-36 torch

body�

NOTICE

The Soft Touch Interconnection cable (#4)

will replace the Crash Protection cable (#3)

on plasma stations utilizing electrical soft

touch option.

Electrical Soft Touch Enclosure

Connection Guide

Soft touch enclosure lid was made transparent to show box detail.

9

7

8

13

B4-200 Plasma Lift Assembly

Station Grounding

Before placing the plasma station into operation,

ensure that the following grounding points are

established:

Lift Electrical Enclosure

•

Soft Touch Electrical Enclosure•

Grounding points should be fastened to bare,

unpainted metal and should measure less than 10

ohms on a digital multimeter�

Do not use star washers to establish

grounding points!

Star washers do not cut painted surfaces

adequately enough to establish ground

potential; ground surfaces should be

against bare metal.

CAUTION

DO NOT cut under water if electrical

soft touch option is installed on

your plasma station!

CAUTION

14

B4-200 Plasma Lift Assembly

Maintenance

Preventative Maintenance

Schedule

Time periods suggested below are based on average

plasma station usage� If station is employed in

a heavy usage cycle, used outdoors, or used on

a multi-torch cutting machine, suggested time

intervals should be shortened� Regularly scheduled

maintenance will signicantly increase the life and

performance of your equipment�

Daily

Wipe dust and fume buildup from lift assembly •

and components�

Check for worn or damaged cables on all lift

•

subassemblies�

Ensure all mechanical fasteners and electrical

•

connections are correct; no stripping of

hardware, connections are tight, exposed wires,

etc�

Check that lift travel limit switches are

•

functioning correctly�

Use your CNC’s station travel buttons to ensure

•

lift assembly has proper, smooth movement�

Replace any worn PT-36 torch consumables�

•

Test Omni® crash protection function; ensure •

that when plasma torch is jarred in any direction,

a crash signal appears at the CNC�

Read all instruction manual’s safety

and maintenance procedures

before beginning any preventative

maintenance!

CAUTION

15

B4-200 Plasma Lift Assembly

Weekly

Check alignment of lift assembly�•

Check Omni® proximity sensor position and •

adjust, if required�

NOTICE

Many replacement parts subject to wear

or used in preventative maintenance

schedules are available directly through

ESAB Cutting Systems.

See “Consumables and Spare Parts”

section in Replacement Parts portion of

this manual before ordering.

Monthly

Clean and lubricate slide assembly (see •

procedure on page 18)�

Check alignment, clean and lubricate Omni®

•

crash assembly (see procedure on page26)�

Semi-Annually

Repeat all previous maintenance procedures�•

Consider calling your ESAB Service •

Representative to schedule an semi-annual

station inspection�

16

B4-200 Plasma Lift Assembly

Maintenance Procedures

The following section contains maintenance

procedures for the lift assembly and components�

This section will provide some basic troubleshooting

methods to return your station to correct operation�

Only qualied maintenance personnel should utilize

these procedures�

17

B4-200 Plasma Lift Assembly

B4-200 Lift

In order for B4 slide assemblies to perform at

optimum levels, it will need to be inspected, cleaned

and lubricated on a weekly basis� The following

procedure will detail steps necessary to correctly

clean and lubricate your slide assembly:

Remove (3) cap screws attaching front cover�

1�

Run lift to lower limit and wipe ball screw with 2�

a clean, dry cloth� Apply lithium based NGLI 2

grease or softer grease directly to screw�

Introduction

The B4-200 heavy duty vertical lift employs an

enclosed motor that turns a ball screw� This is made

possible by using a pair linear bearing blocks and a

drive belt, which lowers or raises the lifter assembly

along linear rails� Direction depends on commands

received form the CNC� The illustration at left is the

B4 lift with some parts hidden for clarity� The three

grease ttings can be accessed without removing lift

covers�

Lift Cleaning and Lubrication

Spindle Ball screw

Spindle Ball nut

Upper Limit switch and cam

Precision Linear rail (2)

Linear Bearing blocks (2)

Lower Limit switch

Lift Electronics Enclosure

Timing belt

Motor / Encoder

Lifter Assembly w/ bellows

1

2

3

4

5

6

7

8

9

10

18

B4-200 Plasma Lift Assembly

Do not use solvents or solvent-based

lubricant to clean ball screw; this can

remove lubricant from sealed linear

bearing blocks.

CAUTION

Run lift to upper limit�3�

Apply same grease to three zerk ttings; apply 4�

0�1 ounce (3cc) or half pump of a grease gun to

each tting�

NOTICE

Lift covers do not need to be removed to

access grease ttings.

See illustration above for tting locations.

Reinstall front cover to lift assembly�5�

Screw Nut

zerk tting

Linear Bearing

zerk ttings

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ESAB M3® Plasma B4 Heavy Duty Lift Assembly m3 CAN Plasma System User manual

ESAB M3® Plasma B4 Heavy Duty Lift Assembly m3 CAN Plasma System User manual

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