ESAB CrossBow User manual

CROSSBOW

Portable CNC Cutting Machine

Instruction

Manual

Article Number 0560951719

Revision Date: September 29, 2014

Revision Number: B

Language: ENG

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Preface

The Crossbow is a portable CNC cutting machine supplied by ESAB Cutting Systems. It may be

equipped with a single oxy-fuel cutting torch, a single plasma cutting torch, or both. It is designed to

provide years of dependable, accurate, repeatable part cutting, with a high degree of reliability, ease of

service and operation.

There are optional features and configurations available which may or may not be included in this

manual. In addition, more capabilities and features may be added in the future, which are not covered

in this manual. ESAB Cutting Systems reserves the right to change or add features and capabilities

without notice. Before operating the machine, one should become familiar with this manual in its

entirety, with special attention to the SAFETY section.

The equipment described in this manual is potentially hazardous. Use caution when installing,

operating, and maintaining this equipment.

The purchaser is responsible for the safe operation and use of all products purchased, including

compliance with all applicable standards in the country of use. See standard ESAB terms and

conditions of sale for a specific statement of ESAB’s responsibilities and limitations on liability.

Information in this document is subject to change without notice. This manual is for the convenience

and use of the cutting machine purchaser. It is not a contract or any obligation on the part of ESAB

Cutting Systems.

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Table of Contents

1 Safety .............................................................................................. 11

1.1 Introduction ........................................................................................................11

1.2 Safety Hazards and Warnings ............................................................................11

1.3 Electrical Grounding ...........................................................................................16

1.4 Service Precautions ...........................................................................................16

1.5 Recommended Safety References .....................................................................17

1.5.1 International ........................................................................................... 17

1.5.2 United States .......................................................................................... 18

1.5.3 Canada ................................................................................................... 19

2 Description ..................................................................................... 21

2.1 Machine Overview ..............................................................................................21

2.2 Machine Components.........................................................................................22

2.3 Machine Dimensions ..........................................................................................23

2.4 Machine Specifications .......................................................................................24

2.5 Axis Orientation ..................................................................................................25

3 Installation ...................................................................................... 27

3.1 Receiving Inspection ..........................................................................................27

3.2 Base Machine Setup ..........................................................................................28

3.2.1 Prepare Rail Track.................................................................................. 28

3.2.2 Install Central Unit on Rail Track ............................................................ 32

3.2.3 Install Cross Beam Assembly ................................................................. 35

3.2.4 Install Torch Lifter ................................................................................... 39

3.2.5 Connect Cables ...................................................................................... 43

3.3 Oxy-fuel Torch Installation ..................................................................................46

3.3.1 Assemble Torch ..................................................................................... 46

3.3.2 Install Torch in Torch Holder with Adaptor .............................................. 47

3.3.3 Connect Torch Hoses ............................................................................. 48

3.3.4 Install Gas Supply Hoses........................................................................ 49

3.3.5 Connect Gas Supplies ............................................................................ 50

3.3.6 Perform Leak Test .................................................................................. 51

3.4 Plasma Torch Installation ...................................................................................52

3.4.1 Install Second Cable Holder ................................................................... 52

3.4.2 Install Plasma Torch ............................................................................... 53

3.4.3 Install Plasma Interface Cable ................................................................ 54

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3.4.4 Install Initial Height Sensing Cable .......................................................... 56

3.4.5 Connect Power and Air to Plasma Unit ................................................... 57

3.5 Initial Power-Up Testing ..................................................................................... 58

3.6 Switching Between Metric and Inch ................................................................... 59

4 Operation ........................................................................................ 61

4.1 Control Panel and Function ................................................................................ 61

4.2 CNC System Features ....................................................................................... 62

4.3 CNC System Technical Specification ................................................................. 62

4.4 Function Keys .................................................................................................... 62

4.5 Input Keys .......................................................................................................... 63

4.6 Operational Overview – Oxy-Fuel Cutting .......................................................... 66

4.7 Operational Overview – Plasma Cutting ............................................................. 66

4.8 Home Screen and Main Menu ............................................................................ 67

4.9 Main Menu Map ................................................................................................. 68

4.9.1 Main Menu .............................................................................................. 68

4.9.2 Auto Mode Menu ..................................................................................... 69

4.9.3 Manual Mode Menu ................................................................................ 70

4.9.4 Edit Mode Menu ...................................................................................... 71

4.10 Auto Mode Screen ........................................................................................... 72

4.10.1 SPEED ................................................................................................... 72

4.10.2 PROG, PIERCE and KERF ..................................................................... 73

4.10.3 Cutting Process Status Indicators ........................................................... 73

4.10.4 Additional Function Key Indicators .......................................................... 73

4.10.5 INPUT and OUTPUT INDICATORS ........................................................ 74

4.10.6 Operating Parameters ............................................................................. 74

4.10.7 Machine Coordinate Display .................................................................... 74

4.10.8 Mode / Status Indicators ......................................................................... 74

4.10.9 Program Coordinates .............................................................................. 74

4.10.10 Graphics Display Area ........................................................................ 74

4.11 Auto Mode Menu Functions ............................................................................ 75

4.11.1 【F1】SKIPTO ....................................................................................... 75

4.11.2 【F2】MANUAL...................................................................................... 75

4.11.3 【F3】RESUME ..................................................................................... 75

4.11.4 【F4】PREVIEW .................................................................................... 75

4.11.5 【F5】KERF ........................................................................................... 77

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4.11.6 【F6】MORE ......................................................................................... 77

4.11.7 【F7】RETURN ..................................................................................... 77

4.12 Auto Mode MORE Window (2

nd

Level) Functions ............................................78

4.12.1 【F1】OUTLINE Function ...................................................................... 78

4.12.2 【F2】WENTAI ...................................................................................... 79

4.12.3 【F3】ROTATE (Program Rotation) ...................................................... 79

4.12.4 【F4】MIRROR ..................................................................................... 80

4.12.5 【F5】SCALE ........................................................................................ 80

4.12.6 【F6】NEST .......................................................................................... 81

4.12.7 【F7】TABBING .................................................................................... 82

4.13 Running a Program in Auto Mode....................................................................83

4.13.1 Select the Part Program or Nest ............................................................. 83

4.13.2 Set Cutting Speed .................................................................................. 83

4.13.3 Move To Starting Position....................................................................... 83

4.13.4 Start Cutting ........................................................................................... 83

4.13.5 Arc Voltage Height Control Operation (Plasma Cutting) ......................... 83

4.14 Functions Available While Running a Program ................................................84

4.15 Functions Available During Program Pause ....................................................85

4.15.1 Program Pause Screen .......................................................................... 85

4.15.2 Key Panel Functions ............................................................................... 85

4.15.3 【F4】JUMP TO (Jump To Any Line or Pierce Point) ............................ 87

4.15.4 【F5】PIERCE# (Go To New Pierce Point) ........................................... 87

4.15.5 【F6】REVERSE (Backward On Path) .................................................. 88

4.15.6 【F7】FORWARD (Forward On Path) ................................................... 88

4.15.7 Re-Start After Jogging ............................................................................ 88

4.16 Resuming Parked Programs ............................................................................90

4.17 SKIPTO (Skip To Starting Point) .....................................................................92

4.18 Edge Starting ..................................................................................................93

4.19 Manual Mode Screen.......................................................................................94

4.19.1 SPEED ................................................................................................... 94

4.19.2 Additional Function Keys and Indicators ................................................. 95

4.20 Manual Mode Menu Functions ........................................................................96

4.20.1 【F1】AUTO .......................................................................................... 96

4.20.2 【F2】STEP........................................................................................... 96

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4.20.3 【F3】MORE .......................................................................................... 96

4.20.4 【F4】MACH-0 (Clear Machine Coordinates) ......................................... 96

4.20.5 【F5】RAPID (Rapid Jog Speed) ........................................................... 96

4.20.6 【F6】PROG-0 (Clear Program Coordinates) ........................................ 96

4.20.7 【F7】RETURN ..................................................................................... 97

4.21 Manual Mode MORE Window (2

nd

Level) Functions ....................................... 98

4.21.1 【F3】REC PT1 and【F4】REC PT2 (Plate Alignment) ........................ 98

4.21.2 【F5】COORDS (Set Coordinates) ........................................................ 99

4.22 Edit Mode ...................................................................................................... 100

4.23 Edit Mode Menu Functions ........................................................................... 100

4.23.1 【F1】NEW .......................................................................................... 100

4.23.2 【F2】LOAD ......................................................................................... 100

4.23.3 【F3】SAVE ......................................................................................... 101

4.23.4 【F4】DEL-FILE ................................................................................... 101

4.23.5 【F5】DEL-LINE .................................................................................. 101

4.23.6 【F6】USB ........................................................................................... 101

4.23.7 【F7】PREVIEW .................................................................................. 102

4.24 USB Access Menu ........................................................................................ 103

4.24.1 【F1】LOAD ......................................................................................... 103

4.24.2 【F2】OUTPUT .................................................................................... 104

4.24.3 【F3】SELECT .................................................................................... 104

4.24.4 【F7】PREVIEW .................................................................................. 104

4.25 Setup Mode Screen (Parameter Settings) ..................................................... 105

4.25.1 【F1】Speed Parameters ..................................................................... 106

4.25.2 【F2】System Parameters ................................................................... 107

4.25.3 【F3】Flame Parameters ..................................................................... 108

4.25.4 【F4】Plasma Parameters ................................................................... 109

4.25.5 【F5】Control Parameters .................................................................... 110

4.26 Shape Library ............................................................................................... 112

4.26.1 Operating Overview – Shape Library .................................................... 113

4.26.2 Shape Evaluation Screen ...................................................................... 114

4.26.3 【F1】OD CUT and 【F2】ID CUT ..................................................... 115

4.26.4 【F3】ROTATE .................................................................................... 116

4.26.5 【F4】NEST ......................................................................................... 117

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4.26.6 【F6】APPLY .......................................................................................118

4.27 Part Programming Instructions ......................................................................... 119

4.27.1 File Format ............................................................................................119

4.27.2 Program Names ....................................................................................119

4.27.3 Program Format ....................................................................................119

4.27.4 Units Of Measurement ...........................................................................120

4.27.5 Programming Mode ...............................................................................120

4.27.6 Axis Orientation .....................................................................................120

4.27.7 G-Codes ................................................................................................121

4.27.8 M-Codes ................................................................................................127

4.27.9 Programming Examples ........................................................................128

5 Maintenance ................................................................................. 133

5.1 Routine Maintenance........................................................................................ 133

5.1.1 Daily Maintenance .................................................................................133

5.1.2 Weekly Maintenance .............................................................................133

5.1.3 Monthly Maintenance.............................................................................134

5.2 Lubrication Points ............................................................................................. 135

5.3 Operating FAQ ................................................................................................. 136

5.4 Basic Troubleshooting ...................................................................................... 137

5.5 Software Service Instructions ........................................................................... 141

5.5.1 Boot Menu .............................................................................................141

5.5.2 Backup and Restore Parameters ...........................................................142

5.5.3 Instructions for Updating Software .........................................................143

5.5.4 Changing Machine Name Text ..............................................................144

5.6 Hardware Service Instructions .......................................................................... 145

5.6.1 Replacing Main Fuse .............................................................................145

5.6.2 Removing the CNC................................................................................146

5.6.3 Servicing Operator Panel Components..................................................148

5.6.4 Adjusting the Main Power Supply ..........................................................149

5.6.5 Switching Input Voltage .........................................................................150

5.6.6 Changing Initial Height Setting ..............................................................152

5.6.7 Reversing Lift Motor Direction ...............................................................153

5.6.8 Replacing Arc Voltage Height Control Board .........................................154

5.6.9 Replacing VHC Sensor Board ...............................................................155

5.6.10 Replacing Motor Driver ..........................................................................156

5.6.11 Removing the Cover ..............................................................................157

5.6.12 Replacing the Main Power Supply .........................................................158

5.6.13 Replacing Bearing Blocks ......................................................................159

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5.6.14 Adjusting Rail Axis Drive Pinion Engagement ....................................... 160

5.6.15 Adjusting Cross Beam Drive Pinion Engagement.................................. 161

5.6.16 Adjusting the V-Wheels ......................................................................... 162

5.6.17 Replacing Drive Motor .......................................................................... 164

5.6.18 Replacing Drive Pinions ........................................................................ 165

5.6.19 Replacing V-Wheels ............................................................................. 166

5.6.20 Replacing the Solenoid Valve ............................................................... 168

5.6.21 Servicing the Torch Lifter ...................................................................... 170

6 Replacement Parts ...................................................................... 173

6.1 Introduction ...................................................................................................... 173

6.2 Ordering Information ........................................................................................ 173

6.3 Parts List .......................................................................................................... 174

6.3.1 Main Assemblies ................................................................................... 174

6.3.2 Central Unit Parts .................................................................................. 175

6.3.3 Motion System Parts ............................................................................. 176

6.3.4 Internal Electrical Parts ......................................................................... 177

6.3.5 Internal Mechanical Parts ...................................................................... 178

6.3.6 Internal Drive System Parts .................................................................. 179

6.3.7 Cables and Connectors......................................................................... 180

6.3.8 Torch Station Parts ............................................................................... 181

6.3.9 Torch Lifter Parts .................................................................................. 182

6.3.10 Plasma Torch Parts .............................................................................. 183

6.3.11 Oxy-Fuel Torch Kit ................................................................................ 184

6.3.12 Oxy-Fuel Cutting Tips ........................................................................... 185

Appendix 1: Programming Code Reference ................................... 187

Appendix 2: Error List ....................................................................... 189

Appendix 3: Shape Library Variables.............................................. 191

Shape 1: RECTANGLE .......................................................................................... 191

Shape 2: CIRCLE ................................................................................................... 192

Shape 3: L-BRACKET ............................................................................................ 193

Shape 4: PIE SHAPE ............................................................................................. 194

Shape 5: TRIANGLE .............................................................................................. 195

Shape 6: CURVE BKT ............................................................................................ 196

Shape 7: CHAMFER .............................................................................................. 197

Shape 8: OVAL ...................................................................................................... 198

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Shape 9: RING........................................................................................................ 199

Shape 10: OCTAGON ............................................................................................. 200

Shape 11: TAB RECTANGLE ................................................................................. 201

Shape 12: CUTOUT ................................................................................................ 202

Shape 13: LINE CUT .............................................................................................. 203

Shape 14: ARC SECTOR ....................................................................................... 204

Shape 15: HOLE CUTOUT ..................................................................................... 205

Shape 16: RECT. CUTOUT .................................................................................... 206

Shape 17: U-SHAPE ............................................................................................... 207

Shape 18: COM-LINE (Common-Line-Cut Rectangles) .......................................... 208

Shape 19: TANK BED ............................................................................................. 209

Shape 20: 4-HOLE FLANGE ................................................................................... 210

Shape 21: 6-HOLE FLANGE ................................................................................... 211

Shape 22: IMPELLER ............................................................................................. 212

Shape 23: 2-HOLE FLANGE ................................................................................... 213

Shape 24: WES TEST ............................................................................................ 214

Appendix 4: Oxy-Fuel Cutting Parameters ..................................... 215

Cutting Data for Oxweld C-69 Torch ....................................................................... 215

Cutting Data for Oxweld C-70 Torch ....................................................................... 215

Appendix 5: PT-37 Plasma Cutting Parameters ............................. 217

Mild Steel Cutting .................................................................................................... 217

Aluminum Cutting .................................................................................................... 218

Stainless Steel Cutting ............................................................................................ 219

Appendix 6: Wiring Diagrams .......................................................... 221

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1 Safety

1.1 Introduction

ESAB cutting machines are designed to operate both safely and effectively. 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 specific safety and industry-related information, obtain and read publications listed in

Recommended References.

1.2 Safety Hazards and Warnings

READ AND UNDERSTAND ALL INSTRUCTION MANUALS BEFORE USING MACHINE.

Ensure personnel read all manuals, in their entirety, with special regard to safety sections. Failure to do

so could result in death or serious injury.

• In addition to ESAB documentation, review third party safety documentation.

• Read entire procedure before operating or performing any equipment maintenance.

• Special attention must be given to all hazard warnings that provide information on personnel

safety and/or equipment damage.

• Read all safety publications made available by your company.

• A knowledgeable operator familiar with the process & hazards must be present while the machine

is in operation

READ AND UNDERSTAND ALL SAFETY LABELS ON MACHINE.

Failure to follow safety label instructions could result in death or serious injury.

SAFETY COMPONENT STATUS.

Operating machine with safety functions disabled will result in serious injury or death.

• UNDER NO CIRCUMSTANCE shall attempts be made by anyone to operate this cutting machine

with emergency stops, interlocks, covers, or incorporated safety functions bypassed or otherwise

circumvented.

CRUSH HAZARD - MACHINE STARTS AUTOMATICALLY.

This equipment moves in various directions and speeds. Moving machinery can crush. Inadvertent

startup can cause serious injury or death.

• Only qualified personnel should operate or service equipment.

• Keep all personnel, materials, and equipment not involved in production process clear of entire

system area.

• Keep tools and clothing away from drive rack and rail.

• Fence off entire work cell to prevent personnel from passing through area or standing in working

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envelope of equipment.

• Follow lockout-tagout procedures before servicing to prevent inadvertent startup.

• Stay clear of rails and cutting table during operation.

• Keep hands clear of moving components.

FLYING DEBRIS HAZARD.

Hot spatter can burn and injure eyes.

• Wear goggles to protect eyes from burns and flying debris generated during operation.

CRUSH/PINCH HAZARD.

Moving machine and lifter can crush or pinch.

• Stay clear of torch during machine operation.

• Ensure others do not enter the machine’s work area during operation.

• Do not operate machine with any protective covers removed.

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 off ALL power before touching or servicing plasma system components (i.e. plasma torch,

plasma power source, 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.

• Follow lockout-tagout procedures before servicing.

SPARK HAZARD.

Heat, weld spatter, and sparks can cause fire 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 and gloves.

• Wear correct eye protection, gloves and flame-retardant clothing that covers all exposed areas.

RADIATION HAZARD.

Plasma arc rays can injure eyes and burn skin.

• Wear correct eye and body protection.

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• 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 reflection and transmission of ultraviolet light.

• Paint walls and other surfaces with dark colors to reduce reflections.

• Install protective screens or curtains to reduce ultraviolet transmission.

BURN HAZARD.

The plasma and oxy-fuel cutting processes can cause severe burns during or after the cutting

sequence.

• Keep hands clear of torch 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.

NOISE HAZARD.

Noise generated from plasma and oxy-fuel cutting can damage your hearing.

• Wear proper hearing protection.

EXPLOSION HAZARD.

Oxy-fuel torches can create explosive gas pockets if flowing gas is not burned.

• Never leave gases turned on if a torch fails to ignite.

• If unignited gas has been flowing from a torch more than a few seconds, allow gas time to

dissipate before re-igniting the torch.

• Explosive gas mixtures can accumulate underneath plate and inside cutting table. Use fans to

dissipate any possible gas pockets.

• If plasma cutting Aluminum on a water table, hydrogen gas pockets may be formed below the

plate. These pockets will explode if ignited by sparks or plasma arc. Explosions can cause serious

personal injury or death.

• If cutting Aluminum over a water table, 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.

• Clean slag (especially fine particles) from bottom of water table frequently.

• All hoses and cables should be inspected regularly & replaced if necessary.

ALUMINUM 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.

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• Do NOT use water injection plasma torches.

• Contact your aluminum supplier for additional safety information regarding hazards associated

with these alloys.

EXPLOSION AND FIRE HAZARD.

Ordinary materials can explode and burn in the presence of oxygen.

• Keep all equipment clean and in good operating condition. All hoses and cables should be

inspected regularly & replaced if necessary.

• Keep entire work area free from oil, grease, and other combustibles.

• Do not purge lines close to an ignition source (i.e., flame or cigarette), towards a person, or near

clothing.

• All parts used to repair oxygen systems MUST BE OIL FREE.

• Never use oxygen as a substitute for compressed air to “dust” clothing or pressure test.

• Never allow oil, grease, or hydrocarbons to come in contact with oxygen gas equipment. Gas

regulators do not require lubrication.

• Never use compressed air for blowing out oxygen gas passages. Compressed air contains oil that

can burn.

• Always refer to oxygen by its proper name - Oxygen. Never call oxygen “air” which could be

confused with compressed air.

EXPLOSION AND FIRE HAZARD.

Fuel gases can explode and burn, causing severe injury and death.

• Do not purge lines close to an ignition source (i.e., flame or cigarette), towards a person, or near

clothing.

• Ventilate any work areas that might accumulate leaking fuel gas.

• Isolate cutting area to protect yourself and others from heat, flame, sparks, and hot slag.

• Personnel should be aware of fuel gas being used and its characteristics.

TOXIC FUME HAZARD.

The oxy-fuel cutting process produces toxic gas containing carbon deposits.

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.

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TOXIC FUME HAZARD.

Hexavalent Chromium Cr(VI) is a toxic chemical within fumes. It is created in a variety of processes,

including plasma cutting of stainless steel. If you plasma cut stainless steel, you will need to comply

with the following to protect your employees from Cr(VI) exposure.

• Exposure to hexavalent chromium must be below the permissible exposure limit (PEL) of 5 µg/m3

for an eight hour time weighted average.

• Workplace or job-specific monitoring must be done to establish and quantify areas of potential

exposure.

• Employees who may be exposed to Cr(VI) must be informed and corrective measures

implemented.

• Protective clothing and respiratory protection must be given to employees who have potential

exposure.

• Medical surveillance of employees with potential exposure must be conducted.

• Potential exposure areas must be indicated with warning signs containing the text shown at left.

• Engineering control must be used to reduce exposures to safe levels.

• Specific details of the standard are complex and may require assistance from occupational health

professionals to reach full compliance.

GAS SUPPLY SYSTEM CONTENTS UNDER EXTREME PRESSURE

Weakened gas system components can explode or release toxic gases causing serious injury and

death.

• Check for leaks at gas connections on all regulators, valves, gas lines, and torches. Ensure all are

in proper working condition before operation begins.

• All hoses and cables should be inspected regularly & replaced if necessary.

• Gas valves should be opened slowly, and shut off when machine is idle. Bleed off line pressure

when machine is inactive.

• Close gas valves before servicing any gas connections, fittings, lines, or regulators.

• Never disconnect any system component that is thought to be under pressure.

• Bleed off regulators when changing gas cylinders. Secure ALL cylinders to prevent falling and

vessel puncture.

• Depressurize system before performing any maintenance, disassembly or repair.

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1.3 Electrical Grounding

Electrical grounding is required for proper SAFETY and equipment operation. Refer to installation

section for detailed grounding instructions.

ELECTRICAL SHOCK HAZARD.

Improper grounding can cause system damage, severe injury or death. Plasma system must be

properly grounded to the cutting table.

1.4 Service Precautions

AVOID ELECTRICAL DAMAGE.

Extreme caution should be used when probing circuitry with an oscilloscope or voltmeter.

Although many steps have been taken to protect integrated circuits, they are susceptible to over voltage

damage. Test probes should be connected while machine power is off to prevent accidental shorting of

components.

Use caution when handling electronic components. When finished servicing, confirm that all circuit

boards are properly seated, all cables are properly connected, all cabinets are closed, and all guards

and covers are reinstalled.

Never plug or unplug a printed circuit board while machine power is on. Instantaneous surges of

electricity can damage electronic components.

ESTABLISH A COMPREHENSIVE ROUTINE MAINTENANCE SCHEDULE.

A program can be established from recommended schedule in this instruction literature.

NEVER PERFORM ANY ARC WELDING ON THIS MACHINE.

Welding can result in large induced currents. These currents can severely damage electronic

components in the machine control system. Damage caused by welding is considered abuse and voids

warranty provisions.

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1.5 Recommended Safety References

The following publications on welding and cutting safety are recommended for your review. These

publications have been prepared to prevent personnel injury and property damage, resulting from

unsafe practices. Although some sources are not related specifically to industrial cutting systems, the

principles of safety apply equally.

1.5.1 International

DIN EN ISO

• DIN EN ISO 3821 Hoses for welding, cutting and allied processes.

• DIN EN ISO 5172 Blowpipes for gas welding, heating, and cutting.

• DIN EN ISO 12100 Safety of Machinery - Basic concepts and general principles for design.

• DIN EN ISO 13849 Safety of Machinery - Safety related parts of control systems.

• DIN EN ISO 13857 Safety of Machinery - Safety distances to prevent hazard zones being

reached by upper and lower limbs.

• DIN EN ISO 14121-1 Safety of Machinery - Risk assessment.

DIN EN

• DIN EN 626-1 Safety of machines, reduction of risks to health

• DIN EN 730 Gas Welding Equipment - Safety devices.

• DIN EN 1037 Safety of Machinery - Prevention of unexpected start-up.

• DIN EN 1088 Interlocking devices associated with guards - Principles for design and selection.

• DIN EN 1127-1 Explosive prevention and protection - Part 1: Basic concepts and methodology.

• DIN EN 7287 Safety markings.

• DIN EN 60825 Radiation safety of laser products.

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1.5.2 United States

ANSI

• ANSI Z49.1 Safety in Welding and Cutting

American Welding Society

• AWS C5.1 Recommended Practices for Plasma Arc Welding

• AWS C5.10/C5.10M:2003 Recommended Practices for Shielded Gases for Welding and Plasma

Arc Cutting.

• AWS C5.2 Recommended Practices for Arc Cutting.

• AWS SP Safe Practices.

Compressed Gas Association

• CGA E-1 Standard for industrial gas hose/fittings.

• CGA SB8-2004 Use of oxyfuel welding and cutting apparatus.

• CGA SB11-2004 Use of rubber welding hose.

• CGA P-1 Precautions for safe handling of compressed gases in cylinders.

OSHA

• OSHA 29 CFR 1910 General Safety

• OSHA 29 CFR 1910.1026 Toxic and Hazardous Substances

• OSHA 3373-10 2009 Hexavalent Chromium

National Fire Prevention Association

• NFPA 51B Standard for fire protection in use of cutting and welding procedures.

• NFPA 51 Standard for installation and operation of oxygen - fuel gas systems for welding and

cutting.

• NFPA 70 2008 National Electric Code.

• NFPA 79 Electrical standard for industrial machinery.

• NFPA 484 Standard for combustible metals.

• NFPA 654 Standard for the prevention of fire and dust explosions from the manufacture,

processing, and handling of combustible particulate solids.

ESAB Cutting Systems

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1.5.3 Canada

CSA

• CSA - Z432 Safeguarding of Machinery

CSA - B149.3-10 Code for the field approval of fuel-related components on appliances and equipment.

• CAN/CSA

• CAN/CSA - W117.2-06 Safety in welding, cutting, and allied processes.

Additional Sources

• Directive 2006/42/EC Machinery Directive

• Form 2035 Precautions and Safe Practices in Welding and Cutting with Oxygen-Fuel Gas

Equipment - ESAB Cutting Systems.

• Form F52-529 Precautions and Safe Practices for Plasma Welding and Cutting - ESAB Cutting

Systems.

• Form 3499 Safety Precautions for Oxygen, Nitrogen, Argon, Helium, Carbon Dioxide, Hydrogen,

and Acetylene - ESAB Cutting Systems.

• Form 5110 Design and Installation of Oxygen Piping Systems - ESAB Cutting Systems.

ESAB Cutting Systems

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