ESAB ULTRAREX UXB Blow Torch Cutting Machine User manual

Warning:

Oxyfuel plasma and laser cutting units together

with the power sources, switch cabinets,

coolers, etc., that are part of the installation,

must never and under no circumstances be run

in explosion-prone areas.

In accordance with DIN-EN-1127-1 and

DIN-EN-13463-1, cutting units and their power

sources, switch cabinets, coolers, etc. are potential

ignition sources.

Change index: 0 Safety note (GB)

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Instruction manual

This instruction manual is intended to enable safe

operation of the ULTRAREX UXB blow torch cutting

machine in accordance with its intended purpose.

Reading and observing the instruction manual will

help to avoid hazards, reduce down times and

increase the reliability and useful life of the machine.

The instruction manual must be available at all times

on the machine. It must be read and applied by all

persons entrusted with work on the machine. In

addition to the instruction manual and the binding

accident prevention regulations applicable in the

country of use, the specialised standards applicable

to safety and expert working must also be observed.

Before you switch on the machine for the first time,

please read through all chapters of this instruction

manual attentively and acquaint yourself thoroughly

with all details.

This instruction manual only contains general

information on operation of the ULTRAREX UXB

blow torch cutting machine.

Actual operation is realised via the connected CNC

controller. This is why you will find exact details of

operation in the separate instruction manual of the

CNC controller.

Instruction manual

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For more in-depth information, ESAB CUTTING

SYSTEMS after-sales service personnel will be

pleased to advise you at all times.

ESAB Cutting SYSTEMS GmbH

Postfach 11 28 § D-61174 Karben

Robert-Bosch-Straße 20 § D-61184 Karben

Phone: (060 39) 40 - 0

Extension, after-sales service: - 333

Fax, after-sales service: - 266

Karben,

This document is intended only for purchasers of our machines and must

neither be duplicated nor communicated to third parties nor made available

without written consent (Law governing copyright and related proprietary rights,

copyright law dated 09.09.1965).

Instruction manual

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Contents

General 6

For your safety 7

General 8

Hazards from the machine 10

Use in accordance with the intended

purpose 13

Safety rules 15

Permitted users 17

Personal protective equipment 18

Workplace 19

Safety measures 20

Emergency behaviour 21

Electrical and gas safety

facilities

22

General 23

Safety facilities prior to

the machine 25

Safety facilities on the machine 26

Checklist for checking

safety facilities 28

Warning information on

the machine 29

Operation 30

General 31

Possibilities of adjusting the burner

holders 32

Flush cutting 36

Preparing work 37

Preparing and switching on the

machine 39

Switching off the machine 42

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Switching off in an emergency 43

Commissioning after

Emergency Stop 44

Work sequences with the CNC

controller 45

Work sequences with the

photoelectronic controller 49

Work sequences for machines

without solenoid valves 53

Cleaning and maintenance 56

Cleaning 57

Cleaning the nozzles 58

Checking the safety facilities 60

Lubricating machine parts 61

Readjustments 62

General 63

Readjusting the track 64

Readjusting the trolley 65

Readjusting the height adjustments 66

Remedying malfunctions 67

Repair 69

Contents

Annexes

Introduction to flame cutting

techniques B-1

Technical data D-1

Overview of the machine M-1

Cutting and consumption tables T-1

Specifications, standards, guidelines

and laws V-1

Tools and options W-1

Electromagnetic compatibility Y-1

Verzeichnis der gültigen Seiten Z-1

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General

The ULTRAREX UXB blow torch cutting machine is

manufactured in accordance with the applicable

technical regulations and the state of the art.

Nevertheless, machines pose risks that cannot be

prevented by design measures. Additional safety

notes are given here to ensure the operator’s

adequate safety. Sufficient safety when handling the

machine is guaranteed only when observing these

notes.

From time to time it is necessary to highlight certain

parts of the text. Highlighted text has different

meanings depending on its importance:

F

Note:

Represents a note which, if observed, will

facilitate working with the machine.

Caution:

Represents a note drawing attention to the fact

that material and the machine could become

damaged.

Warning:

Represents a note drawing attention to a risk of

personal injury or mortal danger.

All figures and sketches in this instruction manual

consist of non-binding depictions.

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For your safety

Overview

General

8

Hazards from the machine

10

Emissions 10

Electromagnetic compatibility 10

Blow torch nozzles 11

Heating flame 11

Hazards from accessories 12

Use in accordance with the

intended purpose

13

Safety rules

15

Regulations for electrical connection

work 16

Regulations for work on the gas

supply 16

Permitted users

17

Personal protective equipment

18

Workplace

19

Safety measures

20

Emergency behaviour

21

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General

Handling of blow torch cutting machines, fuel gases

and oxygen requires specialised knowledge. Training

and instruction of operating personnel in safety

matters are necessary.

You will find general notes on safety and accident

prevention in the national accident prevention

regulations.

1

A whole further series of safety

regulations applies. These are listed below. It is

imperative to obey all regulations listed.

In addition to the instruction manual, the user must

provide instruction with regard to

• general legal regulations,

• binding accident prevention regulations,

• binding environmental regulations,

• supervisory and reporting obligations with regard

to special plant situations (e.g. in relation to work

organisation, work sequences and deployed

personnel etc.)

and to make them public in a suitable location.

For your safety

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1 Please refer to Annex V for further information.

Prior to commencing work, personnel entrusted with

work on the machine must have attentively read the

instruction manual and, in particular, the chapter

entitled ‘For your safety’. This applies particularly to

personnel who work only occasionally on the

machine (e.g. tooling or maintenance).

F

Note:

It is imperative to use workshop equipment ap

-

propriate to the work when carrying out

maintenance work.

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For your safety

Hazards from the machine

The ULTRAREX UXB blow torch cutting machine

features protective equipment. Nevertheless, the

following hazards may arise when using it:

•

hazards to the life and limb of the operator or third

parties,

•

hazards to the machine and other assets of the

user,

•

hazards to efficient operation of the machine.

Emissions

The following emissions can be expected when

carrying out blow torch cutting work:

• sparks,

• slag splashes,

• smoke,

• dust,

• toxic gases (e.g. nitrogen oxides NO

x

, ozone O

3

),

• noise,

• heat radiation, light radiation, UV radiation.

Therefore, adequate ventilation of the workplace and

suitable personal protection of operators must be

ensured.

Noise emission value

On average, the workplace-related emission value of

the blow torch cutting machine at the workplace of

operating personnel is 85 ±2 dB(A).

Electromagnetic compatibility

Please refer to Annex Y for information on

electromagnetic compatibility.

For your safety

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Blow torch nozzles

The blow torch nozzles get hot during operation. If

work has to be done on the nozzles, wait until they

have cooled down or wear protective gloves.

Heating flame

Warning:

Never look into the burner flames without

wearing welder’s protective goggles. Otherwise,

your eyes will be permanently damaged!

The mandatory sign ‘Wear protective goggles’ is

attached to the blow torch cutting machine as a

reminder of this warning.

1

Help to make work on the machine safe:

•

Observe all safety and hazard information on the

machine.

•

Keep all safety and hazard information on the

machine completely in a legible state.

For your safety

Figure 1: Mandatory sign

‘Wear protective goggles’

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1 Please refer to Annex V for further information.

Hazards from accessories

The torches have been manufactured and tested in

accordance with the state of the art. Changes or

conversions must not be implemented on the burners

without the manufacturer’s permission. Inexpert

handling and use that does not conform to the

intended purpose may produce hazards for the

operator and for other persons. The burner and the

machine may also become damaged.

For your safety

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Use in accordance with the

intended purpose

The ULTRAREX UXB blow torch cutting machine is

intended exclusively for cutting metallic plate

workpieces.

Any other use, or use exceeding this scope, e.g.

machining of several workpieces located one on top

of the other, is deemed to not be in conformity with

the intended purpose of the machine.

The following are prerequisites for oxy-fuel blow

torch cutting of metallic plate workpieces:

•

The ignition temperature of the metal must be

lower than its melting temperature.

• The melting temperature of combustion products

must be lower than the melting temperature of the

metal.

F

Note:

You will find an overview of blow torch cutting

techniques in Annex B ‘Introduction to blow

torch cutting techniques’.

Use in accordance with the intended purpose also

includes observance of the instruction manual and

conformity with the inspection and maintenance

conditions.

Use the machine only in a technically perfect

condition and being conscious of safety and hazards.

All malfunctions, in particular those that might have a

detrimental influence on safety, must be remedied

immediately. In the event of changes that have a

bearing on safety or changes in operating behaviour,

the machine must be shut down immediately.

Malfunctions must be reported immediately to the

responsible department or person.

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For your safety

Changes, attachments and conversions that might

have a detrimental influence on safety must not be

implemented on the machine.

This also applies to the installation and the settings

of safety equipment and repairs to these.

Spheres of competence with regard to the different

activities carried out on the machine must be clearly

defined and kept to. There must be no uncertainties

in respect of spheres of competence as these may

endanger the safety of users.

The user must also make sure that only authorised

persons work on the system.

The operator is responsible to third parties within the

operating zone of the system.

The blow torch nozzles must only be used for the

fuel gas stated in the abbreviation on the nozzle.

Improper use of the nozzle will destroy the nozzle

and burner.

Attention must always be paid to ensuring that the

burner does not knock on anything that could push it

out of the vertical position.

Flashback protection of burners and nozzles will be

diminished if use is made of highly soiled or

damaged nozzles.

For your safety

Instruction manual

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Safety rules

When working on the blow torch cutting machine, the

national regulations, specifications and laws

applicable to this machine must be observed.

The user of the blow torch cutting machine is

responsible for conformity with the national

regulations, specifications and laws during operation

of the machine.

Different accident prevention regulations apply in

Germany.

Please refer to Annex V for further information.

Caution:

Work on the gas supply and on the electrical

system must only be carried out by specialists

trained for the purpose.

For your safety

Instruction manual

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Regulations for electrical connection

work

The national regulations, specifications and laws

applicable to electrical connection work must be

observed.

1

Regulations for work on the gas supply

The national regulations, specifications and laws

applicable to work on the gas supply must be

observed.

1

For your safety

Instruction manual

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1 Please refer to Annex V for further information.

Permitted users

Only persons who have reached the age of 18 and

who are acquainted with the equipment and

processes may be entrusted with the task of blow

torch cutting. Youths older than 16 years of age may

operate the blow torch cutting machine provided this

is necessary for them to achieve their training goal

and if their protection is guaranteed by a supervisor.

Only persons who have read and understood the

instruction manual are permitted as operators.

Work on the machine may only be carried out by

reliable personnel.

Only persons trained or instructed by the

manufacturer may be deployed. Personnel’s spheres

of competence with regard to operation, tooling,

maintenance and repairs must be defined clearly.

It has to be assured that only authorised personel will

work on the machine.

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For your safety

Personal protective equipment

Operating personnel must wear protective personal

equipment when operating the ULTRAREX UXB

blow torch cutting machine.

Operating personnel’s protective personal equipment

must consist of the following items:

•

protective helmet,

•

hearing protection,

•

welder’s protective goggles,

•

protective gloves,

•

protective shoes,

•

protective clothing.

Standard mandatory signs are affixed to the

machine.

For your safety

Figure 2: Standard mandatory signs relating to wearing of protective personal equipment

Wear a protective helmet Wear hearing protection Wear welder’s protective goggles

Wear protective gloves

Wear protective shoes

Wear protective clothing

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Workplace

The workplace is located on the side of the machine

in front of the control panel.

Warning:

Do not step onto the moving machine. There is

a risk of injury from getting stuck on moving

parts of the machine.

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For your safety

Safety measures

Caution:

All locations required for operation, maintenance

and repair must always be freely accessible.

The machine must be set up so that a clearance of at

least 500 mm is left on all sides.

Corresponding inner-company instructions and

checks must ensure that the workplace environment

is always kept clean and neat.

Switch off the machine and interrupt the power and

media supplies

• before leaving the machine.

• before carrying out maintenance and cleaning

work.

Warning:

Never remove safety facilities.

Never alter safety facilities.

Never render safety facilities inoperable.

You will otherwise put yourself and others at

risk!

Personnel entrusted with work on the system must

not leave long hair untied, nor wear loose clothing or

jewellery including rings and bracelets. There is a

risk of injury, e.g. from getting caught in moving parts

of the machine.

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For your safety

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