ESAB M3® Plasma A6 Standard Lift Assembly m3 CAN Plasma System User manual

Form Number 0560946014 REV04

Date: 01/ 0 5 /11

®

A6 Standard Lift Assembly

m3 CAN Plasma System

Instruction Manual

23

24

2

7

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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

A6 Plasma Lift Assembly

Contents

Safety

Precautions �� 3

Enclosure Class �� 4

General Safety Recommendations �� 5

Description

Introduction �� 7

Major Components �� 8

A6 Lift/Cable Block Diagram �� 9

Technical Specications �� 10

Installation

Mounting ��11

Electrical Interfacing �� 13

Station Grounding �� 16

Maintenance

Preventative Maintenance Schedule �� 17

Daily �� 17

Weekly �� 18

Monthly �� 18

Semi-Annually �� 18

2

A6 Plasma Lift Assembly

Maintenance Procedures

INA Slide Cleaning and Lubrication �� 20

Reassemble INA Slide �� 24

INA Slide Flange Bearing Replacement Procedure �� 26

Omni Crash Protection �� 30

Description ��30

Function Description �� 31

Replacing / Adjusting the Omni® Sensor ��32

Omni® Sensor Installation �� 33

Omni® Mechanical Alignment ��36

Disassembly �� 37

Lubrication ��38

Limit Switch Positioning and Adjustment �� 39

Technical Descriptions and Troubleshooting

Encoder Height Control �� 40

Introduction ��40

Encoder Station Constant (STA�kon) Reference Chart �� 41

Setting Station Constants using distance calculations �� 41

AVHC Introduction and Oset Adjustment �� 42

Basic A6 Lift Assembly Troubleshooting �� 43

Yaskawa Junma Servopack™ Alarm Indicators �� 45

3

A6 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

A6 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

A6 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

A6 Plasma Lift Assembly

To avoid personal injury and/or equipment dam-

age, lift using method and attachment points

shown below.

CAUTION

7

A6 Plasma Lift Assembly

Introduction

The A6 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 les� During part production, stando

is automatically controlled by taking voltage

measurements between torch nozzle and work

surface�

Finally, A6 lifts include Omni Soft Touch® assemblies

to protect the system during station crashes�

Proximity switches monitor torch position in

mounting� If the torch is jarred in any direction,

process movement will stop and an error report will

be sent to CNC� Illustrations on following pages will

detail major lift components and their location� For

illustrated part breakdown, see end section of this

manual�

Description

8

A6 Plasma Lift Assembly

Major Components

Lift electrical enclosure and adaptor plate

Electrical soft touch box (option)

INA precision slide assembly

Lift motor

Limit switch assembies (upper/lower)

Torch bundle guide ring

OMNI mounting bracket

Plasma warning label

Electrical soft touch wire (option)

OMNI soft touch® assembly

Plasma splatter shield

1

2

3

4

5

6

7

8

9

10

11

12

9

A6 Plasma Lift Assembly

A6 Lift/Cable Block Diagram

Input Power

ACON (CAN)

Motor

Encoder

Switch Interface

Crash Protection

Soft Touch Interconnection

Electrical Soft Touch

Torch Touch Wire

VDR

NOTE - gray dashed line denotes optional electric soft

touch components.

1

2

3

4

5

6

7

8

9

10

A6 Plasma Lift Assembly

Technical Specications

Lift Speed:• 450 IPM [11�43m per minute]

Approximate Vertical Travel: 8�1” [205�5 mm]

•

Approximate Weight of Lift Assembly: 36 lbs� •

[16�3 kg]

Torch Barrel Size: 85�7 mm

•

Component Tolerances•

IHS Accuracy: ± 0�5 mm …

Encoder Accuracy: ± 0�25 mm …

Voltage Accuracy: ± 1 volt …

11

A6 Plasma Lift Assembly

Installation

Mounting

Both the A6 lift and electronics enclosure come

complete with adaptor plates that enable mounting

to almost any vertical surface. See illustrations

below for spacing requirements and hole pattern

dimensions.

O 0.33

[8.38 mm]

4.25

[107.95 mm]

4.25

[107.95 mm]

x6 HOLES

4.41

[112.01 mm]

8.10 [205.50 mm]

(VERTICAL TORCH TRAVEL)

3.21

[81.64 mm]

26.44

[671.58 mm]

9.98

[253.54 mm]

1.57

[40.00 mm]

2.68

[68.00 mm]

A6 Lift Assembly dimensions

NOTE - Lift adaptor

plate can be positioned

over entire length of

slide assembly.

12

A6 Plasma Lift Assembly

11.00

[279.4 mm]

12.00

[304.8 mm]

0.34 THRU

x4 HOLES

5.87

[149.1 mm]

4.87

[123.7 mm]

A6 electrical enclosure w/

adaptor plate

NOTICE

Ensure lift assembly is mounted

plumb; use a torpedo level and

adjust mounting bolts as needed.

Torpedo Level

NOTE - electrical enclosure can

be mounted in any manner;

just ensure cables are not under

any strain or twisted.

13

A6 Plasma Lift Assembly

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�

Junma Motor cable3� : connection is from lift

motor to Yaskawa® amplier connector CNB

(inside lift electrical enclosure)�

Junma Encoder cable

4� : connection is from

lift encoder to encoder splice cable open

connection (inside lift electrical enclosure)�

Switch Interface cable

5� (M12, 5 pin male_

female): connection is from lift electrical

enclosure SB4 to lift assembly limit switches�

Crash Protection cable

6� (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

14

A6 Plasma Lift Assembly

Lift Electrical Enclosure

connection guide

SB2 - Input Power

SB1 - ACON

Motor Cable clamp

Encoder Cable clamp

SB4 - Switch Interface

SB3 - Crash Protection OR

SB3 - Soft Touch Interconnection

SB5 - VDR cable from RAS box

1

2

3

4

5

6

7

A

2

1

A

5

3

4

6

7

OR

15

A6 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

7� (M12, 8 pin

female-female): connection is from lift electrical

enclosure SB3 to soft touch enclosure ST1�

Soft Touch Proximity cable8� (M8 female socket_

free wire end): connection is from X3 (inside

soft touch electrical enclosure) to Omni® Soft

Touch proximity sensor�

Torch Touch wire

9� (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 Proximity cable (#7) will

replace the Crash Protection cable (#6) on

plasma stations utilizing electrical soft

touch option.

See block diagram on page 9 above for

details.

9

7

8

Electrical Soft Touch Enclosure

Connection Guide

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

16

A6 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 2Ω

(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

17

A6 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 both upper and lower limit switches

•

are functioning correctly�

Use your CNC’s station travel buttons to ensure

•

lift assembly has proper, smooth movement�

Replace worn PT-36 torch consumables�

•

Test Omni® crash protection function; ensure •

that when plasma torch is jarred in any direction

that a crash signal appears at the CNC�

Read all instruction manual’s safety

and maintenance procedures

before beginning any preventative

maintenance!

CAUTION

18

A6 Plasma Lift Assembly

Weekly

Check alignment of lift assembly�•

Check Omni® proximity sensor position and •

adjust, if required�

Check encoder IHS height�

•

Clean and lubricate INA slide assembly (see •

procedure on page 14)�

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

Check alignment, clean and lubricate Omni® •

crash assembly (see procedure on page 19)�

Semi-Annually

Inspect guide strip cover on INA slide assembly; •

if cracks are present or surface begins to curl,

replace it and both endplates�

Repeat all previous maintenance procedures�

•

Consider calling your ESAB Service •

Representative to schedule an semi-annual

station inspection�

This guide strip is an integral part for

ensuring inside of the slide assembly

remains free of contaminants.

CAUTION

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ESAB M3® Plasma A6 Standard Lift Assembly m3 CAN Plasma System User manual

ESAB M3® Plasma A6 Standard Lift Assembly m3 CAN Plasma System User manual

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