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Maintenance Manual For Ajan Precision Plasma 260 Amper Plasma Cutting Machines
Maintenance Manual For Ajan Precision Plasma 260 Amper Plasma Cutting Machines
ii
SECTION 1. INDEX
Section name .................................................................................................................. Page number
SECTION 1. INDEX .......................................................................................................................... i
SECTION 2. TABLE OF FIGURES .............................................................................................. iv
SECTION 3. TABLES .................................................................................................................... vii
SECTION 4. COMPANY PROFILE ...............................................................................................1
SECTION 5. INSTALLATION AND ELECTROMAGNETIC COMPATIBILITY .................2
5.1. EMC INTRODUCTION .......................................................................................................... 2
5.2. INSTALLATION AND USAGE ............................................................................................. 2
5.3. ESTIMATION OF AREA ........................................................................................................ 2
5.4. MAIN POWER......................................................................................................................... 3
5.5. EQUIPOTENTIAL BONDINGS ............................................................................................. 3
SECTION 6. SAFETY .......................................................................................................................4
6.1. RECOGNIZE SAFETY INFORMATION .............................................................................. 4
6.2. FOLLOWING SAFETY INSTRUCTIONS ............................................................................ 4
6.3. DANGER, WARNING, CAUTION ........................................................................................ 4
6.4. FIRE AND EXPLOSION RISKS WHILE CUTTING ............................................................ 5
6.4.1. Prevention from Explosion ................................................................................................ 5
6.5. ELECTRIC SHOCK................................................................................................................. 6
6.5.1. Prevention from Electric Shock......................................................................................... 6
6.6. TOXIC FUMES OCCUR WHILE CUTTING ........................................................................ 7
6.7. PLASMA ARC RAY INJURES EYES AND SKIN ............................................................... 7
6.7.1. GROUNDING SAFETY ................................................................................................... 8
6.7.2. SAFETY FOR COMPRESSED CYLINDERS................................................................. 8
6.7.3. GAS CYLINDERS CAN EXPLODE ............................................................................... 8
6.8. NOISE DAMAGE .................................................................................................................... 9
6.9. SAFETY SIGNS AND DESCRIPTIONS .............................................................................. 10
6.10. WELDING FUMES AND GASES ...................................................................................... 12
6.10.1. FUMES AND GASES .................................................................................................. 12
6.10.2. TOXIC FUMES AND GASES ..................................................................................... 13
6.10.3. LOW-TEMPERATURE PLASMA FUMES, EXHAUST GAS PURIFICATION FOR
ORGANIC ..................................................................................................................... 13
SECTION 7. WARRANTY .............................................................................................................14
7.1. AJAN BRAND PLASMA AND OXY-FUEL CUTTING MACHINE WARRANTY
CONDITIONS ..................................................................................................................... 14
7.2. CASES CAUSING OUT OF WARRANTY.......................................................................... 15
SECTION 8. PREUSAGE ...............................................................................................................16
8.1. ATTENTIONS BEFORE STARTING CUTTING WITH PRECISION PLASMA
MACHINES ......................................................................................................................... 16
8.1.1. CONTROL OF THE CYLINDERS AND THEIR PRESSURE ..................................... 16
8.1.2. STARTING GENERATOR ............................................................................................ 16
8.1.3. STARTING CNC UNIT.................................................................................................. 16
8.1.4. CHASSIS CABLE AND CONTROL ............................................................................. 16
i
ii
iii
vi
SECTION 3. TABLES
Table name ..................................................................................................................... Page number
Table 1. Table of safety signs and descriptions ................................................................................. 10
Table 2. IHS limit cable color and functions table ............................................................................ 53
Table 3. X, Y, TR, TL axis drive cables color and functions table ................................................... 54
Table 4. Gas control cable color and functions table ........................................................................ 55
Table 5. Relay control cable color and functions table ..................................................................... 56
Table 6. Gas control and relay control cables color and functions table ........................................... 57
Table 7. Hand control cable color and functions table ...................................................................... 58
Table 8. Limit cable color and functions table .................................................................................. 59
Table 9. Resume cable color and functions table .............................................................................. 60
Table 10. Motor cable color and functions table ............................................................................... 62
Table 11. Motor cable color and functions table ............................................................................... 62
Table 12. Motor cable lengths with respect to Y axis lengths ........................................................... 63
Table 13. Drive power cable color and functions table ..................................................................... 64
Table 14. Current-PLST/OKMO/Arc cable color and functions table .............................................. 65
Table 15. Remote control cable color and functions table ................................................................ 66
Table 16. Plasma transmitter cable color and functions table ........................................................... 68
Table 17. Ohmic-Ohmic IHS-F5 cable color and functions table ..................................................... 69
Table 18. Plasma valve cable color and functions table .................................................................... 70
Table 19. Oxygen(R) valve cable color and functions table ............................................................. 71
Table 20. Head limit(R) cable color and functions table ................................................................... 72
Table 21. Torch height control(R) cable color and functions table ................................................... 73
Table 22. Preheat sensor(R) cable color and functions table ............................................................ 73
Table 23. Oxygen transmitter cable color and functions table .......................................................... 74
Table 24. Oxygen(L) valve cable color and functions table.............................................................. 75
Table 25. Head limit(L) cable color and functions table ................................................................... 76
Table 26. Torch height control(L) cable color and functions table ................................................... 77
Table 27. Preheat sensor(L) cable color and functions table ............................................................. 77
Table 28. Ajan precson plasma 260 plasma generator gas flow rates ............................................. 80
Table 29. precson plasma 260A generator technical specifications ................................................ 86
Table 30. System gas requirement ..................................................................................................... 87
Table 31. System gas requirement ..................................................................................................... 87
Table 32. Mild steel, O2 Plasma/O2 Shield, 30A cutting chart ........................................................ 88
Table 33. Mild steel, O2 Plasma/Air Shield, 40A cutting chart ........................................................ 89
Table 34. Mild steel, O2 Plasma/O2 Shield, 80A cutting chart ........................................................ 90
Table 35. Mild steel, O2 Plasma/O2 Shield, 130A cutting chart ...................................................... 91
Table 36. Mild steel, O2 Plasma/O2 Shield, 260A cutting chart ...................................................... 92
Table 37. Stainless steel, F5 Plasma/N2 Shield, 45A cutting chart .................................................. 93
Table 38. Stainless steel, N2 Plasma/N2 Shield, 45A cutting chart .................................................. 94
Table 39. Stainless steel, Air Plasma/Air Shield, 80A cutting chart ................................................. 95
Table 40. Stainless steel, F5 Plasma/N2 Shield, 80A cutting chart .................................................. 96
Table 41. Stainless steel, Air Plasma/Air Shield, 130A cutting chart ............................................... 97
Table 42. Stainless steel, H35 Plasma/N2 Shield, 130A cutting chart .............................................. 98
Table 43. Stainless steel, N2 Plasma/N2 Shield, 130A cutting chart ................................................ 99
Table 44. Stainless steel, Air Plasma/Air Shield, 260A cutting chart ............................................. 100
Table 45. Stainless steel, H35 Plasma/N2 Shield, 260A cutting chart ............................................ 101
Table 46. Stainless steel, H35 Plasma/N2 Shield, 260A cutting chart ............................................ 102
Table 47. Aluminum, N2 Plasma/N2 Shield, 45A cutting chart ..................................................... 103
vii
viii
SECTION 6. SAFETY
The symbols shown in this section are used at areas where potential risks may
occur. Understand the potential personal injury and follow the instructions to prevent the hazard
when you see a safety symbol in this manual or on your machine.
Read all safety messages and warnings in this manual and safety labels on your machine.
Keep the safety labels on your machine seen. For that, use cleaning materials that does not
damage the labels while cleaning. Replace the damaged and missing labels with a new one.
Learn how to operate the machine and its controls. Do not allow unauthorized or ignorant
person to operate the machine.
Keep the machine in suitable working conditions. Unauthorized modifications on the machine
may affect wrongly the safety and operation of the machine.
If there is possibility of that explosive smokes or vapors exist in the area, do not use plasma
system.
Do not cut containers including pressurized cylinders, hoses or any closed containers.
It can cause fatal shocks or severe burns to touch parts containing electricity.
The plasma systems work in principle of completing electric current between the cutting
torch and the work piece. So since work piece and anything touching the work piece area
part of this electrical circuit, do not touch the torch body while plasma system is
operated.
Warn others not to watch the occurred arc. Use placards or signs.
If the wall coatings around the cutting area are dark, this helps to lower the ultraviolet ray
reflection.
Be sure to connect the work piece and cutting table properly during cutting, not to allow the
work piece displace or fall down.
The grounding should well contact to the work piece. Do not connect it to the piece that will
fall away when cutting is done.
Ground the work piece and work table with appropriate directives.
Use only cylinders, regulators, hoses and fittings advised by the manufacturer.
Identify the noise hazard in the working area of plasma machine with warning signs.
10
10
11
12
13
14
15
Use gauntlet and dry gloves for protection from hot metals, spark, dross and electric shocks.
Use protective helmets against dross and ultraviolet rays.
Do not touch bare cables against electric arcs.
There is ultraviolet ray hazard, follow the directives.
Wear dry, well-built, safety shoes.
Do not cut closed containers that contain flammable, explosive, or unknown materials.
Keep pressurized gas cylinders upright and protective caps in place over valve when the
cylinders are not in use.
8. Magnetic fields caused by the high current may injure the operands using pacemaker or
having heart diseases.
9. Keep a fire extinguisher nearby.
10. There may be flammable and explosive gases while machine is operating. To avoid this, do
not smoke near the machine and gas cylinders.
11. There may be flammable and explosive gases while machine is operating. To avoid this, do
not keep flame available near the machine and gas cylinders.
12. Plasma cutting produces noise that may cause hearing hazards. Use approved ear protection
during cutting.
13. Do not insert any material or your organs into the moving mechanisms that may obstruct the
movement.
14. Do not step onto or do not load onto places where may obstruct machines operation.
15. Do not make contact to hot metals.
11
12
13
SECTION 7. WARRANTY
Ajan Kesme Makinalari San. ve Tic. Ltd. Sti. supplies mechanical and electronic units and all
equipments of your machine completely depending on the made agreements. The installation, first
operation of the machine and the education will be supplied by the manufacturer firm. Ajan Plasma
and Oxygen Cutting Machine mechanical units, electronic units, software and torch are
manufactured under Ajan brand. Ajan Ltd. warrants the machines under all these conditions.
14
The above mentioned mechanical, electronical, software faults or problems which may danger
property or life safety does not claim that our company is under liability.
15
SECTION 8. PREUSAGE
8.1. ATTENTIONS BEFORE STARTING CUTTING WITH PRECISION
PLASMA MACHINES
8.1.1. CONTROL OF THE CYLINDERS AND THEIR PRESSURE
In addition, propane gas is used in oxygen cutting machine.
O2 Oxygen(8.5 bars)
N2 Nitrogen (8.5 bars)
Air (between 7 10 bars)
Propane (2.5 bars)
For stainless steel sheet cutting with plasma cutting machine, H35 and F5 gases are added.
H35 (8.5 bars)
F5 (8.5 bars)
16
The nozzle and electrode is mounted with a torch wrench. During this operation, you
shouldnt use over force.
After replacing cutting tips, purge operation is done from the parameters. This operation
throws out the dust taking place on the tips and checks gas flows.
17
8.2.2. STARTING
The main power switch on the front panel of the generator is turned up, then stop button lock is
turned to left and on, and then start button is pressed.
Pressing is continued until the phase lack and circulation error lights turn off.
Just after phase lack light turns off, circulation error warning light turns off.
Note: It is not needed to open the generator during cutting with precson plasma and P model
machines.
18
The racks and chrome plated rods on machines head group and rolling rails should be kept
clean.
Since the plasma cutting is a dusty process, the moving parts should be kept away from the
dust. In addition, for every work piece loading, the moving parts should be checked visually,
that should be checked whether there exist any materials preventing movement on the racks.
The crane, forklift, etc devices should be controlled; the machine should be kept away from
beat.
The wipers on X and Y axes should be checked every day and be replaced if eroded or
broken down.
The bellows on the machines head group should be checked for stability and be replaced if
eroded or broken down.
The cutting buckets of the ventilation unit should be necessarily checked for fullness,
because this is very important for the suction quality.
The suction system of the machine works with the help of the press handles. These handles
should be checked whether it works well.
The warning labels on the machine should never be taken out, and be replaced if eroded, and
they should be obeyed to.
No combustible materials such as paper, cigarette butt, nylon, etc should be thrown into the
ventilation unit; no water should be used during intervening.
Twice a week, CNC unit and generator unit must be cleaned using dry air or nitrogen gas,
the machine shouldnt be used in one hour after this application.
The jet filter buckets should be cleaned until it is filled in half.
The jet filter cartridges should be neither opened nor cleaned without manufacturer company
control.
19
20
21
22
23
24
25
26
Figure 11. 3000 mm first block cover opening/closing handle system installation drawing
27
28
29
30
11.4. MUFFLER
The system used to decrease the high decibel level occurred in the suction fan.
31
32
33
Figure 17. Total area of the cartridges used in the jet filter
The jet filter is manufactured in 4 different models, such as 6-, 8-, 12- and 16-cardridge, depending
on the ventilation capacity required for the machine. Every cartridge is made up from 24 meter
square burn-delayed plied filter paper.
System dirt level is controlled by electronic filter cleaning unit. With the help of blow level control,
the blow frequency is decreased, cycle is increased. So unnecessary air consumption is prevented.
30% more efficient reverse jet filter cleaning air flows are obtained by dust bag shaker valves
integrated on the filter body. Because of that the cartridges are horizontally mounted, the
maintenance and replacement are easily done. Jet filter unit is additionally preserved with flame
trap that should take place in every plasma cutting table ventilation.
Flame trap holds cigarette butt, burning paper sheets and cloth parts and moves them to the buck it
has.
Ajan jet filter system is a genuine design completely suitable to the world standards. The air suction
fan is mounted outside of the filter and it is suitable for cleansing after long-time usage. The motor
and propeller are equipped with an easily opened and closed cover system.
The complete filter system is transported by demounted during the transportation. The air suction
system has been designed to be fit in any smallest area behind the plasma ventilation table. During
the filter design, space occupation is kept in mind in height in spite of width or length. A muffler
with two walls is mounted on the fan output. The muffler output can be mounted outside of the
building by the customer.
34
1
2
3
4
5
6
7
35
36
PART NAME
Body
Large diaphragm
2a
Diaphragm
3a
Spring
Small diaphragm
Cover
6a
Cover
Plunger
Tube
Coil
10
Connector
37
38
39
40
41
42
43
44
45
46
47
11.13. GENERATOR
48
The cooling liquid may cause skin and eye irritation, and if swallowed, it may be harmful or fatal.
Propileneglicol and benzotriazole may harm skin and eyes. Please keep the labels on the drums. In
any contact, wash the skin or eyes. If swallowed, drink water and call the doctor. Do not try to
regurgitate.
Warning: Use always propileneglicol in the mixture of cooling liquid. Do not use automotive
antifreeze liquids in spite of propileneglicol.
Use always pure water in the mixture of cooling water in order to prevent failures that may occur in
the pump and oxidation in torch cooling system.
49
50
51
52
INTERFACE SHEET
PIN
NO
1
2
3
4
5
6
7
8
9
COLOR
Black
Red
Blue
Yellow
Pink
Brown
Gray
Green
8-White
FUNCTION
IHS-TL
IHS-TR
CRUSHER-TL
CRUSHER-TR
OKMO-TL
OKMO-TR
IHS-TV
IHS-TW
GND
COLOR
FUNCTION
Black
Red
Blue
Yellow
Pink
Brown
Gray
Green
8-White
53
Drive connection
INTERFACE SHEET
PIN
NO
1
2
3
4
5
6
7
8
9
54
COLOR
Black
Red
Blue
Yellow
Pink
Brown
8-White
Gray
Green
FUNCTION
CLK
+5V
0-10V
OVER CURRENT
ZERO MARK
DIR
GND
SFB. ENABLE
CONTROLER OK.
DRIVE
PIN
NO
1
2
3
4
5
6
7
8
9
COLOR
Black
Red
Blue
Yellow
Pink
Brown
8-White
Gray
Green
FUNCTION
PIN
NO
1
2
3
4
5
6
7
8
9
10
11
12
13
INTERFACE SHEET
PIN
FUNCTION
FUNCTION
NO
PW D
14 ANOR.DSRJ.
PW C
15 AMR
PW B
16 VMR
PW A
17 KENO
+5V
18 +5V
GND
19 SETUP
L.ENB.
20 SES
TB A
21 TA D
TB B
22 TA C
TB C
23 TA B
TB D
24 TA A
+12V
25 +12V
GND
PIN
NO
1
2
3
4
5
6
7
8
9
10
11
12
13
LOGIC
PIN
FUNCTION
NO
PW D
14
ANOR.DSRJ
15
PW C
16
AMR
17
PW B
18
VMR
19
PW A
20
KENO
21
+5V
22
+5V
23
GND
24
SETUP
25
L.ENB.
26
FUNCTION
SOUND
TB A
TA D
TB B
TA C
TB C
TA B
TB D
TA A
+12V
+12V
GND
GND
55
INTERFACE SHEET
PIN
NO
1
2
3
4
5
6
7
8
9
56
COLOR
Black
Red
Blue
Yellow
Pink
Brown
Violet
White
Green
FUNCTION
POL(-)
POL(+)
M8
----GND
SET STOP
+5V
RELAY CONTROL
SET START
LOGIC CARD
PIN
NO
1
2
3
4
5
6
7
8
9
COLOR
Black
Red
Blue
Yellow
Pink
Brown
Violet
White
Green
FUNCTION
INTERFACE SHEET
PIN
NO
CABLE NAME
SIGNAL NAME
1
2
3
4
GAS CONTROL
GAS CONTROL
GAS CONTROL
GAS CONTROL
PW
PW
PW
PW
5
6
GAS CONTROL
GAS CONTROL
+5V
GND
GAS CONTROL
L.ENB.
8
9
10
11
21
22
23
24
12
13
14
15
16
17
1
20
18
19
6
9
25
2
3
4
5
7
8
GAS CONTROL
GAS CONTROL
GAS CONTROL
GAS CONTROL
GAS CONTROL
GAS CONTROL
GAS CONTROL
GAS CONTROL
GAS CONTROL
GAS CONTROL
GAS CONTROL
GAS CONTROL
GAS CONTROL
GAS CONTROL
RELAY CONTROL
GAS CONTROL
GAS CONTROL
GAS CONTROL
RELAY CONTROL
RELAY CONTROL
GAS CONTROL
RELAY CONTROL
RELAY CONTROL
RELAY CONTROL
RELAY CONTROL
RELAY CONTROL
RELAY CONTROL
TB A
TB B
TB C
TB D
TA D
TA C
TA B
TA A
+12V
GND
ANOR.DSRJ
AMR
VMR
KENO
POL(-)
SOUND
+5V
SETUP
SET STOP
SET START
+12V
POL(+)
M8
----GND
+5V
RELAY CONTROL
COLOR
D
C
B
A
FUNCTION
Transmitter selection bits
Plasma gas-shield gas-current active
bits
+5V
GND
Current or pressure reading-writing
bits
+12V
GND
--------Pressure information analog input
Voltage information analog input
Black
Brown
Green
Red
Blue
Yellow
Pink
Violet
White
57
INTERFACE SHEET
PIN
COLOR
NO
1
Green
2
Brown
3
White
5
Yellow
Screening chassis
58
FUNCTION
+5V
DATA
CLK
GND
SCREEN
HAND CONTROL
PIN
NO
1
2
3
4
5
COLOR
Green
Brown
White
Yellow
Screening
FUNCTION
+5V
DATA
CLK
GND
INTERFACE SHEET
PIN
NO
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
COLOR
Yellow
Violet
Green
Red
Brown
Green-Brown
Gray
Pink
Black
Blue-Red
Blue
Pink-Gray
White
Green-White
Brown-Yellow
FUNCTION
TL CONT.OK
+TR LIMIT
-TR LIMIT
+TL LIMIT
-TL LIMIT
GND
TW CONT.OK
-----GND
-X LIMIT
+X LIMIT
+Y LIMIT
-Y LIMIT
GND
GND
COLOR
FUNCTION
Yellow
Violet
Green
Red
Brown
Green-Brown
Gray
Pink
Black
Blue-Red
Blue
Pink-Gray
White
Green-White
Brown-Yellow
59
INTERFACE SHEET
PIN
NO
1
2
3
4
5
6
7
8
9
60
COLOR
------------------------Brown
White
-------------------
FUNCTION
RESUME
GND
COLOR
Brown
White
FUNCTION
61
Drive connection
DRIVE
PIN
NO
1
2
3
4
COLOR
Green
Brown
Screen
White
SERVO MOTOR
FUNCTION
R
S
T
EARTH
PIN
NO
1
2
4
3
COLOR
Green
Brown
Screen
White
FUNCTION
R
S
T
EARTH
DRIVE
PIN
NO
1
2
3
4
5
6
7
8
9
62
COLOR
Pink
Gray
Green
Red
Black
Blue
Yellow
8-White
Brown
SERVO MOTOR
FUNCTION
-12VDC
+12VDC
R
S
T
B
A
GND
ZERO MARK
PIN
NO
1
2
3
4
5
6
7
8
9
COLOR
Pink
Gray
Green
Red
Black
Blue
Yellow
8-White
Brown
FUNCTION
MOTOR
CABLE
XR cable
length
XL cable
length
Y cable length
TR cable
length
TL cable
length
1500mm
2000mm
Y AXIS LENGTH
2500mm
185cm
185cm
185cm
185cm
185cm
430cm
470cm
525cm
560cm
665cm
620cm
625cm
680cm
755cm
830cm
605cm
615cm
670cm
745cm
820cm
650cm
685cm
740cm
815cm
890cm
3000mm
4000mm
63
Drive connection
DRIVE
PIN
NO
1
2
3
4
5
6
7
8
9
10
64
COLOR
--------Brown
Yellow-Green
Blue
Brown
Blue
Yellow-Green
Blue
Brown
DRIVE TRANSFORMER
FUNCTION
CURR. +
CURR. 20VAC
0V ML
20VAC
20VAC
0V MH
EARTH
0V MH
+80VDC
PIN
NO
1
2
3
4
5
6
7
8
COLOR
Yellow-Green
Blue
Brown
Blue
Brown
Brown
Yellow-Green
Blue
FUNCTION
EARTH
NEUTR
220VAC
0V MH
20VAC
20VAC
0V ML
20VAC
8000
12000
16000
18000
24000
1350
1750
2150
2500
2900
CNC connection
Generator connection
Table 14. Current-PLST/OKMO/Arc cable color and functions table
CNC
PIN
NO
1
COLOR
GENERATOR
FUNCTION
Black
PIN
NO
1
COLOR
Black
Red
Red
Blue
Blue
Yellow
Yellow
Pink
Pink
Brown
Brown
Gray
Gray
Green
Green
8-White
8-White
CNC
PIN
NO
1
Brown
White
-----
Red
GENERATOR
PLST(+)
PIN
NO
1
Brown
PLST(-)
White
-----
ARC(+)
Red
Blue
ARC(-)
Blue
Dark green
OKMO
Dark green
Light green
OKMO
Light green
-----
-----
-----
-----
COLOR
FUNCTION
FUNCTION
COLOR
FUNCTION
65
3000
4000
6000
8000
12000
16000
18000
24000
700
950
1100
1300
1800
2100
2500
2900
CNC connection
Generator connection
CNC CONNECTION
PIN
NO
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
66
COLOR
1
2
3
4
5
6
7
8
9
10
11
Yellow-Green
Brown
Blue
Black
Yellow-Green
FUNCTION
AIR DRYER(R)
AIR DRYER(S)
PULSE VALVE(R)
PULSE VALVE(S)
GEN. NEUTR
GEN. STOP
GEN. START-STOP
GEN. 220VAC START
FAN STOP
FAN START-STOP
FAN 220VAC START
FAN NEUTR
CNC (R)
CNC (S)
CNC (T)
EARTH
GENERATOR
PIN
NO
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
COLOR
1
2
3
4
5
6
7
8
9
10
11
Yellow-Green
Brown
Blue
Black
Yellow-Green
FUNCTION
3000
4000
6000
8000
12000
16000
18000
24000
700
800
1000
1250
1650
2050
2400
2750
CNC connection
1500
530
2000
550
2500
575
3000
650
4000
750
Generator connection
67
1500
545
2000
545
2500
600
3000
670
4000
745
CNC
PIN
NO
1
2
3
4
5
6
68
COLOR
Brown
White
Yellow
Yellow
White
Brown
BRIDGE
FUNCTION
+15VDC
TR4 Shield gas transmitter
GND
GND
TR3 Plasma gas transmitter
+15VDC
PIN
NO
4
5
9
3
2
1
7
8
9
COLOR
Brown
White
Yellow
Brown
White
Yellow
----------------
CABLE
NAME
TR4
TR4
TR4
TR3
TR3
TR3
1500
610
2000
615
2500
670
3000
745
4000
820
CNC
PIN
NO
1
2
COLOR
Brown
White
Brown
White
Brown
White
FUNCTION
+24VDC
GND
OHMC IHS
OHMIC IHS
+24VDC
GND
BRIDGE
CABLE
OHMIC
OHMIC
OHMC IHS
OHMIC IHS
F5
F5
PIN
NO
1
2
COLOR
FUNCTION
Brown
White
Brown
White
Brown
White
69
1500
525
2000
550
2500
585
3000
660
4000
735
CNC
PIN
NO
1
2
3
4
5
6
7
8
9
10
COLOR
FUNCTION
BRIDGE
CABLE
NAME
GAS A
GAS A
GAS A
GAS A
GAS A
GAS B
GAS B
GAS B
GAS B
GAS B
Yellow
White
Brown
Green
Gray
Yellow
White
Brown
Green
Gray
ATM
AIRS
+24VDC
N2S
O2S
AIR
N2
+24VDC
O2
H35
Brown
Yellow
White
+24VDC
PV3
PV3 Plasma gas
PV3
servo valve
PV4 Shield gas
PV3
servo valve
70
PIN
NO
1
2
3
4
5
6
7
8
9
10
11
12
Green
Yellow
----Brown
White
Gray
Yellow
Brown
Gray
White
Brown
------
O2
AIR
----+24VDC
N2
H35
PV3
+24VDC
O2S
AIRS
+24VDC
------
CABLE
NAME
GAS B
GAS B
----GAS B
GAS B
GAS B
PV3
PV3
GAS A
GAS A
GAS A
------
13
Green
N2S
GAS A
14
Yellow
ATM
GAS A
15
white
PV4
PV3
COLOR
FUNCTION
1500
300
2000
310
2500
330
3000
340
4000
400
CNC
PIN
NO
COLOR
Yellow
White
Green
4
5
6
7
8
9
10
11
12
13
14
15
Brown
Gray
Yellow
Brown
White
Green
Gray
Yellow
White
Green
Brown
------
FUNCTION
PV5 Cutting
servo valve
PV6 Preheat
servo valve
PV7 Propan
servo valve
+24VDC
ATM
CUT(R)
+24VDC
IGNITION(R)
SLOW+24
PREHEAT(R)
FAST+24
FAST+24
PROPAN(R)
SLOW+24
BRIDGE
CABLE
NAME
PIN
NO
COLOR
FUNCTION
CABLE
NAME
PV5
White
FAST+24
PROPAN(R)
PV5
Green
PROPAN(R)
PROPAN(R)
PV5
Brown
SLOW+24
PROPAN(R)
PV5
PV5
CUT(R)
CUT(R)
CUT(R)
CUT(R)
CUT(R)
PROPAN(R)
PROPAN(R)
PROPAN(R)
PROPAN(R)
4
5
6
7
8
9
10
11
12
13
14
15
Yellow
White
Green
Brown
----Yellow
Gray
Green
Gray
Yellow
White
Brown
PV5
PV6
PV7
+24VDC
----FAST+24
TAV(R)
SLOW+24
ATM
KES(R)
ATE(R)
+24VDC
PV5
PV5
PV5
PV5
----PROPAN(R)
CUT(R)
CUT(R)
PV5
CUT(R)
CUT(R)
CUT(R)
71
1500
675
2000
685
2500
740
3000
815
4000
890
CNC
PIN
NO
13
14
--15
16
13
14
9
10
72
COLOR
Red
Blue
----Green
Yellow
Pink
Gray
Brown
White
CONNECTION
PL0306-3 LIMIT CARD
PL0306-3 LIMIT CARD
-----PL0306-3 LIMIT CARD
PL0306-3 LIMIT CARD
PL0430-9 IHS LIMIT CARD
PL0430-9 IHS LIMIT CARD
PL0430-9 IHS LIMIT CARD
PL0430-9 IHS LIMIT CARD
BRIDGE
PIN
NO
1
2
3
4
5
6
7
8
9
COLOR
Red
Blue
----Green
Yellow
Pink
Gray
Brown
White
FUNCTION
+TR LIMIT
+TR LIMIT
-----TR LIMIT
-TR LIMIT
IHS(R)
IHS(R)
CRUSHER(R)
CRUSHER(R)
CNC
PIN
NO
1
2
3
4
5
COLOR
Green
Brown
White
Yellow
Gray
BRIDGE
FUNCTION
PIN
NO
1
2
3
4
5
COLOR
FUNCTION
Green
Brown
White
Yellow
Gray
CNC
PIN
NO
1
2
3
COLOR
Brown
White
-----
BRIDGE
FUNCTION
+15VDC
PREHEAT SENS.(R) OK.
PIN
NO
1
2
COLOR
FUNCTION
Brown
White
73
1500
290
2000
300
2500
315
3000
340
4000
395
CNC
PIN
NO
1
Brown
White
3
4
Yellow
Yellow
White
6
7
Brown
Brown
White
Yellow
74
COLOR
FUNCTION
+15V DC
TR5 Cutting
transmitter
0V
0V
TR6 Preheat
transmitter
+15VDC
+15VDC
TR7 Propan
transmitter
0V
BRIDGE
CABLE
NAME
TR5
PIN
NO
8
Brown
TR5
White
TR5
TR6
6
3
Yellow
Yellow
TR6
White
TR6
TR7
1
4
Brown
Brown
TR7
White
TR7
Yellow
COLOR
FUNCTION
1500
360
2000
375
2500
395
3000
415
4000
470
CNC
PIN
NO
11
12
13
14
6
7
8
9
10
COLOR
Yellow
White
Green
Brown
Yellow
Brown
White
Green
Gray
CABLE
NAME
FAST +24
PROPAN(L)
FAST +24
PROPAN(L)
PROPAN(L) PROPAN(L)
SLOW +24
PROPAN(L)
CUT(L)
CUT(L)
+24VDC
CUT(L)
IGNITON(L) CUT(L)
SLOW +24
CUT(L)
PREHEAT(L) CUT(L)
FUNCTION
BRIDGE
PIN
NO
1
2
3
4
5
6
7
8
9
COLOR
Brown
Green
White
Yellow
Brown
Green
Gray
Yellow
White
FUNCTION
CABLE
NAME
PROPAN(L)
PROPAN(L)
PROPAN(L)
CUT(L)
CUT(L)
CUT(L)
CUT(L)
PROPAN(L)
CUT(L)
75
1500
720
2000
765
2500
820
3000
895
4000
970
CNC
PIN
NO
9
10
--11
12
15
16
11
12
76
COLOR
Red
Blue
----Green
Yellow
Pink
Gray
Brown
White
BRIDGE
FUNCTION
PIN
NO
1
2
3
4
5
6
7
8
9
COLOR
Red
Blue
----Green
Yellow
Pink
Gray
Brown
White
FUNCTION
+TL LIMIT
+TL LIMIT
-----TL LIMIT
-TL LIMIT
IHS(L)
IHS(L)
CRUSHER(L)
CRUSHER(L)
CNC
PIN
NO
1
2
3
4
5
COLOR
Green
Brown
White
Yellow
Gray
BRIDGE
FUNCTION
PIN
NO
1
2
3
4
5
COLOR
FUNCTION
Green
Brown
White
Yellow
Gray
CNC
PIN
NO
1
2
3
COLOR
Brown
White
-----
BRIDGE
FUNCTION
+15VDC
PREHEAT SENS.(L)OK.
PIN
NO
1
2
COLOR
FUNCTION
Brown
White
77
Cooling water losses during consumable replacing are not remarkable in AJAN
PRECISION PLASMA 260AMPER.
AJAN consumable replacing are faster and easier than other companies.
Gas
ring
Gas
diffusor
Main body
Shield
cap
Shield
Nozzle
Electrod
e
Nozzle
body
Torch
main body
Water return
Nozzle conductor
78
TORCH MAIN PIPE (Electrode body) (Material: Brass) Provides water inlet to torch and conducts
electrode current.
TORCH WATER PIPE: (Material: Brass) Cools electrodes.
TORCH MAIN BODY: (Material: TecaPEEK) Directs plasma gas, secondary gas and water inletoutlets and provides electrical insulation.
NOZZLE BODY: (Material: Brass) Fixes nozzle to torch and cools it. At the same time directs to
secondary gas shield head.
ELECTRODE: (Material: Pure copper) Transmit electrical energy to the work piece through plasma
gas.
GAS DIFFUSER: (Material: Vespel-Ceramic) Directs plasma gas to work piece by spinning with
radial end eccentrically holes on it. By this means it determines plasma gas flow and rotating speeds
and provides electrode and nozzle lifetime equality.
NOZZLE: (Material: Pure copper) Provides most appropriate nozzle form sensitive cutting densities
according to selected current level.
GAS RING: (Material: Vespel) Provides homogeneous gas distribution on work piece by spinning
secondary gas.
SHIELD: (Material: Pure copper) Provides outlet to plasma gas and secondary gas to the work piece
and protects nozzle against slag splattering during piercing. In addition provides flow compressing
required for sensitive cutting.
SHIELD CAP: (Material: Brass) Fixes shield to torch and conducts secondary gas. Provides
electrical contact with ohmic contact. It has a long service life since it does not have plastic parts.
79
Figure 36. Ajan PRECISION PLASMA 260AMPER Electrode and Nozzle required life time chart
Figure 37. Ajan precson plasma 130A mper Electrode and Nozzle required life time chart
Table 28. Ajan precson plasma 260 amper plasma generator gas flow rates
80
As clearly seen above, hoses used in classic gas consoles whose lengths are around 5-10 m and
stated with d in Figure 38) have been removed in Ajan automatic gas console, adjustment and onoff valves relocated to an individual unit near to cutting head. Advantages of Ajan gas console
when compared with other CNC plasma cutting manufacturers automatic and manual gas consoles
have been stated below. In classical system (Figure 38) when sheet type is changed, even the same
consumable is used, replacing of the gas in 5-10 m hose with new ones induces 1-2 mins time losses
and 100-200 liters gas losses. As seen in Figure 39, in Ajan automatic gas console, this process
takes place with acceptable gas and time losses, since gases can replace very fast. Another
advantage of fast gas replacing is to control speed, current and flow relations, at the beginning of
the cut and at the end of cut and at corners in continuous relationship with Ajan automatic gas
console. Ajan can do marking-cutting cutting-marking transition in only 0,1 sec.
81
Figure 40. New conception Ajan all inclusive plasma cutting system
82
It secures that the jet filter being switched on before than ventilation unit switched on.
It switches on the ventilation unit through the remote control unit on CNC console.
It switches on the generator unit through the remote control unit on CNC console.
Figure 41. Schema for required connection between units on Ajan all inclusive plasma system
83
13.6. HEIGHT MEASUREMENT SOFTWARE AND HARDWARE WITH 1ARC 2-SLIDING SLEDGE 3-OHMIC CONTACT
Firstly standard in the world: 3 Different Initial Height Control Systems: Only Ajan Plasma and
OXY-FUEL sheet cutting machines utilize these triple methods. This opportunity is an inevitable
feature.
ARK: It is used for painted, nylon coated or oxidized thin sheets or other cases of which heights can
not be measured otherwise. (Shorter nozzle life).
SLIDING SLEDGE: Ohmic contact does not work on painted, nylon coated or oxidized sheets. For
these cases, if sheet is not a bending type, sliding sledge method must be preferred. By this means
negative nozzle life shortening aspect of arc height measurement method will have been eliminated.
OHMIC CONTACT: It is preferred in the cases that electrical contact is possible. But if it is not
supported with sliding sledge system, initial vertical approaching speed will be slow (app. 1
meter/min). If it is supported with sliding sledge system, this speed reaches to 6 meters/min. This
agile Z axis movement is as important as idle feeding speed and cutting speed be. For example 1
hour of time saving will not be exaggeration for a sheet which requires 1000 piercing. All three
cutting modes can be toggled with hand control unit immediately. This feature is possible only in
Ajan plasma cutting machines.
Unlike the other ohmic contact systems, Ajan eliminates the extra cable connected to the Shieldcap. In this way operator is more comfortable for changing the consumables and the risk of cable
becoming loose or braking is eliminated thanks to Ajan new torch design.
External cable and connectors
Internal cable
and connectors
84
THC OFF
THC ON
THC AUTO
When THC AUTO is selected, required arc voltage differential for each piercing is measured real
time by CNC unit and remaining cuttings are done according to corrected arc voltage. Almost all
other CNC plasma systems require manual correction of arc voltage during the cutting periodically
by operator.
Classical System
Starting height
500 piercing
operator
corrected
1000 piercing
operator correction
necessary
Starting height
500 piercing
1000 piercing
85
310 VDC
260Ampere
200VDC
Maximum power
52kW
0.85
Cooling type
Compressed air
Weight
530kg
86
Quality
Pressure
%10
Flow rate
O2 Oxygen
99,5% pure
Clean, dry, oil free
8,5 bars
45 lt/min
N2 Nitrogen
99,99% pure
Clean, dry, oil free
8,5 bars
130 lt/min
Air
8,5 bars
190 lt/min
8,5 bars
45 lt/min
8,5 bars
20 lt/min
99,99% pure
(H35 = 65% Argon, %35
Hydrogen)
99,99% pure
(F5 = 95% Nitrogen, 5%
Hydrogen)
H35
Argon - Hydrogen
F5
Nitrogen - Hydrogen
Mild steel
Stainless steel
Aluminum
Gas types
Plasma
Shield
Plasma
Shield
Plasma
Shield
30A cutting
O2
O2
45A cutting
N2 and F5
N2
N2
N2
50A cutting
O2
AIR
80A cutting
O2
AIR
AIR and F5
130A cutting
O2
AIR
H35, N2 and
AIR
260A cutting
O2
AIR
Marking
N2
N2
N2
AIR and
N2
AIR and
N2
AIR and
N2
AIR and
H35
AIR and
H35
AIR and
N2
AIR and
N2
N2
N2
N2
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120
121
122
123
124
125
126
127
128
Figure 67. Precson plasma automatic gas console plasma plate connection schema
129
Figure 68. Precson plasma single head oxygen plate connection schema
130
Figure 69. precson plasma automatic gas console double head plate connection schema
131
Figure 70. precson plasma double head oxygen plate connection schema
132
Figure 71. Precson plasma automatic gas console double oxygen plate connection schema
133
Figure 72. Precson plasma four head oxygen plate connection schema
134
135
136
137
138
Figure 77. Precson plasma 260Amper +oxygen cutting CNC connection schema
139
Figure 78. Precson plasma 260Amper +double head oxygen cutting CNC connection schema
140
141
142
143
144
145
146
147
148
149
150
Figure 89. Precson plasma double head control card connection schema
151
152
153
154
155
156
157
158
159
160
161
162
163
164
165
166
CNC
NO
1
2
3
4
5
6
7
8
9
10
11
12
13
14
PLAQUETTE NO
PL0430-1
PL0430-4
PL0430-9
PL0430-10
PL0430-12
PL0430-14
PL0430-15
PL0430-16
PL0625-1
PL0240-3
PL2005-2
PL0306-3
PL0404-1
PL0305-4
CARD NAME
LOGIC CONTROL CARD
ARC TRANSFER CARD
IHS LIMIT CARD
FRONT PANEL CARD
OXY1 BLOCK CARD
OXY2 BLOCK CARD
GAS DISCHARGE CARD
OXY MARKING CARD
PROXY CARD
HEIGHT CONTROL CARD
POWER CARD
LIMIT CARD
RESUME CARD
OHMIC SENSOR CARD
GENERATOR
NO
1
2
3
4
5
6
7
8
9
10
11
12
13
PLAQUETTE NO
PL0305-2
PL0305-5
PL0305-6
PL0305-8
PL0340-2
PL0430-2
PL0430-3
PL0430-5
PL0430-6
PL0430-7
PL0430-8
PL0430-11
PL0430-17
CARD NAME
IGBT DRIVE CARD
PHASE LACK CARD
VARISTOR CARD
LED CARD1
CURRENT TRANSFORMER CARD
CONTROL CARD
START CIRCUIT CARD
FIRING CIRCUIT CARD
RESISTANCE CARD
CONDANSER CARD
ARC DIVIDER CARD
PLASMA BLOCK CARD
LED CARD2
JET FILTER
167
168
Cooling liquid
Cooling liquid filter
Wiper
Jet filter cartridges
Ventilation press handle springs
Active carbon filter cartridges
Cooling liquid
Cooling liquid filter
Wiper
Jet filter cartridges
Ventilation press handle springs
Active carbon filter cartridges
Main circuit breaker
Pilot arc circuit breaker
Torch main body
Cooling liquid
Cooling liquid filter
Wiper
Jet filter cartridges
Ventilation press handle springs
Active carbon filter cartridges
Cooling liquid
Cooling liquid filter
Wiper
Jet filter cartridges
Ventilation press handle springs
Active carbon filter cartridges
Main circuit breaker
Pilot arc circuit breaker
Torch main body
Torch hoses and cables
Torch cooling pump
Cooling liquid
Cooling liquid filter
Wiper
Jet filter cartridges
Ventilation press handle springs
Active carbon filter cartridges
Cooling liquid
Cooling liquid filter
Wiper
Jet filter cartridges
Ventilation press handle springs
Active carbon filter cartridges
Main circuit breaker
Procon pump
Pilot arc circuit breaker
Torch main body
Torch hoses and cables
Torch cooling pump
Cooling liquid
Cooling liquid filter
Wiper
Jet filter cartridges
Ventilation press handle springs
Active carbon filter cartridges
Cooling liquid
Cooling liquid filter
Wiper
Jet filter cartridges
Ventilation press handle springs
Active carbon filter cartridges
Main circuit breaker
Procon pump
Pilot arc circuit breaker
Torch main body
Cooling pump motor
Cooling liquid
Cooling liquid filter
Wiper
Jet filter cartridges
Ventilation press handle springs
Active carbon filter cartridges
Cooling liquid
Cooling liquid filter
Wiper
Jet filter cartridges
Ventilation press handle springs
Active carbon filter cartridges
Main circuit breaker
Pilot arc circuit breaker
Procon pump
Torch main body
169
170
171
ENTER key will register the changes for that block and the next block will be highlighted ESC
key will cause editor to return to menu bar (Menu:0) and if some changes made in that particular
block, it will be left unchanged. F2 key will save the edited file. The reserved right zone of the
screen will be used for graphical display for machining and fault messages.
FILE NAME : Displays the name of the file.
START NO: Indicates the start line of the program to be executed.
END NO: Indicates the program finish line.
MENU: Pressing F10 function key will change menu bars under the screen. At the right bottom
corner the name of the menu will be displayed.
Menu 0 (main menu) bar:
Menu 1 bar:
Menu 2 bar:
172
Run: It runs the program written in the screen. Once this key is pressed if everything is OK.
(Limit switches, axis drives). Machine starts running, the menu bar will change as shown below for
the different machine types.
Torch goes down following M7 code, fires and waits for flash transfer.
After flash transfer torch waits preheating time and starts cutting.
Torch goes down following M7 code, preheating gas is released and it is fired.
173
Torch goes down following M9 code, fires and waits for flash transfer.
After flash transfer torch waits preheating time and starts marking.
174
File: Used to load files from disk. When you press this function key the files with TOR
extension will be displayed. Page down page up and arrow keys will highlight the files, pressing the
ENTER button will load that particular file. The same key serves to view list of files existing in the
current directory with extension CAM, DXF and MPG(ESSI code files) by pressing C,
X and W key. Pressing T will again display us files with extension TOR. By pressing S
we can sort files according to their size, D according to their creation date and N by name.
After remembering these files we can link them to our main program in following format G36
mpg or b3 file (ESSI file), G37 dxf file and G38 camfile when ever needed.
To call the programs stored in the memory, select the file and press ENTER. In the main menu a
sub menu is displayed. For files with extension TOR;
175
If we press Y the last opened file is saved and selected file opens, ESC will open the selected
file without saving the last opened file.
To create a new file; select file button by pressing function key F3, press ESC key and type in
8 character file name to the small window that highlights. This file must have a different name
from the list and then the block lines existing already in the editor will be saved as with this new
file name
To save the old file press Y key. To leave the old file unsaved press ESC key.
Pushing Y key saves the old file before creating a new file. Following figure is displayed during
saving.
If we want to open a new blank file with this name B letter has to be pushed
ESC button will cancel operation..
Y button will create the file with different name but same content as the last opened file.
DELETING FILES: Press F3 File function key. High light the file using arrow Keys, Page Up and
Page Down Keys then press DELETE key.
176
Pressing Y Key will delete the file, N Key will cancel the operation.
DelLin: Select the block to be erased and push this function key.
InsLin : Used to insert block after chosen block.
Resume : This function is processed only if machine is in High Speed Machining mode(HM
code is used). If our work stops in an unwanted way, such as electricity cut, by this function we can
continue our process from the breaking point. There is no restriction in using this function, can be
called in any level of our process.
When we press F6Resume we have three choices; ENTER will start the program from the
beginning, F1 from breaking point, and ESC will exit and open menu1.
177
Quit: Used to return back to DOS. If N key is pushed the operation will be cancelled.
18.3. MENU:1
MDI: Used to move axes X, Y (for drill model Z axis can be used) to desired positions when
F1 is pressed. And Used for Entering F (feed rate), S (Spindle period for drill model), SM
(Maximum spindle period for drill model) and G5x (G54, G55, G56, G57) commands. In graphical
screen ENTER MDI will appear:
178
SAMPLE:
Enter MDI: x100 than ENTER will bring X axis to desired position of 100 mm. This operation
for each axis has to be repeated.
GoZERO: Will pull all axis (X,Y) (for drill model Z axis can be used) to 0 position
M Hand : Plasma is controlled by Hand Control Unit. Independently from the program all
axis can be controlled. Only ABORT button in hand control unit is available to exit and go to
the Menu:1.
******************************************
MENU6
*************************************************
*********************************************************************************************************
F4 2: Used to divide axis values shown on the display by two while hand control unit is active.
179
TkOffs: This function is used to offset Powder Marking torch to the cutting torch. Unit the
powder torch marking is positioned or marks according to the cutting torch.
For assigning offset cutting torch positioned to the workpiece zero then pressing F5Reset key to
reseting position. The marking torch positioned same workpiece zero and the press the F7TkOffs
key. For assigning offset press (A) key, for reseting offset values press the (R) key.
FndCnr: This function is used to find corner. If press F8FndCnr key, Find Corner window is
activated. Its necessary to assign 3 point. First of all torch is positioned to first X axis point and
press the 1 key to assign position, and torch position another point in X axis then press the 2 key to
assign second point, finaly torch position in Y axis press the 3 key to assign last position then press
the 4 key to positioning corner.
*************************************************************************************************************
*************************************************************************************************************
180
Reset: X, Y, Z will be reset to 0. You can also reset each axis separately while in manual
positioning (F3M_Hand) by pressing CTRL and related axis. Example: Pressing CTRL + X will
reset X axis to 0.
THC: Used to changed Torch Height Control is active or passive. When F6 function key is
pressed, writing TORCH ON at the bottom of the screen and Torch Height Control is active.If F6
function key is pressed again,writing TORCH OFF and Torch Height Control is passive.
MZR: This must be performed in each start up of the machine to have a reliable positioning
after electricity cut out or shut down of the machine. It searches for machine zero point. Single axis
machine zero point is also possible by pressing in single axis letter keys when prompted. The (G54,
G55, G56, G57) work piece zero point settings are available only if this machine zero operation
will be performed.
181
F_Hght: When F8 function Key is Pressed following menu bar will appear.
Graph: When F9 function key is pressed following menu bar will appear.
Use to control graphically screen, zoom and pan. Zoom scale and pan value will be displayed on the
graphically screen. In case when a DXF file is loaded graphically the figure will respond to these
changes. Down (), Up (), right (), left () Keys will shift the dotted line origin and page up
and page down will change the zoom scale.
182
Example: Codes and Co-ordinate explanations for circular interpolation is given below.
XC
YC
ZC
RA
SA
EA
G3 CWW
I
J
Xs
Ys
Xe
Ye
:
:
:
:
:
:
:
:
:
:
:
:
:
F8 Dxf_In: Type in the name of the DXF file without the extension and press ENTER Key. And
clicking the left mouse button on the entity will give the information about that entity.
183
F7 EssiIn Type in the name and extension (MPG, B3) of the ESSI file and press ENTER Key.
If type only file name all of the 8 characters, load the file with MPG extension.if MPG extension
not exist, try to load file with B3 extension.
If called Essi file is not existing (Mpg and B3) a warning messages will appear.
184
If we dont want to cut all of the shapes in the mpg or dxf file, we can cut only which our indicates
start and end point of the objects in the file.
F5 Start used to choose a start object for cutting with the mouse. Press the F5 button then select the
start object with the mouse
F6 End Used to choose end point for cutting with help of the mouse. Press the F6 button then select
the last object for cutting process with the mouse
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F3 CutPlt When F3 function key is pressed graphically indicates selected objects for cutting
process.
F4 CutAll When F4 function key is pressed canceled which indicates all of the shapes in the file.
Menu: Toggles between Menu:0, Menu:1, Menu:2 The button right corner shows the menu
number.
18.4. MENU:2
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THC OFF DISTANCE: This function is processed if machine is inHigh Speed Machining mode
(code HM is used). In every cutting process, cutting is stopped (M8 is applied) before end, with
this entered distance. This is used in order not to damage the exit point.
UP DISTANCE: This value is travel height of the torch when the torch is passing between the
contours.
MICRO JOINTS DISTANCE: This value is joint to joint distance for cutting part. Micro joints
thickness specified in cutting tables. Distance between each joint specified by this parameter.
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FIRST HEIGHT MODE: for selection initial height sensing type. if switch is selected initial
height taking by mechanically.if arc is selected initial height sensing with arc voltage.
MACHINE TYPE: The parameter used to set the machine as oxygen or plasma. Page_up,
Page_down buttons are used to change machine type. If plasma is selected, PURGE parameter
becomes active. In Oxygen modes this parameter is not active.
THC AT CORNERS: This function is processed if machine is inHigh Speed Machining mode
(code HM is used). The corners with angle greater than 45, this function cancels or
applies(Pg_up/Pg_down) torch height control before 5 mm to the corner and 5 mm after the corner.
AXIS TYPE: This parameter indicates type of the machine X axis. This value must be set by your
machine producer.
CUT CHARTS: Tab or (down (), up () ) key used to select cutting parameter. After choosing
Material type, cutting current and cutting thickness right tables shows which gases is used gas rates
, Arc voltage, cutting speed ,SN(pierce delay time), torch to work distance , pierce height factor,
micro joints thick, consumables (Electrode, Nozzle, Swirlring, Retaining Cap, Serial Numbers)
information. Press OKEY after selection correct parameters to exit main menu.
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PURGE: This parameter is active only Plasma Mode. This parameter used to flowing a gas to the
torch for clean inside to torch and fill the hosepipe with gas with 6 seconds period.
THC OFFSETS: Used to change offset value for the Torches.
NUMBER OF TORCHES: Used to change Torches count.
WORKING TORCH: Used to selected torch. Left Torch, Right Torch or each one.
EXIT: Aborting from menu.
AbsPOs: Shows the actual position of the axis with respect to machine zero point.
G5x: 4 work piece zero points can be assigned for separate locations. Pushing this function key
will open a text window in graphic area for G54, G55, G56, G57. By pressing 4,5,6,7 all axis can
be assigned with these work piece zero points but if single axis assignment is needed that axis have
to be moved to desired position before hand and related work piece zero code must be pressed
together with SHIFT key and than related axis must be entered related tool number that will be
assigning to g5x.(note: all of the tool can be assigned all of the G5x (work piece zeros) thus you
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NOTE: Before assigning work piece datum for (G54, G55, G56, G57) (Menu:1 F7) machine zero
operation has to be performed. Otherwise first go to machine zero warning will appear.
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and
button, the delay time with
button 0,25 second, with
button 1 second
and
and
and
and
and
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NAME
G0
EXPLANATION
Rapid traverse linear move.
G1
G2
G91
M0
When this code is encountered in a program block the machine will stop
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M17
NAME
F
SN
EXPLANATION
Defines the feed rate in mm/min for X, Y axis.
Motion Delay time. The time needed for plasma to hole the work piece
(preheating time for Oxygen Cut). It is displayed as Preheat Time. This
time interval SN changes with the type and the thickness of the work
piece. We can both adjust this value by writing this command to program
line or by using Hand Control Units ET function.
HM
HN
Cancel High-Speed-Machining.
PH
PC
SC
OK
OT
LP
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PROGRAM ROWS
000 F1500 SN.5
001 G59 X0 Y0
002 G0 X12 Y14
003 L9 P1
004 G1 X50
005 L9 P1
006 G1 X70
007 L9 P1
008 G1 X0 Y0
009 F50 M7
010 G3 I5
011 M8
012 M17
Sub program
Sub program end
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Example below shows followed linear and radial movements (clockwise and counter clockwise).
000 F200 G90 SN2
001 G59 X5 Y0
002 M7 F100 G1 X85
003 G3 J5 I0 X90 Y5
004 G1 Y25
005 G3 J0 I-5 X85 Y30
006 G1 X65
007 G2 J5 I0 X60 Y35
008 G1 Y55
009 G3 I-5 J0 X55 Y60
010 G1 X35
011 G3 J-5 I0 X30 Y55
012 G1 Y35
013 G2 I-5 J0 X25 Y30
014 G1 X5
015 G3 J-5 I0 X0 Y25
016 G1 Y5
017 G3 I5 J0 X5 Y0
018 M8
019 G1 X0 Y0
We can also write this program by using Drawing Program and DXF file extension. We draw
the sketch by using Drawing.exe program coming with the machine. The starting line and ending
line also must follow each other. This can be achieved by pedit command. We should think the
drawing as the work piece and pedit the sketch considering this. We should select lines following
each other while pediting. There mustnt be any unselected line left after pedit operation. We should
also place the drawing to origin, 0,0,0. After completing this we can save and exit from drawing
program. In the main window edit the command lines and run the program. While working with
complex designs writing the program line by line can be very long and errors are more possible. By
using drawing program we can get rid of this problem. We dont need any mathematical calculation
after drawing the sketch. We only call the drawing with file extension DXF and run the program.
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