I. Careful
Caution Notice: Always be aware of matters associated with the following warning signs:
General Tip
Before installation and initial use, read this document carefully to avoid actions that may cause property damage or personal injury. You must continually check the specifications and technical conditions of the system (consult equipment labels and associated documents).
This manual provides a brief introduction to the operation steps; For more comprehensive information, please refer to the CNC system manual, plasma power supply manual, arc voltage regulator manual and capacitor regulator manual.
Our company reserves the right to modify the equipment configuration; The content of this book may not be in line with the actual equipment situation. See equipment for details.
We do not accept warranty responsibilities for damage to equipment caused by failure to comply with operational requirements. In case of equipment failure, do not replace parts yourself; please contact our company first.
1. Inspection
Take care: Damaged or defective products must not be put into operation.
2. Transport and Storage
Pay attention: During transport and storage, it is crucial to protect against moisture. It is not permitted to climb or stand on the product, nor should heavy objects be placed on it. Special care must be taken to prevent the front panel and screen from being bumped or scratched.
3. Installation
Take care: The CNC system housing is not designed to be waterproof, therefore, during installation, care must be taken to avoid direct exposure to sunlight and rain.
Pay attention: The installation of CNC systems must prevent the entry of dust, corrosive gases, conductive objects, liquids and flammable materials. CNC systems must be installed away from flammable and explosive items and locations subject to strong electromagnetic interference. The installation of CNC systems must be safe to avoid vibrations.
4. Wiring
Warning: All personnel involved in wiring or inspection must have sufficient skills to perform this task. Electrical wires must not be damaged, compressed or energized when opening the numerical control system housing.
Take care: Voltage rating and polarity on any connector plug must be in accordance with manual specifications. Before connecting a connector or flipping a switch, make sure your hands are dry.
Pay attention: All connections must be correct and secure. The CNC system must be reliably grounded.
5. Commissioning and Operation
Take care: Before operation, it is essential to check the accuracy of the parameter settings. Any modifications to parameters must be within the allowable range defined by the parameter settings.
6. Usage
Warning: Do not open the device case or safety covers during operation as this may result in personal injury and property damage.
When opening the equipment case, the main power supply must be turned off to avoid possible personal injury and property damage.
Do not connect or disconnect machine connectors when the main power supply is on, as this may cause personal injury and permanent damage to the system.
Wait at least two minutes before touching or removing the circuit board and connectors after disconnecting the servo amplifier's main power supply. This is because the residual charge on the device's internal capacitors maintains a dangerous voltage for up to two minutes after the main power supply is turned off.
First, disconnect the plasma power supply before handling the cutting torch to avoid possible personal injury and property damage. When handling the cutting torch, be careful of burns caused by the high temperature of the torch nozzle.
The operator must have the necessary skills for this work. They should have undergone safety training related to flame cutting and plasma cutting. The operator must have basic knowledge of microcomputer operations and be familiar with flame cutting and plasma cutting processes.
Pay attention: Before connecting to the power supply, make sure the switch is in the off position.
Operators must not leave equipment unattended while it is in operation.
Before calling, confirm that all system wiring is correct and error-free.
When using plasma cutting, the steel plate must be level and there must be no significant ripples, otherwise it will affect the accuracy of the cutting size and greatly reduce the service life of the nozzle and electrode.
7. Troubleshooting
Warning: Personnel involved in troubleshooting must have the corresponding professional knowledge and working ability.
Take care: After an alarm occurs, the malfunction must be resolved before the system can be restarted.
8. Power supply
Pay attention: This equipment uses only a 380 V 50 Hz main power supply. The environmental conditions for using the equipment must be in full accordance with the specifications in this manual.
II. Equipment installation
1. Precautions for installing the cutter
1. After unpacking, place the plasma power source in the center left position, with a wooden pad underneath. The control cabinet should be placed in the rear position on the left side of the cutter, allowing the operator to visually monitor the entire cutter and cutting process.
2. Unpack the drag chain on the left side and place it parallel to the mower.
3. Adjust the six-foot screws that come with the machine and level the equipment with a level gauge.
4. Connect the plasma source power cable to the workshop power supply (three-phase 380V, 50HZ), with a power of 8KW.
5. Connect the ground wire of the plasma power source to the grid structure or steel plate of the bench.
6. Connect the power cable from the control board to the workshop power supply (three-phase 380V, 50HZ), with a power of 3KW.
7. Properly connect the plug behind the computer to the control cabinet.
8. Install the monitor and connect the power and signal lines.
9. Connect the water inlet and outlet pipes and fill with water until the depth of the water tank reaches 80 mm.
10. Connect compressed air to the air inlet of the plasma power source using an air tube and adjust the air pressure to 5.0.
11. Sequentially turn on the main power, control cabinet switch, host power, monitor, and plasma power supply.
12. Operate in accordance with the plasma power source manual, system operation manual and user manual. Do not randomly modify the parameters set in the system when you are not familiar with them.
13. If the cutting quality is poor and cannot be resolved, check the electrode and nozzle of the plasma cutting torch. If they are damaged, they must be replaced.
2. Cable routing arrangement
It is recommended to use channels in the floor for the connection cables between the body of the cutting machine and the electrical control cabinet. This method not only protects the cables but also facilitates maintenance.
3. Tag
Mark the effective working range on the cutting table and place the part within this marked range for cutting.
4. Power supply
This device has two power cables: 1. The main power cable of the control system, with a power of 2KW and a three-phase voltage of 380V. 2. The plasma power cable, with a power of 8.4KW and a three-phase voltage of 380V.
The length of the equipment's external cable is about 15m. The main power cable of the control system is a 3+1 cable with a diameter of 2 mm2, and the plasma power cable is a 4-core cable with a diameter of 6 mm2.
Both cables and the air tube slide in a circle through the upper trailer frame and down along the factory wall to enter the main power distribution cabinet, where they are connected to different switches. The control system and plasma power source must be reliably grounded.
To avoid the effects of large power fluctuations (greater than ±10%) and possible transient interference signals, the equipment must be powered by a dedicated line (such as a separate line for CNC equipment from the low voltage distribution room) or by adding a stabilizing device, which can reduce the impact of power quality and electrical interference.
If the equipment workplace has a large number of high-frequency interference sources, such as welding machines, argon arc welding machines, plasma cutting machines, high-power frequency converters, etc., a filter must be installed on the power cable of the CNC system to protect interference.
Sudden power outages can result in the loss of cutting files and the production of waste; Sudden and frequent power outages can cause damage to the software or even hardware of the CNC system. Therefore, for places where frequent power cuts occur, it is advisable to equip the CNC system with a 500W UPS power supply.
5. Gas source
Compressed air is used. When air compressor (compressor flow rate 1m3/min) and plasma power supply are used for cutting purposes, the compressor outlet pressure should be between 6.1-8.2Bar; a pressure of less than 5.5 Bar will seriously affect the quality of the cut.
If the pressure drops below 4 Bar, the plasma power source will damage the electrode and it will not work.
Use a high-pressure rubber-plastic pipe with an inner diameter of φ10mm and a pressure of 2Mpa (20 Bar) for the gas pipe.
III. Cutting operation
1. About preparation
The equipment workplace must be equipped with a strong ventilation system to exhaust the smoke produced during the cutting process.
Before turning on the equipment, make sure that all switches on the equipment are in the off position and that the rotary switch on the back of the plasma power supply is in the horizontal position.
1. Connect the main power switch cabinet to connect the two-way cable.
2. Place the circuit breaker on the equipment’s electrical panel in the ON position.
3. Use the command switch to turn on the system control power; the main interface should appear on the display.
4. Next, turn the rotary switch on the back of the plasma power supply 90° to the vertical position, at which point the power indicator light on the front of the plasma power supply should illuminate.
5. Turn on the air compressor (compressor flow rate 1m3/min), adjust the air compressor pressure control switch to maintain the compressor outlet pressure between 6.1-8.2Bar. If the pressure drops below 6.1Bar, the cutting pressure will decrease, resulting in unstable cutting quality. If the pressure exceeds 8.3Bar, it may damage the plasma power supply air filter.
Adjust the pressure regulator knob on the plasma power supply to maintain the pressure between 5.5-6.0Bar. Turn the plasma power supply current adjustment/gas test knob to the gas test position and confirm that the pressure does not drop below 5Bar. When the pressure drops below 5Bar, it will severely affect the cut quality and may even cause the plasma power supply to stop working.
If the working environment cannot guarantee the supply of clean air, a multi-stage combined filtration system must be installed before the plasma power supply. Otherwise, air containing oil, moisture and dust will cause serious problems such as arc failure and torch damage during cutting.
If plasma cutting is being used, machine start-up preparation has been completed.
2. Setting the automatic height adjuster
(1). Arc Tension Height Adjuster
Set the CNC system cutting mode to plasma mode. Turn on the arc voltage height adjuster power supply.
The. Test that manual adjustment works correctly.
Press the manual up (TORCH↑) and down (TORCH↓) buttons on the height adjuster and observe whether the cutting torch moves in the correct direction.
If you press the manual lift button at the upper limit position of the cutting torch, the torch should not rise. If you press the drop button at this point, the torch should fall.
If you press the manual drop button at the lower limit position of the cutting torch, the torch should not drop.
If you press the lift button at this point, the torch should rise. Confirm that the upper and lower limit actions are reliable.
If the cutting torch cannot rise (or lower), it may be in the upper (lower) limit position or the upper limit switch (lower limit switch) is damaged. Replace the damaged limit switch in time, otherwise the height adjustment motor may be damaged because the switch does not work.
B. Initial placement test
Press the initial positioning button (IHS TEST) on the height adjuster. At this time, the plasma cutting torch should move down at the speed defined by the initial positioning drop pulse width (IHS DOWN PWM).
After the nozzle contacts the steel plate, it pauses and rises at the speed defined by the initial positioning increase pulse width (IHS UP PWM) for a positioning time (IHS time) and stops at a height appropriate arc ignition.
The arc ignition height is generally 1.5 ~ 2 times the cutting height. According to the POWERMAX1000 manual, the cutting height for this power supply is 1.5 mm, so the arc ignition height should be about 3 mm.
Users can adjust the positioning time based on their cutting experience to change the arc ignition height to achieve the best cutting quality while reducing damage to consumables.
w. Arc Voltage Test
Press the home positioning button (IHS TEST) on the height adjuster to bring the cutting torch to the arc ignition height. Press the ARC TEST button on the height adjuster to ignite the arc successfully, and observe the measured arc voltage value in the arc voltage monitor window.
The detected arc voltage value should be close to the set arc voltage value. If the two values differ significantly, adjust the arc voltage set value to make them similar.
Otherwise, the cutting height may be too high during cutting or the cutting torch may drag on the steel plate. Both situations will result in decreased cutting quality and serious damage to cutting torch consumables.
3. Servo System Test
4. Compiling cutting patterns
1. Use professional drawing software (such as AUTOCAD) to draw cutting patterns.
2. Edit using the system's built-in graphics library.
3. Use the system's built-in steel plate nesting function.
After the cutting program is loaded into memory, return to the main interface and check whether the view in the graphical display area meets the requirements.
5. Cutting Parameter Settings
1. Modify the cutting parameters.
2. System Settings.
Refer to the CNC system and arc tension height adjuster manual for specific settings.
6. Cutting process
When using plasma cutting, the operator must wear a hat and safety glasses, in addition to pressing all buttons during the process.
Automatic alignment function for steel sheets: That is, the function (measuring angle). In general, when the operator lifts the steel plate onto the cutting table, it is not easy to align the edge of the steel plate with the Y axis of the equipment.
This function can measure the rotation angle of the steel plate and automatically rotate the cutting pattern to the same angle to reduce cutting waste and improve utilization.
After compiling the cutting pattern, manually move the cutter to the upper left corner of the steel plate, in the main interface, press “F2” key for file, then press “F7” key for part option and press “F7” key for measuring angle, use direction key to move the cutter to the lower left corner of the steel plate, press “F1” key to confirm and return to “part option” interface. The cutting program pattern with the added angle is displayed in the graphical preview area on the left.
1. Press the RUN button to enter the cutting interface. Check again to confirm that the cutoff value meets the requirements, and then press the RUN button again to start automatic cutoff.
Note: Before starting cutting, manually raise the cutting torch to a medium-high position.
2. During the cutting process, monitor the operating status of the machine. In case of malfunction, manually raise the cutting torch and press the STOP button to enter the pause interface. Use functions such as “Forward”, “Electrically Reverse”, “Return on Same Path”, “Return to Start”, “Handle Torch” and “Breakpoint Memory” to troubleshoot.
After troubleshooting, press the RUN button twice to resume cutting. (At the corners of the steel plate, due to large changes in the sensing circuit capacitance, the cutting torch may descend quickly and hit the steel plate.
Therefore, the cutting position should not be too close to the corners of the steel plate (50% of the detection loop should be on the steel plate).
You can also manually turn off the automatic height adjustment feature when the machine reaches the corners of the steel plate. At this time, closely monitor the position of the cutting torch and manually adjust the height of the cutting torch as necessary.)
Note: “Return on Same Path” Function: In the pause interface, pressing “Return on Same Path” allows the machine to move along the cutting path back to the point of malfunction. Press the “Stop” button when the machine reaches the point of failure, stopping the return. Using the “Jog Forward” and “Jog Reverse” buttons together allows you to precisely position the machine in the appropriate location, relight, preheat and restart cutting.
“Jog Forward” and “Jog Reverse” functions: Each press of these buttons moves the machine a certain distance along the cutting path, forward or backward.
The distance is determined by the “Jog Distance” parameter defined in the “General Parameters” parameter interface.
“Handle Torch” function: In the pause interface, pressing “Handle Torch” allows you to move the cutting torch off the steel plate for replacing or handling the cutting torch nozzle. Press the “Return” button to move the machine base back to the stop location and continue cutting.
Note: Cut off the plasma power supply before replacing the nozzle or handling the cutting torch. Reconnect the plasma power supply after handling the cutting torch; otherwise, the plasma power supply will trigger an error alarm. Be careful as the cutting torch nozzle becomes very hot immediately after stopping cutting.
“Breakpoint Memory” function: In the pause interface, pressing “F6” (Breakpoint Memory) saves the remaining unexecuted cutting program. After returning to the main interface, you can perform other operations and press “F2” to enter the “File” interface. Press memory file “F5” and then press breakpoint memory “F2” to load the remaining cutoff values into memory. Return to the main interface to continue cutting. Do not move the machine during this process.
If you wish to abandon cutting, press the STOP button again, then press “F7” to confirm and return to the main interface.
3. After finishing cutting, return to the main interface.
4. Continue cutting other workpieces.
7. Completion of the cut
Once the cut is complete, turn off the air compressor.
Switch to manual mode, move the cutting torch carriage to the left and position the machine in the parking location.
Then turn off the controller. Wait five minutes before turning off the plasma power supply and control system power.
Clean the workspace.
4. Maintenance and Conservation
1. Before starting a shift, you must inspect the air system, plasma power supply, and cutting torch connections for air leaks. If discovered, they must be corrected immediately.
2. Before cutting, check that the cutting nozzle and electrode are aligned with the current setting of the plasma power supply and the thickness of the steel plate being cut. The cutting nozzle cannot be used out of reach. The current intensity should ideally be within 95% of the nozzle working current. For example, the current intensity of a 100A nozzle should ideally be set at 95A.
3. Check that the gas pressure is within the allowable range. Make sure the gas is clean, regularly inspect the operation of the air compressor, frequently check the air filter device, and replace components immediately.
4. After replacing cutting torch components or if it has not been used for a long time, turn the current adjustment knob to the gas test position or manually open each solenoid valve to remove water vapor and impurities from the path air and cutting torch.
5. The guiding surfaces of the longitudinal and transverse rails must be cleaned and lubricated after use.
6. When the operator takes a break or leaves the machine for a long time, the power and air source must be turned off.
7. After using the cutting machine, wait a period of time to allow the electrical cabinet and plasma power supply to cool sufficiently before turning off the power.
8. Regularly inspect and brush the gantry crane rack, clean and lubricate it.
9. Periodically lubricate the carriage lifting mechanism (ball bearings, screws, linear guides). Apply lubricant to the X-axis linear guide slider.
10. Regularly clean the slag under the cutting table and clean the dust layer from the surface of the equipment.
11. Regularly check the functionality of the upper and lower limit switches on the cart and immediately replace any defective switches.
12. Clean the side filter of the machine cabinet monthly with a dry brush. Open the electrical panel every three months to clean the dust inside.
13. Every three months, inspect the reliability of the servo motor elastic clamping mechanism and adjust the spring tension screws to ensure proper pressure.
14. Every three months, check the cart and various cables for wear.
15. Inspect all mounting screws for looseness annually.
16. Check the DC motor brushes annually. Excessive wear on the brushes can affect engine performance or even cause damage. Therefore, regular inspections and replacement of motor brushes are necessary.
17. Even without processing tasks, CNC machines should be turned on regularly, preferably 1 to 2 times a week, each time running idle for about an hour. This helps use the machine's heat to reduce internal humidity and prevent the electronics from getting damp.
18. To avoid the impact of large power fluctuations (greater than ±10%) and possible transient interference signals, the device must be powered with dedicated power (as a separate source for CNC equipment from the low voltage distribution room) or additional voltage stabilizing devices. This can reduce the impact of power quality and electrical interference.
19. Check the tightness of all wiring terminals annually. Wiring terminals may become loose due to prolonged operation and vibration, and loose terminals may become hot and damaged during operation.
V. Appendix
Appendix 1: Plasma Arc Cutting Specifications
A plasma cutting machine is a new thermal cutting equipment.
Its operating principle involves the use of compressed air as the working gas and a high-temperature, high-speed plasma arc as the heat source.
This melts the part of the metal being cut and a high-velocity airflow blows the molten metal away, forming a narrow cutting seam.
Plasma cutting can be used to cut various metal materials such as stainless steel, aluminum, copper, cast iron, and carbon steel. It has the advantages of fast cutting speed, narrow cutting seam, smooth cutting edge, small heat-affected zone, minimal workpiece deformation, simple operation and significant energy-saving effects.
This equipment is suitable for manufacturing, installing and maintaining various mechanical and metallic structures, and for cutting, drilling, filling, beveling and other cutting processes for medium and thin sheets.
Various parameters of the plasma arc cutting process directly affect the stability, cutting quality and effect of the cutting process. The main cutting specifications are briefly described below:
(1) Cutting current
Increasing the cutting current can also increase the plasma arc power, but is restricted by the maximum allowable current. Otherwise, it may cause thickening of the plasma arc column, increase the cutting width and reduce the service life of the electrode. The cutting torch accessory model must match the current plasma power supply configuration. The current intensity should ideally be within 95% of the nozzle working current. For example, the current intensity of a 100A nozzle should not be set to more than 95A.
(2) Gas Flow
Increasing the gas flow can not only increase the tension of the arc column, but also strengthen the compression in the arc column, making the plasma arc energy more concentrated and the ejection force stronger. This can improve cutting speed and quality.
However, excessive gas flow can shorten the arc column, increase heat loss, weaken cutting ability, and even interrupt the cutting process.
(3) Cutting nozzle height
Cutting tip height refers to the distance from the end face of the cutting tip to the surface of the part being cut. This distance is usually 2 to 5 mm. Proper cutting nozzle height is essential to fully exploit the cutting efficiency of the plasma arc.
Otherwise, it could reduce the efficiency and quality of the cut and even cause the cutting nozzle to burn out. The cutting nozzle height can refer to the plasma power supply manual or be determined based on cutting experience.
When drilling, the height of the cutting nozzle should be adjusted to twice the normal cutting height.
(4) Cutting speed
Several factors directly impact the compression effect of the plasma arc, influencing its temperature and energy density. The high temperature and high energy of the plasma arc determine the cutting speed, linking all these factors to the cutting speed.
To guarantee the quality of the cut, it is crucial to increase the cutting speed as much as possible. This not only increases productivity, but also reduces deformation of the parts being cut and the heat-affected zone in the cutting area.
If the cutting speed is inadequate, it can have the opposite effect, increasing slag and reducing the quality of the cut.
(5) Thickness and Cutting Process
The thickness of the steel sheet greatly influences the choice of cutting process. With the same torch, its piercing capacity (thickness) is only half of its cutting capacity (thickness).
For Hypertherm Genuine 100A torch parts, the recommended cutting capacity is 16mm and the piercing capacity is 12mm. Therefore, when the thickness of the steel plate is greater than the drilling capacity, it is not possible to drill and cut directly in the middle of the steel plate.
The cutting start point must be set at the edge of the steel plate to start cutting from the edge.
(6) Steel plate surface pretreatment
Steel plates inevitably form an oxide layer on the surface as they pass through a series of intermediate connections from the steel mill to the cutting shop.
Furthermore, an oxide layer also forms and adheres to the surface of the steel sheet during the rolling process.
These oxide layers have a high melting point, are not easy to melt, and slow down the cutting speed. At the same time, the splash of the oxide layer after heating can easily block the cutting nozzle, reducing the service life of the nozzle and electrode.
Therefore, it is necessary to carry out rust removal pretreatment on the surface of the steel plate before cutting.
The commonly used method is rust removal by sandblasting, followed by spraying anti-rust paint.
Small iron sand is sprayed on the surface of the steel plate with a blasting machine, using the impact force of the iron sand to remove the oxide layer, and then conductive and flame retardant anti-rust paint is sprayed.
Pre-treatment of rust removal and paint spraying before cutting steel plate has become an indispensable part of metal structure production.
Appendix 2: Current Parameter Settings for Arc Voltage Regulator
| Plasma Power Supply | powermax1000 |
| CNC system | JT-00000074 |
| Arc Voltage (v) | 155 |
| Drilling (0.1s) | two |
| Initial Positioning (10ms) | 50 |
| MAX_PWM | 235 |
| MIN_PWM | 160 |
| IHS_UP_PWM | 180 |
| IHS_DPWN_PWM | 200 |
| UP&DOWM_PWM | 200 |
| ARC_MAX_ERROR | 20 |
| DELAY_INPUT_TIME | 5 |
| AUTO_PWM_AMP | 4 |
| UP_BRAKE_TIME | 50 |
| DOWM_BRAKE_TIME | 50 |
| EMERG_LIFT_TIME | 20 |
| EMERG_LIFT_PWM | 200 |
| INTEL_ADJ_RANGE | 20 |
| INTEL_ADJ_STEP | 3 |
| INTEL_ADJ_SIGN | 1 |
| ARC_ACCURACY | two |
| PIERCE_ENABLE_SIGN | 0 |
| IHS_CURRENT_LIMIT | 100 |
| IHS_CURRENT_LIMIT_SIGN | 0 |
