Careful
Warning signs: Always be aware of items associated with the following warning signs:
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Dangers caused by electricity |  |
Regular notice
Regular reminders |
Please read this document carefully before installing and operating the desktop CNC plasma cutting machine. Incorrect operation may result in property damage or personal injury.
Always be sure to check the system specifications and technical conditions as indicated on the device labels and related documentation.
This manual provides a brief overview of the operating procedure. For more detailed information, see the numerical control system specifications, plasma power instruction manual, arc voltage regulator specifications, and capacitor adjustment instruction manual.
1. Acceptance inspection
Be careful
Damaged or defective plasma cutting machines are not available for use.
2. Transport and storage
Be careful
During transportation and storage, it is important to keep the product moisture-proof. Do not climb or stand on the product and avoid placing heavy objects on it. Pay special attention to the front panel and screen to avoid bumps and scratches.
3. Installation
Be careful
The outer layer of the CNC system is not waterproof. During installation, it is important to protect it from direct sunlight and rain.
Attention
When installing the numerical control system, take precautions to prevent the ingress of dust, corrosive gases, conductive objects, liquids and flammable materials.
The system must be installed in a location away from flammable and explosive materials as well as strong electromagnetic interference.
To ensure stable performance, the CNC system must be installed securely and protected from vibration.
4. Wiring
Notice
Personnel responsible for wiring or inspecting the system must have sufficient experience to perform such tasks.
The connecting wires must not be damaged, pinched or pulled. Never open the CNC system case while it is loaded.
Be careful
Make sure the voltage and polarity of any wire plugs meet specifications.
Before inserting or operating the switch, make sure your hands are dry.
Be careful
All wiring must be installed correctly and securely fixed.
The numerical control system must be reliably grounded.
5. Commissioning and operation
Be careful
Before operating the plasma cutting machine, make sure the parameter settings are correct.
Any changes made to parameters must be within the range allowed by the parameter settings.
6. Using
Notice
Do not open the device case or fixed cover during operation as this may result in personal injury or property damage.
Notice
Before opening the device, make sure the main power supply is turned off. Failure to do so could result in personal injury or property damage.
Notice
Do not connect or disconnect the connector of the plasma cutting machine while the main power is on. Doing so may cause damage and permanent damage to the plasma cutter.
Notice
After disconnecting the main power supply, wait at least 2 minutes before touching or removing the circuit board and connector.
The device's residual capacitor charge remains at a dangerous voltage for two minutes after the main power is turned off.
Notice
Do not disconnect plasma power before handling the cutting torch, as this could result in personal injury or property damage.
When handling the cutting torch, be careful of high temperature burns caused by the torch.
Notice
The user must have the necessary skills to operate the machine effectively.
Operators must receive safety training related to flame cutting and plasma cutting.
They must also have basic computer operating knowledge and be familiar with flame cutting and plasma cutting technology.
Attention
Before connecting power, make sure the switch is turned off.
The operator must not leave the equipment unattended while it is in operation.
Confirm all system wiring before turning on power.
Attention
When using the plasma cutting machine, the steel plate must be level and must not show large oscillations. Otherwise, it will affect the cutting size accuracy and greatly reduce the service life of the nozzle and electrode.
7. Troubleshooting
Notice
Personnel responsible for problem solving must have the necessary professional knowledge and work capacity.
Attention
Once an alarm is triggered, the fault must be corrected before restarting.
8. Power supply
Attention
This numerical control system is designed to operate with a 220V 50Hz power supply, and the plasma cutting machine requires a 380V 50Hz power supply.
Please make sure any customized power supply is confirmed before placing an order.
The environmental conditions for using the equipment must be identical to those specified in this manual.
Desktop Plasma Cutter Installation
I. Plasma Cutter Installation Considerations
After unpacking the plasma cutting machine, set the plasma power to the middle left position with the matte plate underneath. Mount the control cabinet on the left side of the plasma cutting machine's front position so that the operator can monitor the entire tabletop plasma cutting machine and the cutting process.
Remove the wire on the left side and place it parallel to the plasma cutting machine.
Fix the plasma cutter with 6 anchor bolts and adjust the equipment using the balance level.
Connect the plasma power power cord to the workshop power supply (3-phase 380V, 50HZ) according to the power specifications.
Connect the plasma power ground wire to the grid frame or steel plate.
Connect the control cabinet power cable to the workshop power supply (220 V two-phase, 50 Hz) with 1.5 kW power.
Connect the plug to the side of the control cabinet.
Connect the power supply and signal line, and connect the plasma arc voltage line and arc line with the CNC cutting machine (refer to the plasma specification to confirm the plasma arc line and arc). See Figure 1 below for guidance:
Figure 1
If the plasma power supply is provided by the user, connect the plasma arc line and arc to the CNC cutting machine as shown in Figure 2 (refer to the plasma specifications to confirm the plasma arc line and arc) .
Figure 2
The wires identified as V+ and V- must be connected to the positive and negative arcs, respectively, of the plasma energy source.
It is important to make sure that the positive and negative arcs are connected correctly, as any error in this regard can result in significant problems.
Make sure that the water inlet and outlet pipes are well connected and that the water level in the sink is 80 mm.
Connect the compressed air supply to the plasma power source inlet and adjust the air pressure to 5.0.
Turn on the main power supply, control cabinet switch, and plasma power.
Follow the instructions provided in the plasma power supply manual, controller operation manual, and user manual. Avoid making changes to system parameters unless you have full knowledge and confidence to do so.
If the cutting quality is not satisfactory and cannot be resolved, check the electrode and nozzle of the plasma cutting torch and replace the damaged parts.
II. The Plasma Cutter Wiring Layout
It is recommended to lay the connecting cable between the main body and the electrical control cabinet of the cutting machine along the geosyncline. This will protect the cable and make maintenance easier.
III. Workspace
The cutting step is marked with an effective working area and the workpiece should only be cut within the limits of this marking.
4. Power supply for plasma cutter
The equipment has two power cables:
The first power cable is for the total power supply of the control system and has a nominal power of 1.5 KW and a 2-phase voltage of 220V.
The second power cable is for the plasma power supply and has a power of 8.4 KW and a three-phase voltage of 380V (this cable is optional).
The length of the side cable of the plasma cutting machine is approximately 4.5 meters. The total control system power cable is a two-phase cable with a wire diameter of 1.5 mm 2 while the plasma power cable is a 4-core cable with a line diameter of 6 mm 2 .
Both cables and air tubes pass through the pneumatic trailer frame and down to the main power unit frame along the plant wall, where they are connected to the appropriate switches and sockets.
It is important to ensure that the control system and plasma power supply are reliably grounded.
To avoid large power fluctuations (> ±10%) and possible electrical interference, it is recommended to use a special power line (such as a dedicated line from the low voltage transformer room) or an additional voltage stabilizer for the CNC plasma. cutter. This will help minimize the impact of power quality and electrical interference.
In a workplace with multiple electric welding machines, argon arc welding machines, plasma cutting machines, or high-frequency interference sources such as high-power inverters, it is recommended to install filters on the power cable of the welding system. numerical control to mitigate interference. .
A sudden power outage can result in the loss of cutting files and the production of waste. Sudden and frequent power outages can also cause damage to the CNC software or hardware.
Therefore, in the event of frequent power outages, it is advisable to consider installing a 500W UPS power supply for the NC system to protect against the potential consequences of power outages.
V. Air Supply
Use compressed air when operating the plasma cutting machine.
The air compressor should have a flow rate of 1m3 /min and the outlet air pressure should be between 6.1-8.2 bar when plasma power is used for cutting.
If the air pressure is less than 5.5 bar, it will seriously affect the cutting quality. If the air pressure drops below 4 bar, the plasma power will damage the electrode and render the plasma cutting machine inoperative.
The air pipe must be made of high pressure rubber pipe with an inner diameter of 10mm and a nominal pressure of 2Mpa (20 bar).
Plasma cutting machine operation
I. Preparation
A powerful ventilation system must be installed in the workplace to eliminate smoke generated during the cutting process.
Before energizing plasma cutting equipment, make sure all switches on the machine are in the closed position.
The rotary switch on the back of the plasma power supply must be in the horizontal position.
Turn on the main power supply by connecting power to the main distribution cabinet, which will supply electricity to the two cables.
Close the circuit breaker in the equipment cabinet to the “ON” position.
Turn on the system control power supply and the main interface should appear on the display.
Then turn the rotary switch on the back of the plasma power 90 degrees to the upright position. The power indicator should be located on the front of the plasma power supply.
Turn on the air compressor (with a flow rate of 1m3 /min) and adjust the air compressor pressure control switch to set the outlet pressure to 6.1-8.2 bar.
If the air pressure is less than 6.1 bar, the pressure may drop during cutting, causing instability in the cut quality.
If the air pressure is greater than 8.3 bar, it may result in damage to the plasma power supply air filter.
Adjust the pressure control knob on the plasma power supply to maintain a pressure of 5.5-6.0 bar.
Turn the gas test/plasma power current adjustment knob to the gas test position to confirm that the pressure will not fall below 5 bar.
If the pressure drops below 5 bar, the cut quality will be severely affected and the plasma power may stop working.
If the working environment is not clean, it is recommended to install a multi-level joint filtration system in front of the plasma power supply. Contaminants such as oil, moisture and dust in the air can cause serious problems such as arc failure and damage to the cutting torch.
Once these preparations are complete, plasma cutting can begin.
II. Automatic height adjustment device setting
Arc Pressure Regulator
Set the NC system cutting mode to plasma mode and turn on the arc voltage regulator.
The parameters for adjusting the arc pressure must only include the arc pressure value, with the drilling time and other positioning time parameters defined by the CNC system.
For more information, see the arc pressure adjustment manual.
III. Servo System
4. Programming Cutting Pattern
Create cutting charts using professional drawing software like AUTOCAD and then edit the programs using programming software.
Use the system-provided library for editing. For more information, see the NC system manual.
Use the metal plate grouping function provided by the system.
After the cutting program is transferred to memory, return to the main interface to ensure that the graphical display area meets the necessary requirements.
V. Setting cutting parameters
Adjust cutting parameters and system settings as needed.
For more information, consult the numerical control system manual and the arc pressure regulator manual. A manual for a specific controller in China may be available for download.
FangLing Shape Cutting Control System Operation and Installation Manual (V2.1)
SAW. The cutting process
Observation:
If there are any discrepancies, consult the most recent numerical control system manual.
During the plasma cutting process, the operator must wear protective equipment such as a hat and safety glasses and protect himself appropriately.
The plasma cutting machine also has an automatic steel plate alignment feature, which measures the angle of rotation.
Normally, it may be difficult for the operator to align the steel plate with the Y axis of the plasma cutter during the lifting process. This feature measures the angle of rotation of the steel plate and automatically rotates the cutting chart to match, thereby reducing waste and improving efficiency.
To use this feature, move the plasma cutting machine to the upper left corner of the steel plate after finishing editing the cutting charts. In the main interface, press the “F2” button in the file section, and then press the “F7” button to measure the rotation angle. Use direction keys to move the plasma cutting machine to the lower left corner of the steel plate and press “F1” to confirm. Finally, return to the interface options section.
Observation:
If there are any discrepancies, consult the most recent numerical control system manual.
During the plasma cutting process, the operator must wear protective equipment such as a hat and safety glasses and protect himself appropriately.
The plasma cutting machine also has an automatic steel plate alignment feature, which measures the angle of rotation.
Normally, it may be difficult for the operator to align the steel plate with the Y axis of the plasma cutter during the lifting process. This feature measures the angle of rotation of the steel plate and automatically rotates the cutting chart to match, thereby reducing waste and improving efficiency.
To use this feature, move the plasma cutting machine to the upper left corner of the steel plate after finishing editing the cutting charts. In the main interface, press the “F2” button in the file section, and then press the “F7” button to measure the rotation angle. Use direction keys to move the plasma cutting machine to the lower left corner of the steel plate and press “F1” to confirm. Finally, return to the interface options section.
Observation:
“Return to Original Point” function:
While in the pause interface, press “Return to original point” to allow the CNC plasma cutting machine to retrace its steps along the cutting path. Once the machine reaches the point of failure, press the “Stop” button to stop the return.
Together with the “Jog Move Forward” and “Jog Move Backward” functions, you can precisely locate the appropriate position, relight, preheat and start cutting again.
“Jog Move Forward” and “Jog Move Backward” function:
Press any key to move the plasma cutting machine forward (or backward) along the cutting path. The distance is determined by the “Jog Movement Distance” parameter in the “Universal Parameter” interface.
“Handle cutting torch” function:
While in the interface, press “Handle Cutting Torch” to move the cutting torch away from the steel plate and make any necessary replacements or adjustments.
Press the “Return” key to move the plasma cutting machine back to the stopped location and continue cutting.
Note: Plasma power must be turned off when replacing the cutting nozzle or making any adjustments. The plasma power must then be turned on again once handling is complete to avoid any error alarms.
Be careful when handling the cutting torch as it becomes very hot immediately after stopping cutting.
“Breakpoint Memory” function:
While in the pause interface, press the “F6” (Breakpoint Memory) key and the system will save the remaining part of the program.
Return to the main interface, perform other tasks if necessary, and press the “F2” button in the “File” interface to access the saved memory file.
Press “F2” for Breakpoint Memory to transfer the remaining cut charts to memory. Return to the main interface to continue cutting.
The plasma cutting machine must not be moved during this process.
If you wish to abandon cutting, press the STOP button again, press “F7” to confirm and return to the main interface.
Once cutting is complete, return to the main interface and continue cutting other objects if necessary.
VII. Complete Plasma Cutting
When you have completed the cutting process, turn off the air compressor.
Enter the jogging state, move the cutting device to the left and place the machine in park position. Then turn off the controller.
After waiting five minutes, turn off power to the plasma, and then turn off power to the control system.
Finally, clean your desktop.
Plasma cutting machine maintenance
Before beginning work on the air loop system, plasma power supply, and cutting torch, it is crucial to inspect for leaks and correct them if found. Before cutting, confirm that the cutting nozzle and electrode are suitable for the plasma power current setting and the thickness of the steel plate. The current setting should be set at 95% of the nozzle working current; for example, if the nozzle is 100A, the current setting should be 95A. Make sure the gas pressure is within the acceptable range and clean the air compressor regularly. Also, regularly check the air filter and replace all necessary accessories.
When replacing cutting parts or if the plasma cutting machine will not be used for a long time, turn the current adjustment knob to the gas test position or manually open the solenoid valve to eliminate any water vapor and impurities from the gas and torch path. After use, clean and lubricate the longitudinal guide and the guide surface of the horizontal guide rail. The operator must turn off the power and gas source when taking a break or leaving the machine unused for an extended period.
After using the CNC cutting machine, wait until the device case and plasma power supply cool down before turning off the power supply. Regularly inspect and clean the rack and lubricate using a brush and lubricate the lifting mechanism (such as ball bearing, screw and linear guide slider).
Add lubricating oil to the X-axis linear guide slider.
Regularly clean the cutting slag under the cutting table and remove any dust from the surface of the plasma cutting equipment.
It is important to regularly check the condition of the upper and lower limit switches and immediately replace any failed switches.
Clean the gray layer on the side of the rack with a dry brush once a month.
Open the electrical panel and clean the inside every three months to remove any gray build-up.
Every three months, inspect the servo motor's elastic clamping mechanism to ensure it is reliable and adjust the spring pressure screws as necessary to maintain proper pressure.
Check your plasma cutter cords for signs of wear every three months.
Inspect the tightness of the screws annually to ensure they are secure.
Check the DC motor brushes annually. Excessive wear on the DC motor can negatively impact its performance and even cause damage to the motor.
Therefore, it is important to regularly inspect and replace the motor brushes.
When not in use, it is recommended to connect the plasma cutting machine to electricity regularly, preferably 1 to 2 times a week. Each time, let the machine run for about 1 hour without processing tasks to take advantage of the heat generated by the machine to reduce internal humidity and prevent moisture from affecting the electronic components.
To minimize the impact of power fluctuations (>±10%) and possible electrical interference, plasma cutting equipment must be powered from a dedicated line (such as from a low voltage transformer room specifically for numerical control equipment) or Equipped with an additional voltage stabilizer. This will help ensure a stable power supply and reduce electrical interference.
Check the fixing of the terminals annually. Terminals can become loose over time due to prolonged operation and vibration, which can cause heat damage if not properly secured.
Appendix:
Appendix 1. Plasma arc cutting specification
The plasma cutting machine is a state-of-the-art hot cutting equipment that uses compressed air as the working gas and the high temperature and speed of the plasma arc as the heat source. The plasma arc partially melts the metal and the high-speed air blows the molten metal to form a narrow cutting seam.
Plasma cutting can be used to cut a variety of metal materials, including stainless steel, aluminum, copper, cast iron, and carbon steel. It offers fast cutting speed, narrow cutting width, smooth cutting surface, minimum heat affected zone, minimum workpiece deformation and ease of operation. Furthermore, plasma cutting has a remarkable energy-saving effect.
Plasma cutting equipment is ideal for use in the manufacturing, installation and maintenance of various machines and for performing cutting and manufacturing tasks such as medium plate cutting, trepanning and chamfering.
Plasma cutting process parameters play a significant role in determining the stability, cutting quality and efficiency of the cutting process.
Key cutting specifications include:
1. Power cut
Increasing the cutting current can increase the plasma arc power, but this is limited by the maximum allowable current. If it is exceeded, the plasma arc column will become thicker, the cutting width will increase, and the electrode life will be reduced.
The cutting torch components must match the plasma power current setting.
The current intensity must be within 95% of the nozzle working current. For example, the current intensity for a 100 A nozzle should be set to 95 A.
2. Gas flow
Increasing the gas flow can increase the voltage of the arc column, making the plasma arc energy more concentrated and the jet force stronger. This can improve cutting speed and quality.
However, if the gas flow is too high, it will shorten the arc column and result in greater heat loss, reducing cutting capacity. In extreme cases, this may prevent the cutting process from proceeding normally.
3. Cutting nozzle height
The cutting height is the distance between the tip of the cutting nozzle and the surface of the material to be cut. Typically it is between 2-5mm.
Maintaining an adequate cutting height is essential to ensure efficient plasma arc cutting. If the cutting height is incorrect, it can result in reduced cutting efficiency and quality and even cause burns to the cutting nozzle.
The height of the cutting nozzle can be found in the plasma power supply specifications or adjusted based on cutting experience.
For drilling, the height of the cutting nozzle should be adjusted to twice the height used during normal cutting.
4. Cutting speed
The factors mentioned above directly impact the compression of the plasma arc and also affect the temperature and energy density of the plasma arc. The temperature and energy density of the plasma arc determine the cutting speed. As such, these factors are all related to cutting speed.
When ensuring cutting quality, it is important to increase the cutting speed as much as possible. This not only increases productivity, but also reduces deformation of the cut piece and the zone of thermal influence of the cut.
If the cutting speed is not adequate, the opposite effect will occur, increasing viscosity and reducing the quality of the cut.
5. Thickness and cutting process
The thickness of the steel plate has a great impact on the selection of the cutting process. Even with the same cutting torch, its piercing capacity (thickness) is only half of its cutting capacity (thickness).
For example, the recommended cutting capacity for a Hypertherm 100A plasma power is 16 mm, while its piercing capacity is 12 mm.
Therefore, when the thickness of the steel plate exceeds the drilling capacity, it is not recommended to drill it directly in the middle. Instead, the cut should start at the edge of the board and work inward.
6. Steel plate surface pretreatment
During the journey from steel production to the cutting shop, the surface of the steel sheet inevitably forms an oxide layer. In addition, the steel sheet also forms an oxide layer on its surface during the rolling process.
These oxide coatings have a high melting point and are difficult to melt, which slows down cutting speed. When heated, the oxidized coating also spatters, causing blockages in the cutting nozzle and reducing the life of the cutting nozzle and electrode.
As a result, it is necessary to carry out rust removal pre-treatment before cutting. This is typically done by removing the rust and applying conductive paint to prevent rust.
A common method is to sprinkle small iron sand on the surface of the steel plate and remove the oxidized layer with the punching force generated by the iron sand. Next, an anti-rust paint with flame retardancy and good conductivity is applied.
Rust removal and pre-treatment with spray paint before cutting steel plate have become an essential step in the production of metal structures.
