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EZ Cut CNC User Manual

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1. Aluminum 1732 ATT 9991 0 092 0 102 9 107 0 111 0 138 __ 0 080 0 078 0 075 0 080 0 090 0 095 0 100 oors 0 074 0 075 0 076 0 083 0 091 0 100 mM NE 105 A Shielded 85 A Shielded 65 A Shielded 45 A Shielded 105 A Unshielded 85 A Unshielded 65 A Unshielded 45 A Unshielded 000 J J ap ly 0 075 0 075 0 075 0 080 0 082 0088 _ 0 070 0 070 0 070 0 070 o o72 o079 0 062 0 058 0 057 foo 1 105 A Shielded Consumables Shield 220993 J Ohmic sensing Retaining Cap 220953 L Nozzle 220990 VD Electrode 220842 Swirl Ring 220994 80 105 A Shielded cutting Mild Steel e Pierce Initial Pierce Height Delay Time Metric English Material Thickness 1 2 5 8 Torch to Work Distance mm 3 2 Torch to Work Distance inches inches inches 0 25 o 00 m 0 Edge Start Edge Start 0 75 Pierce seconds 81 Air flow rate slpm scfh Hot 217 460 Best Quality Settings Cold 250 530 Production Settings Best Quality Settings Production Settings Initial Pierce Height Delay Time Cut Speed Voltage Cut Speed Voltage 0 75 146 148 82 105 A Shielded cutting Stainless Steel Metric Torch Best Quality Settings Production Settings Material M Pierce Thickness to Work Initial Pierce Height De
2. Connect using AP Atheros AR8151 PCI E Gigabit Ethemet Controller This connection uses the following items JM Client for Microsoft Networks dl QoS Packet Scheduler d File and Printer Sharing for Microsoft Networks amp Intemet Protocol Version 6 TCP IPv6 E Intemet Protocol Version 4 TCP IPv4 Link Layer Topology Discovery Mapper 1 0 Driver amp Link Layer Topology Discovery Responder XXX XX X X Tsd Descrinti Transmission Control Protocol Intemet Protocol The default wide area network protocol that provides communication across diverse interconnected networks 6 Click on L Peeeties This will open the Internet Protocol Version 4 TCP IPv4 Properties dialog 7 Click inside the circle next to Use the following IP address Internet Protocol Version 4 TCP IPv4 Properties cere You can get IP settings assigned automatically if your network supports this capability Otherwise you need to ask your network administrator for the appropriate IP settings 7 Obtain an IP address automatically Default gateway Obtain DNS server address automatically Use the following DNS server addresses Preferred DNS server Alternate DNS server Validate settings upon exit 35 36 8 Enter the IP address as 192 168 10 XX where XX is the bay number in reverse e g Bay 51 15 Use the following IP address IP address 192 168 0 15 Subnet mask Def
3. Edge Start 48 85 Air flow rate slpm scfh Pierce Best Quality Settings Production Settings Delay Time Cut Speed Voltage Cut Speed Voltage 0 0 0 0 Pierce Best Quality Settings Production Settings Delay 2 185 125 39 3m L3 H 391 1 3 39s 186 29 15 2 a 18 pm 36 2 20 5 T 4 56 1 0 3 37 22 13 10 p 4s wo 346 m oo 20 0 0 5 o 35 4 9 3 1 1 85 A Shielded cutting Stainless Steel Metric Material Toren Pierce to Work Initial Pierce Height Thickness l Delay Time Distance mm mm m 3 8 250 Edge Start Torch Thickness Delay Time Distance inches inches inches seconds 0 15 250 0 18 300 Edge Start m 1 5 86 Air flow rate slpm scfh Best Quality Settings Production Settings Best Quality Settings Production Settings as 36 28 20 18 A A p 65 80 36 28 195 30 194 20 16 19 m 36 40 8 0 4 19 14 85 A Shielded cutting Aluminum Metric Material Thickness m Torch to Work Distance Torch 0 1 0 2 0 5 0 7 1 0 T p 6 8 DES o oso 600 25 Initial Pierce Pierce Height Delay Time Cut Speed 3800 2650 Edge Start Pierce Delay Time mm seconds mimin 3 0 2 25 English to Work Initial Pierce Material Thickness Distance Height 250 z Cut Speed ipm 300 130
4. steve ezcutcnc com 810 941 7790 o Jim Delaney jim ezcutcnc com 314 614 7567 Error Codes 137 Check E Stop Find Limits Failed Machine Not Homed Out of Bounds System Interrupt XA Home System Interrupt XB Home The Emergency Stop button is pushed in The controller cannot enable motion and the motion buffer is not defined The operator has not found Machine Home The machine loses its Home position upon first boot after an Emergency Stop or after a system interruption The operator selected a location that is beyond the X Y or Z boundaries The proximity switch for the Xa axis has prematurely been tripped Something is obstructing the sensor the sensor is not getting any power or there is too much space between the proximity switch and the sensor The proximity switch for the Xb axis has prematurely been tripped Something is obstructing the sensor the sensor is not getting any power or there is too much space between the proximity switch and the sensor Pull out the Emergency Stop button and reset Machine Home Make sure the Emergency Stop is not active 1 Press okl o then press Correct the location coordinates in the system Make sure the Xa proximity switch is receiving power and is completely unobstructed Check wiring leading to proximity switch There should be a credit card s width 0 03 inches of space between the pr
5. 26GA 22GA 0 02 0 08 18GA 16GA 15 EM 0 14GA 0 12GA 0 10GA 0 3 16 0 m 1 5 1 2 4 06 93 Air flow rate slpm scfh Best Quality Settings Production Settings Cut Speed Cut Speed 0 8 3 Co as 3o 31 2 p 5 5 5 5 gt 94 45 A Shielded cutting Stainless Steel 177 1376 201 427 Torch Initial Pierce Pierce Best Quality Settings Production Settings i Delay Time to Work Height Cut Speed Voltage Cut Speed Voltage Distance mmimin eee te 12500 3 8 250 4400 Material vere Initial Pierce Pierce Production Settings iaiia G penn Delay Time Cut Speed Voltage i 3 3 3 3 2 1 Metric mm 1 5 Vos EN EN aa 95 m 39 350 1 39 0 4 o 0 7000 129 0 159 4 6 0 0 0 o 139 o 130 a 3 39 1o 152 206 3191 52 155 se 155 os 3o im s 40 pm 5 5 5 5 5 4 52 0 0 0 0 0 0 0 95 45 A Shielded cutting Aluminum Air flow rate slpm scfh Cold 201 427 Metric Torch Best Best Quality Settings Settings Production Settings Material Initial Pierce Pierce Thickness oe Height Delay Time Cut Speed Volt Cut Speed Volt Distance ut Spee oltage ut Spee oltage lt a 8250 io 196 250 a 3100 6250 os 159 iaa 28 English Torch Best Quality Settings Best Quality Settings Settings Production Settings Material Ini
6. Glitches PCB Temperature Temperature of the PCB 66 67 Directional Arrows The Directional Arrows allow the operator to move the cutting head in 45 90 135 180 225 270 315 and 360 degree increments 1 Open JobConsole 2 Click on a directional arrow to move the cutting head b Operators can park the gantry or carriage at the high and low set positions of each axis by selecting the following virtual buttons gt X axis High by clicking on Shift and X axis Up al X axis Low by clicking on Shift 4 and X axis Down Y axis High by clicking on Shift 4 and Y axis Left Y axis Low by clicking on Shift 4 and Y axis Right gt gt gt gt 68 Shift The Shift function allows the operator to access the shifted functions available on the virtual keypad 1 Open JobConsole 2 Click on 4 The arrow outline at the top of the virtual keypad will fill in t Ready A Ohnic Sensor Y Surf Ouerride Z Jog Feed Speed L Fast 3 Click on one of the virtual buttons to access the shifted features associated with that button Not all virtual buttons will have shifted features Jog Speed The Jog Speed function allows the operator to change the Jog speed from slow to medium to fast to slow again 1 Open JobConsole 2 Activate motion Kr 3 Click on Jog Speed La to change the Jog speed from slow to fast or back The speed will show in the dialog J
7. ref se Le f oe pom oae pow po e p ew raf se Lue 9e o9 oem oe poem o pem 007 MEDIA m ozs C pee or Material Thickness Gas Pressure Air Bar torch 125 Torch Initial Kerf Width Arc Voltage Working Travel Speed Piercing Pierce Delay Rec Height Height Speed 95 as INE 126 Plasma Education What is Plasma Electrode Norrie Shield Cup Cutting Gas Secondary Gas v pe INN Y aurem What is Plasma The Fourth State of Matter One common description of plasma is to describe it as the fourth state of matter We normally think of the three states of matter as solid liquid and gas For a common element water these three states are ice water and steam The difference between these states relates to their energy levels When we add energy in the form of heat to ice the ice melts and forms water When we add more energy the water vaporizes into hydrogen and oxygen in the form of steam By adding more energy to steam these gases become ionized This ionization process causes the gas to become electrically conductive This electrically conductive ionized gas is called plasma How Plasma Cuts Through Metal The plasma cutting process as used in the cutting of electrically conductive metals utilizes this electrically conductive gas to transfer energy from an electrical power source through a plasma cutting torch to the material being cut The basic plasma arc cutting sy
8. 133 Side Cover The covers on each end of the gantry protecting the X axis motor and limit switches Slag A byproduct of plasma caused by heating a material to its melting point and blowing the material away also referred to as dross Slew A non cutting movement of the system above the material at maximum speed Soft Home Position Any set home position used as the origin for executing programs Stepper Drive An amplifier that controls the action of the stepper motors Stepper Motor An axis motor that uses stepper technology Surface The topside of the material used as the Z axis reference point Swirl The motion of the gases in plasma units necessary to constrict the arc Tool Offset The distance between the center of the plasma unit and the cutting edge The Tool Offset is also the distance between the desired geometry and the center of the tool path usually the radius of the plasma unit Tool Path The path that the center of the plasma unit takes during a cut Transmission The drive system on SF series using a 4 1 belt drive pulley system to produce rotation of the pinion uCito The native language of the controller pronounced micro see tow Vector A line segment showing a particular direction or path X axis The axis that refers to the length of the table front to back X Motor Plate The plate attached to the side of the gantry in which the transmission or gearbox assemblies are bolted Y axis
9. Edit button for the Active Configuration Connection MultiCam V 204 P 2521 xs ConnectionSettings Material Library File C ProgramDatalez cut matlibs Plasma_PowerMax85_Inches xmd Import Material Library From Controller Materials Processes and Sheets Material MS 10 ga New Delete Estimator Settings Print Settings Configurations Active Configuration SampleConfig SampleConfig lt Set Active Advanced Edit Edit SampleConfig Setting File Import Settings Cut Parameter Associations Process Numbers Slew Optimization Output Format 55 Once the Output Format screen pops up locate the Post Settings section at the bottom and select the Edit button Be sure the Output File Type is set to CNC Output Formai V Output Machine Cut Parameters Use keypad tool change messages Convert feedrate to per second T Output part boundaries with ignore tools 7 Output part markers Set Home Position 1 on sheet start IL Park at Sheet Max X on sheet end Output Files amp Sheets One file per sheet type One file per sheet Surface Z 0 Material Surface Table Surface Post Settings Output File Type cnc Edit In the Program End section of the CNC Specific Settings section enter
10. This dialog appears after the system has been restarted 39 Connecting the Machine to the Computer 1 Select Start gt All Programs gt EZ Cut gt Connection Manager B Windows Live Movie Maker 1E Windows Live Photo Gallery e Windows Media Center Plasma Windows Media Player EN Windows Update Documents A XPS Viewer Li Accessories Pictures Li AMD de Catalyst Control Center J Dell Je Dell DataSafe Li EZ Cut E Connection Manager Y EZ Cut H4 EZGCodeCreator5 3 Job Console DE Job Editor ES Job Name Server Default Programs y Job Reporter Y Motion Mechanic Help and Support Music Computer Control Panel Devices and Printers 4 Back Shut down m This will open the Connection Manager dialong E Coco rg a File Add Edit View Sort Tools Help e _unassigned_ MultiCam V 204 P 2374 192 168 0 51 NETI 192 168 0 15 2 Highlight unassigned and select Add gt Selected File Edit View Sort Tools Help Auto Detect Manual Selected V 204 P 2374 19 168 0 51 NETE 192 168 0 15 3 Select at the Default Settings dialog Default Settings Select an existing connection to use to initialize the new connection s None Auto Launch Job Name Server Set prefered Neti using current Neti Cancel 4 Highlight EZCut Plasma xmi and select Open y Select XMI File for MultiCam V 204 P 2374 E een OS C ProgramData ezcut XMI Files y Search XMI
11. and Z assembly off of the proximity limit switches 3 Set Home Click on the directional arrows to place the center of the head assembly over the Home location Click on Set Home al to set Home for the head assembly 71 4 Access Job File Click on Open Job US in the toolbar locate the cut file and open the file Click on Execute from Current Sheet xt in the toolbar l Start Cancel Pause Click on Play P to begin the cutting sequence or press the yellow button at the front of the machine Click on Pause lI to yield the cutting sequence or press the yellow button at the front of the machine Click on Cancel Job to abort the cutting sequence Operators can only cancel a job using this feature when the cutting sequence is in pause mode Operators should never leave the machine unattended during the cutting sequence 72 Training Connection Manager Connection Maneger NC Eile Add Edit View Sort Took Help QoA seot Connections Machine Name Address Type On line Connected ll 1 Open Connection Manager He HdpeQH 1921680131 ByMame Ye No On Line is YES and Connected is YES Motion Mechanic amp kel Open Motion Mechanic and hit f6 to get a lt then type qc and press enter 2 Set following flash parameters exactly as they are entered in the previous qc a 9 set to table cutting size x axis b 10 set to table cutting size y axis c 261 and 262 set to 30 00 d 1091 an
12. conformance with the applicable standards e Safety critical components are replaced with unauthorized spare parts Any unauthorized assembly or accessory that uses or generates a hazardous voltage is added There is any tampering with a safety circuit or other feature that is designed into the product as part of the certification or otherwise CE marking constitutes a manufacturer s declaration of conformity to applicable European directives and standards Only those versions of Hypertherm products with a CE Marking located on or near the data plate have been tested for compliance with the European Low Voltage Directive and the European EMC Directive EMC filters needed to comply with the European EMC Directive are incorporated within versions of the power supply with a CE Marking Certificates of compliance for Hypertherm products are available from the Downloads Library on the Hypertherm web site at https www hypertherm com Differences in national standards Nations may apply different performance safety or other standards National differences in standards include but are not limited to Voltages e Plug and cord ratings Language requirements Electromagnetic compatibility requirements These differences in national or other standards may make it impossible or impractical for all certification test marks to be placed on the same version ofa product For example the CSA versions of Hypertherm s products do not comply w
13. permanently installed e Follow guidelines in Large Enclosure Handling Manual e Label must be reattached if removed for painting To get additional copies of the Large Enclosure Handling Manual or labels call 1 800 355 3560 93268001 Dwg Rev G 12 Danger Danger labels indicate the probability of death or serious injury and usually show the word DANGER in white writing against a red background These labels are normally located in areas where serious injury could occur such as the knife cartridge Pinch point Keep hands clear 13 Notices Notice labels indicate the potential for property damage and usually show the word NOTICE in white writing against a blue backdrop This label is normally located at the front of the machine NOTICE DO NOT LEAVE MACHINE UNATTENDED Safety and Compliance Manual 806690 Revision 0 English Important Read and understand all safety information before using any Hypertherm products 15 A PLASMA ARC CAN DAMAGE FROZEN PIPES Frozen pipes may be damaged or can burst if you attempt to thaw them with a plasma torch STATIC ELECTRICITY CAN DAMAGE CIRCUIT BOARDS Use proper precautions when handling printed circuit boards Grounding Safety Work cable Attach the work cable securely to the work piece or the work table with good metal to metal contact Do not connect it to the piece that will fall away when the cut is complete Work
14. 000 Jog Feed Speed Med 100 Sf be 75 1 Once PLAY to start job is displayed on the Virtual Keypad press MENU Ez Below PAUSE lll Enable Dry Run Use Z keys to change value Z 0 000 Jog Feed Speed Med 100 KE de HU MAD Aa S v alor i Use the Z buttons to change DryRun state then select OK 76 PLAY to start job CANCEL to abort MENU to toggle dry run DRYRUN 0 000 Ohnic Sensor DIS 6 866 Surf Override OFF 0 000 Jog Feed Speed Fs Hed 100 97M UL 11 DRYRUN will be highlighted Yellow in the bottom right hand corner of the Virtual Keypad Display iii Press START PF to execute the job in DryRun mode iv Once the file is complete DryRun mode will be disabled b For cutting i Click on Green Gear 25 at top to send the job to the controller i Click Play E ii After every cut be sure to click CANCEL Re Start Hit to cancel the cut and to clear the error code Move the crosshairs to the restart position Ensure the crosshairs are at the position where you had previously stopped your cut Click Execution on the menu bar at the top of the page and select Execute from Current Position ps then click Play E Hypertherm Cut Parameters Cut Parameters applicable to all materials and processes Max Voltage Gap should always be set to 50 THC Delay should always be 100 greater 0 1 greater than Pierce Delay Ifthe
15. File Edit wiew Controller Tools Window Help 8 x jDGLPRI 568 amp eg0 oeew2 Reboot Load Irit File y cod uCito M2521 U2 11a C166 16M RAM installed Chan8 262144 Chant 512 HC LE U4 46n4 FPGA H21U28 GL KN L2 KDH U h n c 2667 ETC Loading User INIT file Motion Buffer 5888 Loading Teknic Driuer from Location 18 Ho Teknic Driues found pover up home ck At For Help press F1 c Machine ConnectionsiHelper xrni 1192 168 0 69 A 59 The ConnectionManager helps in creating and configuring the connection between a host PC and the machine tool and has built in testing features for diagnosing communications issues and sending email correspondence for assistance Operators can also establish one particular computer to be in charge of all communications which is helpful if multiple computers are connected to a machine ia I File Add Edit View Sort Tools Help Z Q A E So q Connections Machine Name Address Type On line Connected Helper Helper 243 192 168 0 131 By Name LaserGantry 13002 LaserGantry 13002 192 168 0 191 By Name WaterJet Serial WaterJet Serial COM1 9600 None By Serial _No_Connection_Info_ LMC 3849 192 168 50 64 No Connection Info MC 10456 192 168 0 62 No Connection Info MC 12686 192 168 50 66 No Connection Info MC 13281 192 168 0 176 NETI 192 168 0 50 JobConsole The JobConsole program acts as the main graphical interface betw
16. M The Job Editor application allows operators to preview and edit jobs through resizing repositioning or modifying current job files in any way DE JobEditor MultiCam We File View Ted Graphics o ub E O Xt O ba M90 G90 G75 G98 P231 D 1 coo T1 G42 Goo mii G02 G03 G03 G02 G02 G02 Ifm21 X5 251529 Y9 35141 X5 273172 Y9 4248 X5 2867 Y9 50525 IEF X5 363731 Y9 4808 X5 444835 Y9 4504 X5 365645 Y9 3702 X5 251529 Y9 35141 G98 P231 DI Goo mii GO1 GO1 GO1 GO1 GO1 GO1 GO1 G03 G03 G02 G02 G03 G03 G02 GO1 G02 GO1 G03 Gol G03 4 Ready X3 825728 Y8 5657 X3 830916 Y8 74651 X3 81 1629 Y8 91821 X3 76982 Y9 08147 X3 707808 Y9 2366 X3 62773 Y9 38434 X3 531722 Y9 5251 X3 421981 Y9 6594 X2 888472 Y10 143 X2 307845 Y10 568 X1 846453 Y10 940 X1 613497 Y11 2271 X1 606655 Y11 157 X1 634481 Y10 975 X1 624401 Y10 906 X1 56055 Y10 9411 X1 11435 Y11 3130 X1 0866 Y11 33725 X0 6657 Y11 7342 I X0 63585 Y11 7560 X0 005172 Y12 106 m gt GoTo Tools Help b Translated 18 27kb Commands 464 7 UIT LRT K Loaded 18 27 kb text I EI ES Durn WoiE m GS Q amp m m amp a 6 4162 1 2434 om 57 58 MotionMechanic The MotionMechanic e application provides the operator with advanced technical control over the use and setup of the motion controller from a host PC MotionMechanic Terminal Helper 10125 Online
17. M6 48 750 122 48 4360 ma 48 286 122 4s 29 3 48 170 MBE 48 48 MX so 405 Edgestart 290 Edge Start Aluminum 60A Deflector Standard Shield Cup Maximum Life Shield Cup 118 Starter Cartridge Electrode 9 8243 9 8237 9 8210 9 8213 9 8232 Material Thickness re oc am pom MEDION va pom e ors n oso e oes Jae erm Gas Pressure Air PSI torch lead length 85 25 90 50 Torch Initial Kerf Width Arc Voltage Working Travel Speed Piercing Pierce Delay Rec Height Height Speed Lum am e 008 000 008 s em s es ow 000 vm os x os om om om em we es wm ew m os as os om om sas os so 025 om oo 119 Material Bae Pressure Torch Initial Kerf Width l l Arc Voltage Working Travel Speed Piercing Pierce Delay Rec Thickness Air Height Height Speed Bar torch lead Volts mm mm min mm sec ws 4 om Lows ea wn M0 Edge Start 4 w 23 w 24 120 Mild Steel 40A Standard Shield Cup Deflector Maximum Life Shield Cup Starter Cartridge Electrode Torch Initial Kerf Width Arc Voltage Working Travel Speed Piercing Pierce Delay Rec Height Height Speed Material Gas Pressure Thickness Air PSI torch GA in inch lead length ra ae Ce se ra ees sw of ens MEDI P we oz se
18. Material Thickness English Material Thickness inches inches inches 16GA 10GA 3 16 Torch to Work Distance Torch to Work Distance omm orp MEE EE agp Start Initial Pierce Pierce Height Delay Time ER 1 2 Edge Start 90 Air flow rate slpm scfh 209 443 Initial Pierce S us Best Best Quality Settings Settings Best Best Quality Settings _ Settings Production Settings Cut Speed Voltage Cut Speed Voltage 9 65 A Shielded cutting Aluminum Cold Metric Baz Initial Pierce Best Quality Settings Thickness Distance Height Time Voltage 121 124 m m m 2 or 39 32 pS 36 20 English Material Torch Initial Pierce Pierce Delay Best Quality Settings Production Settings to Work Thickness Time Distance Height Cut Speed Voltage CutSpeed Voltage 08 48 tes 32 m 24 1 m Lm m s 39 m a 38 m 98 34 45 A Shielded Consumables Shield 220817 J Ohmic sensing Retaining Cap 220953 LU Nozzle 220941 VD Electrode 220842 Swirl Ring 220994 92 45 A Shielded cutting Mild Steel Metric Material TOL Initial Pierce Pierce Delay to Work Thickness i Height Time Distance E m English Material Foren Initial Pierce Pierce Delay to Work Thickness i Height Time Distance inches inches inches seconds
19. Material MS 10 ga v Process mii geer v Operators can make changes to the material or process by clicking on the Set Cut Parameters tab clicking on Material Type and or Process at the bottom and making a change 4 Click Next in the toolbar at the top and then click on the Process Settings tab a Change the kerf to 0 03 The kerf 1s the width of the arc b Set the different parameters for the cut lead in lead out type of cut etc Material Type Process 1304 O2 Air Parts Kerf 0 03 Marker Lead in type Arc v Stop Short Distance 0 25 Length 1 25 S Early Tool Off Process Settings 180 ide v Early Z Track Off Lead out type Distance 0 6 Length o Roll Around Corners Angle Conventional cut 9 Climb cut Edge quality v Do straight leads when possible Start on a corner Start on a long edge Apply amp ReToolPath 5 Click Next click on the Main Settings tab and make any adjustments as necessary 49 50 Material Type Disable nest Part clearance 9 Nest Result Nest by group Sheet edge clearance 9 Use default sheet size 96 x 48 Main Settings Do material cut out at the end of each sheet Cut Out Side Sheet Library Cut Out Process Tuning Apply amp ReNest 6 Click Next and review the job file EZGCodeCreator5 Connection MultiCam 3 204 P 10267 Configuration SampleConfig ao x LACER HZH H 1 Import
20. The axis that refers to the width of the table left to right Y Carriage Plate The vertical plate behind the Z axis carriage plate where Z axis bearing rails are mounted Y Motor Plate The horizontal plate attached to the Y carriage plate where the Y axis transmission or gearbox assemblies are bolted Z axis The axis that refers to the accessible range of the area above the table Z Carriage Plate The vertical plate on the vertical moving part of the carriage assembly where the cutting tool plate is mounted 134 Z Motor Plate The horizontal plate on top of the Y carriage plate where the Z axis motor is mounted Z Speed The vertical speed of the head assembly 135 Troubleshooting amp Error Codes If an error code is displayed on the computer or on the plasma power supply please do the following Please read the error code in Job Console and or on the plasma power supply o For error codes in Job Console please refer to this user manual o Forerror codes on the plasma power supply please refer to the user manual for your plasma unit Follow the instructions for the error code displayed in Job Console or for the error code on the plasma power supply Inspect and verify the following o Cut procedures o Consumable stack O Air pressure o Drawing if you are cutting a dxf file created from another source o Cleanliness of the material being cut Please try and solve the problem yourself initially Understanding
21. ce ES gt Control Panel Network and Internet Network and Sharing Center X Search Control Panel D Control Panel Home View your basic network information and set up connections Change adapter settings T iw See full map teg Plasma PC Unidentified network Internet settings 2 This computer View your active networks Connect or disconnect Unidentified network Access type No Internet access Public network Connections Local Area Connection Change your networking settings Set up a new connection or network Set up a wireless broadband dial up ad hoc or VPN connection or set up a router or access point Connect to a network Connect or reconnect to a wireless wired dial up or VPN network connection Choose homegroup and sharing options Access files and printers located on other network computers or change sharing settings See also Troubleshoot problems Codes Diagnose and repair network problems or get troubleshooting information Internet Options Windows Firewall Organize v Local Area Connection E Unidentified network Atheros AR8151 PCI E Gigabit Eth 4 Right click on Local Area Connection and select Properties Local Area Connection Unidentified network Wy Disable Status Diagnose Wy Bridge Connections Create Shortcut Delete Wy Rename Wy Properties 5 Scroll to and highlight Internet Protocol Version 4 Bj Local Area Connection Properties
22. design location installation maintenance and use of devices and systems to vent combustion gases and pressures after any deflagration event Consult with the manufacturer or installer of any dry dust collection system for applicable requirements before you install a new dry dust collection system or make significant changes in the process or materials used with an existing dry dust collection system Consult your local Authority Having Jurisdiction AHJ to determine whether any edition of NFPA 68 has been adopted by reference in your local building codes Refer to NFPA68 for definitions and explanations of regulatory terms such as deflagration AHJ adopted by reference the Kst value deflagration index and otherterms Note 1 Hypertherm s interpretation of these new requirements is that unless a site specific evaluation has been completed to determine that all dust generated is not combustible the 2007 edition of NFPA 68 requires the use of explosion vents designed to the worst case Kst value see annex F that could be generated from dust so that the explosion vent size and type can be designed NFPA 68 does not specifically identify plasma cutting or other thermal cutting processes as requiring deflagration venting systems but it does apply these new requirements to all dry dust collection systems Note 2 Users of Hypertherm manuals should consult and comply with all applicable federal state and local laws and
23. expert prior to purchasing installing and operating the equipment 26 Maintenance amp Warranty Hints and Tips The EZ Cut has a very powerful yet easy to use interface Operators who understand their systems and learn the functions can utilize their cutting systems in an efficient and productive manner The following tips complement this knowledge and can be used to the operators advantage 1 Observing Safety Safety glasses and hearing protection should be worn at all times while operating the machine and long hair should be restrained with a cap or net when near the machines Operators should never leave the machine unattended during the cutting sequence and labels should be observed at all times 2 Maintaining the Machine The EZ Cut will produce consistent accurate work as long as it is well maintained Maintenance for this system is easy yet it should not be overlooked Operators may refer to the maintenance chart for more detail All machines should be kept clean when not in use The build up of dust or slag on the system should be cleared daily with special attention focused on the gear rack and bearing rails and the filter on the electronics enclosure should be cleaned All of the bearings should be greased at least twice a month based on an 8 hour work day The bearings should be greased more often if the machine is in use more than 8 hours a day The Lead Screw Z axis should be lubricated with a non aerosol silico
24. feedrate is less than or equal to 200 ipm inches per minute Use Thin Coef should be set to 0 Ifthe feedrate is 201 1pm inches per minute or greater Use Thin Coef should be set to 1 78 79 Estimated kerf width compensation English inches Thickness inches 226A Tas 146A oca sne w 38 02 se 54 3 SCM SHO os Asrieldea ooe 0 088 0 089 0 100 0 107 0 133 es AShisided 0 068 0 071 0 073 0 078 0 090 0 095 0 100 5 AShielded Toas 0 065 0 068 0 070 0 076 0 088 0 080 0 091 45 A Shielded 0 035 0054 0055 0061 0065 00606 Fmecu oom ooe oow ocs LowSpeedFmeCut 0 026 0 030 0 027 oos 1 TT 105 A Unsnisided 9985 0 097 0 098 0 107 0 111 0 125 85 AUnsnielded ooro oors oors ooso ooss oo 45 AUnshielded 0020 0 050 0 051 0 054 0 057 Laas Stainless Steel oore 0 089 0 09 0 092 0 099 0 113 0 068 0 070 0 080 0 094 0 095 0 096 oojoo poo EE 105 A Shielded 85 A Shielded 65 A Shielded 45 A Shielded FineCut p O E TTS os 0 062 ovejo 0027 Foo 0 021 oot To e O OO NO O GC l oO O NIN Gn Ol Low Speed FineCut 65 A Unshielded 0 061 0 064 0 067 0 070 0 072 0080 45 A Unshielded 0 020 0 054 0 052 0 060 0 058 oo58 J
25. is installed Residual current devices RCDs In Australia and some other countries local codes may require the use of a Residual Current Devices RCD when portable electrical equipment is used in the workplace or at construction sites to protect operators from electrical faults in the equipment RCDs are designed to safely disconnectthe mains electrical supply when an imbalance is detected between the supply and return current there is a leakage current to earth RCDs are available with both fixed and adjustable trip currents between 6 to 40 milliamperes and a range of trip times up to 300 milliseconds selected for the equipment installation application and intended use Where RCDs are used the trip current and trip time on RCDs should be selected or adjusted high enough to avoid nuisance tripping during normal operation of the plasma cutting equipment and low enough in the extremely unlikely event of an electrical fault in the equipment to disconnect the supply before the leakage current under a fault condition can pose a life threatening electrical hazard to operators To verify that the RCDs continue to function properly over time both the trip current and the trip time should be tested periodically Portable electrical equipment and RCDs used in commercial and industrial areas in Australia and New Zealand are tested to the Australian standard AS NZS 3760 When you test the insulation of plasma cutting equipment to AS NZS 3760 measure the insulat
26. its shape cutting equipment are used in very small quantities except the coolant and are commercially available with multiple sources that can and will be replaced in the event of a supplier problem associated with REACH Registration or REACH Authorization SVHCs Proper handling and safe use of chemicals Chemical Regulations in the USA Europe and other locations require that Material Safety Data Sheets MSDS be made available for all chemicals The list of chemicals is provided by Hypertherm The MSDS are for chemicals provided with the product and other chemicals used in or on the product MSDS can be downloaded from the Downloads Library on the Hypertherm web site at https www hypertherm com On the Search screen insert MSDS in the document title and click on Search Inthe USA OSHA does not require Material Safety Data Sheets for articles such as electrodes swirl rings retaining caps nozzles shields deflectors and other solid parts of the torch Hypertherm does not manufacture or provide the materials that are cut and has no knowledge whether the fumes released from materials that are cut will pose a physical hazard or health risk Please consult with your supplier or other technical advisor if you need guidance concerning the properties of the material you will cut using a Hypertherm product Fumes emission and air quality Note The following information on air quality is intended for general information only and should
27. oars Material Thickness 121 Gas Pressure Torch Initial Kerf Width Air Arc Voltage Working Travel Speed Piercing Pierce Delay Rec Height Height Speed Bar torch lead Volts mm mm min sec length 9 15 52 152m om as s ta Min 122 Stainless Steel 40A Standard Shield Cup Maximum Life Shield Cup 9 8243 9 8237 9 8208 9 8213 9 8232 Torch Initial Kerf Width Arc Voltage Working Travel Speed Piercing Pierce Delay Rec Height Height Speed Deflector Starter Cartridge Electrode Material Gas Pressure Thickness Air PSI torch GA in inch lead Volts in ipm in sec in length CE are sm wm oar re ew o es o em om ow re core m aro of ew MERC P sm oz Cp oars m ws o em zm om EEIETE pom em o res oo 123 Material Gas Pressure Torch Initial Kerf Width l l Arc Voltage Working Travel Speed Piercing Pierce Delay Rec Thickness Air Height mm sec mm 715 Bar torch lead Volts mm mm min length Edge Start 124 Aluminum 40A Standard Shield Cup Deflector Maximum Life Shield Cup Starter Cartridge Electrode Torch Initial Kerf Width Arc Voltage Working Travel Speed Piercing Pierce Delay Rec Height Height Speed Material Gas Pressure Thickness Air PSI torch GA in inch lead Volts in ipm in sec in length rao ow oe om o 00 o
28. om o9 gt P ue osos se oes me ow 9 o em on aa orso ELM oum um Torch Initial Kerf Width Working Piercing Pierce Delay Rec Height Speed Material Gas Pressure Thickness Air Bar torch lead length Height 1790 870 27 MC 390 Edge Start Edge Start 3 e lt o OD po D D G G Co ND 106 Stainless Steel 100A Standard Shield Cup Maximum Life Shield Cup a 821 E Material Gas Pressure Torch Initial Kerf Width Arc Voltage Working Travel Speed Piercing Pierce Delay Rec Thickness Air l l Height Height Speed PSI torch GA in inch lead Volts in ipm in sec in length NIS uis o lla de se ome oue oss Low os s om oo om p se eme om wm 2 em 20m ow P ss ome Material Gas Pressure Torch Initial Kerf Width Arc Voltage Working Travel Speed Piercing Pierce Delay Rec Thickness Air l Height Height Speed Bar torch lead Volts mm min mm sec mm length Deflector Starter Cartridge Electrode a sr 2m 2r Aluminum 100A Standard Shield Cup Deflector Maximum Life Shield Cup 107 Starter Cartridge Electrode 9 8243 9 8237 9 8212 9 8213 9 8232 Torch Arc Voltage Working Height Material Gas Pressure Thickness Air PSI torch lead length METAN se oss 12 0500 0 625 Material Gas Pressure Thickness Air Working
29. regulations Hypertherm does not by the publication of any Hypertherm manual intend to urge action that is not in compliance with all applicable regulations and standards and this manual may never be construed as doing so 21 Introduction Hypertherm maintains a global Regulatory Management System to ensure that products comply with regulatory and environmental requirements National and local safety regulations National and Local safety regulations shall take precedence over any instructions provided with the product The product shall be imported installed operated and disposed of in accordance with national and local regulations applicable to the installed site Certification test marks Certified products are identified by one or more certification test marks from accredited testing laboratories The certification test marks are located on or near the data plate Each certification test mark means that the product and its safety critical components conform to the relevant national safety standards as reviewed and determined by that testing laboratory Hypertherm places a certification test mark on its products only after that product is manufactured with safety critical components that have been authorized by the accredited testing laboratory Once the product has left the Hypertherm factory the certification test marks are invalidated if any of the following occurs The product is modified in a manner that creates a hazard or non
30. side of the plasma unit used to remove power from the machine excluding the controller board and limit switches 131 External Halt The keypad display that appears when power is applied to the system with the Emergency Stop button pushed in on the keypad pendant Feedrate Override A Hot Key used to adjust the cutting feedrate of the system while a file is being executed Fiducial A reference mark or dot used in MultiVision that allows the CNC machine to recognize the orientation of the material and adjust the cut file accordingly Firmware The operating system of the controller that should only be loaded when instructed Firmware contains all of the low level commands and is the first level of controller software Flash RAM File A file containing all of the machine parameters of a particular plasma unit Settings such as table size and resolution are located in the Flash RAM File which is the third level of controller software Gantry The mechanical part of the plasma unit also known as the bridge which moves the head assembly from the front to the rear of the table G Code The machine code language used by the controller to execute motion commands Gearbox The drive system on Pro series that uses planetary gear reduction to produce rotation of the pinion Good Slag The slag which falls away easily and requires little effort to remove Hard Home Position The home position determined by the location of the targ
31. table Connect the work table to an earth ground in accordance with appropriate national and local electrical codes Input power Be sure to connect the power cord ground wire to the ground in the disconnect box If installation of the plasma system involves connecting the power cord to the power supply be sure to connect the power cord ground wire properly Place the power cord s ground wire on the stud first then place any other ground wires on top of the power cord ground Fasten the retaining nut tightly Tighten all electrical connections to avoid excessive heating Electrical Hazards Only trained and authorized personnel may open this equipment If the equipment is permanently connected turn it off and lock out tag out power before the enclosure is opened If power is supplied to the equipment with a cord unplug the unit before the enclosure is opened Lockable disconnects or lockable plug covers must be provided by others Wait 5 minutes after removal of power before entering the enclosure to allow stored energy to discharge If the equipment must have power when the enclosure is open for servicing arc flash explosion hazards may exist Follow ALL local requirements NFPA 70E in the USA for safe work practices and for Personal Protective Equipment when servicing energized equipment The enclosure shall be closed and the proper earth ground continuity to the enclosure verified prior to operating the equipment after moving O
32. the following into the box G00 X0 YO CNC Specific Settings Post Tools Tool Number 138 Y F Default Tool Description DrillBank Tool Change M38 Tool Activation Tool Unload M48 Tool Deactivation Program Start Sheet End Program End PERDO XO YD Press the OK button to return to the previous screen and Close on all the other open screens to return back to EZ G Code Creator Press the Save Setting icon next to the previously mention Settings icon in the upper right hand corner Now every time a new job is created the output file will have the command to return the machine to the Home position where the job started 56 Motion Controller Utilities The software was developed to provide the operator more options and to interface with the newer Windows software In addition to supporting the DNC function the software also has options for digitizing as well as JobReporter bar code scanning and tool diameter compensation These tools are all written in 32 bit code and run directly from Windows 2000 or higher Suite4 ConnectionManager JobEditor JobConsole MotionMechanic Suite4 Motion Controller Utilities Suite4 contains some additional features for standard PSS options and additional options with more advanced features Operators can access additional information on these features in C Program Files Machine Tools Suite4 JobEditor T s m
33. 000 Jog Feed Speed Fast 100 Time 00 0 ZR UNE 0 L x 0 000 LY 0 000 Feedf 636 D arc Off Qui Off Job name Ready l i i Text view 72 0159 13 1584 The icons in the toolbar allow the operator to modify the cutting file oC S S m Execute from Current Sheet Pause Job Execution Conti ontinue Job Execution Cancel Job B Show Hide Propenies 0000 PM Show Hide Too Filter The virtual keys used to operate the machine are identified below al Z Z Up IE Z Down Jog 45 Jog 360 lt Jog 90 2 Jog Speed Jog 270 b Jog 135 Jog 180 Jog 225 The Shifted virtual keys are identified below Park X Low 61 62 Z Up and Down The Z Up and Down function allows the operator to adjust the Z height of the cutting head 1 Open JobConsole P Zt K 4 2 Click on Z Up E or Z Down A a Z Up E raises the cutting head above the table while Z Down lowers the cutting head to the table Z Up Negative Direction Z Down Positive Direction x 0 000 Ohnic Sensor OFF Ohnic Sensor OFF Y 0 000 Surf Ouerride OFF Surf Ouerride OFF Z 0 050 Jog Feed Speed Fast 100 Operators can park the Z by clicking Shift Feedrate Override The Increase Decrease Feedrate function allows the operator to override the feedrate during a cutting sequence 1 Open JobConsole 2 Open a file and begin cutting 3 Click on Incr
34. 01 00 M5 o 28 025 010 oo 1a os 025 oso ot 111 Material Gas Pressure Torch Initial Kerf Width Arc Voltage Working Travel Speed Piercing Pierce Delay Rec Thickness Air l l Height Height Bar torch lead length 48 48 oom TS ws 48 5865 oons 48 ao 17 48 27es MT 48 48 48 E 8 8 8 8 8 8 8 4 8 4 8 8380 7730 4 4 4 4 4 4 4 4 1070 EN Aluminum 80A Deflector Material Thickness me 609 p ew P ee owes wem Pf ais oars wee P se osas px 0750 re oars Standard Shield Cup Maximum Life Shield Cup Gas Pressure Air PSI torch lead length 85 25 90 50 112 Starter Cartridge Electrode Torch Initial Kerf Width Arc Voltage Working Travel Speed Piercing Pierce Delay Rec Height Height Speed Ts O EC oum oem 09m w oem pom oem e om qu o wo om om om we om we em os 09 we om s es oe o ue om om ws om 113 Material Gas Pressure Torch Initial Kerf Width l i Arc Voltage Working Travel Speed Piercing Pierce Delay Rec Thickness Air Height Height Bar torch lead Volts 114 Mild Steel 60A Standard Shield Cup Maximum Life Shield Cup 9 8243 9 8237 9 8210 9 8213 9 8232 Material Gas Pressure Torch Initial Kerf Width Arc Voltage Working Travel Speed Piercing Pierce Delay Rec Thickness A
35. 1 _DEFAU E BSR File View Text Graphics GoTo Tools Help D A g y X amp OOL WOR rg G Q amp re E B ler E G98 P1020 X96 Y48 Z1 G98 P240 D1 SMS ES 1 G98 P101 D5 G98 P231 D1 G98 P240 D2 5130A O GOO T1 Tool 130A O2 Air GOO X0 565126 Y6 954 X0 957476 Y6 262 X1 027076 Y6 301 X0 887875 Y6 222 X0 957476 Y6 262 X1 077468 Y6 69 X0 405937 Y7 25 080995 Y6 207 12403 Y6 1402 17769 Y6 066C 234901 Y5 994 295434 Y5 92 35905 Y5 860 425502 Y5 797 49453 Y5 735 565869 Y5 67 639242 Y5 61 v gt Translated 6 36kb Commands 263 Loaded 6 36 kb text 5 6039 7 4525 12 Close the EZG Code dialog and return to JobConsole Execute the File 1 Open the job folder l in JobConsole and select the file Pr Rl 2 Set Home 3 Click Play E in JobConsole or press the yellow button at the front of the machine l1 96x48 ms ES 11 25 Hl EB 7 OO T T amp T P Undo Clone Delete Move IC xY Offset 10 1 ex 47 42 KI YI Z Angle 90 Rotate Factor 1 0 Scale Fip x Y Reverse Smooth Reorder T E Tool Set Speed Set Power Set Adding a Return to Home Command Open EZGCode Creator 5 Once open select the Settings icon in the upper right hand corner ampleConfig X wert Delete From the Settings pop up screen find the Configuration section towards the bottom and select the
36. 1mm inr EZ Cut CNC User Manual EZ Cut CNC User Manual Read this manual before using this product Failure to follow the instructions and safety precautions in this manual can result in serious injury or death Keep this manual in a safe location along with the schematics and mechanical drawings shown in the picture below that are included within your shipment Disclaimer Before your EZ Cut CNC Technician leaves your site upon completion of the installation and training he will secure a USB flash drive on the inside of the door to your system s control box This flash drive will contain the following documents The first QC for your system from Motion Mechanic At Show of your system for at least four cuts from the shape library in EZ G Code Creator A digital copy of the EZ Cut CNC User Manual A digital copy of your plasma power supply and torch This flash drive is solely to be used by an EZ Cut CNC technician Do not remove or add any files to the flash drive And do not remove the flash drive unless instructed to do so by your EZ Cut CNC technician Contents Customer Responsibilles Tor Sai e ea E E E E E Te Personal oei Tre TO ote Wok Ara T ais Tris td d HOPES QUIE DU rt psec o E i t OU e EE E PE MEM E E E EE A Power oye cb LAMM ni Taco ac a IE e NER A E EE A uo A II A CAU a E E N Wa r E A E eee ee ee eee eee eee l Dan OT MEE UU E Tm l TN OLN CS NR PES l Hypertherm Safety amp Compliance rai i
37. 50 38 15 0 5 0 18 300 Edge Start 25 20 1 14 Best Quality Settings Best Quality Settings 87 Air flow rate slpm scfh Hot Cold 194 412 236 500 Production Settings Voltage Volts 122 123 126 130 132 134 139 143 146 Production Settings 121 Voltage Volts 122 127 132 135 139 142 4 146 Cut Speed 3 172 104 121 JJ pm 60 48 37 29 20 65 A Shielded Consumables Shield 220817 J Ohmic sensing Retaining Cap 220953 L Nozzle 220819 VD Electrode 220842 Swirl Ring 220994 88 89 65 A Shielded cutting Mild Steel Cold Torch Best Quality Settings Production Settings Material Initial Pierce to Work Thickness Distance Height Cut Speed Voltage Cut Speed Voltage 1100 131 1500 so 40 560 Metric 0 1 6050 124 7000 0 2 5200 125 6100 0 5 2550 127 3240 1700 129 2230 0 7 1 2 50 60 156 142 142 o2 45 70 45 CI 02 EAM 12 English Torch Best Quality Settings Production Settings Material Initial Pierce i to Work l Thickness Distance Height Cut Speed Voltage Cut Speed Voltage 2 0 ipm pm 123 1 2 0 00 2 0 26 CS 14 oz 400 20 26 9 ow EdgeStat aa Ta aa 141 143 8 15 10 1 138 dl zx O 1 1 4 8 12 8 4 8 1 NO 41 43 45 O 65 A Shielded cutting Stainless Steel Metric
38. Bar torch e mm min 2630 2080 1575 1255 e lt o OD XO D D G Initial Kerf Width Piercing i Rec Height Speed Initial Kerf Width Piercing Rec Height mm eo 108 Mild Steel 80A Standard Shield Cup Deflector Maximum Life Shield Cup Starter Cartridge Electrode Material Gas Pressure Torch Initial Kerf Width l i Arc Voltage Working Travel Speed Piercing Pierce Delay Rec Thickness Air l Height Height Speed PSI torch GA in inch lead Volts in ipm in sec in length 1 ooo A OO R IET CD n om MUN MMC NM NN ON CN aof ons _ sre 0488 we 0250 ess _ se 0375 a oso ss 0 625 a ors IA 1 too 109 Material Gas Pressure Torch Initial Kerf Width d Arc Voltage Working Travel Speed Piercing Pierce Delay Rec Thickness Air l Height Height Bar torch lead Volts length 8915 7415 5915 4095 sto EAM Stainless Steel 80A Deflector Material Gas Pressure Thickness Air PSI torch GA in inch lead length 16 0 063 mp em of ose cc aos a 0250 mle aa oso IA a oro Standard Shield Cup Maximum Life Shield Cup 110 Starter Cartridge Electrode Torch Initial Kerf Width Arc Voltage Working Travel Speed Piercing Pierce Delay Rec Height Height Speed to 019 30 025 000 000 s ow 30 025
39. Files D Organize v New folder Xx SS E Name Date modified Type BE Desktop Default xmi 11 24 2010 8 09AM XMI File Jg Downloads EZCut Plasma xmi 11 24 2010 8 08 AM XMI File Recent Places EZCut Plasma mm xmi 11 24 2010 8 08 AM XMI File A Libraries Es Documents 2 Music i Pictures B Videos E Computer amp os C e TRAVELDRIVE E m File name EZCut Plasma xmi v Machine Database xmi 5 Select L at the Connection Manager dialog Connection Manager le Eh The XMI File is missing some modules Do you wish to upload the modules from the controller and load the XMI file 41 This will populate the connection name which should match the machine name E Connection Manager File Add Edit View Sort Tools Help aorta IR as e Tae Tama MultiCam V 204 P 2374 MultiCam V 204 P 2374 192 168 0 51 By Name NETE 192 168 0 15 6 Close the dialog 7 Select Start gt All Programs gt EZ Cut gt Motion Mechanic B Windows Live Movie Maker 1E Windows Live Photo Gallery e Windows Media Center Plasma Windows Media Player Windows Update Documents A XPS Viewer de Accessories Ji AMD de Catalyst Control Center Li Dell J Dell DataSafe i Le EZ Cut Connection Manager SP EZ Cut Bla EZGCodeCreator5 3 Job Console DE Job Editor ES Job Name Server Default Programs y Job Reporter amp Motion Mechanic Help and Suppor
40. ToolPath Nest Output QGQHisacco m MN SS yen co a Ow Back Finish Part Points Start Direction Entity ToolPath Process Depth In Out Window Pan Restore Undo Distance Contour None Order Player Estimator _DefaultSheet 1 Process Numbers Slew Optimization Output Format Print Settings Main 7 Click Finish 8 Add the job name to the Output file 51 52 Generate Output Output Folder Job Name ee Notes n C Disable further preprocessing of the output file Open outputfile in JobEditor v Print Time Estimate o Work Order O Sheet Layout 9 Click on the Browse button lad at the end of the text box next to Output Folder select the folder in which the DXF should be saved and click OK Browse For Folder Output Folder Desktop My Documents Y bmarsh on ENG13 T e My Network Places omm 5 Infrequently Used 3 54 Installer CD 8 13 10 3 sites The folder name will be listed in the dialog Generate Output Output Folder Graphics Job Name Graphic Notes Disable further preprocessing of the output file Open outputfile in JobEditar Print Time Estimate Work Order C Sheet Layout Cost Estimate 10 Click on 11 Review the file in preview and make any changes as needed Close I JobEditor MultiCam 3 204 P 10267 C DOCUMENTS AND SETTINGS BMARSH MUL TICAM OOO WESKTOP GRAPHICS GRAPHIC
41. and their work areas at the point of operation as all EZ Cut machines have been designed and constructed to operate under specific parameters relating to the particular application As a result ANSI B 11 Safety Standards states that It shall be the responsibility of the end user buyer to provide and ensure the use of a guard guarding device awareness barrier awareness device or shield in order to maintain the required level of protection EZ Cut has available certain safety shields and guards applicable to our machines Please contact our office for styles types and prices Personal Safety Precautions WF All customers should become familiar with all aspects of their machines Any person who operates or does any maintenance on this equipment should be aware that safety procedures are an important part of the daily job Customers and related personnel should learn how the equipment functions and be able to respect the capabilities of the machinery Anyone working on or around the equipment should understand the potential losses associated with mishandling the machinery and its parts and be able and willing to follow all safety precautions Sudden movement loud noises horseplay etc must be avoided as such distractions may result in unsafe conditions Accidents can occur if clothing or other articles become entangled in the plasma head or other moving parts of the machines The following suggestions if followed will reduce the c
42. ault gateway 9 Click inside the subnet mask The address should auto populate 10 Set the address to 255 255 254 0 and select L J O Use the following IP address IP address 192 168 0 15 Subnet mask 255 255 254 J Default gateway 11 Close the Local Area Connection dialog and the Control Panel dialog 12 Turn on the controller Installing the Sentinel System Drive 1 Open the software file This will either be from a CD or a system loading dongle 2 Open EZ Cut S4 Installer TT E L cee REN gt Compute O J Seor KINGSTON F p 4 Ft Favorites Date modified Type Bil Desktop de EZCUT S4 INSTALLER B Downloads de Material Libraries File folder E Recent Places J MISC 1 28 2011 8 04 AM File folder de Multicam S4 INSTALLER 1 28 2011 8 02 AM File folder 4 Libraries e Shipped Machine QC files 1 28 2011 8 03 AM File folder gt 4 Documents e TEST CUT DXF FILES 1 28 2011 8 05AM File folder b B Music Le TEST SOFTWARE 1 28 2011 8 03 AM File folder gt 5 Pictures de Value Series Controller Software 1 28 2011 8 03 AM File folder gt E Videos EZCUT S4 INSTALLER Date modified 1 28 2011 8 02 AM File folder 3 Open EZ Cut Virtual Keypad mE ELO K aaa oe je i KINGSTON F EZCUT S INSTALLER y 4 Search EZCUT sa INSTALLER p Organize v Share with Burn Bode Name Date modified Type BE Desktop d EZ CUT MDI Keys 3 14 200119 26 AM File folder d Down
43. bglib 2 0 0 dll 2 libgthread 2 0 0 dll EY MachineParameters4 E MachineParameters4 2 MachineTools Date modified 1 5 2010 11 05 AM 3 29 2011 11 36 AM 5 10 2007 12 32 PM 8 1 2005 9 57 PM 1 10 2006 2 41 PM 1 1 2007 12 00 AM 9 17 2010 3 10 PM 1 1 2007 12 00 AM 3 11 2011 6 33 AM 45 x Search EZ Cut DW Type Si Application Application Application extens Application extens Application extens Compiled HTML Application Compiled HTML SE MachineTools E MachineToolsSuite4 EL MachineUpdate4 E MachineUpdate4 LRA 1 1 1 2007 12 00 AM 1 1 2007 12 00 AM 5 6 2010 2 44 PM Application Compiled HTML Compiled HTML Application e TRAVELDRIVE E i File name MachineTools 9 Click open v The icon will E Li be added to the Add Edit Category dialog 10 Select the icon and click Populating Machine Tools 1 Select Start gt All programs gt EZ Cut and highlight one of the following programs EZGCodeCreator5 Job Console Job Editor Motion Mechanic DAL B Windows Live Movie Maker Y 1E Windows Live Photo Gallery e Windows Media Center Plasma Windows Media Player a Windows Update Documents lt A XPS Viewer de Accessories Ji AMD de Catalyst Control Center Li Dell Li Dell DataSafe Li EZ Cut Connection Manager Y EZ Cut Ha EZGCodeCreator5 Z Job Console UE Job Editor E Job Name Server Default Programs y Job Reporter a
44. circuit VIPERA voltage and the gas flow to the torch see Figure 2 2 280 Volts DC Open circuit voltage can be measured from the electrode to the nozzle Notice that the nozzle is connected to positive in the power supply through a resistor and a relay pilot arc relay while the metal to be cut work piece is connected directly to positive Gas flows through the nozzle and exits out the orifice There is no arc at this time as there is no current path for the DC voltage 2 After the gas flow stabilizes the high frequency circuit is activated The high frequency breaks down between the electrode and nozzle inside the torch in x Pise such a way that the gas must pass through this arc before exiting the nozzle Energy transferred from P High Frequency 5 10KV 2MHz the high frequency arc to the gas causes the gas to become ionized therefore electrically conductive This electrically conductive gas creates a current path between the electrode and the nozzle and a resulting plasma arc 1s formed The flow of the gas forces this arc through the nozzle orifice creating a pilot arc 3 Assuming that the nozzle is within close proximity to the work piece the pilot arc will attach to the Work piece as the current path to positive at the power supply is not restricted by a resistance as the positive nozzle connection is Current flow to the Work piece 1s sensed electronically at the power supply As this current f
45. d 1092 set to 60 00 3 After the qc is complete hit CTRL A then CTRL C and paste contents into Notepad document and save it to your desktop 4 To view all cut parameters hit f6 to get a lt then type show and press enter To reboot the software to its default settings hit f6 to get a lt then type cold and press enter 6 CAUTION Do not change any variables in Motion Mechanic unless you are instructed to do so by a representative of EZ Cut CNC If you change parameters in Motion Mechanic YOU ARE RESPONSIBLE GN EZ G Code Creator e 1 IMPORT is first page of Creator Import Material MS 10 ga Process 85A SHLD File Shape Recent a Set material type and process b Go to Files and select file you are going to cut File Quantity Animals 1 74 dxf 1 c Setquantity d Click NEXT 2 TOOL PATH is second page of Creator a Set Kerf from plasma cutter operating manual set Lead In type amp angle Set Lead Out only on material thicker than 0 5 Stop Short if cutting large quantity of smaller parts Early Tool Off Early Z Track Off wo GP Q 73 Roll Around Corners Always check Do straight leads when possible Always check Start on a corner Only check Start on a long edge when application is appropriate Machine Cut Parameters worm Open Machine Cut Parameters Show Advanced Parameters i Set Feedrate ii Set Cut Height 11 Se
46. d local codes Inspect the input power cord frequently for damage or cracking of the cover Replace a damaged power cord immediately Bare wiring can kill Inspect and replace any worn or damaged torch leads Do not pick up the work piece including the waste cutoff while you cut Leave the work piece in place or on the workbench with the work cable attached during the cutting process Before checking cleaning or changing torch parts disconnectthe main power or unplug the power supply Never bypass or shortcut the safety interlocks Before removing any power supply or system enclosure cover disconnect electrical input power Wait 5 minutes after disconnecting the main power to allow capacitors to discharge Never operate the plasma system unless the power supply covers are in place Exposed power supply connections present a severe electrical hazard When making input connections attach proper grounding conductor first Each Hypertherm plasma system is designed to be used only with specific Hypertherm torches Do not substitute other torches which could overheat and present a safety hazard Fire prevention Be sure the area is safe before doing any cutting Keep a fire extinguisher nearby Remove all flammables within 35 feet 10 m of the cutting area Quench hot metal or allow it to cool before handling or before letting it touch combustible materials Never cut containers with potentially flammable materials
47. e inches seconds 325 325 325 0 1 325 0 08 400 325 240 0 4 5 06 7 m 0 Low Speed FineCut Mild Steel Metric Material Torch E bia Current to Work Thickness Distance os 3 40 1 5 45 English Torch Thickness Distance O 26GA 24GA 30 22GA 20GA 18GA 40 5 16GA 14GA 12GA 4 10GA Not a dross free cut 99 Air flow rate slpm scfh Pierce Delay Initial Pierce Height Time Cut Speed Voltage mm seconds mmiminy Vols 2 2 5 150 1900 Initial Pierce Height P erce Delay Time Cut Speed Voltage 0 1 0 2 0 4 0 5 KA 100 Low Speed FineCut Stainless Steel Air flow rate slpm scfh 181 364 191 404 Metric Torch Recommended Material Pierce Delay Thick Current to Work Initial Pierce Height Ti IcKness Distance Ime Cut Speed Voltage L seconds immimin 7 0 5 2 0 400 0 4 45 Torch Recommended Material Pierce Delay Thickness Current to Work Initial Pierce Height Time Distance Cut Speed Voltage NENNEN seconds ipm A m 26GA 150 69 24GA 150 69 30 22GA T 150 69 20GA 150 69 esa 4o 69 0 4 14GA 69 126A 8 45 10GA os 75 101 Thermal Dynamics Cut Parameters The consumables shown do not include the Ohmic clip You will need to order the Ohmic clip part number 9 8259 along with the other consumables 102 Mild St
48. e daily and weekly cleaning for the EZ Cut Once the racks are clean operators should apply a bead of the lithium based grease 3l Quarterly The X and Y axes covers should be removed from the EZ Cut every three months so that operators can inspect the transmission or gearboxes for wear Operators can engage the pinion all the way into the rack by loosening the mounting bolts of the transmission or gearbox and pushing the assembly up The tabletop bolts should be checked to ensure they are all tight Bi Annually The electrical cabinet should be checked during the bi annual maintenance performed on the EZ Cut Operators should lockout incoming power before opening the cabinet and then vacuum out any debris that may have entered the cabinet during regular working conditions Operators should not use compressed air when cleaning out the cabinet as this action may cause unwanted particles to short out some of the electrical components The belts on all transmissions and Lead Screw Z nuts must be replaced every other year 32 Machine Hardware Torch Installation When installing the machine torch make sure there is enough slack in the cable for the torch to move without straining the torch Also at its lowest point the torch should come no more than 1 2 below the top of the table slats This will help prolong the life of your consumables by allowing adequate space from the cutting surface of the material Securing the Computer Mon
49. e eee ee 6 Y 6 Play Pause and SOD ste ord tnu ves tomi ete en use tease ane UD MMC ER te a 7 ASA P o A A 7 EAE snra EATE etat teen naires uenientem qua E R aad E a rette tacts 7 Conneccion Mahdi CH ssiri dd dean Os eee 7 Moton Mecha dd a A A eee 7 BZGOCode GredtOEuon vente a Mu el MM eo ee ee 7 sn O 0 In ENS 7 Eypertherm Shielded Cut Parameters iS A A ln 7 Thermal Dynamics shielded C ut Paramelets 222 diia 10 Plasma UC A 011 MAA Oe ooo o E OO O E LLL MUSIC M D P ILL eee Led 12 WAS PES a 12 Whatis Plasma The Fourth C e d E iii 12 How Pasma Cuts Tirone a Metak cormier ttbi dee ub OM ee wes tubum desire wees 12 sequence of CPS aris a Plasma C UIT uso es o etre tU o vs o 12 NVanatons ol tie Plasma Cutting POCOS yerepe rei AAA UM 12 TOSS ABV a C as ewe asec ooo eee cee CORRER 13 Troubleshooting amp Error COGS uua wavarsdnwsdadaadavasseeetiadacs e qeu nca ax coda ea wawatiaiads adea uut dad tuu AEE Nat 13 A T T EN 13 Fome wo QUE SUL REN TER RO TORNO Er 14 Customer Responsibilities for Safety As the user of the EZ Cut each customer must follow all safety procedures that are clearly outlined when operating each machine and its parts Failure to do so may result in damage to property or personnel and could even result in death These machines are powerful and should always be treated with care Customers should make plans for safeguarding themselves
50. ease Feedrate L lor Decrease Feedrate L to change the feedrate during a cutting file The percentage increased or decreased will be shown on the virtual keypad Z 0 050 Jog Feed Speed Fast 100 Feedrat amp at 100 diu 75 63 f the Automatic Torch Height Control ATHC is active then the virtual Feedrate Override buttons will be grayed out No feedrate override is possible if the ATHC is on Operators may check Main Menu gt Settings to determine the status of the ATHC Go Home The Go Home function allows the operator to move the cutting head to the last set Home location 1 Open JobConsole ole 2 Click on Go Home L9 The cutting head will move to the last set Home location H K Operators can access the Find Home function by pressing Shift and Go Home 12 This locates the 0 0 and should be selected after the machine is powered up Finding Home will orient the cutting head to the proper starting position 1 Open JobConsole d e 2 Click on Find Home 2 The cutting head will find 0 0 and then move to the last set Home location t Finding Hone 64 Pause The Pause function allows the operator to temporarily halt the cutting sequence This virtual button works in conjunction with the Pause Play button at the front of the machine 1 Open JobConsole 2 Open and run a cutting sequence 3 Click on Pause The cutting sequence will stop and the following text will be visible on the v
51. ec Thickness Air Height Bar torch lead Volts mm length Height Speed 140 48 4800 tao 48 3520 Mo 48 2410 te 48 1860 mm min 3 3 sec y lt D e oO D D o Edge Start Edge Start Edge Start 104 Aluminum 120A Shield Cap Maximum Life Shield Cup Starter Cartridge Electrode Torch Initial Kerf Width Arc Voltage Working Travel Speed Piercing Pierce Delay Rec Height Height Speed PSI torch GA in inch lead Volts in ipm in sec in length AZAR as oars p we os een we om o om om on seems aun c es s ws ow om a orso oum os s eson on os ree m am m esen on Material Gas Pressure Torch Initial Kerf Width Arc Voltage Working Travel Speed Piercing Pierce Delay Rec Thickness Air Height Height Speed Bar torch lead Volts mm min sec Material Gas Pressure Thickness Air 2100 75 35 23 in 845 148 158 164 140 141 143 147 159 164 105 Mild Steel 100A Standard Shield Cup Deflector Starter Cartridge Electrode Maximum Life Shield Cup 9 8243 9 8237 9 8212 9 8213 9 8232 Kerf Width Material Gas Pressure Torch Initial Thickness Air Arc Voltage Working Piercing Pierce Delay Rec Height Height Speed PSI torch GA in inch lead Volts in ipm in sec in length MATAME o ore 3 020 010 008 s oars w em 1 om
52. ed to lead in some paints cadmium in some paints and fillers and beryllium Gases produced by plasma cutting vary based on the material to be cut and the method of cutting but may include ozone oxides of nitrogen hexavalent chromium hydrogen and other substances if such are contained in or released by the material being cut Caution should be taken to minimize exposure to fumes produced by any industrial process Depending upon the chemical composition and concentration of the fumes as well as other factors such as ventilation there may be arisk of physical illness such as birth defects or cancer It is the responsibility of the equipment and site owner to test the air quality in the area where the equipment is used and to ensure that the air quality in the workplace meets all local and national standards and regulations The air quality level in any relevant workplace depends on site specific variables such as o Table design wet dry underwater Material composition surface finish and composition of coatings Volume of material removed Duration of cutting or gouging Size air volume ventilation and filtration of the work area Personal protective equipment Number of welding and cutting systems in operation o Other site processes that may produce fumes Ifthe wor kplace must conform to national or local regulations only monitoring or testing done at the site can determine whether the site is above or below allowable lev
53. eel 120A Shield Cap Maximum Life Shield Cup Starter Cartridge Electrode Material Caspar Torch Initial Kerf Width l i Arc Voltage Working Travel Speed Piercing Pierce Delay Rec Thickness Air l l Height Height Speed PSI torch GA in inch lead Volts in ipm in sec in length 4 4 0 250 139 01425 160 020 020 01 Tae oars Pf a oso se osas a orso pm oars r roo pra ram C pena tse Material Gas Pressure Thickness Air 0 175 Edge Start 0 14 0 175 Edge Start 0 17 0 175 Edge Start 0 15 Torch Initial Kerf Width Piercing Pierce Delay Rec Height Speed o Working Height Arc Voltage Bar torch lead length Volts 3 B A KR RY O llel e sec 9 4270 0 20 2 Co 3070 2120 2 8 1355 Edge Start Edge Start Edge Start Edge Start Q2 e lt o OD D D G 4 45 Stainless Steel 120A Shield Cap Maximum Life Shield Cup Starter Cartridge Electrode 9 8256 9 8237 9 8233 9 8213 9 8232 103 Material Gas Pressure Torch Initial Kerf Width Thickness Air Arc Voltage Working Piercing Pierce Delay Rec Height Height Speed e TE m em me GA in inch lead Volts in ipm in sec in length Lo 0250 in 36 0375 m EE RN EM NE NGC V2 oso BELGES N CEN RN ANT RUE HER NN Material Gas Pressure Torch Initial Kerf Width l Arc Voltage Working Piercing Pierce Delay R
54. een a machine tool and the operator allowing the operator to preview and execute jobs as well as monitor the job progress pause and resume the job move to a specific point in the job and move through the job a single cut at a time z H Mio Ey I DRAA Euir mio TRR amp aSa amp m Es le M90 G90 G75 G98 P231 D 1 eo S o GOO X26 637585 M G03 X26 659836 G03 X26 553804 G02 X26 512886 G03 X26 48748 Y G03 X26 469435 G03 X26 383036 G03 X26 169897 G01 X26 162651 G01 x26 154922 G01 X26 146736 G02 X26 022886 G01 X26 005236 G02 X25 898676 G03 X25 825184 G03 X25 75808 Y G03 X25 747135 G02 X25 876606 G02 X25 864435 G02 X25 831804 G03 X25 728878 G03 X25 654823 G02 X25 462736 G03 X25 568949 G03 X25 496723 G02 X25 506836 G02 X25 75799 Y G03 X25 822065 G03 X25 812372 G02 X25 844418 _ Driveway Toppers 1 1 dxf 60 Virtual Keypad The MultiCam JobConsole Virtual Keypad allows the operator to establish Home override the feedrate check the machine information move the cutting head and start cutting from the computer screen The motion of the machine and the cut file are both represented on the computer in JobConsole PB jobConsole MultiCam V 103 P 2135 Online l ESI File Execution Text Graphics GoTo Tools Help lt D pS 0 E E amp Q amp f S Ready x 0 000 Ohnic Sensor DIS Y 0 000 Surf Override OFF Z 0
55. els To reduce the risk of exposure to fumes o Remove all coatings and solvents from the metal before cutting o Use local exhaust ventilation to remove fumes from the air o Donotinhale fumes Wear an air supplied respirator when cutting any metal coated with containing or suspected to contain toxic elements Assure that thoseusing welding or cutting equipment as well as air supplied respiration devices are qualified and trained in the proper use of such equipment Never cut containers with potentially toxic materials inside Empty and properly clean the container first Monitor or test the air quality at the site as needed Consult with a local expert to implement a site plan to ensure safe air quality 19 ARC RAYS CAN BURN EYES AND SKIN Eye protection Plasma arc rays produce intense visible and invisible ultraviolet and infrared rays that can burn eyes and skin Use eye protection in accordance with applicable national and local codes Wear eye protection safety glasses or goggles with side shields anda welding helmet with appropriate lens shading to protect your eyes from the arc s ultraviolet and infrared rays Skin protection Wear protective clothing to protect against burns caused by ultraviolet light sparks and hot metal Gauntlet gloves safety shoes and hat Flame retardant clothing to cover all exposed areas Cuff less trousers to prevent entry of sparks and slag o Remove any combustibles such as bu
56. ets and limit switches typically at the front right side of the table Head A reference to the particular cutting tool i e Spindle Plasma torch Laser or Oxyacetylene torch Head Mode A designation for multiple head machines either All or Auto Heat Affection The heat treatment of the edge that is caused by the intense heat created by plasma Height Offset An externally selected deviation either above or below the set point Hot Keys The one touch keys on the keypad that perform controller functions HPGL The machine code language that the system executes as a file Init File The second level controller software that contains high level commands Kerf The width of the cut Keypad The part of the pendant with the grid of Hot Keys 132 Lift Height The Z axis distance between the bottom of the plasma unit and the material The Lift Height is also the location of the head assembly during a slew move Light Curtain A boundary around the machine created by parallel infrared light beams that stops the cutting sequence once an object or person crosses the beams Machine Parameters Menu A tool of the Productivity Software Suite that allows the flash RAM file to be modified Menu System The commands that are not assigned to Hot Keys Node A computer or device that is connected to a Class C or Private network which is common in most businesses Operator Station The stand alone board separate from the mac
57. excessive noise can damage hearing Always wear proper ear protection when cutting or gouging unless sound pressure level measurements taken at the installed site have verified personal hearing protection is not necessary per relevant international regional and local codes Significant noise reduction can be obtained by adding simple engineering controls to cutting tables such as barriers or curtains positioned between the plasma arc and the workstation and or locating the workstation away from the plasma arc Implement administrative controls in the workplace to restrict access limit operator exposure time screen off noisy working areas and or take measures to reduce reverberation in working areas by putting up noise absorbers Use ear protectors if the noise is disruptive or if there 1s a risk of hearing damage after all other engineering and administrative controls have been implemented If hearing protection is required wear only approved personal protective devices such as ear muffs or ear plugs with a noise reduction rating appropriate for the situation Warn others in the area of possible noise hazards In addition ear protection can prevent hot splatter from entering the ear DRY DUST COLLECTION INFORMATION At some sites dry dust can represent a potential explosion hazard The U S National Fire Protection Association s 2007 edition of NFPA standard 68 Explosion Protection by Deflagration Venting provides requirements for the
58. g Car The bearing on which an axis moves along a rail also known as a bearing truck There are two bearing cars for each rail Bearing Rail The rail on which the bearing cars ride There are 2 rails for each axis Bevel The angularity between the material surface and the cut edge Bite Size The depth of each pass used in multipass Climb Cut A direction the plasma unit moves along a cut to produce a climbing motion For a closed contour the climb cut is clockwise on the outside of the cut and counter clockwise on the inside of the cut Consumables The components that are used up in the cutting process Conventional Cut The opposite cut of a climb cut or closed counter clockwise on the outside of the cut and clockwise on the inside of the cut Cross over Cable The type of Ethernet connection that is directly connected to the computer Cut Height The Cut Height function is used to indicate the distance the cutting tip is above the surface of the material on a cutting move Cut Speed A Hot Key function that sets the speed of the cut Dross A byproduct of plasma caused by heating a material to its melting point and blowing that material away also referred to as slag Dry Run A controller function that will execute a file with no Z axis movement Dry Run is used to show the operator where the tool will go during the cutting sequence Emergency Stop The red mushroom button located on the screen as well as on the
59. hance of having these types of accidents 1 Wear approved eye and hearing protection at all times when operating the plasma system 2 Restrain long hair with a cap or net when near the machines 3 Avoid wearing neckties and scarves during machine operation 4 Avoid wearing loose fitting clothing during machine operation 5 Avoid wearing hanging jewelry during machine operation 6 Wear cloth or lint free gloves only when handling sharp or hot parts 7 Avoid operating this and any other equipment if affected by alcohol drugs or any other substance or condition that may decrease judgment or alertness 8 Observe and follow all safety signs on the machine and in the surrounding areas 9 Avoid placing hands on the tabletop when the head assembly is turned on 10 Lock out the incoming power supply when any type of maintenance or other work is being performed on the machine Work Area Safety Fire extinguishers should always be readily accessible and operators should always familiarize themselves with the fire prevention recommendations for each component of the CNC system It is important to always keep the work area clean and uncluttered Oil debris or water on the floor can cause unsafe conditions Customers should be sure that all work areas are free of hazardous obstructions and that all tools and other equipment are returned to their proper storage place when not in use Operators should never leave the machine unattended during
60. hine and keypad that allows the operator to turn on auxiliary systems or access dual systems if applicable Park The function used in all 3 axes to place the head assembly at the farthest point away from the material for loading and unloading Patch Cable The type of Ethernet connection that is connected to the computer through a networking component such as a hub switch or router Pause The yellow button on the keypad that puts the controller into Pause mode where action 1s momentarily stopped and can be restarted at the keypad Pendant The control module consisting of the keypad and mechanical inputs Plasma The fourth state of matter or superheated ionized gas used to cut ferrous materials Programmable Soft Home The 9 possible home positions that the operator can store to be recalled at a later time Proximity Restart The controller function that allows the operator to restart a file along any cut move after an interruption such as power outage or tool breakage Rack and Pinion A system of transferring movement from the rotation of the motors to the linear movement of the system by way of gears Self Test A controller function that allows the system to test itself The self test is accessed from the menu system Serial Cable The RS232 cable used to transfer data from the host PC to the controller Servo Drive The Servo amplifier used to move the servo motors Servo Motor The axis motor on a servo system
61. how to solve these issues will you give you a greater understanding of your machine and its capabilities Write down the steps you have taken to try and resolve the issue o Make sure to write these steps down in the same sequence that you applied them and please be very detailed Jf you are unable to remove an error code do the following o Turn offthe controller and let the drives disengage o Turn the controller back on Ifthe problem continues o Turn offthe computer controller and plasma power supply o Turn the computer controller and plasma power supply back on o Open Connection Manager and establish a connection by opening Motion Mechanic o Type f6 for lt type in cold and then press enter to reboot the software Ifyou have cancel a cut before its completion in order to clear an error o Hit Y to cancel the cut Clear the error code by following the steps covered in the previous sections o In Job Console move the crosshairs to the restart position Zoom in to see the contour better o Ensure the crosshairs are at the position where you had previously stopped your cut 136 o Click Execution on the menu bar at the top of the page and select Execute from Current Position QZ o Click Play E Ifyou are still running into problems please contact a representative from EZ Cut CNC Please make sure to have your notes on hand to expedite the process o Kevin Saffa kevin g ezcutenc com 314 303 2038 o Steve Dinsmore
62. inside they must be emptied and properly cleaned first Ventilate potentially flammable atmospheres before cutting When cutting with oxygen as the plasma gas an exhaust ventilation system is required Explosion Prevention Do not use the plasma system if explosive dust or vapors may be present Do not use pressurized cylinders pipes or any other closed container Do not cut containers that have held combustible materials WARNING Explosion Hazard Argon Hydrogen and Methane Hydrogen and methane are flammable gases that present an explosion hazard Keep flames away from cylinders and hoses that contain methane or hydrogen mixtures Keep flames and sparks away from the torch when using methane or argon hydrogen plasma WARNING Explosion Hazard Underwater Cutting with Fuel Gases Do not cut under water with fuel gases containing hydrogen Cutting under water with fuel gases containing hydrogen can result in an explosive condition that can detonate during plasma cutting operations WARNING Hydrogen Detonation with Aluminum Cutting Do not cut aluminum underwater or with water touching the underside of the aluminum Cutting aluminum underwater or with the watertouching the underside ofthe aluminum can result in an explosive condition that can detonate during plasma cutting operations 17 18 Compressed Gas Equipment Safety Never lubricate cylinder valves or regulators with oil or grease Use only cor
63. ion resistance according to Appendix B of the standard at 250 VDC with the power switch in the ON position to verify proper testing and to avoid the false failure of the leakage current test False failures are possible because the metal oxide varistors MOV s and electromagnetic compatibility EMC filters used to reduce emissions and protect the equipment from power surges may conduct up to 10 milliamperes leakage current to earth under normal conditions If you have any questions regarding the application or interpretation of any IEC standards described here you are required to consult with an appropriate legal or other advisor familiar with the International Electrotechnical standards and shall not rely on Hypertherm in any respect regarding the interpretation or application of such standards 23 Higher level systems When a system integrator adds additional equipment such as cutting tables motor drives motion controllers or robots to a Hypertherm plasma cutting system the combined system may be considered a higher level system A higher level system with hazardous moving parts may constitute industrial machinery or robotic equipment in which case the OEM or end use customer may be subjectto additional regulations and standards than those relevant to the plasma cutting system as manufactured by Hypertherm It is the responsibility of the end use customer and the OEM to perform a risk assessment for the higher level system and to provide
64. ir l Height Height Speed PSI torch GA in inch lead Volts in ipm in sec in length a oos n o o oe fans oe asos pw zs m ws e ws ew 0 90 50 aa os f a om so ot oso om 12 oso 132 o 26 0149 075 040 Deflector Starter Cartridge Electrode Material Thickness 115 eee Torch ranar Initial Kerf Width Air Arc Voltage Working Travel Speed Piercing Pierce Delay Rec Height Height Speed Se oe ee ww do lead Volts mm mm min mm sec mm length nus 48 7540 a8 9 21 MX 24 32 6 4 ms 116 Stainless Steel 60A Standard Shield Cup Deflector Maximum Life Shield Cup Starter Cartridge Electrode Material Gas Pressure Torch Initial Kerf Width l Arc Voltage Working Travel Speed Piercing Pierce Delay Rec Thickness Air l Height Height Speed PSI torch GA in inch lead Volts in ipm in sec in length s 655 Ls e 260 020 000 995 raf ems om e we Pao owe sen 2 om o om om om pi oz sas 9m em os sm ox coo P ae 0375 Lowe om w om os om aos m em s em em em IA CA 117 Material Gas Pressure Torch Initial Kerf Width l Arc Voltage Working Travel Speed Piercing Pierce Delay Rec Thickness Air Height Height Bar torch lead Volts mm min length as 48 10890
65. irtual keypad User Paused PLAY to retry or CANCEL to abort Operators may either press Play P in the JobConsole toolbar to continue the cutting sequence or Cancel iS to end the cutting sequence Set Home The Set Home function allows the operator to establish a Home location for the cutting sequence Any time the operator selects Go Home or Find Home the cutting head will reorient itself to the front right corner of the machine and then move to the Set Home location 1 Open JobConsole 2 Click on the directional arrow s needed to move the cutting head to the desired Home location a 4 3 Click on Set Home ES to set a Home location Main Menu The Main Menu function allows the operator to review the system information about the machine and make changes if needed This information can be helpful during diagnostics 1 Open JobConsole 2 Click on Main Menu 3 Review the Main Menu Main Menu Infornation Ethernet Settings 65 4 Click a directional arrow to reach the specific topic for information Only the traditional directional arrows will move the highlighted area 5 Click on OK when the specific topic for information is highlighted This information will be unique to each machine Operators can review the Settings or Ethernet Settings information under each menu item and make changes as needed from the sub menu Settings Settings Settings Auto Torch Height Control Yes Auto Torch Heigh
66. is responsible for the materials being cut as well as for safety and air quality in the workplace The end user must be aware of the potential health risks of the fumes released from the materials being cut and comply with all local regulations National and local environmental regulations National and local environmental regulations shall take precedence over any instructions contained in this manual The product shall be imported installed operated and disposed of in accordance with all national and local environmental regulations applicable to the installed site The European Environmental regulations are discussed later in The WEEE Directive The RoHS directive Hypertherm is committed to complying with all applicable laws and regulations including the European Union Restriction of Hazardous Substances RoHS Directive that restricts the use of hazardous materials in electronics products Hypertherm exceeds RoHS Directive compliance obligations on a global basis Hypertherm continues to work toward the reduction of RoHS materials in our products which are subject to the RoHS Directive except where it is widely recognized that there is no feasible alternative Declarations of ROHS Conformity have been prepared for the current CE versions of Powermax plasma cutting systems manufactured by Hypertherm There is also a RoHS mark on the Powermax CE versions below the CE Marking on the data plate of CE versions of Powermax series units ship
67. ith European EMC requirements and therefore do not have a CE marking on the data plate Countries that require CE marking or have compulsory EMC regulations must use CE versions of Hypertherm products with the CE marking on the data plate These include but are not limited to Australia New Zealand Countries in the European Union Russia It is important that the product and its certification test mark be suitable for the end use installation site When Hypertherm products are shipped to one country for export to another country the product must be configured and certified properly for the end use site 22 Safe installation and use of shape cutting equipment IEC 60974 9 titled Arc Welding Equipment Installation and use provides guidance in the safe installation and use of shape cutting equipment and the safe performance of cutting operations The requirements of national and local regulations shall be taken into consideration during installation including but not limited to grounding or protective earth connections fuses supply disconnecting device and type of supply circuit Read these instructions before installing the equipment The first and most important step 1s the safety assessment of the installation The safety assessment must be performed by an expert and determines what steps are necessary to create a safe environment and what precautions should be adopted during the actual installation and operation Pr
68. itor Once you have the computer and computer monitor connected and in place you will need to secure them to the computer stand on the Xa side of the table Drill a hole through the top of the computer stand as well as the base of the computer monitor Run a 4 bolt through the top of the drilled hole and then secure it below the computer stand with a flat washer and a nut This will secure the computer and monitor protecting them from accidentally being knocked off of the stand Tightening Gantry Bolts After you have found Machine Home turn the controller off and then remove the side covers of the gantry You will see four bolts on the bottom of the gantry Tighten each of these four bolts Repeat these steps for both the Xa and Xb sides of the gantry 33 Machine Software Setting up the Computer for the EZ Cut Operators can set up the software and other connection settings on the EZ Cut by setting up Windows setting up the IP address installing the sentinel system drive connecting the machine to the computer creating a category in the button bar and cleaning up the desktop Setting up Windows L 2 8 9 Turn on the computer Click Next Enter the name e g Plasma and click Next Click Next at the password dialog No password should be entered on the manufacturing floor Customers may choose to set up a password at a later date Click inside the checkbox to accept the license agreement fo
69. ity Seller shall not under any circumstances be liable for special indirect incidental or consequential damages regardless of the form of action whether in contract or in tort including negligence In no event will this warranty obligate Seller for any amount exceeding the price of the goods upon which liability is based Correction of non conformities in the manner and time provided herein constitutes fulfillment of Seller s obligations to Purchaser with respect to Purchaser s purchase of Seller s product The Seller shall have no liability for damages of any kind arising from the installation integration and or use of the apparatus by anyone The Buyer by the acceptance of the equipment will assume all liability for any damages which may result from its use or misuse by the buyer his employees or by others Under no circumstance will the Seller be liable for any incidental or consequential damages or other loss damage or expense of any kind including loss of profits arising in connection with the use or inability to use the products offered by the Seller This warranty is invalid if Purchaser used replacement parts accessories or software that in Seller s sole opinion impaired the safety or performance of the product This warranty supersedes all previous warranties 29 EZ Cut CNC Warranty Claim Method Purchaser will immediately notify Seller in writing upon discovering a warranty claim Operation of the product must be suspended
70. lay Time Distance y Cut Speed Voltage Cut Speed Voltage mm 499 m 3 2 os 19 148 1860 144 eo 20 125 seo 15 eo 182 English Bonis to Work Initial Pierce Height n 12 s ws e M5 105 A Shielded cutting Aluminum Metric Material Thickness Torch to Work Distance English Material Thickness inches Torch to Work Distance inches inches inches 83 Air flow rate slpm scfh Hot 217 460 Cold 250 530 Best Quality Settings Best Quality Settings Settings Le 345 Lao 19 Lm HE 660 166 Edge Star 430 173 340 175 inches TEE i Edge Start Production Settings 144 as Pierce Delay Time Cut Speed mm min 7090 5020 3280 2450 1660 1190 seconds Best Quality Settings Best Quality Settings Settings Production Settings 5 Pierce Delay Time Cut Speed Voltage as Cut Speed seconds O on 110 136 85 A Shielded Consumables Shield 220817 J Ohmic sensing Retaining Cap 220953 LU Nozzle 220816 VD Electrode 220842 Swirl Ring 220994 84 85 A Shielded cutting Mild Steel Metric Material Torch Initial Pierce to Work Thickness Height Distance mm mm mm mm i i 00 4 Edge Start Torch Material Initial Pierce to Work Thickness Height Distance inches inches inches
71. loads de EZ CUT Virtual Keypad 4 1 2018 05 AM pie folder T Recent Places Je junk 3 14 2011 9 52AM File folder Libraries Documents 4 Open Setup Hel EZCUTSA INSTA EZ CUT Virtual Keypad gt Em Search EZ CUT Virtual Keypad p Organize v Open Burn B Videos Name Date modified XMI Files 3 28 201111 22 AM File folder datal 4 6 2011 2 09PM Cabinet File datal hdr 4 6 2011 2 09PM HDR File data2 4 6 2011 2 09PM Cabinet File ikernel ex_ 7 25 2002 5 07 PM EX File Mi Computer amp 05 c ex TRAVELDRIVE E e KINGSTON F Le EZCUT S4 INST Le Material Librari Je MISC Le Multicam S4 IN Lo Shipped Machi de TEST CUT DXF Le TEST SOFTWAI i Value Series Co 4 Genesis4_4 6 1 InstallOptions 10 6 2010 12 27 PM Registration Entries layout bin 4 6 2011 2 09PM BIN File Setup 4 6 2011 2 09 PM Configuration sett setup inx 4 6 2011 2 09PM NX pile 3 Suited6Install 5f46j7 4 6 2011 5 08 PM Compressed zipp Lall Setup Date modified 4 11 2001 7 28 PM Date created 4 11 2001 7 28 PM Application Size 53 5 KB 38 5 Select at the warning Warning A Please connect the USB dongle to finish the installation 6 Move through the Install Shield Wizard following the prompts 7 Select Finish to reboot If the screen does not prompt for rebooting then the operator should manually reboot the system 8 Close the McAfee Software dialog
72. low is sensed the high frequency is disabled and the pilot arc relay is opened Gas ionization is maintained with energy from the main DC arc 4 The temperature of the plasma arc melts the metal pierces through the work piece and the high velocity gas flow removes the molten material from the bottom of the cut kerf At this time torch motion 1s initiated and the cutting process begins AAA Current Sensor Variations of the Plasma Cutting Process Conventional Plasma Cutting This process generally uses a single gas usually air or nitrogen that both cools and produces the plasma Most of these systems are rated at under 100 Amps for cutting materials under 5 8 thick Primarily used in hand held applications Dual Gas Plasma Cutting This process utilizes two gases one for the plasma and one as a shield gas The shield gas is used to shield the cut area from atmosphere producing a cleaner cut edge This is probably the most popular variation as many different gas combinations can be used to produce the best possible cut quality on a given material Water Shield Plasma Cutting This is a variation of the dual gas process where water is substituted for the shield gas It produces improved nozzle and work piece cooling along with better cut quality on stainless steel This process is for mechanized applications only Water Injection Plasma Cutting This process uses a single gas for plasma and utilizes
73. lown or vacuumed off the machine Close attention should be paid to the rack area since dust or slag build up in the rack can cause stalling problems Operators working with systems that have a Lead Screw Z axis should lubricate the screw with a non aerosol silicon based lubricant Operators should not use WD 40 on the Z axis screw for lubrication Using anything other than what is recommended will result in the premature wear of the Z axis screw With Ball Screw systems oil or lithium grease is an acceptable lubricant Make sure to wipe down the V grooves with a light lubricant such as machinist oil in order to prevent galling Weekly The EZ Cut should be cleaned thoroughly each week The filter on the control box should be vacuumed Any build up in the racks or rails should be blown out The filter or filters on the auxiliary equipment systems should be removed and cleaned All fluid levels 1f applicable in the auxiliary equipment systems should be checked and filled if needed Bi Monthly Operators should grease all the linear bearing cars at least twice a month for the EZ Cut Jogging the machine while applying slight pressure in the opposite direction will help force the grease into the bearing cars and incorporate the grease throughout all of the bearings Monthly The racks and Y and Z axes screws should be cleaned with a scrub brush and degreaser once a month following the same lubrication procedure described earlier in addition to th
74. ludes certain cautions warnings dangers and notices placed on the moving parts of the machine e g gantry carriage as well as the stationary parts e g electrical enclosure These labels are in place to encourage employees to observe safe operating practices at all times The text on these labels is almost always capitalized and presented in bold format Any auxiliary equipment e g fume extractor chiller will include vendor specific labels advising the customer of proper safety practices regarding those units as well The most common labels are identified below Cautions Caution labels indicate the potential for minor or moderate injury and are usually yellow with black writing These labels are normally placed on the gantry axis covers and any other covers that are located at the front of MA CAUTION Jl CAUTION EAS EQUIPMENT SIARTS AND STOPS AU 0 VIATICALLY l N DO NOT OPERATI ll EAR PROTECTION 10 Warnings Warning labels indicate the potential for death or serious injury and usually show the word WARNING in black writing against an orange background These labels are normally located in areas where serious injury could be sustained such as the carriage Crush nazard To avoid tip over this equipment must be securely fastened to the floor A WARNING Enclosure is TOP HEAVY Stabilize enclosure before e opening doors ACE f DO NOT remove this label until enclosure is
75. mage Files ico png jpg v 5 Open Program Files x86 Q Browse for image EP ey elk K Computer OS C Program Files 86 y 49 Organize v New folder Search Program Files x86 T E Name Date modified 6 Open EZ Cut EE Desktop d Downloads Recent Places Libraries Documents 2 Music i Pictures B Videos Computer E 05 C di Adobe Ji AMD de ATI Technologies de Bing Bar Installer Le Citrix de Common Files 4 Dell de Dell DataSafe Local Backup de eBay de EZ Cut de Internet Explorer de Java ew TRAVELDRIVE E 2 24 2011 8 14 PM 2 24 2011 8 13 PM 2 24 2011 8 12 PM 2 24 2011 8 46 PM 2 24 2011 8 15 PM 5 3 2011 3 08 PM 2 24 2011 8 52 PM 5 3 2011 3 13 PM 2 24 2011 8 21 PM 5 3 2011 3 10 PM 2 24 2011 8 25 PM 2 24 2011 8 10 PM File name 7 Change the file name type to All Files File folder File folder File folder File folder File folder File folder File folder File folder File folder File folder File folder File folder 8 Scroll down to and select the Machine Tools Application QU de K Computer K OS C gt Program Files x86 EZ Cut Browse for image Organize Fr Favorites HZ Desktop Downloads S Recent Places Libraries Es Documents a Music i Pictures Imi Videos Computer amp os C New folder 3 Name JobServerFactory de KeypadEmulator 2 libeay32 dll 2 li
76. mp Motion Mechanic Help and Support Pictures Music Games Computer Control Panel Devices and Printers 4 Back Shut down pa 2 Right click and carry 1t to the button bar 3 Drop 1t on the Machine Tools icon 4 Repeat steps 1 3 until all of the programs have been loaded under Machine Tools in the button bar 47 Cleaning Up the Desktop 1 Highlight eBay and any other icons on the desktop right click and select Delete This will remove the icons from the main desktop Open S IZArc gt Share with gt W Scan for threats Restore previous versions Ty Combine supported files in Acrobat Include in library K Send to b Cut Copy Create shortcut Delete Rename Properties 2 Right click on a category in the button bar that is not Machine Tools or Recycle and select Delete 3 Repeat step 2 for each category in the button bar excluding Machine Tools and Recycle All categories should be deleted individually 4 Right click on Internet Explorer in the bottom toolbar and select Unpin this program from taskbar Internet Explorer Unpin this program from taskbar 5 Right click on Windows Media EROR and select Unpin this E E deh eh from taskbar e Windows Media Player ESA Unpin this program from taskbar pea Q 48 6 Review the desktop There should be 2 categories in the button bar 1 e Machine Tools and Recycle the Start button and one folder o
77. n based lubricant Operators are cautioned against using the lithium grease when lubricating Lead Screws as this may lead to premature wear of the Lead Screw Ball Screws however can be lubricated with lithium grease Ea Contacting EZ Cut For Sales questions or concerns please direct all necessary email correspondence to the following address support ezcutcnc com Customers with technical questions about their EZ Cut equipment should refer to their User Manual first Any caller with questions regarding an issue that is clearly defined in the manual will be directed back to the manual by the Service Technician If the customer is unable to find the answers in the User Manual he or she may contact the local distributor If the customer still has questions he or she may contact EZ Cut by phone or email When placing a service call customers should include the model number of the EZ Cut plasma system serial number of the unit and full name of the company EZ Cut CNC St Louis Missouri Phone 888 759 7184 EZ Cut CNC 28 EZ Cut CNC Limited Warranty This limited warranty relates to parts and labor Scope of Limited Warranty EZ Cut CNC hereinafter Seller warrants to the purchaser of its products hereinafter Purchaser that the products purchased are free of defects in workmanship or material for the time specified below If Purchaser notifies Seller in writing within the time specified that the prod
78. n the left side of the taskbar and status icons and the clock with date on the far right side of the taskbar Start Up 1 Turn on the computer controller and plasma 2 Open Connection Manager 3 Open Job Console and verify in Connection Manager that both columns Online and Connected say Yes 4 Open EZ G Code Creator Set Up EZ G Code Creator 5 1 Open EZ G Code Creator 5 and click on Files next to Import Import ToolPath Nest Output Y Q L A Back Next Points Bounds Axis File Quantity HNS Lake ntity Open In Out Wil 2 Browse to the job file and click on Open Look in 3 Desktop O My Recent Documents My Documents Pr bmarsh on ENG13 My Network Places my Documents 4 bmarsh on ENG13 my Network Places ape Adobe Acrobat 8 Standard m Adobe Photoshop Elements 6 0 Er iTunes E NC GeoMate tn PDFCreator A QuickTime Player S Skype VLC media player E Yahoo Messenger 5 Infrequently Used 354 Installer CD 8 13 10 sites M engineer notice template ESB Unit Conversion Utility B GoToMeeting Quick Connect WHHTML Codes KRY aii KMT Calculator BE asercuttino AA Ie Ie Ie ABN Em CRACRAC A al ein lS ss a marketing on MultiCam File Server mfs2 iMMatCam Contact Info lt File name Graphic1 Files of type All Files Dimensions 4 46x6 26x0 Open 3 Locate the Defaults section at the bottom left Defaults
79. ning off the plate Thickness Not Found Surf Override Sensor Pause Press CANCEL to Abort Surface Block Ohmic Sensor not Released Material file is corrupt Dirty consumables Positive tip on the plasma torch reference is ground during motion surface proximity switch is engaged consumables are coming into contact with the material or torch ran into metal while the arc is on There is debris in the consumables of the plasma torch the Ohmic clip is not making contact with the torch shield 139 Delete corrupt file and create a new one Clean Change out dirty consumables Cancel cut remove amp clean consumables Check procedures and remove Lead Outs if material is less than or equal to Y thick Clean consumables ensure that Ohmic clip is wired properly and making contact with the torch shield 140 Fume Extraction A Fume Extraction system is recommended for all plasma systems so as to properly handle the fumes and particulates that result from cutting any material EZ Cut systems can be purchased with or without a fume extraction system and are compatible for use with other manufacturers fume extraction systems The plasma system can be purchased independently of the fume extraction system though the frequency of maintenance is similar for both machines and should be followed to extend the life of both the plasma system and fume extraction system The type of material being cut by the pla
80. not be used as a substitute for reviewing and implementing applicable government regulations or legal standards in the country where the cutting equipment will be installed and operated Inthe USA the National Institute for Occupational Safety and Health NIOSH Manual of Analytical Methods NM AM is a collection of methods for sampling and analyzing contaminants in workplace air Methods published by others suchas OSHA MSHA EPA ASTM ISO or commercial suppliers of sampling and analytical equipment may have advantages over NIOSH methods Forexample ASTM Practice D 4185 is a standard practice for the collection dissolution and determination of trace metals in workplace atmospheres The sensitivity detection limit and optimum working concentrations for 23 metals are listed in ASTM D 4185 An industrial hygienist should be used to determine the optimum sampling protocol considering analytical accuracy cost and optimum sample number Hypertherm uses a third party industrial hygienist to perform and interpret air quality testing results taken by air sampling equipment positioned at operator stations in Hypertherm buildings where plasma cutting tables are installed and operated Where applicable Hypertherm also uses a third party industrial hygienist to obtain air and water permits If you are not fully aware and up to date on all applicable government regulations and legal standards for the installation site you should consulta local
81. ocedures for periodic inspection and testing Where required by local national regulations IEC 60974 4 specifies test procedures for periodic inspection and after repair or maintenance to ensure electrical safety for plasma cutting power sources built in conformity with IEC 60974 1 Hypertherm performs the continuity of the protective circuit and insulation resistance tests in the factory as non operating tests The tests are performed with the power and ground connections removed Hypertherm also removes some protective devices that would cause false test results Where required by local national regulations a label shall be attached to the equipment to indicate that it has passed the tests prescribed by IEC60974 4 The repair report shall indicate the results of all tests unless an indication is made that a particular test has not been performed Qualification of test personnel Electrical safety tests for shape cutting equipment can be hazardous and shall be carried out by an expert in the field of electrical repair preferably someone also familiar with welding cutting and allied processes The safety risks to personnel and equipment when unqualified personnel are performing these tests may be much greater than the benefit of periodic inspection and testing Hypertherm recommends that only visual inspection be performed unless the electrical safety tests are specifically required by local national regulations in the country where the equipment
82. og Feed Jog Feed Jog Feed Speed Speed Speed t Slow Med Fast 69 Cancel The Cancel function allows the operator to exit a screen 1 Open JobConsole 2 Open a feature or review a setting as needed 3 Click on Cancel iS once to exit the feature and return to the previous screen or twice to return to the virtual keypad OK The OK function allows the operator to accept an input value 1 Open JobConsole 2 Make a selection from the virtual keypad al 3 Click on OK to accept the value 70 Play Pause and E Stop The Play Pause and E Stop buttons at the front of the machine allow the operator to run pause or halt a job file from the machine rather than at the computer Operators may press the E Stop button to halt all cutting and motion sequences at any point during the cutting process Operators may push the yellow button to run the job file at the beginning of the sequence or if the machine is in Pause mode Operators may push the yellow button to pause the job file while the cutting sequence is in progress Fast Start EZ Cut 1 Turn on Power Locate the power switch the round knob located on the control enclosure Rotate to the ON position Press the power button on the computer JobConsole should automatically start once the computer is turned on 2 Find Machine Hard Home ole Click on Find Home and then to find the Hard Home 0 0 or the Machine Home by indexing the gantry carriage
83. oximity switch and the sensor Make sure the Xb proximity switch is receiving power and is completely unobstructed Check wiring leading to proximity switch There should be a System Interrupt Y Home System Interrupt Z Home Waiting on Arc Enter to re try or CANCEL to Abort The proximity switch for the Y axis has prematurely been tripped Something is obstructing the sensor the sensor is not getting any power or there is too much space between the proximity switch and the Sensor The proximity switch for the Z axis has prematurely been tripped Something is obstructing the sensor the sensor is not getting any power or there is too much space between the proximity switch and the sensor Something is causing the arc to not work 138 credit card s width 0 03 inches of space between the proximity switch and the sensor Make sure the Y proximity switch is receiving power and is completely unobstructed Check wiring leading to proximity switch There should be a credit card s width 0 03 inches of space between the proximity switch and the sensor Make sure the Z proximity switch is receiving power and is completely unobstructed Check wiring leading to proximity switch There should be a credit card s width 0 03 inches of space between the proximity switch and the sensor Ensure your PSI 1s adequate Clean Change out consumables Ensure arc 19 not run
84. ped since 2006 Parts used in CSA versions of Powermax and other products manufactured by Hypertherm that are either out of scope or exempt from RoHS are continuously being converted to RoHS compliance in anticipation of future requirements Proper disposal of Hypertherm products Hypertherm plasma cutting systems likeall electronic products may contain materials or components such as printed circuit boards that cannot be discarded with ordinary waste It is your responsibility to dispose of any Hypertherm product or component part in an environmentally acceptable manner according to national and local codes Inthe United States check all federal state and local laws e Inthe European Union check the EU directives national and local laws For more information visit www hypertherm com weee nothercountries check national and local laws Consult with legal or other compliance experts when appropriate The WEEE directive On January 27 2003 the European Parliament and the Council of the European Union authorized Directive 2002 96 EC or WEEE Waste Electrical and Electronic Equipment As required by the legislation any Hypertherm product covered by the directive and sold in the EU after August 13 2005 is marked with the WEEE symbol This directive encourages and sets specific criteria for the collection handling and recycling of EEE waste Consumer and business to business wastes are treated differently all Hypertherm product
85. pening or servicing Always follow these instructions for disconnecting power before inspecting or changing torch consumable parts 16 Electric Shock can Kill Touching live electrical parts can cause a fatal shock or severe burn Operating the plasma system completes an electrical circuit between the torch and the work piece The work piece and anything touching the work piece are part of the electrical circuit Never touch the torch body work piece or the water in a water table when the plasma system is operating Electric shock prevention All Hypertherm plasma systems use high voltage in the cutting process 200 to 400 VDC are common Take the following precautions when operating this system Wear insulated gloves and boots and keep your body and clothing dry Do not stand sit or lie on or touch any wet surface when using the plasma system Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground If you must work in or near a damp area use extreme caution Provide a disconnect switch close to the power supply with properly sized fuses This switch allows the operator to turn off the power supply quickly in an emergency situation When using a water table be sure that it is correctly connected to earth ground Install and ground this equipment according to the instruction manual and in accordance with national an
86. protection against hazardous moving parts Unless the higher level system is certified when the OEM incorporates Hypertherm products into it the installation also may be subject to approval by local authorities Seek advice from legal counsel and local regulatory experts if you are uncertain about compliance External interconnecting cables between component parts of the higher level system must be suitable for contaminants and movement as required by the final end use installation site When the external interconnecting cables are subjectto oil dust water or other contaminants hard usage ratings may be required When external interconnecting cables are subjectto continuous movement constant flexing ratings may be required It is the responsibility of the end use customer or the OEM to ensure the cables are suitable for the application Since there are differences in the ratings and costs that can be required by local regulations for higher level systems it is necessary to verify that any external Interconnecting cables are suitable for the end use installation site 24 Introduction The Hypertherm Environmental Specification requires RoHS WEEE and REACH substance information to be provided by Hypertherm s suppliers Product environmental compliance does not address the indoor air quality or environmental release of fumes by the end user Any materials that are cut by the end user are not provided by Hypertherm with the product The end user
87. r Windows Click inside the checkbox to accept the license agreement to use the computer Click Next Click to use the recommended settings Set the date and time 10 Click Next 11 Select Home Network as the computer location 12 Wait for Windows to install This may take a few minutes 13 Leave the checkboxes blank and select Finish The desktop will complete its setup 14 Click Next twice 15 Click Finish Setting Up the IP Address 1 Select Start gt Control Panel This will open a dialog 2 Locate Network and Internet and select View Network Status and Tasks ec jum Sl e x E Control Panel y d v ES Search Control Panel D Adjust your computer s settings View by Category System and Security User Accounts and Family Safety Review your computer s status L Add or remove user accounts Back up your computer LS Set up parental controls for any user Find and fix problems Network and Internet Change the theme Connect to the Internet Change desktop background View network status and tasks Adjust screen resolution Choose homegroup and sharing options Hardware and Sound b Clock Language and Region View devices and printers 8 Change keyboards or other input methods Add a device Ease of Access Let Windows suggest settings Programs Optimize visual display Uninstall a program A x Appearance and Personalization 3 Select Change adapter settings in the left toolbar l
88. ras l Mane aoe S ina 2 S T a E A E A 2 SM dio Dy E EE E E EE EMI 2 Nata the TEC TT 2 Cona E PEZ CUL NIC a E 2 0080 000989 8 000 E E E E 2 PLENO Dried AE ANY e E MEM MU dE DM NE 2 FACW CNE Warranty Cana MENO aida 2 MEN creep TITO A 3 Machine m AY E e r EA S 3 IV VAC TAVIS SOINE ri T ND 3 SDE Ip E Compu r TOP ET A Uea ota 3 SAA A PR A nee eee 3 A ACA r A E R 3 OE HD ERE AE Ts aso 3 Installins the Sentinel Sy sie nd DDETVE dae 3 Comme crime mne Machine 10 tie C Orin OW CCL soso sors tete deem ume aches aes cio nea eter tef eee 4 Cre ali a Category m he BUON DP 4 Populatine Machine OS ripio 4 Al AP uo MUNI NIE NUMINE 4 viti BI A A e o O III IIA 4 se Un AM COdS ir 116 ica 4 Execute RU III te bv eeade E i 5 ACIS a Returtido Home Cormiadtu sie ome vtm ete etum HMM M mM HM NIMM P ME 5 Moton Controller UTILI S adi 5 Suited Motion Controller Ultra 5 A CO E E SI a Ree Some an a NUS E 5 Moton Mec iaa 5 Cuna WIAMAG CT AA A d ta euin ep tac cM tea val Goma A IM sown Ce lau oreo 5 nn 0 5 big A I er Rito ee en oP eae Pe Re en E PE 6 band DOV D A e a e e O CO O In a a E E DUE 6 WSC Ue AAA T const ase atone T A ases cu ETA 6 A Oy ORNS TM 6 PAUSE 6 ICM 010 8 see NE TCU 6 Ma NIE 0 10 Rape Ad 6 DitectioHal AIT OW S sets cccr cs ccsacae tios ii taci n 6 n M 6 A TR TUER NN 6 O ing Gente ae e
89. rect gas cylinders regulators hoses and fittings designed for the specific application Maintain all compressed gas equipment and associated parts in good condition Label and color code all gas hoses to identify the type of gas in each hose Consult applicable national and local codes Gas Cylinders can explode if Damaged Gas cylinders contain gas under high pressure If damaged a cylinder can explode Handle and use compressed gas cylinders in accordance with applicable national and local codes Never usea cylinder that is not upright and secured in place Keep the protective cap in place over valve except when the cylinder is in use or connected for use Never allow electrical contact between the plasma arc and a cylinder Never expose cylinders to excessive heat sparks slag or open flame Never use a hammer wrench or other tool to open a stuck cylinder valve Toxic Fumes can cause Injury or Death The plasma arc by itselfis the heat source used for cutting Accordingly although the plasma arc has not been identified as a source of toxic fumes the material being cut can be a source of toxic fumes or gases that deplete oxygen Fumes produced vary depending on the metal that is cut Metals that may release toxic fumes include but are not limited to stainless steel carbon steel zinc galvanized and copper In some cases the metal may be coated with a substance that could release toxic fumes Toxic coatings include but are not limit
90. s are considered business to business Disposal instructions for the CE versions of Powermax plasma systems can be found at www hypertherm com weee The URL is printed on the symbol only warning label for each of these CE versions Powermax series units shipped since 2006 The CSA versions of Powermax and other products manufactured by Hypertherm are either out of scope or exempt from WEEE The REACH regulation The REACH regulation 1907 2006 in force since June 1 2007 has animpact on chemicals available to the European market The REACH regulation requirements for component manufacturers states that the component shall not contain more than 0 196 by weight of the Substances of Very High Concern SVHC 25 Component manufacturers and other downstream users such as Hypertherm are obligated to obtain assurances from its suppliers that all chemicals used in or on Hypertherm products will have a European Chemical Agency ECHA registration number To provide chemical information as required by the REACH regulation Hypertherm requires suppliers to provide REACH declarations and identify any known use of REACH SVHC Any use of SVHC in amounts exceeding 0 1 w w of the parts has been eliminated The MSDS contains a full disclosure of all substances in the chemical and can be used to verify REACH SVHC compliance The lubricants sealants coolants adhesives solvents coatings and other preparations or mixtures used by Hypertherm in on for or with
91. sma system determines the type of fume extraction system most appropriate for the plasma system All operators should consult local authorities prior to installing any fume extraction system as different materials will produce specific fumes and particulates that would be better handled by certain types of fume extraction systems Operators may refer to any EZ Cut Technician for recommendations on a Fume Extraction system for their plasma system The fume extraction system must be turned on and off independently of the plasma system and no adjustments need to be made to the system once it is on Operators should refer to the OSHA guidelines for their state in regards to the proper setup of the fume extraction system recognizing that OSHA can order an investigation if they learn of any disregard for those guidelines The Fume Extraction system includes a ribbed hose for connection and operators are encouraged to purchase a hard plumbing hose to extend the efficiency of the fume extraction system All connectors can be purchased at a regular hardware store and operators should refer to the user manual provided with the fume extraction system for the proper dimensions of those connecting hoses
92. stem consists of a power supply an arc starting circuit and a torch These system components provide the electrical energy ionization capability and process control that is necessary to produce high quality highly productive cuts on a variety of different materials The power supply is a constant current DC power source The open circuit voltage 1s typically in the range of 240 to 400 VDC The output current amperage of the power supply determines the speed and cut thickness capability of the system The main function of the power supply is to provide the correct energy to maintain the plasma arc after ionization The arc starting circuit is a high frequency generator circuit that produces an AC voltage of 5 000 to 10 000 volts at approximately 2 megahertz This voltage is used to create a high intensity arc inside the torch to ionize the gas thereby producing the plasma The Torch serves as the holder for the consumable nozzle and electrode and provides cooling either gas or water to these parts The nozzle and electrode constrict and maintain the plasma jet Sequence of Operating a Plasma Cutter The power source and arc starter circuit are connected to the torch via interconnecting leads and cables These leads and cables supply the proper gas flow electrical current flow and high frequency to the torch to start and maintain the process 127 1 A start input signal is sent to the power supply This simultaneously activates the open
93. t Pictures Music Computer Control Panel Devices and Printers 4 Back Shut down m 8 Press Enter twice This verifies that a connection exists between the computer and the machine 43 Creating a Category in the Button Bar 1 Right click on any button in the button bar and select Add gt Category Delete category Edit Change dock location Change dock color Advanced settings Close the dock 2 Enter the title as Machine Tools Add Edit Category x Title Machine Tools Select an image 3 Scroll to the bottom of the dialog and select Browse Q Add Edit Category am i Title Machine Tools 4 Click on OS C in the left toolbar O Browse for image x O EL Computer OS C E Search OS Cj p Organize v New folder m e x Favorites Name Date modified EE Desktop Li Apps Downloads dell 5 3 2011 3 11 PM File folder S Recent Places Drivers 2 24 20119 30PM File folder di PerfLogs 7 13 2009 10 20 PM File folder E Libraries 3 de Program Files 2 24 2011 8 46 PM File folder b ES Documents Program Files x86 5 3 2011 3 06 PM File folder b 2 Music de Temp 2 24 2011 8 20 PM File folder gt i Pictures N Users 5 3 2011 2 42 PM File folder gt B Videos Le Windows 2 24 2011 8 40 PM File folder 2 24 2011 8 45 PM File folder 4 Computer gt amp os c Pe TRAVELDRIVE E File name y I
94. t Control Ho Use Z keys to change values Use Z keys to change values Ethernet Settings Enternet Info S H U 103 P08185 Hane MultiCan U 103 P IP 192 168 0 51 Mask 255 255 254 0 Activate DHCP Ho Use Z keys to change values Operators who select the Information menu item will begin at the Machine Information screen and may access other machine specific information by clicking specific virtual keys as shown below aN A Decrease Feedrate LZ 1 or Set Home 1 Click Go Home Increase Feedrat to access machine specific information 2 Click Cancel S between screens and then press Cancel S twice to exit the Information sub menu Machine S N U 103 P08185 Hame MultiCan U 103 P Softuare u9 00 3 Firnuare u4 49u M2545r1 2135 IP 192 168 0 51 Mask 255 255 254 0 de 9 Info Inputs Info Inputs ArcLit CE Onhic M E MODBUS Information MODBUS Infornation Bent 32 TH0s 32 MB Loopback Test FPGR Pass Internal Pass External Pass Power Information Pouer Information Web Voltage 7 iaoa Power Glitches PCB Temperature PCB Tenperature 102 70 DegF Each box shows the status of the specific input e Dark off e Bright on MODBUS Information Packets Sent Timeouts MP Loopback Test FPGA Internal External Power Information Incoming 24V Power to the Board Recorded Power
95. t Pierce Delay iv Set Voltage v Set THC Delay vi Set Max Volt Gap Always 50 vii Set Sample THDC vin Set Use Thin Coef ix Close open advanced x Click NEXT 3 Nest is the third page of Creator Part clearance 0 Put dimension in Part Clearance if you have multiple parts gt Sheet edge clearance 0 b Put dimension in Sheet Edge Clearance Use default sheet size 48 x 48 c Put dimensions in sheet size x is first y is second d Ifnecessary change start points gt e Click NEXT 4 OUTPUT is the last page of Creator Click Finish Output Folder C DNCFiles b Choose Output Folder mami c Type in the name of the file It is important to have a system when naming DNC files Preferences d De select box that is titles Open Output File In ee e Click on GENERATE OUTPUT Generate Output f Close 74 Job Console Open small yellow folder gt in top right corner Select the DNC file you want to cut and Open Move the torch to the Sheet Home Click on Sheet Home Y For initial training do not cut use Dry Run until you can go through Creator without hesitation ee 209 9c es a From Job Console select Execute from Current Sheet qe This can also be accomplished by sending the file from EZ GCode Creator D Machine Cor EE PLAY to start job CANCEL to abort MEHU to toggle dry run X 0 000 Ohnic Sensor DIS Y 0 000 Surf Override OFF Z 0
96. tane lighter or matches from your pockets before cutting Cutting area Prepare the cutting area to reduce reflection and transmission of ultraviolet light Paint walls and other surfaces with dark colors to reduce reflection Use protective screens or barriers to protect others from flash and glare Warn others not to watch the arc Use placards or signs Minimum protective Suggested shade Arc current shade number ANSI number for comfort OSHA 29CFR Europe amps Z49 1 2005 ANSI Z49 1 2005 1910 133 a 5 EN 169 2002 siousA 8 8 8 9 W6 wiA 8 89 8 1 asiwi7sa 8 89 A W nsoA 8 9 8 1 3560304 8 9 8 9 30 40A 9 1 9 19 NA Pacemaker and Hearing Aid Operation Pacemaker and hearing aid operation can be affected by magnetic fields from high currents Pacemaker and hearing aid wearers should consult a doctor before going near any plasma arc cutting and gouging operations Toreduce magnetic field hazards o Keep both the work cable and the torch lead to one side away from your body Route the torch leads as close as possible to the work cable Do not wrap or drape the torch lead or work cable around your body Keep as far away from the power supply as possible O OO 20 NOISE CAN DAMAGE HEARING Cutting with a plasma arc can exceed acceptable noise levels as defined by local codes in many applications Prolonged exposure to
97. the cutting sequence Installation Safety An electrician must read and understand the electrical schematics prior to connecting the machine to the local power system Connecting the wrong voltage power will void the warranty All switches should be turned to the OFF position before power is connected The main disconnect switch should always be locked in the OFF position if the machine is left unattended When the machine is installed the electrician or customer should be sure that all motors rotate in the correct direction Power Lockout Instructions EZ Cut machines are equipped with a built in main power lockout device If any kind of repair work or maintenance is being performed to the machine or control cabinet the operator should disconnect power from the machine before starting work 1 Turn the main disconnect switch to the OFF position 2 Flip out the plastic lockout latch 3 Insert any padlock into one of the holes of the lockout latch With the plastic lockout latch in this position the switch cannot be moved to the ON position 4 Throw the bulkhead switch to the OFF position 5 Open the control cabinet 6 Make sure the LEDs on the drives and inverters are not lit It may take a few minutes for the light from the LEDs to fade away 7 Make sure the incoming voltage for L1 L2 and L3 is Ov 8 Follow the operator s standard Tag Out procedure in tagging the disconnect switch Labels Each machine produced inc
98. tial Pierce Pierce to Work Thickness Distances Height Delay Time Cut Speed Voltage Cut Speed Voltage inches inches inches 9 9 seconds im Volts ipm Volts o ws we we FineCut Shielded Consumables Note The cut charts in this section apply to both shielded and unshielded consumables HI Shield 220948 J Ohmic sensing Retaining Cap 220953 1 Nozzle 220930 J Electrode 220842 ES Swirl Ring 220994 96 97 FineCut Mild Steel Air flow rate slpm scfh 181 364 191 404 Metric Torch Recommended Material i Pierce Delay Thick Current to Work Initial Pierce Height Ti IcKness Distance Ime Cut Speed Voltage mm seconds mm min 5 7 1 5 2 25 150 0 4 NO 1 1 2 3 Torch Recommended Material a S Pierce Delay Thickness Current to Work Initial Pierce Height Time Distance Cut Speed Voltage EM z 26GA 325 325 250 45 200 95 FineCut Stainless Steel Metric Material Foren Current to Work Thickness Distance mm m e 0 5 English A 40 5 Torch ma teria Current to Work Thickness Distance IS 26GA 24GA 40 22GA 20GA 5 4 06 08 98 Air flow rate slpm scfh Pierce Delay Initial Pierce Height Time Cut Speed Voltage mm 4 seconds mmiminy vons 2 l Pierce Delay Initial Pierce Height Time Cut Speed Voltag
99. uct has a defect in workmanship or material even though it has been stored installed operated and maintained in accordance with Seller s specifications instructions recommendations and in accordance with recognized standard industry practice and the product was not misused repaired neglected altered or damaged the Seller will repair or replace in its sole discretion those parts of the product determined by Seller to be defective in workmanship or material if said defect is not attributable to Purchaser s acts or omissions This warranty excludes any warranty of merchantability fitness for a particular purpose or other warranty of quality whether expressed implied or statutory Limited Warranty Period The cost of repair or replacement parts 1s covered by this limited warranty on cutting systems for one year from shipment date from Seller s factory Labor expenses are covered by this limited warranty for six months from shipment date from Seller s factory Normal wear items such as switches regulators solenoids drive bands torch lifter motors motor pinions gear rack and similar items are covered by this limited warranty for six months from shipment date from Seller s factory Hoses bulbs and switches are covered by this limited warranty for 30 days Components in the product that were not manufactured by Seller are excluded from this warranty and are covered by the original manufacturer s warranty if any Limitation of Liabil
100. until further notice from the Seller Upon written notice from Purchaser of a warranty claim Seller will contact Purchaser to determine the nature and extent of the repair or replacement necessary Upon receipt of a warranty claim notice Seller will proceed without unreasonable delay to remedy any defect found under the terms of this warranty Seller may at its sole option repair or replace any defective portion of a product or product The warranty shall not extend beyond the time set forth above for any reason The warranty on repairs and replacements shall expire on the same date as the warranty on the originally purchased product that was repaired or replaced All parts returned for repair and or replacement require a return goods authorization RGA number Items sent with no documentation will be returned at the purchaser s expense 30 Maintenance The EZ Cut will provide years of productive service if it is maintained properly There are daily weekly monthly quarterly and yearly maintenance steps required for each machine based on a 40 hour work week Any plasma system used in excess of 40 hours a week should have the maintenance schedule adjusted accordingly Each auxiliary system has specific maintenance procedures that must be addressed in addition to the following maintenance procedures for the CNC machine Daily The EZ Cut should be cleaned off each day and the water lines should be inspected All dust or slag should be b
101. water either radially or swirl injected directly into the arc to greatly improve arc constriction therefore arc density and temperatures increase This process is used from 260 to 750 amps for high quality cutting of many materials and thicknesses This process is for mechanized applications only 128 Shield Cup Cutting Gas Secondary Gas Wor co IN Electrode Nozzle Outer Nozzle Cutting Gas Water Shield Electrode Nozzle Cutting Gas Water injection 129 Precision Plasma Cutting This process produces superior cut quality on thinner materials less than 1 2 at slower speeds This improved quality is a result of using the latest technology to super constrict the arc dramatically increasing energy density The slower speeds are required to allow the motion 31 device to contour more accurately This process is for mechanized applications only jl ug tj z 130 Glossary The following words are most commonly used in reference to the plasma system and associated activities Axis A direction in a coordinate system Plasma units have 3 axes X Y and Z Axis Motor A motor that causes motion in a particular axis Bad Slag The molten metal that quickly cools and requires a grinder for removal Bar Code Scanner A device that allows operators to retrieve information encoded in a bar code label so that specific notes and directions are kept in line with the correct job file Bearin

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