operator manual • keep all fumes and gases from the breathing area. keep your head out of the...

Portable CNC Plasma Cutting Machine

Operator Manual

Dalian Huarui Heavy Industry CNC Equipment Co.,Ltd

VERSION 2

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WARNING

You are responsible for the safe use of the product. HONEYBEE does not and cannot make any guarantee or warranty regarding the safe use of the Product in your environment. Learn how to operate the machine and how to use the controls properly. Do not let anyone operate it without instruction. Model：HBST2005D， HBST2008D Standard Plasma Power Source：Thermadyne CutMaster™ 120 made in USA Printer：Dalian Huarui Heavy Industry CNC Equipment Co., Ltd Add: No. 666, Xinshuini Road Ganjingzi District, Dalian City, Liaoning Province, China Website: www.honeybeecnc.comTel: +86-411-85865100 Fax: +86-411-85866100 Copyright 2008 Dalian Huarui Heavy Industry CNC Equipment Co., Ltd. All Rights Reserved Reproduction of this work, in whole or in part, without written permission of the publisher is prohibited. The publisher does not assume and hereby disclaims any liability to any party for any loss or damage caused by any error or omission in this Manual, whether such error results from negligence, accident, or any other cause. Publication Date: November 10, 2009 Please register your info here: Purchase date: _____________________________ Manufacture No. _____________________________ Lathe work No.______________________________

Dalian Huarui Heavy Industry CNC Equipment Co., Ltd TEL:+86 411 85865100 FAX: +86 411 85866100 - 1 -

http://www.honeybeecnc.com/

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TABLE OF CONTENTS

CHAPTER I SAFETY...................................................................................................3

I. Outline...................................................................................................................... 3 (i) Introduction, Warning Caution........................................................................ 3 (ii) Important Safety Precaution Items ................................................ ………….3

CHARPTER II INTRODUCTION..............................................................................5

I. Contents the Operator Manual Covers .....................................................................4 (i) Main Parameter of the Portable Cutting Machine ................................................. 6 (ii) Main Components of the Cutting Machine ......................................................... 6 (iii) Set Voltage Distribution Output Value of Plasma

CHARPTER III OPERATION .......................................................................................9

I. System Function Introduction .................................................................................. 9 (i) Control Panel ................................................................................................... 9 ( i i)Plasma Cutting Mode Parameter Set ............................................... 10

II. Plasma Power Source Introduction....................................................................... 10 (i) Plasma Power Source Control Panel ............................................................. 13 (ii) Cutting Machine External Wire Connection ................................................ 14 (iii) Portable Cutting Machine Simple Operation Procedures………………….15 (iv) Portable Cutting Machine Operation Notices.............................................. 16

CHAPTER IV COMMON FAULTS . .......................................................................14

I. Common Faults .................................................................................................... .17 II. Maintenance Solution ......................................................................................... .21

APENDIX: CUTTING PARAMETERS OF PLASMA POWER SOURCE


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CHAPTER I SAFETY I. Outline (i) Cautions, Warnings and Directions The content of Cautions, Warnings and Directions in this manual should be noticed carefully by the user. The content is classified into three items:

NOTE

An operation, procedure, or background information which requires additional emphasis or is helpful in efficient operation of the system.

CAUTION A procedure which, if not properly followed, may cause damage to the equipment.

WARNING

A procedure which, if not properly followed, may cause injury to the operator or others in the operating area. (ii) Important Safety Precaution

WARNING

OPERATION AND MAINTENANCE OF PLASMA ARC EQUIPMENT CAN BE DANGEROUS AND HAZARDOUS TO YOUR HEALTH. Plasma arc cutting produces intense electric and magnetic emissions that may interfere with the roper function of cardiac pacemakers, hearing aids, or other electronic health equipment. Persons who work near plasma arc cutting applications should consult their medical health professional and the manufacturer of the health equipment to determine whether a hazard exists. To prevent possible injury, read, understand and follow all warnings, safety precautions and instructions before using the equipment. Call 0411-85865100 or your local distributor if you have any question.

GASES AND FUMES

Gases and fumes produced during the plasma cutting process can be dangerous and hazardous to your health.


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• Keep all fumes and gases from the breathing area. Keep your head out of the welding fume plume. • Use an air-supplied respirator if ventilation is not adequate to remove all fumes and gases. • The kinds of fumes and gases from the plasma arc depend on the kind of metal being used, coatings on the metal, and the different processes. You must be very careful when cutting or welding any metals which may contain one or more of the following: Antimony Chromium Mercury Arsenic Cobalt Nickel Barium Copper Selenium Beryllium Lead Silver Cadmium Manganese Vanadium • Always read the Material Safety Data Sheets (MSDS) that should be supplied with the material you are using. These MSDSs will give you the information regarding the kind and amount of fumes and gases that may be dangerous to your health. • For information on how to test for fumes and gases in your workplace, refer to item 1 in Subsection 1.03, Publications in this manual. • Use special equipment, such as water or down draft cutting tables, to capture fumes and gases. • Do not use the plasma torch in an area where combustible or explosive gases or materials are located. • Phosgene, a toxic gas, is generated from the vapors of chlorinated solvents and cleansers. Remove all sources of these vapors.

Electric Shock

Electric Shock can injure or kill. The plasma arc process uses and produces high voltage electrical energy. This electric energy can cause severe or fatal shock to the operator or others in the workplace. • Never touch any parts that are electrically “live” or “hot.” • Wear dry gloves and clothing. Insulate yourself from the work piece or other parts of the welding circuit. • Repair or replace all worn or damaged parts. • Extra care must be taken when the workplace is moist or damp. • Disconnect power source before performing any service or repairs. • Read and follow all the instructions in the Operating Manual.

Fire and Explosion


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Fire and explosion can be caused by hot slag, sparks, or the plasma arc. • Be sure there is no combustible or flammable material in the workplace. Any material that cannot be removed must be protected. • Ventilate all flammable or explosive vapors from the workplace. • Do not cut or weld on containers that may have held combustibles. • Provide a fire watch when working in an area where fire hazards may exist. • Hydrogen gas may be formed and trapped under aluminum work pieces when they are cut underwater or while using a water table. DO NOT cut aluminum alloys underwater or on a water table unless the hydrogen gas can be eliminated or dissipated. Trapped hydrogen gas that is ignited will cause an explosion.

Plasma Arc Rays

Plasma Arc Rays can injure your eyes and burn your skin. The plasma arc process produces very bright ultra violet and infra red light. These arc rays will damage your eyes and burn your skin if you are not properly protected. • To protect your eyes, always wear a welding helmet or shield. Also always wear safety glasses with side shields, goggles or other protective eye wear. • Wear welding gloves and suitable clothing to protect your skin from the arc rays and sparks. • Keep helmet and safety glasses in good condition. Replace lenses when cracked, chipped or dirty. • Protect others in the work area from the arc rays. Use protective booths, screens or shields.

CHAPTER II INTRODUCTION I. Contents the Operator Manual Covers This manual described the operation and basic maintenance procedures. Only trained and qualified technicians are permitted to repair the machine. The person without training is prohibited to repair or regulate the items which are not mentioned in the manual. Read and understand this entire Manual and your employer’s safety practices before installing, operating, or servicing the equipment.

II. Main Parameters of the Portable Cutting Machine Standard Model HBST2005D(Ⅰ) HBST2008D(Ⅱ) Dimension (mm) 1700*2500 1700*4000 1700*6000 2200*4000 2200*6000Effective Cutting Area (mm)

1200*2000 1200*3500 1200*5500 1600*3400 1600*5400

Input Voltage 400VAC, Three phase，50/60Hz


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Recommend Cutting Thickness

3-20mm

Plasma Power Source Thermadyne CutMater A120(151) Air Compressed Air Cutting Material Mild steel, Stainless steel, Aluminum Torch Height Control Arc Voltage Torch Height Control

NOTE HONEYBEE Portable CNC Plasma Cutting Machine has two types: HBST2005D(General I) and HBST2008D(General II). This operation manual refer to the General II CNC cutting machine and CutMaster 151 plasma power source. If the customers use the Thermadyne A120 plasma power source,please read the manual book carefully. III. Main Components of the Portable Cutting Machine

Picture 2.1 Overall External View Drawing


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Plasma cable holder

Cross beam Torch

Host machine Guide rail

Picture 2.2 Host Machine


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Picture 2.3 Thermadyne CutmasterA120 Plasma with ubassembly

Picture 2.4 Plasma Consumables

CHAPTER III OPERATION

I. System Function Introduction (i) Control Panel There are three parts of the Panel

- 5.7” Display screen; - Power supply control panel; - Function key; - Input/Control Key


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Picture 3.1 System Panel

Emergency Stop

Button Motor Enable

/Disable Button Running Indication

Light Picture 3.2 Operation Control Panel

- Emergency stop Button: Stop all the external signal output, include XY direction

motors. - Motor Enable/Disable Button: When the cutting machine is on power, the Button is up

and in working situation. Button-down means off-line and X/Y direction motor is disable.

- Running Indication Light: When the cutting machine works regularly, the indicator light is on. The light is off under other situations.

NOTE

(ii) Plasma Cutting Mode Parameter Setting 1. If the operation interface shows as the picture 3.3, it is Honeybee system. Users should set parameters as following:

3.3 “HONEYBEE” System Interface


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* Press F3 to enter parameter setting, as picture 3.4

Picture 3.4 Parameter Interface

* Press F1 to enter Speed mode, Just need to modify the cutting limited speed,others don’t need to change.

NOTE Max.speed can be adjusted by the user according to plasma cutting parameters, the max. value must be under 2500. Start speed, adjust time are default and don’t need to change. *Press F4 to enter the Parameter of plasma mode, the user don’t need to change. *Press F5 to enter the control mode. As picture 3.5

NOTE Set 01 for the plasma cutting mode. Work speed can be adjusted by users according to the plasma cutting parameters, but the max. value must be under max. speed. Other parameters need not change.

Picture 3.5CONTROL Mode After set the above parameters, press F6 to save it. Then the parameters setting of plasma

cutting mode finished. “ Honeybee” Generation II system can start plasma cutting.


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II. Plasma Power Source Introduction (i) Plasma Power Source Control Panel

Picture 3.6 Plasma Power Source Control Panel Picture 3.7 Pressure Indicator

1. Output current control:

Sets the output current. The current of the pull-type cutting (the cutting nozzle touch the work

piece) is under 60 Amps, The current of the suspension type cutting (the cutting nozzle cannot

touch the work piece)can exceed 60 Amps.

2. Function Controller

Function Control knob can choose the different Operate Mode.

SET: Can be used the Purifying Equipment , cutting torch and the air inside lead, and adjust

the pressure of gas.

RUN: Can be used the formal cutting operation. RAPID AUTO RESTART: Can be used to restart the pilot arc quickly and keep the cutting without interruption SAVE: In order to keep the long-time manual and machine cutting(not the automatic cutting). The cutting switch can be off once the arc cutting happened. The cutting arc is not staying until the cutting torch moved to the workpiece. Cutting torch switch will be actived again or the lock function of system will be started after the cutting torch left from the edge of workpiece. 3. ON /OFF Switch:


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Controls input power to the power supply, Up is ON, Down is OFF. 4. Air/gas pressure controller

The pressure controller can be used the “Set mode” and adjust the Air/gas pressure. pull out

knobs can adjust and push knobs can save.

5.AC Indicator: Steady light indicates power supply is ready for operation. Blinking light indicates unit is in protective interlock mode. Shut unit off, shut off or disconnect input power, correct the fault, and restart the unit. 6.TEMP Indicator: Indicator is normally OFF. Indicator is ON when internal temperature exceeds normal limits. Shut unit OFF; let the unit cool before continuing operation. 7.Gas Indicator: Indicator is ON when minimum input gas pressure for power supply operation is present. Minimum pressure for power supply operation is not sufficient for torch operation. 8.DC Indicator: Indicator is ON when DC output circuit is active. 9. Abnormal state Indicator: Abnormal state Indicator is light when the loop happened troubles. 10. Pressure Indicator: Pressure indicator is light according to the pressure value of the pressure control button (#4).Picture 3.7

(ii) CNC Plasma Cutting Machine External Wire Connection

2P to IHS 4P to Torch

6P to Plasma

Picture 3.11 Power Supply Sockets


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Shield cap Cutting table (material) Cross beam end Plasma power end

Picture 3.12 External wire connection end

2P to IHS Cutting table end 1 Shield cap 2 Cutting table (material)

4P to Torch Cross beam end 4P socket 1 1 Motor 2 2 Motor 3 3 Electromagnetic valve 4 4 Electromagnetic valve

6P to Plasma Plasma power end 14P socket 1 3 Pilot arc+ 2 4 Pilot arc - 3 6 Voltage distribute+ 4 5 Voltage distribute -

(iii) Portable Cutting Machine Operation Simple Procedures (1) After check the host machine and external wire connection, and turn on the cutting machine.

(2) Choose PARAMETER—CONTROL—FLAME/PLASMA, SET 1 to choose plasma mode, save the setting.

(3) Refer to the CutMasterA120 plasma power source manual and cutting parameter charter,

and install consumables which suitable for steel plate thickness. Regulate the Output Current Control on the plasma power operation panel and make it match the consumables specification. Check the plasma power supply external wire connection. After everything checked, turn on the power and regulate the gas flow rate.


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(4) At cutting start, please make a test like this: Move the plasma torch and make it to the plate 10mm distance, use conducting metal to link the work table and the shield cap of the torch. Normally the torch should lift until it stop link to the work table. Otherwise, please check the connection between work table and cable, auto initial position cable and shield cap.

(5) After success test, move the plasma torch to the cutting initial position, choose cutting program, need not set any parameter and press start directly, then the Portable Plasma Cutting machine begin running. (iv) Portable Cutting Machine Operation Notices (1) The base of portable cutting machine can’t be put on the work table directly, must fix the Transversal Beam with the Longitudinal Rails Frame. (2) When install the plasma torch, note the torch and the steel plate should be absolutely vertical, then fix it. (3) Because of gravity, shorten possibly the cross beam stretch distance and avoid unstable of the torch and influence cutting quality.

(4) The quality cutting thickness of CutMasterA120 is 3mm—15mm, Please cut steel

plate within this thickness range. Please note thermal distortion of steel plate during cutting.

(5) Refer to the CutMasterA120 operation manual and choose suitable current, gas pressure,

consumables and cutting speed according to the steel plate thickness. (6) Set suitable input and output wire position according to the steel plate thickness and cutting drawings. (7) Regulate kerf compensation value according to the consumables specifications.

CHAPTER IV Common Faults I. Common Faults 1. Penetration power shortagea．Cutting speed is much too fast. b．Cutting torch inclination is too much large c．Cutting steel is too much thickness. d．Spare parts of Cutting torch is damaged. e．Cutting current is too small. f．Wrong air pressure. 2. Main Arc puts out


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a. Cutting speed is too mush slow b. The distance is very large both cutting torch and steel. c. Cutting current is much too strong. d. The cable is broken. e. The parts of cutting torch is damaged 3．The cutting scrap is too much. a. Cutting speed is too much slow. b. The distance is very large both cutting torch and steel c. The parts of cutting torch is damaged d. Cutting current is not suitable e. Air pressure is wrong 4．The parts of cutting torch have short lifetime a. There are oil and humidity b. Cutting steel is too much thickness c. Time of Starting Arc is too long d. Air pressure is too low. e. Assembly of Cutting torch is not suitable. 5．It is difficult for starting Arc. a. The parts of cutting torch is damaged. b. Air pressure is wrong II. Maintenance Solution

Instruction The actual maintenance frequency can be adjusted by the operation environment. Check the machine after it work for 6 hours or Daily operation. 1. To replace the cutting torch consumables parts if they are damaged or worn. 2. To replace the cutting torch or the cable if they were damaged. 3. Check the plasma power, twice opening power supply and voltage and flow rate. 4. Cleaning the cable of plasma power and get rid of the humidity. 5. To replace the input power cable and wire if they were damaged. Check the machine after it work for 30hours or every week: 1. Check if the fan is formal and air current is enough. 2. Operator must below out all dusty and filth form machine.

Note Please do not blow the air into power supply when to clean the machine. The metal particle will disturb the sensitive electronic component and cause of the damage of device. Check the machine after it work for six months or 720 hours: 1. Check the air filter, then clean and replace it by requirement. 2. Replace the wire and hose if it is the leakage and flaw. 3. Replace the switch if it is hit by arc or worn.


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Appendix: Parameters of Plasma power source


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operator manual • keep all fumes and gases from the breathing area. keep your head out of the...

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