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TABLE OF CONTENTS HANDHELD PENDANT (KEYPAD) OVERVIEW 2 GENERAL OPERATION Finding HOME 3 Machine Parking 3 LOADING MATERIAL 4 Setting HOME 4 Plate Rotation 5 Speed Control 5 MACHINE TOOL SETUP General 6 Torch Selector Switch 6 Material Library 6,7 PLASMA OPERATION 8 PC Comm (PC communications-program Loading) 8 Program Execution 8,9 Dry Run 9 Step and Repeat 9 Params 2D (Cutting Parameter Adjustment) 10,11 OXY-FUEL OPERATION 12 Gas/Pressure Settings 12 Setting Surface 13 Oxy-Fuel Preheat controls 13,14 Torch Ignition/Hi-Preheat 15 Oxy-Fuel Gas Manifold 16 Cutting Oxygen 16 Final Setup / Program Selection 17 Program Execution / Height Adjust 18 APPENDICES 19 1. X Axis Wheel Lubrication 19 2. OXY-FUEL Cutting Charts 19,20 1
HANDHELD PENDANT (KEYPAD) OVERVIEW 2
1. Inspect machine for debris and obstructions to travel 2. Power up 6000 controller 3. Finding HOME - at each Boot (initialization) the machine must be referenced (find its limits (0,0) Press Shift + Find Home to reference machine Machine will find its home in the Z axis, then the Y and X axes Machine Parking For easier plate loading, you may park the machine at the far end by pressing SHIFT + 8 NOTE: SHIFT + 2, 4, 6, or 8 will park the machine in that direction. PARK means to travel at slew (max) speed to the limit of travel 3
4. LOADING MATERIAL Load material to be cut onto the table. Plate location is not as important as its squareness. When loading large plate or heavy materials, it may not be possible to square the sheet sufficiently. The PLATE ROTATION feature may be used to rotate the program to match sheet orientation See Pg. 5 5. SETTING HOME JOG the machine to the lower right hand corner of the plate to be cut. PRESS SET HOME, then ENTER 4
PLATE ROTATION (rotate part to fit sheet) SET HOME at the lower right hand corner of the material, then JOG to the upper right hand corner. PRESS SET HOME again, then PRESS the DOWN (2 KEY). When you press EXECUTE, to run your program, you will be prompted to accept or cancel the degrees of rotation. Speed Control Bring the torch down to the plate. For more accurate control of torch movement, once you are close to the plate, Press the OCP speed control, to SLOW Each Press of the Speed Control Key toggles from Med, to Fast, to Slow And bring torch tip as close as is safe without jamming the torch into the material (within a 1/16 ) 5
6. MACHINE TOOL SETUP a. Turn ON the Plasma unit and gases or turn ON Oxy-fuel gases. Be sure you have the gases required for the material to be cut turned on. All others should be turned off. While turning gases off is not required, gas loss by seepage will be minimized. NOTE: Always be sure to open or close valves completely. ALL plasma gas outlet pressures MUST be set to 120 psi (flowing) See manual plasma manual for gas test procedure b. On the keypad PRESS the MATERIAL LIBRARY button 6. MACHINE TOOL SETUP Cont. c. You will be prompted for MATERIAL TYPE. Use the 8 and 2 keys to scroll up and down to the proper type (Mild Steel, Stainless Steel, Aluminum, or Oxy Fuel), then PRESS ENTER. 6
d. Next you are prompted for SHIELD or UNSHIELDED, select SHIELDED (Only PowerMax units use unshielded consumables) e. You will be then prompted for AMPERAGE (plasma) or TIP SIZE (Oxy-Fuel) Use the 8 and 2 keys to INCREASE or DECREASE f. Use the 4 and 6 keys to move left and right between AMPERAGE/TIP SIZE and MATERIAL THICKNESS. Use the 8 and 2 keys to select the proper thickness, then Press ENTER NOTE: When changing plasma consumables DO NOT pull Ohmic Sensor by wire. Grasp the connector to remove. 7. PLASMA OPERATION Inspect machine for debris and obstructions to travel Be sure you have the correct consumables for the amperage and material thickness desired. Use only plasma manufacturer s parts. 7
8. Press PC COMM, use the up/down arrow keys to select the program you wish to cut, then Press ENTER 11. Press EXECUTE. The program will be checked as a valid program. Any out of bounds error means that the program cannot be started at its present Home position, as it will run out of space in the given direction, prior to completing the cut. 12. Press Execute a 2 nd time to begin cut. or DRY RUN (machine follows the toolpath at max speed without firing the torch) Dry run can be used to check a part, check sizing, etc. 8
Once the program has been validated, Pressing the 2 key will allow you to Dry Run Or STEP and REPEAT (Onboard rectangular nesting) Pressing the 2 key again, allows you to select how many times the part is to be cut. 13. Program Completion Depending on the software you are using at the end of cut, you will be asked to Press START to Continue, which returns you to the SET HOME POSITION or cuts off the scrap material. Otherwise when the program is complete it simply returns to the MAIN MENU Congratulations! You have cut your first part. CHANGING CONSUMABLES Most plasma systems over 100 amps are water cooled. This means that as long as the plasma unit is powered on, there is coolant flowing through the torch. The plasma unit must be shutdown to change consumables. Autogas units (HPR) have their power applied by the controller. To power down the plasma unit you go to MENU, UTILITY, then CHANGE TIP. You must press ENTER twice to turn the unit off. PARAMS 2D Select MENU, then PARAMS 2D Check PARAMS 2D to verify the proper settings for the material to be cut, 9
In PARAMS 2D, use the Arrow keys to navigate through the selections. NOTE: Z UP, and Z DOWN, can be used to Page Up and DOWN through the selections 10
There have been some additions to the standard Params 2D MENUS ARC FACTOR Arc Factor sets the percentage of the feedrate at which arcs will be cut. The range is 0 1. An arc factor of.4 means that if the material feedrate is set to 100 ipm, then arcs will be cut at 40 ipm. Adjustable arc feedrate can help maintain arc s cylindrical quality NOTE: In conjunction with ARC FACTOR parameters 194 195 affect arc cutting. See your tech rep for more information 11
PERF This is a YES/NO toggle. Perf refers to perforated metal. Metal with holes or gaps cause a loss of ground, which would normally halt the cutting process. Selecting YES will allow the cutting process to continue by not monitoring arc loss. NOTE: Once a change to the material setup has been verified over a number of cuts, you can UPDATE MATERIAL LIBRARY, and your settings will be saved. 12
7. OXY FUEL SETUP a. Turn on Oxygen and Acetylene gases Set Gas regulator pressure to appropriate settings for the tip / material to be cut. For more info on setups see appendix, and refer to your Welding/Cutting guides b. Setting Oxy-Fuel Torch Surface Jog the Z axis down until your torch tip touches the plate (within 1/16 ) Press SET SURFACE. Select torch 2 (2 may already be displayed, Press 2, to be sure, ENTER 13
Be sure Low Preheat Controls and Torch adjustment knobs are set to OFF, LOW PREHEAT CONTROL c. Set Home Oxy Fuel Set the plate/part home. Normally the right lower corner in reference to the OCP (Operator Control Pendant) To SET HOME jog the machine to the desired HOME position, and Press HOME, then ENTER 14
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c. TORCH IGNITION Jog machine to a convenient location for torch ignition. Open torch preheat adjustment knobs slightly. Turn ON Lo-Preheat Fuel, ignite gas with striker Turn ON Lo-Preheat Oxygen Torch Settings Adjust Low / Ignition gases until a flame approx 8-10 long is achieved, with 3 well defined cones near the tip ~.125-.250 long Preheat Height and Cut Height should be approximately the same. Cones should just touch the material. Pierce height should be somewhat higher to avoid fouling the tip. d. HI-PREHEAT Press SHIFT + 9 to access the gas setting menu. Select Hi-Preheat, and observe the flame for proper preheat flame (see torch/welder s manual) Select Hi-Preheat Adjust gas pressure according to the cutting chart. Flame will shorten, and become more intense cones should remain well defined. 16
Proper gas regulator settings may also be verified by pressing the Manual Solenoid Actuators, and adjusting gauges visually. The Cutting Oxygen has a metering valve to increase or decrease the cutting Oxygen flow. e. CUTTING OXYGEN Select CUT OXYGEN, using the CUT OXYGEN REGULATOR (center reg), adjust flame for an ENVELOPE 4-5 long (see welder s manual for pressure) 17
f. FINAL SETUP Select LOW PREHEAT then LAST HOME (Shift then SET HOME) to return to PLATE HOME position g. Select your Program, using the PC Comm, button 18
h. Pressing EXECUTE will prompt you to light the flame. Pressing EXECUTE a 2 nd time will move the torch to the PIERCE POINT, and lower the torch to the PREHEAT HEIGHT. The controller will automatically go into Hi-Preheat. Press the 2 key which allows a DRY RUN (actual cut motions, without the torch) of the cut. This can be helpful on thicker materials, in essence preheating the entire toolpath When you are satisfied that the material has been sufficiently preheated (puddling and some splatter will occur at pierce point) pressing EXECUTE the 3 rd time will begin the cutting sequence. The pierce sequence automatically turns on the CUTTING OXYGEN; the torch will raise slightly to PIERCE HEIGHT, and then waits a predetermined PIERCE DELAY TIME (See 2D Params) NOTE: THE Z HEIGHT MAY BE ADJUSTED (ON THE FLY) WHILE CUTTING At the end of cut the excess cutting oxygen will be dumped (see dump valve behind Cutting Oxygen regulator, returning the torch to Lo-Preheat settings. Raise the torch using Z UP. Turn the Oxygen and Fuel Lo-Preheat switches to OFF. A slight Pop may be heard when torch is extinguished. You are now ready to cut your next plate. Good Work! Congratulations once again. Welcome to the Multicam family of motion controls and products. 19
Appendices 1. X Axis Wheel Lubrication The X axis wheels and gear rack require oiling. The oil required is MOBIL Vactra #2 Due to the viscosity a lever-type Oil Gun is also required. This should be a Lever-Type Oil Gun Heavy Duty 26 oz. Capacity These items can be found in an MSC catalog (this catalog is given as reference only) 2. OXY-FUEL Cutting Charts 20
2. OXY-FUEL Cutting Charts Cont. 21