Multicam Oxy-Fuel, Plasma Operations Guide - 6000 Series
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Multicam Oxy-Fuel, Plasma Operations Guide - 6000 Series
TABLE OF CONTENTS
HANDHELD PENDANT (KEYPAD) OVERVIEW
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GENERAL OPERATION
Finding HOME
Machine Parking
LOADING MATERIAL
Setting HOME
Plate Rotation
Speed Control
MACHINE TOOL SETUP – General
Torch Selector Switch
Material Library
3
3
4
4
5
5
6
6
6,7
PLASMA OPERATION
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PC Comm (PC communications-Program Loading)
Program Execution
Dry Run
Step and Repeat
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8,9
9
9
Params 2D (Cutting Parameter Adjustment)
10,11
OXY-FUEL OPERATION
Gas/Pressure Settings
Setting Surface
Oxy-Fuel Preheat controls
Torch Ignition/Hi-Preheat
Oxy-Fuel Gas Manifold
Cutting Oxygen
Final Setup / Program Selection
Program Execution / Height Adjust
APPENDICES
1. X Axis Wheel Lubrication
2. OXY-FUEL Cutting Charts
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12
13
13,14
15
16
16
17
18
19
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19,20
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HANDHELD PENDANT (KEYPAD) OVERVIEW
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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
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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
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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”)
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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.
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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.
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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 2nd 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.
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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,
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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
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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
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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.
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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
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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
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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.
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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)
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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
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h. Pressing EXECUTE will prompt you to light the flame.
Pressing EXECUTE a 2nd 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 3rd 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.
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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
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2. OXY-FUEL Cutting Charts – Cont.
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