Manual Hycut 2.55E CE PDF [PDF]

Citation preview

HC1020/1225/1530



Portable NC Cutting Machine Operator Manual Version 2.55E



Value Product Creator



www.hycut.cn



Portable NC Cutting Machine HC1020/1225/1530



Operator Manual Version 2.55E



Shenyang HyCut NC Tech. Co., Ltd. SHENYANG, LIAONING, P. R. of CHINA http://hycut.cn Copyright ©2009



All Rights Reserved



www.hycut.cn



Important statement ※ It is suggested that all operators should carefully read and understand these items before operating the equipment. Repeatedly mentioned content in the manual should be grasped importantly and paid more attention to. Examine packing carton if there is any damage during transportation after receiving the equipment. After packing carton, examine equipment component if there is any damage during transportation; examine if the articles in the cartons correspond with which are listed in the packing list (if ordering more than 1 sets, please according to the tags on packing carton, grouping and matching to use). Know Related Knowledge The operators must be familiar with the cutting elements and related practice regulations of oxy-gas and plasma. The performance and parameter also need griping before operating. The machine can not be disassembled by unprofessional person. Refer to the manual and consult the technicians if there comes to problems. Installation and Use The user is responsible for installing and using the equipment according to the manufacturer’s instructions. If electromagnetic disturbances are detected then it shall be the responsibility of the user to resolve the situation with the technical assistance of the manufacturer. In some cases this remedial action may be as simple as earthing the casing, see Earthing of Work piece. In other cases of using plasma cutting machine, it could involve constructing an electromagnetic screen enclosing the power source and the work complete with associated input filters. In all cases electromagnetic disturbances must be reduced to the point where they are no longer troublesome. Using Environment System allowable working environment temperature is 0℃-60℃, relative humidity is 0-85%. Don’t make dust and iron powders enter system interior, especially don’t make liquid enter host. In such environment as high temperature, high wet many dusts and causticity gas to work, need taking special protection. Assessment of Area Before using the equipment to cut, the user shall make an assessment of potential electromagnetic problems in the surrounding area. The following shall be taken into account: 1. Using oxygen and gas cutting: a. Time of day that cutting or other activities are to be carried out. 2. Before using plasma cutting equipment, potential electromagnetic problems in the surrounding area: a. Other supply cables, control cables, signaling and telephone cables; above, below and adjacent to the cutting equipment. b. Radio and television transmitters and receivers. c. Computer and other control equipment. d. Safety critical equipment, for example guarding of industrial equipment. e. Health of the people around, for example the use of pacemakers and hearing aids.



HC1020/1225/1530 Operator Manual



I



Important statement f. Equipment used for calibration or measurement. g. Immunity of other equipment in the environment. User shall ensure that other equipment being used in the environment is compatible .This may require additional protection measures. Consider time of day that cutting or other activities, flammable materials and the size of the surrounding area. The surrounding area may extend beyond the boundaries of the premises. Maintenance of Cutting Equipment The cutting equipment must be routinely maintained according to the manufacturer’s recommendations. When the cutting equipment is in operation, the cutting equipment should not be modified. In particular, the gear and rack meshing clearance should be adjusted and maintained according to the manufacturer’s recommendations. Plasma Cutting Question ●Method of Reducing Emission Mains Supply The equipment must be connected to the mains supply according to the manufacture’s recommendations. If interference occurs, it may be necessary to take additional precautions such as filtering of the mains supply. Consideration should be given to shielding the supply cable of permanently installed cutting equipment, in metallic conduit or equivalent. The shielding should be connected to the cutting mains supply so that good electrical contact is maintained between the conduit and equipment enclosure and the cutting power source enclosure. ●Equipotential Bonding Bonding of all metallic components in the cutting installation and adjacent to it should be considered. However, metallic components bonded to the work piece will increase the risk that the operator could receive a shock by touching these metallic components and the electrode at the same time. The operator should be insulated from all such bonded metallic components. ●Earthing of Work Piece Where the work piece is not bonded to earth for electrical safety, nor connected to earth because of its size and position, a connection bonding the work piece to earth may reduce emissions in some, but not all instances. Care should be taken to prevent the earthing of the work piece increasing the risk of injury to users, or damage to other electrical equipment. Where necessary, the connection of the work piece to earth should be made by a direct connection to the work piece, but in some countries where direct connection is not permitted, the bonding should be achieved by suitable capacitances selected according to national regulations. Note: The cutting circuit may or may not be earthed for safety reasons. Changing the earthing arrangements should only be authorized by a person who is competent to assess. ●Screening and Shielding Selective screening and shielding of other cables and equipment in the surrounding area may alleviate problems of interference. Screening of the entire plasma cutting installation may be considered for special applications.



II



HC1020/1225/1530 Operator Manual



Warranty Guarantee Genuine HyCut parts are the factory-recommended replacement parts for your HyCut system. Any damage caused by the use of other than genuine HyCut parts may not be covered by the HyCut warranty. Warning You have the responsibility to safely use the product. For safe use in your working environment, HyCut cannot give any guarantee or warranty. General HyCut warrants that products shall be free from defects in materials and workmanship for following warranty period, under proper and normal use, (i) host within one year; (ii) track and beam within six months; (iii) torch within three months. HyCut, at its sole option, shall repair, replace, or adjust, free of charge, any Products covered by this warranty which shall be retuned with HyCut’s prior authorization (which shall not be unreasonably withheld), properly packed, to HyCut’s place of business, all costs, insurance and freight prepaid, and which examination proves not to be free from defects in materials and workman-ship. HyCut shall not be liable for any repairs, replacements, or adjustments of Products covered by this warranty, except those made pursuant to this paragraph or with HyCut’s written consent. This warranty shall not apply to any product which has been mishandled, incorrectly installed, modified or assembled by you or any other person. HyCut shall be liable for breach of this warranty only if it receives written notice of such breach within the applicable warranty period specified herein above. Distributor and OEM can provide different or complementary guaranty, but they provide those for you not to be authorized, which cannot mean HyCut Company gives you any guaranty. Guarantee not Included: (i) any accident violating using requirement; (ii) damage caused by natural scourge; (iii) unload, remodel and repair if not allowed. Warranty Period: From distributor and OEM delivery date for users, but store in them not beyond three months, if beyond the period, only extend three months warranty period. Patent Indemnity Except only in cases of products not manufactured by HyCut or manufactured by a person other than HyCut not in strict conformity with HyCut’s specifications, and in cases of designs, processes, formulae or combinations not developed or purported to be developed by HyCut, HyCut agrees to indemnify, protect and hold harmless Distributors and their customers against any and all liability or claims in any manner imposed upon or accruing against Distributors and their customers because of the use in or about the construction or operation of Equipment or any design, system, formula, combination, article or material which infringes or alleges to infringe on any patent or other right. Distributors shall notify HyCut promptly upon learning of any action or threatened action in connection with any such alleged infringement, and each party may appoint its own counsel for any such action or threatened action. The equipment structure has gained country practical new type patent: 200720011857.9.



HC1020/1225/1530 Operator Manual



III



Warranty Indemnity Limit In any case, HyCut won’t compensate any personal or team accident, consequence, indirect or punitive loss (including not limited loss profit), whatever compensation is according to violate contract, civil infringement, strict responsibility, violate guarantee, main use failure or other cases, even have been told appearing the loss. Indemnity Utmost Limit In any case, compensation of HyCut lawsuit caused by using related product (whatever compensation is according to violate contract, civil infringement, strict responsibility, violate guarantee, main use failure or other cases), cannot go beyond cumulative total of causing compensated product. Insurance In any case, you must have and keep the insurance, when appearing any lawsuit, to protect HyCut from loss. National and Local Codes National and local codes governing plumbing and electrical installation shall take precedence over any instructions contained in this manual. IN NO EVENT shall HyCut be liable for incidental or consequential injury to persons or property damage by reason of any code violation or poor work practices. Equity Transfer Only when selling all or most assets or capital stock, but inheritors agree with the term, you can transfer equity.



IV



HC1020/1225/1530 Operator Manual



Content Important Introductions ………………………………………………………………………… I Guarantee………………………………………………………………………………………III Chapter One Safety Recognize Safety Information…………………………………………………………………1-1 Follow Safety Instructions………………………………………………………………………1-1 Cutting Can Cause Fire or Explosion…………………………………………………………1-1 Incorrect Operation can Cause Accident………………………………………………………1-2 Electric Shock can Kill…………………………………………………………………………1-2 Electric Shock Precaution………………………………………………………………………1-2 Cutting can Cause Poisonous Smog……………………………………………………………1-3 Plasma Arc can Cause Injury and Burns………………………………………………………1-3 Arc Rays can Burn Eyes and Skin……………………………………………………………1-3 Grounding Safety………………………………………………………………………………1-4 Compressed Gas Equipment Safety……………………………………………………………1-4 Gas Cylinders can Explode if Damaged………………………………………………………1-5 Gas Cutting Safety………………………………………………………………………………1-5 Noise Protection………………………………………………………………………………1-5 Pacemaker and Hearing Aid Operation…………………………………………………………1-5 Warning Label…………………………………………………………………………………1-6 Chapter Two Technical Regulations 2.1 Introduction…………………………………………………………………………………2-1 Product Introduction…………………………………………………………………………2-1 Product Characteristic………………………………………………………………………2-1 Product Highlight……………………………………………………………………………2-1 2.2 Main Technical Specifications, Parameters…………………………………………………2-2 2.3 Outside Measurement………………………………………………………………………2-3 2.4 Sign…………………………………………………………………………………………2-3 Chapter Three Setup 3.1 Receipt and Carrying Equipment…………………………………………………………3-1 3.2 Claims………………………………………………………………………………………3-1 3.3 Packing List…………………………………………………………………………………3-1 3.4 Equipment Appearance……………………………………………………………………3-2 3.5 Equipment Assembly ………………………………………………………………………3-3 3.5.1 The Connection between Host and Track………………………………………………3-3 3.5.2 Transverse Track Installation…………………………………………………………3-3 3.5.3 Assemble Torch………………………………………………………………………3-3 3.5.4 Gas Tightness Check…………………………………………………………………3-4 3.5.5 The Connection between Power and Control Line……………………………………3-4 3.5.6 Earthing………………………………………………………………………………3-4 3.5.7 Atmogenic Assembly…………………………………………………………………3-4 3.5.8 Torch Adjustment………………………………………………………………………3-4 3.5.9 Equip Plasma User with Plasma Cable Bracket Assembly (Option)…………………3-5 Chapter Four Use and Operate 4.1 Introductions of Panel and Keyboard………………………………………………………4-1 4.1.1 Panel Styles……………………………………………………………………………4-1 HC1020/1225/1530 Operator Manual



V



Content 4.1.2 Function Keys Definition………………………………………………………………4-1 4.2 System Operation…………………………………………………………………………4-2 4.2.1 System Main Interface…………………………………………………………………4-2 4.2.2 Setting…………………………………………………………………………………4-2 4.2.2.1 Renew……………………………………………………………………………4-3 4.2.2.2 Speed………………………………………………………………………………4-3 4.2.2.3 Control……………………………………………………………………………4-4 4.2.2.4 System……………………………………………………………………………4-4 4.2.2.5 Save……………………………………………………………………………… 4-5 4.2.3 Start……………………………………………………………………………………4-5 4.2.3.1 USB…………………………………………………………………………… 4-5 USB Read Failure……………………………………………………………………4-5 USB…………………………………………………………………………………4-5 USB Open……………………………………………………………………………4-6 Transmission……………………………………………………………………………4-6 4.2.3.2 Host…………………………………………………………………………4-7 Host Open………………………………………………………………………4-7 New After Open…………………………………………………………………………4-7 4.2.3.3 Start New…………………………………………………………………………4-8 Edit After Opening……………………………………………………………………4-8 Graph……………………………………………………………………………………4-8 Step……………………………………………………………………………………4-8 Select……………………………………………………………………………………4-9 Demo…………………………………………………………………………………4-9 Zero……………………………………………………………………………………4-9 Start……………………………………………………………………………………4-10 Setting Up Breakpoint…………………………………………………………………4-10 Power Down Restore…………………………………………………………………4-11 Hand Movement Speed………………………………………………………4-11 Cutting Slot Compensation……………………………………………………………4-12 Preheated Time Intelligent Memory…………………………………………………4-13 4.2.4 Other Important Function ……………………………………………………………4-13 4.2.5 Equipment Important Function Repeat………………………………………………4-13 Emergency………………………………………………………………………………4-13 4.3 Instruction System…………………………………………………………………………4-14 4.3.1 Function Word Definition……………………………………………………………4-14 4.3.2 Coordinate System……………………………………………………………………4-14 4.3.3 G Instruction…………………………………………………………………………4-14 1）G92 Reference Point Setting…………………………………………………………4-14 2）G00 Rapid Moving……………………………………………………………………4-14 3）G01 Cutting along Straight Line………………………………………………………4-14 4）G02/G03 Arc Cut………………………………………………………………………4-15 5）Others…………………………………………………………………………………4-15 4.3.4 M Function……………………………………………………………………………4-16 4.4 Operation and Use…………………………………………………………………………4-16 4.5 Plasma Cutting Linkage Control………………………………………………………4-17 4.5.1 Sketch…………………………………………………………………………………4-17 4.5.2 Plasma Arc Voltage Auto-Tracking System…………………………………………4-17



VI



HC1020/1225/1530 Operator Manual



Content 4.5.2.1 System Compose and External Connecting Diagram……………………………4-17 4.5.2.2 The Paraphrase for Every Parameter of Function Board…………………………4-18 4.5.3 Setting…………………………………………………………………………………4-19 4.5.3.1 Parameter Setting Process of Control Panel……………………………………4-19 4.5.3.2 Compensation Up………………………………………………………………4-19 4.5.3.3 Starting Arc Height(Initial Position)……………………………………………4-19 4.5.3.4 Plasma Arc Voltage Collecting…………………………………………………4-19 4.5.3.5 Setting Sensitivity Parameter……………………………………………………4-20 4.5.4 Attentions……………………………………………………………………………4-20 4.5.5 Solve Problem…………………………………………………………………………4-20 4.5.5.1 Definition of Connecting Electric Cable…………………………………………4-20 4.5.5.2 Accidents Signal Checking Method……………………………………………4-20 4.6 Using technique of plasma cutting linkage control………………………………………4-21 4.6.1 Sketch…………………………………………………………………………………4-21 4.6.2 Necessary and Sufficient Conditions…………………………………………………4-21 4.6.3 System Setting before Using Portable NC Cutting Machine…………………………4-21 Chapter Five Maintenance & Parts 5.1 Routine Maintenance………………………………………………………………………5-1 5.2 Basic Troubleshooting………………………………………………………………………5-2 More Technical Questions……………………………………………………………………5-2 5.3 Clearance Adjustment………………………………………………………………………5-3 5.3.1 Clearance Adjustment between Host and Track………………………………………5-3 5.3.2 Clearance Adjustment between Beam and Host………………………………………5-3 5.4 System Circuitry……………………………………………………………………………5-4 5.5 Consumable Parts…………………………………………………………………………5-5 5.5.1 Cutting Nozzles………………………………………………………………………5-5 5.6 Gas Cutting Technics Reference……………………………………………………………5-6 1、Propane+Oxygen(GK3 Isotonic Nozzle) ………………………………………………5-6 2、Acetylene+Oxygen………………………………………………………………………5-6



HC1020/1225/1530 Operator Manual



VII



Content



VIII



HC1020/1225/1530 Operator Manual



Chapter One



Safety



In This Section: Recognize Safety Information…………………………………………………………………1-1 Follow Safety Instructions………………………………………………………………………1-1 Cutting can Cause Fire or Explosion…………………………………………………………1-1 Incorrect Operation can Cause Accident……………………………………………………1-2 Electric Shock can Kill…………………………………………………………………………1-2 Electric Shock Precaution………………………………………………………………………1-2 Cutting can Cause Poisonous Smog……………………………………………………………1-3 Plasma Arc can Cause Injury and Burns………………………………………………………1-3 Arc Rays can Burn Eyes and Skin……………………………………………………………1-3 Grounding Safety………………………………………………………………………………1-4 Compressed Gas Equipment Safety……………………………………………………………1-4 Gas Cylinders can Explode if Damaged………………………………………………………1-5 Gas cutting Safety………………………………………………………………………………1-5 Noise Protection………………………………………………………………………………1-5 Pacemaker and Hearing Aid Operation…………………………………………………………1-5 Warning Label…………………………………………………………………………………1-6



HC1020/1225/1530 Operator Manual



1-0



1-00



HC1020/1225/1530 Operator Manual



Safety Recognize Safety Information



The symbols shown in this section are used to identify potential hazards. When you see a safety symbol in this manual or on your machine, understand the potential for personal injury, and follow the related instructions to avoid the hazard. Follow Safety Instructions



Read carefully all safety messages in this manual and safety labels on your machine. ·Keep the safety labels on your machine in good condition. Replace missing or damaged labels immediately. ·Learn how to operate the machine and how to use the system properly. Do not let anyone operate it without instruction. ·Keep your machine in proper working condition. Unauthorized modifications to the machine may affect safety and machine service life. Danger, Warning, Caution A signal word DANGER or WARNING is used with a safety symbol. DANGER identifies the most serous hazards. ·DANGER and WARNING safety labels are located on your machine near specific hazards. ·WARNING safety messages precede related instructions in this manual that may result in injury or death if not followed correctly. ·CAUTION safety messages precede related instructions in this manual that may result in damage to equipment if not followed correctly. Cutting Can Cause Fire or Explosion



Fire Prevention, Explosion Prevention ·Be sure the area is safe before doing any cutting. Keep a fire extinguisher nearby. ·Remove all flammables within 35 feet (10m) 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 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. ·Do not use the equipment if explosive dust or vapors may be present. 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.



HC1020/1225/1530 Operator Manual



1-1



Safety Warning Hydrogen Detonation with Aluminum Cutting ·When cutting aluminum underwater, or with the water touching the underside of the aluminum, free hydrogen gas may collect under the work piece and detonate during plasma cutting operations. ·Install an aeration manifold on the floor of the water table to eliminate the possibility of hydrogen detonation. Incorrect Operation can Cause Accident Incorrect operation can cause equipment damage. If seriously mistake operation happens, it can make inflammable gas outside cause explosive possibility. Moreover, suffer electric shock and burn danger. ·When using, ensure the connection line and appendix well. ·When flame cutting, follow welding and cutting accident precaution measure. ·Don’t let cloth and body twist into moving equipment, cause body injury. ·When moving equipment, host can move on track, so does beam, avoid host slipping outside track, beam outside host. ·Any parts including with track and beam, cannot be hit. ·Equipment surrounding avoids strong shake. ·Don’t allow to change safe device, but after insurance pipe damages, no connection with wire or other conductor, no change original device parameter, cause lose protection effect. Electric Shock can Kill Touching live electrical parts can cause a fatal shock or severe burn. ·Operating and maintaining the equipment exits potential danger, according to installing program and specification manual, safely install and operate the equipment. Open the equipment by trained maintaining person. ·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 Usually plasma systems use high voltage in the cutting process (200 to 400VDC 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. ·Don’t round or avoid safe switch. 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, ensure that it is correctly connected to earth ground. 1-2



HC1020/1225/1530 Operator Manual



Safety ·Install and ground plasma equipment according to the instruction manual and in accordance with national and local codes. · Inspect the input power cord frequently for damage. Replace a damaged power cord immediately. ·Inspect and replace any worn or damaged torch leads. ·Do not pick up the work piece, including the waste cutoff, while you cut. ·Before checking, cleaning or changing torch parts, disconnect the main power or unplug the power supply. ·Before removing any power supply or system enclosure cover, disconnect electrical input power. Wait 5 minutes after disconnection 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. Cutting can Cause Poisonous Smog Cutting can produce toxic fumes and gases that deplete oxygen and cause injury or death. ·Keep the cutting area well ventilated or use an approved air-supplied respirator. ·Do not cut in locations near degreasing, cleaning or spraying operations. The vapors from certain chlorinated solvents decompose to form phosgene gas when exposed to ultraviolet radiation. ·Do not cut metal coated or containing toxic materials, such as zinc(galvanized),lead, cadmium or beryllium, unless the area is well ventilated and the operator wears an air-supplied respirator. The coatings and any metals containing these elements can produce toxic fumes when cut. ·This product, when used for cutting equipment, produces fumes or gases which contain chemicals known to the State of California to cause birth defects and ,in some cases, cancer. Plasma Arc can Cause Injures and Burns Plasma arc comes on immediately when the torch switch is activated. The plasma arc will cut quickly through gloves and skin. Keep away from the torch tip. ·Do not hold metal near the cutting path. ·Never point the torch toward yourself or others. 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 or local codes. ·Wear eye protection (safety glasses or goggles with side shields, or a 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. HC1020/1225/1530 Operator Manual



1-3



Safety ·Cuffless trousers to prevent entry of sparks and slag. ·Remove any combustibles, such as butane lighter or matches, from your pockets before cutting. Cutting Area: Prepare the cutting area to reduce reflection and transmission of ultraviolet or 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. 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. Worktable: Connect the worktable to an earth ground, in accordance with appropriate national or 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. Fasten the retaining nut tightly. ·Tighten all electrical connections to avoid excessive heating. Compressed Gas Equipment Safety Compressed gas bottle when blowing up, transporting and reserving, exists some danger, can cause explosion and fire. ·Never lubricate cylinder valves or regulators with oil or grease. ·Use only correct gas cylinders. Regulators, hoses and fittings designed for the specific application. ·Maintain all compressed gas equipment and associated pares in good condition. ·Before gas cylinder, open its valve, after blow thin power or dirty, close it. Then use after connecting decompression. ·Open valve, operator should stand gas jet side and slowly start it, avoid gas towards body. ·Prohibit on stressed gas bottle, remove leak using screw down valve and washer nut ways. ·Never touch gloves oil and fat, cotton yarn and tools with gas bottle, valve, decompression and pipeline. ·When operating, gas bottle is from away open flame or heat source beyond 5m. ·Don’t place gas bottle on passage (elevator room, stairs), prevent from hitting. If having any difficulties, take proper protection measure. ·Never using oxygen to replace compression air to blow clear work cloths, gas pipeline, or use pressure test and air-powered tool air source. ·Label and color-code all gas hoses to identify the type of gas in each hose. Consult applicable national or local codes.



1-4



HC1020/1225/1530 Operator Manual



Safety Gas Cylinders can Explore 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 or local codes. ·Never use a 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. Gas Cutting Safety



Read and understand cutting machine operation and uses safety requirements. If users have any requirements, please consult distributors and manufacturers. ·Oxygen and gas hose cannot use each other, never replace with other hose. ·Torch no staining oil. ·When gas cutting ignition, using firing gun. ·When gas cutting, appearing cracking and backfire, immediately close preheated oxygen and cutting oxygen valve, then close gas valve, finally clear dirt in gas channel with needle. ·Finish working, decompression unload pressure order: close high pressure gas bottle valve, let off all remaining gas in decompression, release pressure adjuster to make watch hand to Zero. ·When gas source pressure is low, need exchanging gas, first close all valve switches, then exchange gas, when operating, do it according to dangerous gas safe operation rules. Noise Protection



Prolonged exposure to noise from cutting or gouging can damage hearing. ·Use approved ear protection when using plasma system. ·Warn others nearby about the noise hazard.



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. To reduce magnetic field hazards by following ways: ·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.。



HC1020/1225/1530 Operator Manual



1-5



Safety Warning Label This warning label is affixed to some equipment. It is important that the operator and maintenance technician understand the intent of these warning symbols as described. The numbered test corresponds to the numbered boxes on the label. 1. Cutting sparks can cause explosion or fire. Keep flammables away from cutting. Keep a fire extinguisher nearby, and have a watchperson ready to use it. 3. Electric shock from torch or wiring can kill. Protect 3.1 Wear insulating gloves. Do not wear wet or damaged gloves. 4. Breathing cutting fumes can be hazardous to your health. 4.1 Keep your head out o the fumes. 4.2Use forced ventilation or local exhaust to remove the fumes. 4.3 Use ventilating fan to remove the fumes. 5. Arc rays can burn eyes and injure skin. 5.1 Wear hat and safety glasses. Use ear protection and button shirt collar. Use welding helmet with correct shade of filter. Wear complete body protection. 6. Become trained and read the instructions before working on the machine or cutting. 7. Do not remove or paint over (cover) warning labels



1-6



HC1020/1225/1530 Operator Manual



Chapter Two



Technical Regulations



In This Section: 2.1 Introduction…………………………………………………………………………………2-1 Product Introduction…………………………………………………………………………2-1 Product Characteristic………………………………………………………………………2-1 Product Highlight……………………………………………………………………………2-1 2.2 Main Technical Specifications, Parameters…………………………………………………2-2 2.3 Outside Measurement………………………………………………………………………2-3 2.4 Sign…………………………………………………………………………………………2-3



HC1020/1225/1530 Operator Manual



2-0



2-00



HC1020/1225/1530 Operator Manual



Technical Regulations 2.1 Introduction Product Introduction: The product is of the characteristics of saving space, high producing efficiency and facility to take, and can cut automatically, with high cutting precision and material utility. It is well-designed, with light weight and small measurement, easy to be moved, fitting indoor and outdoor working environment. It can help all sized enterprises to improve producing efficiency and reduce producing cost. It can be widely used in cutting and using material working procedure of carbon steel (flame cutting), stainless steel, aluminum (plasma cutting) and other metal material, and especially in single and batch production of various parts. Product Characteristic: Portable NC Flame/Plasma Cutting Machine can program to cut any parts of plane graphs making of straight lines and arcs, as large gantry cutting machine. It configures 5.7 inch LCD, dynamic and static graphic display, which makes it intuitionistic and easy to learn. You can either program directly on the machine, or directly transform program files with CAD files on computer, and transmit into the machine by USB interface to cut. All-steel and antimagnetic outside frame of host ensures reliable and stable operation of CNC system. Product Highlight: ●HyCut V2.55E system research and development and design by ourselves; Program real optimization design, easy to learn and use, strong function; ●16 bits high speed CPU, inside FLASH memory, outside USB interface; ●Save 30 programs, each about 2048 lines，64 bytes every line; ●5.7 inch high-resolution dot matrix LCD, configure key-press operation modes, easier operation; ●40 Subdivision stepper motor driver, 1.8°stepper motor, smooth movement, low noise, high running precision; ●Electrical Clutches operation button, achieve rapid positioning; ●Thermostat fan design, start when cooling; ●Eliminate high frequency interference, optional integrated plasma initial positioning and automatic height tracking functions, adapted to kinds of plasma powers.



HC1020/1225/1530 Operator Manual



2-1



Technical Regulations 2.2 Main Technical Specifications and Parameters Models



HC1020



HC1225



Input power source



HC1530



220V±10%



LCD



50Hz



HC1630



220W



5.7 Inch LCD，blue screen with white words



Effective cutting range X×Y(mm) Beam cross-section size



1000×2000



1225×2500



1500×3000



1600×3000



50×60mm



Beam length (mm)



1530



1780



2030



2130



Beam weight (kg)



11.2



12.4



13.9



14.7



Track length (mm)



2500



3000



3500



3500



Track weight (kg)



33.6



40.5



46.9



46.9



Cutting speed (mm/min) Cutting thickness (Flame) (mm) Cutting thickness (Plasma)(mm)



50-2000 5-150mm According to customer’s plasma power supply



Gas pressure (Mpa)



0.01—0.3



Oxygen pressure (Mpa)



0.3—0.7



Types of gas



Propane or Acetylene



Measurement Host (mm) Track



460×330×260 2500×273×60



3500×273×60



3500×273×60



Packing measurement (mm) Weight



510×400×343 29.1kg 2630×460×370 3130×460×370 3630×460×370 87.8kg 101.3kg 118.8kg



3630×460×370 118.8kg



Host Track



Host weight (kg)



3000×273×60



19



*Standard configuration is propane cutting nozzle if no special requirement.



2-2



HC1020/1225/1530 Operator Manual



Technical Regulations 2.3 Outside Measurement



Model Beam



Model Track



HC1020/1225/1530 Operator Manual



2-3



Technical Regulations 2.4 Sign Following signs can appear on panel, tag and switch. Start



Off



Strong Electricity



Stop(Pause)



On



Protect Earthing



Offline On-Off(Emergency)



2-4



HC1020/1225/1530 Operator Manual



Chapter Three



Setup



In This Section: 3.1 Receipt and Carrying Equipment…………………………………………………………3-1 3.2 Claims………………………………………………………………………………………3-1 3.3 Packing List…………………………………………………………………………………3-1 3.4 Equipment Appearance……………………………………………………………………3-2 3.5 Equipment Assembly………………………………………………………………………3-3 3.5.1 The Connection between Host and Track………………………………………………3-3 3.5.2 Transverse Track Installation…………………………………………………………3-3 3.5.3 Assemble Torch………………………………………………………………………3-3 3.5.4 Gas Tightness Check…………………………………………………………………3-4 3.5.5 The Connection between Power and Control Line……………………………………3-4 3.5.6 Earthing………………………………………………………………………………3-4 3.5.7 Atmogenic Assembly…………………………………………………………………3-4 3.5.8 Torch Adjustment………………………………………………………………………3-4 3.5.9 Equip Plasma User with Plasma Cable Bracket Assembly (Option)…………………3-5



HC1020/1225/1530 Operator Manual



3-0



3-00



HC1020/1225/1530 Operator Manual



Setup



3.1 Receipt and Carrying Equipment Warm ·Equipment weight can reach 60kg，when installing and carrying, two people finish it. 1. Verify that all parts and items on your order have been received. Alert your distributor if any parts or items are damaged or missing. 2. If there is evidence of damage, refer to the Claims section below. All communications regarding this equipment must include the model number and equipment number. 3. Before setting up and operating the system, read the Safety section of this manual. 3.2 Claims Claims for damage during shipment: If your unit was damaged or lost during shipment, you must file a claim with the carrier. Claims for defective parts: If any of the parts are defective, please contact your distributor. 3.3 Packing List Examine parts, contrast with icon description.



HC1020/1225/1530 Operator Manual



3-1



Setup 3.4 Equipment Appearance



3.5 Equipment Assembly This portable NC cutting machine is decompounded transporting and needs assembling by the consumer. Please assemble the machine strictly according to the following procedures and be careful to avoid damage to the component, which can help to guarantee the cutting quality and performance. ※ When assembling many sets, matching to use. Because the clearance of gear and rack has been adjusted better before leaving factory. Warm Assembling incorrectly or inappropriately can harm your body. 3.5.1 The Connection between Host and Track Before assembling, the chassis and the track are packed separately in the carton. There is a fixing hole in the chassis and an installation bolt is also embedded into the aperture in the supporting chassis. Connect the chassis and the track with the enclosed nut. Then align the pulley on the slide of the chassis and the orbit on two sides of the track. Push as the aspect of arrowhead horizontally until the body inserts into the orbit. 3-2



HC1020/1225/1530 Operator Manual



Setup 3.5.2 Transverse Track Installation



Pull on the control line of the beam through the nick on the side of the machine in advance. Then push the beam as the aspect shown in illustration. Pay attention to the cooperation between track and pulley. 3.5.3 Assemble Torch Fix up the cutting torch and keep it upright to the horizontal level. The holder should also be fixed up with the beam with connection bolt. Connect the interface of preheating oxygen, cutting oxygen with solenoid valve and gas tube to the equipment. Wind up each plug's nut, and the screw of gas-run plug is levorotatory with the marks on the nut. Pay attention to the direction while connecting as well as the color of gas tube. The red one is gas, and the black stands for oxygen. The tie-in is marked.



HC1020/1225/1530 Operator Manual



3-3



Setup 3.5.4 Gas Tightness Check Examine the gas tightness of the gas circuit by the soap solution method under the working pressure. The equipment can put into use after affirm that there is not any leakage. 3.5.5 The Connection between Power and Control Line Warm Electrocution can harm body safety. Before maintaining, cut off power. The equipment configures standard 3m power cable, directly plugs into Multi-plug Socket; Beam control line connects power panel plug on equipment back, and revolve tight. 3.5.6 Earthing Using the equipment must comply with national or local electrical requirement, correctly grounded through the power cord. Also see in Earthing in the Safety section of this manual. 3.5.7 Atmogenic Assembly Warm Gas pressure can not exceed rating pressure equipment requires. If pressure is too high, air pipe can burst.。 About atmogenic assembly of oxygen, propane, or acetylene, carry out it according to concerned local and country regulations. ●Supply tie-in and hoop of oxygen and gas respectively, connect and revolve tight respectively. ●When supplying, tie-in and hoop of oxygen and gas are in packing. ●Oxygen pressure can not exceed rating pressure equipment technical parameters; otherwise, valve can not open. When needing use pressure of big flow and exceed rating value, please contact the manufacturer. 3.5.8 Torch Adjustment When assembling torch, vertical with work piece, to gain vertical cut. With square, make torch aim the position of 0°and 90°.



Torch



3-4



HC1020/1225/1530 Operator Manual



Setup 3.5.9 Equip Plasma User with Plasma Cable Bracket Assembly (Option) ·Assemble every component and fix up the plasma cable with tighten wire. Insert the plasma cutting gun into the holder. Attention: Refer to plasma cutting machine manual, grounding plasma power groundwire with equipment casing.



HC1020/1225/1530 Operator Manual



3-5



Setup



3-6



HC1020/1225/1530 Operator Manual



Chapter Four



Use and Operate



In This Section: 4.1 Introductions of Panel and Keyboard………………………………………………………4-1 4.1.1 Panel Styles……………………………………………………………………………4-1 4.1.2 Function Keys Definition………………………………………………………………4-1 4.2 System Operation…………………………………………………………………………4-2 4.2.1 System Main Interface…………………………………………………………………4-2 4.2.2 Setting…………………………………………………………………………………4-2 4.2.2.1 Renew……………………………………………………………………………4-3 4.2.2.2 Speed………………………………………………………………………………4-3 4.2.2.3 Control……………………………………………………………………………4-4 4.2.2.4 System……………………………………………………………………………4-4 4.2.2.5 Save ……………………………………………………………………………… 4-5 4.2.3 Start……………………………………………………………………………………4-5 4.2.3.1 USB …………………………………………………………………………… 4-5 USB Read Failure……………………………………………………………………4-5 USB…………………………………………………………………………………4-5 USB Open……………………………………………………………………………4-6 Transmission……………………………………………………………………………4-6 4.2.3.2 Host…………………………………………………………………………4-7 Host Open………………………………………………………………………4-7 New After Open…………………………………………………………………………4-7 4.2.3.3 Start New…………………………………………………………………………4-8 Edit After Opening……………………………………………………………………4-8 Graph……………………………………………………………………………………4-8 Step……………………………………………………………………………………4-8 Select……………………………………………………………………………………4-9 Demo…………………………………………………………………………………4-9 Zero……………………………………………………………………………………4-9 HC1020/1225/1530 Operator Manual



4-0



Start……………………………………………………………………………………4-10 Setting Up Breakpoint…………………………………………………………………4-10 Power Down Restore…………………………………………………………………4-11 Hand Movement Speed ……………………………………………………………… 4-11 Cutting Slot Compensation……………………………………………………………4-12 Preheated Time Intelligent Memory …………………………………………………4-13 4.2.4Other Important Function…………………………………………………………… 4-13 4.2.5 Equipment Important Function Repeat……………………………………………4-13 Emergency………………………………………………………………………………4-13 4.3 Instruction System…………………………………………………………………………4-14 4.3.1 Function Word Definition……………………………………………………………4-14 4.3.2 Coordinate System……………………………………………………………………4-14 4.3.3 G Instruction…………………………………………………………………………4-14 1）G92 Reference Point Setting………………………………………………………4-14 2）G00 Rapid Moving…………………………………………………………………4-14 3）G01 Cutting along Straight Line………………………………………………………4-14 4）G02/G03 Arc Cut………………………………………………………………………4-15 5）Others…………………………………………………………………………………4-15 4.3.4 M Function……………………………………………………………………………4-16 4.4 Operation and Use…………………………………………………………………………4-16 4.5 Plasma Cutting Linkage Control………………………………………………………4-17 4.5.1 Sketch…………………………………………………………………………………4-17 4.5.2 Plasma Arc Voltage Auto-Tracking System…………………………………………4-17 4.5.2.1 System Compose and External Connecting Diagram……………………………4-17 4.5.2.2 The Paraphrase for Every Parameter of Function Board…………………………4-18 4.5.3 Setting…………………………………………………………………………………4-19 4.5.3.1 Parameter Setting Process of Control Panel……………………………………4-19 4.5.3.2 Compensation Up………………………………………………………………4-19 4.5.3.3 Starting Arc Height(Initial Position)……………………………………………4-19 4.5.3.4 Plasma Arc Voltage Collecting…………………………………………………4-19 4.5.3.5 Setting Sensitivity Parameter……………………………………………………4-20 4.5.4 Attentions……………………………………………………………………………4-20 4.5.5 Solve Problem…………………………………………………………………………4-20 4.5.5.1 Definition of Connecting Electric Cable…………………………………………4-20 4.5.5.2 Accidents Signal Checking Method……………………………………………4-20 4.6 Using technique of plasma cutting linkage control………………………………………4-21 4.6.1 Sketch…………………………………………………………………………………4-21 4.6.2 Necessary and Sufficient Conditions…………………………………………………4-21 4.6.3 System Setting before Using Portable NC Cutting Machine…………………………4-21



4-00



HC1020/1225/1530 Operator Manual



Use and Operate 4.1 Introductions of Panel and Keyboard 4.1.1 Panel Styles



(4-0)



4.1.2 Function Keys Definition 【F1】~【F5】Function keys: Corresponding content of LCD screen nether pane, different interfaces with different functions. 【 】Back or Cancel key. 【 】When programming, insert character key; restart in case of power down, return to breakpoint key after setting up breakpoint. 【 】When programming, delete current character key; setting break off key when suspending cutting. 【PgUp/S↑】When reading USB interface and programming, page up key; in other case, torch up key, press it up, uplift stop up. 【PgDn/S↓】When reading USB interface and programming, page down key; in other case, torch down key, press it down, uplift stop down. 【 】When programming, input top character when pressing double characters key, once valid; In graph interface, it is hand moving speed show, cancel key. 【 】enter key. 【 】speed increases key, when press once, speed add 1% according to setting limit value, when press long time, continuous add. 【 】speed decrease key, when press once, speed decrease 1% according to setting limit value, when press long time, continuous reduction. HC1020/1225/1530 Operator Manual



4-1



Use and Operate 【Y+/↑】 【Y-/↓】 【X-/←】 【x+/→】When programming and choosing program, cursor direction key; in other case, torch direction key, press once, move according to defined direction, press any direction key again, running stops. 【 】on-off switch. Press it, yellow light on, all stops, axis X and axis Y motor offline, move optionally host and beam, torch rapidly positioning. Press it again, the button resets, and the yellow light off, cancel on-off, host and beam motors electrified lockup. When cutting, advice not to use it, it can affect cutting precision. 【 】Program start key. 】Program stop(pause) key. 【 The following function keys are only used in graph interface: 【 】Cutting slot compensating function key. Press once, input cutting slot compensating value, press it again, compensating comes into effect. 【 】Gas and preheated oxygen valve hand switch key. 【 】Graph rotation function key(Invalid). 【 】Cutting oxygen valve hand switch key in graphic interface. 【 】Punch fix program hand switch key in graphic interface, when program starts, invalid. 【 】As 【 】、【 】、【 】off all keys by hand. 4.2 System Operation 4.2.1 System Main Interface



(4-1)



System enters main interface when starting the machine (Picture 4-1). In any interface, if there is no content within corresponding screen nether pane on the top of 【F1】~【F5】, the key is invalid. 4.2.2 Setting Before using the equipment, you need to know and do necessary parameter setting. In general, parameter has been setting the best mode when the equipment leaves the factory, so you mustn’t adjust it. Only when you have special requirement, for example, when high speed or low speed cutting, you can adjust concerned parameter setting.



(4-2)



Press or touch【Stup】,enter system parameter setting interface. Set concrete parameter under its menu (Picture 4-2). Under its menu, conceal each key hardware diagnosis function. When pressing any key-press, screen middle character please setup parameters beneath displays KEY: corresponding number, which shows the key isn’t damaged. If no number is shown, it shows the key is damaged. If no number is shown when pressing any key, wire connection between main board and keyboard or main board can appear questions. 4-2



HC1020/1225/1530 Operator Manual



Use and Operate 4.2.2.1 Renew Press or touch【Rnew】,【Rnew】type becomes white, the screen shows renew setting? (Picture4-3), If not, press or touch other keys to enter other setting.



(4-3)



(4-4)



Press or touch【Rnew】again, confirm the restore, all setting parameter will be restored EW setting(Picture4-4); if press or touch【Retn】, return to main interface when starting machine, operate content under【Strt】.



(4-5)



4.2.2.2 Speed Press or touch【Sped】, 【Sped】type becomes white, the screen enters speed parameter setting interface (Picture4-5). Press 【Y+/↑】 【Y-/↓】 【X-/←】 【x+/→】and number keys to alter relevant parameter.



Moving limit speed stipulates hand and G00 Max speed; processing limit speed limits G01, G02, G03 Max speed. When system starts, default moving speed and processing speed is 70% of setting value. Before cutting, set in advance according to your processing speed or adjust anytime when cutting. Press once 【 】and【 】, speed increases and decreases 1% according to setting limit speed value, press long time, continuously increase or decrease. Start speed, moving speed and processing limit speed unit: mm/min. Speedup time is relative value.



(4-6)



Speed Max Speed Start Speed



Start Speed



Adj Time



Time Adj Time



HC1020/1225/1530 Operator Manual



4-3



Use and Operate 4.2.2.3 Control Press or touch【Ctrl】,【Ctrl】type becomes white, the screen enters Time-lapse interface (Picture4-6). Press【Y+/↑】 【Y-/↓】 【X-/←】 【x+/→】and number keys to alter relevant parameter. Parameter unit is 1% second.



Cutting gun down: After using G00 transferring position, the cutting gun falls to suitable height. After transferring the G00, you should go down the cutting gun before machining. Preheat: It is the preheat time before when steel plate perforation. In the course of actual cutting, it will show by countdown. When preheat perforation is not enough, press【stop】key to extend preheat time until pressing【Start】to stop preheating, then start to cut. Actual preheated time will be remembered by the system, and remember the current time. Perforation rising and perforation falling: Under fixed cycle of preheat perforation, after preheating time finished, cutting gun rises to run cutting gun perforation rising delay. Then start cutting, and carry out additional +00000 cutting gun perforation stay delay*( In the course of perforation fixed cycle, sometimes gun makes an action of perforation down, but steel plate doesn’t penetrate, or when plasma cutting, plasma cutting machine usually has air supply function in advance, setting this time can ensure gun move again when gun penetrates the plate.). Then cutting gun starts falling to carry out cutting gun perforation falling delay, start cutting when cutting gun arrives to schedule preheat height. Cutting gun rises before opening cutting oxygen in order to avoid jamming the cutting gun’s gate when opening cutting oxygen. Because of gravity, the time of falling is shorter than rising. Cutting gun rising: It is usually used before G00 transferring and after finishing cutting. The cutting gun rises to suitable height in order to avoid knocking between cutting gun and steel plate in the course of blank moving. After finishing cutting gun rising, carrying out additional +00000 cutting gun rising stay delay*, avoid causing workpiece surface damage when moving torch because of cutting oxygen off delay. See M function -M07, M08 instruction in the section 4.3.4. 4.2.2.4 System Press or touch【Sys】, 【Sys】type becomes white, the screen enters system parameter setting interface (Picture4-7). Press 【Y+/↑】 【Y-/↓】 【X-/←】 【x+/→】and number keys to alter relevant parameter.



(4-7)



Electric gear parameter value N and M, is counted by modulus of motor and gear and rack, ensure equipment running size precision, usually parameter can not be changed！ Inverted clearance means when gear and rack clearance is adjusted abnormally, input appropriate value, to ensure equipment to running precision. Usually advise not to adjust the parameter, but using mechanical adjusted mode. Unit: 1%mm. Power down restore, touch screen and arc control function can all set up “on” or “off”. Press 【Y-/↓】、 【Y+/↑】to move cursor to “on” or “off”, press 【X-/←】or【x+/→】 again, change into opposite state, it can be changed cycling, confirm that according to the display state. 4-4



HC1020/1225/1530 Operator Manual



Use and Operate 4.2.2.5 Save



(4-8)



Press or touch【Save】, 【Save】type becomes white, the parameter has been saved (Picture4-8). Exchanged parameter can be finished once, then again press or touch to save, no exchange one parameter to save once. Press or touch【 Retn】,return to main interface when starting machine. 4.2.3 Start Press or touch 【 Strt 】 ,system enters main working interface(Picture 4-9).



(4-9)



System Program Source: 【USB】outside USB interface removable flash disk; 【Host】inside flash memory existing program; 【New】new program file on local host. Press or touch【Retn】,return to upper menu.



(4-10)



4.2.3.1 USB USB Read Failure Press or touch【USB】,system enters USB working mode. If there is no USB in USB interface or insert inapposite USB, it shows USB fail (Picture 10). Press or touch【Retn】,return to upper menu.



(4-11) USB If there is USB in USB interface, USB designated content file will be read( Picture 4-11). Press 【 Y+/↑ 】【 Y-/↓ 】【 X-/← 】 【x+/→】,after choosing file, press or touch 【Open】to open program, or touch file name to open it directly. Press or touch【Retn】,return to upper menu.



HC1020/1225/1530 Operator Manual



4-5



Use and Operate USB mode, provides 50 files read, every page shows 10 files on every page, press 【PgUp】and【PgDn】page turning. The system only supports less than 8G capacities USB, and must new a hycut.cn file below USB root directory when using, put CNC and TXT program file to root directory, file name must be less than 9 characters being composed of number and letter or number or letter, not be Chinese character. Memory equipment such as hard disk, USB and so on, must format then to use. USB usually be formatted before leaving factory, is mostly FA T16 (FAT) form. USB Open Choose program, press or touch【Open】,open selected program(Picture 4-12). Press or touch 【 Grap 】 ,enter program processing graph interface.



(4-12)



Press or touch【Retn】,return to upper menu. When the file in the USB exceeds 2,040 lines, the screen nether shows: the program overflows. At this time, the program only carry out to 2,040 lines, latter lines cannot run. There are only 2,040 lines program transfered into the system, which means it can cut normally to 2,040 line. Transmission Press or touch【Tras】,system points out please input file:0000, press number key to input new file name, press or touch again【Conf】to confirm, or press or touch【Canc】to cancel the cooperation. If there is name repetition with new file name in local host memory, the screen shows file name repetition, press or touch【Conf】,again input new file name, press or touch again【Conf】.File name can be input repeatedly, until there is no name repetition. When input file name, press or touch 【Conf】,when no file name repetition, file starts transfer (Picture 4-13). File finishing transmission, system enters program line interface (Picture 4-16).



(4-13)



USB file transmission, designated file in USB designated directory saves to host memory, easier to use. Host can not edit and delete file in USB, and cannot save file in host to USB. 4-6



HC1020/1225/1530 Operator Manual



Use and Operate 4.2.3.2 Host In (Picture 4-9) interface, press or touch【Host】, system enters to local host working mode(Picture 4-14). Press 【Y+/↑】 【Y-/↓】 【X-/←】 【x+/→】or touch screen to choose program, can press or touch【Del】delete or press or touch【Open】 open program file. Twice touch or touch and stay always on file name, file can be opened. Choose program, press or touch【Del】, the screen shows Delete?, press or touch【Del】again, delete selected file, if not delete, press or touch【Canc】(Picture 4-15).



(4-14)



(4-15)



It can save 30 files in local host. If going beyond, again input or new, system shows program filled. Delete useless file, transmit or new again. Host Open Choose program, press or touch【 Open 】 , system enters program line interface(Picture 4-16). If exiting, press or touch【Retn】. New After Open Press or touch【New】, system points out Please input file:0000, press number key to input new file name, press or touch again 【Conf】to confirm, or press or touch【Canc】to cancel the cooperation(Picture 4-17). If there is name repetition with new file name in local host memory, the screen shows file name repetition, press or touch【Conf】, again input new file name, press or touch again 【Conf】.File name can be input repeatedly, until there is no name repetition. Press or touch 【Canc】to cancel the current cooperation.



(4-16)



(4-17)



File name must be four numbers. Except【New】, press or touch【Canc】 and 【 DelL 】 ,using in edit, other function can enter directly before not cancel.



HC1020/1225/1530 Operator Manual



4-7



Use and Operate 4.2.3.3 Start New



(4-18)



After【New】,enter【Edit】(Picture 4 -18), 【Edit】type becomes white,【DelL】is valid only in the mode. Edit easy file with keyboard. Press or touch【Edit】again, cancel edit mode. In program line interface,【New】,【Host】, 【Edit】, 【Grap】, and 【Retn】, are valid, press or touch enter corresponding interface, no matter what interface enter, program has been saved. Press or touch【Grap】, enter graph processing interface. Edit program, no concerned program save, it will be automatically saved.



Edit after Opening Press or touch【Edit】, system enter file edit interface(Picture 4 -19).



(4-19)



Press【Y+/↑】 【Y-/↓】 【X-/←】 【x+/→】to move cursor, edit and modify program. Operate ditto. Graph Press or touch【Grap】, enter graph process interface(Picture 4 -20). Screen shows the file scale graph. Operate following functions: Every valve on and off; cutting starts. In all modes (except USB and edit modes), cutting gun up and down functions are allowed;



(4-20)



Torch direction keys can be cursor moving keys only when cursor appears, selection moving key when choosing program, touch move direction keys in other situations. When program runs, direction key is unallowable. Including Step, Select, Demo and Start cutting. Step Press or touch【Step】, system enters step mode. Press direction key once, torch moves one inch increment in corresponding direction, aim to exactly position torch. Press【G】, modify inch increment, press【 】 confirm. Quantity unit is 1%mm, 00500 is 5mm. Press or touch【Canc】,cancel elected function. 4-8



HC1020/1225/1530 Operator Manual



Use and Operate



Only when selected function is cancelled, choose other function.



(4-21)



(4-22)



Select Press or touch【Sect】,system enters single running mode (Picture 4-22) . Strt】once, system runs one program, when cutting,【 Stop】becomes valid. Press【 Single program finished running, press【



】,cancel single function.



Demo Press or touch【Demo】,system enters simulate mode(Picture 4-23). Cursor automatically moves on screen orbit, test program validity, outside no movement. Press【



(4-23)



】,cancel single function.



It is invalid to cancel touch function in 【Sect】and 【Demo】modes, press 【Canc】to cancel current mode. Zero Press or touch 【Zero】,system enter origin mode(Picture4-24). Torch current coordinate X and Y are set up 0.0, if moving torch, position cursor is recorded, after torch stops, press or (4-24) touch 【RtZr】, torch automatically returns to 0.0. Press or touch【Canc】,cancel selected function. The function is very useful before starting flame cutting. After torch positioning, move quickly torch to suitable position by origin function, then return to confirmed place. After adjusting torch position and flame, press 【 Strt】, cut and process work piece. HC1020/1225/1530 Operator Manual



4-9



Use and Operate Start (4-25) Press【 Strt】,program starts running. Cursor will come along parts processing orbit and cutting synchronous movement. The lower right shows Process (Picture4-25). Right shows movement states of gas (+preheated oxygen), cutting (oxygen) valve, ○ off, ● on, nozzle○ stop up and down, ↑up, ↓down. Stop】in processing, program pauses, Press【 cutting shuts down, again press【 Strt】, cutting goes on, advance hand starting cutting, Stop】,press【 】to cancel, finish current program, can repeatedly operate. After press【 return to upper menu; if pressing 【F1】,cursor and torch return according to original orbit, again press【 Stop】, the equipment stops movement, press【 Strt】, cutting goes on, advance hand starting cutting, can repeatedly operate. Back function can be used when work piece isn’t cut penetrating. Gun can return to any point along original orbit, then again start program to cut work piece. Torch can always return to starting point. *Only when source program order is complete sentence, back function can precisely run. Pause cutting mode,【Canc】and【Back】touch function is invalid. Press【F1】and【 】to make the function.



(4-26)



Setting up Breakpoint Press 【 Stop 】 in any position when processing, set up breakpoint (Picture 4-26).The function can be used to replace cutting and nozzle when cutting. Press 【 Stop】 when processing, cutting pauses, shut down gas again, press 【 】, set up a breakpoint in program pause position, cursor stays. Again press 【 Zero 】 ,set up current position as coordinate 0.0,again press 【Y+/↑】【Y-/↓】 and 【X-/←】 【x+/→】to move gun to the place which can easily replace gun and nozzle, finish replacing, again press or touch 【RtZr】(Picture 4-27), gun will quickly return to breakpoint, after ignition, hand cutting key, press 【 Strt】 will go on cutting. The function can be used repeatedly; breakpoint record position is the last setting position. Setting breakpoint function can be derived used, for example, displacement perforation function and so on. In setting breakpoint mode, use inch function to adjust gun position, and use directly 【Y+/↑】 【Y-/↓】【X-/←】【x+/→】to move gun, but this moment cautiously operate, because no



4-10



HC1020/1225/1530 Operator Manual



Use and Operate return parameter return origin can start cutting. Origin speed is by moving limit speed multiplying, press【 】、【 】to increase and decrease speed. Moving speed is pressing 【 】、 【 】to increase and decrease speed when equipment moves, actual value doesn’t show on the screen. Press once to increase or decrease 1% of moving limit speed, press long continuously increase and decrease, until respectively reach limit value100% and 1%. In setting breakpoint mode, 【Sect】and 【Demo】function is unallowable. Power Down Restore Power dower happens when processing, if restoring cutting work piece, operate as following (Picture 4-28): System in case of power down, don’t move equipment, system will automatically record processing point when power down, when power is on, open machine to find the unfinished file of cutting, open and enter graph interface, press【 】,cursor moves to the point of power down, ignition and preheat, hand cutting, press 【 Strt 】 ,equipment automatically runs cutting from point power down.



(4-28)



In breakpoint return mode, 【Sect】and 【Demo】function is unallowable. Hand Movement Speed Press 【Y+/↑】 【Y-/↓】 【X-/←】 【x+/→】in any mode to start machine by hand, press 【



】、 【 】to increase and decrease speed, actual value won’t show on the screen. Press once, increase or decrease 1% of moving limit speed, press long continuously increase or decrease, until respectively reach 100% and 1% of limit value. In graph interface, press 【MS/Shift】, the screen upper right can appear MS×××× (Picture 4-29), which means current speed is ××××mm/min ， at this time, press any key 【Y+/↑】 【Y-/↓】 【X-/←】 【x+/→】, after cutting gun moves along direction X or Y, press 【 】 or【 】to adjust moving speed.



(4-29)



If using hand cutting, adopt this way to adjust hand cutting speed. Note that hand speed must be adjusted when machine moves, or adjusting speed is automatic cutting speed. Above description who mentioned “or touch”， refer to touch function when using touch screen. HC1020/1225/1530 Operator Manual



4-11



Use and Operate Cutting Slot Compensation (4-30) No matter how to adopt flame cutting or plasma cutting, remaining cutting slot in cutting position. Because of adopting different techniques and plate thickness, cutting slot width is different. Usually, consider cutting slot width in order to get eligible parts in accordance of drawing. There are two ways to solve in the course of practice. One is software compensation, before generating codes, consider cutting slot width according to experience, but once setting up cutting slot by this way, don’t adjust cutting slot width by changing code way, only generate codes again, so when a program adopts different cutting ways and plate thickness, you must generate codes again according to situations; the other is system hardware operation compensation, when generating codes, don’t consider cutting slot width compensation, but adopt system hardware operation compensation way, reach to cutting slot compensation in system inside by solidified program count, the way merit is adjusting cutting slot width at any time (Picture 4-30). (4-31) In graph interface, press 【 】cutting slot compensation function key, cursor flicker on the screen upper right cutting slot compensation, press 【 】 again after inputting cutting slot compensation value, system shows “Operating” (Picture 4-31), after finishing operating, the cursor disappears, compensation comes into effect. Then press Start】to cut workpiece. 【 When using cutting slot compensation, note that you must choose to adopt machine compensation way when software generates codes, cutting slot compensation is effective. Because when software generates codes, there is no G40, G41 and G42 code in software compensation program, don’t run compensation order. (4-32) Cutting slot compensation value cannot be more than any circular arc radius in cutting graphics. If inputting value more than any circular arc radius, screen below shows “CutC ＞ Radius, input again”(Picture 4-32) , input again right value, press 【 】, until it is right.



4-12



HC1020/1225/1530 Operator Manual



Use and Operate Preheated Time Intelligent Memory When cutting plate by flame way, you must preheat the plate before cutting, but different plate thickness and original temperature states will all affect plate preheated time, the time is usually longer for the first time. (4-33) W can set up the preheated time longer when setting parameter. When using, program runs to preheated, the screen bottom appears the time countdown, carry out next order after finishing preheated time. The user can press 【 Start】to start cutting if preheated time is enough according to the practice situation on the spot. At this moment, preheated time is automatically recorded, when program run next preheated order again, it will carry out according to the recorded time. Preheated time remember, it always records the final time. Start again, first preheated time always carries out setting time in setup parameter. 4.2.4Other Important Function Emergency In any emergency, unless it is unnecessary, press emergency button on the left of the machine, at this moment, the machine power down, switch indicator light is still on, the system screen will continue to be on for a few seconds, these are all normal phenomenon. In any emergency, only when essential, press 【 】clutch switch(Emergency),this moment, yellow light on keys is on, all stops, axis X and Y motor offline, but system is power supply mode, gas and preheat oxygen valve switch keep in original mode.



4.2.5 Equipment Important Function Repeat ●system default G90 absolute coordinate program mode under G71 metric system unit ●Edge Cutting●Preheated Time Intelligent Memory ●Cutting Slot Compensation ●Midway Exchange Nozzle●Power Down Restore●Zero Function●Return To Cut Again●Perforation Stay Time●Cutting Shut Stay Time



HC1020/1225/1530 Operator Manual



4-13



Use and Operate 4.3 Instruction System 4.3.1 Function Word Definition preparation function G assistance function M axis X coordinate figure X axis Y coordinate figure Y when arc working, central coordinate figure minus axis X starting point value. I when arc working, central coordinate figure minus axis Y starting point value. J arc radius R Attention: instruction order is former program ahead of latter program (except transfer subprogram), in the same program, M is ahead of G



4.3.2 Coordinate System The system adopts standard coordinate system (rectangular coordinate system), ---right hand Descartes rectangular coordinate system. 4.3.3 G Instruction 1）G92 Reference Point Setting Before running program, setting working start point coordinate value in the program beginning, and use absolute coordinate setting. Format：G92 X0 Y0 If the content of X and Y don’t follow G92, coordinate X, Y is reference point. Generally, when using machine tool origin positioning, X and Y don’t follow G92. 2）G00 Rapid Moving This instruction can carry out cutting gun getting to specified position quickly. When two axis all have displacement, System will move straight from the start to destination by the most limited speed. When G00 exerting, it will not be effected by speed magnification. Format：G00 Xn Yn for example： G92 X0 Y0 G00 X120 Y280 M02



●Position of current cutting-gun ○Position of anticipate cutting-gun 3）G01 Cutting along Straight Line This instruction can carry out torch getting to straight specify position, as cutting moving instruction, Single axis or double axes can move along straight interpolation, the speed of process is specified by F instruction. 4-14



HC1020/1225/1530 Operator Manual



Use and Operate Format：G01 Xn Yn for example： G92 X0 Y0 G00 X200 Y95 G01 X80 Y235 M02



●Position of current cutting-gun ○Position of anticipate cutting-gun 4）G02/G03 Arc Cut This instruction uses for arc cutting, it is divided into sequence arc G02(anticlockwise)，inverse arc 03(clockwise). Format：G02/03 Xn Yn In Jn or G02/03 Xn Yn Rn for example (G02)： G90 X0 Y0 G00 X40 Y50 G02 X160 Y0 I60 J20 G28 M02



for example (G03)： G90 X0 Y0 G00 X40 Y50 G03 X160 Y0 I60 J20 或 G03 X160 Y0 R63.25 G28 M02



●Position of current cutting-gun ○Position of anticipate cutting-gun Illustration: ●The value of I and J is increment that relative to start point of X and Y direction center. (Center subtract start point) ●R is radius. (R is positive value, When arc≤180°, you can use R to represent radius. ●If you specified I，J, no R. If you specified R, no I and J. 5）Others G70



English system (G20)



G71



Metric system (G21)



G90



abstract value coordinate program mode (system default) all points’ reference point is abstract zero point



G91



relative value(increment)coordinate program mode random point is former point position as reference point, no abstract zero point.



G41



cutting sewing left compensation



G42



cutting sewing right compensation



G40



cancel compensation



G28



Axis X and Y return to reference point simultaneously, equal to running G00



HC1020/1225/1530 Operator Manual



4-15



Use and Operate 4.3.4 M Function M02 Program finishes instruction; program ending must finish by the instruction. M07 Preheat perforation fixed circle, operate order as follow: ●When cutting-gun descending, starting cutting-gun down time delay; ●Preheat time delay; ●When cutting-gun ascending, running punch cutting-gun up time delay; ●Open cutting (oxygen), carry out additional cutting perforation stay delay; ●Cutting gun falling, carry out cutting gun perforation falling delay; ●Cutting-gun punch stay time delay; ●Running follow-up program. M08 Close cutting cycle, operate order as follow: ●Close cutting oxygen; ●Cutting gun rising, carry out cutting gun rising delay, carry out additional cutting gun stay delay; ●Running follow-up program. When running M07 and M08 instructions, if pressing 【 Strt】, skip specific ongoing action, and immediately jump to next action; if pressing 【 Stop】, pause the action, until press 【 Strt】, the program goes on running and immediately jump to next action. The function is very useful when flame cutting preheat time is not enough or too long, and avoid hand gun up or down in excess. 4.4 Operation and Use Warm Sparkle and heat metal can injure eyes and scald skin ●The operator must have professional cutting training and skillfully operate it, nonprofessional person cannot operate it. ●Track and bean adjust clearance by eccentric axis, long time use, clearance can become big and flexible. Check that appearance before operation, when essential, tight it, see content in Installing. ●Adjust cut plate, keep the plane with track. ●According to plate thickness and texture, choose proper nozzle, nozzle is vertical with plate, choose rational cutting speed and preheat time and suitable gas and cutting oxygen pressure. ●Anybody cannot touch flame area after ignition. Operator does his best to take less splash cutting mode to protect nozzle. Check heating flame and cutting oxygen jet, if nozzle dirty or damaged, replace and clear it in time. Clearing nozzle uses special tools. ●If backfire happens when cutting, shut in time gas valve, cut off power, machine off. If backfire valve is burn off, stop using it, replace it by professional persons. ●Operator should always pay attention to equipment running, if there is exceptional situation such as having gas and other peculiar smell, shut gas valve, prohibit leaving scene after opening machine. ●After finishing work, first shut gas valve, let out residual gas in pipe, shut power. ●Shut power if long time leaving machine. ●Don’t permit standing, stepping and weight lie on track, no hitting. 4-16



HC1020/1225/1530 Operator Manual



Use and Operate 4.5 Plasma Cutting Linkage Control 4.5.1 Sketch HyCutTM portable NC flame/plasma cutting machine could connect with any kinds of plasma cutters in theory, three using method as follows: 1) Cut automatically by connecting the plasma cutter switch end to attached switch wire of cutting machine without tracking and initial position, this way need to adjust to appropriate distance between cutting nozzle and plate by hand before cutting. When cutting, still adjust the distance anytime according to the flatness and thickness of plate, so it is relative not easy to control, it adapt to the extreme flat or thicker plate for slow cutting. 2) Connect plasma arc voltage tracking system(THC system), carry out cutting by arc voltage tracking without initial position, this way need to adjust to appropriate distance between cutting nozzle and plate by hand before cutting. When cutting, THC system will collect electric voltage continuously, the more distance, the larger electric voltage, otherwise, the same reason. System could control distance just right according to pre-set the arc voltage value, it has large helpful for out of flatness plate. 3) Connect plasma arc voltage tracking system, carry out cutting by arc voltage tracking and initial position, before every cutting, cutting gun go down automatically until touch the steel plate then rebound to preset height immediately(this action means initial position), cutting process is same with 2). After one section cutting, cutting gun auto go up to preset safe height, then move to next cutting section until finish cutting. This way has high automation and no manual intervene. If plate rust or bad electric-conduction, it is not easy to achieve initial position, then cut as 2). 4.5.2 Plasma Arc Voltage Auto-Tracking System 4.5.2.1 System Compose and External Connecting Diagram



HC1020/1225/1530 Operator Manual



4-17



Use and Operate 4.5.2.2 The Paraphrase for Every Parameter of Function Board Show window totally have seven showing state, except state is initial preparing state, others are self-set items, every items setting range is 000-255, details as follows: ---------------- Initial preparing state, or standby state; ---------------- Plasma arc voltage setting, unit is V, range general 80-180V; ---------------- Arc striking height (initial position) setting, the larger value, the larger distance between cutting nozzle and work-piece; ---------------- Sensitivity coarse adjustment, generally no need to change, the larger value, the lower sensitivity; ---------------- Sensitivity fine adjustment, the larger value, the lower sensitivity; ----------------Compensation up setting, as opposed to compensation down, up speed is slower due to gravity function, make them accord by offering compensation, the larger value, the more compensation and the faster speed. 【 Select】button, at self-set item, press repeatedly this button to change over cursor to intended value position, here value is bouncing all the time. 【 ┼/↑】 and 【 ─/↓】 button, ①press【 Select】button move the cursor to the value that want to modify, change the value by pressing this button; ②At initial preparing state, press【 ┼/ ↑】, cutting gun goes up, press again stop, press【 ─/↓】, cutting gun goes down, press again still stop, convenient for observing the up and down speed, then set correct compensation up value. Set/Save】button, change over → → → → → function in sequence by 【 pressing this button, meantime saved the last value. 【 Back/Test】button, ①At initial preparing state, press the button to carry out initial position action; ②At any self-setting item and collecting state, press this button could back to 【



state. Collect】button, used for collecting arc voltage, method find in 4.5.3.3. Any plasma cutting which fix THC system, before adjust every parameter, make sure arc control switch is “on”, refer to 4-4 page “4.5.3.4system”. Warning Plasma arc light and hot metal may harm eyes and scald skin, please make precaution



4-18



HC1020/1225/1530 Operator Manual



Use and Operate 4.5.3 Setting 4.5.3.1 Parameter Setting Process of Control Panel 1、Set compensation up value , it define by testing the actual up and down speed. 2、Set arc striking height (initial position) value . 3、Set arc voltage value, at unknown plasma cutter situation, collect arc voltage by hand trial cutting. 4、Observe tracking effect, set sensitivity value and if necessary. 4.5.3.2 Compensation Up Connect THC system with portable NC cutting machine correctly in advance , fix cutting gun to its clamper, keep cutting gun perpendicular to plate, turn on all power, make initial position switch “on”. a. At state, press【 ┼/↑】button, cutting gun go up , observe up speed, press【 ┼/↑】button again, stop going up. press【 ─/↓】button, cutting gun go down, press【 ─ /↓】again, stop gong down, then compare up and down speed. value. b. If up and down is near to the same, no need to change c. If up speed is lower, press【 Set/Save】button to change over to “ ” item, pre-set one value, then press【 Return/Test】button back to state, then do as “a” step, repeatedly like this until up and down speed are same. 4.5.3.3 Starting Arc Height (Initial Position) Non-contact plasma cutter’s starting arc and the best cutting height is decided by the performance of plasma cutter. Set the arc striking height by setting item, and tracking by this height. state, press【 Return/Test】button, cutting gun go down, then stop after a. At rebounding to one height when touch the plate, press【 Set/Save】button change over to “ ” state, repeatedly item, after preset one value, press【 Return/Test】button back to like this to observe height until satisfy. The larger value, the larger distance. 4.5.3.4 Plasma Arc Voltage Collecting Before cutting you should set suitable arc voltage if cut work-piece which connect THC system, it could help cutting gun to keep constant distance with plate’s arc ups and downs to achieve stable cutting for out of flatness plate. If can’t define arc voltage, then define by collecting. a. Refer to 4-11page “manual moving speed” method to adjust MS speed same with normal cutting work-piece speed. b. Select a flat area on edge of pre-cut plate, length about 50-100mm, fix initial position to arc striking height. At preparing state, press【 Collect】button, this time digital tube show xxx, and bouncing at some frequency, this is the state that prepare to collect. c. Press【 】button on system panel , after piecing the hole, press any button to make machine moving straightly, this time check the value on digital tube, press again 【 Collect】button when the value is relative stable, this time value shows xxx(xxx means arc voltage when plasma cutter cut stably), close cutting at immediately, about 3 second, system rebound to state, collect voltage successfully. d. Before collecting action could press【 Return/Test】button at any time to stop current action, and press【 Set/Save】button could check value, if collecting voltage is normal, press 【 Return/Test】back to state, then finish cutting. If cutting effect isn’t perfect, reset arc voltage again to adjust the best tracking state, in general, if cutting gun goes down all the time even touch steel plate means voltage is low, otherwise, voltage is high. HC1020/1225/1530 Operator Manual



4-19



Use and Operate 4.5.3.5 Setting Sensitivity Parameter The THC system collect the arc voltage by PMW pulse-width modulation theory , regard the set voltage as the base standard to keep and achieve rise or fall action with plate in cutting process, and respectively means sensitivity coarse adjustment and sensitivity fine adjustment. a. Sensitivity coarse adjustment , the larger value, the lower sensitivity. Generally set as . . b. Sensitivity coarse adjustmen , the larger value, the lower sensitivity. Generally set as c. Please set value firstly meantime keep value no change in order to stability and simplify of system. If value is lower than 200 and the sensitivity no obvious change, then to adjust value. 4.5.4 Attentions 1、If arc voltage tracking with initial position, need to make the initial position switch “on”, the indicator light is up this time. if the plate that will be cut have oxidize sign and don’t conduct electricity then initial position function lose effectiveness and also don’t rebound when torch touch the steel plate, this time close the snap switch at once then start again, adjust the arc striking height by hand or sweep away the oxide layer of steel plate then continue to operate. 2、When plasma cutting , the arc voltage have close relation with thickness of plate, machine speed, the performance of plasma cutter. When setting value, consult professional person and refer to plasma cutter manual. 4.5.5 Solve Problem 4.5.5.1 Definition of Connecting Electric Cable Connecting cable totally have 4 couples wire, connect by 9 core aviation plug and socket, 7 and 8 connect together, 9 hang in the air. Reliable connecting is core of arc voltage control. 4.5.5.2 Accidents Signal Checking Method Take down 8 core plug of beam (Prevent electric motor downward movement), then take down 9 core wire on collecting case, then test by multi-meter. 1）Check plasma switch action if normal Let system enter graph interface, make multi-meter two probe touch 1,2 wire separately then press down cutting button to check 1,2 wire if close; Press down cutting button again, check 1,2 wire if disconnect. 2）Check initial position if normal Make multi-meter two probe touch 5,6 wire separately, press【 Return/Test】button, check 5,6 wire if close, close is normal state. make multi-meter one probe touch 7 or 8 wire and another touch machine case, check if have voltage. Normal voltage value is 18V or so. 3）Check if have collecting voltage Connect one side of 9 core plug to collecting case, take down another side from host, make multi-meter two probe touch 3,4 wire separately, at cutting state, should have voltage output. If check any problem as above method, solve it respectively, otherwise submit professional person. 4-20



HC1020/1225/1530 Operator Manual



Use and Operate 4.6 Using technique of plasma cutting linkage control 4.6.1 Sketch HyCutTM Portable NC Flame/Plasma Cutting Machine could connect with any kinds of air plasma cutter machine，achieving perfect cutting effect，more techniques are necessary to learn. 4.6.2 Necessary and Sufficient Conditions 1、Operator have grasped the basic theory and operating technique of plasma cutting; 2、Plasma cutter must have non-contact arc striking function; 4.6.3 System Setting before Using Portable NC Cutting Machine 1、No configure or don’t use HyCut THC system, must set arc control switch “Off” in “System” (Picture 4-6-1); 2、Configure and use HyCut THC system, must set arc control switch “On” and save in “System”(Picture 4-6-2);



(4-6-1)



(4-6-2)



3、“Time-lapse” parameter setting is the key for plasma cutting , every time cutting gun from initial position to piece , all press as this order: “Torch down→Preheat→Piece Up →Piece Down →(Normal cutting until finish) → Torch up ”(Picture 4-6-3), so setting these parameter correctly is the key for using plasma cutting.



(4-6-3)



HC1020/1225/1530 Operator Manual



(4-6-4)



4-21



Use and Operate 3.1 “Torch Down” means the time after cutting gun idling run to intended position then goes down to certain height， this judge by your experience. There are two situation when plasma cutting: one is no configure THC or configure but don’t use initial position,, this situation you could set the time but usually not so accurate; Another is configure THC and use initial position, this situation should keep 00000 value, because cutting will go down automatically then rebound when touch the steel plate . 3.2 “Preheat” means preheat time when used for flame cutting, if plasma cutting, regard it as stay time that cutting gun quickly move to intended position, this could stable cutting gun instead of shaking seriously, if moving speed isn’t very quick, no need to set. 3.3 “Piece Up”, include previous value and back value. Previous value means the lifting time of cutting gun when piecing, used for protecting spray nozzle because sometimes the spraying dreg could damage and shorten lifetime of machine ， of course， this decide by plasma piecing ability and make sure don’t close arc; Back value means piece stop time, thicker steel plate need a little long piecing time, otherwise the same. Some plasma cutter machine, when start the cutting switch could deliver gas in advance, but attention that the piecing time must longer than deliver gas time, otherwise, cutting gun will start running when without piecing through steel plate. 3.4 “Piece Down”, is responding parameter for “Piece Up”, generally , after setting piece up time , then set piece down time, finish piecing then back to normal cutting height, but due to gravity function, the value for piece up is a little higher than piece down. 3.5 “Torch Up” means after cutting one section, cutting gun should lift to certain height，then idling run to next cutting point，generally 1.5 second is ok(Picture 4-6-4). The value after torch up means stop time after torch up to certain height, this usually used for flame cutting to avoid residual gas burn the work-piece, and no need to set this value when plasma cutting. Plasma cutting which fix THC system, please make sure every wires connect correctly and reliably.



4-22



HC1020/1225/1530 Operator Manual



Chapter Five



Maintenance & Parts



In This Section: 5.1Routine Maintenance………………………………………………………………………5-1 5.2Basic Troubleshooting………………………………………………………………………5-2 More Technical Questions……………………………………………………………………5-2 5.3 Clearance Adjustment………………………………………………………………………5-3 5.3.1 Clearance Adjustment between Host and Track………………………………………5-3 5.3.2 Clearance Adjustment between Beam and Host………………………………………5-3 5.4 System Circuitry……………………………………………………………………………5-4 5.5 Consumable Parts…………………………………………………………………………5-5 5.5.1 Cutting Nozzles………………………………………………………………………5-5 5.6 Gas Cutting Technics Reference……………………………………………………………5-6 1、Propane+Oxygen(GK3 Isotonic Nozzle) ………………………………………………5-6 2、Acetylene+Oxygen………………………………………………………………………5-6



HC1020/1225/1530 Operator Manual



5-0



5-00



HC1020/1225/1530 Operator Manual



Maintenance & Parts The environment for the portable NC cutter is relatively execrable and full of metal dust. The machine should be cleaned and maintained entirely. 5.1 Routine Maintenance Warning Electric shock can kill Disconnect electrical power before performing any maintenance. All work requiring removal of the power supply cover must be performed by a qualified technician.



Each Use



Every Week



Every 3 Months



1.Check gas pressure if within stated range，pipeline、valve、air pipe tie-in if loose or leak gas，hope if damage, gas safe device if effective，when necessary, tightening or replacing. 2. Check torch if loose, nozzle if damage. 3. Clear track and rack surface, don’t permit kernel and splash keeping on rack， keep smooth. 1. Orbit and trolley smooth. 2. Check main gas-in if have rubbish, each valve and pressure meter if working normally.



Replace damaged labels. Replace damaged power line or plug. Check track and each Check all driving parts Check all press button screw whether loose or whether loose or not， and choose switch not ，check control line check gear and rack, performance, replace connection whether loose when necessary, adjust it. damaged parts. or not.



Every 6 Months



HC1020/1225/1530 Operator Manual



Clean the inside of the power supply with air pressure or vacuum.



5-1



Maintenance & Parts 5.2 Basic Troubleshooting Error Cause 1、LCD no show when normally starting 1.1Check 220V power，fuse on socket; machine. 1.2Open the machine case，then check the wire of socket and switch if fall off; 1.3Check input power of ring transfer if 220V; 1.4 Check if the fuse of power board burned out，or if the 9 core plugs on the back of 5V power and system loose or fell off. 2、The machine shows a blue screen or color 2.1Check system back LCD readjust resistor, fault or no system interface. left and right full travel route adjust and watch. 3、When cutting, cursor normally follow 3.1Check step motor drive and R transformer if graph on LCD, but host no move or a connect power; direction no move. 3.2 Check step motor drive plug and connect line, driver and step motor if fall off host; 3.3Check axle end gear of step motor if loose. 4、Disk U file error, messy code or no read 4.1Confirm Disk U OK; file. 4.2 Disk U if FAT16(FAT) or FAT32(FAT) form, no format NTFS form; 4.3 If build hycut.cn directory under Disk U root directory, and program files are in this directory. 4.4 Open the machine case to check if USD wire fell off 4.5 Insert the disk U to the back of the system directly 5 、 After starting machine, press keys 5.1Confirm press keys if damage by using press without action or parts without reaction. keys diagnosis function; 5.2Check host and keyboard line if loose or fall. 6、Valve or motor no motion. 6.1Confirm valve or motor if damage. 6.2 Confirm press keys if damage by using press keys diagnosis function; 6.3 Check power panel 8 cores socket, cable on beam and connect insert parts on end if have output when press button; 6.4Switch 24V if normal, plug if fall off; 6.5Check host and function panel line connect if loose or fall off; 6.6Check system main board if indicator light on in press key. 7、When equipment moves, shake strongly. 7.1Motor gear and rack clearance irrelevancy, adjust it; 7.2Beam and host or host and track clearance irrelevancy, adjust it. 7.3 Check the driver if normal More Technical Questions If you are unable to fix the problem with your system by following this basic troubleshooting guide, please contact distributor or manufacturer. 5-2



HC1020/1225/1530 Operator Manual



Maintenance & Parts 5.3 Clearance Adjustment After running and using the equipment for a long period, some parts can loose, which can effect cutting precision, need adjusting clearance. 5.3.1 Clearance Adjustment between Host and Track If there is looseness between host and track, eccentric axis can be used for fastening in this procedure. After fastening it by turning the eccentric axis, turn this axis less than one circle anticlockwise to make the eccentricity mark as shown in illustration. When set up the eccentricity position, turn the corresponding nut forcibly. Eccentricity Mark



Eccentricity Mark



Eccentricity Mark



5.3.2 Clearance Adjustment between Beam and Host If there is looseness between beam and track, eccentric axis can be used for fastening in this procedure. After fastening it by turning the eccentricity axis, turn this axis less than one circle anticlockwise to make the eccentric mark as shown in illustration. When set up the eccentricity position, turn the corresponding nut forcibly.



HC1020/1225/1530 Operator Manual



5-3



Maintenance & Parts 5.4 System Circuitry



5-4



HC1020/1225/1530 Operator Manual



Maintenance & Parts 5.5 Consumable Parts 5.5.1 Cutting Nozzles Propane Nozzle NO. 0 1 2 3 4 5



Cutting Oxygen Hole Diameter mm 0.7 0.9 1.2 1.5 1.8 2.1



Cutting Thickness mm 5~10 10~20 20~35 35~60 60~90 90~130



Acetylene Nozzle NO. 00 0 1 2 3 4 5



Cutting Oxygen Hole Diameter mm 0.8 1.0 1.2 1.4 1.6 1.8 2.0



Cutting Thickness mm 5~10 10~20 20~30 30~50 50~70 70~90 90~120



HC1020/1225/1530 Operator Manual



5-5



Maintenance & Parts 5.6 Gas Cutting Technics Reference：



Nozzle NO.



1、Propane+Oxygen(GK3 Isotonic Nozzle) Cutting Oxygen Cutting Cutting Gas Pressure Hole Thickness Speed MPa Diameter



00 0 1 2 3 4 5 6 7



mm



mm



0.7 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.4



5~10 10~20 20~30 30~50 50~70 70~90 90~120 120~160 160~200



mm



600~450 0.2~0.3 480~380 0.2~0.3 400~320 0.25~0.35 350~280 0.25~0.35 300~240 0.3~0.4 260~200 0.4~0.6 210~170 0.4~0.6 180~140 0.5~0.8 150~110 0.6~0.9



Nozzle NO.



2、Acetylene+Oxygen Cutting Oxygen Cutting Cutting Hole Thickness Speed Diameter



00 0 1 2 3 4 5 6 7 8



mm



mm



0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.4 2.8 3.2



5~10 10~20 20~30 30~50 50~70 70~90 90~120 120~160 160~200 200~270



Oxygen



mm



Gas Consumption



Propane >0.03 >0.03 >0.03 >0.03 >0.04 >0.04 >0.04 >0.05 >0.05



Gas Pressure MPa Oxygen



600~450 0.2~0.3 480~380 0.2~0.3 400~320 0.25~0.35 350~280 0.25~0.35 300~240 0.3~0.4 260~200 0.3~0.4 210~170 0.4~0.6 180~140 0.5~0.8 150~110 0.6~0.9 120~90 0.6~1.0



Oxygen m³/h 0.9~1.3 1.3~1.8 2.5~3.0 3~4 4.5~6 5.5~7 8.5~10.5 12~15 21~24.5



Propane l/h 340 340 470 470 620 620 620 780 1000



Gas Consumption



Propane >0.03 >0.03 >0.03 >0.03 >0.04 >0.04 >0.04 >0.05 >0.05 >0.05



Remarks



Remarks



Oxygen Acetylene m³/h l/h 0.9~1.3 340 1.3~1.8 340 2.5~3 470 3~4 470 4.5~6 620 5.5~7 620 8.5~10.5 620 12~15 780 21~24.5 1000 26.5~32 1000



Note: cutting condition in the chart: 1. Oxygen purity is no less than 99.5%. 2. Cutting steel carbon content ≤0.45%. 3. Cutting way is vertical. 4. Oxygen pressure is cutting oxygen pressure in front of cutting torch.



5-6



HC1020/1225/1530 Operator Manual



EC DECLARATION OF CONFORMITY According to the following EC Directives - Machinery Directive : 98/37/EC - Low Voltage Directive : 2006/95/EC - Electromagnetic Compatibility Directive : 2004/108/EC The undersigned, _ _, representing Shenyang HyCut NC Tech. Co., Ltd. / No. 30, Huahai Road, Economic & Technological Development Zone of Shenyang 110141, Liaoning Province, P. R. of China, manufacturer, declares that the machine described hereafter:



Portable NC Flame/Plasma Cutting Machine Model: HC1015, HC1020, HC1225, HC1530



Provided that it is used and maintained in accordance with the general accepted codes of good practice and the recommendations of the instructions manual, meet the essential safety and health requirements of the Machinery Directive, Low Voltage Directive and Electromagnetic Compatibility Directive. For the most specific risks of this machine, safety and compliance with the essential requirements of the Directive has been based on elements of: • EN ISO 12100-1: 2003 / Safety of Machinery - Basic concepts, general principles for design Part 1: Basic terminology, methodology. • EN ISO 12100-2: 2003 / Safety of Machinery - Basic concepts, general principles for design Part 2: Technical principles and specifications. • EN 294: 1992 / Safety of machinery - Safety distance to prevent danger zones being reached by the upper limbs • EN 349: 1993 / Safety of machinery - Minimum gaps to avoid crushing of parts of the human body • EN 414: 2000 / Safety of machinery - Rules for the drafting and Presentation of safety standards • EN 418: 1992 / Safety of machinery - Emergency stop equipment, functional aspects - Principles for design • EN 953: 1997 / Safety of machinery - Guards - General requirements for the design and construction of fixed and movable guards • EN 954-1: 1996 / Safety of machinery - Safety-related parts of control systems Part 1: General principles for design • EN 983: 1996 / Safety of machinery - Safety requirements for fluid power systems and their components Pneumatics • EN 1037: 1995 / Safety of machinery - Prevention of unexpected start-up • EN 1050: 1996 / Safety of machinery - Principles for risk assessment • EN 1070:1998 / Safety of Machinery - Terminology • EN 1088: 1995 / Safety of machinery - Interlocking devices associated with guards - Principles for design and selection • EN ISO 14122-1:2001 "Safety of machinery - Permanent means of access to machinery – Part 1: Choice of fixed means of access between two levels" • EN ISO 14122-2:2001 "Safety of machinery - Permanent means of access to machinery – Part 2: Working platforms and walkways" • EN ISO 14122-3:2001/ Safety of machinery - Permanent means of access to machinery – Part 3: Stairs, stepladders and guard-rails • EN ISO 14122-4:2004 "Safety of machinery - Permanent means of access to machinery – Part 4: Fixed ladders" • EN 60204-1: 2006 / Safety of machinery - Electrical equipment of machines - Part 1: General requirements. Industrial electrical device. • EN 61000-6-2 : 2001 / Electromagnetic compatibility (EMC) Part 6-2 : Generic standards - Immunity for industrial environments • EN 61000-6-4 : 2001 / Electromagnetic compatibility (EMC) Part 6-4 : Generic standards - Emission standard for industrial environments Date: Signature: Qualification:



HC1020/1225/1530 Operator Manual



General Manager



Shenyang HyCut NC Tech. Co., Ltd.



Add：No. 30, Huahai Road, Shenyang Economic & Technological Development Zone 110141 Liaoning Province, P. R. of China Tel：(86)24-25817560 25819560 Fax：(86)24-25374560 Website：http://www.hycut.cn E-mail：[email protected]