maintenance manual for ajan precision plasma 260 amper plasma

AJAN ELEKTRONIK SERVIS SANAYI TICARET LTD. STI.

MAINTENANCE MANUAL FOR AJAN PRECISION

PLASMA 260 AMPER PLASMA CUTTING MACHINES

MAINTENANCE MANUAL FOR AJAN PRECISION PLASMA CUTTING MACHINES

INDEX

ii


INDEX

i

SECTION 1. INDEX Section name .................................................................................................................. Page number

SECTION 1. INDEX .......................................................................................................................... i

SECTION 2. TABLE OF FIGURES .............................................................................................. iv

SECTION 3. TABLES .................................................................................................................... vii

SECTION 4. COMPANY PROFILE ...............................................................................................1

SECTION 5. INSTALLATION AND ELECTROMAGNETIC COMPATIBILITY .................2

5.1. EMC INTRODUCTION .......................................................................................................... 2

5.2. INSTALLATION AND USAGE ............................................................................................. 2

5.3. ESTIMATION OF AREA ........................................................................................................ 2

5.4. MAIN POWER......................................................................................................................... 3

5.5. EQUIPOTENTIAL BONDINGS ............................................................................................. 3

SECTION 6. SAFETY .......................................................................................................................4

6.1. RECOGNIZE SAFETY INFORMATION .............................................................................. 4

6.2. FOLLOWING SAFETY INSTRUCTIONS ............................................................................ 4

6.3. DANGER, WARNING, CAUTION ........................................................................................ 4

6.4. FIRE AND EXPLOSION RISKS WHILE CUTTING ............................................................ 5

6.4.1. Prevention from Explosion ................................................................................................ 5

6.5. ELECTRIC SHOCK................................................................................................................. 6

6.5.1. Prevention from Electric Shock ......................................................................................... 6

6.6. TOXIC FUMES OCCUR WHILE CUTTING ........................................................................ 7

6.7. PLASMA ARC RAY INJURES EYES AND SKIN ............................................................... 7

6.7.1. GROUNDING SAFETY ................................................................................................... 8

6.7.2. SAFETY FOR COMPRESSED CYLINDERS ................................................................. 8

6.7.3. GAS CYLINDERS CAN EXPLODE ............................................................................... 8

6.8. NOISE DAMAGE .................................................................................................................... 9

6.9. SAFETY SIGNS AND DESCRIPTIONS .............................................................................. 10

6.10. WELDING FUMES AND GASES ...................................................................................... 12

6.10.1. FUMES AND GASES .................................................................................................. 12

6.10.2. TOXIC FUMES AND GASES ..................................................................................... 13

6.10.3. LOW-TEMPERATURE PLASMA FUMES, EXHAUST GAS PURIFICATION FOR

ORGANIC ..................................................................................................................... 13

SECTION 7. WARRANTY .............................................................................................................14

7.1. AJAN BRAND PLASMA AND OXY-FUEL CUTTING MACHINE WARRANTY

CONDITIONS ..................................................................................................................... 14

7.2. CASES CAUSING OUT OF WARRANTY.......................................................................... 15

SECTION 8. PREUSAGE ...............................................................................................................16

8.1. ATTENTIONS BEFORE STARTING CUTTING WITH PRECISION PLASMA

MACHINES ......................................................................................................................... 16

8.1.1. CONTROL OF THE CYLINDERS AND THEIR PRESSURE ..................................... 16

8.1.2. STARTING GENERATOR ............................................................................................ 16

8.1.3. STARTING CNC UNIT .................................................................................................. 16

8.1.4. CHASSIS CABLE AND CONTROL ............................................................................. 16


INDEX

ii

8.1.5. USAGE OF CUTTING TIPS .......................................................................................... 16

8.1.6. OPERATING JET FILTER ............................................................................................ 17

8.2. ATTENTIONS BEFORE STARTING CUTTING WITH P MACHINES ........................... 18

8.2.1. CONTROL OF THE CYLINDERS AND THEIR PRESSURE ..................................... 18

8.2.2. STARTING ..................................................................................................................... 18

8.2.3. USAGE OF OXYGEN CUTTING TIPS ........................................................................ 18

SECTION 9. MAINTENANCE INSTRUCTIONS ....................................................................... 19

SECTION 10. REPLACEMENT PLANS ...................................................................................... 20

SECTION 11. MECHANICAL PARTS ......................................................................................... 25

11.1. VENTILATION UNIT ......................................................................................................... 25

11.2. CUTTING TABLE ............................................................................................................... 28

11.3. SUCTION FAN .................................................................................................................... 29

11.4. MUFFLER ............................................................................................................................ 31

11.5. JET FILTER ......................................................................................................................... 32

11.5.1. THE DESCRIPTION OF THE JET FILTER PANEL ................................................. 35

11.5.2. DUST BAG SHAKER VALVE .................................................................................... 37

11.6. PLASMA HEAD UNIT ....................................................................................................... 38

11.7. PLASMA BRIDGE UNIT ................................................................................................... 39

11.8. X AXIS GEARBOX ............................................................................................................. 41

11.9. Y AXIS GEARBOX ............................................................................................................. 42

11.10. AJAN X-Y AXIS AC SERVO MOTOR ........................................................................... 43

11.11. AJAN Z AXIS AC SERVO MOTOR ................................................................................ 44

11.12. AJAN PLASMA TORCH .................................................................................................. 45

11.12.1. AJAN PLASMA TORCH CONNECTION DIAGRAM ............................................ 47

11.13. GENERATOR .................................................................................................................... 48

11.13.1. TORCH COOLING SYSTEM .................................................................................... 49

11.14. CNC UNIT ......................................................................................................................... 50

11.15. GENERATOR CONNECTION ......................................................................................... 51

SECTION 12. CABLES ................................................................................................................... 52

12.1. INTERFACE SHEET CONNECTION CABLES ............................................................... 52

12.1.1. IHS LIMIT CABLE ...................................................................................................... 53

12.1.2. X, Y, TR, TL AXIS DRIVE CABLES ......................................................................... 54

12.1.3. GAS CONTROL CABLE ............................................................................................. 55

12.1.4. RELAY CONTROL KABLOSU .................................................................................. 56

12.1.5. GAS CONTROL AND RELAY CONTROL CABLES FUNCTIONS ....................... 57

12.1.6. HAND CONTROL CABLE ......................................................................................... 58

12.1.7. LIMIT CABLE .............................................................................................................. 59

12.1.8. RESUME CABLE ......................................................................................................... 60

12.2. DRIVE CONNECTION CABLES ....................................................................................... 61

12.2.1. MOTOR CABLE .......................................................................................................... 62

12.2.2. DRIVE POWER CABLE .............................................................................................. 64

12.3. CNC-GENERATOR CABLE CONNECTIONS ................................................................. 65

12.3.1. CURRENT-PLST/OKMO/ARC CABLE ..................................................................... 65

12.3.2. REMOTE CONTROL CABLE ..................................................................................... 66

12.3.3. ELECTRODE-NOZZLE CABLE ................................................................................. 67

12.4. Y AXIS CABLE CONNECTIONS ...................................................................................... 68

12.4.1. PLASMA TRANSMITTER CABLE ............................................................................ 68


INDEX

iii

12.4.2. OHMIC-OHMIC IHS-F5 CABLE ................................................................................ 69

12.4.3. PLASMA VALVE CABLE .......................................................................................... 70

12.4.4. OXYGEN(R) VALVE CABLE .................................................................................... 71

12.4.5. HEAD LIMIT(R)-THC(R)-PREHEAT SENSOR(R) CABLE ..................................... 72

12.4.6. OXYGEN TRANSMITTER CABLE ........................................................................... 74

12.4.7. OXYGEN(L) VALVE CABLE .................................................................................... 75

12.4.8. HEAD LIMIT(L)-THC(L)-PREHEAT SENSOR(L) CABLE ..................................... 76

SECTION 13. AJAN PRECISION PLASMA 260AMPER SPECIFICATIONS .......................78

13.1. AJAN PLASMA TORCH SCHEMA AND CONSUMABLES .......................................... 78

13.2. AJAN PRECISION PLASMA SYSTEM CONSUMABLES LIFETIMES AND GAS

CONSUMPTIONS ............................................................................................................... 80

13.3 PRECISION PLASMA 260AMPER PLASMA AUTOMATIC GAS CONSOLE .............. 81

13.4. ALL INCLUSIVE CONTROL PANEL ............................................................................... 82

13.5. REMOTE CONTROL HARDWARE .................................................................................. 83

13.6. HEIGHT MEASUREMENT SOFTWARE AND HARDWARE WITH 1-ARC 2-SLIDING

SLEDGE 3-OHMIC CONTACT ......................................................................................... 84

13.7. AUTOMATIC CUTTING HEIGHT CORRECTION SOFTWARE RELATED TO

ELECTRODE AND NOZZLE WEAR ............................................................................... 85

13.8 PRECISION PLASMA 260AMPER GENERATOR ........................................................... 86

13.9. SYSTEM GAS REQUIREMENT ........................................................................................ 87

SECTION 14. CUTTING CHARTS ...............................................................................................88

SECTION 15. CNC UNIT AND GENERATOR CARDS ..........................................................108

SECTION 16. CONNECTION SCHEMAS .................................................................................124

16.1. PLASMA GENERATOR CIRCULATION SCHEMA ..................................................... 137

16.2. CARDS USED IN AJAN PRECISION PLASMA PLASMA CUTTING SYSTEM........ 167

SECTION 17. PRECISION PLASMA 260AMPER SPARE PARTS CHART ........................168

SECTION 18. AJAN OXYGEN- PRECISION PLASMA 260AMPER PLASMA

DESCRIPTION OF THE CNC UNIT .....................................................................................170

18.1. GUIDE FOR THE OPERATION OF THE UNIT ............................................................. 170

18.2. MENU: 0 (MAIN MENU) ................................................................................................. 173

18.3. MENU:1 ............................................................................................................................. 178

18.4. MENU:2 ............................................................................................................................. 186

18.5. OPERATION OF HAND CONTROL UNIT .................................................................... 192

18.6. G PREPARATORY AND AUXILIARY FUNCTIONS USED IN CNC ......................... 194

18.7. AUXILIARY CODES: ....................................................................................................... 195

18.8. SAMPLE PROGRAMS ..................................................................................................... 195


TABLE OF FIGURES

iv

SECTION 2. TABLE OF FIGURES Drawing name ................................................................................................................ Page number

Figure 1. Protectors used during cutting.............................................................................................. 7

Figure 2. General replacement plan ................................................................................................... 20

Figure 3. 3000x12000 mm plasma machine with jet filter replacement plan ................................... 21

Figure 4. 3000x6000 mm plasma machine with jet filter replacement plan ..................................... 22

Figure 5. 3000x12000 mm plasma machine without jet filter replacement plan .............................. 22

Figure 6. 2000x6000 mm plasma machine without jet filter replacement plan ................................ 23

Figure 7. 2000x6000 mm plasma machine with jet filter replacement plan ..................................... 23

Figure 8. 3000x6000 mm plasma machine without jet filter replacement plan ................................ 24

Figure 9. 3000 mm first block ventilation system ............................................................................. 25

Figure 10. 3000 mm first block ventilation unit installation drawing ............................................... 26

Figure 11. 3000 mm first block cover opening/closing handle system installation drawing ............ 27

Figure 12. 1500 mm cutting table installation drawing ..................................................................... 28

Figure 13. Suction fan ....................................................................................................................... 29

Figure 14. Suction fan installation drawing ...................................................................................... 30

Figure 15. Muffler ............................................................................................................................. 31

Figure 16. Jet filter ............................................................................................................................ 32

Figure 17. Total area of the cartridges used in the jet filter .............................................................. 34

Figure 18. Jet filter panel ................................................................................................................... 35

Figure 19. Dust bag shaker valve spare part list ................................................................................ 37

Figure 20. Plasma head installation drawing ..................................................................................... 38

Figure 21. Plasma bridge installation drawing .................................................................................. 39

Figure 22. Plasma bridge unit installation drawing ........................................................................... 40

Figure 23. X axis gearbox installation drawing................................................................................. 41

Figure 24. Y axis gearbox installation drawing................................................................................. 42

Figure 25. Ajan X-Y axis AC servo motor installation drawing ....................................................... 43

Figure 26. Ajan Z axis AC servo motor installation drawing ........................................................... 44

Figure 27. Ajan plasma torch installation drawing ........................................................................... 45

Figure 28. Ajan plasma torch connection diagram ............................................................................ 47

Figure 29. Generator .......................................................................................................................... 48

Figure 30. Torch cooling liquid drum warning label ........................................................................ 49

Figure 31. CNC unit .......................................................................................................................... 50

Figure 32. Generator connection diagram ......................................................................................... 51

Figure 33. Interface sheet connection cables ..................................................................................... 52

Figure 34. Drive................................................................................................................................. 61

Figure 35. Ajan torch schema ............................................................................................................ 78

Figure 36. Ajan precısıon plasma 260 amper Electrode and Nozzle required life time chart ........... 80

Figure 37. Ajan precısıon plasma 130 amper Electrode and Nozzle required life time chart ........... 80

Figure 38. Other conventional automatic gas consoles ..................................................................... 81

Figure 39. Ajan automatic gas console .............................................................................................. 81

Figure 40. New conception Ajan all inclusive plasma cutting system .............................................. 82

Figure 41. Schema for required connection between units on Ajan all inclusive plasma system ..... 83

Figure 42. Ajan initial height control systems................................................................................... 84

Figure 43. Ohmic system comparison ............................................................................................... 84

Figure 44. Torch height control systems comparison ....................................................................... 85

Figure 45. precısıon plasma 260 Amper generator ........................................................................... 86

Figure 46. Arc transfer card............................................................................................................. 108

Figure 47. Firing box card ............................................................................................................... 109


TABLE OF FIGURES

v

Figure 48. Flow card ........................................................................................................................ 110

Figure 49. IGBT driver card ............................................................................................................ 111

Figure 50. IHS limit card ................................................................................................................. 112

Figure 51. Interface sheet ................................................................................................................ 113

Figure 52. precısıon plasma generator control card ........................................................................ 114

Figure 53. precısıon plasma Generator control card........................................................................ 115

Figure 54. Condenser card ............................................................................................................... 116

Figure 55. Logic control card .......................................................................................................... 117

Figure 56. Logic control card .......................................................................................................... 118

Figure 57. Front panel card.............................................................................................................. 119

Figure 58. Power card ...................................................................................................................... 120

Figure 59. Resistance card ............................................................................................................... 121

Figure 60. Start circuit ..................................................................................................................... 122

Figure 61. Varistor card ................................................................................................................... 123

Figure 62. Plasma plate ................................................................................................................... 124

Figure 63. Plasma plate hose gas connection schema ..................................................................... 125

Figure 64. Oxygen plate .................................................................................................................. 126

Figure 65. Oxy-Plasma hose gas connection schema ...................................................................... 127

Figure 66. Plasma plate card connection schema ............................................................................ 128

Figure 67. precısıon plasma automatic gas console plasma plate connection schema .................... 129

Figure 68. precısıon plasma single head oxygen plate connection schema..................................... 130

Figure 69. precısıon plasma automatic gas console double head plate connection schema ............ 131

Figure 70. precısıon plasma double head oxygen plate connection schema ................................... 132

Figure 71. precısıon plasma automatic gas console double oxygen plate connection schema ....... 133

Figure 72. precısıon plasma four head oxygen plate connection schema ....................................... 134

Figure 73. precısıon plasma triple head plate connection schema ................................................. 135

Figure 74. Interface connection schema .......................................................................................... 136

Figure 75. Plasma generator circulation schema ............................................................................. 137

Figure 76. precısıon plasma 260A generator connection schema .................................................. 138

Figure 77. precısıon plasma 260A+oxygen cutting CNC connection schema ................................ 139

Figure 78. precısıon plasma 260A+double head oxygen cutting CNC connection schema ........... 140

Figure 79. Arc voltage divider connection schema ........................................................................ 141

Figure 80. Arc voltage control system connection schema ............................................................. 142

Figure 81. Axis control system connection schema ........................................................................ 143

Figure 82. precısıon plasma generator control card connection schema ......................................... 144

Figure 83. Flow LED control system connection schema ............................................................... 145

Figure 84. Plasma start control card connection schema ................................................................ 146

Figure 85. Jet filter system connection schema ............................................................................... 147

Figure 86. precısıon plasma 260A main power connection schema ............................................... 148

Figure 87. precısıon plasma oxygen+marking control card connection schema ............................. 149

Figure 88. IGBT drive system connection schema ......................................................................... 150

Figure 89. precısıon plasma double head control card connection schema..................................... 151

Figure 90. precısıon plasma double head plate connection schema ................................................ 152

Figure 91. Logic card input-output control connection schema ...................................................... 153

Figure 92. Plasma control connection schema ................................................................................ 154

Figure 93. precısıon plasma power control connection schema ...................................................... 155

Figure 94. CNC power system connection schema ......................................................................... 156

Figure 95. Remote control start-stop system connection schema ................................................... 157

Figure 96. Servo motor drive system connection schema ............................................................... 158

Figure 97. THC unit system connection schema ............................................................................. 159


TABLE OF FIGURES

vi

Figure 98. Logic card input-output controls schema ....................................................................... 160

Figure 99. Generator fan, CNC connection schema ........................................................................ 161

Figure 100. Generator fan, CNC connection schema ...................................................................... 162

Figure 101. Interface DSUB output sockets connection schema .................................................... 163

Figure 102. precısıon plasma block connection output connection schema ................................... 164

Figure 103. precısıon plasma 260A connection schema ................................................................. 165

Figure 104. precısıon plasma CNC plasma main transformer ........................................................ 166

Figure 105. Hand control unit label ................................................................................................. 192


TABLES

vii

SECTION 3. TABLES Table name ..................................................................................................................... Page number

Table 1. Table of safety signs and descriptions ................................................................................. 10

Table 2. IHS limit cable color and functions table ............................................................................ 53

Table 3. X, Y, TR, TL axis drive cables color and functions table ................................................... 54

Table 4. Gas control cable color and functions table ........................................................................ 55

Table 5. Relay control cable color and functions table ..................................................................... 56

Table 6. Gas control and relay control cables color and functions table ........................................... 57

Table 7. Hand control cable color and functions table ...................................................................... 58

Table 8. Limit cable color and functions table .................................................................................. 59

Table 9. Resume cable color and functions table .............................................................................. 60

Table 10. Motor cable color and functions table ............................................................................... 62

Table 11. Motor cable color and functions table ............................................................................... 62

Table 12. Motor cable lengths with respect to Y axis lengths ........................................................... 63

Table 13. Drive power cable color and functions table ..................................................................... 64

Table 14. Current-PLST/OKMO/Arc cable color and functions table .............................................. 65

Table 15. Remote control cable color and functions table ................................................................ 66

Table 16. Plasma transmitter cable color and functions table ........................................................... 68

Table 17. Ohmic-Ohmic IHS-F5 cable color and functions table ..................................................... 69

Table 18. Plasma valve cable color and functions table .................................................................... 70

Table 19. Oxygen(R) valve cable color and functions table ............................................................. 71

Table 20. Head limit(R) cable color and functions table ................................................................... 72

Table 21. Torch height control(R) cable color and functions table ................................................... 73

Table 22. Preheat sensor(R) cable color and functions table ............................................................ 73

Table 23. Oxygen transmitter cable color and functions table .......................................................... 74

Table 24. Oxygen(L) valve cable color and functions table.............................................................. 75

Table 25. Head limit(L) cable color and functions table ................................................................... 76

Table 26. Torch height control(L) cable color and functions table ................................................... 77

Table 27. Preheat sensor(L) cable color and functions table ............................................................. 77

Table 28. Ajan precısıon plasma 260 plasma generator gas flow rates ............................................. 80

Table 29. precısıon plasma 260A generator technical specifications ................................................ 86

Table 30. System gas requirement ..................................................................................................... 87

Table 31. System gas requirement ..................................................................................................... 87

Table 32. Mild steel, O2 Plasma/O2 Shield, 30A cutting chart ........................................................ 88

Table 33. Mild steel, O2 Plasma/Air Shield, 40A cutting chart ........................................................ 89

Table 34. Mild steel, O2 Plasma/O2 Shield, 80A cutting chart ........................................................ 90

Table 35. Mild steel, O2 Plasma/O2 Shield, 130A cutting chart ...................................................... 91

Table 36. Mild steel, O2 Plasma/O2 Shield, 260A cutting chart ...................................................... 92

Table 37. Stainless steel, F5 Plasma/N2 Shield, 45A cutting chart .................................................. 93

Table 38. Stainless steel, N2 Plasma/N2 Shield, 45A cutting chart .................................................. 94

Table 39. Stainless steel, Air Plasma/Air Shield, 80A cutting chart ................................................. 95

Table 40. Stainless steel, F5 Plasma/N2 Shield, 80A cutting chart .................................................. 96

Table 41. Stainless steel, Air Plasma/Air Shield, 130A cutting chart ............................................... 97

Table 42. Stainless steel, H35 Plasma/N2 Shield, 130A cutting chart .............................................. 98

Table 43. Stainless steel, N2 Plasma/N2 Shield, 130A cutting chart ................................................ 99

Table 44. Stainless steel, Air Plasma/Air Shield, 260A cutting chart ............................................. 100

Table 45. Stainless steel, H35 Plasma/N2 Shield, 260A cutting chart ............................................ 101

Table 46. Stainless steel, H35 Plasma/N2 Shield, 260A cutting chart ............................................ 102

Table 47. Aluminum, N2 Plasma/N2 Shield, 45A cutting chart ..................................................... 103


TABLES

viii

Table 48. Aluminum, Air Plasma/Air Shield, 130A cutting chart .................................................. 104

Table 49. Aluminum, H35 Plasma/N2 Shield, 130A cutting chart ................................................. 105

Table 50. Aluminum, H35 Plasma/N2 Shield, 260A cutting chart ................................................. 106

Table 51. Aluminum, Air Plasma/Air Shield, 260A cutting chart .................................................. 107

Table 52. Cards used in precısıon plasma plasma cutting system ................................................... 167

Table 53. precısıon plasma 260A spare parts chart ......................................................................... 168

Table 54. G and preparatory M codes used in CNC........................................................................ 194

Table 55. Auxiliary codes used in CNC .......................................................................................... 195


COMPANY PROFILE

1

SECTION 4. COMPANY PROFILE

Manufacturer since 1973 Ajan Elektronik, established in 1973, started its life by manufacturing uninterruptable power supply

systems. The firm decided to manufacture Electrical Discharge Machines and released the first

machine in 1975 to the market.

In early years due to the conditions of the day, the company manufactured hydraulic machines, but

today the company switched to AC servo controlled machines.

Ajan Elektronik started to work on CNC projects in 1988–89, and manufactured the first CNC

Erosion Machine in 2000. Continuing working on this subject in R&D department, the company

developed and manufactured CNC Milling Machines, CNC Lathes, CNC Plasma and Oxy-Fuel

Cutting Machines, CNC Drilling Machines and CNC Laser Cutting Machines.

All the CNC control units and software, servo drives and AC servo motors of the manufactured

machines are completely own production of the company.

Ajan Elektronik provides AjanCAD Ajan Drawing software free of charge with the manufactured

machines to the customers.

The company supplies 85% of the raw and intermediary materials used in manufacturing of the

machines, whose design is completely done by itself, from the domestic market. Hence, the

company supports the economy of the country.

In addition, Ajan Elektronik began many new projects according to the customer demands.

As a result of giving importance to quality, the company has won ISO 9001:2000 Quality

Certificate on June 24th 2003.

AJAN ELEKTRONIK SERVIS SAN. VE TIC. LTD. STI.

Address : Merkez Mah. 67. Sk. No:3 Sasali-Cigli / Izmir / TURKEY

Web : www.ajancnc.com

e-mail : [email protected]

Tel : +902323273480

Fax : +902323273430


INSTALLATION AND ELECTROMAGNETIC COMPATIBILITY

2

SECTION 5. INSTALLATION AND ELECTROMAGNETIC COMPATIBILITY

5.1. EMC INTRODUCTION

Ajan Plasma Machine with CE mark is built compliance with machinery directive 98/37/EC, low

voltage directive 73/23/EEC and EMC directive 89/336/EEC.

CNC PLASMA AND

OXY-FUEL CUTTING

MACHINES

TS EN 292–1/292–2

TS 10316 EN 60204–1

TS EN 50370–2

TS EN 61000–6–2

TS EN 1050

TS EN 61310–1/2

TS EN 61496–1

TS EN 1037

TS EN 953

TS EN 563

TS EN ISO 9001:2000

5.2. INSTALLATION AND USAGE

The user is responsible for the specified directives while using Ajan brand plasma, oxygen

machines and equipments. During solving any electromagnetic problem, at first the technical

documents supplied by the manufacturer firm then technical assistance of the firm must be applied.

In some cases, although the defects can be simply solved, because of unauthorized actions may

cause the solution hard.

5.3. ESTIMATION OF AREA

The user should specify the area’s situation by taking into account the following electromagnetic

influence risks before the installation.

Supply cables, control cables, telephone cables near the machine’s control units

Radio and television transmitters and receivers

Computer and other control units

Safety critical equipments

The health devices like pacemaker and hearing equipments and the people using these

Calibration and measurement devices

The indicated influences differ depending on the building structure and other activities in the

surrounding area. These may extend beyond the surrounding area.


INSTALLATION AND ELECTROMAGNETIC COMPATIBILITY

3

5.4. MAIN POWER

The grounding must take place at the main power.

The main power of the machine must be connected in accordance to the manufacturer’s directives.

If any interference or undulation at the current occurs, a filter (regulator) can be added to the main

power or the supply cable can be shielded. In addition, it is advised that the electrical supply cable

must be in length of maximum 5 meters and the temperature of the ambiance must not extend 40ºC.

Under the case of that the allowed temperature is extended, the cutting current should be reduced. It

is suitable for the cables to be put into a metal conduit in order to prevent having hazards.

5.5. EQUIPOTENTIAL BONDINGS

The machine produces high voltage during firing. The operator must not touch the cutting

equipments (torch, electrodes, etc.) during firing in order to prevent an electric shock. In addition to

this, unearthed work piece and all equipments connected to the machine includes high voltage

during cutting and this causes critical risk. So grounding of the work piece and all equipments must

be supplied.


SAFETY

4

SECTION 6. SAFETY

6.1. RECOGNIZE SAFETY INFORMATION

The symbols shown in this section are used at areas where potential risks may

occur. Understand the potential personal injury and follow the instructions to prevent the hazard

when you see a safety symbol in this manual or on your machine.

6.2. FOLLOWING SAFETY INSTRUCTIONS

Read all safety messages and warnings in this manual and safety labels on your machine.

Keep the safety labels on your machine seen. For that, use cleaning materials that does not

damage the labels while cleaning. Replace the damaged and missing labels with a new one.

Learn how to operate the machine and its controls. Do not allow unauthorized or ignorant

person to operate the machine.

Keep the machine in suitable working conditions. Unauthorized modifications on the machine

may affect wrongly the safety and operation of the machine.

6.3. DANGER, WARNING, CAUTION

DANGER word identifies the most serious hazards like “ELECTRIC SHOCK CAN KILL”.

WARNING symbol follows the instructions that may cause injury or death when they are not

correctly obeyed. “OXYGEN CUTTING CAN CAUSE EXPLOSION”

A CAUTION safety message identifies the instructions that may cause damage to the machine

or equipment if it is not correctly followed. “COOLING PUMP WILL BE DAMAGED IF IT IS

RUN WITH WATER ONLY”


SAFETY

5

6.4. FIRE AND EXPLOSION RISKS WHILE CUTTING

Prevention from Fire

Keep safety of the cutting area before starting to cut and place a fire extinguisher near you.

Do not place any flammable or explosive materials within 2 meters of the cutting area.

Do not handle the hot cut material or wait until it cools.

Do not cut containers including flammable or explosive material, pressurized gases or toxic

materials.

Flammable atmosphere should be removed from the area before cutting.

WARNING

Explosion Hazard

Argon-Hydrogen

Hydrogen is a flammable gas that may cause an explosion hazard. Keep cylinders and hoses

containing Hydrogen away from the flame. Keep torch hoses away from flame and spark during

Hydrogen-Argon plasma cutting.

6.4.1. Prevention from Explosion

If there is possibility of that explosive smokes or vapors exist in the area, do not use plasma

system.

Do not cut containers including pressurized cylinders, hoses or any closed containers.


SAFETY

6

6.5. ELECTRIC SHOCK

It can cause fatal shocks or severe burns to touch parts containing electricity.

The plasma systems work in principle of completing electric current between the cutting

torch and the work piece. So since work piece and anything touching the work piece area

part of this electrical circuit, do not touch the torch body while plasma system is

operated.

6.5.1. Prevention from Electric Shock

All Ajan plasma systems work with open circuit 300 V direct current high voltage principle.

Follow the instructions indicated below for safety:

Wear insulated gloves, boots, and dry clothes.

Do not contact to wet any surface while operating the plasma system.

Prevent physical contact from the ground or any material in connection with the ground.

For that, you can use dry insulating mat or cover. If the working area is damp, be

careful.

Inspect frequently the durability of main supply cables. Replace the damaged cables

with a new one. Bare wiring can cause kill.

Disconnect the main power before cleaning or changing the parts of torch unit.

Do not pick up the work piece or cut materials during cutting.

Before acting on the electric unit, disconnect electrical connections and wait for

minimum 5 minutes to let the capacitors discharge.

Connect grounding conductor when making input connections.

Ajan plasma systems are designed for only specific Ajan torches. It causes danger to use

other torches.


SAFETY

7

6.6. TOXIC FUMES OCCUR WHILE CUTTING

Plasma and oxygen cutting can cause gases that can reduce oxygen and cause injury or death.

Ventilate the cutting area well and remove the occurring gases from the atmosphere.

Do not make cutting near places where cleaning processes are done.

Use a ventilation system while cutting materials containing Lead, Cadmium, or Beryllium.

Otherwise, since poisonous gases and fumes occur while cutting, it can cause injury or

death.

Do not cut the containers containing toxic materials. Empty and clean properly.

6.7. PLASMA ARC RAY INJURES EYES AND SKIN

Plasma arc rays produce visible or invisible rays that may burn eyes and skin.

Use eye protectors suitable to the cutting parameters.

While cutting, use protectors specified by ISO 4850 and TS.

Helmet type with lift-up glass Helmet type with fixed glass

Headgear with fixed glass Helmet with handle

Figure 1. Protectors used during cutting


SAFETY

8

Use clothes protecting against burns caused by ultraviolet rays, sparks and hot metal.

Wear gauntlet gloves, safety shoes and helmet.

Flame resistant clothes for persons working in the cutting area.

Use protective screen or barrier against violent light.

Warn others not to watch the occurred arc. Use placards or signs.

If the wall coatings around the cutting area are dark, this helps to lower the ultraviolet ray

reflection.

6.7.1. GROUNDING SAFETY

Be sure to connect the work piece and cutting table properly during cutting, not to allow the

work piece displace or fall down.

The grounding should well contact to the work piece. Do not connect it to the piece that will

fall away when cutting is done.

Ground the work piece and work table with appropriate directives.

6.7.2. SAFETY FOR COMPRESSED CYLINDERS

Do not lubricate cylinder valves or regulators.

Use only cylinders, regulators, hoses and fittings advised by the manufacturer.

Connect all fitting hoses in appropriate to color grouping.

6.7.3. GAS CYLINDERS CAN EXPLODE

Do not use cylinders if they are not stood up or well arranged.

Do not force to open stuck valves and never apply stroke.

Do not work making flame or spark near explosive gas cylinders.

Do not cut near cylinders that may flame or explode.

Control frequently the gas cylinder fittings against leakage.

Make sure the fittings should be carefully done by an authorized person.


SAFETY

9

6.8. NOISE DAMAGE

There is a hearing loss hazard during prolonged cutting and piece removal processes applying

stroke.

Use ear bung during plasma cutting.

Identify the noise hazard in the working area of plasma machine with warning signs.


SAFETY

10

6.9. SAFETY SIGNS AND DESCRIPTIONS

Table 1. Table of safety signs and descriptions

1 2 3 4

5 6 7 8

9 10 11 12

13 14 15


SAFETY

11

1. Use gauntlet and dry gloves for protection from hot metals, spark, dross and electric shocks.

2. Use protective helmets against dross and ultraviolet rays.

3. Do not touch bare cables against electric arcs.

4. There is ultraviolet ray hazard, follow the directives.

5. Wear dry, well-built, safety shoes.

6. Do not cut closed containers that contain flammable, explosive, or unknown materials.

7. Keep pressurized gas cylinders upright and protective caps in place over valve when the

cylinders are not in use.

8. Magnetic fields caused by the high current may injure the operands using pacemaker or

having heart diseases.

9. Keep a fire extinguisher nearby.

10. There may be flammable and explosive gases while machine is operating. To avoid this, do

not smoke near the machine and gas cylinders.

11. There may be flammable and explosive gases while machine is operating. To avoid this, do

not keep flame available near the machine and gas cylinders.

12. Plasma cutting produces noise that may cause hearing hazards. Use approved ear protection

during cutting.

13. Do not insert any material or your organs into the moving mechanisms that may obstruct the

movement.

14. Do not step onto or do not load onto places where may obstruct machine’s operation.

15. Do not make contact to hot metals.


SAFETY

12

6.10. WELDING FUMES AND GASES

Welding fumes are an unavoidable by-product of the welding and cutting process. All these

processes generate fumes, only the type and amount vary from process to process. It consists of

particulate fume, the part you can see, and gaseous fume, the part you cannot see, but can

sometimes smell.

Exposure of welders to welding fumes depends on many factors: the most important of which is

actual type of welding is being done.

For example, FCAW, MMA, MIG, thermic lancing and plasma cutting tend to produce the highest

amounts of most particulate fumes, while TIG, plasma welding, oxy-fuel welding, laser welding,

laser cutting and submerged arc normally give very little.

TIG, plasma welding, MIG, laser cutting and welding tend to produce the most gaseous fumes

while MMA, plasma cutting and FCAW normally produce very little.

The potential effect of exposure to welding or cutting fumes depends on the composition of the

fumes.

The health effects of exposure to fumes include irritation of the upper respiratory tract (nose and

throat), tightness in the chest, wheezing, metal fume fever, lung damage, bronchitis or pneumonia,

possibly even cancer or emphysema.

Possible control measures include doing things such as changing or modifying the process, or the

way the job is done.

6.10.1. FUMES AND GASES

The nature of fume depends upon the metal being cut and upon any coating. Cutting of stainless

steel is potentially the most hazardous as the fumes will contain chromium and nickel. Copper and

its alloys are also commonly cut and can also produce a significant fume hazard. The risks from

fumes should be assessed in accordance with HSE Guidance Note EH54 Assessments of exposure to

fume from welding and allied processes.

Oxides of nitrogen are formed during plasma cutting and could accumulate in areas of poor

ventilation. These are likely to be most significant during plasma cutting where air or nitrogen is

used as the plasma gas. Ozone is most likely to be formed during cutting of aluminum or stainless

steel.

Where inert gases are used they may accumulate in contained spaces causing an asphyxiation risk.

This is most likely to occur when the gas is significantly heavier than air e.g. argon/nitrogen

mixtures.

In poorly ventilated areas, flammable gases may also produce a risk.

Gases, particularly oxides of nitrogen, are a more significant hazard at hand-held cutting than at

mechanized cutting as the operator is in close proximity to the torch.


SAFETY

13

6.10.2. TOXIC FUMES AND GASES

Plasma arc cutting can produce toxic fumes and gases that deplete oxygen and cause serious injury.

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.

6.10.3. LOW-TEMPERATURE PLASMA FUMES, EXHAUST GAS PURIFICATION FOR ORGANIC

On principle, the purification device uses corona current and high power pulse discharge principle,

so that the air around the plate becomes a low-temperature plasma.

Plasma with many high-energy (OH-, O2-, H+, O3) ions are surrounding the plate, with energy of

the plasma can interrupt a variety of organic molecules of gas between the key elements so that the

decomposition of harmful gases to the fumes, formaldehyde, xylene, sulfur dioxide, ammonia

nitrogen oxides and other harmful gases and odor generated degradation and oxidation, deal with

organic material and degradation of smell effectively. In addition the purification equipment

compared with electrostatic precipitator, low power consumption, more efficient purification, and

so on.


WARRANTY

14

SECTION 7. WARRANTY

Ajan Kesme Makinalari San. ve Tic. Ltd. Sti. supplies mechanical and electronic units and all

equipments of your machine completely depending on the made agreements. The installation, first

operation of the machine and the education will be supplied by the manufacturer firm. Ajan Plasma

and Oxygen Cutting Machine mechanical units, electronic units, software and torch are

manufactured under Ajan brand. Ajan Ltd. warrants the machines under all these conditions.

7.1. AJAN BRAND PLASMA AND OXY-FUEL CUTTING MACHINE WARRANTY CONDITIONS

1- The warranty period is 2 (two) years after the machine delivery.

2- All the parts of the machine are under our company’s guarantee.

3- Under the case when the machine has been broken down in the guarantee period, the

maintenance period is added to the warranty period. The maintenance period is 15 days

excluding the transportation under the case when the machine fault is overcome by the

manufacturer factory.

4- The approved technical staff can interfere to the fault on the machine in 48 hours after the

customer informs the manufacturer.

5- The faults, determined by the technical staff, caused by the design and production are

overcome free of charge.

6- In cases when the machine fault is out of warranty, the applied service fare is €80.00+VAT

for the year 2009. The prices of the spare part to be replaced will be sent by ourselves. The

spare part prices are valid for the year 2009 and the applicable unit price change is under the

manufacturer’s right.

7- Under the case when the machine is broken down because of either material, or

workmanship, or installation faults; the maintenance will be done without any name under

either workmanship charge, or replaced part charge, or anything else.

8- The problems; caused by the usage against to the subjects noted on the manual and the extra

apparatus or spare parts without any approval or information of the manufacturer; are out of

warranty.


WARRANTY

15

7.2. CASES CAUSING OUT OF WARRANTY

1- In case the machine isn’t operated by firms’ authorized technical service,

2- The machine faults which were overcome by unauthorized services,

3- In case of the faults caused by carriage, replacement and usage problems,

4- The faults caused by not cleaning the machine or not maintaining of the periodically

maintainable places,

5- Paint applied on the machine, cooling liquid, unsuitable cleaning chemical materials, the

problems caused by cutting with consumables and apparatus unapproved by manufacturer,

6- The faults and unqualified cuttings caused by false usage of operator,

7- The problems and faults because of wrong usage of consumables,

8- The faults and unqualified cuttings occurred by unqualified gas usage on machine,

9- The faults and unqualified cuttings occured because of unfiltered moistured air used during

cutting

10- The faults and problems occured because of not following warnings and signs on the

machine,

11- The problems caused by line voltage to the machine,

12- The faults and problems caused by the software installed on the machine by the network or

any external memory devices,

13- The problems caused by unapproved revision on the software on the machine,

14- The problems occured because of not following maintenance instructions of the machine,

15- The spare parts, software, equipments, torch consumables or apparatus installed on the

machine without any information, approval or control of the manufacturer,

16- The fault maintenance and modifications on the machine by the technical support or any

technical staff of the manufacturer,

17- The mechanical or electronical damages occurred by the replacement and transportation of

the machine,

18- The loss of life or property and faults caused by the installation or deinstallation and without

technical support of the manufacturer,

19- The loss of life or property and faults caused by any parasitic interference or fluctuation on

the power line,

20- The loss of life or property and faults caused by not obeying the safety warnings or wrong

usage,

The above mentioned mechanical, electronical, software faults or problems which may danger

property or life safety does not claim that our company is under liability.


PREUSAGE

16

SECTION 8. PREUSAGE

8.1. ATTENTIONS BEFORE STARTING CUTTING WITH PRECISION PLASMA MACHINES

8.1.1. CONTROL OF THE CYLINDERS AND THEIR PRESSURE

In addition, propane gas is used in oxygen cutting machine.

O2 – Oxygen(8.5 bars)

N2 – Nitrogen (8.5 bars)

Air (between 7 – 10 bars)

Propane (2.5 bars)

For stainless steel sheet cutting with plasma cutting machine, H35 and F5 gases are added.

H35 (8.5 bars)

F5 (8.5 bars)

8.1.2. STARTING GENERATOR

Generator, which only takes place with plasma cutting machines, is got ready by starting before

cutting. This operation is done by circuit breaker on the front panel of the generator is turned on,

then the stop button is unlocked by turning left, and then start button is pressed.

Pressing is continued until the phase lack and circulation error lights turn off.

Just after phase lack light turns off, circulation error warning light turns off.

8.1.3. STARTING CNC UNIT

The switch on the right side cover of the CNC unit is turned to (1) position, and then computer start

is waited for.

If after this operation, the computer cannot be started, ON switch on the front panel is pressed and

then the computer starts.

The driver fail warnings on the computer screen show that the machine is stopped.

Starting:

Stop button is turned on by turning left.

Start button is pressed until the driver fail warnings disappear.

8.1.4. CHASSIS CABLE AND CONTROL

The cable, between the table on which the cutting is done and the rolling rails which provides the

bridge movement, functions as chassis between the ventilation system and the rolling rails. There is

another chassis cable between the rolling rails and the generator.

It’s impossible for the plasma cutting to be done when the chassis cables loose, break, etc.

8.1.5. USAGE OF CUTTING TIPS

During replacement of the consumable parts, some instructions take place that should be obeyed.

Otherwise, the mistakes you did affect the cutting quality, causes consumable life-time and even

causes that the machine gets out of order until the service personnel intervenes.

The parameters that should be obeyed:

During consumable replacement, an ambient purified from dust should be obtained.

The consumables which drops on the floor or exposed to stroke shouldn’t be used.


PREUSAGE

17

The nozzle and electrode is mounted with a torch wrench. During this operation, you

shouldn’t use over force.

After replacing cutting tips, purge operation is done from the parameters. This operation

throws out the dust taking place on the tips and checks gas flows.

8.1.6. OPERATING JET FILTER

The iron dust, occurring during the work piece cut, is conveyed to the jet filter with the aid of fan.

It’s checked with panel on the front side. The working system of the shaker valves cleaning the

filters is adjusted from this panel.

The iron dusts shaken off the filters are detained in the buckets at the bottom.

The buckets should be cleaned with dust mask.

The jet filter should be operated with the remote control on the fan and the generator CNC

unit.


PREUSAGE

18

8.2. ATTENTIONS BEFORE STARTING CUTTING WITH P MACHINES

8.2.1. CONTROL OF THE CYLINDERS AND THEIR PRESSURE

The gases used with P model plasma cutting machines:

Air (between 7 – 10 bars)

The gases used with P model oxygen cutting machines:

Oxygen (8.5 bars)

Propane (3 bars)

The air, used for cooling antenna and antenna bowl obtaining the torch cutting height during oxygen

cutting, should be connected to the system.

Aim for using air in oxygen cutting machine:

Because of overheat, the antenna cannot sense the correct height of the torch.

After adjusting the output pressures of the cylinder and the compressor, they are set suitable with

respect the regulators in front of the generator from the parameters.

Note: After adjusting the cutting current from the parameters, the same ampere is set on the

generator.

8.2.2. STARTING

The main power switch on the front panel of the generator is turned up, then stop button lock is

turned to left and on, and then start button is pressed.

Pressing is continued until the phase lack and circulation error lights turn off.

Just after phase lack light turns off, circulation error warning light turns off.

Note: It is not needed to open the generator during cutting with precısıon plasma and P model

machines.

8.2.3. USAGE OF OXYGEN CUTTING TIPS

The set of heating nozzle and nozzle is mounted on the tip of the torch. The cutting capability of the

nozzle is marked on it.

The tip marked as (10-25) is used during 10 to 25 mm thick sheet cutting.

NO TORCH: The “No Torch” error is turned on when the magnets holding the torch are taken

apart. The touching magnet surfaces are purified from the dust to overcome this error. If the error

goes on, the cable connected to the magnets should be checked.

IHSTR: This error takes place on left top of the screen during each torch elevation. It appears

during cutting, and if cutting is stopped, it turns to IHSTR error.

You can get rid of the error using the remote control.


MAINTENANCE INSTRUCTIONS

19

SECTION 9. MAINTENANCE INSTRUCTIONS

The racks and chrome plated rods on machine’s head group and rolling rails should be kept

clean.

Since the plasma cutting is a dusty process, the moving parts should be kept away from the

dust. In addition, for every work piece loading, the moving parts should be checked visually,

that should be checked whether there exist any materials preventing movement on the racks.

The crane, forklift, etc devices should be controlled; the machine should be kept away from

beat.

The wipers on X and Y axes should be checked every day and be replaced if eroded or

broken down.

The bellows on the machine’s head group should be checked for stability and be replaced if

eroded or broken down.

The cutting buckets of the ventilation unit should be necessarily checked for fullness,

because this is very important for the suction quality.

The suction system of the machine works with the help of the press handles. These handles

should be checked whether it works well.

The warning labels on the machine should never be taken out, and be replaced if eroded, and

they should be obeyed to.

No combustible materials such as paper, cigarette butt, nylon, etc should be thrown into the

ventilation unit; no water should be used during intervening.

Twice a week, CNC unit and generator unit must be cleaned using dry air or nitrogen gas,

the machine shouldn’t be used in one hour after this application.

The jet filter buckets should be cleaned until it is filled in half.

The jet filter cartridges should be neither opened nor cleaned without manufacturer company

control.


REPLACEMENT PLANS

20

SECTION 10. REPLACEMENT PLANS

Figure 2. General replacement plan


REPLACEMENT PLANS

21

Figure 3. 3000x12000 mm plasma machine with jet filter replacement plan


REPLACEMENT PLANS

22


Figure 5. 3000x12000 mm plasma machine without jet filter replacement plan


REPLACEMENT PLANS

23




REPLACEMENT PLANS

24



MECHANICAL PARTS

25

SECTION 11. MECHANICAL PARTS

11.1. VENTILATION UNIT

They are the systems sucking and removing the dangerous gases and dust occurring during the

plasma cutting application away from the medium. As the working principle, the air suction occurs

when the pressure handles on the working area are opened by pressure sheet on the machine’s

bridge unit, and it sucks the dust and gas in the cutting area. The sheet to be cut is placed on the grid

blocks. After the cutting process, the dross and some cutting wastes are collected in the cutting

buckets. For a long life and proper operation of the ventilation unit, it should be frequently cleaned

depending on the fullness ratio.

Figure 9. 3000 mm first block ventilation system


MECHANICAL PARTS

26

Figure 10. 3000 mm first block ventilation unit installation drawing


MECHANICAL PARTS

27

Figure 11. 3000 mm first block cover opening/closing handle system installation drawing


MECHANICAL PARTS

28

11.2. CUTTING TABLE

It is used in the oxygen cutting machines. The sheet to be cut is placed on the cast parts. The cast

parts help in decreasing the harms of strong flame and dross occurring during cutting to the cutting

grids.

Figure 12. 1500 mm cutting table installation drawing


MECHANICAL PARTS

29

11.3. SUCTION FAN

The fan system obtaining suction on the ventilation unit. It has the suction capacities 5,000 m3/h,

10,000 m3/h and 15,000 m3/h depending on the width and length ratio of the ventilation unit.

Figure 13. Suction fan


MECHANICAL PARTS

30

Figure 14. Suction fan installation drawing


MECHANICAL PARTS

31

11.4. MUFFLER

The system used to decrease the high decibel level occurred in the suction fan.

Figure 15. Muffler


MECHANICAL PARTS

32

11.5. JET FILTER

Figure 16. Jet filter


MECHANICAL PARTS

33


MECHANICAL PARTS

34

Figure 17. Total area of the cartridges used in the jet filter

The jet filter is manufactured in 4 different models, such as 6-, 8-, 12- and 16-cardridge, depending

on the ventilation capacity required for the machine. Every cartridge is made up from 24 meter

square burn-delayed plied filter paper.

System dirt level is controlled by electronic filter cleaning unit. With the help of blow level control,

the blow frequency is decreased, cycle is increased. So unnecessary air consumption is prevented.

30% more efficient reverse jet filter cleaning air flows are obtained by dust bag shaker valves

integrated on the filter body. Because of that the cartridges are horizontally mounted, the

maintenance and replacement are easily done. Jet filter unit is additionally preserved with flame

trap that should take place in every plasma cutting table ventilation.

Flame trap holds cigarette butt, burning paper sheets and cloth parts and moves them to the buck it

has.

Ajan jet filter system is a genuine design completely suitable to the world standards. The air suction

fan is mounted outside of the filter and it is suitable for cleansing after long-time usage. The motor

and propeller are equipped with an easily opened and closed cover system.

The complete filter system is transported by demounted during the transportation. The air suction

system has been designed to be fit in any smallest area behind the plasma ventilation table. During

the filter design, space occupation is kept in mind in height in spite of width or length. A muffler

with two walls is mounted on the fan output. The muffler output can be mounted outside of the

building by the customer.


MECHANICAL PARTS

35

11.5.1. THE DESCRIPTION OF THE JET FILTER PANEL

1 Filter pressure gauge

2 Cartridge indicator

3 Blow period

4 Dirt level

5 Filter clean

6 Filter dirty

7 Filter dirt warning lamp Figure 18. Jet filter panel


MECHANICAL PARTS

36

1. FILTER PRESSURE GAUGE:

The permeability of the jet filter cartridge is decreased by fullness, and so pressure on the

cartridges gets high. The fullness of the cartridge is observed by the pressure gauge. 700-

2,000 Pascal value means workable level; however 2,000-3,000 Pascal value means a

critical operation level in Ajan brand jet filters. The cartridges should be replaced when

critical values are reached. The cartridges used in Ajan jet filter systems are made from

flame-retardant paper and the m2 values are shown in Figure 17.

WARNING:

Do not use any cartridge not approved by the manufacturer in Ajan jet filter systems.

2. CARTRIDGE INDICATOR:

The filter unit blows in adjusted periods in order to clean the cartridges. This indicator

indicates the cartridge group to be blowen.

3. BLOW CYCLE:

Synchronized to other adjustments.

4. DIRT LEVEL:

It is used to determine the cartridge dirt level. The cartridge blow cycles are adjusted

depending on the determined dirt level (the ideal value is 1,000 Pascal).

5. FILTER CLEAN:

It is used to adjust the blow cycle when the filter is in clean mode (the ideal value is 15 sec.).

6. FILTER DIRTY:

It is used to adjust the blow cycle when the filter is in dirt mode (the ideal value is 6 sec.).

7. FILTER DIRT WARNING LAMP:

The LED that warns that the filters reached the determined dirt level.


MECHANICAL PARTS

37

11.5.2. DUST BAG SHAKER VALVE

Definition: Dust bag shaker valves are designed for the systems that discharges pressured air swift

and produce air strokes as shock. It operates in the same way with other 2-way solenoid valves. But

input and output connections are perpendicular (90°) to each other. So it sends air as stroke (shock)

and it is also called Air Shock (Jet Filter) valve.

PART NO PART NAME

1 Body

2 Large diaphragm

2a Diaphragm

3 Large diaphragm spring

3a Spring

4 Large body cover

5 Small diaphragm

6 Cover

6a Cover

7 Plunger

8 Tube

9 Coil

10 Connector

Figure 19. Dust bag shaker valve spare part list


MECHANICAL PARTS

38

11.6. PLASMA HEAD UNIT

Figure 20. Plasma head installation drawing

The system supplying plasma torch movement


MECHANICAL PARTS

39

11.7. PLASMA BRIDGE UNIT

Figure 21. Plasma bridge installation drawing


MECHANICAL PARTS

40

Figure 22. Plasma bridge unit installation drawing


MECHANICAL PARTS

41

11.8. X AXIS GEARBOX

Figure 23. X axis gearbox installation drawing

The system supplying machine

movement in X axis


MECHANICAL PARTS

42

11.9. Y AXIS GEARBOX

Figure 24. Y axis gearbox installation drawing

The system supplying machine

movement in Y axis


MECHANICAL PARTS

43

11.10. AJAN X-Y AXIS AC SERVO MOTOR

Figure 25. Ajan X-Y axis AC servo motor installation drawing


MECHANICAL PARTS

44

11.11. AJAN Z AXIS AC SERVO MOTOR

Figure 26. Ajan Z axis AC servo motor installation drawing


MECHANICAL PARTS

45

11.12. AJAN PLASMA TORCH

Figure 27. Ajan plasma torch installation drawing


MECHANICAL PARTS

46


MECHANICAL PARTS

47

11.12.1. AJAN PLASMA TORCH CONNECTION DIAGRAM

Figure 28. Ajan plasma torch connection diagram


MECHANICAL PARTS

48

11.13. GENERATOR

Figure 29. Generator


MECHANICAL PARTS

49

11.13.1. TORCH COOLING SYSTEM

The plasma generator torch cooling tank is emptied before transportation and 20 lt. cooling liquid is

transported in the generator with the machine. A mixture of 30% Propileneglicol (C3H8O2), 69.9%

deionized water and 0.1% Benzotriazole (C6H5N3) is suggested for Ajan cooling liquid. This

mixture prevents freezing up to –12°C.

Warning: The operations in colder than the above indicated degree, the propileneglicol ratio should

be increased. For the required ratios and material supply, please contact the manufacturer company.

WARNING

Figure 30. Torch cooling liquid drum warning label

The cooling liquid may cause skin and eye irritation, and if swallowed, it may be harmful or fatal.

Propileneglicol and benzotriazole may harm skin and eyes. Please keep the labels on the drums. In

any contact, wash the skin or eyes. If swallowed, drink water and call the doctor. Do not try to

regurgitate.

Warning: Use always propileneglicol in the mixture of cooling liquid. Do not use automotive

antifreeze liquids in spite of propileneglicol.

Use always pure water in the mixture of cooling water in order to prevent failures that may occur in

the pump and oxidation in torch cooling system.


MECHANICAL PARTS

50

11.14. CNC UNIT

Figure 31. CNC unit


MECHANICAL PARTS

51

11.15. GENERATOR CONNECTION

Figure 32. Generator connection diagram


CABLES

52

SECTION 12. CABLES

12.1. INTERFACE SHEET CONNECTION CABLES

Figure 33. Interface sheet connection cables


CABLES

53

12.1.1. IHS LIMIT CABLE

8x2x0,22mm² screened cable Length: 27cm 9-pin female DSUB 9-pin male DSUB

Interface sheet connection IHS limit card (PL0430–9) connection

Table 2. IHS limit cable color and functions table

INTERFACE SHEET IHS LIMIT CARD (PL0430–9)

PIN NO

COLOR FUNCTION PIN NO

COLOR FUNCTION

1 Black IHS-TL 1 Black

2 Red IHS-TR 2 Red

3 Blue CRUSHER-TL 3 Blue

4 Yellow CRUSHER-TR 4 Yellow

5 Pink OKMO-TL 5 Pink

6 Brown OKMO-TR 6 Brown

7 Gray IHS-TV 7 Gray

8 Green IHS-TW 8 Green

9 8-White GND 9 8-White


CABLES

54

12.1.2. X, Y, TR, TL AXIS DRIVE CABLES

8x2x0,22mm² screened cable Length: 90cm 9-pin female DSUB 9-pin male DSUB

Interface sheet connection Drive connection

Table 3. X, Y, TR, TL axis drive cables color and functions table

INTERFACE SHEET DRIVE

PIN NO


COLOR FUNCTION

1 Black CLK 1 Black

2 Red +5V 2 Red

3 Blue 0-10V 3 Blue

4 Yellow OVER CURRENT 4 Yellow

5 Pink ZERO MARK 5 Pink

6 Brown DIR 6 Brown


8 Gray SFB. ENABLE 8 Gray

9 Green CONTROLER OK. 9 Green


CABLES

55

12.1.3. GAS CONTROL CABLE

26-pin flat cable Length: 78cm 25-pin female DSUB 26-pin female header

Interface sheet connection Logic card connection

Table 4. Gas control cable color and functions table

INTERFACE SHEET LOGIC

PIN NO

FUNCTION PIN NO

FUNCTION PIN NO

FUNCTION PIN NO

FUNCTION

1 PW D 14 ANOR.DSRJ. 1 PW D 14 SOUND

2 PW C 15 AMR 2 ANOR.DSRJ 15 TB A

3 PW B 16 VMR 3 PW C 16 TA D

4 PW A 17 KENO 4 AMR 17 TB B

5 +5V 18 +5V 5 PW B 18 TA C

6 GND 19 SETUP 6 VMR 19 TB C

7 L.ENB. 20 SES 7 PW A 20 TA B

8 TB A 21 TA D 8 KENO 21 TB D

9 TB B 22 TA C 9 +5V 22 TA A

10 TB C 23 TA B 10 +5V 23 +12V

11 TB D 24 TA A 11 GND 24 +12V

12 +12V 25 +12V 12 SETUP 25 GND

13 GND 13 L.ENB. 26 GND


CABLES

56

12.1.4. RELAY CONTROL KABLOSU

10x0,22mm² screened cable Length: 75cm. 9-pin male DSUB 9-pin female socket

Interface sheet connection Logic card connection

Table 5. Relay control cable color and functions table

INTERFACE SHEET LOGIC CARD

PIN NO


COLOR FUNCTION

1 Black POL(-) 1 Black

2 Red POL(+) 2 Red

3 Blue M8 3 Blue

4 Yellow ----- 4 Yellow

5 Pink GND 5 Pink

6 Brown SET STOP 6 Brown

7 Violet +5V 7 Violet

8 White RELAY CONTROL 8 White

9 Green SET START 9 Green


CABLES

57

12.1.5. GAS CONTROL AND RELAY CONTROL CABLES FUNCTIONS Table 6. Gas control and relay control cables color and functions table

INTERFACE SHEET

PIN NO

CABLE NAME SIGNAL NAME COLOR FUNCTION

1 GAS CONTROL PW D Transmitter selection bits

2 GAS CONTROL PW C

3 GAS CONTROL PW B

Plasma gas-shield gas-current active bits 4 GAS CONTROL PW A

5 GAS CONTROL +5V +5V

6 GAS CONTROL GND GND

7 GAS CONTROL L.ENB. Current or pressure reading-writing bits

8 GAS CONTROL TB A

8-bit current or pressure value information

9 GAS CONTROL TB B

10 GAS CONTROL TB C

11 GAS CONTROL TB D

21 GAS CONTROL TA D

22 GAS CONTROL TA C

23 GAS CONTROL TA B

24 GAS CONTROL TA A


13 GAS CONTROL GND GND

14 GAS CONTROL ANOR.DSRJ ---------

15 GAS CONTROL AMR Pressure information analog input

16 GAS CONTROL VMR Voltage information analog input

17 GAS CONTROL KENO

Mode selection bits 1 RELAY CONTROL POL(-) Black

20 GAS CONTROL SOUND


19 GAS CONTROL SETUP DRY CUT, Machine type (Pls-Oxy)and plasma right-left selection bits

6 RELAY CONTROL SET STOP Brown

9 RELAY CONTROL SET START Green


2 RELAY CONTROL POL(+) Red Marking-cutting bit

3 RELAY CONTROL M8 Blue Plasma start bit

4 RELAY CONTROL ----- Yellow -----

5 RELAY CONTROL GND Pink GND

7 RELAY CONTROL +5V Violet +5V

8 RELAY CONTROL RELAY CONTROL White Relay control bit


CABLES

58

12.1.6. HAND CONTROL CABLE

4x0,34 mm² screened cable Length: 225cm. 9-pin female DSUB 5-pin female mic

Interface sheet connection Hand control connection

Table 7. Hand control cable color and functions table

INTERFACE SHEET HAND CONTROL

PIN NO


COLOR FUNCTION

1 Green +5V 1 Green +5V

2 Brown DATA 2 Brown DATA

3 White CLK 3 White CLK

5 Yellow GND 4 Yellow GND

Screening chassis SCREEN 5 Screening


CABLES

59

12.1.7. LIMIT CABLE

16x0,22 mm² screened cable Length: 30cm 15-pin male DSUB 15-pin female DSUB

Interface sheet connection Limit card (PL0306–3) connection

Table 8. Limit cable color and functions table

INTERFACE SHEET LIMIT CARD (PL0306–3)

PIN NO


COLOR FUNCTION

1 Yellow TL CONT.OK 1 Yellow

2 Violet +TR LIMIT 2 Violet

3 Green -TR LIMIT 3 Green

4 Red +TL LIMIT 4 Red

5 Brown -TL LIMIT 5 Brown

6 Green-Brown GND 6 Green-Brown

7 Gray TW CONT.OK 7 Gray

8 Pink ------ 8 Pink

9 Black GND 9 Black

10 Blue-Red -X LIMIT 10 Blue-Red

11 Blue +X LIMIT 11 Blue

12 Pink-Gray +Y LIMIT 12 Pink-Gray

13 White -Y LIMIT 13 White

14 Green-White GND 14 Green-White

15 Brown-Yellow GND 15 Brown-Yellow


CABLES

60

12.1.8. RESUME CABLE

2x0,22 mm² screened cable Length: 110cm. 9-pin male DSUB 2-pin cord end sleeve

Interface sheet connection 220VAC relay NC contact tips

Table 9. Resume cable color and functions table

INTERFACE SHEET 220VAC RELAY NC CONTACT TIPS

PIN NO


COLOR FUNCTION

1 ------- 1 Brown

2 ------- 2 White

3 -------

4 -------

5 Brown RESUME

6 White GND

7 -------

8 -------

9 -------


CABLES

61

12.2. DRIVE CONNECTION CABLES

Figure 34. Drive


CABLES

62

12.2.1. MOTOR CABLE

8x2x0,22mm²+ 3x1mm² screened cable 9-pin female DSUB and 4-pin female Phoenix 9-pin female DSUB and 4-pin female mic

Drive connection Servo motor connection

Table 10. Motor cable color and functions table

DRIVE SERVO MOTOR

PIN NO


COLOR FUNCTION

1 Green R 1 Green R

2 Brown S 2 Brown S

3 Screen T 4 Screen T

4 White EARTH 3 White EARTH

Table 11. Motor cable color and functions table

DRIVE SERVO MOTOR

PIN NO


COLOR FUNCTION

1 Pink -12VDC 1 Pink

2 Gray +12VDC 2 Gray

3 Green R 3 Green

4 Red S 4 Red

5 Black T 5 Black

6 Blue B 6 Blue

7 Yellow A 7 Yellow


9 Brown ZERO MARK 9 Brown


CABLES

63

Table 12. Motor cable lengths with respect to Y axis lengths

MOTOR

CABLE

Y AXIS LENGTH

1500mm 2000mm 2500mm 3000mm 4000mm

XR cable

length 185cm 185cm 185cm 185cm 185cm

XL cable


Y cable length 620cm 625cm 680cm 755cm 830cm

TR cable


TL cable



CABLES

64

12.2.2. DRIVE POWER CABLE

10-pin female Phoenix 8-pin female Phoenix

Drive connection Drive transformer connection

Table 13. Drive power cable color and functions table

DRIVE DRIVE TRANSFORMER

PIN NO


COLOR FUNCTION

1 ----- CURR. + 1 Yellow-Green EARTH

2 ----- CURR. - 2 Blue NEUTR

3 Brown 20VAC 3 Brown 220VAC

4 Yellow-Green 0V ML 4 Blue 0V MH

5 Blue 20VAC 5 Brown 20VAC

6 Brown 20VAC 6 Brown 20VAC

7 Blue 0V MH 7 Yellow-Green 0V ML

8 Yellow-Green EARTH 8 Blue 20VAC

9 Blue 0V MH

10 Brown +80VDC


CABLES

65

12.3. CNC-GENERATOR CABLE CONNECTIONS

12.3.1. CURRENT-PLST/OKMO/ARC CABLE

8x2x0,22+4x2x0,22mm2 screened cable

X Axis Length

(mm) 3000 4000 6000 8000 12000 16000 18000 24000

Cable Length (cm) 800 900 1100 1350 1750 2150 2500 2900

9-pin male DSUB (plst/okmo/arc) 9-pin female DSUB (current)

9-pin male DSUB (plst/okmo/arc) 9-pin female DSUB (current)

CNC connection Generator connection

Table 14. Current-PLST/OKMO/Arc cable color and functions table

CNC GENERATOR

PIN NO


COLOR FUNCTION

1 Black 1 Black

2 Red 2 Red

3 Blue 3 Blue

4 Yellow 4 Yellow

5 Pink 5 Pink

6 Brown 6 Brown

7 Gray 7 Gray

8 Green 8 Green

9 8-White 9 8-White

CNC GENERATOR

PIN NO


COLOR FUNCTION

1 Brown PLST(+) 1 Brown

2 White PLST(-) 2 White

3 ----- 3 -----

4 Red ARC(+) 4 Red

5 Blue ARC(-) 5 Blue

6 Dark green OKMO 6 Dark green

7 Light green OKMO 7 Light green

8 ----- 8 -----

9 ----- 9 -----


CABLES

66

12.3.2. REMOTE CONTROL CABLE

12x0,75+4x1,5mm2 cable

X Axis Length

(mm) 3000 4000 6000 8000 12000 16000 18000 24000

Cable Length (cm) 700 950 1100 1300 1800 2100 2500 2900

16-pin female socket 16-pin cord-end sleeve


Table 15. Remote control cable color and functions table

CNC CONNECTION GENERATOR

PIN NO


COLOR FUNCTION

1 1 AIR DRYER(R) 1 1

2 2 AIR DRYER(S) 2 2

3 3 PULSE VALVE(R) 3 3

4 4 PULSE VALVE(S) 4 4

5 5 GEN. NEUTR 5 5

6 6 GEN. STOP 6 6

7 7 GEN. START-STOP 7 7

8 8 GEN. 220VAC START 8 8

9 9 FAN STOP 9 9

10 10 FAN START-STOP 10 10

11 11 FAN 220VAC START 11 11

12 Yellow-Green FAN NEUTR 12 Yellow-Green

13 Brown CNC (R) 13 Brown

14 Blue CNC (S) 14 Blue

15 Black CNC (T) 15 Black

16 Yellow-Green EARTH 16 Yellow-Green


CABLES

67

12.3.3. ELECTRODE-NOZZLE CABLE

X Axis Length

(mm) 3000 4000 6000 8000 12000 16000 18000 24000

Cable Length (cm) 700 800 1000 1250 1650 2050 2400 2750

Y Axis Length (mm) 1500 2000 2500 3000 4000

Cable Length (cm) 530 550 575 650 750

50mm² circular lug (electrode) 16mm² circular lug (nozzle)

50mm² circular lug (electrode) 16mm² circular lug (nozzle)



CABLES

68

12.4. Y AXIS CABLE CONNECTIONS

12.4.1. PLASMA TRANSMITTER CABLE

2x(4x0,34)mm2 screened cable

Y Axis Length (mm) 1500 2000 2500 3000 4000

Cable Length (cm) 545 545 600 670 745

6-pin female socket 9-pin female DSUB

Logic card (PL0430-1) TK8 connection Plasma plate card (PL0430-11) connection

Table 16. Plasma transmitter cable color and functions table

CNC BRIDGE

PIN NO


COLOR CABLE NAME

1 Brown +15VDC 4 Brown TR4

2 White TR4 Shield gas transmitter 5 White TR4

3 Yellow GND 9 Yellow TR4

4 Yellow GND 3 Brown TR3

5 White TR3 Plasma gas transmitter 2 White TR3

6 Brown +15VDC 1 Yellow TR3

7 ------

8 ------

9 ------


CABLES

69

12.4.2. OHMIC-OHMIC IHS-F5 CABLE


Y Axis Length (mm) 1500 2000 2500 3000 4000

Cable Length (cm) 610 615 670 745 820

2x2-pin cord-end sleeve, 2-pin female socket

2x2-pin cord-end sleeve, 2-pin female socket

Logic card (PL0430-1) TK4 NO:8 conn. IHS limit card (PL0430-9) connection Logic card (PL0430-1) TK22 connection

Ohmic card (PL0305-4) TK1 NO:2-3 conn. Ohmic card (PL0305-4) TK1 NO:6-7 conn.

Plasma plate card (PL0430-12) conn.

Table 17. Ohmic-Ohmic IHS-F5 cable color and functions table

CNC BRIDGE

PIN NO

COLOR FUNCTION CABLE PIN NO

COLOR FUNCTION

Brown +24VDC OHMIC Brown

White GND OHMIC White

Brown OHMC IHS OHMC IHS Brown

White OHMIC IHS OHMIC IHS White

1 Brown +24VDC F5 1 Brown

2 White GND F5 2 White


CABLES

70

12.4.3. PLASMA VALVE CABLE

4x0,34mm2+2(5x0,34)mm2 screened cable

Y Axis Length (mm) 1500 2000 2500 3000 4000

Cable Length (cm) 525 550 585 660 735

2x10-pin female Phoenix 15-pin female DSUB

Logic card (PL0430-1) TK4, TK2 connection Plasma plate card (PL0430-11) conn.

Table 18. Plasma valve cable color and functions table

CNC BRIDGE

PIN NO

COLOR FUNCTION CABLE NAME

PIN NO


1 Yellow ATM GAS A 1 Green O2 GAS B

2 White AIRS GAS A 2 Yellow AIR GAS B

3 Brown +24VDC GAS A 3 ----- ----- -----

4 Green N2S GAS A 4 Brown +24VDC GAS B

5 Gray O2S GAS A 5 White N2 GAS B

6 Yellow AIR GAS B 6 Gray H35 GAS B

7 White N2 GAS B 7 Yellow PV3 PV3

8 Brown +24VDC GAS B 8 Brown +24VDC PV3

9 Green O2 GAS B 9 Gray O2S GAS A

10 Gray H35 GAS B 10 White AIRS GAS A

11 Brown +24VDC GAS A

3 Brown +24VDC PV3 12 ------ ------ ------

4 Yellow PV3 Plasma gas servo valve

PV3 13 Green N2S GAS A

5 White PV4 Shield gas servo valve

PV3 14 Yellow ATM GAS A

15 white PV4 PV3


CABLES

71

12.4.4. OXYGEN(R) VALVE CABLE

4x0,34mm2+2(5x0,34)mm2 screened cable

Y Axis Length (mm) 1500 2000 2500 3000 4000

Cable Length (cm) 300 310 330 340 400

16-pin female Phoenix 15-pin female DSUB

Front panel card (PL0430-10) TK2 conn. Oxygen1 plate card (PL0430-12) conn.

Table 19. Oxygen(R) valve cable color and functions table

CNC BRIDGE

PIN NO


PIN NO


1 Yellow PV5 Cutting servo valve

PV5 1 White FAST+24 PROPAN(R)

2 White PV6 Preheat servo valve

PV5 2 Green PROPAN(R) PROPAN(R)

3 Green PV7 Propan servo valve

PV5 3 Brown SLOW+24 PROPAN(R)

4 Brown +24VDC PV5 4 Yellow PV5 PV5

5 Gray ATM PV5 5 White PV6 PV5

6 Yellow CUT(R) CUT(R) 6 Green PV7 PV5

7 Brown +24VDC CUT(R) 7 Brown +24VDC PV5

8 White IGNITION(R) CUT(R) 8 ----- ----- -----

9 Green SLOW+24 CUT(R) 9 Yellow FAST+24 PROPAN(R)

10 Gray PREHEAT(R) CUT(R) 10 Gray TAV(R) CUT(R)

11 Yellow FAST+24 PROPAN(R) 11 Green SLOW+24 CUT(R)

12 White FAST+24 PROPAN(R) 12 Gray ATM PV5

13 Green PROPAN(R) PROPAN(R) 13 Yellow KES(R) CUT(R)

14 Brown SLOW+24 PROPAN(R) 14 White ATEŞ(R) CUT(R)

15 ------ 15 Brown +24VDC CUT(R)


CABLES

72

12.4.5. HEAD LIMIT(R)-THC(R)-PREHEAT SENSOR(R) CABLE

(2x0,50)mm2+(5x0,34)mm2+(4x2x0,34)mm2 screened cable

Y Axis Length (mm) 1500 2000 2500 3000 4000

Cable Length (cm) 675 685 740 815 890

8-pin cord-end sleeve, 5-pin female socket, 3-pin female socket

9-pin female DSUB

Limit (PL0306-3), IHS limit (PL0430-9) card cn. Logic card (PL0430-1)TK3 connection Front panel card (PL0430-10)TK3 connection

THC head connection Torch height control(R) connection

Preheat sensor(R) connection

Table 20. Head limit(R) cable color and functions table

CNC BRIDGE

PIN NO

COLOR CONNECTION PIN NO

COLOR FUNCTION

13 Red PL0306-3 LIMIT CARD 1 Red +TR LIMIT

14 Blue PL0306-3 LIMIT CARD 2 Blue +TR LIMIT

--- ----- ------ 3 ----- -----

15 Green PL0306-3 LIMIT CARD 4 Green -TR LIMIT

16 Yellow PL0306-3 LIMIT CARD 5 Yellow -TR LIMIT

13 Pink PL0430-9 IHS LIMIT CARD 6 Pink IHS(R)

14 Gray PL0430-9 IHS LIMIT CARD 7 Gray IHS(R)

9 Brown PL0430-9 IHS LIMIT CARD 8 Brown CRUSHER(R)

10 White PL0430-9 IHS LIMIT CARD 9 White CRUSHER(R)


CABLES

73

Table 21. Torch height control(R) cable color and functions table

CNC BRIDGE

PIN NO


COLOR FUNCTION

1 Green TORCH HEIGHT CNTR.(R) 1 Green

2 Brown GND 2 Brown

3 White -12V 3 White

4 Yellow GND 4 Yellow

5 Gray +12V 5 Gray

Table 22. Preheat sensor(R) cable color and functions table

CNC BRIDGE

PIN NO


COLOR FUNCTION

1 Brown +15VDC 1 Brown

2 White PREHEAT SENS.(R) OK. 2 White

3 -----


CABLES

74

12.4.6. OXYGEN TRANSMITTER CABLE


Y Axis Length (mm) 1500 2000 2500 3000 4000

Cable Length (cm) 290 300 315 340 395

9-pin female socket 9-pin male DSUB

Logic card (PL0430-1) TK9 connection Oxygen1 plate card (PL0430-12) connection

Table 23. Oxygen transmitter cable color and functions table

CNC BRIDGE

PIN NO


PIN NO

COLOR FUNCTION

1 Brown +15V DC TR5 8 Brown

2 White TR5 Cutting transmitter

TR5 7 White

3 Yellow 0V TR5 6 Yellow


5 White TR6 Preheat transmitter

TR6 2 White

6 Brown +15VDC TR6 1 Brown

7 Brown +15VDC TR7 4 Brown

8 White TR7 Propan transmitter

TR7 5 White



CABLES

75

12.4.7. OXYGEN(L) VALVE CABLE

4x0,34mm2+5x0,34mm2 screened cable

Y Axis Length (mm) 1500 2000 2500 3000 4000

Cable Length (cm) 360 375 395 415 470

16-pin female Phoenix 9-pin female DSUB

Front panel card2 (PL0430-10) TK2 conn. Oxygen2 plate card (PL0430-14) conn.

Table 24. Oxygen(L) valve cable color and functions table

CNC BRIDGE

PIN NO


PIN NO


11 Yellow FAST +24 PROPAN(L) 1 Brown PROPAN(L)

12 White FAST +24 PROPAN(L) 2 Green PROPAN(L)

13 Green PROPAN(L) PROPAN(L) 3 White PROPAN(L)

14 Brown SLOW +24 PROPAN(L) 4 Yellow CUT(L)

6 Yellow CUT(L) CUT(L) 5 Brown CUT(L)

7 Brown +24VDC CUT(L) 6 Green CUT(L)

8 White IGNITON(L) CUT(L) 7 Gray CUT(L)

9 Green SLOW +24 CUT(L) 8 Yellow PROPAN(L)

10 Gray PREHEAT(L) CUT(L) 9 White CUT(L)


CABLES

76

12.4.8. HEAD LIMIT(L)-THC(L)-PREHEAT SENSOR(L) CABLE

(2x0,50)mm2+(5x0,34)mm2+(4x2x0,34)mm2screened cable

Y Axis Length (mm) 1500 2000 2500 3000 4000

Cable Length (cm) 720 765 820 895 970

8-pin cord-end sleeve, 5-pin female socket, 3-pin female socket

9-pin female DSUB

Limit (PL0306-3), IHS limit (PL0430-9) card con. Logic card (PL0430-1) TK2 connection Front panel card2 (PL0430-10) TK3 connection

THC head connection THC(L) connection

Preheat sensor (L) connection

Table 25. Head limit(L) cable color and functions table

CNC BRIDGE

PIN NO


COLOR FUNCTION

9 Red PL 0306-3 LIMIT CARD 1 Red +TL LIMIT

10 Blue PL 0306-3 LIMIT CARD 2 Blue +TL LIMIT

--- ----- ------ 3 ----- -----

11 Green PL 0306-3 LIMIT CARD 4 Green -TL LIMIT

12 Yellow PL 0306-3 LIMIT CARD 5 Yellow -TL LIMIT

15 Pink PL 0430-9 IHS LIMIT CARD 6 Pink IHS(L)

16 Gray PL 0430-9 IHS LIMIT CARD 7 Gray IHS(L)

11 Brown PL 0430-9 IHS LIMIT CARD 8 Brown CRUSHER(L)

12 White PL 0430-9 IHS LIMIT CARD 9 White CRUSHER(L)


CABLES

77

Table 26. Torch height control(L) cable color and functions table

CNC BRIDGE

PIN NO


COLOR FUNCTION

1 Green TRCH HGT. CONTR.(L) 1 Green

2 Brown GND 2 Brown

3 White -12V 3 White

4 Yellow GND 4 Yellow

5 Gray +12V 5 Gray

Table 27. Preheat sensor(L) cable color and functions table

CNC BRIDGE

PIN NO


COLOR FUNCTION

1 Brown +15VDC 1 Brown

2 White PREHEAT SENS.(L)OK. 2 White

3 -----


AJAN PRECISION PLASMA 260 AMPER SPECIFICATIONS

78

SECTION 13. AJAN PRECISION PLASMA 260 AMPER SPECIFICATIONS

13.1. AJAN PLASMA TORCH SCHEMA AND CONSUMABLES

Cooling water losses during consumable replacing are not remarkable in AJAN

PRECISION PLASMA 260AMPER.

AJAN consumable replacing are faster and easier than other companies.

Figure 35. Ajan torch schema

TORCH MAIN PIPE (Electrode body) (Material: Brass) Provides water inlet to torch and conducts electrode current.

TORCH WATER PIPE: (Material: Brass) Cools electrodes.

TORCH MAIN BODY: (Material: TecaPEEK) Directs plasma gas, secondary gas and water inlet-outlets and provides electrical insulation.

NOZZLE BODY: (Material: Brass) Fixes nozzle to torch and cools it. At the same time directs to secondary gas shield head.

ELECTRODE: (Material: Pure copper) Transmit electrical energy to the work piece through plasma gas.

GAS DIFFUSER: (Material: Vespel-Ceramic) Directs plasma gas to work piece by spinning with radial end eccentrically holes on it. By this means it determines plasma gas flow and rotating speeds and provides electrode and nozzle lifetime equality.

NOZZLE: (Material: Pure copper) Provides most appropriate nozzle form sensitive cutting densities according to selected current level.

GAS RING: (Material: Vespel) Provides homogeneous gas distribution on work piece by spinning secondary gas.

SHIELD: (Material: Pure copper) Provides outlet to plasma gas and secondary gas to the work piece and protects nozzle against slag splattering during piercing. In addition provides flow compressing required for sensitive cutting.

SHIELD CAP: (Material: Brass) Fixes shield to torch and conducts secondary gas. Provides electrical contact with ohmic contact. It has a long service life since it does not have plastic parts.

Electrode and water inlet Secondary gas inlet

Nozzle conductor

Water return Plasma gas inlet

Ohmic contact conductor

Shield cap

Shield

Gas ring

Nozzle

Gas diffusor

Electrode Nozzle

body

Main body

Torch main body

Pilot arc conductor

Supplying ohmic contact conductor through torch body is a feature seen only in Ajan precısıon plasma

260amper torch

Ohmic contact conductor



79



80

13.2. AJAN PRECISION PLASMA SYSTEM CONSUMABLES LIFETIMES AND GAS CONSUMPTIONS

AJAN minimizes the consumption material cost added to total cutting cost by means of

consumption material techniques it developed. For this reason, AJAN provides the following cost

table to its customers. Total value of consumption materials plus gas and electric costs constitute

%2-%5 of the 1 kg sheet cost that will be cut on condition of changing according to shape number

and sheet thicknesses. AJAN Consumption Materials Lifetime and Quality tables and gas flows

have been given in below figure.

Figure 36. Ajan PRECISION PLASMA 260AMPER Electrode and Nozzle required life time chart

Figure 37. Ajan precısıon plasma 130A mper Electrode and Nozzle required life time chart

Table 28. Ajan precısıon plasma 260 amper plasma generator gas flow rates



81

13.3. PRECISION PLASMA 260 AMPER PLASMA AUTOMATIC GAS CONSOLE

(Ensures faultless operation & time and gas savings)

Automatic gas console is an equipment and software, which should be used in every modern

PLASMA and OXY-FUEL systems. Basically, it consists of CNC control unit, software, additional

interface card, servo valves and sensitive pressure measurement devices. This system controls the

required gas type, gas pressures, piercing height, pierce delay, cutting height, arc voltage for each

determined sheet thickness, sheet type and cutting current. During speed reduction speed, it controls

THC off distances, current, speed, pressure relations. These controlled parameters makes

comfortable during cutting for the operator.

The specs of Ajan automatic gas console that makes the system superior than other automatic

gas consoles:

Figure 38. Other conventional automatic gas consoles

Figure 39. Ajan automatic gas console

As clearly seen above, hoses used in classic gas consoles whose lengths are around 5-10 m and

stated with “d” in Figure 38) have been removed in Ajan automatic gas console, adjustment and on-

off valves relocated to an individual unit near to cutting head. Advantages of Ajan gas console

when compared with other CNC plasma cutting manufacturers’ automatic and manual gas consoles

have been stated below. In classical system (Figure 38) when sheet type is changed, even the same

consumable is used, replacing of the gas in 5-10 m hose with new ones induces 1-2 mins time losses

and 100-200 liters gas losses. As seen in Figure 39, in Ajan automatic gas console, this process

takes place with acceptable gas and time losses, since gases can replace very fast. Another

advantage of fast gas replacing is to control speed, current and flow relations, at the beginning of

the cut and at the end of cut and at corners in continuous relationship with Ajan automatic gas

console. Ajan can do marking-cutting cutting-marking transition in only 0,1 sec.



82

13.4. ALL INCLUSIVE CONTROL PANEL

(Dryer, Ventilation, Generator, Jet Filter)

Plasma cutting systems comprise of following tools and equipments.

GENERATOR

VENTILATION

JET FILTER

All these elements need electricity. Required electrical energy and gas distribution responsibility is

left to the customer in conventional assemblies. Customer will call electric and pneumatic

technicians believing that they are good for these assemblies. Final picture possibly will disturb

both customer and machine supplier. For precluding this:

A central panel that includes everything needed for Ajan Plasma and OXY-FUEL cutting systems is

provided and above mentioned 4 units are fed through this panel. Mutual accusations between

customer and manufacturer are eliminated. Since advanced plasma cutting technologies have been

used in the world in recent years, solving such installation problems by machine supplier will be far

better and economic. Because a company having 35 years of experiences like Ajan should know all

kinds of problem about these systems better than other individuals.

Cable and hose lengths are calculated separately for all sizes and categories are used in Ajan All

Inclusive system. By this means there shall be no cable and hoses crawling around that could cause

to accidents.

Figure 40. New conception Ajan all inclusive plasma cutting system



83

13.5. REMOTE CONTROL HARDWARE

(Dryer, Ventilation, Generator, Jet Filter)

Plasma OXY-FUEL cutting systems must never be considered separately in respect of Ajan

Machine’s understanding. Because they work together. For example if dryer is not operated, jet

filter should not be operated or without jet filter being operated ventilation should not be operated.

All these units must be controlled depending to each other. Ajan all inclusive dealt with system

understanding as the first over the world, and presented these advantages to the customers with the

best market prices. Thus, it gave the remote control ability of GENERATOR, VENTILATION,

JET FILTER to the operator through the CNC console.

It secures that the jet filter being switched on before than ventilation unit switched on.

It switches on the ventilation unit through the remote control unit on CNC console.

It switches on the generator unit through the remote control unit on CNC console.

Figure 41. Schema for required connection between units on Ajan all inclusive plasma system



84

13.6. HEIGHT MEASUREMENT SOFTWARE AND HARDWARE WITH 1-ARC 2-SLIDING SLEDGE 3-OHMIC CONTACT

Firstly standard in the world: 3 Different Initial Height Control Systems: Only Ajan Plasma and

OXY-FUEL sheet cutting machines utilize these triple methods. This opportunity is an inevitable

feature.

ARK: It is used for painted, nylon coated or oxidized thin sheets or other cases of which heights can

not be measured otherwise. (Shorter nozzle life).

SLIDING SLEDGE: Ohmic contact does not work on painted, nylon coated or oxidized sheets. For

these cases, if sheet is not a bending type, sliding sledge method must be preferred. By this means

negative nozzle life shortening aspect of arc height measurement method will have been eliminated.

OHMIC CONTACT: It is preferred in the cases that electrical contact is possible. But if it is not

supported with sliding sledge system, initial vertical approaching speed will be slow (app. 1

meter/min). If it is supported with sliding sledge system, this speed reaches to 6 meters/min. This

agile Z axis movement is as important as idle feeding speed and cutting speed be. For example 1

hour of time saving will not be exaggeration for a sheet which requires 1000 piercing. All three

cutting modes can be toggled with hand control unit immediately. This feature is possible only in

Ajan plasma cutting machines.

Painted and thin sheets Painted and thick sheets All kinds of clean sheets

Arc Sliding sledge Ohmic contact

Figure 42. Ajan initial height control systems

Unlike the other ohmic contact systems, Ajan eliminates the extra cable connected to the Shield-

cap. In this way operator is more comfortable for changing the consumables and the risk of cable

becoming loose or braking is eliminated thanks to Ajan new torch design.

Conventional Ohmic Contact System Ajan Ohmic Contact System

Figure 43. Ohmic system comparison

External cable and connectors

Internal cable and connectors



85

13.7. AUTOMATIC CUTTING HEIGHT CORRECTION SOFTWARE RELATED TO ELECTRODE AND NOZZLE WEAR

This feature exists only in Ajan plasma cutting systems. Electrode insert material wears during

plasma cutting process. This naturally leads to arc voltage increases up to 20 V. For example a torch

working with 3 mm height can rub to the work piece at the end of 1000 piercing. Ajan CNC plasma

cutting system has 3 torch height control system.

THC OFF

THC ON

THC AUTO

When THC AUTO is selected, required arc voltage differential for each piercing is measured real

time by CNC unit and remaining cuttings are done according to corrected arc voltage. Almost all

other CNC plasma systems require manual correction of arc voltage during the cutting periodically

by operator.

Classical System Ajan THC AUTO-Control System

Starting height 500 piercing

operator corrected

1000 piercing operator correction

necessary

Starting height 500 piercing 1000 piercing

Eliminates operator correction necessity for worn materials.

Figure 44. Torch height control systems comparison



86

13.8. PRECISION PLASMA 260 AMPER GENERATOR

Table 29. PRECISION PLASMA 260 AMPER generator technical specifications

Maximum open circuit voltage (OCV) 310 VDC

Maximum output current 260Ampere

Maximum output voltage 200VDC

Maximum power 52kW

Power factor (cos Φ) 0.85

Cooling type Compressed air

Weight 530kg

Figure 45. precısıon plasma 260Amper generator



87

13.9. SYSTEM GAS REQUIREMENT

Table 30. System gas requirement

Quality Pressure

± %10 Flow rate

O2 Oxygen 99,5% pure

Clean, dry, oil free 8,5 bars 45 lt/min

N2 Nitrogen 99,99% pure

Clean, dry, oil free 8,5 bars 130 lt/min

Air Clean, dry, oil free 8,5 bars 190 lt/min

H35

Argon - Hydrogen

99,99% pure

(H35 = 65% Argon, %35

Hydrogen)

8,5 bars 45 lt/min

F5

Nitrogen - Hydrogen

99,99% pure

(F5 = 95% Nitrogen, 5%

Hydrogen)

8,5 bars 20 lt/min

Table 31. System gas requirement

Mild steel Stainless steel Aluminum

Gas types Plasma Shield Plasma Shield Plasma Shield

30A cutting O2 O2 - - - -

45A cutting - - N2 and F5 N2 N2 N2

50A cutting O2 AIR - - - -

80A cutting O2 AIR AIR and F5 AIR and

N2 - -

130A cutting O2 AIR H35, N2 and

AIR

AIR and

N2

AIR and

H35

AIR and

N2

260A cutting O2 AIR H35 and AIR AIR and

N2

AIR and

H35

AIR and

N2

Marking N2 N2 N2 N2 N2 N2


CUTTING CHARTS

88

SECTION 14. CUTTING CHARTS Table 32. Mild steel, O2 Plasma/O2 Shield, 30A cutting chart


CUTTING CHARTS

89

Table 33. Mild steel, O2 Plasma/Air Shield, 40A cutting chart


CUTTING CHARTS

90

Table 34. Mild steel, O2 Plasma/O2 Shield, 80A cutting chart


CUTTING CHARTS

91



CUTTING CHARTS

92



CUTTING CHARTS

93

Table 37. Stainless steel, F5 Plasma/N2 Shield, 45A cutting chart


CUTTING CHARTS

94

Table 38. Stainless steel, N2 Plasma/N2 Shield, 45A cutting chart


CUTTING CHARTS

95

Table 39. Stainless steel, Air Plasma/Air Shield, 80A cutting chart


CUTTING CHARTS

96

Table 40. Stainless steel, F5 Plasma/N2 Shield, 80A cutting chart


CUTTING CHARTS

97



CUTTING CHARTS

98

Table 42. Stainless steel, H35 Plasma/N2 Shield, 130A cutting chart


CUTTING CHARTS

99

Table 43. Stainless steel, N2 Plasma/N2 Shield, 130A cutting chart


CUTTING CHARTS

100



CUTTING CHARTS

101



CUTTING CHARTS

102



CUTTING CHARTS

103

Table 47. Aluminum, N2 Plasma/N2 Shield, 45A cutting chart


CUTTING CHARTS

104

Table 48. Aluminum, Air Plasma/Air Shield, 130A cutting chart


CUTTING CHARTS

105

Table 49. Aluminum, H35 Plasma/N2 Shield, 130A cutting chart


CUTTING CHARTS

106

Table 50. Aluminum, H35 Plasma/N2 Shield, 260A cutting chart


CUTTING CHARTS

107

Table 51. Aluminum, Air Plasma/Air Shield, 260A cutting chart


CNC UNIT AND GENERATOR CARDS

108

SECTION 15. CNC UNIT AND GENERATOR CARDS

Figure 46. Arc transfer card



109

Figure 47. Firing box card



110

Figure 48. Flow card



111

Figure 49. IGBT driver card



112

Figure 50. IHS limit card



113

Figure 51. Interface sheet



114

Figure 52. Precısıon plasma generator control card



115

Figure 53. precısıon plasma Generator control card



116

Figure 54. Condenser card



117

Figure 55. Logic control card



118

Figure 56. Logic control card



119

Figure 57. Front panel card



120

Figure 58. Power card



121

Figure 59. Resistance card



122

Figure 60. Start circuit



123

Figure 61. Varistor card


CONNECTION SCHEMAS

124

SECTION 16. CONNECTION SCHEMAS

Figure 62. Plasma plate


CONNECTION SCHEMAS

125

Figure 63. Plasma plate hose gas connection schema


CONNECTION SCHEMAS

126

Figure 64. Oxygen plate


CONNECTION SCHEMAS

127

Figure 65. Oxy-Plasma hose gas connection schema


CONNECTION SCHEMAS

128

Figure 66. Plasma plate card connection schema


CONNECTION SCHEMAS

129

Figure 67. Precısıon plasma automatic gas console plasma plate connection schema


CONNECTION SCHEMAS

130

Figure 68. Precısıon plasma single head oxygen plate connection schema


CONNECTION SCHEMAS

131

Figure 69. precısıon plasma automatic gas console double head plate connection schema


CONNECTION SCHEMAS

132

Figure 70. precısıon plasma double head oxygen plate connection schema


CONNECTION SCHEMAS

133

Figure 71. Precısıon plasma automatic gas console double oxygen plate connection schema


CONNECTION SCHEMAS

134

Figure 72. Precısıon plasma four head oxygen plate connection schema


CONNECTION SCHEMAS

135

Figure 73. Precısıon plasma triple head plate connection schema


CONNECTION SCHEMAS

136

Figure 74. Interface connection schema


CONNECTION SCHEMAS

137

16.1. PLASMA GENERATOR CIRCULATION SCHEMA

Figure 75. Plasma generator circulation schema


CONNECTION SCHEMAS

138

Figure 76. Precısıon plasma 260Amper generator connection schema


CONNECTION SCHEMAS

139

Figure 77. Precısıon plasma 260Amper +oxygen cutting CNC connection schema


CONNECTION SCHEMAS

140

Figure 78. Precısıon plasma 260Amper +double head oxygen cutting CNC connection schema


CONNECTION SCHEMAS

141

Figure 79. Arc voltage divider connection schema


CONNECTION SCHEMAS

142

Figure 80. Arc voltage control system connection schema


CONNECTION SCHEMAS

143

Figure 81. Axis control system connection schema


CONNECTION SCHEMAS

144

Figure 82. Precısıon plasma generator control card connection schema


CONNECTION SCHEMAS

145

Figure 83. Flow LED control system connection schema


CONNECTION SCHEMAS

146

Figure 84. Plasma start control card connection schema


CONNECTION SCHEMAS

147

Figure 85. Jet filter system connection schema


CONNECTION SCHEMAS

148

Figure 86. Precısıon plasma 260Amper main power connection schema


CONNECTION SCHEMAS

149

Figure 87. Precısıon plasma oxygen+marking control card connection schema


CONNECTION SCHEMAS

150

Figure 88. IGBT drive system connection schema


CONNECTION SCHEMAS

151

Figure 89. Precısıon plasma double head control card connection schema


CONNECTION SCHEMAS

152

Figure 90. Precısıon plasma double head plate connection schema


CONNECTION SCHEMAS

153

Figure 91. Logic card input-output control connection schema


CONNECTION SCHEMAS

154

Figure 92. Plasma control connection schema


CONNECTION SCHEMAS

155

Figure 93. Precısıon plasma power control connection schema


CONNECTION SCHEMAS

156

Figure 94. CNC power system connection schema


CONNECTION SCHEMAS

157

Figure 95. Remote control start-stop system connection schema


CONNECTION SCHEMAS

158

Figure 96. Servo motor drive system connection schema


CONNECTION SCHEMAS

159

Figure 97. THC unit system connection schema


CONNECTION SCHEMAS

160

Figure 98. Logic card input-output controls schema


CONNECTION SCHEMAS

161

Figure 99. Generator fan, CNC connection schema


CONNECTION SCHEMAS

162

Figure 100. Generator fan, CNC connection schema


CONNECTION SCHEMAS

163

Figure 101. Interface DSUB output sockets connection schema


CONNECTION SCHEMAS

164

Figure 102 Precısıon plasma block connection output connection schema


CONNECTION SCHEMAS

165

Figure 103. Precısıon plasma 260Amper connection schema


CONNECTION SCHEMAS

166

Figure 104. Precısıon plasma CNC plasma main transformer


CONNECTION SCHEMAS

167

16.2. CARDS USED IN AJAN PRECISION PLASMA PLASMA CUTTING SYSTEM

Table 52. Cards used in precısıon plasma plasma cutting system

CNC

NO PLAQUETTE NO CARD NAME

1 PL0430-1 LOGIC CONTROL CARD

2 PL0430-4 ARC TRANSFER CARD

3 PL0430-9 IHS LIMIT CARD

4 PL0430-10 FRONT PANEL CARD

5 PL0430-12 OXY1 BLOCK CARD

6 PL0430-14 OXY2 BLOCK CARD

7 PL0430-15 GAS DISCHARGE CARD

8 PL0430-16 OXY MARKING CARD

9 PL0625-1 PROXY CARD

10 PL0240-3 HEIGHT CONTROL CARD

11 PL2005-2 POWER CARD

12 PL0306-3 LIMIT CARD

13 PL0404-1 RESUME CARD

14 PL0305-4 OHMIC SENSOR CARD

GENERATOR


1 PL0305-2 IGBT DRIVE CARD

2 PL0305-5 PHASE LACK CARD

3 PL0305-6 VARISTOR CARD

4 PL0305-8 LED CARD1

5 PL0340-2 CURRENT TRANSFORMER CARD

6 PL0430-2 CONTROL CARD

7 PL0430-3 START CIRCUIT CARD

8 PL0430-5 FIRING CIRCUIT CARD

9 PL0430-6 RESISTANCE CARD

10 PL0430-7 CONDANSER CARD

11 PL0430-8 ARC DIVIDER CARD

12 PL0430-11 PLASMA BLOCK CARD

13 PL0430-17 LED CARD2

JET FILTER


1 PL0430-13 JET FILTER CARD


PRECISION PLASMA 260AMPER SPARE PARTS CHART

168

SECTION 17. PRECISION PLASMA 260AMPER SPARE PARTS CHART

Table 53. Precısıon plasma 260AMPER spare parts chart

6 months or 300 arc hours Cooling liquid

Cooling liquid filter

Wiper

Jet filter cartridges

Ventilation press handle springs

Active carbon filter cartridges

1 year or 600 arc hours Cooling liquid


Wiper




Main circuit breaker

Pilot arc circuit breaker

Torch main body

1,5 years or 900 arc hours Cooling liquid


Wiper




2 years or 1,200 arc hours Cooling liquid


Wiper






Torch main body

Torch hoses and cables

Torch cooling pump

2,5 years or 1,500 arc hours Cooling liquid


Wiper





PRECISION PLASMA 260AMPER SPARE PARTS CHART

169



Wiper





Procon pump


Torch main body

Torch hoses and cables

Torch cooling pump



Wiper






Wiper





Procon pump


Torch main body

Cooling pump motor



Wiper






Wiper






Procon pump

Torch main body


AJAN OXYGEN-PRECISION PLASMA 260AMPER PLASMA DESCRIPTION OF THE CNC

UNIT

170

SECTION 18. AJAN OXYGEN-PRECISION PLASMA 260AMPER PLASMA DESCRIPTION OF THE CNC UNIT

18.1. GUIDE FOR THE OPERATION OF THE UNIT

AJAN CNC OXY-PLAZMA is controlled via soft keys shown for the different menus at the

bottom of the screen. A hand control unit is also incorporated for the manual control. Status

monitoring is achieved by open windows on top of the screen continuously and some other

temporary messages are issued whenever needed at the appropriate parts of the screen.

Axis Speed: Indicates the actual speed of the axis. Can be controlled by

either program line or hand control unit’s override function. Maximum

value can be 15 m/min.

SN(Motion Delay Time): Time needed for cutting Pierce from arc transfer

to the motion. This is also controlled by hand control unit “SN” key.

WD(Torch to Work-Distance): Distance that is travel height to work

piece during cutting all shape. This value is auto set due to material type,

cutting current and material thickness

PH(Pierce Height): Distance that is height for first applied arc voltage

drop torch and ground or initial height for cutting. Only use in Plasma

Machines

TIMER: Indicates the last period with kind of hour, minute and second when

machine run or simulate the program with F7DryRun function. When press

“S” key, indicates time.

X axis indication in millimeter

Y axis indication in millimeter

TV Torch axis indication in millimeter.

TW Torch axis indication in millimeter.

TL Torch axis indication in millimeter.

TR Torch axis indication in millimeter.

Z axis indication in millimeter for machines with drill.



UNIT

171

For Plasma Machines

Indicates actual value of Plasma Cut Pressure for Left Torch in work time

Indicates actual value of Shield Pressure for Left Torch in work time

Indicates actual value of Plasma Cut Pressure for Right Torch in work time

Indicates actual value of Shield Pressure for Right Torch in work time

Indicates Plasma Cut Pressure of the enter by Operator.

Indicates Shield Pressure of the enter by Operator.

Indicates Plasma Cut Pressure of the enter by Operator.

Indicates Shield Pressure of the enter by Operator.

For Oxygen Machines

Indicates actual value of Oxygen Cut Pressure in work time

Indicates actual value of Oxygen Heat Pressure

Indicates actual value of LPG pressure in work time.

Indicates LPG Pressure of the enter by operator.

Indicates Oxygen Heat Pressure of the enter by Operator

Indicates Oxygen Cut Pressure of the enter by Operator



UNIT

172

PROGRAMMING: Programming is possible in main menu (Menu:0). The reserved part for

programming is the left zone of the screen and is activated by pressing ENTER key. Total 255 lines

can be programmed. 40 characters per line is possible. Further programming lines can be achieved

by calling the names of other subprograms. Programming editor works similar to popular editor

programs. In Menu:0 bar arrow keys, Page_Up and Page_Down keys are active.

Pressing ENTER key will bring the following window.

ENTER key will register the changes for that block and the next block will be highlighted “ESC”

key will cause editor to return to menu bar (Menu:0) and if some changes made in that particular

block, it will be left unchanged. F2 key will save the edited file. The reserved right zone of the

screen will be used for graphical display for machining and fault messages.

FILE NAME : Displays the name of the file.

START NO: Indicates the start line of the program to be executed.

END NO: Indicates the program finish line.

MENU: Pressing F10 function key will change menu bars under the screen. At the right bottom

corner the name of the menu will be displayed.

Menu 0 (main menu) bar:

Menu 1 bar:

Menu 2 bar:



UNIT

173

18.2. MENU: 0 (MAIN MENU)

Run: It runs the program written in the screen. Once this key is pressed if everything is OK.

(Limit switches, axis drives). Machine starts running, the menu bar will change as shown below for

the different machine types.

For Plasma Mode:

Torch goes down following M7 code, fires and waits for flash transfer.

After flash transfer torch waits preheating time and starts cutting.

Code M8 finishes cutting and torch is up.

For OxyCut Mode:

Torch goes down following M7 code, preheating gas is released and it is fired.

Cutting oxygen is released after preheating time.

Cutting process is performed.



UNIT

174

Code M8 finishes cutting and torch is up.

For Marking Mode:

Torch goes down following M9 code, fires and waits for flash transfer.

After flash transfer torch waits preheating time and starts marking.

Code M10 finishes marking and torch is up.

The only way to stop the motion momentarily is to press the PAUSE button in hand control unit,

pressing again the PAUSE button will resume the motion pressing the ABORT button will cause

machine to go in stand by mode(Menu:0) if you press the F11 or F12 keys position indicators stops

the updating coordinates. If PAUSE button is pressed while machining the following menu will

appear.



UNIT

175

With this auxiliary menu bar we can change the set values for corresponding function keys in

increasing and decreasing mode without restarting the program. And also we can offset the axis

position values by pressing plus and minus buttons in hand control unit for the selected axis in hand

control unit. If one of the work piece coordinate codes like G54, G55, G56, G57 is active this offset

resumes back in the next block otherwise if “G59” is active, axis will remain offset during entire

machining. These functions can be changed on the fly from hand unit also. Read description of hand

control unit.

Save: Saves the contents of the edited program.

File: Used to load files from disk. When you press this function key the files with “TOR”

extension will be displayed. Page down page up and arrow keys will highlight the files, pressing the

ENTER button will load that particular file. The same key serves to view list of files existing in the

current directory with extension “CAM”, “DXF” and “MPG”(ESSI code files) by pressing “C”,

“X” and “W” key. Pressing “T” will again display us files with extension “TOR”. By pressing “S”

we can sort files according to their size, “D” according to their creation date and “N” by name.

After remembering these files we can link them to our main program in following format G36

“mpg or b3 file (ESSI file)”, G37 “dxf file” and G38 “camfile” when ever needed.

To call the programs stored in the memory, select the file and press “ENTER”. In the main menu a

sub menu is displayed. For files with extension “TOR”;



UNIT

176

If we press “Y” the last opened file is saved and selected file opens, “ESC” will open the selected

file without saving the last opened file.

To create a new file; select “file button” by pressing function key F3, press ESC key and type in

8 character file name to the small window that highlights. This file must have a different name

from the list and then the block lines existing already in the editor will be saved as with this new

file name

After pressing the “ENTER” Key following line appears.

To save the old file press “Y” key. To leave the old file unsaved press ESC key.

Pushing Y key saves the old file before creating a new file. Following figure is displayed during

saving.

After this operation following menu bar appears.

If we want to open a new blank file with this name “B” letter has to be pushed

“ESC” button will cancel operation..

“Y” button will create the file with different name but same content as the last opened file.

DELETING FILES: Press F3 File function key. High light the file using arrow Keys, Page Up and

Page Down Keys then press “DELETE” key.



UNIT

177

Pressing “Y” Key will delete the file, “N” Key will cancel the operation.

DelLin: Select the block to be erased and push this function key.

InsLin : Used to insert block after chosen block.

Resume : This function is processed only if machine is in “High Speed Machining” mode(HM

code is used). If our work stops in an unwanted way, such as electricity cut, by this function we can

continue our process from the breaking point. There is no restriction in using this function, can be

called in any level of our process.

When we press “F6Resume” we have three choices; “ENTER” will start the program from the

beginning, “F1” from breaking point, and “ESC” will exit and open menu1.

DryRun: It simulates the program graphically without moving the axes.

In dry run pressing “ESC” Key will end scanning the file.



UNIT

178

Block: Sets the start and end block number of the program by pushing F8 function Key in

Menu:0. Enter start number for the program push ENTER, write the end number push ENTER if

the number is more than three digit it will automatically skip to next procedure. At the end if will

return back to the main menu.

Quit: Used to return back to DOS. If N key is pushed the operation will be cancelled.

Menu: Used to switch menu bars for Menu:0, Menu:1, Menu:2.

18.3. MENU:1

MDI: Used to move axes X, Y (for drill model Z axis can be used) to desired positions when

F1 is pressed. And Used for Entering F (feed rate), S (Spindle period for drill model), SM

(Maximum spindle period for drill model) and G5x (G54, G55, G56, G57) commands. In graphical

screen ENTER MDI will appear:



UNIT

179

SAMPLE:

Enter MDI: x100 than “ENTER” will bring X axis to desired position of 100 mm. This operation

for each axis has to be repeated.

GoZERO: Will pull all axis (X,Y) (for drill model Z axis can be used) to “0” position

M Hand : Plasma is controlled by Hand Control Unit. Independently from the program all

axis can be controlled. Only “ABORT” button in hand control unit is available to exit and go to

the Menu:1.

****************************************** MENU6 *************************************************

*********************************************************************************************************

F4 ÷2: Used to divide axis values shown on the display by two while hand control unit is active.

Reset: Using this key is same as Menu1 F5 key.

Xangle: This key cancels machine’s XY plane and rotated XY plane to entering angle value.

Before using this key torch must be positioned one corner of the workpiece and reset all axes then



UNIT

180

other corner must be positioned. After these routines press the F6 Xangle key. Angle will be

displayed then confirm this value and close this menu. This value can be in by Manuel manner.

TkOffs: This function is used to offset Powder Marking torch to the cutting torch. Unit the

powder torch marking is positioned or marks according to the cutting torch.

For assigning offset cutting torch positioned to the workpiece zero then pressing F5Reset key to

reseting position. The marking torch positioned same workpiece zero and the press the F7TkOffs

key. For assigning offset press (A) key, for reseting offset values press the (R) key.

FndCnr: This function is used to find corner. If press F8FndCnr key, Find Corner window is

activated. It’s necessary to assign 3 point. First of all torch is positioned to first X axis point and

press the 1 key to assign position, and torch position another point in X axis then press the 2 key to

assign second point, finaly torch position in Y axis press the 3 key to assign last position then press

the 4 key to positioning corner.

*************************************************************************************************************

*************************************************************************************************************



UNIT

181

DryCut: Used to working in simulation mode with movements. Machine is working with all of

the functions but don’t cut and don’t apply arc voltage. Only travel on the workpiece.When pressing

F5DryCut function key, appears DRYCUT word over editor window of the screen.and machine

works with DryCut mode when pressed F1Run to Menu :0..If press F4DryCut function key again,

the machine is canceled DryCut mode and works normally. For toggle DryCut mode select DryCut

button then press the Fast button. in hand control unit.

Reset: X, Y, Z will be reset to “0”. You can also reset each axis separately while in manual

positioning (F3M_Hand) by pressing CTRL and related axis. Example: Pressing CTRL + X will

reset X axis to 0.

THC: Used to changed Torch Height Control is active or passive. When F6 function key is

pressed, writing TORCH ON at the bottom of the screen and Torch Height Control is active.If F6

function key is pressed again,writing TORCH OFF and Torch Height Control is passive.

MZR: This must be performed in each start up of the machine to have a reliable positioning

after electricity cut out or shut down of the machine. It searches for machine zero point. Single axis

machine zero point is also possible by pressing in single axis letter keys when prompted. The (G54,

G55, G56, G57) work piece zero point settings are available only if this machine zero operation

will be performed.



UNIT

182

F_Hght: When F8 function Key is Pressed following menu bar will appear.

Graph: When F9 function key is pressed following menu bar will appear.

Use to control graphically screen, zoom and pan. Zoom scale and pan value will be displayed on the

graphically screen. In case when a “DXF” file is loaded graphically the figure will respond to these

changes. Down (), Up (), right (), left () Keys will shift the dotted line origin and page up

and page down will change the zoom scale.



UNIT

183

Example: Codes and Co-ordinate explanations for circular interpolation is given below.

XC : Center for “X” axis

YC : Center for “Y” axis

ZC : Center for “Z” axis

RA : Radius

SA : Start angle

EA : End angle

G3 – CWW : Arc direction clock-wise or counter clock-wise

I : X axis distance from the center to actual position

J : Y axis distance from the center to actual position

Xs : “X” axis start point

Ys : “Y” axis start point

Xe : “X” axis end point

Ye : “Y” axis end point

F8 Dxf_In: Type in the name of the DXF file without the extension and press “ENTER” Key. And

clicking the left mouse button on the entity will give the information about that entity.



UNIT

184

If called DXF file is not existing a warning message will appear.

F7 EssiIn Type in the name and extension (MPG, B3) of the ESSI file and press “ENTER” Key.

If type only file name all of the 8 characters, load the file with MPG extension.if MPG extension

not exist, try to load file with B3 extension.

If called Essi file is not existing (Mpg and B3) a warning messages will appear.



UNIT

185

If we don’t want to cut all of the shapes in the mpg or dxf file, we can cut only which our indicates

start and end point of the objects in the file.

F5 Start used to choose a start object for cutting with the mouse. Press the F5 button then select the

start object with the mouse

F6 End Used to choose end point for cutting with help of the mouse. Press the F6 button then select

the last object for cutting process with the mouse



UNIT

186

F3 CutPlt When F3 function key is pressed graphically indicates selected objects for cutting

process.

F4 CutAll When F4 function key is pressed canceled which indicates all of the shapes in the file.

Menu: Toggles between Menu:0, Menu:1, Menu:2 The button right corner shows the menu

number.

18.4. MENU:2



UNIT

187

Param.: This key used to opening parameters menu. Optional key is “T”.

THC OFF DISTANCE: This function is processed if machine is in“High Speed Machining” mode

(code “HM” is used). In every cutting process, cutting is stopped (M8 is applied) before end, with

this entered distance. This is used in order not to damage the exit point.

UP DISTANCE: This value is travel height of the torch when the torch is passing between the

contours.

MICRO JOINTS DISTANCE: This value is joint to joint distance for cutting part. Micro joints

thickness specified in cutting tables. Distance between each joint specified by this parameter.



UNIT

188

d=Micro Joints Distance

FIRST HEIGHT MODE: for selection initial height sensing type. if switch is selected initial

height taking by mechanically.if arc is selected initial height sensing with arc voltage.

MACHINE TYPE: The parameter used to set the machine as oxygen or plasma. Page_up,

Page_down buttons are used to change machine type. If plasma is selected, PURGE parameter

becomes active. In Oxygen modes this parameter is not active.

THC AT CORNERS: This function is processed if machine is in“High Speed Machining” mode

(code “HM” is used). The corners with angle greater than 45°, this function cancels or

applies(Pg_up/Pg_down) torch height control before 5 mm to the corner and 5 mm after the corner.

AXIS TYPE: This parameter indicates type of the machine X axis. This value must be set by your

machine producer.

CUT CHARTS: Tab or (down (), up () ) key used to select cutting parameter. After choosing

Material type, cutting current and cutting thickness right tables shows which gases is used gas rates

, Arc voltage, cutting speed ,SN(pierce delay time), torch to work distance , pierce height factor,

micro joints thick, consumables (Electrode, Nozzle, Swirlring, Retaining Cap, Serial Numbers)

information. Press “OKEY” after selection correct parameters to exit main menu.



UNIT

189

Menu for AJAN PRECISION PLASMA 260AMPER model

PURGE: This parameter is active only Plasma Mode. This parameter used to flowing a gas to the

torch for clean inside to torch and fill the hosepipe with gas with 6 seconds period.

THC OFFSETS: Used to change offset value for the Torches.

NUMBER OF TORCHES: Used to change Torches count.

WORKING TORCH: Used to selected torch. Left Torch, Right Torch or each one.

EXIT: Aborting from menu.

AbsPOs: Shows the actual position of the axis with respect to machine zero point.

G5x: 4 work piece zero points can be assigned for separate locations. Pushing this function key

will open a text window in graphic area for G54, G55, G56, G57. By pressing 4,5,6,7 all axis can

be assigned with these work piece zero points but if single axis assignment is needed that axis have

to be moved to desired position before hand and related work piece zero code must be pressed

together with SHIFT key and than related axis must be entered related tool number that will be

assigning to g5x.(note: all of the tool can be assigned all of the G5x (work piece zeros) thus you



UNIT

190

have 4 tool and 4 work piece zeros) If the number of the tool that is entered by users is illegal

assigning of work piece zeros to tool not be occurred. And there is a message tool not legal on

screen appears. Process can be done only entering legal tool number.

NOTE: Before assigning work piece datum for (G54, G55, G56, G57) (Menu:1 F7) machine zero

operation has to be performed. Otherwise “first go to machine zero” warning will appear.



UNIT

191

GetPrg : When this function key is pressed the following menu appears.

“Y” To call a program with a new path name.

“ENTER” To accept already existing path written in memory.

“ESC” To cancel the operation.

NOTE 1: Path name up to 30 characters is possible

2: If you enter “P” shortcut key, you can reach last entered program.

T_Rst: Reset the Timer.

Turk: Changes program language to Turkish.

Menü: Toggles the menu.



UNIT

192

18.5. OPERATION OF HAND CONTROL UNIT

Figure 105. Hand control unit label

FEED Percent override of the entered feed value by F during programming.

ARC VOLTAGE Percent override of the arc voltage value

PAUSE: Serves to stop the machines axis movements temporarily. Pressing this

button again will resume the motion.

ABORT: This button serves to stop the operation of machining and motion, when

PAUSE button is active. It also serves to exit from the manual positioning mode.

This button is enabled or disabled the Torch Height Control.

If press the or buttons when THC MODE button is enable, in

Oxygen Machines LPG pressure is increase or decrease. With button 0,005

bar, with button 0,01 bar, with button 0,1 bar increase or decrease.

This Button is used to change IHS MODE with button. Values

SW(Switch),ARC or OFF. If pressing and buttons when HIS

MODE button is enable, PH (Pierce Heigt) value is increase or decrease. With

button 0,05 mm, with button 0,1 mm, with button 1 mm increase

or decrease.

This button is used to selected the working torch with button.

If press and buttons when THC SEL button is enable, in Plasma

Machine, SCF (Shield Cut Pressure )with button 0,05 bar, with button

0,1 bar, with button 1 bar, in Oxygen Machines OT (Heat Pressure) with

button 0,01 bar, with button 0,1 bar, with button 1 bar increase or



UNIT

193

decrease.

If the DRYCUT button is active and press the button, The Machine is

working in DRYCUT mode. Writing DryCut on the left of the screen. If press

ve buttons when DRYCUT is active, in Plasma machines PCF

(Plasma Cut Presure ) with button 0,05 bar, with button 0,1 bar, with

button 1 bar, in Oxygen Machines OK (Oxygen Cut Pressure) with

button 0,01 bar, with button 0,1 bar, with button 1 bar increase or

decrease.

If the SN button is active, press and button, the delay time with

button le 0,1second, with button 0,25 second, with button 1 second

increase or decrease.

It is selected in manual positioning mode to move Tv Torch by pressing and + button the Tv Torch can be moved to desired position.

It is selected in manual positioning mode to move Tw Torch by pressing and + button the Tw Torch can be moved to desired position.

It is selected in manual positioning mode to move TL Torch by pressing and + button the TL Torch can be moved to desired position.

It is selected in manual positioning mode to move TR Torch by pressing and + button the TR Torch can be moved to desired position.

It is selected in manual positioning mode to move X axis by pressing and +

button the axis can be moved to desired position.

It is selected in manual positioning mode to move Y axis by pressing and +

button the axis can be moved to desired position.

It causes axis to be moved by 1 micrometer increments in jogging mode while

manual positioning. When active the LED will be illuminated. Pressing again the

same button or one of the other two jog buttons will disable the function of this

button




button




button

Used to position axis in “-” direction while machine is in manual control mode or

decrement the selected values while machining.

Used to position axis rapidly while machine is in manual control mode when

pressed together with + or buttons.



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Used to position axis in “+” direction while machine is in manual control mode or

increment the selected values while machining.

18.6. G PREPARATORY AND AUXILIARY FUNCTIONS USED IN CNC

Table 54. G and preparatory M codes used in CNC

NAME EXPLANATION

G0 Rapid traverse linear move.

G1 Linear move with the programmed speed F.

G2 Clock wise circular interpolation. (CW)

G3 Country clock wise circular interpolation (CCW)

G36

Used to call files with MPG or B3 extensions (ESSI File).First type G36

then press space then type in the 8 characters only file name or file name

with extension.(MPG or B3).If type only file name all of the 8

characters, load the the file with MPG extension.if MPG extension not

exist, load file with B3 extension.

G37 Used to call files with DXF extension. First type G37 then press space

then type in the 8 character file name. Do not type extension.

G38 Used to call tool path files with CAM extension. First type G38 then

press space then type in the 8 character file name. Do not type extension.

G40 Cancels tool radius compensation

G41 Tool radius compensation to the left

G42 Tool radius compensation to the right.

G50 Cancels mirror image effected mode

G51

G51 X_x Y_y I_ı p J_jp

_x : Center coordinate value of X axis

_y : Center coordinate value of Y axis

_ıp : indicate make mirror image effect on X axis as to sign of the ip

_jp : indicate make mirror on Y axis as to sign of the jp

G54-G55

G56-G57

G54: First work pieces zero point.

G55: Second work pieces zero point.

G56: Third work pieces zero point.

G57: Forth work piece zero point.

G59 Work piece zero point shown by the actual axis indicator positions. F5

will reset positions.

G72

When machining DXF files this code causes torch retraction when the

end point of the first contour does not coincide with the start point of the

next contour

G75

Disables G72 and discontinuous contours are connected to each other.

Care must be taken when original drawing has large discontinuous

separations.

G90 Absolute coordinate system

G91 Incremental coordinate system

M0 When this code is encountered in a program block the machine will stop



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until operator hits a key.

M7

Used for Plasma/Oxygen firing. Is executed when program comes the

line M7 is written. Torch goes down and Plasma/Oxygen fires and

cutting starts.

M8 Written after M7. Cancels Plasma/Oxygen cutting. And torch goes up.

M9 Used for Plasma Marking. Is executed when program comes the line M9

is written. Torch goes down and Plasma fires and marking starts.

M10 Written after M9. Cancels Plasma Marking. And torch goes up.

M17

Indicates the end block for the subroutine

L: Indicates the start of the block that ha to be repeated.

P: Indicates the subroutine repeat number.

EXAMPLE: L10 P3

This will call a block starting t line 10 and repeats the part until M17 is

written 3 times.

IMPORTANT NOTE: Subroutines are written always outside the main

program blocks. (i,e they must be written after the program end number.4

nested subroutines are possible.

18.7. AUXILIARY CODES:

Table 55. Auxiliary codes used in CNC

NAME EXPLANATION

F Defines the feed rate in mm/min for X, Y axis.

SN

Motion Delay time. The time needed for plasma to hole the work piece

(preheating time for Oxygen Cut). It is displayed as “Preheat Time”. This

time interval “SN” changes with the type and the thickness of the work

piece. We can both adjust this value by writing this command to program

line or by using Hand Control Unit’s “ET” function.

HM Code for High-Speed-Machining.

HN Cancel High-Speed-Machining.

PH Defines Pierce Height.

PC Define Plasma Cut Pressure.

SC Defines Plasma Shield Pressure.

OK Defines Oxygen Cut Pressure.

OT Defines Oxygen Heat Pressure.

LP Defines LPG Pressure.

18.8. SAMPLE PROGRAMS

Three drill and preparing subprogram



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PROGRAM ROWS

000 F1500 SN.5

001 G59 X0 Y0

002 G0 X12 Y14

003 L9 P1

004 G1 X50

005 L9 P1

006 G1 X70

007 L9 P1

008 G1 X0 Y0

Start and end lines

009 F50 M7

010 G3 I5

011 M8

Sub program

012 M17 Sub program end

Usage of “I” and “J” Parameters in Radial Movement

To make radial movements on the workpiece we should set “I” (distance of the circle from “X”

axis) and “J” (distance of the circle from “Y” axis). These distances can be either plus (+) or

minus (-). Also according to the direction of the circle, radial “G” codes (“G2” for clockwise and

“G3” for counter-clockwise) must be used. We should care to the “G” codes written after

coordinates are entered. We can use “G1” or “G3” after “G2”. Finally by using F7 DryRun

command on the main menu(menu0) program can be checked graphically and errors, if there are,

can be corrected.



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Example below shows followed linear and radial movements (clockwise and counter clockwise).

000 F200 G90 SN2

001 G59 X5 Y0

002 M7 F100 G1 X85

003 G3 J5 I0 X90 Y5

004 G1 Y25

005 G3 J0 I-5 X85 Y30

006 G1 X65

007 G2 J5 I0 X60 Y35

008 G1 Y55

009 G3 I-5 J0 X55 Y60

010 G1 X35

011 G3 J-5 I0 X30 Y55

012 G1 Y35

013 G2 I-5 J0 X25 Y30

014 G1 X5

015 G3 J-5 I0 X0 Y25

016 G1 Y5

017 G3 I5 J0 X5 Y0

018 M8

019 G1 X0 Y0

We can also write this program by using “Drawing Program” and “DXF” file extension. We draw

the sketch by using Drawing.exe program coming with the machine. The starting line and ending

line also must follow each other. This can be achieved by “pedit” command. We should think the

drawing as the work piece and pedit the sketch considering this. We should select lines following

each other while pediting. There mustn’t be any unselected line left after pedit operation. We should

also place the drawing to origin, 0,0,0. After completing this we can save and exit from drawing

program. In the main window edit the command lines and run the program. While working with

complex designs writing the program line by line can be very long and errors are more possible. By

using drawing program we can get rid of this problem. We don’t need any mathematical calculation

after drawing the sketch. We only call the drawing with file extension “DXF” and run the program.



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Dxf.exe program must be same directory with plasma program. If not, dxf files is not run with

plasma program.

Below preparing a DXF file is explained graphically.

The appropriate program to run this DXF file is;

(drawing is saved as RADIUS)

Program is writen as:

000 RADIUS PROGRAM

001 G90 F200

002 G59 X0 Y0 X0

003 G72 SN1.5

004 G37 RADIUS

005 M8

Program name is written. The necessary feed is given. By using “G59” starting coordinates are

selected. To call a “DXF” file “G37” is written. With “G37” plasma automatically fires, there is no

need to write “M7” code if using “G37”. After cutting we should write “M8”. “G72” is used to

stop cutting while passing between contours. This should be written before “G37”. As it is

explained above more complex sketches can be prepared by using drawing program and writing

shorter program lines. We should select start line as 001 and end line as 005.

Using parameters and preparing subprograms for consecutive cutting processes:

SUBDAIRE. TOR

000 G59 F1000

001 G1 X0 Y9

002 R1=0 R2=3

003 SN2

004 L6 P4

//Work piece zero point shown by the actual axis indicator

positions.

//Moves to starting point

//Parameters

//Preheating time, depands on the type cutting current ,and

thickness of the workpiece

//Calling subprogram starting at line 6, 4 times



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005 G90 G1 X0 Y0

006 G91 X10

007 M7

008 G1 X–1

009 G2 I=R2

010 M8

011 R1+6

012 G1 X=R1

013 R2+3

014 M17

//Moving to zero point in absolute coordinate system

//Subprogram start

//Moving 4 unit on x direction in incremental coordinates

//Plasma fires

//Moving -1 unit on x direction in incremental coordinates

//Moving R2 unit on I direction-clockwise in incremental

coordinates

//Cancel plasma firing

//Increase R1 by +6

//Moving R1 unit on x direction in incremental coordinates

//Increasing R2 by +3

//Subprogram end

Documents

maintenance manual for ajan precision plasma 260 amper plasma