THERMACUT EX-TRACK Manual de usuario

PORTABLE CNC CUTTING SYSTEM

Operator Manual

EX-0-902-001

N-22063

Revision Date: December 01, 2019

Revision Number: 01.3

Language: English

EX-TRACK®

Operator Manual, Revision T-12

Foreword

Thank you for purchasing the Thermacut®EX-TRACK®CNC Cutting System, the system is available

with a oxy fuel cutting torch. The system has been designed and manufactured to deliver: reliability,

dimensional accuracy and reproducible proﬁle part cutting. The system is easy to operate and

maintain, read this instruction manual before proceeding, be aware, there is a potential for danger

upon installation, operating or maintaining the system.

It is the responsibility of the operator/user to ensure the safe use/handling of the system, refer to

Thermacut’s terms and conditions of sale for speciﬁc responsibilities and limitations on liability.

Information in this document is subject to change without notice. The manual is for the convenience

and use of the Thermacut®EX-TRACK®CNC Cutting System purchaser, it is not a contract or

obligation on the part of Thermacut®“The Cutting Company”.

Safety precautions

This instruction manual describes the correct, effective and safe use of the system. All personnel

involved in the use or maintenance of the system should read this instruction manual thoroughly

and familiarize themselves in the correct and safe method of operation. A copy of this instruction

manual should be kept with the system at all times for easy reference.

EX-TRACK®

Operator Manual, Revision T-1 3

Foreword........................................................................................................................ 2

Safety precautions ........................................................................................................ 2

1. SAFETY INSTRUCTIONS ............................................................................9

1.1. General system safety precautions .................................................................. 12

1.1.1. System safety .................................................................................................... 12

1.1.2. Personal protective equipment ...................................................................... 12

1.1.3. Safety precautions prior to handling and operation ................................... 13

1.2. Plasma/oxy fuel gas cutting safety awareness................................................. 14

1.2.1. Prevention of fire and explosion..................................................................... 14

1.2.2. Safe use of gas pressure regulators .............................................................. 14

1.2.3. Gas cylinder handling and storage ............................................................... 14

1.2.4. Oxy fuel gas hose safety precautions ........................................................... 14

1.2.5. Risk of fire ......................................................................................................... 15

1.2.6. Risk of burn injury ........................................................................................... 15

1.2.7. Safety in the workplace ................................................................................... 16

2. LOCATION OF WARNING AND SAFETY LABELS .....................................18

3. SPECIFICATION .......................................................................................22

3.1. System overview.................................................................................................. 23

3.1.1. Main features .................................................................................................... 23

3.1.2. Range of application........................................................................................ 23

3.2. System parts description .................................................................................... 23

3.3. Technical parameters.......................................................................................... 24

3.4. Torch height controller........................................................................................ 24

3.5. Gas supply............................................................................................................ 25

4. UNPACKING AND ASSEMBLY..................................................................26

4.1. Packing list............................................................................................................ 27

4.2. System assembly ................................................................................................. 28

4.2.1. Parts check ........................................................................................................ 28

4.2.2. Fitting the main unit on to the longitudinal guide rail................................. 28

4.2.3. Fitting the transverse guide rail...................................................................... 29

4.2.4. Fitting the torch height controller .................................................................. 29

4.2.5. Gas supply connection.................................................................................... 30

4.2.6. Electrical connection ....................................................................................... 30

5. CUTTING PROCESS .................................................................................32

5.1. Prior to operating the system............................................................................. 33

INDEX

EX-TRACK®

Operator Manual, Revision T-14

5.1.1. Input voltage settings ...................................................................................... 33

5.1.2. EX-TRACK®placement ..................................................................................... 33

5.1.3. Oxy fuel nozzle choice..................................................................................... 33

5.1.4. Regulated gas supply ...................................................................................... 33

5.1.5. Oxy fuel cut charts............................................................................................ 33

5.1.6. Pre-ignition check............................................................................................. 34

5.2. Ignition and flame adjustment - oxy propane cutting .................................... 34

5.3. Cut quality ............................................................................................................ 35

5.4. Preheat time ......................................................................................................... 35

5.5. Torch operation.................................................................................................... 35

5.6. Flashback and backfire prevention................................................................... 36

5.6.1. Flashback prevention ..................................................................................... 36

5.6.2. Backfire prevention ......................................................................................... 36

6. SYSTEM OPERATION...............................................................................38

6.1. Oxy fuel cutting (prior to operation) ................................................................. 39

6.2. Plasma arc cutting (prior to operation)............................................................. 40

7. MAINTENANCE .......................................................................................41

7.1. Cleaning the system............................................................................................ 42

7.2. System lubrication............................................................................................... 42

7.3. Drive motor adjustment...................................................................................... 42

7.4. Oxy fuel nozzle maintenance............................................................................. 42

8. CIRCUIT DIAGRAM ..................................................................................43

8.1. Plasma interface................................................................................................... 44

9. OPERATION.............................................................................................45

9.1. Control panel functions ...................................................................................... 48

9.2. CNC system functions......................................................................................... 48

9.3. System main menu .............................................................................................. 49

9.3.1. Menu features................................................................................................... 49

9.3.2. Main function F-key menu............................................................................... 50

9.4. Automatic function.............................................................................................. 50

9.4.1. Interfaces and inputs ....................................................................................... 51

9.4.1.1. Speed ............................................................................................................. 51

9.4.1.2. Prog, pierce, kerf .......................................................................................... 51

9.4.1.3. Work mode - running status ....................................................................... 51

9.4.1.4. Input and output signals ............................................................................. 51

9.4.1.5. System parameters display ......................................................................... 51

9.4.1.6. System coordinates display ......................................................................... 52

9.4.1.7. Zoom function [key 1]................................................................................... 52

9.4.1.8. Return [key 2]................................................................................................. 52

EX-TRACK®

Operator Manual, Revision T-1 5

9.4.1.9. Dry run [X]...................................................................................................... 52

9.4.1.10. Speed [Y] ..................................................................................................... 53

9.4.2. Auto processing menu [MAIN MENU → F1 (AUTO)] .................................. 53

9.4.2.1. Pierce point [F1 (SECTION)] ........................................................................ 53

9.4.2.2. Manual mode [F2 (MANUAL)] ..................................................................... 53

9.4.2.3. Break point [F3 (BRK)]................................................................................... 53

9.4.2.4. Graphics display [F4].................................................................................... 54

9.4.2.5. Kerf [F5].......................................................................................................... 54

9.4.2.6. More [F6]........................................................................................................ 54

9.4.2.6.1. [F1 OUTLINE] PERIMETER FUNCTION ................................................... 55

9.4.2.6.2. Rotate (re-orientation) [F3] ....................................................................... 55

9.4.2.6.2.1. Re-orientation angle processing .......................................................... 55

9.4.2.6.3. Mirror [F4]................................................................................................... 56

9.4.2.6.4. Scale [F5]..................................................................................................... 56

9.4.2.6.5. Nest [F6]...................................................................................................... 56

9.4.2.6.6. Tabbing - bridge function [F7 BREAK] .................................................... 57

9.4.2.7. Return [F7]...................................................................................................... 57

9.5. Automatic program mode.................................................................................. 57

9.5.1. Cutting speed................................................................................................... 58

9.5.2. Process start point ............................................................................................ 58

9.5.3. Active key functions when running a program............................................. 58

9.5.4. Active key functions in pause mode .............................................................. 59

9.5.5. Select program................................................................................................. 61

9.5.6. Edge start cutting............................................................................................. 61

9. 6. Manual mode...................................................................................................... 62

9.6.1. Manually controlled functions ........................................................................ 62

9.6.1.1. [↑] [↓] [←] [→] [UP] [DOWN] [LEFT] [RIGHT] directional control keys [G]63

9.6.1.2. Mode switching [F1] ..................................................................................... 63

9.6.1.3. Step [F2] ......................................................................................................... 63

9.6.1.4. More [F3]........................................................................................................ 63

9.6.1.4.1. P-START [F3] a P-END [F4] ........................................................................ 64

9.6.1.4.2. Coordinates settings [F5].......................................................................... 64

9.6.1.4.3. Origin [F7]................................................................................................... 64

9.6.1.5. Mach-0 [F4].................................................................................................... 64

9.6.1.6. Rapid [F5]....................................................................................................... 64

9.6.1.7. Prog-0 [F6] ..................................................................................................... 64

9.6.1.8. Return [F7] ..................................................................................................... 64

9.7. Editing function ................................................................................................... 65

9.7.1 Edit function ...................................................................................................... 65

9.7.1.1. New [F1] ......................................................................................................... 65

9.7.1.2. Load [F2] ........................................................................................................ 65

9.7.1.3. Save [F3] ........................................................................................................ 66

9.7.1.4. Delete files [F4] ............................................................................................. 66

EX-TRACK®

Operator Manual, Revision T-16

9.7.1.5. Delete line [F5] .............................................................................................. 66

9.7.1.6. USB [F6].......................................................................................................... 66

9.7.1.7. View [F7]......................................................................................................... 66

9.8. Setup [F4 PARAMER] .......................................................................................... 66

9.8.1. Process definition - speed............................................................................... 66

9.8.2. Speed parameters [F1].................................................................................... 67

9.8.3. System parameters .......................................................................................... 68

9.8.4. OXY parameters ............................................................................................... 69

9.9. Plasma parameters.............................................................................................. 70

9.9.1. Control parameters ......................................................................................... 71

9.9.2. THC .................................................................................................................... 73

9.9.3. Save [F7]............................................................................................................ 74

9.9.4. Gallery function ................................................................................................ 74

9.9.5. Graphics library ................................................................................................ 74

9.9.6. Graphics library (shape development).......................................................... 75

9.9.7. Shape check...................................................................................................... 75

9.9.7.1. Inside diameter cut [F1] and [F2] Outside diameter cut.......................... 75

9.9.8. Graphics library (nest function) ...................................................................... 76

9.10. Program function............................................................................................... 76

9.10.1. CNC program symbols (G - codes).............................................................. 76

9.10.2. File types ......................................................................................................... 77

9.10.3. File names....................................................................................................... 77

9.10.4. Units of measurement ................................................................................... 77

9.10.5. Programming ................................................................................................. 77

9.10.6. System axes .................................................................................................... 77

9.10.7. G-codes .......................................................................................................... 78

9.10.8. G92 – program zero point............................................................................. 78

9.10.9. G90 – absolute commands ........................................................................... 78

9.10.10. G91 – incremental commands .................................................................. 78

9.10.11. G20 – imperial mode .................................................................................. 78

9.10.12. G21 – metric mode ...................................................................................... 78

9.10.13. G00 – rapid travel......................................................................................... 79

9.10.14. G01 – linear interpolation (motion in a straight line) .............................. 79

9.10.15. G02- G03 – circular interpolation (motion along a circular arc)............. 79

9.10.16. G04 – pause/dwell ....................................................................................... 79

9.10.17. G40 – kerf off (compensation factor)......................................................... 79

9.10.18. G41 – kerf left ............................................................................................... 80

9.10.19. G42 – kerf right............................................................................................. 80

9.10.20. G28 – return to reference point (zero position)........................................ 80

9.10.21. G22 / G80 – cycle command (loop function) ........................................... 80

9.11. M - codes............................................................................................................ 80

9.11.1. M00 - stop....................................................................................................... 80

9.11.2. M02 – program end ...................................................................................... 80

EX-TRACK®

Operator Manual, Revision T-1 7

9.11.3. M07 – cutting sequence start ....................................................................... 80

9.11.4. M08 – cutting sequence stop ....................................................................... 81

9.11.5. Additional M-codes ....................................................................................... 81

10. FAQ’s Operating the system .................................................................82

10.1. FAQ’s Operating the system............................................................................ 83

10.2. Basic trouble shooting...................................................................................... 85

10.3. Software service instructions - Boot menu..................................................... 92

10.4. Backup and restore parameters...................................................................... 93

10.5. Changing System name text............................................................................ 95

10.6. Hardware service instructions.......................................................................... 95

10.6.1. Replacing main fuse ...................................................................................... 95

11. Warranty terms and conditions.............................................................97

S Mark; ......................................................................................................................... 98

CE Mark;....................................................................................................................... 98

C-Tick Mark;................................................................................................................. 98

12. Certiﬁcation and compliance symbols..................................................98

Appendix: Graphics library .........................................................................99

Shape 1 ......................................................................................................................101

Shape 2 ......................................................................................................................101

Shape 3 ......................................................................................................................101

Shape 4 ......................................................................................................................102

Shape 5 ......................................................................................................................102

Shape 6 ......................................................................................................................102

Shape 7 ......................................................................................................................103

Shape 8 ......................................................................................................................103

Shape 9 ......................................................................................................................103

Shape 10....................................................................................................................104

Shape 11....................................................................................................................104

Shape 12....................................................................................................................104

Shape 13....................................................................................................................105

Shape 14....................................................................................................................105

Shape 15....................................................................................................................105

Shape 16....................................................................................................................106

Shape 17....................................................................................................................106

Shape 18....................................................................................................................106

Shape 19....................................................................................................................107

Shape 20....................................................................................................................107

Shape 21....................................................................................................................107

Shape 22....................................................................................................................108

EX-TRACK®

Operator Manual, Revision T-18

Shape 23....................................................................................................................108

Shape 24....................................................................................................................108

Shape 25....................................................................................................................109

Shape 26....................................................................................................................109

Shape 27....................................................................................................................109

Shape 28....................................................................................................................110

Shape 29....................................................................................................................110

Shape 30....................................................................................................................110

Shape 31....................................................................................................................111

Shape 32....................................................................................................................111

Shape 33....................................................................................................................111

Shape 34....................................................................................................................112

Shape 35....................................................................................................................112

Shape 36....................................................................................................................112

Shape 37....................................................................................................................113

Shape 38....................................................................................................................113

Shape 39....................................................................................................................113

Shape 40....................................................................................................................114

Shape 41....................................................................................................................114

Shape 42....................................................................................................................114

Shape 43....................................................................................................................115

Shape 44....................................................................................................................115

Shape 45....................................................................................................................115

Shape 46....................................................................................................................116

Shape 47....................................................................................................................116

Shape 48....................................................................................................................116

Shape 49....................................................................................................................117

Shape 50....................................................................................................................117

Notes:.........................................................................................................................118

Revision history: ........................................................................................................119

EX-TRACK®

Operator Manual, Revision T-1 9

SECTION 1.

SAFETY INSTRUCTIONS:

1.1. General system safety precautions ............................................................................... 12

1.1.1. System safety ................................................................................................................. 12

1.1.2. Personal protective equipment ................................................................................... 12

1.1.3. Safety precautions prior to handling and operation ................................................ 13

1.2. Plasma/oxy fuel gas cutting safety awareness.............................................................. 14

1.2.1. Prevention of fire and explosion.................................................................................. 14

1.2.2. Safe use of gas pressure regulators ........................................................................... 14

1.2.3. Gas cylinder handling and storage ............................................................................ 14

1.2.4. Oxy fuel gas hose safety precautions ........................................................................ 14

1.2.5. Risk of fire ...................................................................................................................... 15

1.2.6. Risk of burn injury ........................................................................................................ 15

1.2.7. Safety in the workplace ................................................................................................ 16

1. SAFETY INSTRUCTIONS

EX-TRACK®

Operator Manual, Revision T-110

Safety Instructions

Many accidents are caused by disregard for basic safety rules in the operation, inspection and

maintenance of devices. So carefully read, fully understand, and comply with the safety measures

and precautions described in this instruction manual and on the system before operating,

inspecting, and maintaining the system.

The system safety label categories are as follows:

WARNING

CAUTION

NOTICE SIGNS

This symbol is used as a warning message or a warning label. It is positioned at

places that could cause injury or serious accident.

This symbol is used as a caution message or a caution label. It is positioned at places

that could cause slight injury or system damage. This is also used as a caution for

highly dangerous actions.

This symbol shows system operators and maintenance engineers items that relate

directly to damage of systems and surrounding facilities and equipment.

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