ESAB CROSSBOW Instruction Manual Download Page 215

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ESAB Cutting Systems

CROSSBOW

Page 215

Appendix 4: Oxy-Fuel Cutting Parameters

Cutting Data for Oxweld C-69 Torch

For use with fuel gases other than Acetylene.

1515 Series Nozzles

Nozzle

Steel Thickness

Cutting Oxygen

Cutting

Speed

in./min.

Size

Part No.

In.

Pressure,

psig

Consumption,

CFH

08Z85

1/4

20 - 25

55 - 60

18 - 24

1/2

30 - 35

70 - 80

14 - 22

08Z86

3/4

30 - 35

135 - 155

12 - 20

35 - 40

150 - 165

11 - 17

1-1/2

40 - 45

160 - 210

10 - 15

08Z87

25 - 30

215 - 245

9 - 13

30 - 35

235 - 290

7 - 10

100

35 - 40

270 - 320

6 - 9

Cutting Data for Oxweld C-70 Torch

For use with Acetylene.

1502 Series Nozzles

Nozzle

Steel

Thickness

in.

Gas Pressure, psig

Cutting

Speed

in./min.

Size

Part No.

Cutting

Oxygen

Preheat
Oxygen

Acetylene

1/4"

08Z67

1/8 - 1/4

20 - 40

5 - 7

16 - 25

1/2"

15Z17

3/8 - 1/2

30 - 40

5 - 7

14 - 23

1-1/2"

15Z18

5/8 - 1-1/2

30 - 40

5 - 7

12 - 21

15Z19

2 - 4

25 - 55

6 - 8

5 - 14

Summary of Contents for CROSSBOW

Page 1: ...CROSSBOW Portable CNC Cutting Machine Instruction Manual Article Number 0560951719 Revision Date September 29 2014 Revision Number B Language ENG...

Page 2: ......

Page 3: ...ge or add features and capabilities without notice Before operating the machine one should become familiar with this manual in its entirety with special attention to the SAFETY section The equipment d...

Page 4: ...ation 25 3 Installation 27 3 1 Receiving Inspection 27 3 2 Base Machine Setup 28 3 2 1 Prepare Rail Track 28 3 2 2 Install Central Unit on Rail Track 32 3 2 3 Install Cross Beam Assembly 35 3 2 4 Inst...

Page 5: ...66 4 8 Home Screen and Main Menu 67 4 9 Main Menu Map 68 4 9 1 Main Menu 68 4 9 2 Auto Mode Menu 69 4 9 3 Manual Mode Menu 70 4 9 4 Edit Mode Menu 71 4 10 Auto Mode Screen 72 4 10 1 SPEED 72 4 10 2 PR...

Page 6: ...ltage Height Control Operation Plasma Cutting 83 4 14 Functions Available While Running a Program 84 4 15 Functions Available During Program Pause 85 4 15 1 Program Pause Screen 85 4 15 2 Key Panel Fu...

Page 7: ...4 23 2 F2 LOAD 100 4 23 3 F3 SAVE 101 4 23 4 F4 DEL FILE 101 4 23 5 F5 DEL LINE 101 4 23 6 F6 USB 101 4 23 7 F7 PREVIEW 102 4 24 USB Access Menu 103 4 24 1 F1 LOAD 103 4 24 2 F2 OUTPUT 104 4 24 3 F3 S...

Page 8: ...eshooting 137 5 5 Software Service Instructions 141 5 5 1 Boot Menu 141 5 5 2 Backup and Restore Parameters 142 5 5 3 Instructions for Updating Software 143 5 5 4 Changing Machine Name Text 144 5 6 Ha...

Page 9: ...6 3 1 Main Assemblies 174 6 3 2 Central Unit Parts 175 6 3 3 Motion System Parts 176 6 3 4 Internal Electrical Parts 177 6 3 5 Internal Mechanical Parts 178 6 3 6 Internal Drive System Parts 179 6 3 7...

Page 10: ...LINE Common Line Cut Rectangles 208 Shape 19 TANK BED 209 Shape 20 4 HOLE FLANGE 210 Shape 21 6 HOLE FLANGE 211 Shape 22 IMPELLER 212 Shape 23 2 HOLE FLANGE 213 Shape 24 WES TEST 214 Appendix 4 Oxy Fu...

Page 11: ...re procedure before operating or performing any equipment maintenance Special attention must be given to all hazard warnings that provide information on personnel safety and or equipment damage Read a...

Page 12: ...plasma operation Turn off ALL power before touching or servicing plasma system components i e plasma torch plasma power source or electronic enclosures Do not touch live electrical components Keep al...

Page 13: ...tion EXPLOSION HAZARD Oxy fuel torches can create explosive gas pockets if flowing gas is not burned Never leave gases turned on if a torch fails to ignite If unignited gas has been flowing from a tor...

Page 14: ...its proper name Oxygen Never call oxygen air which could be confused with compressed air EXPLOSION AND FIRE HAZARD Fuel gases can explode and burn causing severe injury and death Do not purge lines cl...

Page 15: ...ng signs containing the text shown at left Engineering control must be used to reduce exposures to safe levels Specific details of the standard are complex and may require assistance from occupational...

Page 16: ...d while machine power is off to prevent accidental shorting of components Use caution when handling electronic components When finished servicing confirm that all circuit boards are properly seated al...

Page 17: ...O 12100 Safety of Machinery Basic concepts and general principles for design DIN EN ISO 13849 Safety of Machinery Safety related parts of control systems DIN EN ISO 13857 Safety of Machinery Safety di...

Page 18: ...ubber welding hose CGA P 1 Precautions for safe handling of compressed gases in cylinders OSHA OSHA 29 CFR 1910 General Safety OSHA 29 CFR 1910 1026 Toxic and Hazardous Substances OSHA 3373 10 2009 He...

Page 19: ...onal Sources Directive 2006 42 EC Machinery Directive Form 2035 Precautions and Safe Practices in Welding and Cutting with Oxygen Fuel Gas Equipment ESAB Cutting Systems Form F52 529 Precautions and S...

Page 20: ...ESAB Cutting Systems CROSSBOW Page 20...

Page 21: ...wide variety of applications from small fab shops to giant shipyards The portable nature of the machine allows it to be moved to where the cutting is needed rather than bringing the steel plates to a...

Page 22: ...achine may be equipped with an oxy fuel torch or a plasma torch If the machine is purchased with both oxy fuel and plasma torches one torch must be removed in order to install and use the other Figure...

Page 23: ...3 Machine Dimensions Figure 2 Crossbow Dimensions A Overall Track Length 2200 or 4000 mm 86 or 157 in B Cross Beam Width 2362 mm 93 in C Effective cutting length 1220 or 3100 mm 4 ft or 10 ft D Effec...

Page 24: ...1 bar 0 15 psi Oxygen Pressure 0 10 bar 0 150 psi Gas Type Acetylene Propane or Natural Gas Plasma Power Source ESAB PowerCut Series or ESP 101 featuring PT 37 torch Notes The Crossbow is equipped wi...

Page 25: ...ine axis is defined as if the operator is positioned facing the machine front Left to right torch is motion in the X plus X direction Right to left motion is X minus X direction Motion away from the o...

Page 26: ...ESAB Cutting Systems CROSSBOW Page 26...

Page 27: ...all crates and boxes for any signs of shipping damage A claim must be filed with the shipping company immediately if any damage is found Open the crates and boxes and inventory the items to make sure...

Page 28: ...h the help of a second person grasp the Rail Track assembly at each end and carefully turn it over and lay it on its back avoiding damage to the drive rack Set the track on pieces of wood to protect t...

Page 29: ...stems CROSSBOW Page 29 Step 2 Arrange T Slot Nuts Locate the captive T Slot Nuts in the frame and move them to the desired locations Figure 5 T Slot Nuts Number Description 1 Frame Slots 2 M8 Captive...

Page 30: ...r Feet to the bottom of the Rail Track assembly using the supplied M8 screws Leave the screws loose until the three feet are attached and arranged in the desired location then tighten Figure 6 Install...

Page 31: ...ck Upright With the help of a second person turn rail track upright and set it on a stable level surface where the end of the Rail Track is easily accessible Figure 7 Rail Track Assembled Number Descr...

Page 32: ...t weighs approximately 28 Kg 61 lbs Step 1 Lift and hold Central Unit One person must carefully lift and hold the Central Unit near the end of the rail as shown below Care must be taken to avoid bumpi...

Page 33: ...ove the unit further onto the Rail Track while holding it level The second person should then guide the second set of Bearing Blocks onto the end of the Guide Rail After the second set of Bearing Bloc...

Page 34: ...e of these in the last bolt hole at each end of the rail to prevent the Central Unit from sliding off the end of the Rail Track Remove the existing M6 screw from the hole and insert the new one throug...

Page 35: ...1 Lift and hold Cross Beam Carefully lift the Cross Beam and hold it parallel to the floor and perpendicular to the heat shield on the side of the Central Unit Orient the drive rack mounted on the Cro...

Page 36: ...e to slowly push the Cross Beam through the Central Unit as it fits through the second set of V Wheels and then engages with the drive pinion Figure 12 Inserting Cross Beam Number Description 1 Centra...

Page 37: ...d after the Cross Beam is inserted into the Central Unit but before any hoses or cables are connected to the Cross Beam Install one of the two Cable Holders at the left hand end of Cross Beam Slide po...

Page 38: ...til the top of the post is flush with the inside of the Cable Clamp This will allow it to turn freely After the plasma torch lead is installed it will prevent the Cable Clamp from coming unscrewed fro...

Page 39: ...o Motorized Lifter Insert the supplied M8 screw through the back of the Torch Lifter and into the Torch Holder then tighten Make sure the Torch Holder is level perpendicular to the Torch Lifter Figure...

Page 40: ...ing tang on the end of the Cross Beam through the Joint Spacer and into the threaded hole on the Torch Lifter mounting lug Adjust the Torch Lifter until it is vertical and then tighten the screw Figur...

Page 41: ...nnect Lift Motor Cable Connect the 2 Pin Lift Motor cable connector between the Torch Lifter and the Cross Beam as shown below Figure 17 Connecting Lift Motor Cable Number Description 1 Torch Lifter 2...

Page 42: ...lder is used to hold the torch that is not in use Insert the supplied M8 screw through the hole in the mounting tang on the back side of Cross Beam and into the threaded hole on torch holder Adjust to...

Page 43: ...of the Central Unit and the end of the Cross Beam Figure 19 Lift Motor Solenoid Cable Number Description 1 4 Pin Cross Beam Connector pull sleeve 2 4 Pin Central Unit Connector screw on Connect one en...

Page 44: ...CROSSBOW Page 44 Connect other end to 4 pin socket at end of Cross Beam Figure 21 Connecting Lift Motor Solenoid Cable to Cross Beam Number Description 1 4 Pin Lift Motor Solenoid Cable Socket 2 Cros...

Page 45: ...Power Cable Number Description 1 To central unit IEC power socket 2 To AC power source plug type varies with region Plug the IEC connector to the Power Cable Socket in Connector Panel on rear of Cent...

Page 46: ...s application Figure 24 Oxy Fuel Torch Assembly Number Description 1 Oxy Fuel Torch Part Number 28X47 C 69 or 28X53 C 70 2 Preheat Oxygen Inlet 3 Needle Valve Part Numbers 3395 Oxygen 4 Check Valve Pa...

Page 47: ...l Torch into the Torch Holder as shown Arrange the torch so that the needle valves are easily accessible Tighten the torch holder as necessary to hold the torch firmly in place Do not over tighten Fig...

Page 48: ...s as shown Be sure to connect preheat oxygen and cutting oxygen hoses to the correct fittings The Cutting Oxygen fitting is connected to outlet of solenoid valve Figure 26 Connecting Torch Hoses Numbe...

Page 49: ...fuel gas supply hoses to the inlet fittings on the Cross Beam as shown Figure 27 Connecting Gas Supply Hoses Number Description 1 Fuel Gas Supply Hose Part Number 0560949423 2 Fuel Gas Inlet Fitting...

Page 50: ...ppropriate regulators shut off valves and flashback arrestors per applicable codes Figure 28 Gas Supply Connections Number Description 1 Oxygen Regulator Customer Supplied contact ESAB for part number...

Page 51: ...o ensure there are no gas leaks anywhere in the system 1 Pressurize gas supply lines to machine 2 Close supply valve unscrew regulator adjusting screws 3 Watch regulator output gauge for pressure drop...

Page 52: ...The Cable Holders are only required if a plasma torch is installed If an oxy fuel torch is also used do not install the second Cable Holder until after the oxy fuel torch hoses are installed Screw the...

Page 53: ...mage to the threads on the torch body Assemble the PT 37 plasma torch with one of the Shields with IHS Lug Insert the torch into the torch holder rotating as necessary so the IHS Lug fits through the...

Page 54: ...CNC and 3 Arc Voltage feedback from the Power Source to the Automatic Height Control system in the Central Unit Figure 31 Plasma Interface Cable Number Description 1 14 Pin Plasma Power Supply Connec...

Page 55: ...the 14 pin plug into the matching socket at the ESAB Plasma Power Source Figure 33 PowerCut Machine Interface Pigtail Figure 34 ESP 101Machine Interface Socket Number Description 1 Plasma Power Suppl...

Page 56: ...ngle 2 pin connector at one end Figure 35 IHS Cable Number Description 1 2 Pin Crossbow Machine Connector 2 Ground Wire Black 3 Torch Shield Wire Red Insert the 2 pin plug into the mating socked on th...

Page 57: ...ly connected to the plate that is being cut In a permanent installation this should be bolted to the cutting table to provide a permanent reliable connection to work ground and the plate that is being...

Page 58: ...unction of the Cutting Oxygen solenoid valve For systems equipped with plasma 6 In the SETUP mode CONTROL Parameters set the PLASMA OXY FUEL setting to 1 for Plasma Press F7 to save changes Press ESC...

Page 59: ...eed parameters to appropriate values for Inch measurement system Below are recommended values Recommended SPEED parameters for Inch measurement system START SPEED 20 CORNER ACCEL 0 15 MAX JOG SPEED 12...

Page 60: ...ESAB Cutting Systems CROSSBOW Page 60...

Page 61: ...power to drives torch lifter and output relays To restore power turn the button clockwise until it pops out E Stop button must be released before power is switched on or else the CNC may not function...

Page 62: ...e upgrades 4 3 CNC System Technical Specification Processor ARM7 Industrial CPU Display 7 Color LCD Input output 13 input 8 output channels optically isolated Coordinated CNC axes 2 Axes dimensional a...

Page 63: ...Keys Figure 40 Input Keys Number Description 1 Program input keys 2 Manual jog and feed rate control keys 3 Process Control keys 4 Start Stop keys Input Keys Description Input Keys Usage Green key st...

Page 64: ...Rate The Speed Override Percentage is reduced with every press The CUTOXY and OFF keys can be used to manually open and close the Cutting Oxygen solenoid valve The PIERCE key can be used to start a Pi...

Page 65: ...o input G codes in the Program Editor Alternate function is Continue In Auto Mode the Continue function overrides the preheat timer without recording the time In Manual Mode the Continue function sele...

Page 66: ...cutting oxygen 6 Move the torch to the initial cutting position above the plate 7 Load the program in the Auto mode press green Start button and begin cutting 4 7 Operational Overview Plasma Cutting M...

Page 67: ...cription 1 Main Menu 2 Function keys F1 AUTO Run programs to cut shapes or nests automatically F2 MANUAL Manually jog the machine and position the torch F3 EDIT Create or modify programs in an editor...

Page 68: ...unctions and the subsequent menus are discussed in more detail in the following sections 4 9 1 Main Menu ESC AUTO MANUAL EDIT SETUP DIAGNOSE LIBRARY Activate Shape Library Not used Select oxy fuel or...

Page 69: ...gram Resume a Parked Program Switch to Manual Mode Jog Skip to any pierce point in the program for starting Return to Main Menu 2nd Menu Level More functions ESC OUTLINE WENTAI ROTATE MIRROR SCALE NES...

Page 70: ...ero the Program Coordinates Toggle Rapid Jog Speed Zero the Machine Coordinates 2nd Menu Level More functions Step a fixed distance in X or Y Switch back to Auto Mode Return to Main Menu 2nd Menu Leve...

Page 71: ...storage Save program in the editor to the program storage memory Load a program from storage into editor and Auto Mode New blank program for editing Return to Main Menu USB Disk Access Menu ESC LOAD O...

Page 72: ...Status Indicator Prompts 9 Program Coordinates 10 Program Graphics Display Area 4 10 1 SPEED In Automatic Mode at the top left corner of the screen it shows the Feed Rate Override Percentage and the r...

Page 73: ...onal Function Key Indicators This section serves as prompts for additional functions that can be accessed by keys on the CNC front panel during various operating modes They also act as indicators to d...

Page 74: ...eheat Time in seconds 4 10 7 Machine Coordinate Display These X and Y coordinates are the machine coordinates indicating the position of the machine relative to the zero point for the overall X and Y...

Page 75: ...You can also choose whether to start running the program from the new start point at the current machine location or at the appropriate position relative to the Program Zero Point Refer to the SKIPTO...

Page 76: ...the graphical preview you may zoom in for a closer look at the programmed path Press the 1 key to zoom in to the graphic display Press once to zoom in to 2x normal size Press a second time to see 4x n...

Page 77: ...to accesses the next lower level of the Auto Mode menu See section 4 12 for details 4 11 7 F7 RETURN The RETURN function is used to rapidly move the machine back to either the Program Zero Point or t...

Page 78: ...o Mode Menu To return to the Auto Mode Menu press the ESC key 4 12 1 F1 OUTLINE Function The OUTLINE function is used to check if a program or nest will fit on a plate In this mode the machine will ex...

Page 79: ...prompt will appear in the Mode Status Area asking RELOCATE YES NO Press ENTER to confirm relocating the program or press ESC to abandon the change This operation can be repeated as necessary to fit t...

Page 80: ...is possible to select X Mirror Y Mirror and No Mirror by repeatedly pressing the F4 key When X Mirror is selected the program will be flipped in the X Axis Left Right When Y Mirror is selected the pro...

Page 81: ...a single part program to be nested using pattern nesting columns and rows A program must be loaded before using the Nest function Press F6 to start a Nest The Nesting Dialog will appear as shown below...

Page 82: ...d to the mother plate in order to reduce distortion or for secondary forming operations When F7 is pressed it turns on Tabbing Mode Figure 58 Tabbing Bridge Indicator BRIDGE is displayed on screen in...

Page 83: ...reasing or decreasing the Feed Rate Override Percentage using the F and F keys or it can be entered directly by pressing the F key and then typing in the desired speed on the number keypad The Feed Ra...

Page 84: ...Down When Oxy Fuel Cutting pressing S while the program is running will lower the motorized torch lifter When Plasma cutting press S during the first few seconds of the cut in order to reduce the cutt...

Page 85: ...relocate the program service the torch or adjust the plate The machine will move at Jog Speed ESC Park Program Pressing the ESC key while the program is paused will cause the CNC to exit abandon the...

Page 86: ...g while the program is running will lower the motorized torch lifter CUTOXY Manual Process Re Start Press this key to re start the cutting process PIERCE Auto Process Re Start The PIERCE key can be us...

Page 87: ...gure 62 Auto Mode Pause JUMPTO Function When the desired point is found press START to execute the motion Upon pressing START key the machine will automatically move to the selected position and then...

Page 88: ...sons why the torch might need to be jogged to a different location during Program Pause such as 1 Lost cut requiring cleaning or changing of the nozzle 2 Need to re pierce in the scrap or on the plate...

Page 89: ...ess will start immediately upon selecting this option Note Be sure to have the plate sufficiently preheated if flame cutting before selecting this option with either the START key or the ENTER key bec...

Page 90: ...CNC memory and if the Program Rotation angle and Scaling Factor have not been changed If the position of cutting torch has not changed since the program was interrupted then the program can be re sta...

Page 91: ...k to the point where it left the programmed path at cutting speed Upon reaching that point it will continue cutting along the programmed path without stopping The cutting process will start immediatel...

Page 92: ...to highlight the desired option Press the START key or the ENTER key to select the desired operation If START FROM HERE is selected the CNC will display the program graphic with a green cross showing...

Page 93: ...ppear Figure 70 Input Pierce Number Use the Up and Down keys to highlight the desired option If flame cutting preheat the plate first When ready press the START key or the ENTER key to select the desi...

Page 94: ...5 Input Output Status Indicators 6 Operating Parameters 7 Machine Coordinates 8 Mode Status Indicator Prompts 9 Program Coordinates 10 Program Graphics Display Area 4 19 1 SPEED The Manual Mode inter...

Page 95: ...in Manual Mode activates Continuous Jog mode which will be indicated on screen In this mode pressing any of the four direction arrow keys will start the torch jogging in that direction and motion wil...

Page 96: ...start machine motion The machine will begin moving in the selected direction and will continue moving until the Step Distance has been covered Motion can be stopped by pressing the STOP key 4 20 3 F3...

Page 97: ...o Point or the Machine Zero Point Press F7 to activate the RETURN function A dialog will appear prompting the user to select which zero point to use Figure 73 Selecting RETURN Point Use the Up and Dow...

Page 98: ...The torch is jogged to two points along the front edge of the plate and the angle is automatically calculated and recorded in the CNC To use the Plate Alignment function jog the torch to a point on th...

Page 99: ...hine position 2 SETUP COORDINATES This option allows the user to manually enter new values for the Program Coordinates When selected an input field appears in the Mode Status area prompting the user t...

Page 100: ...nu Functions 4 23 1 F1 NEW Use this function to open the program editor with an empty new file for editing The program code can be manually entered using the key panel See section 4 27 for information...

Page 101: ...keypad to type a file name then press ENTER to save the file Press ESC to abandon the changes without saving Notes The program name and extension name should never exceed 12 characters 4 23 4 F4 DEL...

Page 102: ...REVIEW The PREVIEW function displays a graphic of the program This function is available in the program editor and also in the program listing when using the LOAD function from either program memory o...

Page 103: ...m will display the listing of available programs on the USB disk as shown below Figure 82 USB Program Listing Use the Up and Down arrow keys to select a file Once the desired file is highlighted press...

Page 104: ...he USB disk into the CNC s program memory Use this function after pressing the F1 key LOAD to display the list of programs on the USB disk Use the Up and Down arrow keys to navigate the file list Pres...

Page 105: ...ONTROL General Control Parameters including selection for Plasma Flame Process and Inch Metric switching Use the Up and Down keys to move through the list of parameters There are more parameters than...

Page 106: ...L Acceleration time in and out of corners MAX JOG SPEED The top speed of the machine in the Manual Jog Mode and while executing a rapid positioning move during a program G00 command mm min or inch min...

Page 107: ...ioning accuracy DENOMINATOR Denominator of electronic axis scaling ratio used to adjust positioning accuracy MACHINE ORIGIN Origin point for the Machine Coordinates PROGRAM ORIGIN Origin point for the...

Page 108: ...mmended on Crossbow TORCHDN TIME M71 Timer to drive torch down at start of oxy fuel cut PIERCEUP HIGH M72 Timer to raise torch at beginning of piercing PIERCEDN HIGH M73 Timer to lower torch at end of...

Page 109: ...SIGNAL Wait for arc on signal from the plasma power source before starting motion MAX TIME FOR ARC ON Max time waiting for the arc on signal before generating an error PIERCE TIME Travel delay after...

Page 110: ...E LENGTH Y Actual length of steel plate in Y axis Only used when running very large programs SYNCHRO XZ YZ For dual side drive gantries selects whether Z axis is synchronized with X axis or Y axis Not...

Page 111: ...ECT Crash detect CRASH IHS USE SAME INPUT Used on machines where the torch tip touch is used to detect both IHS and Crash signal CRASH PAUSE TORCHUP Pause or raise torch on crash RAISE TORCH ON PAUSE...

Page 112: ...ape Library Main Screen This system includes the 24 variable shapes shown above which can be adjusted to different sizes by entering a few parameters Use the arrow keys to move the cursor and highligh...

Page 113: ...Evaluation Screen Enter nest parameters if necessary Verify all parameters using the F6 APPLY function 3 Press the ESC key to exit the Shape Evaluation Screen The shape is temporarily stored in memory...

Page 114: ...1 Shape Library Parameter Entry Use the number keypad the arrow keys and the ENTER key to input the desired values When parameters are entered the CNC will check the dimension and show a warning if a...

Page 115: ...OSSBOW Page 115 4 26 3 F1 OD CUT and F2 ID CUT These functions change the shape between an outside cut OD and an inside cut out ID The default condition is OD CUT See the example below OD CUT ID CUT F...

Page 116: ...ted by a fixed amount such as 45 or 90 degrees to fit on a plate To use press the F3 key An entry will appear prompting the user to enter a rotation angle as shown below Figure 93 Shape Library Rotati...

Page 117: ...igure 95 Shape Library NEST Function Enter the desired parameters for number of rows and columns The Row Height and Column Width will be calculated automatically based on the size of the part but may...

Page 118: ...changes and view the results Figure 97 Results of Shape Library NEST Function 4 26 6 F6 APPLY Press the F6 key when finished entering parameters to apply the changes and view the results of changing t...

Page 119: ...adius of an arc can be used in lieu of I and J or kerf width F Feed rate cutting speed for G01 G02 and G03 4 27 1 File Format Part programs are simple text files written in ASCII format Any PC may be...

Page 120: ...ms can be written in either absolute or incremental modes Absolute programming is selected by a G90 code at the very beginning of the program Incremental programming is selected by a G91 code at the v...

Page 121: ...amming Mode Informs the control that all programmed dimensions are absolute coordinates referenced from an absolute zero point When used this code must appear at the beginning of the program FORMAT G9...

Page 122: ...the F command FORMAT G01 Xn Yn Or G01 Xn Yn Fn Figure 99 Programming a Straight Line Incremental In incremental the dimension specified is the displacement from the start point of the line If there is...

Page 123: ...tial Circle An arc is programmed by specifying the endpoint and center point of the arc Figure 100 Programming an arc Incremental Arc In incremental both the endpoint and center point dimensions are s...

Page 124: ...be incremental for both Incremental and Absolute modes programming is the same EXAMPLE G02 J7 0 OR G03 J7 0 G04 Pause Delay This command is used to create a time delay When used the delay time is spec...

Page 125: ...mount which needs to be determined by measurement of the actual cut width and will change with every thickness of material and type of cutting The controller will automatically offset the cut path by...

Page 126: ...xecute a loop G22 indicates the start of a loop It uses the parameter L to indicate the number of loop cycles to perform G80 marks the end of the loop All lines of program code between the G22 and G80...

Page 127: ...reheat time is finished turns on cutting oxygen and initiates pierce timer d When pierce timer is finished releases machine motion 2 When plasma cutting a Holds machine motion b Performs and Initial H...

Page 128: ...ESAB Cutting Systems CROSSBOW Page 128 4 27 9 Programming Examples Program Example 1 Figure 104 Programming Example 1 R 0 5 2 75 6 0 D 3 0 75 75 9 25 R 1 5 8 75 1 0 5 0 0 P1 P2 Y X...

Page 129: ...3 X 75 Y 75 J 75 Lead In 7 G03 I 1 5 Cut Circle 8 G03 X 75 Y 75 I 75 Lead Out 9 M08 Cutting Process OFF 10 G40 Kerf Off 11 G00 X5 25 Y3 5 Rapid Move to P2 12 G41 Activate Kerf Left 13 M07 Cutting Proc...

Page 130: ...ESAB Cutting Systems CROSSBOW Page 130 Program Example 2 Figure 105 Programming Example 2 Y X D 1 50 D 2 0 D 1 0 P 0 0 25 25 2 20 1 50 1 50 1 79 3 75 80 1 15 45 1 0 30 30 15 35 34 1 16 37 50 13 87...

Page 131: ...X3 0 Y3 95 G41 M07 G01 Y 3 2 G03 X 75 Y 75 J 75 G01 X 1 09 G01 X 29 Y 5 G03 X 37 Y 37 I 87 J 5 G01 X 5 Y 29 G01 Y1 79 G01 X1 15 Y1 15 G02 X 7 I 35 J 35 G01 X1 4 Y 1 4 M08 G40 M02 1 2 3 4 5 6 7 8 9 10...

Page 132: ...ESAB Cutting Systems CROSSBOW Page 132...

Page 133: ...heck for proper operation of e stop button and drive engage switch 10 Visually inspect condition of torch consumables for wear and cutting deposits slag Replace as needed 11 Check for frayed worn hose...

Page 134: ...installed tight and free of accumulated slag or rust 6 Perform functional test of all buttons and switches replace if necessary 7 Check all cable plugs and sockets on the rear of the unit inspect for...

Page 135: ...ning the two lower cover mounting screws 2 Slide cover off Torch Lifter by pulling it upwards 3 Clean any dust or soot accumulation from Torch Lifter Screw and Torch Lifter Guide Rods 4 Lubricate Torc...

Page 136: ...opped and abandoned manually follow the procedures in section 4 16 Resuming Parked Programs 2 If there is a loss of power while cutting the program can easily be recovered as long as the machine is no...

Page 137: ...air plug Check condition of both wires in IHS cable Wires may be broken Replace Cable Check connection of black ground wire to plate ground Connection may be loose or disconnected Plate may not have s...

Page 138: ...power line to ensure power is not being momentarily interrupted c Remove power and re boot the control One of the motors does not turn Check wiring from drive amp to motor Loose connection Secure all...

Page 139: ...make of USB disk The USB disk may not be compatible with this CNC Use only compatible USB disks Check the file system format on the USB disk The USB disk may be formatted incorrectly This CNC only sup...

Page 140: ...c starts Check ground Work Table connection of the Initial Height Sensing cable Electrical noise loose ground connection Make sure ground connection is tight and is making good electrical contact Make...

Page 141: ...This will delete all programs in memory This option should be used if a program becomes corrupt and cannot be deleted from memory by the normal procedure 2 FACTORY RESET This option will restore all p...

Page 142: ...hen this mode is selected the F7 key changes to show FACTORY in each of the Parameter Groups All changes that are made will be saved as Factory Settings when the F7 key is pressed 2 SAVE PARAMETERS TO...

Page 143: ...matically start the update operation 4 If the update is successful the system will display UPDATE SUCCESSFUL and sound one beep If the update fails the system will display UPDATE FAILED and sound cont...

Page 144: ...o a text file called NAME txt to be supplied by ESAB Copy this file onto a USB disk and insert into the USB port The following key sequence must be activated from the Home Screen Press the ESC key rep...

Page 145: ...onnector on the Connector Panel at rear of Central Unit 1 Remove all incoming power from the unit 2 Use a small flat head screwdriver to pull out the fuse holder 3 Replace the fuse only with the same...

Page 146: ...panel Set it aside 4 Carefully remove the CNC from the Central Unit turn it over and set it face down in front of the Central unit Figure 112 Removing CNC Bezel Number Description 1 CNC Unit 2 CNC be...

Page 147: ...ystems CROSSBOW Page 147 Figure 113 Disconnecting CNC Number Description 1 CNC Unit 2 Plugs XS1 XS3 and XS12 3 Power Supply Terminals The CNC unit can now be carefully packaged and sent for repair or...

Page 148: ...C 3 Remove the CNC bezel by removing the four screws at the corners of the CNC panel Set it aside 4 Carefully remove the CNC from the Central Unit turn it over and set it face down in front of the Cen...

Page 149: ...position to short to ground or any metal object 3 Attach a DC Volt meter to the output terminals of the Main Power Supply measuring between V and V terminals Remove the two screws mounting the power s...

Page 150: ...e all incoming power from the unit 2 Place a towel or other soft material in front of the Central Unit to avoid scratches or damage to the CNC 3 Remove the CNC bezel by removing the four screws at the...

Page 151: ...light and a small screwdriver to move position of Input Power Voltage Selector Switch on main power supply Figure 117 Selecting Input Voltage on Main Power Supply Number Description 1 Main Power Supp...

Page 152: ...ht for plasma piercing is set by a DIP switch on the VHC Sensor board as shown in the table at right Note The height value in mm is for reference only It is not calibrated to this exact distance Adjus...

Page 153: ...direction of the lift motor use the following procedure 1 Follow above procedure for Servicing Operator Panel Components 2 Locate the VHC Sensor PC board 3 Locate the plug with the two motor wires at...

Page 154: ...erator Panel Components 2 Carefully note the position of each wire connected to terminal strip on top of board 3 Un wire four wires from terminal strips on top of board 4 Un plug wire connector from b...

Page 155: ...te the position of wires connected to terminal strip on top of board 3 Note the position of the DIP Switches 1 through 4 4 Un wire two wires from terminal strip 5 Un plug wire connectors from board 6...

Page 156: ...emoving the four screws at the corners of the CNC panel 4 Carefully remove the CNC from the Central Unit turn it over and set it face down in front of the Central unit 5 Un plug the connectors from th...

Page 157: ...ck inlet connections and process tools on end of Cross Beam 7 Remove all screws mounting Heat Shield to side of Central Unit Do not remove Stand Offs 8 Remove all screws mounting CNC and Control Switc...

Page 158: ...connected to the terminal strip on top of the power supply It is recommended that a photo be taken of the actual wire arrangement using a digital camera 3 Note the position of the Input Voltage Select...

Page 159: ...er from left end of Cross Beam by loosening clamp and sliding off end of beam 6 Carefully remove Cross Beam from Central Unit and set in a safe place being careful to avoid damaging drive rack inlet c...

Page 160: ...hold the lock nuts on bottom of Central Unit Mounting holes are slotted 3 Slide the Drive Motor until Drive Pinion lightly touches Drive Rack Do not adjust pinion with too much pressure into rack it w...

Page 161: ...rt Cross Beam through Central Unit while cover is removed Do not reassemble Cable Holders or other items to Cross Beam 4 Slide the Motor Mounting Plate upwards until Drive Pinion lightly touches Drive...

Page 162: ...r screws holding Motor Mounting Plate to Rear Cross Drive Mount Panel and slide Cross Beam Drive Motor down to disengage the pinion 4 Loosen all four Shaft Mounting Nuts on both ends of both upper V W...

Page 163: ...ness and motion of Cross Beam 8 Tighten Lock Nuts while holding Tension Screw with a wrench 9 Re check tightness of V Wheels and motion of Cross Beam Do no over tighten it will bind the motion 10 Foll...

Page 164: ...lug the electrical connection to the Drive Motor 3 X Axis Motor Cross Axis Remove the four screws mounting the motor to the adjusting plate Do not loosen screws on the Motor Mounting Plate 4 Y Axis Mo...

Page 165: ...3 Measure and record distance from end of Drive Pinion to face of motor housing so new pinion can be installed to same position on shaft 4 Use a small gear puller to remove drive pinion from motor sh...

Page 166: ...h upper V Wheel Shaft 3 Remove the four screws holding Front Cross Drive Mounting Panel to base plate 4 Remove Shaft Mounting Nuts lock washers and flat washers from Front Cross Drive Mounting Panel e...

Page 167: ...nts from the V Wheel Shafts as necessary 7 Clean and lubricate V Wheel Shaft 8 Reassemble in reverse order 9 Adjust V Wheel Tension per the above procedure Figure 133 V Wheel Assembly Number Descripti...

Page 168: ...re 1 Remove all incoming power from machine 2 Shut off and disconnect oxygen supply 3 Remove cut oxygen torch hose from hose fitting on top of solenoid valve 4 Remove coil from valve body by unscrewin...

Page 169: ...om coil by removing Anchor Screw 6 Unscrew valve body from pipe 7 Unscrew hose fitting from valve body Figure 135 Removing Solenoid Coil Number Description 1 Solenoid Coil 2 Coil Socket 3 Valve Body 4...

Page 170: ...It is recommended that the lift be replaced as a complete unit The following information is provided as a reference in case further disassembly is performed Figure 136 Removing Lift Cover Number Desc...

Page 171: ...s Disassembly is not recommended Figure 137 Torch Lift Assembly Number Description 1 Bottom Cover 2 Bearing Spacer 3 Lower Shaft Holder 4 Guide Rods 5 Mounting Lug 6 Screw 7 Nut 8 Upper Shaft Holder 9...

Page 172: ...ESAB Cutting Systems CROSSBOW Page 172...

Page 173: ...dividual components included on this machine Numbers that identify parts in the illustration are given in the list where applicable along with part numbers and descriptive information 6 2 Ordering Inf...

Page 174: ...Description Part Number 1 Central Unit 0 560 954 751 2 Rail Track Assembly 4000 mm 10 Travel 0 004 453 029 Rail Track Assembly 2200 mm 4 Travel 0 004 453 100 3 Stabilizer Feet 0 004 453 064 4 Motorize...

Page 175: ...art Number 1 E Stop Pushbutton 0 004 453 002 2 Drive Engage Toggle Switch 0 004 453 003 3 Drive Power Indicator Lamp 0 004 453 004 4 Control Switch Panel Plate 0 004 453 010 5 CNC Unit 0 004 453 008 6...

Page 176: ...Part Number 1 Drive Rack Y Axis rail axis 0 004 453 063 2 Rubber Bumper Rail Stop 0 003 762 002 3 M6x40 mm Socket Head Cap Screw SS 0 006 101 036 4 Linear Rail 4000 mm 0 004 453 066 5 Drive Rack X Axi...

Page 177: ...rts Figure 141 Internal Electrical Parts Item Description Part Number 1 Arc Voltage Control Board Initial Height Sensing Board Supplied together 0 004 453 043 2 Main Power Supply 24V 0 004 453 019 3 S...

Page 178: ...s Figure 142 Internal Mechanical Parts Item Description Part Number 1 Electrical Cabinet 0 004 453 025 2 Stepper Motor 0 004 453 014 3 Forward Cross Drive Mount Panel 0 004 453 020 4 Rear Cross Drive...

Page 179: ...em Description Part Number 1 Stepper Motor 0 004 453 014 2 V Wheel 0 004 453 021 3 Drive Pinion 0 004 453 013 4 Cross Drive Motor Mounting Plate 0 004 453 023 5 Centering Spacer Sleeve 0 004 453 028 6...

Page 180: ...Socket Plasma Interface 0 004 453 048 3 Lift Motor and Solenoid Valve Cable 4 pin 0 004 453 049 4 4 Pin Plug and Socket Lift Motor and Solenoid Valve 0 004 453 047 5 Initial Height Sensing Cable 2 pin...

Page 181: ...Motorized Torch Lifter 0 004 453 032 2 Oxy Fuel Torch Adaptor 30 mm ID 0 004 453 056 Oxy Fuel Torch Adaptor 31 75 mm ID For Oxweld C 69 70 Torch 0 004 453 057 3 Torch Holder 0 004 453 053 4 Cut Oxygen...

Page 182: ...Number REF Complete Torch Lifter 0 004 453 032 1 Lift Motor 0 004 453 068 2 Micro Switch 0 004 453 044 3 Guide Shaft 0 004 453 065 4 Screw Rod 0 004 453 067 5 Screw Nut 0 004 453 061 6 Lifter Cover 0...

Page 183: ...0 2 Electrode Standard 0558005220 Electrode Silver 0558004875 3 Nozzle 50 Amp 0558004878 Nozzle 60 Amp 0558008417 Nozzle 70 Amp 0558005219 Nozzle 90 Amp 0558007680 Nozzle 100 Amp 0558004879 4 Nozzle R...

Page 184: ...h Kit for Acetylene 0560954397 1 Check Valve Oxygen 639110 2 Needle Valve Oxygen 3395 3 Torch C 69 Fuel Gases other than Acetylene 28X47 Torch C 70 Acetylene 28x53 4 Nozzle See page 185 5 Check Valve...

Page 185: ...Fuel Cutting Tips Figure 149 1515 Series Nozzles Figure 150 1502 Series Nozzles 1515 Series Part Number 1502 Series Part Number Size 4 1 4 08Z85 1502 1 8 08Z67 Size 6 3 4 1 1 2 08Z86 1502 3 8 15Z17 Si...

Page 186: ...ESAB Cutting Systems CROSSBOW Page 186...

Page 187: ...n Yn In Jn Fn G03 Xn Yn Rn Counter Clockwise Circular Motion with Optional Feed Rate Parameter G04 G04 Ln Time Delay with Time Parameter L n seconds G20 G20 Inch Mode G21 G21 Metric Mode G22 G22 Ln St...

Page 188: ...ESAB Cutting Systems CROSSBOW Page 188...

Page 189: ...wrong 22H Circle G02 G03 diameter wrong 24H Circle G02 G03 terms wrong 2AH Extra program line no torch moving 34H Illegal operation 40H Emergency stop key pressed 41H X axis positive direction limit 4...

Page 190: ...ESAB Cutting Systems CROSSBOW Page 190...

Page 191: ...ESAB Cutting Systems CROSSBOW Page 191 Appendix 3 Shape Library Variables Shape 1 RECTANGLE WIDTH HEIGHT...

Page 192: ...ESAB Cutting Systems CROSSBOW Page 192 Shape 2 CIRCLE RADIUS...

Page 193: ...ESAB Cutting Systems CROSSBOW Page 193 Shape 3 L BRACKET WIDTH HEIGHT TOP W BOTTOM W...

Page 194: ...ESAB Cutting Systems CROSSBOW Page 194 Shape 4 PIE SHAPE ANGLE RADIUS...

Page 195: ...ESAB Cutting Systems CROSSBOW Page 195 Shape 5 TRIANGLE WIDTH HEIGHT CURVED R...

Page 196: ...ESAB Cutting Systems CROSSBOW Page 196 Shape 6 CURVE BKT INNER R BOTTOM W OUTER R...

Page 197: ...ESAB Cutting Systems CROSSBOW Page 197 Shape 7 CHAMFER WIDTH HEIGHT LFTCHAMF BOTTOM W RGTCHAMF...

Page 198: ...ESAB Cutting Systems CROSSBOW Page 198 Shape 8 OVAL INNER R BOTTOM W OUTER R...

Page 199: ...ESAB Cutting Systems CROSSBOW Page 199 Shape 9 RING INNER R OUTER R...

Page 200: ...ESAB Cutting Systems CROSSBOW Page 200 Shape 10 OCTAGON WIDTH HEIGHT TOPCHAMF BOTCHAMF LFTCHAMF RGTCHAMF...

Page 201: ...ESAB Cutting Systems CROSSBOW Page 201 Shape 11 TAB RECTANGLE WIDTH HEIGHT TAB LENGTH RGT SIDE LFT SIDE...

Page 202: ...ESAB Cutting Systems CROSSBOW Page 202 Shape 12 CUTOUT WIDTH HEIGHT DEPTH RGT SIDE LFT SIDE...

Page 203: ...ESAB Cutting Systems CROSSBOW Page 203 Shape 13 LINE CUT WIDTH HEIGHT...

Page 204: ...ESAB Cutting Systems CROSSBOW Page 204 Shape 14 ARC SECTOR ANGLE INNER R OUTER R...

Page 205: ...ESAB Cutting Systems CROSSBOW Page 205 Shape 15 HOLE CUTOUT WIDTH HEIGHT RADIUS LFT SIDE BOT DIST...

Page 206: ...ESAB Cutting Systems CROSSBOW Page 206 Shape 16 RECT CUTOUT WIDTH HEIGHT INNER W INNER H LFT SIDE OFFSET B...

Page 207: ...ESAB Cutting Systems CROSSBOW Page 207 Shape 17 U SHAPE OUTER R INNER R LEG LENGTH...

Page 208: ...ESAB Cutting Systems CROSSBOW Page 208 Shape 18 COM LINE Common Line Cut Rectangles WIDTH HEIGHT COLUMNS ROWS...

Page 209: ...ESAB Cutting Systems CROSSBOW Page 209 Shape 19 TANK BED WIDTH HEIGHT RADIUS BOTTOM W...

Page 210: ...ESAB Cutting Systems CROSSBOW Page 210 Shape 20 4 HOLE FLANGE INNER R OUTER R HOLE AX HOLE R...

Page 211: ...ESAB Cutting Systems CROSSBOW Page 211 Shape 21 6 HOLE FLANGE INNER R OUTER R HOLE AX HOLE R...

Page 212: ...ESAB Cutting Systems CROSSBOW Page 212 Shape 22 IMPELLER L OUT R L HOLE R R HOLE R HOLE DIST R OUT R...

Page 213: ...ESAB Cutting Systems CROSSBOW Page 213 Shape 23 2 HOLE FLANGE RADIUS INNER R HOLE R CENTER DIST MINOR R...

Page 214: ...ESAB Cutting Systems CROSSBOW Page 214 Shape 24 WES TEST WIDTH...

Page 215: ...0 35 70 80 14 22 6 08Z86 3 4 19 30 35 135 155 12 20 1 25 35 40 150 165 11 17 1 1 2 38 40 45 160 210 10 15 8 08Z87 2 50 25 30 215 245 9 13 3 75 30 35 235 290 7 10 4 100 35 40 270 320 6 9 Cutting Data f...

Page 216: ...ESAB Cutting Systems CROSSBOW Page 216...

Page 217: ...8 0 625 0 200 0 275 0 075 151 0 95 0 075 10 12 50 Amp Material Thickness Initial Height Pierce Height Cuttng Height Arc Voltage Pierce Delay Kerf Width Optimum Speed Maximum Speed Fraction Decimal In...

Page 218: ...ess Initial Height Pierce Height Cuttng Height Arc Voltage Pierce Delay Kerf Width Optimum Speed Maximum Speed Fraction Decimal Inches Inches Inches Volts Sec Inches IPM IPM 1 4 0 250 0 200 0 200 0 08...

Page 219: ...20 30 1 2 0 500 0 200 0 240 0 125 144 0 50 0 091 12 18 50 Amp Material Thickness Initial Height Pierce Height Cuttng Height Arc Voltage Pierce Delay Kerf Width Optimum Speed Maximum Speed Fraction Dec...

Page 220: ...ESAB Cutting Systems CROSSBOW Page 220...

Page 221: ...ESAB Cutting Systems CROSSBOW Page 221 Appendix 6 Wiring Diagrams...

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Page 232: ...ESAB 123 372 2123 ESAB Welding and Cutting Products PO BOX 100545 Ebenezer Road Florence SC 29501 0545 http www esab cutting com ESAB Cutting Systems Canada 6010 Tomken Road Mississauga Ontario Canada...

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