Lincoln Electric ESSENTIAL OXYCUTTING Safety Instruction For Use And Maintenance Download Page 3

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8695 4985

ESSENTIAL OXYCUTTING

CONTENTS

A - IDENTIFICATION ......................................................................................................................... 1

B - SAFETY INSTRUCTIONS ............................................................................................................ 3

1 - GENERAL SAFETY INSTRUCTIONS ................................................................................ 3

2 - AIRBORNE NOISE ............................................................................................................. 4

3 - ELECTRICAL SAFETY ....................................................................................................... 5

4 - USE OF PERSONAL PROTECTIVE EQUIPMENT ............................................................ 5

5 - INSTRUCTIONS FOR THE USE OF GAS ......................................................................... 5

6 - CONDITIONS FOR USE ..................................................................................................... 6

7 - RISK OF HEATING ............................................................................................................. 7

C - DESCRIPTION ............................................................................................................................. 9

1 - POSSIBILITIES OF THE ESSENTIAL OXYCUTTING INSTALLATION ............................ 9

2 - INSTALLATION ON LINCOLN ELECTRIC MACHINE ....................................................... 10

3 - ESSENTIAL OXY CUTTING GAS ASSEMBLY (REF. A)................................................... 12

4 - CYCLE FUNCTION ASSEMBLY ........................................................................................ 13

5 - ESSENTIAL OXYCUTTING SOLENOID VALVE ASSEMBLY (REF. B) ............................ 13

6 - LONGITUDINAL BUNDLES (FL) ........................................................................................ 14

7 - TRANSVERSE BUNDLES (FT) .......................................................................................... 14

8 - TOOL HOLDER (REFERENCE P) ..................................................................................... 14

9 - TORCH OPTION (REFERENCE OC)................................................................................. 15

10 - FUEL GAS REGULATION KIT ......................................................................................... 15

D - MONTAGE INSTALLATION ........................................................................................................ 17

1 - CONDITIONS OF INSTALLATION ..................................................................................... 17

2 - CONNECTION .................................................................................................................... 19

E - OPERATOR MANUAL ................................................................................................................. 21

1 - OPERATOR CONTROLS ................................................................................................... 21

2 - ADJUSTMENTS .................................................................................................................. 22

3 - GAS SUPPLY CHANGE ..................................................................................................... 22

4 - CYCLE ................................................................................................................................ 23

F - MAINTENANCE ............................................................................................................................ 25

1 - SERVICING ......................................................................................................................... 25

2 - TROUBLESHOOTING ........................................................................................................ 27

3 - SPARE PARTS ................................................................................................................... 31

PERSONAL NOTES .......................................................................................................................... 38

Summary of Contents for ESSENTIAL OXYCUTTING

Page 1: ...TTING INSTALLATION ESSENTIAL OXYCUTTING SAFETY INSTRUCTIONS FOR USE AND MAINTENANCE INSTALLATION N 0708 5005NG 0708 5015NG EDITION EN Instructions for use REF 8695 4985 REVISION D DATE 09 2018 Original instructions ...

Page 2: ... Please refer to the enclosed CE declaration to identify the directives applicable to it The manufacturer will not be held responsible where items not recommended by themselves are associated with this product For your safety there follows a non restrictive list of recommendations or requirements many of which appear in the employment code Finally we would ask you kindly to inform your supplier of...

Page 3: ...ON ON LINCOLN ELECTRIC MACHINE 10 3 ESSENTIAL OXY CUTTING GAS ASSEMBLY REF A 12 4 CYCLE FUNCTION ASSEMBLY 13 5 ESSENTIAL OXYCUTTING SOLENOID VALVE ASSEMBLY REF B 13 6 LONGITUDINAL BUNDLES FL 14 7 TRANSVERSE BUNDLES FT 14 8 TOOL HOLDER REFERENCE P 14 9 TORCH OPTION REFERENCE OC 15 10 FUEL GAS REGULATION KIT 15 D MONTAGE INSTALLATION 17 1 CONDITIONS OF INSTALLATION 17 2 CONNECTION 19 E OPERATOR MANU...

Page 4: ... spare parts see safety instructions for use and maintenance ISEE N 8695 7050 Safety instructions 8695 4986 Optional Essential torch ignition 8695 4987 Optional Essential sensing MACH HP torch option instruction manual MACH OXY torch option instruction manual 8695 4673 OXY VXK bevelling unit option REVISIONS REVISION B 10 16 DESIGNATION PAGE Creation in several languages REVISION C 09 18 DESIGNATI...

Page 5: ...1 A IDENTIFICATION Please enter the number of your equipment in the following box Quote this information in all correspondence 1 Manufacturing factory code 4 Year manufactured 2 Manufacturing year code 5 Product type 3 Product serial no ...

Page 6: ...A IDENTIFICATION 8695 4985 C A 2 ESSENTIAL OXYCUTTING ...

Page 7: ... general safety instructions and those specific to this process The machine must be operated by a person trained in its use and hazards For general safety instructions please refer to the specific manual supplied with the equipment reference 8695 7050 Special security instructions are also recommended in the documentation of the options or the extraction table ...

Page 8: ... FRANCE central assembly building This site has been qualified by APAVE Nord Ouest 5 rue de la Johardière 44800 Saint Herblain FRANCE This qualification was the subject of Report n 12296847 2 2 Measurements MACH OXY MACH HP The use of a helmet is required with a noise level above 80dB for the operator and for persons located nearby The noise generated by the process can cover external sound warnin...

Page 9: ...C The igniter manages high voltage at low intensity 4 USE OF PERSONAL PROTECTIVE EQUIPMENT In the operating phase and also in the adjustment phase appropriate personal protection is required see document 8695 7050 for more details Standard EN 169 requires the use of shade 7 dark glass for the outputs from this process 5 INSTRUCTIONS FOR THE USE OF GAS See section 3 Safe use of gas of the document ...

Page 10: ...month If these conditions are not met please contact us For cutting welding workshops a minimum air renewal rate of 15 hour is recommended 6 CONDITIONS FOR USE The installation is designed to operate with an appropriate extraction table please call us for rating Regularly check the effectiveness of the extraction Under the standard EN ISO 15012 4 the following speeds are required for oxycutting in...

Page 11: ...may be exposed to high temperatures and be damaged rapidly components pipes wires Heating of parts also disrupts sensing and thus adversely affects the cutting quality THE SOLUTION MAY CONSIST IN modifying the cutting program to distance the succession of cuts while cutting the pieces and or using a cutting table with fume extraction so as to carry away as many calories as possible from the bottom...

Page 12: ...B SAFETY INSTRUCTIONS 8695 4985 C B 8 ESSENTIAL OXYCUTTING ...

Page 13: ...t of pure oxygen NB The speed and quality pair can be selected differently depending on the end destination of the cut parts Quality and productivity requirements closer metallurgical dimensional or geometrical tolerances surface conditions speed etc make it necessary to use modern guiding machines The cutting values and speeds depend on the type of torch and gas used Gas usable with all torches P...

Page 14: ...his installation may be used in an integrated manner on a machine supplied by us The main functions are accessible by the NC This installation can manage the plasma cutting function for a maximum of 2 torches and the oxycutting function for a maximum of 4 torches depending on the modules selected ...

Page 15: ...ng gas assembly B Essential oxycutting solenoid valve assembly C Cycle function assembly OP Sensing option 8695 4987 OA Ignition option 8695 4986 OC Torch option Supplied with the torch FL Longitudinal bundles FT Transverse bundles G1 Fuel G2 Oxygen Heating and Cutting I Programming interface 8695 4944 P Tool holder Supplied with the tool holder ...

Page 16: ...as assembly must be installed A machine may have only one gas assembly and thus 4 torches The functions of the assembly are as follows Regulating the gas pressure going to the torches Flushing the cutting and heating oxygen line at the end of cutting the program There is a specific box model for the use of acetylene For other fuel gases the propane model is used The box is supplied wired in the ma...

Page 17: ...g the sensing function and processing feedback from sensing if the option is installed Controlling the tool holder position vertical movement 5 ESSENTIAL OXYCUTTING SOLENOID VALVE ASSEMBLY REF B This assembly is present for each installed torch It is assembled on the tool holder carriage The commands come from the oxy cutting gas assembly to which it is connected It includes the controls of soleno...

Page 18: ...nge for the other fuel gases from the gas assembly to the solenoid valve assembly Solenoid valve control bundle from the gas assembly to the solenoid valve assembly Tool holder control bundle from the gas assembly to the tool holder Tool holder power bundle from main cabinet to tool holder Air pipe optional if the sensing option is present 8 TOOL HOLDER REFERENCE P The tool holder is used for rais...

Page 19: ...ith Mach Oxy and Mach HP torches Refer to the torch documentation for more details about the torches and associated options consumables angle adapters strip cutting etc 10 FUEL GAS REGULATION KIT If the customer s fuel gas network is unstable we recommend the use of a gas regulation kit that includes a pressure reducer valve The kit is fitted on the fuel gas line before the Essential oxy cutting s...

Page 20: ...C DESCRIPTION 8695 4985 C C 16 ESSENTIAL OXYCUTTING ...

Page 21: ...top valve in case of arrival by pipe Do not install gases other than those defined in this manual risk of leaks Never exceed the maximum pressure specified for the supply to the installation Starting up the gas sources Please refer to the section CYLINDER CHANGE PROCEDURE of the safety booklet 8695 7050 If the sensing option is present see the specifications for compressed air in the document 8695...

Page 22: ... at the entry to the machine Use Nature P in bars 10 Max output in m h for X torches 1 2 3 4 mm 200 80 60 50 MACH OXY Cutting Oxygen 8 2 22 23 5 23 5 26 Heating Oxidants Oxygen Fuel Acetylene 1 4 0 85 0 85 1 05 1 4 Propane 1 8 0 6 0 6 1 1 3 MACH HP Cutting Oxygen 8 2 22 23 5 23 5 26 Heating Oxidants Oxygen Fuel Acetylene 1 4 0 85 0 85 1 05 1 4 Propane 1 8 0 6 0 6 1 1 3 1 2 LAYOUT OF CABLES AND FLE...

Page 23: ... hand pitch One olive fitting M16x150 nut left hand pitch One olive fitting M20x150 nut right hand pitch One olive fitting G3 8 nut right hand pitch One olive fitting G3 8 nut left hand pitch One nipple G3 8 right hand pitch M16 150 right hand pitch to adapt to a female fitting near the supply One nipple G3 8 left hand pitch M16 150 left hand pitch to adapt to a female fitting near the supply Impo...

Page 24: ...D MONTAGE INSTALLATION 8695 4985 C D 20 ESSENTIAL OXYCUTTING ...

Page 25: ... 1 2 TORCH MOVEMENT CONTROLS At any time except if there is a fault or if the torch is not selected the height of each torch can be modified in slow speed To do so use the buttons in the UI available in the documentation 8695 4944 in the sections relating to Essential oxycutting Caution these height modifications can have an effect on the sensing height setpoints if the option is present see docum...

Page 26: ... particularities size and location of striking cutting quality etc also influence cutting quality The post processor must comply with the recommendations of Air Liquide 2 2 TOOL HOLDER HEIGHT See specific documentation of tool holder 3 GAS SUPPLY CHANGE When the gas supply is changed cylinder change for example we recommend the following Shut the cylinder to change For the heating oxygen and fuel ...

Page 27: ... down to drilling height C Overheating phase sheet piercing This stage does not exist with sheet edge starts D Cutting stage the cutting pressure increases gradually no step in the case of sheet edge and it moves from overheating pressure to heating pressure Then the XY movement starts At the end of the cut if the program is not completed heating resumes up to the next strike B At the end of the p...

Page 28: ...E OPERATOR MANUAL 8695 4985 D E 24 ESSENTIAL OXYCUTTING ...

Page 29: ...and a lint free cloth never use solvents or grinding materials Monthly Date of maintenance Check that the gas circuit operates properly pressure gauge pressure regulator electrovalve valve couplings etc Note any piping showing the slightest signs of fatigue wear damage should be replaced by a standard identical pipe Check the condition of all the electrical cables especially near the torches and i...

Page 30: ...be damaged while changing the pipes Fittings must be degreased and cleaned of dust before assembly risk of explosion To change a valve on the unit first take the line off its support then take the valve off the line Olive type fittings are screwed on directly Adhesive must be applied on other fittings and valves The adhesive must be compatible with oxygen Risk of explosion If acetylene is being us...

Page 31: ...e emergency stop does not mean that there is no voltage in the box The fuses E1 F14 and F15 power the motors of the tool holders Description n FUSE 5X20 5A 250V FSF F10 to F16 switch off the 24V power to the rest of the process Description FUSE 5X20 5A 250V FSF While troubleshooting the Air Liquide technician may ask you to check the status of the indicators inputs outputs E2 and also those on eac...

Page 32: ...ng up The process needs operating feedback from the extraction to start Start up the extraction and check if it is working correctly 51 The emergency stop is active The process cannot start without switching on the power to the machine Remove the cause of the emergency stop and switch the power back on 52 Fault No air The process with optional probe cannot start without compressed air Check if air...

Page 33: ...s fault Difference between the setpoint and the heating oxygen gas measurement too large 10 of the setpoint for 5 seconds Change the supply empty or open the supply valve 1203 Fuel gas fault Difference between the setpoint and the fuel gas measurement too large 10 of the setpoint for 5 seconds Change the supply empty or open the supply valve 1204 One of the torches is at its upper travel limit whi...

Page 34: ... alarm Correct the fault and set the tool holder position if required Two torches cannot be selected The two torches are not identical type probe Select two identical torches Cutting cannot be started Lack of extraction or ineffective extraction Air pressure too low Start clean the extraction before cutting Open the air valve or start the compressor Cutting is not correct Several possible causes R...

Page 35: ...f parts duly completed Please specify in the Order column the number of parts desired and indicate the type and the serial number of your equipment For items noted on the photos or sketches but not in the tables send a copy of the page concerned highlighting the particular mark For example normally in stock not in stock on request Item Ref Stock Order Designation 1 W000XXXXXX Machine interface boa...

Page 36: ... 8695 4985 C F 32 ESSENTIAL OXYCUTTING 3 1 Gas assembly and solenoid valve assembly A Gas assembly B Solenoid valve assembly OA Ignition option OC Torch option G1 Fuel supply G2 Oxygen supply for heating and cutting ...

Page 37: ...d pipe G4 07052947 Transverse heating oxygen pipe G5 07052946 Transverse cutting oxygen pipe G40 W000381937 Propane line selecting solenoid valve W000381938 Acetylene line selecting solenoid valve G41 W000381940 Cutting O2 line Selecting solenoid valve G42 W000381943 Heating O2 line Selecting solenoid valve G43 W000381937 Ignition solenoid valve propane W000381938 Ignition solenoid valve acetylene...

Page 38: ...F MAINTENANCE 8695 4985 C F 34 ESSENTIAL OXYCUTTING 3 2 Process and tool holder control system in main cabinet ...

Page 39: ...tor variable drive E2 W000400412 X20BC00G3 Ethercat coupler module W000400413 X20PS9400 power supply module W000400414 X20CM8281 input output module W000383711 X20BB80 back panel W000383702 X20BM11 back panel W000383703 X20TB12 terminal block For parts order give the quantity required and put the number of your machine in the box below TYPE Number ...

Page 40: ...F MAINTENANCE 8695 4985 C F 36 ESSENTIAL OXYCUTTING 3 3 Fuel gas regulating kit Propane fuel gas Acetylene fuel gas ...

Page 41: ...ck not in stock on request Item Ref Stock Order Designation G50 W000290104 PROPANE GPL NM 86 PRESSURE REDUCER VALVE G51 W000290102 AD NM 86 PRESSURE REDUCER VALVE For parts order give the quantity required and put the number of your machine in the box below TYPE Number ...

Page 42: ...MAINTENANCE 8695 4985 C F 38 ESSENTIAL OXYCUTTING PERSONAL NOTES Lincoln Electric France S A S Avenue Franklin Roosevelt 76120 Le Grand Quevilly 76121 Le Grand Quevilly cedex www lincolnelectriceurope com ...

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