Lockformer Vulcan 2900 Operator'S Manual Download

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711 OGDEN AVE. LISLE IL. 60535-1399 PHONE 630-964-8000 FAX 630-964-5685

REV 08-98

H. WEISS MACHINERY & SUPPLY

PHONE: (718) 605-0395 - www.hweiss.com

Summary of Contents for Vulcan 2900

Page 1: ...711 OGDEN AVE LISLE IL 60535 1399 PHONE 630 964 8000 FAX 630 964 5685 REV 08 98 H W E I S S M A C H I N E R Y S U P P L Y H WEISS MACHINERY SUPPLY PHONE 718 605 0395 www hweiss com...

Page 2: ...tment nut as shown in the illustration then fully thread a leveler into each leg DO NOTANCHOR THE TABLE TO THE FLOOR A Lockformer installation technician will level the equipment and secure it to the...

Page 3: ...USED TO SECURE THE MACHINE DURING SHIPPING REPLACE THE TWO SOCKET HEAD CAP SCREWS SECURING THE BRACKETS ON THE CARRIAGE WITH THE SHCS IN THE BAG ATTACHED TO THE TORCH HEAD ALLEN WRENCH INCLUDED REMOVE...

Page 4: ...LOW BRACKETS BEFORE REMOVINGTABLE THESE BRACKETS ARE FOUND ON BOTH SIDES OF THE VULCAN MACHINE BRACKET REMOVAL CONT H W E I S S M A C H I N E R Y S U P P L Y H WEISS MACHINERY SUPPLY PHONE 718 605 039...

Page 5: ...bracket 2 Remove the bracket by removing the four mounting screws B 3 Lower the carriage REMOVE THIS BRACKET BEFOREOPERATINGTHIS MACHINE PHOTO 1 PHOTO 2 B WHEEL BRACKET REMOVAL CONT WHEEL SIDE OF CARR...

Page 6: ...nt and personnel INSTANT ON TORCHES The machine torch is an instant on torch These torches fire produce a plasma arc immediately after torch switch closure or remote switch closure for a machine torch...

Page 7: ...emoval Do not touch the front of the torch when starting it After cutting allow time for the front of the torch to cool Qualified first aid personnel and facilities should be available at or near any...

Page 8: ...ible substances nearby that might be ignited by its heat ELECTRICAL HAZARDS AND PRECAUTIONS Primary Safety Directive To perform any maintenance or do any work with the machine s electrical components...

Page 9: ...ARNING The plasma system uses compressed gas Observe proper precautions when handling and using compressed gas equipment and cylinders Refer to the Index at the end of this section When cutting with t...

Page 10: ...ground wire is properly connected Conform to national state and local standard when fastening the power ground wire to the power supply chassis CSA standards recommends placing the power cord ground w...

Page 11: ...y are not working The interlocks turn off the power supply when the retaining cap is loosened Never bypass or shortcut the safety interlocks on any of the plasma system units Do not use the Plasma Uni...

Page 12: ...n Association 470 Atlantic Avenue Boston MA 02210 617 770 3000 NFPA Standard 51 Oxygen Fuel Gas Systems for Welding and Cutting NFPA Standard 70 1978 National Electrical Code NFPA Standard 51B Cutting...

Page 13: ...REVIEWSAND UNDERSTANDS THE MANUAL S PERTAINING TO THE MACHINE IT IS THE USER S RESPONSIBILITYTO UNDERSTANDAND FOLLOW THE MANUFACTURER SINSTRUCTIONSONMACHINEOPERATIONAND MAINTENANCE AND TO OBSERVEALL P...

Page 14: ...RESSURIZED ESCAPING HYDRAULIC OIL EVEN AN INVISIBLE PINHOLE LEAK CAN PENETRATE BODY TISSUES CAUSING SERIOUS INJURY WHEN LOOKING FOR LEAKS USE A PIECE OF WOOD OR CARDBOARD NEVER USE THE HANDS OR ANY OT...

Page 15: ...R IMPLIED CAPACITIES WARNING BEFORE PERFORMING ANY MAINTENANCE ON THIS MACHINE BE SURE THAT THE MAIN DISCONNECT SWITCH IS SHUT OFF AND LOCKED IN PLACE WARNING DO NOT OPERATE ANY EQUIPMENT WITHOUT GUAR...

Page 16: ...al ControlPower OnProcedure InitialTorch HeadSet UpProcedure EmergencyStop Plasma Unit Set Up Job Download ExhaustActivation DryRun Operation of Control During Cutting Releasing a Job to Start a New J...

Page 17: ...tics Information Specifications Input OutputInterface SystemMalfunctionIsolation Normal Fiber Optic Operation Quick Test Will Not Download Checking the Fiber Optic System Checking the Fiber Optic Cabl...

Page 18: ...AXIS SUPPORTROD CONTROLLER PRECISION BEARING SUPPORTROD Y 2 RAIL PROTECTED CABLE TRACK Y 1 RAIL Y RAILSPREADER Y AXIS DRIVE PRECISIONLINEAR BEARINGS X AXIS GANTRY WELDMENT Y AXIS RACKGEAR X AXISHOME S...

Page 19: ...Uncrating 3 Location of Machine 4 Checklist for Rail System 5 Drive Rack 6 Grounding Procedure Power Supply 7 Ventilation 8 Fiber Optic Cable Reference H W E I S S M A C H I N E R Y S U P P L Y H WEI...

Page 20: ...ant so be sure to providespaceforstockpilingmaterialandmovingitbyhoist truck orothermeans Adequatelighting and ventilation must be available for safety reasons as noted in the safety material Machine...

Page 21: ...nect the Vulcan to an AC power source for its use exclusively Do not operate any other machinery from the same power line as the Vulcan 6 Be certain that no wire is placed where it can be affected by...

Page 22: ...xtensions connect a short ground wire between the 2 rails where they butt together Then move ground wires described in item e to the end of each extended Rail that is closest to Ground Rod NOTE Supply...

Page 23: ...nut The end of the sensor should be set to allow 062 clearance between it and its pickup block located on the carriage CAUTION APPROPRIATE CLEARANCE MUST BE PROVIDED OR DAMAGE WILL RESULT To install t...

Page 24: ...EMERGENCY STOP LOCKFORMER 5395 CONTROLLER STAR GROUND POINT PLASMAARC POWER SUPPLY GROUND ROD CUTTINGTABLE H W E I S S M A C H I N E R Y S U P P L Y H WEISS MACHINERY SUPPLY PHONE 718 605 0395 www hw...

Page 25: ...ma Unit Set Up 6 Job Download 7 Exhaust Activation 8 Dry Run 9 Operation of Control During Cutting 10 Releasing a Job to Start a New Job 11 Lost Cut Recovery 12 Vulcan Download Quick Chart 13 Manual D...

Page 26: ...e to the coordinates 0 0 on the table SEE ILLUSTRATION 1 Machine Jog The machine jog keys are split off from the other keys and are positioned on the left side of the panel Unlike the other panel keys...

Page 27: ...t on the work piece e To lower or raise the torch in relation to the material turn the height adjustment knob until the correct height is achieved then tighten the two set screws f Set Gap B to about...

Page 28: ...re specified in the manual Adjust the amperage knob on the plasma unit to the setting specified in the Hypertherm manual 4 EMERGENCY STOP The Emergency Stop circuit used on the Lockformer 5395 Control...

Page 29: ...ws prompt messages and the right shows the three soft key functions If a function required is not displayed on the screen it may be accessed by using either the up or the down arrow keys so long as th...

Page 30: ...Vulcan parts program 2 To select an insulation job from the Vulcan program Input your choice and press the ENTER key JOB TYPE 0 SHEET 1 PART 2 INS After entering the job number the office computer wi...

Page 31: ...ed Cut Pierces Job 9 OPERATION OF CONTROLLER DURING CUTTING CAUTION HAVE ALL PERSONNEL STAND CLEAR OF THE PATH OF THE CUTTING TORCH WHICH CAN TRAVERSE THE ENTIRE LENGTH OF THE TABLE S NOTE Pieces of t...

Page 32: ...ed the override speed and the percentage speed change Pressing the F1 or F2 speed keys causes the feed rate to increase or decrease by 3 respectively If a large speed change is required the operator m...

Page 33: ...eep the key pressed until the torch reaches the cut loss point on the workpiece Hold F1 to Backup Slow Back Slow Skip Resume If you wish to abort the job press the down arrow to access theABORTkey Thi...

Page 34: ...quit 8 Press F1 Cut when ready EXECUTEABLANK 1 Turn on all power 2 Press the DRIVES ON key 3 Press the AUTO ZERO key 4 Press F1 Download Press F1 Speed to change speed Press F2 Kerf to change kerf 5 P...

Page 35: ...press the ENTER key 6 Press F2 to set the Y axis coordinate then press the ENTER key 7 Press F3 to set the speed of the machine then press the ENTER key If necessary press the DOWN ARROW once to VIEW...

Page 36: ...r from one another When editing type the necessary dimensions for that particular piece Once finished press F3 Create The operator will then be able to begin cutting EXAMPLE The following is an exampl...

Page 37: ...Y Scrap Digitize Bottom Left Bottom Right Top Left Top Right None Scale Scale Both X Scale Y Scale Rotate Mirror None X Y Repeat None Straight Staggered Sel Job Restart Del Job Tool box Speed Kerf Ofs...

Page 38: ...Mem Clear Mem Info Interface Word Addr Program Ring ESSI Program Ring GPS HPGL Program Ring HPGL 3D Program Ring Tests Version PAL Opts Screen Char Test Contrast Keyboard Jog Keys Buzzer Sys Power In...

Page 39: ...0 0 POINT Home Position WORKPIECE STOPS AMC4 CONTROLLER ILLUSTRATION 1 WORKPIECE T M APPROX TORCH SET UP POINT H W E I S S M A C H I N E R Y S U P P L Y H WEISS MACHINERY SUPPLY PHONE 718 605 0395 www...

Page 40: ...ILLUSTRATION 3 H W E I S S M A C H I N E R Y S U P P L Y H WEISS MACHINERY SUPPLY PHONE 718 605 0395 www hweiss com...

Page 41: ...afety 2 Inspection and Upkeep 3 Lubrication 4 Reinstallation and Assembly of the Vulcan Torch Head 5 Torch Height Adjustment H W E I S S M A C H I N E R Y S U P P L Y H WEISS MACHINERY SUPPLY PHONE 71...

Page 42: ...ipment d Clean all components particularly electrical parts where metallic particles can cause short circuits blow out Torch Ball casters as explained later Keep all rails racks rollers pinions clean...

Page 43: ...tion If a torch head is ever to be removed and a new one installed or if a torch head has to be reset use the following procedures Disconnect primary power leads and gas tanks before beginning actual...

Page 44: ...crews as shown in Photos 2 and 3 and remove the lower Assembly from the Head as shown in Photo 4 PHOTO 2 PHOTO 3 PHOTO 4 Page 3 H W E I S S M A C H I N E R Y S U P P L Y H WEISS MACHINERY SUPPLY PHONE...

Page 45: ...wo line wrenches 5 16 and 7 16 disconnect the tubing fittings 5 Perform the steps above in reverse to install a new Torch head 3 Remove the torch assembly from the holder casting Now remove the torch...

Page 46: ...Torch use the torch height adjustment knob to set the bottom of the Torch Nozzle to 1 16 minimum above the sheet and retighten the set screws The Ball Casters and Torch Nozzle are now in correct relat...

Page 47: ...rs resting on sheet is only a starting setting see Section 2 for more information on setting Torch properly for different thicknesses of stock Whenever drastically changing thickness of stock to be cu...

Page 48: ...51494 X Drive Motor Assembly 51495 X Drive Motor Assembly 51648 Rail Assembly 51526 Rail Assembly 20 ft Single Park 51659 Rail Assembly 20 ft Double Park 52637 Torch Lifter Assembly 58470 Floating Hea...

Page 49: ...r Optic Operation 5 Quick Test Will Not Download 6 Checking the Fiber Optic System 7 Checking the Fiber Optic Cable 8 Bit Driver Sensitivity Adjustment 9 Bypassing the Fiber Optic System 10 Office Cab...

Page 50: ...in Description EIA 1 Protective Ground AA 2 Transmitted Data BA to Bit Driver 3 Received Data BB to Bit Driver 4 Request to Send CA to Bit Driver 5 Clear to Send CB From Bit Driver 6 Data Set Ready CC...

Page 51: ...receptacles The transmitted signal will be reflected off the bottom of the cup back into the optical receiver to accomplish analog loopback The DCD status LED should be ON If not check for RTS signal...

Page 52: ...GENEVA IL 60134 PHONE 630 232 8640 WARNING This equipment generates uses and can radiate radio frequency energy and if not installed and used in accordance with the instructions manual may cause inte...

Page 53: ...D does not work check the following on office bit driver a DCD and RD light always on Remove optic cable Point back of bit driver toward a room light Does RD light go out Check optic cable and or adju...

Page 54: ...IFO FITTED SERIAL HOST PORT FAILED This is normal If NOT check the following a No Lights Flash Could be a problem in testing Recheck testing procedure b Still No Lights Flash Indicates a faulty intern...

Page 55: ...lue sensitivity potentiometer counterclockwise until the RD diode on the front panel lights up see diagram below If RD is already on go to step 2 2 Turn the same potentiometer clockwise until the RD d...

Page 56: ...2 Cutting Errors 3 Torch Movement 4 Computer Block 5 Flash Program InstructionstoInstallNewTableSet UpSoftware ComputerSet Up ControllerConfiguration H W E I S S M A C H I N E R Y S U P P L Y H WEISS...

Page 57: ...1 Inspect Home Switch for visible damage X Home is at the end of the bridge Y Home is on the Y 1 rail 2 Check the gap between Home Switch and the Homing Plate for both the X and Y Home Give an allowa...

Page 58: ...heck air pressure Minimum air pressure must be 40 psi 3 Checkfor24VDCatlifterassembly If yes replace the 4 way valve If no check cable and fuses on back of controller Torch head goes up and down too f...

Page 59: ...tin computer Place an X in the Use CTS box by pressing the spacebar 6 Press the tab key to change to Download Event Symbols and place an X in the small box by using the spacebar 7 Press the tab key to...

Page 60: ...H W E I S S M A C H I N E R Y S U P P L Y H WEISS MACHINERY SUPPLY PHONE 718 605 0395 www hweiss com...

Page 61: ...H W E I S S M A C H I N E R Y S U P P L Y H WEISS MACHINERY SUPPLY PHONE 718 605 0395 www hweiss com...

Page 62: ...H W E I S S M A C H I N E R Y S U P P L Y H WEISS MACHINERY SUPPLY PHONE 718 605 0395 www hweiss com...

Page 63: ...FUSE ACCESS PLATE MAIN FUSE MAIN ON OFF SWITCH BATTERY HOLDER 24 V D C LIFTER MARKER A 1 1 1 R T GROUND INTERIOR OF NEE CONTROLLER GENERAL ASSEMBLY INTERNAL BIT DRIVER NEE CONTROLLER BACK PANEL LAYOUT...

Page 64: ...SECTION 7 ADDITIONAL INFORMATION H W E I S S M A C H I N E R Y S U P P L Y H WEISS MACHINERY SUPPLY PHONE 718 605 0395 www hweiss com...

Page 65: ...emblyDrawings and Parts List FiberOptics Information Vulcan Troubleshooting Vendor Material Operation and Procedures Lockformer Vulcan Maintenance AssemblyDrawings and Parts List FiberOptics Informati...

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