M.G.

GAS CUTTING MACHINE

CNC SYSTEM : BURNY PHATOM
CUSTOMER :

M/s. VOLTAS. CO. LTD,

MUMBAI

REFURBISHED BY:

BALAJI AUTOTECH Pvt. Ltd.,

216, NEETHI MARGA, SIDDARTHA NAGARA
MYSORE-570 011, PH.: 0821-2474102

e-mail: balaji_autotech@yahoo.com

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MECHANICAL MANUAL
1. ASSEMBLY DRAWINGS
1.1

GAS REG. AND DISTRIBUTION (MO7061)

1.2

MOTOR MTG. ASSY.

1.3

GEN ARRANGEMENT

1.4

RAIL ASSEMBLY

2. SPARE PARTS LIST ASSEMBLY DRAWINGS

3. DESCRIPTION OF PROCESS AND EQUIPMENT
3.1

Process

3.2

Gas supply to the machine

3.3

Hoses and connection

3.4

Pressure regulators

3.5

Nonreturn valves

4. INSTRUCTIONS FOR SAFETY

5. STARTING-UP

AND MAINTANANCE

5.1

Selecting the Nozzles

5.2

Setting the gas pressure

5.3

Igniting and adjusting the flame

5.4

Maintenance of torches, nozzles & non return valves

5.5

Starting the cut and hole-piercing

5.6

Hole-piercing

5.7

Cutting by means of multi-bevel heads

5.8

Cutting speed

6. MACHINE CUTTING NOZZLES

6.1

Maintenance instructions for flame cutting nozzles

7. TYPICAL OPERATING DATA FOR FLAME CUTTING NOZZLE

-2-

8. GAS REGULATOR AND CONTROLS

9. OPERATING INSTRUCTIONS FOR ESAB PRESSURE REGULATORS

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-5-

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-7-

-8-

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- 10 -

2. SPARE PART LIST

SL.
DESCRIPTION
NO.
1 PINION 22T/1.5M
2 RACK-1
3 RACK-2
DEEP GROVE BALL
4 BEARING
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19

AIR CONDITIONER
CABLE DRAG CHAIN
GAS REGULATOR
GAS REGULATOR
GAS REGULATOR
PRESSURE GAUGE
PRESSURE GAUGE
SILENCER
HTD PULLEY 22-8M-27
HTD PULLEY 44-8M-30
CLAMPING BUSH
HTD BELT
ROCK DRILL HOSE
RED HOSE
BLUE HOSE
2 WAY SOLENOID
20 VALVE
2 WAY SOLENOID
21 VALVE

DRG/TYPE
M06498
M06496
M06497
6305-2RS1
TURBO-450M2
(ADVANCE)
055.30.75.100-46 LINKS
IDA4B
IOX14
IOX13B
0-14 KG/CM2, 1/4 BSP
0-4 KG/CM2, 1/4 BSP
1/2" BSP
M06511
M06512
RCK13, 20x47
480-8M-20
20mm ID, BLACK COLOR
8mm ID
8mm ID
FD204NCFBRV3LDBSP,
220VAC WITH LED
FS204NCFBRV3LDBSP
WITH 220VAC WITH LED

3. Description of processes and equipment

3.1 Process

- 11 -

QTY UOM

AXIS / TYPE

3 NO
46 NO
5 NO

X/Y
X/Y
X/Y

6 NO

X/Y

1
4
2
1
2
2
1
1
3
3
3
3
40
30
60

NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
MT
MT
MT

PANEL
Y
GAS
GAS
GAS
OXYGEN
ACETYLENE
OXY
BO
BO
BO
BO
GAS
ACETYLENE
OXYGEN

4 NO

ACETYLENE

8 NO

OXYGEN

Oxy-fuel flame cutting is that thermal cutting process which is executed with a fuel
gas/oxygen flame and cutting oxygen. The material is heated locally to ignition temperature
and combusted at this point in the stream of cutting oxygen. The heat which is produced by
the heating flame and on combustion of the material permits a continuous process of
combustion in the stream of cutting oxygen. The reaction is propagating in the depth and
upon movement in the feed direction. The oxides produced mixed with weld metal also
called cutting slag are ejected by the cutting oxygen jet, thereby producing the cutting
kerf.
Flame cutting of materials is only possible of they meet the following requirements:
1. The material which is heated to ignition temperature must combust in the
oxygen stream production fluid oxides, which can be ejected.
2. The ignition temperature of the material must be below its melting point.
3. The combustion heat of material must be as great as possible and its thermal
conductivity as low as possible.
4. These requirements are met by all structural steels, many low alloy steels and
steel castings a well as titanium.
3.2 Gas supply to the machine
Attention!
Please observe the following regulations:
Accident prevention regulations for oxygen (VBG 62)
Technical regulations for acetylene plants and calcium carbide stores (TRAC)
Safety devices for sewer gas, long distance gas (e.g. propane, butane)DVGM,
memorandum G 606.

Oxygen
According to requirements, it is possible to use batteries or bundles of cylinders, or cold
vaporisers. Depending on the facilities available, the flame cutting machine can be supplied
via the works system or direct from the gas supply source.
Fuel gas
-Acetylene
Depending on the consumption level, batteries or bundles of cylinders, or generator, may
be used for supplying acetylene.

- 12 -

-fuel gas mixtures *

dependent on the consumption level, map gas is supplied by single cylinders, cylinder
batteries or tanks.
-propane
Generally speaking, a liquid gas tank with a vaporizing station is installed for supplying
propane.
-Natural gas
Natural gas is provided via pipelines. The minimum pressure at the torch inlet must be
observe (see cutting tables).
Extraction points
The extraction points should be selected on the basis of the minimum quantities of gas
required and the types of fuel gas to be used.
Literature
Storage and distribution stations (cylinder batteries, bundles, vaporizer stations) for
technical gases
Pipework fittings for technical gases
Gas supply equipment (extraction point fittings ) for flame cutting machines
Determining the nominal bores of pipe work and fittings for gases

3.3

Hoses and connections

Oxygen
Fuel gas (except liquid gas)
: Red
Propane/butane/fuel gas mixtures * : Orange
Compressed air

: Blue
: Black

Hoses must be secured with suitable hose clips or hose joints.

The length of the hoses should be such that it does not impede the travel of the crosscarriage.
Do not confuse the hoses for heating and cutting oxygen.

- 13 -

Connections comply with DIN 8542

3.4

Pressure regulators

Depending on the type of machine, the pressure regulators are located at the extraction
point or at the central control of the machine.
All regulators are of the directly controlled, proportional type. The valve cone is
controlled, proportional type. The valve cone is controlled via a diaphragm by means of
the interaction of gas pressure and spring pressure or control pressure. The outlet pressure
remains constant even in the event of fluctuating inlet pressures.
The gas throughput of the pressure regulators incorporated in the machine corresponds
with the performance range of the machine.
If no pressure regulators are incorporated in the machine, it is necessary to select
extraction point pressure regulators which correspond with the maximum gas throughput.
3.5

Nonreturn valves

In order to secure the hoses and the gas supply lines in the flame cutting machine,
nonreturn valves with flame arresters are mounted between hoses and torch adjustment
valves.
On flame cutting machines whish are equipped with ignition devices, the fuel gas outlet for
the ignition torch must be located between the Nonreturn valves and the torch adjustment
valve.
For arrangement of the nonreturn valve see fig.1.
For flame cutting machines which are equipped with machine cutting torches MS 3450
with integrated ignition refer to the Instruction Manual.

Fig.1 Arrangement of the nonreturn valves

1. Solenoid valve for ignition device
2. Adjustment Valve for ignition torch
3. Ignition torch
4. Machine cutting torch
5. Torch adjustment valves
6. Installation possibility for test pressure gauge
(T irons and pressure gauge, see page No.--)
7. Nonreturn valves
8. Fuel gas supply line
9. Heating oxygen supply line
- 10.
14Cutting
oxygen supply line

4. Instructions for safety

1. The machine must not be started without the prescribed safety device mounted at
the ex-action point of the central fuel gas supply line.
2. The user has to use the fuel gas specified for the machine.
3. The machine cutting torches should be operated exclusively with the fuel gas for
which they are marked. The messer griesheim machine cutting torches are to be
combined only with the corresponding cutting nozzles from messer griesheim of the
same type of gas.
4. When switched on the machine must be under the supervision of the operating
personnel.
5. Within the working range of the machine, sufficient clearance is to be kept to
rotating units, oppositely directed torch carriages or similar equipment.
6. Before work is started (change of shift ) the operating personnel must make sure
that the machine, in particular the cutting torches, is ready for operation. The screw
connections of the gas pipings and at the torch must be tightened firmly and gastight.
7. All adjustment valves on non-used machine cutting torches are to be closed by
hand.
8. Ignition, adjustment and extinguishing of the flame are to be carried out in
accordance with the instruction manual.
9. To avoid fire and explosion hazards gases or gas mixtures should by no means
escape uncontrolled, especially where water or suction tables are used.
10.

For manual ignition of the torches only suitable gas igniters should be used.

11.

Check after electrical ignition that all pre-selected torches have been ignited.

12.

In case of clogged flame cutting nozzles, after flame flashback or backfiring,

immediately close the adjustment valves for fuel gas, heating oxygen by hand in the
given order.

13.

On exchangeable units, e.g. single torches, triple torch units, the individual gas
connections are to be made work-like. When the units are not connected, the supply
lines for exchangeable units are to be closed gas-tight.

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14.

During flame cutting, the following personal protective means are to be used. The
operating personnel should not keep easily inflammable goods in their clothing.
The operator must wear:
an another for the protection of the truck (leather)
protective glasses with lateral protection and standardized protective filters

In addition, the operator shall be equipped with:

gloves
safety shoes
leggings (as far as necessary)
protective helmet
personal acoustic protection
(Capsular or in form of wad or plugs)

Inflammable materials are to be stored out of the sparking area only.

16.

Oxygen must not come into contact with parts contaminated with oil or greases
(also clothing).

17.

It is prohibited to use oxygen for cleaning, cooling or venting.

18.

In case of longer interruptions of work, e.g. end of shift, weekend or repairs, close
the shutoff valves at the extraction points (fuel gas, heating oxygen, cutting oxygen,
compressed air, water).

19.

Defective torches, nozzles, valves, hoses, nonreturn valves, pressure regulators,

pressure gauges etc. are to be replaced or repaired by qualified personnel only.

20.

The flame cutting machine and its torch units are to be serviced according to the
instruction manual.

21.

The machine must not be operated during the execution of maintenance, repair,
adjustment and inspection works. The same applies to the exchange of torch units,
torches, nozzles and similar parts.

22.

Apart from the afore-mentioned change of torch units, cutting torches and nozzles
and, no structural changes or modifications must be made to the machine.

5.

15.

Starting-up and maintenance

5.1 Selection the nozzles

- 16 -

Select the appropriate type of nozzle for the torch according to the workpiece thickness
that is to be cut and screw it into the torch head of the machine cutting torch making sure
that no gas is leaking. For this job use suitable tools and apply a counter grip at the flat
faces of the faces of the torch head. The cutting range, required cutting oxygen pressure
and type of gas are as per make of nozzle head.
Attention:
Combine nozzles only with torches of the same type of gas
A
P
M
C
Y

= Acetylene
= Propane
= methane (natural gas )
= Town gas
= Fuel gas mixtures
(methyl-acetylene propadiene mixtures:
Mapp gas etc.)

5.2 Setting the gas pressures

For cutting oxygen, heating oxygen and fuel gas. With the valves open (central control and
torch valves) set the pressure in accordance with the adjusting screw on the pressure
regulator.
For measuring the pressure at the torch inlet, test pressure gauges are available which are
to be installed between the machine cutting torches and the torch adjustment valves.
Close the central control and torch valves again.
When the cutting operation has been completed or interrupted for a longer period of time,
relive the pressure regulators by turning back the adjusting screws and close the extraction
point valves.

5.3 Igniting and adjusting the flames

When the gas pressures have been set at the pressure regulators, open all central control
valves. At each individual torch : fully open the heating oxygen valves, open the fuel
gas valve slightly, allow the issuing gas mixture to flow uncombusted for a few seconds,
then ignite and set a neutral flame.
Attention !

- 17 -

During ignition, the torches must be at least 100 mm above the workpiece surface.
Setting the heating flame
1. Acetylene/oxygen
With the heating oxygen valve open, first set surplus acetylene with the fuel gas valve on
the cutting torch (identified by the licking, undefined, luminous flame cone, see figure
- 2A).
Then reduce the acetylene supply until the longest, sharply defined cone is obtained, see
figure- 2B.
Since the hearing flame has to provide only a certain proportion of the thermal
requirements for the cutting process, it must be adjusted accordingly i.e. it is
uneconomical if the heating flame is too large, especially as the desired sharpness of the
cut edge is also adversely affected.
The size of the heating flame is set with the heating oxygen valve of the torch, the
volume of fuel gas for the neutral flame being proportioned at the same time using the
fuel gas valve.
Check the cutting oxygen jet. It must flow in a straight, cylindrical form the nozzle and
must not flutter. The heating flame must surround the oxygen jet concentrically (See
Figure 2 C).
When each torch has been set individually as described above, it is necessary to operate
the central control valves.
The corresponding cutting oxygen valves for the individual torches remain open at all
times, whilst the individual heating oxygen and fuel gas valves are used only as
adjustment valves.
If it is necessary to turn off an individual torch, first close the cutting oxygen valve,
then the fuel gas valve and, finally, heating oxygen valve.

- 18 -

Fig. 2 setting the heating flame

A
B
C

heating flame with surplus acetylene

Neutral heating flame
Correct form and position of the oxygen jet
in relation to the heating flame

2. Propane/ oxygen, map gas/ oxygen,

Methane / oxygen, town gas/ oxygen

- 19 -

In the case of slow-combusting gases such as propane, map gas, methane and town gas, it is
not quite as easy to recognize the correct flame setting for flame cutting as with acetylene.
With some practice, however, it is possible to identify the most economic setting for these
gases, too, by the size and color of the flame
5.4 Maintenance of torches, nozzles and nonreturn valves
Protect torches from damage. Keep the nozzles clean at all times and, if dirty, use only
suitable nozzle cleaners, wire brushes or nozzles cleaning powder. Please pay attention to
the detailed Maintenance instructions for flame cutting nozzles
Soiled and damaged nozzles impair the cutting quality and flashback safety of the torch.
( see also maintendvce instructions foThheavyduty flame cutting nozzles art. No.
0.810.996.)
The flame arresters of the non return valves are made of sintered metal and are soiled in
the course of time by carbon deposits resulting from flashbacks or dirt from the supply
lines. This increases the pressure loss and impairs the function of the torch.
Therefore, the nonreturn valves are to be replaced dependent on the dirt produced.
In the event of flashback, the flame penetrates into the torch where it continues to burn in
the mixing zone, producing whistling, hissing noises. In order to prevent damage to, or
even destruction of the torch, immediately close
Fuel gas valve
Heating oxygen valve
Cutting oxygen valve

at the corresponding torch

In the given order.

Then allow the torch to cool down and remedy the defect. Should flashback recur, we
recommend that the torch is passed to an authorized workshop for inspection and repair.

5.5

Starting the cut and hole-piercing

Set clearance between nozzle and surface of work-piece in accordance with the cutting
table. Position the torch suspension in the direction of the cut so that the cutting jet does
not grub up the workpiece surface. When the ignition temperature of the material is
reached, open the cutting oxygen and switch on the machine drive. The cutting jet must
produce sharp edges when starting the cut.
5.6 Hole-piercing

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If the cut is to be started at a hole within the workpiece, the starting hole can be pierced
in the following ways:
5.61 By means of hand cutting torch:
preheat the piercing point well. When the material has been heated up to its ignition
temperature, slightly incline the torch and, at the same time, gradually open the cutting
oxygen valve. Then swivel the torch until the torch head is in a vertical position.

Fig. 3 Hole-piercing with the machine cutting torch

5.62 With the machine cutting torch (Figure 3):
Ignite the fuel gases, set nozzle clearance according to table and heat the material to
ignition temperature. Then switch on the machine drive and slowly open the cutting
oxygen valve (proportioning valve ) so that the molten material does not damage the
nozzles.
5.43

With the automatic hole-piercing system:

5.6

Cutting by means of multi-bevel heads :

5.71

Torch sequence with endlessly rotating multibevel heads

For K-cuts (type of kerf DHY according to DIN 8551) by means of endlessy rotating
multibevel heads, the torches are to be arranged s shown in Fig., observe the sense of
travel.

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1
2
3
4
5
6
7

Torch I
Torch II
Torch III
Work piece
Scrap
scanning feeler
scanning feeler

Fig. 4a Sequence of torches with endlessly rotating multi-bevel heads

For sequence of torches with non-rotating multibevel heads, see the following page,
section 5.72.

5.72 Torch sequence with endlessly rotating multibevel heads

For K-cuts (type of kerf DHY according to DIN 8551), the torches are to be arranged as
shown in fig. the clearance between the individual torches is bigger than in case of the
multibevel head of Fig., because sharp cuts cannot be executed by this unit.

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1
2
3
4
5
6

Fig.4b

Torch I
Torch II
Torch III
Work piece
Scrap
Cutting direction

Sequence of torches with non-rotating multibevel heads,

5.8 Cutting speed

experienced operators can tell from the way the sparks fly and from the noise produced by
the cutting process whether the cutting speed is right
figure 10 shows the pattern of sparks that is produced by the correct, inadequate and
excessive cutting speeds.

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Cutting direction
Cutting speed correct

Cutting direction
Cutting speed too high

Cutting direction
Cutting speed too low

Fig. 5 Cutting speed

Note :
Sharp, satisfactory cut edges can be obtained only if the heating flame is correctly set!
The cutting speed can be infinitely varied during cutting.
6.

Machine cutting nozzles

6.1 Maintenance instructions for flame cutting nozzles

- 24 -

Heavy-duty flame cutting nozzles are of high cutting performance and a long service life.
They are manufactured with great precision, carefully checked and packed so that
damages during transport are being excluded.
Corrosion protective agents, rust and scale on the surface of the sheets to be cut as well as
spattering of slag are the reasons for deposits, contamination or damage to the nozzles.
The nozzles must be cleaned.
6.1.1

Wet cleaning

A simple and protective way of nozzles cleaning is wet cleaning.

For this purpose, usually 50 grs. Of nozzles cleaning powder are dissolved in 1l of water.
The cutting nozzles to be cleaned are put into solution for 8-12 hours (according to the
degree of contamination). Then they are rinsed with flowing water and dried.
6.1.2

Mechanical cleaning

Cleaning the nozzle faces

Slight contamination on the face of the cutting nozzles and within the direct vicinity of the
mouth of the preheat flues of the cutting oxygen conduit can be removed by means of a
soft brass brush
Cleaning the cutting oxygen conduit
The tightest orifice (Fig. 6, section1) of the cutting oxygen conduit is cleaned with a
orifice cleaning needle

Contamination of the conic or conic/cylindrical widening are effectively removed by

means of wet cleaning (item 6.1.1)

- 25 -

Fig. 6
Small contaminations and slight burring deposits at the nozzle exit edge (fig. 7) can be
removed with the WRF 6358 tapered orifice cleaning needle.

Fig. 7
Cleaning attempts with unsuitable tools with sharp edges (twist drills, triangular scraper,
reamer etc.,) lead to the destruction of wall and form of conduit.

- 26 -

Fig. 8
6.1.3

Cleaning the preheat flues

Cleaning the preheat slots

Contaminations of the preheat slots can only be removed by means of a suitable slot
cleaner which must follow the guide motion from A to B

Fig. 9
Cleaning the preheat orifice
Small contaminations of the preheat orifice can be removed with an orifice cleaning
needle or a cleaning drill.

- 27 -

Fig. 10
Important hint for the use of gas mixing nozzles
Because of their high operating reliability, gasmixing nozzles are used preferably in sites
where high thermal stress has to be reckoned with. When nozzles are changed or
especially when new nozzles are used, it is important to strongly tighten the thumbscrew
so that the sealing surface of the nozzles may adjust to the sealing surface of the torch
head(Fig. 11).
In case of extreme heating of cutting nozzle and torch head and subsequent cooling down,
it may happen that the nozzle in the torch head loosens and gets leaky. Therefore the
thumbscrew must be tightened again after the first thermal stress. Thereby it is necessary
to use the torch spanner and to apply a counter grip on the torch head.
Damaged sealing surface in the torch head or on the nozzle must be reconditioned by
means of suitable milling tools (Fig. 12+13)
Only unobjectionable torches and nozzles guarantee: good sealing, reliable work, long
service life and the highest cutting results.

- 28 -

Fig. 11

Fig. 13

Fig. 12
Torch head with milling tool WSF 7019

Nozzle with milling tool WSF 7022

7. TYPICAL OPERATING DATA FOR FLAME CUTTING NOZZLE

- 29 -

- 30 -

- 31 -

8. GAS REGULATORS AND CONTROLS

The preheat gas and oxygen regulators and the cutting oxygen control regulator and their
respective gages are located on the gas regulator panel conveniently located above CNC
pendent. These controls function as follows:
The HIGH PRE-HEAT FUEL GAS pressure regulator is used for setting the high pressure
of pre-heat fuel used to provide a hot flame for fast starts. The LOW PREHEAT FUEL
GAS pressure regulator is used for setting the lower pressure used for normal operation.
With the preheat switch in the on position the gage reads the pressure set by the low
pressure regulator and preheat fuel gas at this pressure is available to all torches. When
high preheat switch is selected the gage reads the pressure set by the high pressure
regulator, and preheat fuel gas at this pressure is available to all torches.
NOTE
In setting high and low pressures, it is best to set the high pressure
setting first to avoid the possibility of a low pressure that is
actually above the high pressure setting.
The high preheat oxygen pressure regulator is used for setting the high pressure of preheat
oxygen used to provide a hot flame for fast starts. The low pressure regulator is used for
setting the lower pressure used for normal operation. With the preheat switch in the on
position the gage reads the pressure set by the low pressure regulator and preheat fuel gas
at this pressure is available to all torches. When high preheat switch is selected the gage
reads the pressure set by the high pressure regulator, and preheat fuel gas at this pressure is
available to all torches.
The pressure set on the CUTTING OXYGEN control regulator is the cutting oxygen
pressure made available to all torches during normal operation by the main oxygen flow
regulator. This is the pressure registered on the gage. When CUTTING OXYGEN switch is
placed in ON position, cutting oxygen pressure at the torches and on the gage builds up to
this regulated pressure at a rate controlled by the position of the PIERCING VALVE
adjustment knob.
The PIERCING VALVE adjustment knob sets the rate at which the main oxygen flow
regulator builds up cutting oxygen pressure to that set by the control regulator. Clockwise
rotation of the knob increases the length of time required for pressure buildup.
NOTE
In turned clockwise all the way it is possible to completely shut off
the control pressure to the piercing valve, preventing the piercing
valve from opening the cutting oxygen supply line when the
CUTTING OXYGEN switch is placed in the ON position.

- 32 -

Fig. 14 Gas regulator panel

1.
2.
3.
4.
5.
6.
7.
8.
9.

Cutting oxygen pressure gauge

Acetylene pressure gauge
Piercing regulator
Cutting oxygen pressure gauge
Acetylene pressure gauge
Acetylene regulator - low
Acetylene regulator - High
Cutting oxygen regulator

9. OPERATING INSTRUCTIONS FOR ESAB PRESSURE REGULATORS

CHECK BEFORE USE
1. Use correct regulator for gas and pressure rating.
2. The regulator if stored for a long time in ON position may have caused permanent
deformation of diaphragh, spring and valve.
3. All gauge pointer at zero process adjusting knob screwed fully out and down stream
valve or closed.

- 33 -

4. Ensure that no grease oil or foreign substance as entered to the regulator become
dangerous during operation.
5. Ensure that the regulator as not be stored in low ambient temperature causing
freeze.
6. Ensure that all dirt dust moisture and foreign substance are blown out from the hose
pipe.
7. Ensure sufficient gas is available for the job in hand once the gauge pointer has
steadied, open the cylinder valve one future turn.
8. Ensure the regulator inlet & nut are compatible with the seating and thread of the
cylinder or pipeline outlet.
INSTRUCTION FOR SAFE OPERATION
1. Cylinder should be located where they not be knocked or contaminated with oil or
greases and be securely supported in a vertical position. All cylinder or pipelines
key operated valve should have a key fitted or adjacent to them to ensure rapid
closure in case of emergency.
2. Prior to fitting a regulator, the valve seating and regulator inlet, should be examined
for signs of damage or contamination with oil, greases or paint. If present regulator
should be removed form service.
3. Oxygen and inert gas regulators have connection with right hand threads to tighten
turn clockwise, while fuel gas regulator have left-handed thread to tighten anticlockwise.
4. Never change a regulator inlet to enable it to be used with another gas.
5. Regulator should be fitted using the correct size of spanner should not be used as
they will tend to turn the hexagon nut. Excess force should not be required or used
as it could damage the threads.
6. Position the regulator so that there is minimum obstruction of the cylinder valve
spindle key. In an emergency it may be necessary to stop the exit of gas in the
shortest time possible.
OPERATING THE REGULATOR DURING USE
1. Slowly open the cylinder or pipeline valve one full turn, using cylinder key or the
hand wheel. Key operated valves should require no addition leverage. If excessive
force is required to open, then the cylinder should be removed from service after
closing the valve.

- 34 -

2. Ensure contents pressure is resistering on the contents gauge or indicator if fitted.

Propane regulator do not have any indicating contents as the pressure within the
cylinder is dependent on the ambient temperature.
3. Test the valve/regulator inlet joint detergent in water solution, with a paint brush
that there is no leakage.
4.

The safety relief valve in the regulator automatically controls the system. The
safety valve will give vent pressure above 1.5 times of delivered working pressure.

5. In regulator the inlet and outlet bonnets have relief holes as preventive measures in
case of accidental failure.
6. Screw the pressure adjusting knob in a clockwise direction to increase pressure and
in an anti-clock direction to decrease pressure until the required working pressure in
recorded on the outlet pressure gauge.
7. Shielding gas regulator are fitted with a flow gauge instead of an outlet pressure
gauge. Flow is recorded in L/min & ft. / hr. operation of the pressure adjusting knob
will control flow of gas through a minute orifice in the outlet and ensure an even
delivery of gas which can be monitored on the flow gauge.
CLOSING DOWN THE REGULATOR AFTER USE
1. Release the pressure adjusting knob immediately after use avoid damage of the
diaphagram. If in ON position, it may give permanent deform to the diaphagram,
thereby stopping the function of regulator.
2. Clean the surface and store it properly in the package to ensure that dirt, dust do not
enter the regulators.

ESAB REGULATORS COMPLY WITH ISI & ISO STANDARDS

SINGLE STAGE REGULATOR
Gas

Application

Max. Outlet
Max Flow
Model
Pressure(Bar)
(L/Min.)

- 35 -

Acetylene

Pre-heat cutting

1.0

250

IDA-4B

Oxygen

Pre-heat cutting

10.0

1000

IOX-13B

Oxygen

Heavy cutting & heating

14.0

3300

DO

IOX-14

DO NOT

Keep the pressure regulators in neat and clean

place free from any dust, grease or oily
substance.

Do not use oily or greasy substance to the

regulators or the pipe lines otherwise there may
be excessive heat in the regulator and may even
Cause Explosion.

Ensure that the cylinder valve is slowly

opened.

Do not open the cylinder valves suddenly and fully

otherwise a sudden surge may cause damage to the
internal component.

Use the control valve for flow of gas and open

it slowly according to the requirement of gas
for use.

Do not remove or tamper with the safety valve.

Safety valve is provided for venting out any

excess pressure of gas.

Do not remove or tamper with the safety valve.

In two stage regulator first stage is present.

So not adjust the first stage.

The gas pressure regulation Sophisticated

equipment.

Do not cause rough handling.

ELECTRICAL SAFETY
1. All electrical/electronic trouble shooting and repair should be undertaken only
by personnel who are properly trained and have adequate knowledge and skill.
2. It must be assumed at all times that POWER in ON so all conditions must be
treated as live. This practice develops a caution that may prevent an accident.
3. REMOVE LOAD from circuit or equipment.

- 36 -

4. OPEN disconnect or breaker and (a) lock in open position or (b) remove fuses
or (c) install Hold-Off tag or (d) have someone stand by. A switch in the open
position with a lock that you only have a key for is positive protection from
someone accidentally turning power on while you are working.
5. MAKE CERTAIN you have opened the circuit by using the proper test
equipment. NOTE: Test equipment must be checked at regular intervals.
6. Capacitors MUST be given time to discharge, otherwise it should be done
manually with CARE.
7. When trouble shooting LIVE equipment, the necessary pre-cautions must be
taken as follows:
a) MAKE CERTAIN your tools and body are clear of ground.
b) Use extra PRECAUTION in DAMP areas.
c) BE ALERT and work without any outside distraction.
8. BEFORE applying POWER to any equipment, it must be established without a
DOUBT that all persons are CLEAR.
9. The CONTROL PANEL DOORS shall be open ONLY when it is necessary to
check out the electrical equipment or wiring. After CLOSING the door, make
certain that the disconnecting means is operating properly with the
DISCONNECT HANDLE MECHANISM.
10. ALL COVERS on junction boxes must be CLOSED before leaving any job
11. BEFORE STARTING, read and understand all WARNING markings and
notices.
12. READ all marking such as nameplates and identification plates.
13. DO NOT alter circuits unless authorized to do so by the manufacturer.
14. DO NOT alter or by-pass protective interlocks.
15. DO NOT place jumper wires across fuses.
16. DO NOT alter over current protective devices.
17. WHEN conductors are REPLACED, they shall conform to the manufacturers
SPECIFICATIONS, including PROPER COLOR CODING.
18. GROUND connections cause fault currents to flow directly into the ground
instead of following through the body into the ground. ALL ELECTRICAL
APPARATUS MUST BE PROPERLY GROUNDED.
19. Use CAUTION when connecting test equipment probes to test points. SHOCK
HAZARDS could exist at the test points or in the test point area and/ or
TRANIENTS induced by the probes could cause a MACHINE ACTION.
20. AVOID wearing glasses that have a METAL FRAME.

- 37 -

21. AVOID wearing a necklace or chain that is made of METALLIC substance.

ELECTRICAL AND MAINTENANCE TRAINING

1. Burny phantom system package
a) PC based CNC unit with LCD display
b) Hard drive
c) Floppy drive with USB port
d) AC Servo drive for 3 Axis ( X-axis, XX-axis and Y-axis)
e) AC Servo motors (3 nos.) with 1:25 inbuilt gearbox)
2. System related cards in the cabinet & test points.
a) Front panel PCB for oxy process control front panel switches like Igniter
ON/OFF Input/Output, Preheat gases ON/OFF, Cutting oxygen
Input/Output, Water spray I/O, Auto height ON/OFF, Station selection
Input/Outputs, Lifter Up/Down Input/Output and Emergency logic interface
In this PCB there are ISO test points i.e., (+5V, Gnd.) (+15V, Gnd.) (+24V,
Gnd.)
3. Encoder Interface cards:
This is used for Encoder feedback from X, XX and Y- axis Interface
between CNC and drive. Test points: +5V, Gnd.
4. Back panel:
Back panel consisting of 15 connectors, they are 10 Recp, 11 Recp, 12
Recp, 14 Recp, 15 Recp, 16 Recp. Encoder connector (X, Y and XX-axis),
RS232-1, RS232-2 connecters, 49 Recp, Motor power connector-3Nos, and
CNC input power supply connector.
10 RECP:
This connector is Interfaced from Burny to Electrical panel for plasma
operation (optional) only we used External E-STOP contact, Crash Sensor
contact both shorted in the panel for reset the machine (see circuit diagram).
11 RECP:
This connector also used for plasma application we are not connected any
pins to oxy process logics
12 RECP:
This connector is used for Igniter sol ON/OFF, Igniter spark plug ON/OFF,
and Vent logic, vent sol ON/OFF (optional) see circuit diagram.
14 RECP:

- 38 -

This connector is used for Station1 and 2 preheat gas and oxy solenoid
ON/OFF, Cutting oxy sol ON/OFF and station 1 & 2 torch lifter up/down
(see circuit diagram)
15 RECP:
This connector is used for Station3 and 4 preheat gas and oxy solenoid
ON/OFF, Cutting oxy sol ON/OFF and station 3 & 4 torch lifter up/down.
But in this connector we are not used any pins to up/down No.3 torch lifter.
Because there is no drive only hardware relay logics has been made (see
circuit diagram).
5. DC power supply board:
This card is used for feed DC supply to all 3 axis drives.
Input 230V AC, output 360V DC.
6. SMPS:
This is used for +24V DC logics.
7. Relay card:
This card is used to get the solenoid supply for oxy process logics.
8. Electrical I/F panel:
This consisting of Relay cards for solenoid ON/OFF, SMPS-2Nos. One
smps for clutches ( 24V DC operated), another for Relay logics, MCBs and
bridge rectifier for torch-3 up/down (input 230V AC, output 230V DC)
9. Drive tuning (X-axis, Y-axis and XX-axis):
Procedure:- Before connecting communication cable switch off CNC
connect communication cable from drive to CNC.

a)
b)
c)
d)
e)

Switch on CNC
Select personal computer setting
Click start
Move arrow keys to program
Select Burny Phantom BL Drive tuning then

Communication screen will come,

Select COMMUNICATION, click OK.
Now screen is ready to drive communication
Press TOOLS

- 39 -

Click RESTORE BACKUP, in this file select required motor ID for example
3102A A230GS-3000RPM
Press OK or SAVE
Note: Please check Motor ID No. and note down.
Select SETUP
Click Servo tuning, press OK.
Select SETUP
Click Analog I/O
And
Calculate the required motor RPM
DesiredTableSpeed

* GearRatio
PinionCircumference

Required Motor rpm=

Where Pinion Circumference= Piniondiameter *

= 3.1415927
What we entered in the system is
6000( RapidMovementOfTable)

* 50
32mm * 3.14

=304.54
This value to be entered in the setup Analog I/O screen. This value obtained from
RPM

3000

Required motor rpm= Voltage = 9.5V = 304.54

Go to SETUP
Click Save to NVM
Press yes
Go to TOOLS
Click Backup Amp
Save the file by Entering X axis tuning
This is used to communicate
Same procedure to be followed for other two axis.
Close the communication screen and shutdown the CNC system and switch off and
switch on.
Press menu on CNC screen
Click Utilities
Select system setup
Select motion configuration
Select required axis eg (x or y)
Now calculate the Required Encoder pulses/mtr
Ticks meter =

EncoderLines * GearRatio
*K *4
PinionDiameter *

Ticks meter =

2000 * 50
*1000 * 4
32 * 3.14

- 40 -

Ticks/meter= 3892700
Enter this value into X axis Ticks/meter parameter
Then move the axis by starting the graph and adjust Aff, Vff, D Gain and P Gain.
Up to graph should be straight line without any variations. This procedure to be
followed for all 3 axis and the press save and save to file

Encoder connector 3Nos.:

These connectors are I/F from Burny CNC I/F card to motor encoder.
RS232-1 and RS232-2 connector:
These two are COM 1 and COM2 communication connectors for program
Transmit and Receive from PC to CNC.
Pin configuration
Burny

Computer
9 Pin D connector

2
3
7
9
8

3
2
5
7
8
1
4
6

RD
TD
Gnd Com
RTS
CTS
DSR

RECP 49 Connector:
This Connector is used for limit switch functions X+ hard limit, X-hard
limit, Y+ hard limit and Y- hard limit (see circuit diagram).
CNC I/P power supply connector:
230V 3 pin.
Trouble shooting, diagnostic function tracing conducted.
Measurement of table has been conducted.

- 41 -

FAULT AND TROUBLE SHOOTING:

1. External stop error:
Release emergency stop PB and check error message goes OFF, if not check
external emergency and cross sensor contacts on Recp 10 on back panel or check
interphase panel TB contacts as per circuit is closed.
2. Drive fault:
This fault occurs due to encoder pulses missing or encoder cable removed or motor
over loaded due to mechanical jam like clutch problem, rack and pinion mismatch ,
motor power cable fault.
For encoder checking: First remove corresponding axis motor assembly and
remove gear box on motor and rotate encoder for one rotation CW and check the
feed back on system screen, if OK rotate in CCW direction check again. If the
encoder counting is alright, continue checking next step. In case of mechanical jam,
check rack and pinion for correct meshing, check for blockage of teeth due to
presence of foreign objects and if yes, clean thoroughly.
3. System software related fault:
System is not initializing properly system will gives the error message on the
screen. Note down the error message please refer manual for trouble shooting the
system software related problems

Check to be done daily, weekly monthly

Daily clean the rack and rails
Clean air conditioner filter weekly
Check spring tension of X, XX and Y axis motor assembly every 12 months

- 42 -

BURNY SYSTEM PARAMETERS

- 43 -

SLNO
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15

AXIS TRAJECTORY
DESCRIPTION
JOG ACCELERATION
MAX ACCELERATION
MAX JOG VELACITY
MAX VELOCITY
S CURVE ACCELERATION GAIN
USE S CURVE
DESABLE RAIL SLAVE
GOAL POINT TOLERENCE
CORNER SPEED
AXIS JERK FILTER
BACK UP VELOCITY
MINIMUM CORNER ANGLE
MAXIMUM CORNER ANGLE
RAPID STOP ACCELERATION
W_ ARC ACCE/DERATE

- 44 -

UNIT
0.2 m/s/s
0.2 m/s/s
0.1 m/s
0.1 m/s
10
FALSE
FALSE
0.1
0.0008
0.1
0.12 m/s
11
22
0.5 m/s/s
70%

SLNO
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25

MACHINE PARAMETERS
DESCRIPTION
MIN. OFF TIME
BLEED OFF DELAY
SW SENCE TIME
PLASMA ARC ON DELAY
PLASMA ARC OFF DELAY
PLASMA START DELAY
PLASMA ARC ON SENCE TIME
MARKER VELOCITY
MARKER DELAY
TEACHABLE PREHEAT
DEFAULT DWELL
PUNCH MARK1 DELAY
PUNCH MARK2 DELAY
RAPID PIERCE RADIOUS
RAPID PIERCE VELOCITY
PRESSURE BLEED DOWN TIME
OXY RAISE TIMER
PLASMA RAISE TIMER
ENABLE PLASMA 1 DOWN PLATE
ENABLE PLASMA 2 DOWN PLATE
IGNITOR ON TIMER
IGNITOR ON GAS TIMER
PLASMA 2 START DELAY
PLASMA 2 ARC ON DELAY
SWITCH LIMIT WARNING

- 45 -

UNIT
0 (S)
0 (S)
0.01 (S)
0 (S)
2.0 (S)
3.0 (S)
0.01 (S)
0.1 m/s
4 (S)
FALSE
0 (S)
0 (S)
0 (S)
0.0032 (m)
0.01 (m/s)
0.5 (S)
5 (S)
2 (S)
FALSE
FALSE
3 (S)
5 (S)
2 (S)
2 (S)
FALSE

SLNO
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20

I/O CONFIGARATION
DESCRIPTION
INVERT HEIGHT DISABLE
USE RS 422
FEEDRATE THRESH
FEEDRATE THRESH HYST
SPEED POT MINIMUM
SPEED POT MAXIMUM
SPD POT MAX PERCENTAGE
PLASMA HEIGHT DISTANCE
USE FRONT PANEL SPEED POT
OK TO RUN TYPE
ENABLE RAPID STOP
ENABLE C AXIS LOCK
BACK PANEL MO
SPECIAL OP #1
SPEED DAC CHANEL
SPEED TYPE
SPEED VOLTS CUT
SPEED ZERO VOLTS
OXY PIERCE TYPE
HEIGHT DISABLE START

- 46 -

UNIT
FALSE
FALSE
95%
2%
0V DC
4.046V DC
120%
0.01 (m)
TRUE
1
FALSE
FALSE
0 BOARD #
0#1
0%
0
0
0
0
FALSE

SLNO
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16

AXIS X AND Y
DESCRIPTION
AXIS MINUS LIMIT SOFTWARE
AXIS PLUS LIMIT SOFTWARE
ZERO VOLT OFF
DB FACTOR
DB THRSHOLD
DEFAULT AFF
DEFAULT D GAIN
DEFAULT I GAIN
DEFAULT P GAIN
DEFAULT VFF
INVERT ENCODER
FOLLOWING ERROR LIMIT
STOP FOLLOWING ERROR
INVERT PWR AMPLIFIER
TICKS PER METER
BACKLASH

NOTE:
DONT CHANGE ANY PARAMETERS

- 47 -

UNIT
100 (m)
100 (m)
0V
0 UNITLESS
0 (m/s)
0.1 Vcy cy/m
0 V cy/m
35 V/m/cy
2720 V/m
99 Vcy/m
FALSE
100 m
100 m
FALSE
3861700
0