English Plasma Manual HPR 260 BPLH

USER MANUAL
PLASMA CUTTING MACHINE
MODEL BPL-H 3006

No part of this Users Manual may be reproduced or transmitted by any without Prior
permission of Baykal Makine Sanayi ve Ticaret A..
TABLE OF CONTENTS
A.
GENERAL MACHINE INFORMATION ................................................................................................. 5

1.
Safety Features of Your Plasma Machine ....................................................................................................... 6
2.
Important Safety Information and Instructions ............................................................................................. 8
3.
Overall Drawing of the Machine .................................................................................................................. 14
4.
Lifting and Transportation ........................................................................................................................... 14
5.
Unpacking and Installation .......................................................................................................................... 16
B.
OPERATING AND MAINTENANCE INSTRUCTIONS ..................................................................... 20

1.
Technical Data .............................................................................................................................................. 20
2.
Main Part ..................................................................................................................................................... 20
3.
PC DT12 Control Unit .................................................................................................................................... 21
4.
Hypertherm HPR_260 Plasma Power Supply ............................................................................................... 22
5.
Filtering System (Optional) ........................................................................................................................... 26
6.
CAD Software (Lantek Expert II Cut Plus) ..................................................................................................... 27
C.
OPERATING THE PLAZMA CUTTING MACHINE .......................................................................... 29

1.
a.
b.
c.
d.
e.
Electrical Connection .................................................................................................................................... 29

Electrical Cabinet ...................................................................................................................................... 29
Control Panel ............................................................................................................................................ 32
X -axis Limit Switches ............................................................................................................................... 34
Z -axis proximity switches ........................................................................................................................ 35
Y- axis limit switches ................................................................................................................................ 36
a.
b.
c.
Using the Machine and Operating Software ................................................................................................ 36

Numeric Control Nc And Cage ........................................................................................................... 37
PC DT12 .................................................................................................................................................... 37
Cage .......................................................................................................................................................... 38
a.
b.
c.
d.
e.
f.
Using the Machine ....................................................................................................................................... 39

Start up ..................................................................................................................................................... 39
Adjustment (referencing to zero):............................................................................................................ 42
Manual mode: .......................................................................................................................................... 44
Plate rotation: .......................................................................................................................................... 47
Automatic Mode ...................................................................................................................................... 49
Simulation ................................................................................................................................................ 52
2.
3.
4.
a.
b.
Control Software .......................................................................................................................................... 54

Main Menu ............................................................................................................................................... 55
i.
Active Functions ................................................................................................................................... 56
ii. Drop Down Menu ................................................................................................................................. 56
iii.
NC Info ............................................................................................................................................. 57
iv.
Colors of NC Alarm Board / Plc Alarm Board.................................................................................... 57
v. State Icons ............................................................................................................................................ 57
vi.
Exit from the Application Package ................................................................................................... 58
Adjustment ................................................................................................................................................... 59
2
i.
c.
d.
F1 Zero Search .......................................................................................................................................... 59
Manual ......................................................................................................................................................... 60
i.
F1 I/O ........................................................................................................................................................ 61
ii. F2 Axes ..................................................................................................................................................... 63
iii.
F3 Move Axis ........................................................................................................................................ 64
iv.
F4 Users Variables ............................................................................................................................... 64
v. F5 Speed ................................................................................................................................................... 65
vi.
F6 Manual Cutting ................................................................................................................................ 65
vii.
F7 XY Plate Rotation ............................................................................................................................. 66
Automatic ..................................................................................................................................................... 68
F7 Directory .............................................................................................................................................. 69
F2 User Rotation....................................................................................................................................... 69
F3 Graphics ............................................................................................................................................... 70
i.
F4 Zoom Area ....................................................................................................................................... 71
ii. F5 Step By Step ..................................................................................................................................... 72
d. Graphic Colors .......................................................................................................................................... 73
e. F1 Execute ................................................................................................................................................ 74
i.
F6 Oxy Parameters ............................................................................................................................... 75
ii. F7 Tool Head Change (Drill Parameters) .............................................................................................. 77
iii.
F12 Previous ..................................................................................................................................... 77
iv.
F1 Go On ........................................................................................................................................... 79
v. F1 Input ................................................................................................................................................ 80
vi.
F1 Simulated ..................................................................................................................................... 80
vii.
Error Page ......................................................................................................................................... 81
viii.
F1 Detail ........................................................................................................................................... 82
ix.
F2 Help ............................................................................................................................................. 82
x. F3 CNC log-file ...................................................................................................................................... 83
xi.
F4 PLC Historical ............................................................................................................................... 83
a.
b.
c.
5.
a.
b.
6.
a.
b.
c.
d.
e.
Configuration Setting ................................................................................................................................... 88

General ..................................................................................................................................................... 89
Syncro Files ............................................................................................................................................... 90
Serial Port ................................................................................................................................................. 91
ISO Parameters ......................................................................................................................................... 92
Error Codes of Syncro ............................................................................................................................... 93
a.
b.
c.
d.
Maintenance and Inspectation .................................................................................................................... 98

Types and Frequency of Inspectations ..................................................................................................... 98
Troubleshooting ....................................................................................................................................... 99
Conditions of storage, re-utilization and scrapping ............................................................................... 102
Lubrication ............................................................................................................................................. 103
7.
D.
Program Archive ( Plasma ISO ).................................................................................................................... 84

F1 New ..................................................................................................................................................... 86
F2 Open .................................................................................................................................................... 86
F1 Edit........................................................................................................................................................... 86
F6 Editing ...................................................................................................................................................... 87
F7 Find .......................................................................................................................................................... 88
PRINCIPLES OF PLASMA CUTTING TECHNOLOGIES .............................................................. 106

Cut Charts ....................................................................................................................................................... 109
Consumables .................................................................................................................................................. 110
Recording Consumable Life ............................................................................................................................ 112
Consumable Life ............................................................................................................................................. 112
i.
Pierce Height ...................................................................................................................................... 113
3
ii. Reducing Errors .................................................................................................................................. 113

Cut Quality ..................................................................................................................................................... 114
Reading the Cut .......................................................................................................................................... 114
Bevel Angle ................................................................................................................................................. 114
Decreasing Dross (Slag) .............................................................................................................................. 115
Appearance of Cut...................................................................................................................................... 116
Reading Lag Lines ....................................................................................................................................... 117
Effects of Cutting Speed on Arc Voltage .................................................................................................... 118
Cutting Direction ........................................................................................................................................ 119
Cutting Holes .............................................................................................................................................. 120
E.
ELECTRIC CIRCUIT DIAGRAM ........................................................................................................ 121
F.
SPARE PARTS ............................................................................................................................................ 137
G.
APPENDIXES .......................................................................................................................................... 144
APPENDIX A: ISO Programming ......................................................................................................................... 144

Structure of Iso Programs .............................................................................................................................. 144
G Functions .................................................................................................................................................. 144
M Functions.................................................................................................................................................. 145
G Codes Programming ................................................................................................................................. 146
Meaning of M Functions ................................................................................................................................ 148
Example of ISO program ................................................................................................................................ 150
APPENDIX B: Cut Charts .................................................................................................................................... 152
A. GENERAL MACHINE INFORMATION

1
Registered Trademark
Baykal Mak. San. ve Tic. A..
Machine Type
Plasma BPL-H 3008
Serial Number
Year Of Manufacture
Address Of Manufacturer
2009
Baykal Mak. San. ve Tic. A..
Organize Sanayi Blgesi Yeil Cad.
No: 24 16140
Bursa / TURKEY
0090 - 224 - 243 16 10
0090 - 224 - 243 12 86
Address Of The Authorized Dealer
, 115114, ,
. .7, .1,
1-
.: (495) 223 02 81
: (495) 223 02 82
www.cf-industry.ru,
info@cf-industry.ru
1. Safety Features of Your Plasma Machine
Emergency switches operate to stop the machine in emergency and have to be

used any time that a dangerous situation advises to stop immediately the
machining, or anytime that it is necessary to get in some areas around the
machine for inspectation or maintenance. More than one emergency switches has
been placed on the machine in the following areas in compliance with the
essential requirements of the Machine Directive and the indications of the EN
418 rule.: on the left and right size of the beam (see Figure- 1) and on the control
panel (see Figure- 2).
Figure- 1
Figure- 2
6
Control lights are placed on the beam. It is equiped with the following lights to
indicate what kind of function of the machine is working (see Figure- 3)
The red light lights up when the machine is in emergency stop.
The green light lights up when the machine is working.

The yellow light lights up when the reset of the machine takes place
Figure- 3
Cable and hose carriers are assembled to protect cables and gas hoses in order to
avoid the hose and cable entanglement and their eventual consequent demages,
in order to reduce potential dangers.
Push buttons were thought and realized in compliance with the essential
requirements of the Machine Directives and with the indications of EN 292 rule.
Main switch (on the cover of electric panel ) for controlling the machine, it has
two position;
1. OFF position (0 position): on such position the electric equipment of the
machine is completely isolated.
2. ON position (1 position): when the switch is on this position the console

is under tension. (machine is energized)
2. Important Safety Information and Instructions
!!!
Danger
Cutting can cause fire or explosion.
Remove all flammables within 10 m of the cutting area. Never cut containers
with potentially flammable materials inside - they must be emptied and properly
cleaned first
When cutting with oxygen as the plasma gas, an exhaust ventilation system is
required
Be sure the area is safe before doing any cutting. Keep a fire extinguisher nearby
Quench hot metal or allow it to cool before handling or before letting it touch
combustible materials
Ventilate potentially flammable atmospheres before cutting
Do not use the plasma system if explosive dust or vapors may be present
Do not cut pressurized cylinders, pipes, or any closed container
Do not cut containers that have held combustible materials
Oxygen and methane are flammable gases that present an explosion hazard.
Keep flames away from cylinders and hoses that contain methane or hydrogen
mixtures. Keep flames and sparks away from the torch when using methane or
argon-hydrogen plasma.
!!!
Danger
Electric shock can kill
Touching live electrical parts can cause a fatal shock or severe burn.
Operating the plasma system completes an electrical circuit between the torch
and the workpiece. The workpiece and anything touching the workpiece are part
of the electrical circuit.
Never touch the torch body, workpiece table when the plasma system is
operating.
Wear insulated gloves and boots, and keep your body and clothing dry.
Do not stand, sit or lie on - or touch - any wet surface when using the plasma
system.
Insulate yourself from work and ground using dry insulating mats or covers big
enough to prevent any physical contact with the work or ground. If you must
work in or near a damp area, use extreme caution.

Provide a disconnect switch close to the power supply with properly sized fuses.
This switch allows the operator to turn off the power supply quickly in an
emergency situation.
Install and ground this equipment according to the instruction manual and in
accordance with national and local codes.
Inspect the input power cord frequently for damage or cracking of the cover.
Replace a damaged power cord immediately. Bare wiring can kill.
Inspect and replace any worn or damaged torch leads.
Do not pick up the workpiece, including the waste cutoff, while you cut. Leave
the workpiece in place or on the workbench with the work cable attached during
the cutting process.

Before checking, cleaning or changing torch parts, disconnect the main power or
unplug the power supply.
Never bypass or shortcut the safety interlocks.
Before removing any power supply or system enclosure cover, disconnect

electrical input power. Wait 5 minutes after disconnecting the main power to
allow capacitors to discharge.

Never operate the plasma system unless the power supply covers are in place.
Exposed power supply connections present a severe electrical hazard.
When making input connections, attach proper grounding conductor first.
Each Hypertherm plasma system is designed to be used only with specific

Hypertherm torches. Do not substitute other torches which could overheat and
present a safety hazard.
!!!
Danger
Cutting can produce toxic fumes and gases that deplete oxygen and cause injury
or death.
Keep the cutting area well ventilated or use an approved air-supplied respirator.
Do not cut in locations near degreasing, cleaning or spraying operations. The

vapors from certain chlorinated solvents decompose to form phosgene gas when
exposed to ultraviolet radiation.
Do not cut metal coated or containing toxic materials, such as zinc (galvanized),
lead, cadmium or beryllium, unless the area is well ventilated and the operator
wears an air-supplied respirator. The coatings and any metals containing these
elements can produce toxic fumes when cut.
Never cut containers with potentially toxic materials inside -they must be
emptied and properly cleaned first.
Danger
!!!
A plasma arc can cause injury and burns.

Plasma arc comes on immediately when the torch switch is activated. The
plasma arc will cut quickly through gloves and skin.
10
Keep away from the torch tip.
Do not hold metal near the cutting path.
Never point the torch toward yourself or others.
!!!
Danger
Arc rays can burn eyes and skin.
Eye Protection Plasma arc rays produce intense visible and invisible
(ultraviolet and infrared) rays that can burn eyes and skin.
Use eye protection in accordance with applicable national or local codes
Wear eye protection (safety glasses or goggles with side shields, and a welding
helmet) with appropriate lens shading to protect your eyes from the arc's
ultraviolet and infrared rays.
Skin Protection Wear protective clothing to protect against burns caused by
ultraviolet light, sparks andhot metal.
Gauntlet gloves, safety shoes and hat
Flame-retardant clothing to cover all exposed areas.
Cuffless trousers to prevent entry of sparks and slag.
Remove any combustibles, such as a butane lighter or matches, from your

pockets before cutting.
Cutting Area Prepare the cutting area to reduce reflection and transmission of
ultraviolet light:
Paint walls and other surfaces with dark colors to reduce reflection.
Use protective screens or barriers to protect others from flash and glare.
Warn others not to watch the arc. Use placards or signs.
11
!!!
Warning
Graunding Safety
Work Cable : Attach the work cable securely to the workpiece or the work
table with good metal-to-metal contact. Do not connect it to the piece that will
fall away when the cut is complete.
Work Table : Connect the work table to an earth ground, in accordance with
appropriate national or local electrical codes
Be sure to connect the power cord ground wire to the ground in the disconnect
box.
If installation of the plasma system involves connecting the power cord to the
power supply, be sure to connect the power cord ground wire properly.
Place the power cord's ground wire on the stud first, then place any other ground
wires on top of the power cord ground. Fasten the retaining nut tightly.
!!!
Tighten all electrical connections to avoid excessive heating.
Danger
Gas cylinders can explode if damaged
Gas cylinders contain gas under high pressure. If damaged, a cylinder
can explode.
Handle and use compressed gas cylinders in accordance with applicable national
or local codes.
Never use a cylinder that is not upright and secured in place.
Keep the protective cap in place over valve except when the cylinder is in use or
connected for use.
Never allow electrical contact between the plasma arc and a cylinder.
Never expose cylinders to excessive heat, sparks, slag or open flame.
Never use a hammer, wrench or other tool to open a stuck cylinder valve.
12
!!!
Warning
Noise can damaged hearing.
Prolonged exposure to noise from cutting or gouging can damage
hearing.
Use approved ear protection when using plasma system.
!!!
Warn others nearby about the noise hazard.
Warning
A plasma arc can damaged frozen pipes.
Frozen pipes may be damaged or can burst if you attempt to thaw them with a
plasma torch.
!!!
Warning
Pacemaker and hearing aid operation.
Pacemaker and hearing aid operation can be affected by magnetic fields from
high currents. Pacemaker and hearing aid wearers should consult a doctor before
going near any plasma arc cutting and gouging operations. To reduce magnetic
field hazards:
Keep both the work cable and the torch lead to one side, away from your body
Do not wrap or drape the torch lead or work cable around your body.
Keep as far away from the power supply as possible.
13
3. Overall Drawing of the Machine
Figure- 4: Overall
view of the machine and represantation of the axes
4. Lifting and Transportation
Lifting the bed assembly:

The bed assembly must be lifted with proper belts and hook as shown in
Figure- 5. The bed assembly is equiped with two eyebolts adequate to ensure
the sling works properly.
Figure- 5
14
Lifting the bridge:

The bridge must be lifted with proper belts and hook as shown in Figure- 6.
The bridge is equiped with two belt holes.
Figure- 6
Lifting the exaust ventillation system:

The exaust ventilation system must be lifted with proper belts and hook as shown in
Figure- 7. The belts must be set under two sides.
15
Figure- 7
Transportation of all units:

All units are packed, loaded onto a truck with crane, positioned and fatened to
avoid damage, transported to their destination and unloaded from the truck.
You must use suitable equipment to move these parts inside the plant such as
forklifts, bridge cranes. Make sure that you use approved-type accessories
(belts, chains and hooks with maximum load indicated or boards on the forks)
5. Unpacking and Installation
!
Assembly and installation will be done by BAYKAL technicians.
Before the machine is delivered, prepare the electric power, gas and pneumatic
supply lines needed to operate the machine.
Air for pneumatic systems must be filtered and dry before it is let into the circuit
16
You must first study the layout of the machine to find the most appropriate place
for it in the shop so that the various phases of the production cycle can be carried
out in the simplest and most ergonomic manner.
The floor where the machine will be placed on, must not present neither holes or
juts, that may compromise the stability, duration and noise caused by vibrations
because of a wrong positioning; the floor needs to respect some proper
constructive characteristics.
Overall dimensions of the machine must be considered when installing
The machine will be levelled and screwed on the floor by BAYKAL

technicians.
Machine will stand on the steel washer on the floor shown in Figure- 8
Figure- 8
17
All components of the machine, namely Main part, Hypertherm Plasma Power
Supply, Filtering System and Control Unit (Electric panel and Control Unit), will
be placed by BAYKAL technicians.
For minimum installation dimensions, see Figure- 9 below.
Installation dimensions will be determined later in the installation place.
18
Figure- 9: Installation Diagram

19
B. OPERATING AND MAINTENANCE INSTRUCTIONS

1. Technical Data
Baykal BPLH 3006 Plasma Cutting Machine consists of three parts.

1. Main Part (Work table, Moving parts and Electric cabinet)
2. Hypertherm Hydefinition Plasma Power Supply
3. CAD Software
2. Main Part
Technical Specifications
Machine width
: 5200 mm
Machine lenght
: 10000 mm
Cutting width
: 3000 mm
Cutting lenght
: 8000 mm
Cutting range
: 400 mm
Working Table height
: 745 mm
Supply voltage
: 380 V 10 %
Frequency
: 50 60 Hz 2 %
Power consuption
: 45 kW
Working temperature
: Min -10 C ila Max +40 C
Ideal working temperature
: +5 C ila +30 C
Y axis driving system
: Double sided and two directional longitudinal

driving
Y axis guiding
: Lineer rail system
Y axis motors
: Brushless AC servomotors
Y axis movement
: Rail driving
20
X axis driving system
: Two directional driving
X axis guiding
: Lineer guiding system
X axis motors
: Brushless AC servomotors
X axis movement
: Pinion on rack rail driving
Positioning speed
: Max 30 meter/min
Visual warning devices
: Coloured lamps
Control
: Windows based CNC unit
Fume exausting system
: Pneumatic valves controlled by CNC
3. PC DT12 Control Unit
Processor: EPIA 1000 MHz
Operating system: Windows XP Professional
Memory: 512 MB
HardDisk: 80GB
4 Serial Ports
4 USB Ports
1 PS2 port for Mouse
1 PS2 port for Keyboard
Trackballor external keyboard
21
Display LCD SVGA800x600 TFT Touchscreen

2 Ethernet Ports
Audio Connectors
VGA Port
4. Hypertherm HPR_260 Plasma Power Supply
HPR_260 HyPerformance cutting unit consists of six parts. Power supply, gas
console, RHF console, Valve assembly and torch assembly. HPR_260 unit can be
easily used to cut materials. HPR_260 is designed to cut mild steel, stainless steel
and aliminium. By means of Gas control unit, you can cut different materials
using different gases and gas combinations.
Power unit:
This unit supplies current from 30 up to 260 Amps and have a 311 Volt DC
current. By means of PCB microprocessor which controls plasma functions, it
automatically performs the start-up sequence, machine interface functions, gas
and cutting parameters and the stop time sequence.
The Cutting- and Pearcing-Highs are same following

Material
Mild steel
Stainless steel
Aluminum
Amper
260
260
260
Max. cutting
65
50
50
Max. pearcing
38
32
25
22
Air Quality & Pressure

quality
O2 oxygen
purity 99.5%
clean, dry, il-free
purity 99.99%
clean, dry, il-free
clean, dry, il-free
N2 Nitrogen
Air
H35 Argon-hydrogen
Purity 99.995%
(H35=65% Argon, 35%
Hydrogen)
purity 99.98%
(F5=95 Nitrojen, 5% Hydrogen)
F5 Nitrogen-hydrogen
Mild Steel
Gas-Types
Cutting 30 to45 A
Cutting 80 A
Cutting 130 A
Plasma
O2
O2
O2
pressure +/- 10 %
827 kPa / 8.3 bar
120 psi
827 kPa / 8.3 bar
120 psi
827 kPa / 8.3 bar
120 psi
827 kPa / 8.3 bar
120 psi
Flow rate
4250 I/h 150
scfh
7080 I/h 250
scfh
7080 I/h 250
scfh
4250 I/h 150
scfh
827 kPa / 8.3 bar

120 psi
4250 I/h 150

scfh
Stainless Steel
Shield
O2
Air
Air
Plasma
N2 & F5
F5
N2 & H35
Shield
N2
N2
N2
Aluminium
Plasma
Air
Shield
Air
H35 & Air
N2 & Air
Power unit:
Maximum OCV ( U0)
Maximum output current (I2)
Output voltage (U2)
Duty cycle rating (X)
Cooling
Ambient temperature/ Duty
cycle
Supply voltages
: 311 VDC
: 260 Amps
: 50-175 VDC
: 100% at 45.5 KW ,40, (140 F)
: Forced air (F class)
: Power supply will operate between -10 and +40 C.
( + 14 and 104 F )
: 400 VAC CE, 3 Faz, 50-60 Hz, 32 Amp
23
24
HPR 260 Consumables

HPR 260 consumables are 7 pieces. You see the details about consumables below
Material
Current
Marking (15 A)
30 Amp
80 Amp
Mild Steel
130 Amp
200 Amp
260 Amp
Marking (15A)
45 Amp
45 Amp
Stainless 80 Amp
Steel
130 Amp
130 Amp
200 Amp
260 Amp
15 Amp
Aluminu 45 Amp
130 Amp
m
130 Amp
200 Amp
260 Amp
Plasma
Gas
N2
O2
O2
O2
O2
O2
N2
N2
F5
F5
N2
H35
H35
H35
N2
Air
Air
H35
H35
H35
Schield
Gas
N2
O2
Air
Air
Air
Air
N2
N2
N2
N2
N2
N2
N2
N2
N2
Air
Air
N2
N2
N2
Min. Thickness
(mm)
Max.Thickness
(mm)
0.5
2
3
6
6
6
20
38
50
64
0.8
0.8
4
6
10
10
10
4
6
10
20
25
20
50
1.2
6
10
10
6
6
25
25
20
50
25
Electrode life:
1.
2.
3.
Group change: It consists of a nozzle, an electrode and a shield. It is a easy

wearing group. Their wearing live depends on piercing number and cutting
period. They should be changed always as a set. Change them when the gas holes
blocked and erosion in nozzle (nozzle always must be round and not signs of ark
in its surface) or when electrode is damaged.
Shield
Swirl ring: It is a less wearing part. In case of corrosion, demage or blocked
holes, it must be changed.
Shield cap: It should be changed once a year or in case of corrosion, demage,

missing material, crack or burned.
*** For more information See related manual.***
5. Filtering System (Optional)
The machine has a fume exausting system under the grid bench to exaust the dust
and fume existing during cutting process. In order to be sucked out these
subtances, a filtering and ventiation system is provided with the machine. This
system must be connected to the small openings in the back side of the machine
by special pipelines. This unit is optional and if customer decides to purchase it
saperately, please contact with Baykal machinery for correct choise.
26
6. CAD Software (Lantek Expert II Cut Plus)

Specifications
Powerful database structure and file system
Common use in same database with other computers connected to the same
Network
Easy switching among the databases in a system
Improved import and export options
Program structure with modules such as CAD (Computer aided Designing),

material, sheet (plate), Language, Configuration, operation center
Easy drawing with parametric shapes
A class, functional drawing interface
Complete control advantage over cutting process with Nesting options
Complete control advantage over cutting process with Machining options
Complete control advantage over cutting process with Lead-in / Lead-out

options
Complete control advantage over cutting process with Remnant plate and
saving options
Manual, semi-automatic and full automatic nesting and machining options
Complete control over machine with kerf, plate and cutting simulations
Auxiliary functions such as part test, dimensions e.g.
Multi-torch connection support
Improved common cutting options
Computing cutting time and cuting cost accurately
Printing copy for machine operator
Designing proper configurations and taking G codes after defining different

machines
Custom settings on User interface
27
Supported Operating Systems

Win2K, WindowsXP, Windows Vista, Windows 7.
Options
Tube cutting (Duct): This is a powerful module for calculating HVAC
and DUCT figures in which users simply select and enter the dimensions.
Thus the figure will be automatically developed, ready for machining.
Expert III: This is a system that provides integrated manegement of the
whole production process in sheet metal manufacturing environments.
28
C. OPERATING THE PLAZMA CUTTING MACHINE

1. Electrical Connection
a. Electrical Cabinet
Figure- 10:Electrical Cabinet
29
15
7 8 9 10 1112 15
16
14
13
17
18
Figure- 11: Inside the cabinet
Figure- 12
30
No
Description
1.
Main Transformer (Electrical diagram label or representation 2T1 )
2.
DC Power Supply (Electrical diagram label 2G2 )
3.
Laser pointer (Electrical diagram label 6A1 )
4.
Input Boards (Electrical diagram label IN1,IN2, IN3 )
5.
Output Boards (Electrical diagram label MUS1,MUS3 )
6.
Control Fuses (Electrical diagram label from 1F1 to 1F10 )
7.
Plug (Electrical diagram label 2E1 )
8.
Phase control
9.
Smoke absoption system Motor Switch
10.
Control Relays (Electrical diagram label 3K1 and 3K3 )
11.
Emergency stop module (Electrical diagram label 3A1 )
12.
Plasma On Relay (Electrical diagram label 9K2 )
13.
Main Switch (Electrical diagram label 2Q1 )
14.
Syncro-PLC (Electrical diagram label CNC-X, CNC-Y, CNC-S and CNC-Z )
15.
Terminals
16.
THC-Cart
17.
Noise Filter (Electrical diagram label 2FT1 )
18.
X ,Y,S and Z Axis Motor Drivers (Electrical diagram label X,Yand S (Slave) axis )
19.
A,B axis Drivers.
31
b. Control Panel
Electrical Label
NC12
Name
Description
Main Control Unit
Main control unit is an industrial PC which controls all

functions of the machine.
This switch is used for turn on or off the PC *
NC12 ON/OFF
Switch
RUN
Activates emergency module, servo drivers and I/O

module.
STOP
Halts the axis movement and cutting process.
START
Starts the axis movement and cutting process.
RETRACE
After machine is stoped, this button retraces the machine

to the begining of the last contour.
Reference points
The axis move on the refence points
JOG Z +
It makes Z axis move incrementally in the positive

direction.
JOG Z -
It makes Z axis move incrementally in the negative

direction.
32
VENTILATIN START
Starts ventilation system
10
VENTILATION STOP
Stops the exaust ventilation system
11
Park position
When pressing this button, machine goes to the

predefined parking position
12
Emergency Stop Button
In case of emergency
13
JOYSTICK
It is used for positioning the machine manually.
14
Oxy Torch 1 Up
Used to move the Oxy Torch 1 Up
15
Oxy Torch 1 Down
Used to move the Oxy Torch 1 Down
16
Oxy Torch 2 Up
Used to move the Oxy Torch 2 Up
17
Oxy Torch 2 Down
Used to move the Oxy Torch 2 Down
18
Ignition
Used to ignite the oxy torch.
19
Preheat On/Off
Used to open preheat valves.
20
Cut On/Off
Used to open cut valves.
21
Mode Selection
Auto / Manual selection.
22
Potansiometre
Used to adjust the height of the Oxy Torch.
33
c. X -axis Limit Switches
No
Electrical Label
Name
5S1
+ limit switch X axis
5S3
Zero reference switch (X=0 point)
5S2
- limit switch X axis (located on the other corner)
34
d. Z -axis proximity switches
(1)
(2)
(3)
No
Electrical Label
4S3
Touching sensor
4S1
Torch protection
4S2
Name
Torch protection
5S7
The top limit switch (Under the cover)
5S8
The bottom limit switch (Under the cover)
35
e. Y- axis limit switches
No
Electrical Label
Name
5S6
Zero reference switch (y=0 point)
5S5
- limit switch Y axis
5S4
+ limit switch Y axis (on the back side of the machine)
2. Using the Machine and Operating Software

This section follows the principle to examine the different subjects by starting
from the functions which are available in the main menu at the machine starting
and then the many submenus as they are available.
The whole is preceded by the introduction and by general topics. After the
section concerning the menu functions, there are some additional subjects.
Some functions can be available more than once in the different menus. Unless
otherwise established, the functions are described in only one chapter you have
to refer to every time that the functions are mentioned again.
36
a. Numeric Control Nc And Cage
The Numerical Control PC DT12 is the real industrial PC ("NC") which is

subdivided into two parts: the real PC and the external keyboard.
From now on, by NC we'll mean the PC control unit, including the unit based on
PC Pentium MMX 233 MHz and its physical interfaces (Screen, Keyboard,
Floppy Disk, Serial), while by CAGE we'll mean the cards all together, including
the 68000 microprocessor unit that is in charge of the real control of the machine
tool.
As a general rule this handbook will refer to the NC as this unit concerns the
operator and the application program. Some references to the Cage will be made
when required.
b. PC DT12
From the outside the NC looks like the above board.
The handbook refers often to the "cursor shift keys" or to the "function keys" and
to the ENTER key.
The monitor is a color TFT 800x600 Touch Screen
37
At the back there are the connectors for the four service serial lines (Ex.:
Unloading of Files from CAD), the connector of the parallel port and the
connector for the keyboard.
The screen output is on a 15-pole standard connector and it is foreseen for VGA
monitor.
WINDOWS is the operating system. The supplied version is generally the
latest available and anyway the one considered as the most suitable for the
characteristics of the Teseo Application Package.
c. Cage
By CAGE we mean the part controlling the axes movements and the
management of the digital INPUTS/OUTPUTS. Physically, this structure is able
to receive a variable configuration of cards with its own CPU which is able to
run the programs and the instructions given by the NC.
The CAGE communicates with the PC DT12 by an external serial cable. There
are also the CPU card, the INPUT/OUTPUT cards and those for the Axes
Control and the Supply Unit. The supply unit gives also the power supply
voltages for the PC part.
In case of bad working, check the fuses of the supply unit (even if leds are on)
The Cage includes also the PLC (CPU card) and it is in the buffer. The buffer
of the CPU card can include other important data.
The removal of the CPU card from the cage doesn't imply any loss of data as
the buffer is on the CPU itself. For the same reason, never put the CPU card
on metal parts if you don't want it to be damaged.
38
ATTENTION
Pay the greatest attention to the tightening of the cards and the connectors on
the Cage.
The operations about the cage (cards and connectors) must be carried out
subject to manufacturer's agreement.
3. Using the Machine
Operating of the plasma cutting machine can be explained in five phases.

1. Start up
2. Adjustment (Zero referencing)
3. Manual Mode
4. Automatic Mode
5. Simulation
a. Start up
On starting, the PC DT12 and the Cage execute different initialization phases
that end up in their mutual connection and in the machine preparation for the
user's operations.
Every unit executes its own initialization phase (or "bootstrap") with different
characteristics and times.
In particular, the cage executes a comparatively shorter phase, compared to the

PC DT12, where the PLC boots and remains in the wait state. During this phase,
some external and internal protections avoid any movement or action not
foreseen by the Manufacturer or Teseo.
39
The PC DT12 executes a normal bootstrap, peculiar to PCs, composed of the

BIOS start with the self-diagnosis of the storage and the peripherals, the
installation of the drivers and then the loading of WINDOWS and the application
package.
On starting, the Application Package checks the presence of the drivers and
the necessary initialization files; in case of anomaly, the execution is aborted
and the control is given to WINDOWS . In this case, put in contact with
BAYKAL.
After checking the presence of these components, the Application Package starts
the connection with the Cage.
If the connection between the units is successful, the home page of the
application package is displayed on the screen and the starting phase can be
considered as ended.
Prior to starting up the machine, check the emergency stop buttons and limit
switches in all axis against any demage or mechanically function lost.
Be sure of nobody to stand on the work table or to access to movement area of

the machine axis.
Check the gas hoses to be connected to the gas console properly.
Check rack rails against any demage .
40
Do not forget connecting power cable of the machine and the hypertherm unit
to the nearest power supply.
1.
Turn on the main switch to position I (Figure- 13:a).
The machine will be energized.
(a)
(b)
(c)
Figure- 13
Turn on the PC DT12 on/off switch on control panel to position on

(Figure- 13:b)
2.
PC DT12 unit will be energized and control software will start

automatically after windows will have been loaded.
You will see the Main menu in the screen.
Press the Run button (See Figure- 13:c)

3.
Emergency module, servo drivers and I/O modules will be activated.
41
b. Adjustment (referencing to zero):
The machine always must be referanced to the zero position of the machine XY
coordinate system before starting cutting.
1.
Press F1 Adjustment key in Main menu on the PC DT12 unit (See Figure- 14).
You will see adjustment menu in the screen.
Figure- 14
2.
Press F1 Zero search key on the PC DT12 unit (see Figure- 15).
42
Figure- 15
Press the start button ( Number 4 ) on the control unit (see Figure- 16).
3.
The machine will move to the origin (0,0) of the machine coordinate
system.
The origin of the coordinate system is determined according to the

zero switch (X an Y axis electrical connection in section 6.3.1)
position in X and Y axis.
The torch will be in upper position in Z axis.
NOTE:
43
Figure- 16
c. Manual mode:
Press F2 Manual key in the Main menu on the PC DT12 unit (see Figure- 17).
In manual menu;
a) You can cut plates manually using the manual cutting option
b) You can set plate position using the plate rotation option in manual menu
c) The machine can be positioned manually using the joystick on the control
panel or entering position value directly .
d) You can observe I/O states when the machine starts up.
e) You can also determine the reference point of the plate without using plate
rotation option. In order to that, take the torch to any point above the plate
and press the zero point button on the control panel.
44
Figure- 17
Manual cutting:
You can cut plates manually using the joystick on control panel in this mode.
1.
a.
Press F6 Manual cutting key in Manual Menu (see Figure- 18) on PC

DT12 unit.
2.
The cutting speed window will pop up.
Enter the cutting speed according to the cutting charts in Appendix C.

3.
Press F1 to confirm the speed value.
45
Figure- 18
4.
Keep the Joystick ( Number 13 ) pressed (see Figure- 19).
Torch will descend and touch the plate. Thus it will be referenced
and rise to the cutting hight.
After a time setted in CNC parameters, hypherterm unit will open
the gas flow and fire up the plasma gas.
46
Figure- 19
5.
Use the joystick to control the cutting direction.
! REMEMBER: When cutting, keep the joystick pressed.

6.
To stop cutting, release the joystick.
d. Plate rotation:
Plate rotation is used for parallelizing the plate sides to the machine
X-Y coordinate system. If the plate sides on the work table is not parallel to
the machine sides, you should make plate rotation.
b.
1.
Press F7 Plate rotation key in manual menu (see Figure- 20).
47
Figure- 20
Fig.- 6.3.2.9
2.
Select point 1 over the plate using joystick and confirm with F1 (see
Figure- 20)
3.
Select point 2 over the plate using joystick and confirm with F1. (see
Figure- 20)
4.
Select point 3 over the plate using joystick and confirm with F1. (see
Figure- 20)
48
5.
Press F7 to confirm all points (see Figure- 20)
6.
You will see pop-up window in the screen showing the plate angle
and offset.
Press F2 to confirm the values in pop up window.
DO NOT forget reseting the plate rotation after cutting the rotated plate. In
order to reset plate rotation;
Press F6 Reset key in the plate rotation menu.
e. Automatic Mode
In this mode, you can cut pre-programmed plates with a CAD software.
To select automatic mode, press F3 Automatic key in Main menu (see in Figure21).
Figure- 21
49
1.
Insert a flash disk including CAD produced programs to the USB port.
2.
Press F4 Copy Programs key.
System ask which programs you want to copy to the default directory.
Note: If your machine is connected to a network, CAD programs can be sent

directly to the program directory of the machine from any local computer
connected to the same network.
3.
Select program using the up-down arrows in the key pad and press OK
4. After copying the programs to the directory, select a program to be cutcut

using up-down arrows.(See in Figure- 22)
Figure- 22
50
NOTE : If you want to start cutting from any line in the program;
5.
Press F5 Resume Program key in Automatic menu

Select the program line from which you want to start cutting using updown arrow keys.
Press F1 to confirm
Press start button. Cutting will start from that line.
Press F1 Execute key .(See in Figure- 23).
Figure- 23
Torch Parameters
6. Press F4 Torch Parameters key (See in Figure- 24).
Note: If the CAD software is used correctly all the parameters will come
automatically from the software.
51
Figure- 24
7. Press Start button ( Number 4 ). Cutting will start.

Note : While the cutting is going on, press F2 Torch Blocking key. So the torch
hight will NOT change during cutting.
Note : Press F3 Gpraphic key to observe cutting from graphical veiw.
f. Simulation
After pressing F1 Execution key in Automatic menu, press F1 Simulation key

(See in Figure- 25. Then press Start button.
The machine will start simulating the cutting process.
Note : In order to make simulation when cutting process is going on, press stop
button to halt the cutting process. Then press F1 Simulation key. The machine
will start simulating the cutting process.
52
Figure- 25
53
4. Control Software
Software Organisation:
Start up
MAIN MENU
MANUAL
AUTOMATIC
ADJUSTMEN
Zero Search
I/O
Execute
Axes
Move
User Rotation
User Variables
Graphics
Speed
Copy Program
Manual Cutting
Resume Program
XY Plate Rotation
Tool Radius
Directory
54
a. Main Menu
The page layout is common to all the pages of the submenus of the NC.
Sometimes windows can be displayed in the area called "Working Area" (e.g.
Automatic or Graphics), but basically there are always five fixed areas.
Namely:
State icons
Active Menu Board
NC Alarm Board
PLC Alarm Board
Function Keys
: Diagnosis icons of the machine state

: It displays the currently active menu
: It displays the alarms generated by the cage
: It displays the messages from PLC
: They allow to see the next submenu or to
enable the associated function
The F12 key is common to all menus and it allows to go back to the previous
menu or, in case of Main Menu, to terminate the Application Package
55
i.
Active Functions
The active functions are
F1 :
F2 :
Adjustment Setting of axes and tongs reading

Manual
F3 :
Automatic Automatic execution/continuation of ISO programs
F6:
Shutdown A short cut to shut down the NC
F7:
Diagnostic It has not been implemented yet.
F12 :
ii.
Manual shifting operations of the axes
Exit
Exit from the application
Drop Down Menu
By the ALT key or F10 you can access the drop-down menu with the following functions:
File\Exit
(Alt+F4)
Exit from the application package.
Management\Parameters It enables the editor of the machine tables

(Ctrl+F1)
Management\Programs
(Ctrl+F2)
It enables the editor of the ISO programs
Page\PLC Errors
(F9)
It displays the page of PLC error diagnostics
Page\NC Info
(Ctrl+I)
It displays the info page about the cage SW
Preferences\Alarm
colors selection
(Ctrl+A)
It allows to change the default colours of the alarm messages
Preferences\Graphics
colors selection
(Ctrl+G)
It allows to change the default colours of the graphics window
Help
(Alt+H)
It enables the on-line help of the application package by

means of Microsoft Internet Explorer
56
iii.
NC Info
It displays the information about software (EPROM type and version and PLC
name and version) installed on the Cage.
iv.
Colors of NC Alarm Board / Plc Alarm Board

When you press the mouse right key near one of the two message boards of
the application package, you can change the default colours of the boards by
means of a colour interactive window.
v.
State Icons
At the right top of the window of the application package there are 4 icons
with the following mean:
ICONS OF COMMUNICATION STATE

: They signal the state of the serial
57
communication
: Simulated Status (Green = OFF;
Yellow = ON)
:They signal the EMERGENCY state of
the machine (green = OK;
red = EMERGENCY)
:They signal the HOLD state of the
machine (green = OK; yellow = HOLD)
vi.
Exit from the Application Package
The exit from the application package is not a normal working condition
for the machine-tool. You have to exit only if you really know what you
want to do and we don't recommend this exit if you haven't a good
knowledge of WINDOWS. Wrong operations can damage the Application
package or one of its components and consequently the machine can be put
out of service until the Manufacturer or Teseo repair the damaged parts.
An unintentional exit doesn't cause any damage and all you have to do is to
turn off and then to start again the PC DT12 by executing again the setting
phases.
When the NC gives the control to WINDOWS and even if the PLC is still
working, it is not possible to execute any operation of axes movement and
head movement either.
Always close the WINDOWS session before turning off the PC DT12 so as to
avoid any damage to the Application package or to one of its components.
58
b. Adjustment
The setting menu allows the operator to execute the axes references
The following function keys are active:
i.
F1 :
Zero search
It executes the axes reference cycle
F12 :
Back
Back to the previous page
F1 Zero Search
The axes reference is essential to execute movements different from JOGs. By the
key 'F1 Zero Search', the PC DT12 gets ready to start the cycle. It is necessary to
press START in order to start the reference search of every axis.
59
c. Manual
By "manual" we mean a particular condition of the PC DT12 that allows more
direct operations of the machine-tool without changing the essential safety
conditions.
F1 :
I/O
It displays the input and output list
F2 :
Axes
It allows to move the axes on target
F3 :
Move
It moves the axis to the desired distance
F4 :
User Variables
It shows the value of some variable used also while cutting
F5 :
Speed
Changes the speed manually by arrow keys
F6:
Manual Cutting
It allow manual cutting operation.
F7:
XY Plate rotation In that case the plate can placed using 3 points.
F12 :
Previous
60
i.
F1 I/O
By means of F1 key it is possible to display the list of outputs and inputs
alternatively.
F1 Inputs
By this window it is possible to check the input state. The input state is
represented (for the 4 cards) in the synoptic table on the right bottom. The page
shows the first 13 inputs. Any other input can be displayed by means of the keys
PAGE
/PAGE .
The selected input is red-highlighted in the list and bordered in yellow in the
synoptic table. The joined words allow a faster identification of the module
concerned. The first field is an input description, the second, third and fourth
field define the module, byte and bit corresponding to the selected input
respectively.
61
F1 Outputs
By this window it is possible to check the output state. The output state is
represented (for the 4 cards) in the synoptic table on the right bottom. The page
shows the first 13 outputs. Any other output can be displayed by means of the
keys PAGE
/PAGE .
The selected output is red-highlighted in the list and bordered in yellow in the
synoptic table. The joined words allow a faster identification of the module
concerned. The first field is an input description, the second, third and fourth
field define the module, byte and bit corresponding to the selected input
respectively.
62
ii.
F2 Axes
The keys and
of the cursor control pad allow to select the axis to be moved.
Axes shifting (JOGGING)
In the axes shifting, also called JOGGING, the axes are moved by means of
JOYSTICK on the control board. The movement is fast and the speed can be
controlled using F5 Speed option. The PC DT12 just displays the positions of the
axes, while the movement limits are entrusted to the limit stop of axes over-run.
!
You always move the axes in manual mode by only using the joystick. That is
you dont need any software function or option in manual menu to succeed
jogging operation. It is enough to be in manual menu. Simply use the joystick to
move the machine.
An axis on a limit stop of maximum run can be shifted in the opposite
direction only
63
iii.
F3 Move Axis
With the function 'F3 Move', the desired value is requested by an interactive
window and it refers to the currently selected axis (highlighted in red and shown
in the prevous picture). After entiring the desired position by numerical key, if
you press the pushbutton "Move" of the interactive window, the PC DT12 moves
the selected axis to the desired value.
iv.
It is not necessary to set the axes in order to move them by JOG.
Without setting, the displayed values could be wrong.
F4 Users Variables
64
The black left window is upgraded with the list of some user variables that are
displayed also in Automatic Menu during cutting. In this page the more
important are the ORIGIN variables that mean the virtual zero of the sheet.
While entering in Manual menu they are cleared and the user can change
them pressing the Button (Zero Point) on the control board. On pressing this
button, the NC reads the axis positions and use them as new virtual zero for the
sheet.
v.
F5 Speed
This window allows to control the speed. By means of the arrow keys it is
possible to increase/decrease the speed.
vi.
F6 Manual Cutting
This function allows to cut plates manually. When you press Manual Cutting
key, a pop up window will open. This window determines axes speed in manual
cutting opetration.
65
vii.
F7 XY Plate Rotation
This function allows the plates settled in wrong way to be parallelized to

machine coordinate system.
66
The left bottom side of window you can see a representation for this operation.
At first you must selects points in the plate by Joystick. Then confirm these one
after another points by F1 Confirm point key. After confirming every point by
one by, press F6 Confirm all points key. At that moment, a pop up window will
appear and shows new parameters for the plate references.
After completing cutting operation according to the rotated plate, DO NOT

FORGET reseting the created reference point. In order to do that press F6 Reset
plate rotation key. So the reference point will be set to the initial value
adjusted in Adjustment menu.
67
d. Automatic
This window includes not only the function keys of the Automatic but also
the list of PRG files available in the NC memory storage. These files are
called Part Programs and generated by direct writing or imported in the
NC memory storage from an external Floppy Disk. By means of the cursor
control keys (arrows) it is possible to select one of the available files and to
send it for execution or to display it graphically.
F1 : Execute
Program execution
F2 : User rotation
F3 : Graphics
Graphic display of the program
F4 : Copy Programs
It copies the Part Programs directly from floppy
F5 : Resume Program
It lets to resume a Part Program from the last step worked.
F6 : Tool Radius
It shows the table of the tools Radius ( Kerf ) .
F7 : Directory
Choice of Part Program directories
F12 :
Previous

68
a. F7 Directory
By means of the cursor keys it is possible to move in the directory tree (ENTER
allows to open the selected directory).
With the Up and Down Arrows Key it is possible to select a directory, then
press F1 to enable it as storage directory.
F1
OK
It enables the selected directory as directory storing Part Program
b. F2 User Rotation
F2
69
c. F3 Graphics
It is possible to have a graphic display of the selected Part Program.
The working surface of the machine with the pertaining values and all the
workings are displayed. It is not a CAD, but just a graphic aid for the display of
the PPs generated.
F1 :
Overall view
It executes the graphics by displaying the whole

working
F2 :
Scale up
F3 :
Scale down
It scales down the zoom
F4 :
Zoom area
It allows to scale up a part of the working
F5 :
Step by step
It executes the graphics one instruction at a time
F6 :
Tool Correction
F7:
Show work
It scales up the zoom
It executes the graphics with tool correction ( kerf ).
70
Back
F12 :
Since to implement the graphics the same functions of program

generation/control are enabled, the same geometric errors that would come out
during the program execution in Automatic are detected. Therefore the following
controls are active: axis limits, space occupied by tongs and, in case of active
tool correction, also the figure feasibility. It is a good test for the program
feasibility.
Even if some paths can be displayed incorrectly (in particular with the
ZOOM) because of numeric truncation, controls are executed with the
greatest numerical precision. So, badly displayed situations can be unreal,
while the errors signalled are real for the NC.
i.
F4 Zoom Area
It allows to zoom in on a selected area of the currently displayed graphics
71
ii.
F5 Step By Step
It allows the step-by-step execution (an ISO instruction at a time) of the graphics
of the selected program.
72
d. Graphic Colors
By pressing the Preference Graphic colors on the graphics window it is
possible to change the default colours of the graphics window.
Change
It allows to change the colour of the graphic element selected by

means of a colour interactive window
Preview
It implements the graphics with the current colours but doesn't save
any modification about them
OK
It implements the graphics with the current colours and stores the
current layouts on disk
Ondo
Resets the last change
73
e. F1 Execute
74
In this condition, if you press START the machine begins running the
program. While cutting the NC shows the line of the Part Program that is
active.. After the program execution, if you press START again the
execution restarts.
During the program running it is possible to interrupt the axes movement by
means of the button STOP on the console. This causes the stop on ramp on
the path and the call to the upper dead point of the torch. From this
condition it is possible to restart by pressing again the button START or to
abort the execution by F8. During the program running, the key F8 causes
the exit from the current window by generating an emergency request to the
axes checker and the consequent cycle abort.
The following function keys are active :
i.
F1
Simulated
It enables the simulating function of the machine
F2
Torch Blocking
Block the torch hight control
F3
Graphics
Graphic display of the program
F6
Oxy Parameters
Used for entering oxy cutting parameters.
F7
Tool Head Change Used for entering drill parameters.
F8
Previous
It terminates the automatic session and goes back to the previous

page
F6 Oxy Parameters
75
Oxy Preheat (msec)=Preheating time.

Propan Preheat(msec)= Time for enabling the preheat valve.
Oxy Torch Rise (msec) = This is the time for the oxy torch distance between the parts.
Oxy Torch Ignite (msec)= Time for igniting the torch after pressing the start button.
Ignite Valve Delay (msec)= Time for the ignition valve.
By pressing F3 go to the next page for additional parameters.

Oxy Torch Pierce (msec)= Time for piercing.
Oxy Torch Uptime(msec)= Piercing height.
Oxy Torch Regulation Delay (msec)= Time for enabling the capasitive sensor.
76
ii.
F7 Tool Head Change (Drill Parameters)
Timer clamp down (1=0.1 sec)= Time for the clamps.

Timer raise drill ( 1=0.1 sec)= Raising time for the drilling tool.
Timer drill down (1=0.1 sec)= Lowering time for the drilling tool.
Timer end work drill ( 1=0.1 sec)= Waiting time before raising the drilling head.
Timer first mov drill ( 1=0.1 sec)= Time for the first movement of the drilling tool.
Timer Quick Mov (1=0.1 sec)= Not used.
Timer oil drill (1=0.1 sec)= Not used.
Timer no oil (1=0.1 sec)= Not used.
iii.
F12 Previous
It allows to terminate the program running.
F12 Previous
If you confirm the termination of the current automatic session, the function of
go on program will be enabled.
77
78
iv.
F1 Go On
Sometimes, after an EMERGENCY or a RESET that caused the

automatic execution of a Part Program to be aborted, it is necessary to
restart this execution. This restart is possible, always within the automatic
session, by pressing the function key 'F1 Go on'.
The editor will display on the screen the Part Program and the last line
executed will be highlighted. So you must look for the previous G00
Instruction, select it and then press F8.
It is possible also to restart from a different piece scrolling up or down the
Part Program. You can restart only from a G00 Instruction, otherwise the
NC will prompt an error message.
F1
Input
It allows to insert additional ISO lines
F2
Reset
It reloads the original version of the program

(without any additional ISO line)
F8
Back
It runs the program from the selected line
79
v.
F1 Input
vi.
F1 Simulated
If this function is enabled, the machine starts to execute the Part Program without
cutting. It is useful for testing or jumping a piece already cut.
80
vii.
Error Page
The error page allows to display any active PLC error. For every active error, the
following information can be available:
error description (PLC error number and description)
position of component/s involved in the error
81
Detail
It displays the detail of the component/s involved in the

currently selected error
Help
It opens the on-line help at the PLC error page and it displays
the information about the currently selected error
F3
CNC log-file
It displays the NC error historical
F4
PLC log-filel
It displays the PLC error historical
F8
Close
It closes the error page
F1
F2
viii.
F1 Detail
It displays the detail of the component/s involved in the currently selected error.
ix.
F2 Help
It opens the on-line help (by means of Microsoft Internet Explorer) at the PLC
82
error page and it displays the information about the currently selected error.
x.
F3 CNC log-file
It displays the NC error historical.
xi.
F4 PLC Historical
It displays the PLC error historical
83
5. Program Archive ( Plasma ISO )
Press Ctrl+F2
The Program File application has the functions of
generation/replacement/maintenance of Part Program generated by both the NC
and the outside (CAD or another source).
Part Program, hereinafter called PP, means the programs in ISO language
written by the user. Some functions are available in AUTOMATIC (see the
pertaining chapter) with the same characteristics, but they will be treated with
full particulars in this chapter.
By entering this page, the list of PPs available in the machine and the active
function keys are displayed.
84
The left windows shows the current directory, the right one shows the list of
programs of the current directory; the bottom left window shows the current disk
and the bottom right one shows the currently selected file.
It is possible to scroll these lists by means of the vertical arrows and the
tabulation keys.
From this menu it is possible to access the following functions:
F1
New
Generation of a new file by editor
F2
Open
Opening of a selected file
F3
Delete
Deletion of a selected file
F4
Rename
F5
Copy
Copy of a selected file
F12
Exit
Exit from the Program File application
It change name to the selected file
85
a. F1 New
A new empty file with .PRG extension is generated.
b. F2 Open
In this page it is possible to choose whether to edit the previously selected Part
Program or to display its graphics.

F1 :
Edit
It changes the file by editor
F2 :
Graphics
It displays the file graphics
F8 :
Back
F1 Edit
In this page it is possible to edit the previously selected Part Program.

NB: according to the current terminology of Editors, "Block" means a group of
some lines.

F1
Go to
It allows to reach the specified line (no. of line)
F2
Change
It allows the modification of the current line
F3
Delete
It deletes the current line
F4
Insert
It inserts a new blank line
F5
Graphics
F6
Editing
F7
Find
It displays the program graphics

It enables the editing operations on text blocks
It finds a text string within the program
86
Back
F12
This editor is an easy instrument conceived to create small PPs or to

modify existing PPs; in this case, we recommend to keep a copy.
NB: All the operations of line insertion/deletion and Block insertion/deletion

modify the progressive numbering that automatically fits into the new situation.
F6 Editing
This page is dedicated to the management of text blocks within the PP.

F1
Select
It allows to select a block
F2
Copy
It stores the selected block
87
F3
Cut
It erases the selected block and stores it
F4
Paste
It pastes a previously stored block beginning from the current

line
F12
Back
F7 Find
This page is dedicated to the management of text block within the PP
6. Configuration Setting
The configuration setting application package allows to modify the different

interface parameters.
88
a. General
This table allows to define all the parameters of the user interface.
89
b. Syncro Files
This category allows to define:

the file of machine parameters to be used for the interface (it is possible to
choose among all
those available in the CFG subdirectory of the interface
directory);
the file of machine initialization to be used for the interface (it is possible to
choose among all those available in the CFG subdirectory of the interface
directory);
the eprom version used (so as to correctly display and manage the above
mentioned parameters).
90
c. Serial Port
This category allows to define all the configuration parameters of the PC serial
port used to connect to the Syncro.
91
d. ISO Parameters
This category allows to define all the parameters concerning the ISO compiler
for the generation of Part Program:
machine configuration (punching machine only);
ISO programming system A or B;
insertion of the ISO source instruction number in the compiled program so as
to be able to display the ISO instruction under execution during the program
execution;
insertion of the ISO source instruction in the compiled program for the
program generation control.
92
e. Error Codes of Syncro

System errors
The Synchro system errors are divided into the following typologies:
Executor's errors
Axis handler's errors
Executors errors
The control execution error codes can be displayed during the program
execution.
They can be identified by the following format:
00.XX.YYYY
00 = System Errors.
XX = Executor's Number
YYYY = Error coding
The Error Coding shows one of the following codes
.
Unknown instruction
Not implemented instruction
Instruction not admitted for immediate execution
Instruction not admitted in program execution
Inexistent program
Unavailable axis
Repeated axis
Axis not reset
Out-of-limit Axis Value
10
Moving axis
11
DIGITAL IO number not admitted
93
12
DIGITAL IO number repeated
13
Jog analog output value not acceptable
14
Speed value not acceptable
15
Acceleration value not acceptable
16
Instruction not admitted in interpolation
17
Axis not enabled for interpolation
18
Program in receiving phase
19
Program already opened
20
Out-of-limit X value linear interpolation
21
Out-of-limit Y value linear interpolation
22
Out-of-limit Z value linear interpolation
23
Z variation not admitted linear interpolation
24
X radius not admitted circular interpolation
25
Y radius not admitted circular interpolation
26
Too big working angle circular interpolation
27
Out-of-limit X value circular interpolation
28
Out-of-limit Y value circular interpolation
29
Out-of-limit Z value circular interpolation
30
Z variation not admitted circular interpolation
31
Not linear axis in interpolation X,Y,Z
32
Not polar axis in interpolation tangency
33
Too many polar axes in interpolation tangency
34
Out-of-limit polar axis value in interpolation
35
Program with wrong checksum
36
Not erasable program (LNC)
37
Wrong variable name
38
Interpolator already used
39
Interpolator not enabled

94
40
Direct control to slave axis
41
Control cannot be executed by master axis
42
Slave axis not admitted
43
Active slave axis
44
Wrong master/slave ratio
45
Missing Master axis
46
Scale factor not acceptable
47
Axis Value on Scale not acceptable
48
Control cannot be executed Axis on Scale
49
Acquisition of flying value not initialized
50
Unavailable flying value
51
Instruction not admitted in Interpolation Search
52
DAC number not admitted (available axis)
53
Synchronous axis
54
Program execution block timeout
55
Number of turned axes not admitted
56
Control cannot be executed on turned axis
57
Axis not turned in interpolation
58
Offset executors not congruent
59
Axis not in maintenance
90
Pressed stop
91
Pressed hold
92
Overtemperature
93
Interpolator error
94
Wrong machine parameters
95
Machine parameters checksum error
99
ALL_AXIS function not implemented
95
The following errors can be displayed during the execution preparation:
200
Unknown SBL control
201
Inexistent program
202
Too many programs sent: the maximum limit is 150
203
Insufficient storage for programs
204
Syntax error on SBL control
205
Radius tolerance error on CIR, CIL controls (for circular interpolation only)
206
Interpolation without previous source MOV (see SBL handbook)
207
Wrong program number (from 1 to 30000)
208
Missing executor
209
Executor in motion in program sending
210
Out-of-limit value
211
Variable in interpolation value
212
Control not accepted
213
Too big radius in circular interpolation
214
Program sending with wrong checksum
250
Busy executor for direct control
251
Executor's error during the execution in circular buffer
252
Reset hold by SPR control
96
Axis handlers errors
They can be identified by the following format:

01.XX.YYYY
01 = Axis Handler's Errors
XX = Axis Number
YYYY = Error coding
The Error Coding can take one of the following values.
Driver not ready
Axis against upper hardware L.S.
Axis against lower hardware L.S.
Max. tracking error exceeded
DAC ZERO offset max. compensation exceeded
Axis against upper emergency limit stop
10
Max. tracking error in interpolation exceeded
11
Timeout axis in tolerance
12
Out-of-limit axis positioning
13
Axis value overflow
14
Master/slave max. disalignment error exceeded
15
Flying value input switching alarm
20
Out-of-limit axis in interpolation
NB: "EXECUTOR" means one of the active tasks on the CAGE.
97
7. Maintenance and Inspectation
General maintenance and cleaning of the machine requires careful attention.

Therefore the machine must be shut-off before starting any maintenance work.
a. Types and Frequency of Inspectations
Inspectation
Grid replacement
Period
Responsibility
Four times a year
Operator
X axis rack-rail cleaning (Use iron

brush and compressed air)
Once a month
Operator
Y axis rack-rail cleaning (Use iron

brush and compressed air)
Once a month
Greasing (Lubrication) of the torch

support sliding blocks (Use F type
grease FD5, FD10, FD12)
Once a month
Operator
Operator
Y axis floating shaft support greasing

(Put grease on the bearing lubricators)
Once a month
Operator
X axis floating shaft support greasing

(Put grease on the bearing lubricators)
Once a month
Operator
Check the Torch

(Before starting cutting, check the main
body of the torch and spare parts are in
a good state. Check that there are no
burnings or color change on the torch
spare parts or demage)
Check the Torch and Plasma
generator cables.
(Against any burn, demage and wear)
Operator
Daily
Once a month
Operator
Once a month
-------
Plasma generator cleaning

(see related manual)
98
Check cooling fan in electric panel

against functionality
Daily
Operator
Twice a month
--------
Once a year
(It depends on
machined sheet and
amount of work)
Operator
Safety & limit switches against

loosening or damage
weekly
Operator
Terminal connections
of the electrical installation
Once a year
Qualified
electrician
Gas (hoses) connections against

loosening or damage
Daily
Operator
Cleaning Fume and dust filter

(see related manual)
Cleaning the exusting system
b. Troubleshooting
This part is organized as follows:

1. Problem is stated
2. List of causes
3. The solutions
Problem
Machine can NOT be
zero- referenced.
Possible causes
1. Torch protection sensor
is off.
2. One of the emergency
stop buttons is pressed.
Solution
1. a. Fix the torch in its
place
b. Check the
proxymities. ( Leds
must be lighting)
2. a. Check the
emergency
stop buttons.
b. See the inputs in
Manual menu. All
inputs must be
active. If
99
not, the buttons

would
not be working
properly
Manual Jogging can
not be done.
The first cause above. (in item

1)
Note: If a problem occurs in
torch protection sensor, the Z
axis can be moved upwards
manually.
Note1: Check inputs in
manual menu.
The following inputs must be
active.
A TIME OUT error

occurs in any axis
Programs can not be

copied from floppy
driver.
Using Resume
Program options, a
problem exists.
Programs can not be
seen
In automatic mode,
machine starts moving
before completing
piercing.
Servo drivers error
1. Floppy driver does not

work
2. Corrupted diskette
3. File extention is
different from PRG.
Change parameter Fn00A .

If error increases, decrease
the valu in that parameter.
1. Change floppy
driver
2. Change diskette
3. Ckeck file
extentions in
diskette.
You probably start the cutting

process from M codes.
Do not start cutting from

M codes
Wrong programs directory
Change the directory.
1. Wrong torch parameter

2. The contact in P10
relay in electrical
cabinet
1. Increase the OK TO
MOVE delay
parameter in torch
paramaters
2. Change the relay
100
In automatic mode,
machine waits too
much to move after
completing piercing
Torch crashes the plate
The plasma ark does

not fire
Wrong torch parameter
1. Wrong torch
parameters
2. Torch sensor does not
work
See the plasma generator

manual
Excess burns occurs
1. Exausting system
problems
2. Filter problem
Serial communication
error in PC DT12
control unit
1. Increase the Torch

adj.delay parameter
in torch parameters
2. Check Torch
sensor in torch
assembly

manual
The cut is interrupted
Plasma does not pierce

the plate
Decrease the OK TO
MOVE delay parameter in
torch paramaters
1. Exausting system
may be filled with
slags. Clean the
system
2. See Filtering
system manual

manual
1. Cable problem between
control unit and PLC
2. Parameter error
1. Check the serial

connection cable
2. Load default
initialize fle
(SYS42001.ini)
101
c. Conditions of storage, re-utilization and scrapping
a.
Storage:
In cases where the machine is not to be used for a long period of time, the
following precautions must be taken:
Disconnect electrical supply to the machine, and write so on the electric

panel as a reminder for future use.
The storage place of the machine must be indoor with protection against
humidity, dust, and danger of fire.
Lubricate the moving parts by an anti-rust lubricant.
Lubricate plastic hoses against cracking.
Cover the machine by a nylon cover for protection against dust.
b.
Re-utilization:
Take the following steps if the machine is to be reutillised after a long period of
storage:
c.
All electrical components must be checked by a qualified electrician to

make sure that all are properly functional. Replace the faulty components.
The machine body and mechanical parts must be checked through by an
authorised and qualified personnel, and the machine must be prepared for
operation according to the operating instructions.
Scrapping
When the machine completes its efficient operating life, it must be dismantled.
You must dispose of various materials in accordance with current local
regulations. In order to take the machine out of service, you must first isolate it
by disconnecting all power supplies to make sure that it is entirely safe. Ferrous
materials must be scrapped. Plastic materials must be disposed of by special
firms authorized to transport and dispose of these items according to current
local waste disposal regulations.
102
d. Lubrication
Bed assembly lubrication points:
Point 1,2,3 and 4 (see Figure- 26). Use F type grease FD5, FD10, FD12
Lubricate these points at least two times a month
Figure- 26
Beam carriage assembly lubrication points:
Point 5 and 6 (see Figure- 27). Use F type grease FD5, FD10, FD12
103
Figure- 27
Torch assembly lubrication points:
Point 7 and 8 (see Figure- 28). Use F type grease FD5, FD10, FD12
Point 9 ball bearing screw connected to z axis motor.
104
9.
Figure- 28
105
D. PRINCIPLES OF PLASMA CUTTING TECHNOLOGIES

Plasma:
"the fourth state of matter"
The first three states of matter are solid, liquid and gas. For the most commonly
known substance - water - these states are ice, water and steam. If you add heat
energy, the ice will change from a solid to a liquid, and if more heat is added, it
will change to a gas (steam). When substantial heat is added to a gas, it will
change from gas to plasma, the fourth state of matter.
Plasma definition
Plasma is an electrically conductive gas. The ionization of gases causes the
creation of free electrons and positive ions among the gas atoms. When this
occurs, the gas becomes electrically conductive with current-carrying
capabilities. Thus, it becomes a plasma.
Plasma in nature
One example of plasma, as seen in nature, is lightning. Just like a plasma torch,
the lightning moves electricity from one place to another. In lightning, gases in
the air are the ionization gases.
Cutting with plasma
Plasma cutting is a process that utilizes an optimized nozzle orifice to constrict a
very high-temperature, ionized gas so that it can be used to melt and sever
sections of electrically
conductive metals. The plasma arc melts the metal, and the high velocity gas
removes the molten material.
Figure- 29
106
Gas Selection
Selecting the proper gas for the material you are cutting is critical to get a quality
cut.
Plasma gas
Plasma gas is also called the cutting gas. Gas that is ionized in the plasma
process, exits through the nozzle orifice.
Examples
Air
Oxygen
Nitrogen
Argon-Hydrogen
Shield gas
The shield gas is the secondary gas in the plasmaprocess. It surrounds the arc and
is used to help constrict the arc and cool the torch. It creates the cutting
environment, which, among other things, affects the edge quality.
Shield gas
The shield gas is the secondary gas in the plasmaprocess. It surrounds the arc and
is used to help constrict the arc and cool the torch. It creates the cutting
environment, which, among other things, affects the edge quality.
Examples
Air
Air-Methane
CO2
Nitrogen
Oxygen-Nitrogen Methane
Selecting the right gas
Gas quality is critical for the proper operation of plasma arc cutting systems and
optimal cut quality. Any contaminates can cause misfiring, poor cut quality or
poor consumable life. Contaminates can be: gas impurities, moisture, dirt, piping
system contaminates or improper gases (ie. air in Og systems leaks, not
following proper purge procedures when changing gas).
107
GAS SELECTION CHART

System
HyPerformance
MAX200 &
HT2000
HT4001
HT4400
Material
Mild Steel
Plasma Gas
O2
Shield Gas
02&N2
Stainless Steel Air, H35 & N3
Air, Air & Methane, N3
Aluminum
Air, H35 & N3
CH4, N2
Copper
Mild Steel
02
02
O2 & N2
Air
Stainless Steel Air, H35
Air, N2
Aluminum
Air
Air
Mild Steel*
02
H20
Stainless Steel N2
H20
Aluminum
N2
H20
Mild Steel
O2
02&N2
Stainless Steel N2
02&N2
Aluminum
O2&N2
N2
O2 cutting is only for 340 amps maximum. Must use N2 for higher current.
Figure- 30
108
Cut Charts
Using cut charts
The cut charts in the instruction manual give all parameters needed to set
up your system to cut.
Flow rates should always be adjusted according to the cut charts, unless
additional notes section gives tips on adjusting to improve cut quality. It
may be necessary to adjust travel speeds and torch-to-work-distance/arc
voltage settings to optimize cut quality and system performance.
Following sections of this manual will instruct you how to make these
adjustments.
Purge gases for at least 1 minute after changing consumables and before cutting.
Figure- 31
109
Consumables
Installing consumables
Select consumable parts using the appropriate cut chart.
Install consumables using the tools provided in your parts kit. DO NOT
OVERTIGHTEN.
Lubricate all consumable 0-rings with silicone grease that is provided in
the consumable parts kits. Do not over-apply, only a thin film is needed.
Apply the lubricant to your fingers (only enough to glisten) and then
lubricate 0-rings.
Electrodes and nozzles should be replaced as a set. Swirl rings should be
replaced when necessary, usually every 5-10 electrode/ nozzle changes.
Shields, retaining caps, etc. only need replacing when they are physically
worn or when cut quality becomes poor.
Protect your investment: use only genuine Hypertherm parts.
110
Figure- 32
111
Recording Consumable Life
Recording consumable life is an important task that should be done each

time consumables are changed.
With records like this, you will easily see when you are having a
consumable life problem, which will aid in effective troubleshooting.
Consumable Life
In addition to proper set-up and operation, consumable life can be increased by

following these steps:
The average life of the consumables is dependent on the number of pierces and
length of cut. Consumable life is not solely gauged by the number of pierces.
See graph below.
Figure- 33
112
i.
Pierce Height
Proper pierce height is critical for long consumable life, cut quality and to avoid
misfiring.
Pierce height should be 1.5-2 times the torch cut height.
Piercing too close to the plate will cause blow-back slag to enter the
torch. This will cause consumable damage and possibly damage the
torch.
Piercing too high will cause excessive pilot arcing. This will cause
excessive nozzle wear.
If you are using the Hypertherm Command THC, review the instruction manual
for more information on piercing and some of its features that will reduce
consumable damage.
ii.
Reducing Errors
Reducing errors will add considerable life to your consumables. Errors

are generally caused by not starting and/or stopping the cut on the plate or
running the
arc off the plate. This interrupts the Longlife process.
Every error equals approximately 10-15 pierces on most systems. The
HPR_260 is more sensitive to errors; each error equals more than 15
pierces.
Errors should be less than 10% of the number of pierces.
113
Cut Quality
Reading the Cut
There are four basic measurements used to determine good cut quality:
Bevel Angle
Dross Levels
Appearance of Cut
Lag Lines
(Mild Steel O2 cutting only)
The adjustments that the operator can make to improve these qualities are:
Torch Height or Arc Voltage
Cut Speed
Remember: the cut charts are the place to start, but cut speed and torch height
may need to be adjusted on some materials.
Bevel Angle
By increasing or decreasing the height of the torch, the bevel angle can
be changed.
This is done by adjusting the Arc Voltage setting on plasma systems
with arc voltage
torch height control (THC). If the plasma system is not equipped with
THC, then it
must be manually adjusted.
If the angle is not equal on all sides of a cut part, then the torch may not
be square to the plate and will need to be adjusted.
Figure- 34
114
Decreasing Dross (Slag)

Top dross
Splatter appears on the top edge of both pieces of the plate. Lower the voltage in
increments of 5 volts (maximum) until top dross disappears. Usually only seen
with air plasma.
High-speed dross
Fine, roll-over dross that welds to bottom edge.Cleaning requires chipping or

grinding. Reduce cut speed to decrease high-speed dross.
Low-speed dross
Globular dross that forms in large deposits. Comes off very easily, in large
pieces. Increase cut speed to decrease low-speed dross.
Figure- 35
115
More on dross
Some types of metal inherently cut with more dross than others. Some of
the more difficult plates and treatments are:
High carbon content
Shot-blasted plate
Cold-rolled steel
Clean metal surfaces

Aluminum
Warm or hot metal
Some of the easier types are:

Hot-rolled steel
Oil-pickled steel
If plate has an oily, scaly or rusty surface, cut with this side down.
A water muffler or underwater cutting will tend to increase dross levels.
Appearance of Cut
When cutting metals besides mild steel with O2, lag lines are not a good
indicator of
cut speed.
Bevel angle, dross levels and appearance of the cut must be factored
together. The
smoothness or roughness of the face and the dross levels will determine
correct speed.
Concave cut face is due to torch-to-work distance being too low or
consumables are worn.
Convex cut face is due to torch-to-work being too high or consumables
are worn.
Figure- 36
116
Reading Lag Lines

Mild Steel, 02 cutting only
Using the lag lines of a cut are an excellent way to determine proper cut
speeds.
The lines should generally trail the cut by approximately 10-15 degrees.
When the lines are more vertical, the speed is too low.
When the lines are more trailing, the speed is too high.
Figure- 37
117
Effects of Cutting Speed on Arc Voltage
As cutting speed increases, arc voltage decreases and vice versa.

Cutting speed changes:
When going in and out of corners*
At beginning and end of a cut*
When cutting circles and contours*
Reaction of THC
Torch will dive as speed decreases**
Torch will rise as speed increases**
*This will cause dross in corners and contours.

**THC must be turned off or "Locked Out" when speed decreases.
Figure- 38
118
Cutting Direction
Due to the swirling action of the plasma gas, one side of the cut will
always have a bevel angle. This is called the "bad side" of the cut.
In order to get the minimum amount of bevel on your production pieces,
the torch must travel in the proper direction. The "good side" is on the
right as the torch is traveling away from you. Refer to picture.
The swirl direction can be reversed, by using different swirl rings on
some models to achieve the opposite results (Used for cutting mirror
image parts).
Figure- 39
Clockwise: Cutting outer boundary of part. Part falls out.

Counter-Clockwise: Cutting inside hole. Scrap falls out.
119
Cutting Holes
Cutting internal holes can be very difficult with plasma. The minimum
hole size, assuming excellent motion control characteristics are:
HyDefinition(O2 on mild steel)
1
/8" (3 mm) plate and less: 3 /16 (4,7 mm)
Above 1/8" (3 mm): 1.5 times material thickness
Conventional (O2 on mild steel)
3 to 12.7 mm plate: 2 times material thickness
Above 3 mm: 1.5 times material thickness
For best results:
Turn THC off.
Reduce speed.
Make lead-in perpendicular to side.
Minimize lead-out. Only enough for part to drop out
Figure- 40
120
E. ELECTRIC CIRCUIT DIAGRAM
121
122
123
124
125
126
127
128
129
130
131
132
133
134
135
136
137
138
139
140
141
F. SPARE PARTS
142
143
G. APPENDIXES
APPENDIX A: ISO Programming
Structure of Iso Programs
Introduction
The ISO programs known by NC need some rules. The block syntax is explained in the
Manufacturer's handbook. Hereinafter we severally give some information about the
writing of an user's ISO file.
We want to stress that some rules are automatically complied with by the NC on the file
creation:
the first line of every file is the string "(PROGRAM START)" and the last line is the
string "(PROGRAM END)" (they are identified by character '%' in the file);
the first useful line must include character "O" followed by the program number;
Ex.: O100
it is possible to insert some commentary lines (in round brackets) between the program
number and the beginning of the ISO instructions (for instance the program name);
Ex.: (PLASMA)
the program lines are automatically numbered.
G Functions
G00
Start cutting point
G01
Linear interpolation
G02
Clockwise circular interpolation
G03
Counter-clockwise circular interpolation
G40
Deletion of tool radius compensation
G41
Tool radius compensation to the profile left
G42
Tool radius compensation to the profile right
G52
Change Origins
144
G70
No cutting movement
G90
Absolute programming
G91
Incremental programming
M Functions
M00
Stop Program
M02
End Program
M17
Plasma Down
M18
Plasma Off
M19
Plasma On
M20
Plasma Up
M75
Disable THC (Torch Height Control )
M76
Enable THC (Torch Height Control )
M98
Call Subroutine
M99
End Subroutine
145
G Codes Programming
Rapid positioning followed by a start of cutting

G00 X <q> Y <q>
q : values of axes expressed in mm
G00
G00 is a modal code and it keeps active until the next programming of a
positioning instruction. If it is combined with G70 no cutting is executed after the
positioning.
Linear interpolation
G01
G01 X <q> Y <q> F <s>

s : interpolation speed expressed in thousand of mm per minute
G01 is a modal code and it keeps active until the next programming of a
positioning instruction. It is necessary to program the value of at least an axis.
146
Circular interpolation
G02 X <q> Y <q> I <q> J <q> F <s>
G02 X <q> Y <q> R <q> F <s>
s : interpolation speed expressed in thousand of mm per minute
G02
G03
G02 and G03 are modal code and they keep active until the next programming of
a positioning instruction.
G02 clockwise circular interpolation
G03 counter-clockwise circular interpolation
They cause the generation of an arc or a whole circumference beginning from the
current position of axes until the position identified by X and Y coordinates. I
and J center coordinates are given as incremental distances from the
corresponding X and Y starting positions.
Deletion of tool radius compensation

G40 D0.
G40
This code cancels the tool radius compensation previously programmed by G41
and G42 codes.
Tool radius compensation to the path left

G41 D <n>
G41
n : it identifies the tool radius from the tool radius table

This code enables the tool radius compensation to the left of the programmed
path.
147
Tool radius compensation to the path right

G42 D <n>
G42
n : it identifies the tool radius from the tool radius table

This code enables the tool radius compensation to the right of the programmed
path.
Change origins
G52 X <q> Y <q>
G52
q: offset axes in mm
This command changes the values of next movement
Absolute programming
G90
Instruction G90 enables the absolute programming. The values expressed in

every instruction after G90 are interpreted as absolute values compared to the
program zero.
Incremental programming
G91
Instruction G91 enables the incremental programming. The values of every

instruction are added to those of the previous instruction for every axis. To go
back to the absolute programming (default) it is necessary to use the instruction
G90
Meaning of M Functions
Program stop
M00 This function allows the program execution stop so as to allow the operator to
intervene in the working cycle.
The program execution will restart after pressing the CYCLE START
148
pushbutton
Program end
M02
M30
This function causes the program end and the turning off of the CYCLE ON
light.
Down Plasma
M17
It forces the movement down of the torch
Plasma Off
M18
It set off the plasma
Plasma ON
M19
It set on the plasma
Up Plasma
M20
It forces the movement down of the torch
Disable THC
M75
It is used when cutting without the control of height of the torch. For example it
is useful to stop THC at the beginning and end of cutting a piece.
149
Enable THC
M75
It enables THC that is the default.
M98
Call Subroutine
M98
Followed by the name of a subroutine, it means the jump to the subroutine.
End Subroutine
M99
It means the return from the subroutine to the main program
Example of ISO program

This example is purely as an indication.
%
O9178
G90
G100 X2500 Y8000 Z10
G177 X6 Y3 Z130
G199 X300
G52 X0 Y0
M06 T1
G00 X1793.51 Y7007.07
M17
M19
G03 X1800.0 Y7001.0 I6.49 J0.43 F1900
G01 X2001.0 Y7001.0
G01 X2001.0 Y-1.0
G01 X-1.0 Y-1.0
G01 X-1.0 Y7001.0
G01 X1800.0 Y7001.0
150
G03 X1804.48 Y7005.09 I-0.0 J4.5

M18
M20
M30
%
151
APPENDIX B: Cut Charts
152
153
154
155
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157
158
159
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161
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USER MANUAL

PLASMA CUTTING MACHINE

MODEL BPL-H 3006

GENERAL MACHINE INFORMATION ................................................................................................. 5

Safety Features of Your Plasma Machine ....................................................................................................... 6

Important Safety Information and Instructions ............................................................................................. 8

Overall Drawing of the Machine .................................................................................................................. 14

Lifting and Transportation ........................................................................................................................... 14

Unpacking and Installation .......................................................................................................................... 16

OPERATING AND MAINTENANCE INSTRUCTIONS ..................................................................... 20

Technical Data .............................................................................................................................................. 20

Main Part ..................................................................................................................................................... 20

PC DT12 Control Unit .................................................................................................................................... 21

Hypertherm HPR_260 Plasma Power Supply ............................................................................................... 22

Filtering System (Optional) ........................................................................................................................... 26

CAD Software (Lantek Expert II Cut Plus) ..................................................................................................... 27

OPERATING THE PLAZMA CUTTING MACHINE .......................................................................... 29

Electrical Connection .................................................................................................................................... 29

Using the Machine and Operating Software ................................................................................................ 36

Using the Machine ....................................................................................................................................... 39

Control Software .......................................................................................................................................... 54

F1 Zero Search .......................................................................................................................................... 59

Configuration Setting ................................................................................................................................... 88

Maintenance and Inspectation .................................................................................................................... 98

Program Archive ( Plasma ISO ).................................................................................................................... 84

PRINCIPLES OF PLASMA CUTTING TECHNOLOGIES .............................................................. 106

ii. Reducing Errors .................................................................................................................................. 113

ELECTRIC CIRCUIT DIAGRAM ........................................................................................................ 121

SPARE PARTS ............................................................................................................................................ 137

APPENDIXES .......................................................................................................................................... 144

APPENDIX A: ISO Programming ......................................................................................................................... 144

A. GENERAL MACHINE INFORMATION

Baykal Mak. San. ve Tic. A..

Plasma BPL-H 3008

Address Of The Authorized Dealer

1. Safety Features of Your Plasma Machine

Emergency switches operate to stop the machine in emergency and have to be

The green light lights up when the machine is working.

2. ON position (1 position): when the switch is on this position the console

2. Important Safety Information and Instructions

Ventilate potentially flammable atmospheres before cutting

Do not cut pressurized cylinders, pipes, or any closed container

Do not cut containers that have held combustible materials

work in or near a damp area, use extreme caution.

Inspect and replace any worn or damaged torch leads.

the cutting process.

Never bypass or shortcut the safety interlocks.

Before removing any power supply or system enclosure cover, disconnect

allow capacitors to discharge.

When making input connections, attach proper grounding conductor first.

Each Hypertherm plasma system is designed to be used only with specific

present a safety hazard.

Do not cut in locations near degreasing, cleaning or spraying operations. The

A plasma arc can cause injury and burns.

Keep away from the torch tip.

Do not hold metal near the cutting path.

Never point the torch toward yourself or others.

Use eye protection in accordance with applicable national or local codes

Gauntlet gloves, safety shoes and hat

Flame-retardant clothing to cover all exposed areas.

Cuffless trousers to prevent entry of sparks and slag.

Remove any combustibles, such as a butane lighter or matches, from your

Warn others not to watch the arc. Use placards or signs.

Tighten all electrical connections to avoid excessive heating.

* For more information See related manual.*

* For more information See related manual.*