INOVA Torch Height Control System
Contents
1. 2 3 Mechanical Installation Gav aaa du 2 3 Electrical Installations hs TR Ge i 2 4 Voltage Divider Installation 1 2 5 KALIBURN SR 45i Voltage Divider Installation 2 6 KALIBURN SR 100i Voltage Divider 2 7 Preliminaty Ee 2 8 Section 3 Operation atout dodo eet 3 1 Operalins CODO eb Ato e adea ec 3 1 LED P ncllofls 3 1 Pres C Ut SEDID 3 2 cedet 3 3 Section 4 Troubleshooting 27 sse 4 1 Voltage Divider sales 4 3 Section 5 Maintenance do ope 5 1 General 5 1 ATC Control Console idv rr eda qai AE ps il at ud 5 1 ATE POSION IE DAG tea goat anda ee einen ae red eh GN 5 2 Section 6 Parts List aoo tee edito emet 6 1 Control onsole socie 6 1 Positioner Optional 6 3 ING Cable M M 6 5 as i S2. 216 7 50 191 1 56 14 50 13 9 50 241 10 63 270 Figure 1 1 Control Console Mounting Dimensions 1 2 Specifications Voltage Divider Stock Number iio ose 730003 Height 1 75 45 mm 3 75 95 mm ERE 2 4 61 mm Weight 2 5 oz 1 kg Division 1 20 7 3 75 95 i 5 CHASSIS 2 00 51 O GROUND SIGNAL WIRE 20 5 P S SIGNAL User s Manual 75 19 2 80 71 2 40 Note Overall height is 2 00 51 mm including standoffs and components Figure 1 2 Voltage Divider Mounting Dimensions 1 3 61 Specifications ATC User s Manual Positioner optional Stock Number sags 730015 e naa 24 in 610 mm IGI 4 5 in 114 mm BESES 4 5 in 114 mm Weight 18 Ib 8 1 kg iicet M M VM c 10 in 254 mm aute 18 Ib 8 1 kg Positioning Speed 40 in min 1016 mm min TOP VIEW 8 8 224 2 90 74 MOUNTING BAR INSTALL BAR REAR CHANNEL OF POSITIONER 2 5 16 BOLT 8 MM Gen wo 6 00 152 Mounting Dimensions Without Safety Mount Torch Clamp Size Dimension
3. 900321 900323 900313 710023 700018 900310 900308 700024 700275 700223 700285 700017 700033 700235 700034 700290 1 ONO ONO ON DPN RB RB RN NR BAR motor Spring Brake washer Retaining ring Bearing housing Ball screw bearing assembly Track bearing Carriage plate Eccentric journal 3 8 24 lock nut Track rod Positioner cover Motor plate Spring Motor coupling Brake plate Bearing Top plate Bearing screw coupling Extrusion Screw shaft bushing 1 4 28 lock nut Precision bolt Carriage adaptor 3 8 16 X 1 2 set screw Ball screw nut Bearing clamp Bottom plate Torch clamp 1 3 8 Torch clamp 1 3 4 Torch clamp 2 Torch clamp 2 1 4 Relcon safety mount optional Relcon mounting package 1 3 8 Relcon mounting package 1 3 4 Relcon mounting package 2 Relcon mounting package 2 1 4 6 3 Parts List User s Manual lan WV 8 02 68 Figure 6 2 ATC Positioner 6 4 Parts List User s Manual NC Cable Assembly 711059 AMP PLUG P N 709016 LE EUN SOCKETS P N 709018 E rs STRAIN RELIEF P N 709015 ni 115VAC Black 115VAC White Belden 19129 or Alpha 1952 3 conductor 18 AWG Ground Corner
4. A Dimension B 1 3 8 4 86 123 7 39 188 1 3 4 5 07 129 7 55 192 2 5 17 131 7 65 194 2 1 4 5 30 135 7 90 201 Mounting Dimensions With Safety Mount Torch Clamp Size Dimension A Dimension ALL 7 53 191 10 01 254 Figure 1 3 Positioner Mounting Dimensions 1 4 Specifications ATC User s Manual Torch Mounting Options for use with KALIBURN positioner only 1 1 3 8 Torch Clamp PN 700024 2 1 3 4 Torch Clamp PN 700275 3 2 Torch Clamp PN 700223 4 2 1 4 Torch Clamp PN 700285 5 Relcon Safety Mount PN 700017 use with one of the packages below 6 1 3 8 Relcon Safety Mount Package PN 700033 Consists of Relcon torch clamp 1 3 8 PN 700213 b Relcon clamp PN 700211 c All mounting hardware 7 1 3 4 Relcon Safety Mount Package PN 700235 Consists of a Relcon torch clamp 1 3 4 PN 700234 b Relcon clamp PN 700211 c All mounting hardware 8 2 Relcon Safety Mount Package PN 700034 Consists of a Relcon torch clamp 2 PN 700212 b Relcon clamp PN 700211 c All mounting hardware 9 2 1 4 Relcon Safety Mount Package PN 700290 Consists of a Relcon torch clamp 2 1 4 PN 700266 b Relcon clamp PN 700211 c All mounting hardware 1 5 Specifications User s Manual Features Arc Voltage Control AVC During the plasma cutting process the ATC provides arc voltage control to maintain the proper torch height The desired arc vo
5. Belden 8777 or Alpha 6010 5 pair 22 AWG Socket Location Color Function 1 Black 115 Black 2 Green Ground 4 White 115 White 5 Black Corner ground 6 Red Corner signal 8 Black AVC ground 9 Green AVC signal Notes 1 2 3 Corner function requires normally open contacts that close to freeze height in corners AVC function requires normally open contacts that close on main arc transfer to activate arc voltage control For stand alone units the NC cable is supplied by the customer AMP connectors and sockets provided by KALIBURN Figure 6 3 NC Cable 6 5 Parts List User s Manual Motor Cable Motor Cable For KALIBURN Positioner Assembly 711058 STRAIN RELIEF PN 709023 STRAIN RELIEF PN 709015 LL AMP PLUG PN 709022 AMP PLUG PN 709016 SOCKETS PN 709018 SOCKETS PN 709018 Socket Location Color Function Socket Location 1 Black Down 1 2 Green Up 2 3 White 115VAC Black 3 4 Key 3 Motor Cable For Other Positioners Belden 19129 or Alpha 1952 3 115VAC 3 conductor 18 AWG White Black ip LIFTER MOTOR GREEN ES AMP PLUG P N 709022 24 240 SOCKETS P N 709018 2 WHITE STRAIN RELIEF P N 709025 3 BN BLACK DOWN 1 Socket Location Color Function 1 Black Down 2 Green Up 3 White Motor Common Notes 1
6. When using the ATC without up down switch the up and down outputs from the ATC are connected to the up down switch on the cutting machine 2 Cable supplied by customer AMP connectors and sockets provided by KALIBURN Figure 6 4 ATC Motor Cable 6 6 Parts List User s Manual Voltage Divider Cable Assembly 711061 STRAIN RELIEF PN 709023 AMP PLUG PN 709022 SOCKETS PN 709018 Socket Location Color Function 1 Black Signal 4 Red Signal 3 Key Notes 1 The Signal and Signal connections are connected to the KALIBURN voltage divider fast on terminals 2 For stand alone units the voltage divider cable is supplied by the customer AMP connectors and sockets are provided by KALIBURN Figure 6 5 ATC Voltage Divider Cable 6 7 Parts List User s Manual Signal Ground Wire Assembly 711060 CONNECT TO WORK TABLE 56 C STAR GROUND FORK TERMINAL P N 709075 GREEN 10 AWG Notes 1 Signal ground wire is connected between the Star Ground terminal on the rear panel of the ATC control console and the star ground point on the cutting table 2 For stand alone units the signal ground wire and fork terminal are supplied by the customer Figure 6 6 ATC Signal Ground Wire Hook up Kit Stock Number 730001 Part Number Quantity Description 709018 15 Socket 709022 2 Plug 4 position 709023 Strain relief 4 position 2 709016 1 Pl
7. found at the end of this section Check the wiring between the voltage divider and the ATC control console The relay contacts that activate the AVC input are closed 2 Replace Opto 2 on the p c board 3 Replace the ATC p c board 1 Replace Opto 1 on the p c board 2 Replace the ATC p c board 1 Thumbwheel voltage set too high Perform the voltage divider check out found at the end of this section Replace the thumbwheel assembly 4 Replace the ATC p c board Replace the AVC Delay potentiometer Replace the p c board 4 2 Troubleshooting ATC User s Manual Voltage Divider Check Out Perform the following steps to test the voltage divider for proper operation Do not connect voltmeter to the power supply output until after the cutting has transferred to the workpiece and the high frequency circuit has deenergized The high frequency arc starting circuit will destroy digital voltmeters 1 Apply power to the ATC cutting machine and plasma power supply 2 Place the ATC Auto Manual switch in the Manual position and manually lower the torch to the proper cutting height 3 Program a 6 X 6 square and depress cycle start on the N C machine 4 After the cutting arc transfers to the workpiece measure the d c voltage between P S and P S on the voltage divider p c board inside the plasma power supply 5 Now verify that d c voltage between Signal and Signal is 1 20 of the vol
8. plasma arc cutting system Please see the plasma power supply manufacturer s operating manual for information on eye skin and hearing protection as well as other information required to safely operate the equipment ATC System Components The ATC System consists of the following components ATC Control Console ATC Voltage Divider System Manual ATC Torch Positioner complete systems only Torch Clamp complete systems only Interface Cables complete system only Hook up Kit stand alone systems only see Section 6 for details Torch Safety Mount optional 1 1 Specifications ATC User s Manual Specifications Control Console Stock Number SSe Ta tes epi uo rande 732001 Stand alone with up down switch 732001 Stand alone without up down switch 730010 Input Power os 115V AC 50 60Hz Input Current S e M Tesis bier Poems Amp nny nte p tse oa eU as 3 5 in 89 mm Width 10 63 270 mm Depth 8 5 in 216 mm 5 Ib 2 26 kg Arc Voltage Range oo secet edi diee ts 50 200 volts Control Accuracy eter 3VDC 1 PWR uP VOLTAGE 1 3 4 3 57 91 UP AUTO AVC DELAY ATC Y DOWN MAN MIN MAX AN i 4 188 4 8 8 5
9. when cutting too fast or when excessive power is used to cut a given plate thickness 2 A negative cut angle top dimension of piece larger than the bottom dimension usually occurs when the torch standoff distance is too low or when the cutting speed is too slow 3 Top dross usually occurs when the torch standoff distance is too high 4 Bottom dross usually occurs when the cutting speed is either too slow slow speed dross or too fast high speed dross Low speed dross is easily removed while high speed dross usually requires grinding or chipping off 5 Note that different material compositions have an effect on dross formation 3 3 This page intentionally left blank Troubleshooting ATC User s Manual Section 4 Troubleshooting The following chart lists general troubleshooting guidelines for the ATC system Please contact KALIBURN technical support for any issues not covered in this section Before any tests are performed make sure the two system fuses are good Both fuses are located on the rear panel of the control console Also check the power PWR LED on the front panel of the control console Problem Possible Cause Solution No automatic voltage control AVC 1 motor fuse blown while cutting 2 Manually raise and lower the torch with the inch up down switch on the control console to verify that the positioner is operational 3 Auto manual switch is in the manual position 4 Remove the top cover of t
10. 0i and drill four holes in the upper left corner of the inside back panel for voltage divider installation See Figure 1 2 for voltage divider mounting dimensions 2 Remove the paint around the lower left hand voltage divider mounting hole This will provide a chassis ground point for the white ground wire on the voltage divider 3 Install the voltage divider with the 4 6 32 X 3 8 screws provided Orient the board so the white ground wire is on the left Mount the white ground wire under the stand off leg where the paint was removed 4 The SR 100i has built in wiring harness for a voltage divider Each of the wires has a label indicating where it is to be connected Note that all of the wires will not be used with the height control Connect the Signal Signal P S and P S wires to their respective terminals on the voltage divider 5 Ifthe voltage divider cable supplied with the ATC has fast on terminals on the power supply end it will have to be modified with a plug and strain relief part numbers 709022 amp 709023 and four sockets part number 7709018 Cut off the four fast on connectors and wire the plug as follows Signal Pinl Signal Pin 4 Now connect cable to the outside of the SR 100i at the P7 plug 2 7 Installation User s Manual Preliminary Test After all of the wiring and interconnecting cables have been installed the system may be checked for proper operation Please use the
11. ATC User s Manual ATC Automatic Torch Height Control System Revision 7 5 16 07 Manual Part Number 718006 KALIBURN 455 Fleming Road Charleston SC 29412 USA 800 252 2850 Toll free 843 795 4286 Phone 843 795 8931 Fax www kaliburn net This page intentionally left blank User s Manual Limited Warranty KALIBURN expressly warrants that this product shall be free from defects in materials and workmanship under proper and normal use for the intended function of such equipment for a period of one 1 year This product is intended for commercial use and is not intended for personal family or household purposes There are no warranties which extend beyond the description on the face hereof All other warranties either expressed or implied including any implied warranty of merchantability or fitness for any particular purpose are expressly excluded If this product or any component thereof is determined to be defective in manufacture KALIBURN will repair or replace the defective component or product The buyer s remedies are limited to the return of the product for repair or replacement of any non conforming product or part at the sole discretion of KALIBURN No freight charges of any kind are covered under this warranty All returned goods shall be at the buyer s risk and expense Beyond this remedy KALIBURN will not be responsible for any special incidental or consequential damages or i
12. D s illuminated ATC inch up down switch 2 Remove the top cover of the ATC control console and replace Opto 1 on the p c board 3 Replace the ATC p c board 4 1 Troubleshooting Torch dipping in corners while cutting Torch moves upward on main arc transfer Torch moves upward when 115 VAC is applied Torch moves downward when 115 VAC is applied voltage control is operational but the torch stand off distance is extremely high No arc voltage control delay 1 2 Faulty voltage divider 2 Faulty voltage divider ATC User s Manual Remove the top cover of the ATC control console Program a 6 X 6 square While looking at the corner LED LED2 on the p c board make a cut In each of the corners the LED should momentarily illuminate If the LED does not illuminate check the corner height freeze relay in the numerical control The contacts should be normally open and should close in the corners If the relay is working properly check the N C cable for open wires If the cable is good replace the p c board If the LED remains illuminated during the cut and turns off in the corners the normally closed contacts in the numerical control are being used and should be changed to the normally open set of contacts Check the Signal Ground connection to the ATC control console The Signal Ground wire must be connected to the star ground on the cutting table Perform the voltage divider check out
13. R This LED is located on the front panel of the ATC console When illuminated it is a visual indication the 115 VAC has been applied to the console See Figure 3 1 Arc Voltage Control AVC The ATC system has two AVC LED s One is located on the p c board inside the control console and is designated LED1 This LED illuminates to indicate that the AVC input to the ATC system has been activated The other AVC LED is located on the front panel of the control console The front panel LED illuminates to indicate that the AVC delay timer has elapsed and arc voltage control has been initiated See Figure 3 1 Up Down These LED s are located on the front panel of the control console and illuminate whenever there is an AVC output to move the torch up or down See Figure 3 1 Corner This LED is located on the p c board inside the control console and is designated LED2 This LED illuminates to indicate that the corner height freeze input to the ATC system has been activated When illuminated arc voltage control mode is disabled See Figure 3 1 3 1 Operation User s Manual PWR UP VOLTAGE 119 21410 UP AUTO AVC DELAY O O DOWN MAN MIN MAX Figure 3 1 ATC Control Console Pre Cut Setup Before making a cut with the ATC system perform the following setup sequence to ensure proper operation 1 Program the corre
14. S lt lt tran 1 39vL10A K lt nos lt lt 1 0 l l 8 lt lt lt 8 ONO 7 OAV L d K 6 9 l K lt lt lt G 2NO uanu00 KX lt lt 9 9NO l l K lt NMOG lt lt L MLN l Z Zd KS ESS l K Hros lt lt 81 9 X OVASLIL l K lt 1 OVASL IL lt Z ONOD NYD 4 Figure 7 4 ATC System Schematic Consoles Without Up Down Switch
15. VAC to 230VAC at 3 amps Refer to Figure 6 4 for details Signal Ground Wire This wire provides the arc voltage control reference information It must be connected to the star ground point as described above It is extremely important that the Signal Ground Wire and the plasma power supply work ground lead are both connected to the star ground point The Signal Ground Wire is not a safety ground It is part of the voltage feedback circuit used for arc voltage control See Figure 6 6 for further information Voltage Divider Cable This cable connects the ATC console to the voltage divider printed circuit board located in the plasma power supply Refer to Figure 6 5 for cable details See below for specific hook up information 2 4 Installation User s Manual Voltage Divider Installation General 1 WARNING TURN OFF ALL POWER BEFORE WORKING ON EQUIPMENT The voltage divider connections to the plasma power supply are important The proper connection reduces high frequency noise picked up by the voltage divider The voltage divider provides a feedback signal that is derived from the actual cutting arc voltage of the plasma power supply The ATC control uses this feedback signal to control the cutting height of the torch The voltage divider used in the ATC supplies a 20 1 signal This simply means that a cutting voltage of 100 volts results in a signal of 5 volts provided to the control The power supply positive P S an
16. ct arc voltage for the material being cut Refer to the plasma power supply operation manual for cutting parameters Place the Auto Manual switch in the Auto position Manually lower the torch to the correct pierce height Set the AVC Delay potentiometer to minimum If necessary this can be changed at a later time Place the Auto Manual switch in the Auto position Manually lower the torch to the correct pierce height Initiate a cycle start on the cnc machine After the main arc transfers to the workpiece the AVC LED on the front panel should illuminate indicating that the arc voltage control mode has been activated The AVC LED should remain illuminated throughout the cut but should momentarily extinguish in the corners indicating that the corner height freeze input has been activated 3 2 Operation ATC User s Manual Cut Quality Before the optimum cutting condition can be achieved on a particular material type and thickness the machine operator must have a thorough understanding of the cutting characteristics of the plasma system When the cut quality is not satisfactory the cutting current speed or torch height may need to be adjusted until the proper cutting condition is obtained The following guidelines should be useful in determining which cutting parameter to adjust 1 A positive cut angle top dimension of piece smaller than the bottom dimension usually occurs when the torch standoff distance is too high
17. d power supply negative P S connections on the voltage divider should be connected to the proper output points of the plasma power supply In general if the power supply used has chopper control the connections will be made at the output of the power supply If the power supply used is a drooping type power supply and only has a diode bridge then the connections will be made directly to the diode bridge The ATC voltage divider cable connects to the signal positive Sig and signal negative Sig connections on the voltage divider The 20 1 feedback signal is sent to the ATC control console via these two connection points Refer to the appropriate section for specific voltage divider installation for the plasma system you are using Voltage divider installation instructions are given for the following plasma cutting systems KALIBURN 5 451 KALIBURN SR 100i 2 5 Installation ATC User s Manual KALIBURN SR 45i Voltage Divider Installation WARNING TURN OFF ALL POWER BEFORE WORKING ON EQUIPMENT 1 Remove the back panel of the SR 45i and drill four holes in the upper left corner of the inside back panel for voltage divider installation See Figure 1 2 for voltage divider mounting dimensions 2 Remove the paint around the lower left hand voltage divider mounting hole This will provide a chassis ground point for the white ground wire on the voltage divider 3 Install the voltage divider with
18. following procedure 1 2 Make sure that all power to the plasma power supply is off Apply 115 VAC to the ATC console and verify that the front panel power LED is illuminated Using the inch up down switch check the positioner for proper operation Place the auto manual switch in auto Set the AVC delay potentiometer to minimum Set the voltage thumbwheel to 150 Simulate an arc transfer by connecting pin 8 to pin 9 of the N C connector The torch should immediately begin to move up The system is now ready for operation 2 8 Operation ATC User s Manual Section 3 Operation Operating Controls AVC Delay Potentiometer This potentiometer is used to delay arc voltage control after the cutting arc has transferred to the workpiece The delay time begins when the plasma cutting arc is established and is adjustable from 0 to 6 seconds See Figure 3 1 AVC Auto Manual Switch When this switch is in the auto position arc voltage control is enabled provided that no other function has the arc voltage control mode disabled When the switch is in the manual position arc voltage control is disabled See Figure 3 1 Arc Voltage Thumbwheel This switch is used to set the desired arc voltage It is capable of adjusting the voltage from 50 to 200 volts in 5 volt increments See Figure 3 1 Inch Up Down Switch optional This switch provides manual control of the torch positioner See Figure 3 1 LED Functions Power PW
19. h alate 6 6 Voltage Divider C able scite merda itu mis 6 7 Sienal Ground WV The esos NOI RV isi 6 8 Hookup Sum 6 8 User s Manual Section 7 7 1 Illustrations Figure 1 1 Control Console Mounting Dimensions 1 2 Figure 1 2 Voltage Divider Mounting Dimensions 1 3 Figure 1 3 Positioner Mounting 008 1 4 Figure 2 1 System Interconnection Diagram 2 2 Figure 3 1 ATO Control Console ioo octo diis iens 3 2 Figure 6 1 ATC Control Console e ea tenia 6 2 Figure 6 2 Positioner ota tec eite relier Iit Lote EON E Urt da co Pede ends 6 4 Figure 6 3 m 6 5 4 Motor Cable 6 6 Figure 6 5 AIG Voltage Divider Cable 6 7 Figure 6 6 ATC Signal Ground Wire os tut odes 6 8 Figure 7 1 ATC I O Schematic Consoles With Up Down Switch 7 1 Figure 7 2 ATC System Schematic Consoles With Up Down Switch 7 2 Figure 7 3 ATC I O Schematic Consoles Without Up Down Switch 7 3 Figure 7 4 System Schematic Consoles Without U
20. he ATC control console and apply 115 VAC to the system Lower the torch toward the workpiece activate the plasma and verify that the AVC LED LED1 on the p c board illuminates If the LED does not illuminate check the relay that activates the AVC input If the p c board AVC LED does illuminate verify that the AVC LED on the front panel illuminates after the AVC delay times out If the Up or Down LED s illuminate but the positioner does not move replace relays Opto 1 and Opto 2 on the p c board If there is still no arc voltage control replace the p c board 5 Verify that the corner LED LED2 on the p c board is illuminated only during a part s corner If the corner LED is illuminated continuously check the corner output relay from the numerical control contacts should only be closed in corners If the relay contacts are working properly and the LED remains on disconnect the N C cable If the LED goes out check the cable for shorts If the LED remains on replace the p c board 6 Faulty voltage divider Perform the voltage divider check out found at the end of this section No auto torch up front panel AVC and 1 Verify that the torch moves up with the Up LED s illuminated inch up down switch 2 Remove the top cover of the ATC control console and replace Opto 2 on the p c board 3 Replace the ATC p c board No auto torch down front panel AVC 1 Verify that the torch moves down with the and Down LE
21. is not corroded which can result in poor contact If the connection is corroded clean with a wire brush 3 While the torch is cutting increase the thumbwheel setting by 5 volts The up LED should illuminate and the torch should move up 4 While the torch is cutting decrease the thumbwheel setting by 5 volts The down LED should illuminate and the torch should move down 5 Set the AVC Delay potentiometer to mid range and initiate a cycle start Approximately 3 seconds after arc transfer the arc voltage control should activate Return the potentiometer to the previous setting 5 1 Maintenance ATC User s Manual ATC Positioner optional 1 2 Use the inch up down switch to move the positioner to the full up position Disconnect 115 VAC from the ATC Remove the positioner cover and blow out the inside of the positioner with clean dry compressed air Lubricate all four track rods where the carriage bearings ride with a light coat of WD 40 or equivalent Lubricate the ball screw with a light coat of WD 40 or equivalent Apply 115 VAC power to the ATC Use the inch up down switch to raise and lower the torch through several cycles While moving the torch up and down verify that the movement is smooth If the positioner movement is not smooth locate the cause and make the necessary adjustments 5 2 Parts List User s Manual Section 6 Parts List Control Console Assembly 732001 Note See Fig
22. lt 2 ULW l gt gt 2 g ed K l l 9 lt OVASI 1 H31114 4 gt gt ann K lt 1 OVASLI gt 81 lt Z OND OVAGLI 01 UTI NIE 1 S3NO SNIL OAV OLV Figure 7 2 ATC System Schematic Consoles With Up Down Switch User s Manual Schematics NO M3N3OO sow L 318VN3 9 9 9 2NO 318VN3 10 1 02 JOVIIOA OXY L d lt lt J 6 9N9 MVIS NO OAV Nee WNOIS BV AYON wN9IS INdNI P MAGIA JOVLIOA L O lt lt OVASLL lt OV SIL _ 9NO9 owas 9 lt lt lt lt IHM OWAGL 1 Kd lt 418 OVASIIL 82d 21 HOLOW H3NOILISOd Figure 7 3 ATC I O Schematic Consoles Without Up Down Switch User s Manual Schematics O1nv gt 5 OAV NIN NMOG Y 2 E v O S3NO 8 B 4 t 8 SN3L SC3YGNNH OAV vi vd 9 4 8 T vd 8l vd T Ild K lt anne lt lt Fs TWNO
23. ltage may be adjusted with the thumbwheel switch during the cut if necessary as well as prior to starting the cut The arc voltage can be adjusted in 5 volt increments Corner Height Freeze This feature allows the arc voltage control to be disabled while cutting It is used to prevent the torch from diving into the workpiece during corners or to deactivate the control at any given time during cutting AVC Delay An adjustable 0 6 second AVC delay pierce delay potentiometer has been provided on the front panel of the ATC control This allows the operator to vary the time at which the arc voltage control activates after arc transfer and is normally used when initially piercing thick plates that requires the torch to be stationary for a given length of time Limit This feature automatically terminates arc voltage control when the actual arc voltage exceeds the set voltage by 12 volts This prevents the torch from hitting the workpiece when crossing a kerf or running off the edge of a plate 1 6 Installation ATC User s Manual Section 2 Installation Initial Inspection KALIBURN has taken special care in packaging your ATC control system to prevent damage in shipping Before unpacking your system please examine the shipping container for any signs of damage If damage is evident open and inspect the contents Contact the shipping carrier and file for damages if necessary Next it will be necessary to contact KALIBURN or your local s
24. ng dimensions ATC Positioner The torch positioner to be used should be rigidly mounted and operate freely All mechanical play of the positioner should be minimized In addition it is imperative that the positioner has good braking action Poor braking will result in oscillation about the set arc voltage See Figure 1 3 for positioner mounting dimensions Voltage Divider The voltage divider should be securely mounted inside the plasma power supply See Figure 1 2 for voltage divider mounting dimensions 2 3 Installation User s Manual Electrical Installation 1 WARNING TURN OFF ALL POWER BEFORE WORKING ON EQUIPMENT The ATC console has been designed for quick safe and easy installation All components of this system are connected with AMP connectors Before attempting to make any of these connections be sure that all electrical power to the machine as well as the plasma power supply has been removed After the ATC system components have been securely mounted use the following procedures to complete the electrical installation Refer to Figure 2 1 for interconnecting cable details Numerical Control N C Cable This cable provides 115 VAC corner and AVC inputs to the ATC control console Refer to Figure 6 3 for details Motor Cable This cable provides the up down outputs from the ATC console to the motor of the torch positioner The ATC control console is designed to operate positioner motors rated from 24
25. njury to the person or property of anyone by reason of any defect in any equipment sold hereunder Returned Goods Procedure KALIBURN utilizes a returned goods procedure which must be followed before returning any items for repair replacement or restocking This means that a returned goods authorization number must be obtained prior to shipment to KALIBURN It will be necessary for the customer to provide a description along with the stock number and serial number if applicable of the item to be returned In no case will a returned shipment be accepted by KALIBURN without the proper returned goods authorization number ATC User s Manual TABLE OF CONTENTS Section 1 Specifications 1 1 System orate 1 1 eria 1 1 System Components ss se Saee ran od mti eil 1 1 SDECLTCdUODS dus Cases tt 1 2 Features 1 6 Section 2 Installation tete etae ati leta niente 2 1 ARTA RS CELI Sepia cise sg teas SR had mss 5 2 1 Grounding Requite Herbs 2 1 SV SLCMIIMEELCONTICCUIOM 2 2 Numerical Control N C Machine Interface
26. p Down Switch 7 4 This page intentionally left blank Specifications ATC User s Manual Section 1 Specifications System Description The ATC torch height control system has been designed to provide arc voltage control capabilities to any plasma system The ATC is available in three configurations 1 as a complete system including torch positioner 2 as a stand alone arc voltage control excluding torch positioner and up down switch and 3 as a stand alone arc voltage control with up down switch and excluding torch positioner When a torch positioner not manufactured by KALIBURN is used it is imperative that the positioner has good braking action to eliminate any potential oscillation problem since a full speed up or down output is generated when the designed arc voltage deadband is exceeded Safety Installation as well as repairs made to the ATC System should only be performed by qualified personnel The ATC System makes use of both A C and D C circuitry for operation Remember 115VAC can be fatal if not handled in safe manner In addition it will be necessary to make connections to the D C output of the plasma power supply These voltages can be in excess of 300 volts Fatal shock hazard does exist Exercise extreme caution while working in these areas Please refer to the plasma power supply manufacturer s operating manual for additional information Various other safety hazards exist while operating a
27. r system ATC CONSOLE UP ANC DELAY ac 79 9 lt LJ c T E 2 gt PLASMA TORCH alae z POWER SUPPLY POSITIONER rl O lt lt 1 Z o E 2 i gt 2 O gt VOLTAGE DIVIDER CONSOLE STAR GROUND WORKPIECE Figure 2 1 System Interconnection Diagram 2 2 Installation User s Manual Numerical Control N C Machine Interface Signals AVC Arc Voltage Control Input The ATC requires a relay contact closure on this input to enable the arc voltage control mode The contacts must be rated for 18 VDC 1 5 mA Corner Freeze Input The ATC requires a relay contact closure on this input to disable arc voltage control during automatic operation The corner relay contacts should close any time the x y machine speed decreases below the programmed speed The contacts must be rated for 18 VDC 1 5 mA Mechanical Installation ATC Console The ATC control console s small size and light weight allow it to be conveniently mounted at the operator s panel of the cutting machine This location is required because it will be necessary for the operator to change arc voltage settings and manually position the torch Four mounting holes have been provided in the base of the ATC console for this purpose See Figure 1 1 for control console mounti
28. tage measured between P S and P S For example if you measured 150 VDC between P S and P S you should measure 7 5 VDC between Signal and Signal 6 the voltage between P S and P S was 0 VDC check the connections between the voltage divider and the power supply output If the voltage between P S and P S was correct but the voltage divider output is incorrect replace the voltage divider 4 3 This page intentionally left blank Maintenance ATC User s Manual Section 5 Maintenance General The purpose of this section is to provide vital information concerning routine maintenance and preventive maintenance procedures for the ATC console Because this system is solid state the amount of care and required maintenance is minimal Remember preventive maintenance procedures as well as routine maintenance will never totally eliminate emergency service calls but can and will reduce the number of these calls By beginning to use the procedures now you will ensure that the equipment is always operating at its optimum ATC Control Console 1 visual check of the AMP connectors should be performed weekly Ensure that the connectors are properly installed and that none of the cables have pulled out of the strain reliefs 2 visual check of the Signal Ground should be made at the ATC control console as well as at the star ground connection point on the cutting table Pay careful attention that the table connection
29. the 4 6 32 X 3 8 screws provided Orient the board so the white ground wire is on the left Mount the white ground wire under the stand off leg where the paint was removed 4 Connect the black wire of the voltage divider cable marked Signal to the Signal terminal on the voltage divider 5 Connect the red wire of the voltage divider cable marked Signal to the Signal terminal on the voltage divider 6 Using the single conductor red wire provided connect the voltage divider terminal labeled P S power supply positive to the green connection plug on the I O board position 1 far right hand side 7 Using the single conductor black wire provided connect the voltage divider terminal labeled P S power supply negative to the green connection plug on the I O board position 6 This is counted from right to left 1 being on the far right 8 If the voltage divider cable supplied with the has fast on terminals on the power supply end it will have to be modified with a plug and strain relief part numbers 709022 amp 709023 and four sockets part number 7709018 Cut off the four fast on connectors and wire the plug as follows Signal Pinl Signal Pin 4 Now connect the cable to the outside of the SR 45i at the P7 plug 2 6 Installation User s Manual KALIBURN SR 100i Voltage Divider Installation WARNING TURN OFF ALL POWER BEFORE WORKING ON EQUIPMENT 1 Remove the back panel of the SR 10
30. ug 9 position 709015 1 Strain relief 9 position 709028 4 Insulated disconnects Notes 1 ATC hook up kit is provided with stand alone systems only 6 8 User s Manual Schematics Section 7 Schematics S ONO YANYOO 9 ONO lt lt NO 43NY00 T 8 ME e C 6 4 A lt ANNOYS TVN9IS AINE 14 lt lt lt IVNDIS vN9IS L GA _a K6 IHM VASIL Sd y 9NO Ke 1 lt owas it Sd L 2NO God ILV NYS OVASLL YOLOW YANOILISOd Figure 7 1 ATC I O Schematic Consoles With Up Down Switch User s Manual Schematics gt gt i 2 1 lt lt lt GNNOYD TVNAIS l l oS 1 44 id Ke lt t OlnV NVW K TWNOS lt lt tran gt 61 JOVLIOA l Weit E K lt ngs lt lt 1 0 Xv gt 8 8 6 lt lt lt 7 m gt 6 L d lt lt lt 6 6 lt lt lt G OND gt 41 N YANYOO 6 lt lt lt 9 7 1 lt lt gt gt 21 gt lt L ULW gt 9 z zak lt
31. upplier and inform them of the damage so replacement parts can be ordered If no damage is evident remove the packing slip and verify that all items have been received Grounding Requirements The ATC console is a high gain electrical device that requires specific grounding procedures This is necessary to ensure that electrical noise and high frequency noise do not interfere with its normal operation The Signal Ground connection located on the rear of the ATC control should be connected directly to the point known as star ground See Figure 3 1 for more information The star ground point is where all subsystems are grounded to the cutting table including the work ground lead of the plasma power supply There should be one cable connected from the star ground point to a driven earth ground rod which should be located as close as possible to the star ground point The ground rod should be at least 3 4 inch in diameter and should be driven into the earth s permanent moisture layer The length of this ground rod varies from installation to installation This ground rod should have been installed during the installation of the N C machine Please refer to The National Electrical Code Article 250 Section H Ground Electrode System or other appropriate code 2 1 Installation User s Manual System Interconnection The ATC system interconnection diagram Figure 2 1 will assist you in identifying components and cables upon receipt of you
32. ure 6 1 Item Number Part Number Quantity Description 10 11 Not Shown Not Shown 12 13 14 15 16 Not Shown Not Shown Not Shown Not Shown 700307 700308 700331 700330 708101 704009 701051 710004 708002 708003 709010 709033 709012 709003 709001 709034 707001 730002 709035 709036 709037 709038 NO Mld Front panel decal Rear panel decal Base Cover Thumbwheel assembly LED Potentiometer 100K Potentiometer knob Switch auto manual Switch up down Fuse holder Fuse 1A Fuse 3A Receptacle 9 pin Receptacle 4 pin Binding post Line filter ATC p c board Plug P1 Plug P2 Plug P3 Plug P4 6 1 Parts List User s Manual TOP VIEW FRONT VIEW 5 REAR VIEW 2 Figure 6 1 ATC Control Console 6 2 Parts List User s Manual Positioner Assembly 730015 Optional Note See Figure 6 2 Item Number Part Number Quantity Description 1 10 11 12 13 14 16 17 18 19 20 21 22 23 24 25 26 27 28 29 Not Shown Not Shown Not Shown Not Shown Not Shown Not Shown Not Shown Not Shown Not Shown 700036 700022 710005 710008 700012 900332 900319 900302 900318 900320 900314 700207 700305 710003 700306 700011 710009 900309 900327 900317 900336
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