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Service Manual
EX-0-903-001
N-22824
EX-TRACK®
Foreword
Thank you for purchasing the Thermacut® EX-TRACK® CNC Cutting System, the system is available
with an oxy fuel cutting torch, optionally a plasma system can be added. The system has been
designed and manufactured to deliver: reliability, dimensional accuracy and reproducible profile
part cutting. The system is easy to operate and maintain, read this instruction manual before
proceeding, be aware, there is a potential for danger upon installation, operating or maintaining the
system.
It is the responsibility of the operator/user to ensure the safe use/handling of the system, refer to
Thermacut’s terms and conditions of sale for specific responsibilities and limitations on liability.
Information in this document is subject to change without notice. The manual is for the convenience
and use of the Thermacut® EX-TRACK® CNC Cutting System purchaser, it is not a contract or
obligation on the part of Thermacut® The Cutting Company.
Safety precautions
This instruction manual describes the correct, effective and safe use of the system. All personnel
involved in the use or maintenance of the system should read this instruction manual thoroughly
and familiarize themselves in the correct and safe method of operation. A copy of this instruction
manual should be kept with the system at all times for easy reference.
INDEX
Foreword������������������������������������������������������������������������������������������������������������������������ 2
Safety precautions�������������������������������������������������������������������������������������������������������� 2
1. SAFETY INSTRUCTIONS����������������������������������������������������������������������������5
1.1. General system safety precautions �������������������������������������������������������������������� 8
1.1.1. System safety������������������������������������������������������������������������������������������������������ 8
1.1.2. Personal protective equipment������������������������������������������������������������������������ 8
1.1.3. Safety precautions prior to handling and operation������������������������������������� 9
1.2. Plasma/oxy fuel gas cutting safety awareness������������������������������������������������� 10
1.2.1. Prevention of fire and explosion�������������������������������������������������������������������� 10
1.2.2. Safe use of gas pressure regulators �������������������������������������������������������������� 10
1.2.3. Gas cylinder handling and storage ��������������������������������������������������������������� 10
1.2.4. Oxy fuel gas hose safety precautions ����������������������������������������������������������� 10
1.2.5. Risk of fire ��������������������������������������������������������������������������������������������������������� 11
1.2.6. Risk of burn injury ������������������������������������������������������������������������������������������� 11
1.2.7. Safety in the workplace����������������������������������������������������������������������������������� 12
3. DIAGNOSTIC�������������������������������������������������������������������������������������������18
3.1. Checks������������������������������������������������������������������������������������������������������������������ 19
3.2. Required instrumentation����������������������������������������������������������������������������������� 19
3.3. Troubleshooting�������������������������������������������������������������������������������������������������� 19
3.4. Visual inspection�������������������������������������������������������������������������������������������������� 19
3.5. Troubleshooting sequence�������������������������������������������������������������������������������� 19
4. BLOCK DIAGRAM������������������������������������������������������������������������������������20
5. SPECIFICATION���������������������������������������������������������������������������������������22
6. EXPLODED VIEWS�����������������������������������������������������������������������������������23
6.1. Exploded view A�������������������������������������������������������������������������������������������������� 24
6.2. Exploded view B�������������������������������������������������������������������������������������������������� 26
6.3. Exploded view C�������������������������������������������������������������������������������������������������� 28
7. TROUBLESHOOTING�������������������������������������������������������������������������������29
7.1. CNC unit is not responding when turned ON������������������������������������������������� 30
7.2. Torch is not moving on Y, X axis, when we press arrow button in manual
mode���������������������������������������������������������������������������������������������������������������������������� 32
7.3. Torch is not moving on S axis, when press button PgUP↑ and PgDN↓ in
manual mode�������������������������������������������������������������������������������������������������������������� 35
7.4. Solenoid valves are not opening – no gas in from the oxyfuel torch������������ 37
7.5. Torch Height Control is not working in automatic cutting mode������������������ 39
7.6. There is no ignition, but plasma power supply is fully working��������������������� 42
Notes:��������������������������������������������������������������������������������������������������������������������������� 44
Revision history:���������������������������������������������������������������������������������������������������������� 45
SECTION 1.
SAFETY INSTRUCTIONS:
Safety Instructions
Many accidents are caused by disregard for basic safety rules in the operation, inspection and
maintenance of devices. So carefully read, fully understand, and comply with the safety measures
and precautions described in this instruction manual and on the system before operating,
inspecting, and maintaining the system.
WARNING
This symbol is used as a warning message or a warning label. It is positioned at
places that could cause injury or serious accident.
CAUTION
This symbol is used as a caution message or a caution label. It is positioned at places
that could cause slight injury or system damage. This is also used as a caution for
highly dangerous actions.
NOTICE SIGNS
This symbol shows system operators and maintenance engineers items that relate
directly to damage of systems and surrounding facilities and equipment.
Warning symbols
Be careful not to get your Possible injury to fingers if caught in the insertion
fingers caught! part.
1. The system casing is made from cast Aluminium and sheet metal, exercise care when
handling, do not let the system drop from any height, and protect the system from falling
objects.
2. Oxygen and fuel gas fittings and connections should be tightened using a suitable wrench,
perform a leak test and retighten as required.
3. When fixing a nozzle to the oxy fuel torch, tighten the nut with two wrenches. In addition,
avoid damaging the seat of the nozzle since this may cause flashback.
4. Never disassemble the system other than during maintenance and inspection. Otherwise,
a system malfunction may occur.
5. Never modify the system. Modification can be very dangerous and voids the warranty.
6. Switch the power off when the system is not in use.
7. Never use the system outside in the rain, the system may malfunction, this could result
in serious injury or death.
8. This system is not intended for use with plasma cutting power supplies that utilize high-
frequency (H/F) arc ignition.
2. Replace hoses that are showing signs of cracking, leaking, and damage caused by sparks,
heat, open flame, crushed etc.
3. When installing hoses, do not over-tighten the fitting.
4. Exercise care when using/transporting hoses.
5. Do not drag the hoses when moving the system.
6. Perform Periodic safety checks to confirm the condition of the hoses, as a minimum the hoses
should be free from signs of damage, age related wear/cracking with no gas leaks from the
hoses or fittings.
7. Where possible use the minimum length of hose between the gas supply point and the
EX-TRACK®, this reduces the risk of excess hose being damaged or causing a trip hazard. A
shorter hose may improve gas flow.
1. The work area should be free from flammable liquids, gases, vapors and other combustible/
flammable materials, ensure that suitable fire extinguishers for use on: Gas/Electrical/Hot
metal fires are suitably located, locate fire buckets with sand/water as necessary.
2. Allow the parent material, profile cut parts and scrap time to cool down before moving them.
3. Never cut in to sealed or open canisters/containers that have been used for gases or
flammable products.
1. Do not cut near flammable liquids, gases, vapors or other combustible/flammable materials.
Remove flammable materials from the work area, flying sparks are a source of ignition
2. Never cut into sealed or open canisters/containers that have been used for gases or
flammable products.
3. Do not keep lighters or matches on your person.
4. When operating the EX-TRACK® system, maintain a safe distance from the torch.
5. To minimize the risk of injury, the appropriate Personal Protective Equipment must be worn.
6. For Oxy fuel cutting, ensure that the nozzle is correctly seated and tightened so as not to
damage the seat/sealing area and prevent “Flashbacks” to the system.
• When fixing a nozzle to the torch, use two wrenches to avoid damage to the torch.
Over-tightening the nozzle will result in the nozzle overheating during the cutting
process, making the nozzle more difficult to remove.
• Damage to the taper of the nozzle can cause “Flashbacks”.
7. An appropriate method of gas leak detection should be used to check the torch, hoses,
connectors, vales and regulators, a suitable “Flashback Arrestor” compatible with selected
gases should be fitted to reduce the risk of fire or explosion.
DANGER! DO NOT use oil or grease products on the Oxygen hose/torch/valve/regulator or
connections, spontaneous combustion can cause a fire and lead to an explosion. To prevent
any risk of cross contamination, it is advisable NOT to permit the use of oil or grease on any
of the Oxy fuel supply or delivery components.
8. Check the following prior to igniting the Oxy fuel torch: Ensure that the torch is correctly
seated and fixed in to the torch mount. The appropriate Personal Protective Equipment is to
be worn/used. Check the work area for obstacles, hazardous/flammable materials. Check that
the input and output gas pressures are correct and suitable for the job in hand.
9. Appropriate Personal Protective Equipment is to be worn/used when handling the torch,
nozzle, idler wheel locking device, allow adequate time for the system to cool down after
cutting.
ATTENTION: Prior to starting the cutting process, perform a system/equipment check to ensure
there are no gas leaks or visible damage to component parts. If during the cutting process there is
the odor from a gas leak, immediately press the E-Stop button to isolate the electrical power supply,
turn OFF the gas supply at the torch and then at the point of supply - Cylinder/Manifold. Do not use
the system until it has been checked and deemed safe to use by a suitably qualified person. You are
responsible for your own safety as well as others.
SECTION 2.
Warning and Safety labels have been affixed to the system for the purpose of hazard awareness
and correct use of the system. Prior to operating the system carefully read the labels and follow the
instructions. Do not remove labels. Always keep the labels legible.
SAFETY
1
!Caution! Caution!
Read operator’s manual
The symbol shown in this section means: !Caution! !Beware! Follow the safety instructions to avoid danger.
¡There are possible hazards with this procedure!
Only qualified persons should install, operate, maintain and
When you find this symbol in the manual or on the system, repair the system.
be cautious, and follow the related instructions to avoid the
Keep out of reach of children.
hazard.
2
PLASMA ARC RAYS CAN BURN EYES AND SKIN
Arc rays from the cutting/gouging processes produce intense • Use face protection (welding helmet or shield) with
visible and invisible rays that can burn eyes and skin. the correct shade of filter lens fitted to protect your
eyes and face (see Table 1.1).
Use protective clothing made from durable, flame-resistant
• Warn people of the dangers of looking at the arc, use
material, appropriate footwear and hand protection.
signs to warn/inform.
3
CUTTING CAN CAUSE FIRE OR FLYING SPARKS (ARC SPRAY)
EXPLOSION CAN CAUSE INJURY, FIRE OR
EXPLOSION
FIRE PREVENTION Flying sparks are created during the metal cutting/gouging
processes; the area should be kept free from flammables.
• se face shield/safety glasses with side protection.
U
• Keep flammable items away from the work area.
• Wear flame resistant clothing, footwear and hand
• Ensure that there is a fully charged fire extinguisher in the
protection.
work area
• Use earplugs/defenders that are flame resistant to
• Ventilate the work area, check for flammable/combustible
prevent sparks entering the ear and to reduce the
gases, liquids and materials, remove prior to cutting as
noise level.
they present a fire risk.
EXPLOSION PREVENTION
• Do not cut in areas containing explosives, flammable • o not operate the system in areas with an
D
gases or vapors. atmosphere containing high concentrations of dust,
• Do not place the system on, over, or near combustible flammable gases or vapors.
surfaces. • Do not use the system to cut pressurized containers
that have not been de-pressurized, vented and
cleaned.
4
ELECTRIC SHOCK CAN KILL
Touching electrical parts could cause a fatal shock or severe • Periodically check the power supply cable, to insure
burns. that the outer insulation is intact. Replace the power
supply cable immediately if damaged. DO NOT use
• Do not touch live electrical components.
the system with bare or exposed wires, this is highly
• Wear dry insulated gloves, shoes and protective clothing.
dangerous.
• Insulate yourself from the work and ground using dry
• Before removing the cover or handling any of the
insulating material large enough for the work area.
internal components of the system, wait 5 (FIVE)
• The working area should be clean and dry.
minutes to ensure complete discharge of the
• Switch OFF the system for cleaning and maintenance
capacitors.
operations.
• Keep the system in good condition; repair or replace
• Do not wrap cables around your body.
damaged parts immediately. Maintain the system in
• Turn OFF the machine when not in use.
accordance with the manual.
5
PLASMA ARC CAN INJURE HOT PARTS CAN CAUSE
SEVERE BURNS
The plasma arc is activated immediately after the torch trigger Caution! After cutting, the work piece will be HOT!
is depressed.
• Do not touch hot parts bare handed, wear suitable
• urn OFF the power before changing the torch
T hand protection.
consumables, the plasma arc can burn through skin and • Allow cooling time before handling.
gloves.
• Do not place your hand or hold the work piece near the
cutting path.
• Do not point the torch toward yourself or other persons.
6
SMOKE AND GASES CAN BE HAZARDOUS
7
CAUTION WHEN CUTTING MAGNETIC FIELD CAN
AROUND GAS CYLINDERS AFFECT PACEMAKERS
Gas cylinders which contain gas under high pressure can
rupture and explode if damaged. • People with pacemakers/hearing aids should avoid
close contact with plasma arc power supply.
• Handle and use compressed gas cylinders in accordance
• People with pacemakers/hearing aids should consult
with local or national codes.
their doctor before operating plasma arc power
• Never allow electrical contact between the plasma arc
supply.
and a cylinder.
• Never expose cylinders to excessive heat, sparks, slag or
flames.
Protection glass
Plasma Arc Cutting shade number
Current per
ISO 4850:1979
Table 1.1
SECTION 3.
DIAGNOSTIC:
3.1. Checks������������������������������������������������������������������������������������������������������������������ 19
3.2. Required instrumentation����������������������������������������������������������������������������������� 19
3.3. Troubleshooting�������������������������������������������������������������������������������������������������� 19
3.4. Visual inspection�������������������������������������������������������������������������������������������������� 19
3.5. Troubleshooting sequence�������������������������������������������������������������������������������� 19
3.1. Checks
This section will describe the steps for effective troubleshooting or malfunction.
3.3. Troubleshooting
The primary investigation is to establish the source of the fault, on the CNC unit, gas console, lifter.
• Check the rails and outside parts of the CNC unit, longitudinal arm, gas console, lifter.
• Check all cable leads and their connection.
• Check the emergency stop button and its function.
SECTION 4.
BLOCK DIAGRAM:
SECTION 5.
SPECIFICATIONS:
SECTION 6.
EXPLODED VIEWS:
Parts description A
Parts description B
Parts description C
Item Part No. DESCRIPTION
120 EX-0-706-105 Input power cord
121 EX-0-706-106 Rail assembly
122 EX-0-706-107 Longitudinal guide console
123 EX-0-706-108 20X2 Gear Rack (M1.273)
124 EX-0-706-109 Double-shaft rail (Ø12)
125 EX-0-803-004 CNC Interface connection lead 6m
SECTION 7.
TROUBLESHOOTING:
Possible malfunction: CNC controller/display is not illuminating, when you turn on the CNC unit.
Cause:
Measurement:
• Check the connection of the power cord into this power socket.
• Check out, if E-stop button is pushed down or up. If down, pull it up. If up, check the cables
and microswitches in the E-stop button.
• Check the connection (continuity) of the cables from power socket into the switching power
supply (L, N, GND)
• Check the adjusted voltage on the switching power supply (230/110V) – regarding local
power line.
• Measure voltage between L and N terminal on the SPS. There has to be 230VAC +- 15% or
110VAC +-15%.
• If there is the voltage between L and N, measure output from the switching power supply.
There has to be 24VDC between terminals V+ and V-. If no, replace SPS.
• If the output from SPS is 24VDC, measure the voltage on the CNC controller. There has
to be 24VDC. If there is voltage, replace the CNC controller. If no, check the continuity of the
cables.
Cause:
Measurement / Solution:
• Measure input voltage for the Stepper motor driver. It has to be 24VDC between terminals
GND and +VDC (or V+ and V-). If not, check the cables from the SPS into the driver.
• Measure the input signals for the driver from the CNC controller. Measure DC voltage
on the terminals DIR + and DIR – on the Stepper motor driver. You have to be in a Manual
mode in software.
Turn OFF the rapid function. The driver above SPS is for Y axis. Driver under Torch Height Controller
(THC) is for X axis. When you’re holding Y+ button (arrow), there has to be voltage between positive
2-3V. When you’re holding Y- button (arrow), there has to be voltage between negative 2-4V. If no,
check out continuity of the cables which lead into these DIR+ and DIR- terminals.
• If no, check out continuity of the cables which lead into these DIR+ and DIR- terminals from
the CNC controller. If the cables are ok, there is malfunction of CNC controller – replace it.
• Check with oscilloscope output signals which lead into the Stepper motor. The signal has
rectangle shape. Alternatively, if no oscilloscope is available, swap one stepper motor with
the other (same type). If it works, stepper needed replacement.
You have to be in Manual mode in software. Turn OFF the rapid function. Put the probes on
the driver terminals A+ and A- and hold Y+ button (arrow) on the keyboard of CNC controller
– you have to see the signals as on the picture above.
Then repeat all procedure on the driver terminals B+ and B- and hold Y- button (arrow) on
the keyboard of CNC controller. If you see the signal, check the cables which lead into the
step driver. If the cables are OK – replace the Stepper motor.
• If the Stepper motor driver is ok, but torch is still not moving, check the transmission and
the belt between the transmission and pinion gear of the Stepper motor. Check as well the
wearing of the pinion gear itself. If all steps described above are ok, replace Stepper motor
itself.
Pinion gear
• Check the (#) V-wheels and the bearing on the bottom of the CNC unit. Clean the surface
of the double-shaft rails. Use a silicone grease if necessary, to lubricate the rails. Check the
free movement of longitudinal arm.
Cause:
• Check the connectivity of the cables on the torch lifter (black rubber cap).
• CNC controller is not sending signals into the relay PCB.
• THC controller is not sending signals into the lifter motor.
• Lifter motor malfunction.
• There is no voltage for supplying the lifter motor driver.
• Issue with transmission of the lifter.
• Cable or Relay PCB issues.
Measurement / Solution:
• Remove the black rubber cap from the torch lifter and check the connectivity of the two
connectors, if they are connected properly.
• Check out the signals leading from CNC controller into the relay board. You have to be in
a Manual mode in software. Turn OFF the rapid function.
Measure voltage between cable 205 and GND (green wire), which leads into the relay PCB.
There has to be 24VDC. Then hold button PgUP↑ on the keyboard of CNC controller and
measure the voltage again.
There has to be voltage between 0-1VDC. Repeat the same procedure between the cable
204 and GND. There has to be 24VDC when the button PgDN↓ is not depressed.
When you hold button PgDN↓ on the keyboard of CNC controller, there has to be voltage
between 0-1VDC. If yes on both, the CNC controller is sending signals properly. If not, check
the cable leads between CNC controller and relay board. If they are ok, replace CNC
controller.
• Check the both fuses on the relay PCB with measurement of continuity. If they are
damaged, replace them.
• Check the function of the relays in the Relay PCB. They have to do a “click sound” when you
press the button PgDN↓ or PgUP↑ and LEDs has to illuminate. For PgDN↓ has to illuminate
LED 1 and LED 2 (left picture) and for PgUP↑ has to illuminate LED 1 and LED 3 (right
picture).
• If there is no “click sound” or LEDs are not illuminating – replace Relay PCB.
• Measure input voltage of THC controller (left picture). There has to be 24VDC. If yes, then
measure the output signals (right picture), which leads into the torch lifter – on the
terminals MOT+ and MOT-.
There has to be: +- 24VDC when you holt the buttons PgUP or PgDN. If not, replace THC
controller. If yes, check out the cable leads (continuity test) to the lifter motor
(machine connector pins 3+4). If the cable leads are ok, firstly check the transmission of lifter.
If the transmission is ok, then replace lifter motor.
Cause:
• CNC controller doesn’t send the signals into the relay PCB.
• Relay PCB is damaged.
• Cable lead is broken (machine connector and cable in the longitudinal arm).
• Solenoid valves are damaged.
Measurement / Solution:
• Measure the voltage between cable 405 (pin #5 on the machine connector) and GND
when the PREHEAT button is pressed on the keyboard of CNC controller. Oxy cutting
mode has to be chosen. There has to be: 24VDC. If not, check the cable leads from the CNC
controller into the relay board. If the cable is ok, replace CNC controller.
Do the same procedure between cable 403 (pin #2 in the machine connector) and GND
when CUTOXY button is pressed.
• Check out the relays on the relay PCB, which switch the solenoid valves (left picture). Relay
#6 is for the PREHEAT solenoids (right picture). Relay #4 is for the CUTOXY solenoid.
There has to be a “click sound” on certain relay when press the PREHEAT or CUTOXY button
and LED of the relay has to illuminates when the button is pressed. If there is no “click sound”
or LED is not illuminated – replace the relay PCB.
• Check out by continuity test the cable leads from Relay PCB into the machine connector on
the connector panel. If these cables are ok, check the cable inside of longitudinal arm
by the same continuity test. If the cable inside the arm is OK, check the coils which control
solenoids. On the coil has to be 24VDC when the PREHEAT or CUTOXY is pressed and 0VDC
in the buttons are depressed.
Coil
Solenoid valve
Cause:
Measurement / Solution:
• Check the real arc voltage by multimeter in the plasma power supply during the cutting on
the work lead terminal (+) and TCS socket connector (-). There has to be voltage based on type of
torch and type of plasma power supply (check the operator manuals of the torch and plasma power
supply). If there is a voltage regarding manual, let’s continue by the next step. If no = malfunction of
the plasma power supply (check the service manual).
• Check arc voltage ratio adjusted in the plasma power supply voltage divider.
EX-TRACK® CNC needs input ratio 50:1, including same 50:1 to be delivered from plasma
power supply (check separately). Check the cables by continuity test, which leads from CNC
connector (Pins 5+6) into the CNC voltage divider (terminal J6 on the CNC voltage divider).
If these cables are ok, check out the jumper by continuity test. Jumper must be on the position as on
the picture (yellow).
J6 terminal
+ = pin 6 on CNC connector Jumper 50:1 Jumper 1:1
- = pin 5 on CNC connector
Note: If the power supply doesn’t have own voltage divider and it is necessary to send real arc
voltage from the plasma power supply (picture above) into the EX-TRACK® CNC, please do these
steps (On your own risk and responsibility!):
a) Monitor actual running plasma arc voltage from the plasma power supply
(2 separate wires) – positive wire from the work lead terminal and negative from the
torch power wires connection).
b) Connect these two wires with real voltage into the connector of CNC voltage divider
(with the correct polarity).
• If the voltage ratio is set to 50:1 in plasma power supply and CNC voltage divider is
connected as described above, measure divided arc voltage on the output of CNC voltage
divider. There has to be voltage in range 2,6V-2,9V between V terminal and 24- terminal
(during cutting process) - in case of adjusted cutting arc voltage 130-140V in CNC controller.
If desired voltage is there, CNC voltage divider works well. If not, replace it.
• Check the THC settings in the CNC controller. For proper parameters check user manual.
• Check the function of the switch in the plasma holder.
• Measure voltage between ZERO and 24V- (COM) on the THC controller.
If there is no voltage change the THC controller. There has to be 24VDC when the torch
holder is at the bottom position. When we lift up the plasma torch holder, there has to be 0V.
If there is the voltage difference when we lift up the torch/plasma holder, the switch is OK.
If no, do a continuity test of the cables from the switch to THC controller (pins 6+7 in Machine
connector on the left side of CNC unit). If the cables are OK, replace the switch.
Measurement / Solution:
• Check, if the CNC cable is properly connected between CNC unit and plasma power
supply, if yes, and there is still no ignition, check the CNC cable by continuity test – pins 3 and
4. If the cable is OK, measure voltage on THC controller between ARC OUT and -24V . There
has to be 0VDC during the cutting process. If not, replace THC controller. If there is 24VDC,
check the cables leading from ARC OUT and -24V (THC controller) into the CNC voltage
divider - terminals -24V and ST.
Notes:
Revision history:
1. Revision Nr: 01.1 - 10/2020 Official release
Distributor details:
THERMACUT, k. s.
Sokolovská 574, Mařatice
686 01, Uherské Hradiště
Czech Republic
www.thermacut.cz
sales@thermacut.cz