EC Maintenance Spareparts List ENG

OPERATING MANUAL
PLASMA CUTTING MACHINE
Series EC
January 2006
1/22
Tomášikova 28, 821 01 Bratislava, tel: +421 2 602 91 859, fax: +421 2 654 28 364
http://www.microstep-gruppe.com e-mail: rela@zutom.sk
1. INTRODUCTION ............................................................................................................................ 3
2. CUTTING MACHINE DESCRIPTION............................................................................................. 3
2.1 Machine frame .................................................................................................. 3
2.2 Longitudinal movement (AXIS X) ...................................................................... 3
2.3 Transversal movement (AXIS Y)....................................................................... 4
2.4 Vertical movement (AXIS Z).............................................................................. 4
2.5 Working table .................................................................................................... 4
2.6 Control system .................................................................................................. 4
2.7 Operational unit (POJ) ...................................................................................... 5
3. TECHNICAL SPECIFICATIONS .................................................................................................... 5
3.1 Technical parameters........................................................................................ 5
3.2 Energetic requirements ..................................................................................... 5
3.3 Type of working surround.................................................................................. 6
4. TRANSPORT AND STORAGE ...................................................................................................... 6
5. PRECAUTIONARY STEPS ............................................................................................................ 7
6. MAINTENANCE.............................................................................................................................. 8
6.1 Maintenance plane............................................................................................ 8
6.2 Description of lubrication points ........................................................................ 9
6.3 List of spare parts ........................................................................................... 10
7. LIQUDATION OF DEVICE ........................................................................................................... 15
7.1 Liquidation of rubbish ...................................................................................... 15
7.2 Recycling ........................................................................................................ 15
8. ATTACHMENT ............................................................................................................................. 16
2/22
1. INTRODUCTION
The cutting machine of series EC represents modern highly productive machine,
which is determined for division of metal semifinished products. Device uses
technology of thermal cutting by way of high temperature plasma. After agreement
with producer it is possible to order the machine with cutting device with oxygen-
acetylene torch. Maximum thickness of cut material depends on specific kind of
plasma generator.
Cinematic of the machine is based on three continuously axes. Lengthwise and
diagonal motion (axis X and axis Y) are practised in horizontal plain, lift along the
axis Z presents vertical motion. Cutting is performed by working head, which moves
in two axes above the workpiece. Material is placed on interchangeable steel laths of
working table. Tank under the working table is for interception of rubbish. Gases
which arise by cutting are aspirated by exhaust system out of space of working table.
This machine is very easy to operate and it has very neat cut. Control system is
realized by industrial computer, which manage control of all three axes (CNC). You
can find description of the machine, directions and rules for correct operations in this
manual.
2. CUTTING MACHINE DESCRIPTION

2.1 Machine frame
Frame of the machine is made by two lines of sturby legs, which carry main profiles
for realization of motion along axis „Z“. Legs of machine are adjustable for setting the
machine to horizontal position. Setting is practised by four adjustable screws on each
leg of the machine. Linear rails and gear racks are placed on main profiles. It
provides lengthwise move (axis X). Whole frame is protected against rust by
protective powder painting.
2.2 Longitudinal movement (AXIS X)
Lengthwise move is made by portal. This portal joints left and right consol, which is
moving in pair of linear rails lengthwise of the machine frame. Each consol is
equipped with propulsive unit. The unit is consists of the direct current motor with IRC
sensor, gearbox and divided pinion. Transfer of forces is reached by drive of pinion
placed on gear rack. Reaction forces are caught by pair of linear bearings and linear
rails on each side.
Divided pinion of the servomechanism allows reducing backlash of the gear.
Backlash you can reduce by bilateral swing out of both pinion wheels. It will cause
the extension in the pinion spring.
End positions are controlled by inductive sensors and secured by mechanical back
stops. Parts of propulsive mechanism are protected against the dust, other impurities
and against the mechanical damage by covers.
Steel parts are protected against rust by special painting.
3/22
2.3 Transversal movement (AXIS Y)
Move along axis Y is carry out by one or several drives (depends on specification of
the machine), placed on portal with square section. Pair of rails and pair of linear
bearings for every drives are placed on the portal. Motion along axis “Y” is realized
by direct-current motor with IRC sensor and gearbox, which drive the cutting head.
Complete body of motions, holds its own servomechanism for axis “Z” is placed on
linear bearings. Forces are caught by pair of linear bearings on two linear rails.
End positions are controlled by inductive sensors and secured by mechanistic back
stops. Solid of motions, as well as the rest of steely parts are protected against the
rust by protective painting.
2.4 Vertical movement (AXIS Z)
The last one of moves is realized by gearing of gear rack and pinion. Movable part of
the unit is leaded on two linear rails with bearings. Whole propulsion is screwed to
placing board of the portal. Propulsion of axis “Z” is realized by direct-current motor
with IRC sensor, which by way of reduction gearbox drive leading rod with gear rack.
Cutting torch is by way of the holder connected to the leading rod. In this part there
are: device of electronic anti-collision protection and mechanism of initial height
setting with IHS sensor.
End positions are controlled by inductive sensors and secured by mechanical
stoppers. Steel parts are protected against the rust by protective painting.
2.5 Working table
Working table is created by similar construction as frame of the machine described in

chapter 2.1. Legs of the working table carry grate with lamella, which created working
part of the table. Working table is used for placement of workpieces in working area
of the machine. Horizontal establishment towards the plain of move of torch is
enabled by adjustable legs of the working table. Suction of gases which arise during
the cutting process is realized through the space of the tank by way of exhaust
system.
2.6 Control system
Control system is placed in independence case. There is industrial computer with

CNC control system MSNC including the power electronics of the machine inside.
There are communication peripheral devices (display, keyboard and mouse)
including the main switch and the button for emergency stop (central stop) in the top
part. Connection between the machine and control system case is realized by electric
wires placed in the protection duct. Distribution of energy to concrete drives is made
by using the electrical cables placed in the cable chain ducts as well.
4/22
2.7 Operational unit (POJ)
Control unit is placed on both sides of the machine and it is stuck to the side
consoles of the portal. Operators can control the cutting machine during the hand
mode, using the system of push buttons from these places. Operators also can
operate simple control during the automatic work mode. There is a button “central
stop”, which can stop the machine in case of emergency immediately on each
console.
3. TECHNICAL SPECIFICATIONS
3.1 Technical parameters
General dimensions by order

Size of the working area by order
Maximal portal clearance 250 mm
Position speed 20 m.min-1
Maximal cutting speed 20 m.min-1
Repeatable positioning accuracy ± 0,075 mm
Maximal thickness of the cut material depends on type of plasma
Type of plasma generator by order
Type of control system MSNC 500
Exhaust system of the cutting table by order
General weight of machine ~ 2700 kg (without accessories)
3.2 Energetic requirements
Energetic parameters:
Nominal voltage 230 V/ 50 Hz

Maximal current load 16 A
Operating pressure of compressed air 6 bar
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3.3 Type of working surround
The machine is appointed for the work only in the internal areas, which are medially
hard circumstances. The cutting machine must not come to the contact with
aggressive substances, which could cause added corrosion of some of its parts
(acids, organic substances, sea water etc.).
Work surround:
Range of the working temperatures + 10 C to + 35 C

Relative air humidity 0 to 90 %
Explosive environment no
Dust nuisance medially low
When you use the machine in incorrect environment, is necessary to consult your
aim with the producer or authorized seller of the machine!
4. TRANSPORT AND STORAGE

Transport before the first using of the machine is performed by the producer or by the
company which is for this purpose assigned by the producer. By additional transports
in addiction of the distance, there is possibility to make this activity with the device
distributed into the basic subassemblies. Unplug all energy connections before any
manipulation. It is necessary to disconnect the plasma generator, exhaust system
and console with the control system of the machine. All of the movable parts have to
be dismounted or secured against any accidental move before any manipulation. You
will prevent possible damages of the machine or health injury of workers.
If you have any niggles about transport you can contact the producer of the machine
or company, which has experience with this kind of transport. Single parts have to be
adequately packed in order to be protected against the damage. Because of the
relativity big weight of some construction units, use suitable handling equipments.
The cutting machine, which is not used for its purpose is able to be stored potentially
for non - limited time. All single parts have to be cleaned of the working stuff, all
working circuits have to be let out before the storage. Leading surfaces and other
functional units have to be covered by suitable preservative stuff.
The machine can be stored in dry environment if its single units are not exposed to
meteorological influences with temperatures from +5 C to + 45 C.
The machine should not be exposed to influence of sunshine for a long time,
otherwise colouring firmness of surface painting can be changed and plastic or
rubber parts can weather partially.
If the mentioned conditions are not fulfilled, the producer cannot guarantee correct
function of the machine or its components.
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5. PRECAUTIONARY STEPS
The cutting machine EC type is appointed for cutting practically all kinds of metal
materials and metal alloys. Maximal dimensions of semi finished products appointed
for cutting depend on dimensions of the working table and clearance of the portal and
on the type of plasma generator. It is forbidden to exceed any of the maximal
technical parameters appointed by producer of the machine.
For the operators is strongly recommended to take the training course about working
with this machine before the start. Read the precautionary steps about the work with
plasma or oxygen- acetylene devices before set in motion. It is recommended to use
working clothes and footwear, gloves and goggles for eyes protection while you are
working. The plasma generator generates hot plasma and relatively intensive light as
well. Do not look straight to the cutting torch without protection of your eyes, it can
damage your eyes or you can go blind.
It is necessary to use handling devices if the weight of the material requires it during
the manipulation with the semi finished products. Do not forget that cut material was
exposed to high temperature of plasma so it can stay hot for some time after cutting
process. Wait until the temperature will be tolerable. You will prevent possible burn of
skin or possibility of fire foundation. It is allowed to manipulate with the material only
if the machine is in stand by mode, or if it does not work. It is prohibited to stay close
to the cutting torch or however manipulate with cut work pieces if the machine is in
cutting mode. It is denied to cut containers under pressure, or any devices
accumulating the energy. Also it is denied to cut containers with dangerous or
flammable content.
It is forbidden to start the machine, if any of covers is damaged or if it is not correctly
attached.
In case of collision situation, health threat of operators or in case of another
breakdown situation, stop the machine immediately by pushing the button CENTRAL
STOP, which is placed on the panel of the main control unit and on the both control
consoles on the machine. In case that fire appears, immediately disconnect all of the
energy inputs of the machine and try to put out the fire on your own. If you can not
put out the fire, you have to inform the dispatching of the fire service.
You should use suitable fire extinguisher (powder or CO2). In case of necessary stop
of the machine, clear away the reason of stopping, before you will turn the machine
on again. If it is necessary perform a perfunctory check of the machine.
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6. MAINTENANCE
It is necessary to perform periodical checks of the machine and its maintenance for
preserve its high lifespan and trouble free working. Operators and workers
manipulating with material should be acquainted with information said in this chapter.
6.1 Maintenance plane
Immediately
If there were an accidental collision situations, during the work of the machine, while
loading the material on the working table or by influence of programming collision
course of cutting head, it is necessary to check damaged parts and in case of
necessary it is required to do the fast change or reparation of damaged parts. High
attention should be given to the parts around the cutting torch (sensor IHS, parts of
the cutting head, cables etc.). Also the covers of linear rails, covers of electro-motors
etc. should be controlled.
Emphasize, these information especially to operators and to the persons
manipulating with the cut material.
Worn down or another way of damaged laths on the grate of the working table is
necessary to change if you want to preserve set of perpendicularity of cutting head
owing to the workpiece. Laths can be ordered from the producer, or seller of the
machine (have a look to list of spare pieces). If you realize, that jet of the cutting
burner is worn down too much, immediately replace it with a new one. If it will not be
replaced, the quality of the cut will go down. After long term use with worn down jet,
the cutting torch can be damaged. It is possible to order the jets from the producer or
from the seller of the machine (have a look to the list of spare pieces).
Once per week
Depending on the working environs and on the kind of working circumstances it is

necessary to do visual control of whole machine (especially business ends). If it is
necessary you should clean the machine of rests of cut material and of another
mess. You should dedicate more attention to linear rails of all three axes, cutting
head and its locality, sensor IHS and etc. Information about maintenance of
technological part of machine is in manual for plasma cutting devices. We
recommend to control state of filters of exhaust system, and if it is necessary, you
should clean it or change it. The working table should be cleaned of the dirt or of the
rest of cut material as well.
Do the lubrication of important business ends, bearings and linear rails. You can find
technical drawings of individual positions of lubrication points in the end of this
document. Before lubrication take away necessary covers. Use plastic lubricant
Dynalub 510, Castroll LM, Shell LX2, or another compatibly type of lubrication. Apply
lubricant by using the grease gun. Quantity of plastic lubricant needed for one place
is appointed by appraisal. If lubricant starts to extrude from slippery or rolling
imposition, that means you used enough of lubricant. You should not save the
lubricant, but do not use too much of lubricant as well. When you do not use enough
8/22
of lubricant you can get rubber the components or you can induce their excessive
wear and tear. When you use too much of lubricant, you can induce reduction of
kinematical possibilities of specific kinematical couple.
6.2 Description of lubrication points
Lubrication points refer to linear bearings along all of three axes and piston pale on
sensor IHS. There are seven lubrication points on the machine.
Lubrication points (axis „X“)

It is important to lubricate linear bearings. Linear bearings are on both sides of the
machine. Access to lubrication points is from bottom side of the covers on axis X.
You can see all lubrication points in detailed view on picture number 1 in attachment.
Procedure:
• apply the plastic lubricant to lubrication places on linear bearings by using the
grease gun.
Lubrication points (axis „Y“)

In this part it is necessary to lubricate linear bearings on both sides. You can see all
lubrication points in detailed view on picture number 2 in attachment.
Procedure:
grease gun.
Lubrication points (axis „Z“)

There are lubrication points on linear bearings on the axis Z. Lubrication is performed
by grease gun, which applies lubricate to right places. For better access to the
lubrication points, you should replace covers. You can see all lubrication points in
detailed view on picture number 2 in attachment.
Procedure:
grease gun.
Another lubrication points:

For correct function of sensor IHS you should lubricate piston rod and guiding rods of
linear pneumatic cylinder. Drawing of marked point is on picture number 3 in
attachment.
Procedure:
• eject the piston rod of pneumatic cylinder on sensor HIS,
• apply plastic lubricant on surface of the piston rod and on the surface of the
guiding rods,
• try functionality of sensor HIS,
• clear away rest of lubricant.
9/22
6.3 List of spare parts
In next tables, you can find complete list of spare parts offered by producer. In
case of special demand, please contact producer or the seller of devices. Delivery of
spare parts is realized by order. The producer reserves the law for determination of
date of delivery.
10/22
EC 3001.20 CONSOLE X (Fig. 4, 5)
Pos. Name / description Ordering number Quantity Producer Note
1 Main console X 2 – EC – 037 2pcs MS – Rela – PA

2 Gantry Y 2 – EC – 0014 1pc MS – Rela – PA
Qty. depends on
3 Block foot 2 – EC – 0018 MS – Rela – PA length
4 Main girder 2 – EC – 0019 2pcs MS – Rela – PA
5 Cable chain duct console 4 – HS – 725 1pc MS – Rela – PA
Qty. depends on
6 Base plate 3 – EC – 0079 MS – Rela – PA length
7 Cable chain duct X 1pc MS – Rela – PA
8 P.O.J holder 3 – EC – 0074 1pc MS – Rela – PA
9 P.O.J. panel 3 – HS – 432 1pc MS – Rela – PA
10 Back stop Y 2pcs MS – Rela – PA
11 Protection shield of gantry 1pc MS – Rela – PA
12 Guide lines cover X 3 – EC – 0071 2pcs MS – Rela – PA
Qty. depends on
13 Supporting pulley for cable chain X 3 – HS – 715 MS – Rela – PA length
14 Front cover 3 – EC – 0093 1pc MS – Rela – PA
15 P.O.J cover 4 – EC – 0190 2pcs MS – Rela – PA
16 Inner cover 4 – EC – 0178 2pcs MS – Rela – PA
17 Back cover 4 – EC – 197 2pc MS – Rela – PA
18 Bottom cover 3 – EC – 0097 2pcs MS – Rela – PA
19 Pinion cover X 3 – EC – 0089 1pc MS – Rela – PA
20 Cable chain duct holder 2 – EC – 0020 1pc MS – Rela – PA
21 X motor flange 4 – EC – 0187 1pc MS – Rela – PA
22 Terminal board 4 – EC – 186 1pc MS – Rela – PA
23 Terminal board M 4 – EC – 0193 1pc MS – Rela – PA
24 Gantry holder 2pcs MS – Rela – PA
Qty. depends on
25 Rack 25 4 – EC – 0152 Mädler length
26 Bolster 4 – EC – 0153 10pcs MS – Rela – PA
27 Sensor X holder 4 – EC – 0194 2pcs MS – Rela – PA
28 Orifice 4 – EC - 0201 2pcs MS – Rela – PA
29 Pivot pin 4 – EC – 0181 2pcs MS – Rela – PA
31 Pulley Y - moving 24 – 5M – 25 1pc Walther-Flender
32 Cable chain 1 0555.030.075.200 1pc Kabelschlepp
33 Cable chain 2 0665 066 150 200 1pc Kabelschlepp
34 Induction sensor HIS – M8 – 421 01 6pcs HIS
35 Longitudinal guides R 1010 030 00 2pcs Rexroth
36 Runner blocks R1704 430 70 4pcs Rexroth
37 Pinion X 32z – m2 3 – LS – 394,395 2pcs Mädler
38 Gearbox X EPG 79/2.15.14.5.R.16 3pcs ControlTechniques
39 Electromotor DCM 3D 30/06 – A1 3pcs ControlTechniques
40 IRC sensor IRC 9040-2000LB 3pcs Microstep-Rela
11/22
SENSOR IHS (Fig. 6)
1 Cover 3 – MC – 215 1pc MS – Rela – BA

2 Flange 1 3 – MC – 217 1pc MS – Rela – BA
3 Contact plate Ø95 4 – MC – 337 1pc MS – Rela – BA
4 Cable clip 4 – MC – 345 2pcs MS – Rela – BA
5 Sensor cover 4 – MC – 342 1pc MS – Rela – BA
6 Cable holder 4 – MC – 340 1pc MS – Rela – BA
7 Sensor flange 3 – MC – 219 1pc MS – Rela – BA
8 HIS sensor holder 3 – HS – 714 1pc MS – Rela – BA
9 Diode plate 4 – HS – 762 1pc MS – Rela – BA
10 Laser diode holder 4 – MC – 473 1pc MS – Rela – BA
11 Pneumatic valve ADUL-12-100-P-A 1pc FESTO
12 Protecting cover for cables 1pc
13 Laser diode 1pc
14 Grommet 1pc
15 Sensor spring 1pc Alcomex
16 Inductive sensor HIS - M8 - 421 01 1pc HIS
27 Piston position sensor 150 855 T913 2pcs FESTO
12/22
EC 3001.20 CUTTING HEAD (Fig. 7, 8)
1 Cutting head body 2 – EC – 0013 1pc MS – Rela – PA

2 Drive carrier 3 – EC – 0057 1pc MS – Rela – PA
3 Machine gantry 180x180 1pc MS – Rela – PA
4 Pinion Z 4 – EC – 0024 1pc MS – Rela – PA
5 Handle 4 – EC – 0115 1pc MS – Rela – PA
6 Cam body 4 – EC – 0101 1pc MS – Rela – PA
9 Fixture 4 – EC – 0103 1pc MS – Rela – PA
10 Rod 4 – EC – 0107 1pc MS – Rela – PA
11 Console 4 – EC – 0108 1pc MS – Rela – PA
12 Side cover LP 3 – EC – 0056 2pcs MS – Rela – PA
15 Top cover 4 – EC – 0075 1pc MS – Rela – PA
16 Bottom cover 4 – EC – 0132 1pc MS – Rela – PA
17 Rear cover 4 – EC – 0079 1pc MS – Rela – PA
18 Bearing pin 4 – EC – 0111 3pcs MS – Rela – PA
21 Sensor holder bottom 4 – EC – 0119 1pc MS – Rela – PA
22 Sensor holder top 4 – EC – 0123 1pc MS – Rela – PA
26 Lock plate 4 – EC – 0116 1pc MS – Rela – PA
27 Longitudinal guides - side 2 – EC – 0007 1pc MS – Rela – PA
28 Longitudinal guides - top 2 – EC – 0008 1pc MS – Rela – PA
30 Plasma rod – small 2 – EC – 0004 1pc MS – Rela – PA
32 Rack PLM 3 – EC – 0058 1pc MS – Rela – PA
34 Plasma holder 4 – EC – 0100 1pc MS – Rela – PA
35 Plasma box 3 – EC – 0049 1pc MS – Rela – PA
38 Cable chain console 4 – EC – 0042 1pc MS – Rela – PA
40 Electromotor Z DCM 2B 1pc ControlTechniques
42 IRC sensor IRC 9040-2000LB 1pc MS – Rela – BA
43 Gearbox SP DHV 028 100 1pc MEZ Mohelnice
44 Clutch OX25B 1pc Oldham
45 Runner block Z WS 1 1pc ISEL
46 Pressure spring TLZ160.141.0340 1pc PFS Brezova
47 Inductive sensor HIS - M8 - 421 01 3pcs HIS
48 Ball bearing 6001 2Z 3pcs SKF
Length depends
49 Longitudinal guides Y LF - 2 1pc ISEL on gantry width
50 Runner block Y WS - 4 1pc ISEL
51 Lock device GN 615 - M12 - K 1pc IMP Kontakt
54 Plasma control unit 1pc By order
55 Anti-collision holder 1pc MS – Rela – BA
64 Plasma torch 1pc By order
13/22
EC 3001.20 OTHERS
1 Grate 6pcs MS – Rela – PA for EC 3001. 20

2 Lamella for cutting table 45pcs MS – Rela – PA for EC 3001. 20
3 Plasma torch nozzle 1pc
14/22
7. LIQUDATION OF DEVICE
After finish lifetime of the machine it is necessary to arrange its correct liquidation,
decommissioning from run. It is necessary to switch off machine and unplug all
energy sources at first.
7.1 Liquidation of rubbish
Rubbish from particles of molten cut metal arises during the cutting with plasma or
with oxygen-acetylene burner. It is possible to move this accumulated rubbish out to
the dump for durable rubbish.
When you cut material with heavy metal components (special alloys etc.) it is
necessary to notice this fact to dump workers, in other not to contaminate ground
water. However the producer recommends to consult the liquidation of rubbish with
authority for protection of environment.
7.2 Recycling
After putting the machine out of the operation it is possible to recycle individual
materials used for building of cutting machine. All of steel parts and parts made of
non ferrous metals and plastic parts should be moved to separate rubbish.
Electronics and cable bundles are necessary to be moved for next recycling in to the
company appointed for this purpose. You can find detailed information at relevant
office for environment in your country.
15/22
8. ATTACHMENT
I – Lubrication point
Fig. 1 Lubrication points (Axis X)
16/22
I
I I – Lubrication point
Fig. 2 Lubrication points (Axis Y, Z)
17/22
I
I – Lubrication point
Fig. 3 Lubrication points – sensor IHS
18/22
Fig. 4 Console X Front view (spare parts)
19/22
Fig. 5 Console X Side view (spare parts)
20/22
C-C
Fig. 6 IHS SENSOR (spare parts)
21/22
Fig. 7 Cutting head (spare parts)
22/22

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OPERATING MANUAL

PLASMA CUTTING MACHINE

2. CUTTING MACHINE DESCRIPTION

2.2 Longitudinal movement (AXIS X)

2.4 Vertical movement (AXIS Z)

2.5 Working table

Working table is created by similar construction as frame of the machine described in

2.6 Control system

Control system is placed in independence case. There is industrial computer with

3.1 Technical parameters

General dimensions by order

3.2 Energetic requirements

Nominal voltage 230 V/ 50 Hz

Range of the working temperatures + 10 C to + 35 C

4. TRANSPORT AND STORAGE

6.1 Maintenance plane

Once per week

Depending on the working environs and on the kind of working circumstances it is

6.2 Description of lubrication points

Lubrication points (axis „X“)

Lubrication points (axis „Y“)

Lubrication points (axis „Z“)

Another lubrication points:

1 Main console X 2 – EC – 037 2pcs MS – Rela – PA

1 Cover 3 – MC – 215 1pc MS – Rela – BA

1 Cutting head body 2 – EC – 0013 1pc MS – Rela – PA

1 Grate 6pcs MS – Rela – PA for EC 3001. 20

7.1 Liquidation of rubbish

Fig. 2 Lubrication points (Axis Y, Z)

Fig. 6 IHS SENSOR (spare parts)

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