OXYFUEL CUTTING

HAND-OUT
 Preface

1 Preface
Copyright © 2014 Voortman

All rights reserved.

No part of this publication may be reproduced, stored in a retrieval system, or

transmitted in any form or by any means, electronic, mechanical, photocopying,
recording or otherwise without the prior written permission of Voortman.

Due to continued product development this information may change without notice.
The information and intellectual property contained herein is confidential between
Voortman and the customer and remains the exclusive property of Voortman. If you
find any problems in the documentation, please report them to us in writing. Voortman
does not guarantee that this document is error-free.

This manual is the original version.

Disclaimer Notice

Voortman reserves the right to change the construction and/or configuration of the
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machine at any time without being obliged to adjust earlier supplies accordingly. The
material in this manual is believed adequate for the intended use of the machine. If the
machine is used for purposes other than those for which it is intended, confirmation of
their validity and suitability must be obtained.

Machine type plate

This information is shown on the machine type plate:

● Manufacturer contact details.

● Machine number (this is the sales ordernumber).

OXYFUEL CUTTING 3
 Preface

● Year of construction (this is the year the type plate is initially filled in).

● Power supply (Voltage, Phases and Frequency).

The location of the machine type plate depends on the type of machine.

If a system has more machines, there is only one machine type plate for the complete
system.

Environmental aspects

The owner and/or user of the machine is responsible for the removal of waste
materials (oil, etc.) in accordance with the statutory legislation or regulations that are
in force.

Decommissioning

At the end of the operational life of the machine, the owner and/or user are
responsible for the safe disassembly of the machine and for the removal of the parts,
in accordance with the statutory legislation or regulations in force.

1.1 Intended use of the equipment

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General

The machine is developed and designed to be used only for its intended application.
Intended use also includes the compliance with the manufacturer's instructions and
the instructions of the Original Equipment Manufacturer (OEM).

Any other use is considered unintended.

The machine must only be used in technical correct condition and in accordance with
the safety regulations.

Also intended is the use of additional equipment and accessories produced and/or
supplied by the manufacturer.

Intended use VCS

The equipment is used for oxyfuel cutting and/or plasma cutting of parts from or out of
steel plates or similar processes.

Also intended is the use of additional equipment and accessories produced and/or
supplied by the manufacturer.

OXYFUEL CUTTING 4
 How to get assistance

2 How to get assistance

2.1 Service
Reliability, availability and productivity are maintained when the Voortman machines
are regular serviced by specialists. To serve this purpose Voortman has its own
service department and team of skilled engineers.

A malfunction during production can have a great impact on a company, if the

production process is disturbed and the continuity is interrupted. The Voortman
service team is highly capable of repairing the cause of disruptions and minimize the
effects of any interruption.

Make sure you have these details present for quick and smooth handling:

● The number of the machine (you can find it on the type plate on the machine).

● In case of succession of a previously reported problem, the notification number of the

event.

For fast and efficient service regarding installation, maintenance, parts and
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consumables, training and other technical issues, a special telephone number and e-
mail address is available on the service-tab of our website:

www.voortman.net

2.2 Parts and Consumables

Also of great importance for the lifetime of the machine is the use of correct parts and
consumables. In our large fully stocked automated warehouse we have all the parts
and consumables for our own build machines and other brands in stock.

For fast and efficient service regarding installation, maintenance, parts and
consumables, training and other technical issues, a special telephone number and e-
mail address is available on the service-tab of our website:

www.voortman.net

2.3 Maintenance
To reduce failures and down-time of the machine to a minimum Voortman offers you
the possibility to conclude a maintenance contract. This contract includes:

● Periodic inspection of the machine in accordance with a check list.

OXYFUEL CUTTING 5
 How to get assistance

● Prepare and send you the completed inspection report in which is mentioned:

- The maintenance tasks that are carried out.

- Advise to keep your machine in optimal condition.

● Record all inspection reports that give the possibility to optimize preventive
maintenance in the future.

2.4 Manufacturer contact details

The manufacturer of this machine is Voortman Steel Machinery. For more information
please contact us:

Voortman

P.O. Box 87

7461 AB Rijssen

The Netherlands

Telephone: +31 (0)548 536 373

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Telefax: +31 (0)548 536 374

Internet: www.voortman.net
E-mail: info@voortman.net

OXYFUEL CUTTING 6
 Table of Contents

Table of Contents
1 Preface ....................................................................................................... 3
1.1 Intended use of the equipment .................................................... 4

2 How to get assistance .............................................................................. 5

2.1 Service ......................................................................................... 5
2.2 Parts and Consumables .............................................................. 5
2.3 Maintenance ................................................................................ 5
2.4 Manufacturer contact details ....................................................... 6

3 Safety ......................................................................................................... 9
3.1 General safety ............................................................................. 9
3.2 Electrical safety ........................................................................... 10
3.2.1 Electrical safety equipment .......................................... 10
3.3 Personal safety ............................................................................ 11
3.4 Specific safety instructions cutting systems ................................ 12
3.5 Safety requirements during maintenance .................................... 12
3.6 Noise level ................................................................................... 13
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3.7 CE-Certificate .............................................................................. 13

3.8 Safety labels ................................................................................ 15

4 Description ................................................................................................ 19
4.1 Process ........................................................................................ 19
4.2 Oxyfuel cutting quality ................................................................. 20
4.3 Oxyfuel gas supply ...................................................................... 21
4.4 Automatic clearance control ........................................................ 22

5 Operation ................................................................................................... 25
5.1 Fuel gas choice ........................................................................... 25
5.1.1 Acetylene ..................................................................... 25
5.1.2 Propane ........................................................................ 26
5.1.3 MAPP ........................................................................... 26
5.1.4 Propylene ..................................................................... 26
5.1.5 Natural gas ................................................................... 26
5.2 Nozzle choice .............................................................................. 26
5.2.1 Add torch ...................................................................... 27
5.3 Set the clearance control sensor system ..................................... 28
5.4 Set gas pressure ......................................................................... 29
5.4.1 Set gas and oxygen supply .......................................... 30
5.5 Preheat flame .............................................................................. 31
5.6 Cutting flame ............................................................................... 31
5.7 Cutting steel ................................................................................. 31
5.8 VCS: Cutting unit manager: Cutting unit oxyfuel ......................... 32

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 Table of Contents

6 Automatic oxyfuel cutting process ......................................................... 37

6.1 Surface start (default) .................................................................. 38
6.2 Edge start .................................................................................... 38
6.2.1 Set edge start ............................................................... 40
6.3 Panel buttons ............................................................................... 42

7 Maintenance .............................................................................................. 45
7.1 Clean oxyfuel cutting tips ............................................................. 45
7.2 Clean ring electrode .................................................................... 45

8 Troubleshooting ....................................................................................... 47
8.1 Correct cutting ............................................................................. 47
8.2 Incorrect cutting ........................................................................... 47
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OXYFUEL CUTTING 8
 Safety

3 Safety
The safety information in this set of guidelines is compiled as a general indication of
safe procedures relating to the handling of the machine.

NOTE
Voortman declines to put the information forward as complete and all-embracing and
can therefore not accept liability for possible omissions.

General safety was promoted during the design of the machine and the surroundings
there of by attaching various safety facilities. Even so, care must be taken at all times
as accidents can always occur.

Always obey local regulations in accordance with the statutory legislation or

regulations in force.

Any safety instructions described in OEM documentation is mandatory.

3.1 General safety

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WARNING
It is not permitted to by-pass or switch-off safety devices.

WARNING
The body of drives can become hot; make sure the ventilators of the drives function
correctly.

WARNING
Do not come in the working area of the machine during operation.

WARNING
Do not come in the working area of the infeed- and outfeed conveyor during operation.

WARNING
Do not come in the working area of the cross-transports during operation.

WARNING
Do not look in the laser beam! This may result in severe eye damage.

● If you are not familiar with the machine, read this manual and especially this chapter
‘Safety’ before you operate the machine.

● Only operate the machine, if you have knowledge of the operation of the machine, the
control devices and safety devices.

● Only trained and qualified persons are allowed to operate the machine or carry out
maintenance tasks. Inexperienced persons are only permitted in vicinity of the
machine under supervision of an experienced and trained engineer.

● Personal protection devices such as safety helmet, safety glasses and safety shoes
are mandatory.

OXYFUEL CUTTING 9
 Safety

● If the warning system (light or sound signal) is out of order, repair immediately.

● Changes to the machine, without written permission of Voortman, are not permitted.

● Always use original parts and consumables. Voortman takes no responsibility if

damage occurs because non original parts and consumables are used. When non
original parts and consumables are used, the warranty is void.

● Make sure all panels and covers are installed and closed correctly before starting the
machine.

● Make sure you are always aware of the total situation.

3.2 Electrical safety

WARNING
Do not open the electrical cabinets during operation. Electrical power can result in
severe injuries or death. Contact an experienced and trained engineer if opening is
absolutely necessary.

WARNING
Consider all circuits live until the main power switch is 'OFF', then wait for at least 3
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minutes. Lock the switch.

WARNING
Be aware that stored electrical energy remains in the electrical cabinet (capacitors)
until 30 minutes after the main switch is set to 'OFF'.

WARNING
Keep your clothing, hands and feet dry.

WARNING
Do not wear rings, watches, metal-rimmed glasses or jewellery when working on
electrical circuits.

WARNING
Magnetic fields from high currents can have an unwanted effect on pacemaker and
hearing aid operation.

WARNING
Pacemaker and hearing aid users must consult a doctor before working with the
system because plasma cutting and gouging can affect the operation of those aids.

3.2.1 Electrical safety equipment

The machine has this electrical safety equipment:

● Emergency stop button(s).

OXYFUEL CUTTING 10
 Safety

● Emergency stop cord.

● Safety bumpers.
The gantry has safety bumpers at the front and rear side. If a bumper hits an object
(e.g. a person) the machine stops immediately.

NOTE
The safety bumpers can also be used as manual emergency stop.

As long as a safety bumper is activated, it is possible to reset the machine and

manually move the gantry, in the opposite direction only, with the buttons on the
operating panel. This is to release the object that activated the safety bumper.
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Legend:

1 Safety bumpers

2 Emergency stop cord

3 Emergency stop button(s)

3.3 Personal safety

Take these precautions when working with the machine:

● Do not wear rings, watches, jewellery, ties or loose clothing.

● Keep long hair covered (e.g. with a net).

● Do not leave tools, parts or left over products on the work floor as this can cause
accidents.

● Use lifting equipment to move material >10 kg.

● Wear safety gloves (Workpieces can have sharp edges).

OXYFUEL CUTTING 11
 Safety

3.4 Specific safety instructions cutting

systems
WARNING
Specific danger and safety instructions applicable to the plasma installation are
described in the plasma source user manual. That information is mandatory. This
section gives a summary of major dangers.

● Plasma and oxyfuel torches can be very hot.

● A plasma arc can cause injury and burns.

● Arc rays can burn eyes and skin.

● Wear eye protection in accordance with EN 175.

● Wear protective clothing in accordance with ISO 11611.

● Cutting can cause fire and/or explosion.

● Components of the exhaust system can become very hot.

● Make sure a fire extinguisher is available near the machine.

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● Never touch the workpiece or the torch. This can cause severe burn or fatal shock.
When it is absolutely necessary, before touching the workpiece or the torch, make
sure all electrical power is switched off and the workpiece and torch are completely
cooled down.

● Plasma arc rays produce intense visible and invisible rays (ultraviolet and infrared).

● Prolonged exposure to noise from cutting or gouging can damage hearing.

● Some metals e.g. stainless steel, aluminium, carbon steel, zinc (galvanised) copper,
can release toxic fumes. Wear Personal Protective Equipment and obey the national
and/or local regulations.

3.5 Safety requirements during maintenance

WARNING
Make sure the hydraulic system is depressurized before maintenance. Pressurized
fluid can cause severe injuries.

WARNING
Do not look in the laser beam! This may result in severe eye damage.

WARNING
Consider all circuits live until the main power switch is 'OFF', then wait for at least 3
minutes. Lock the switch.

WARNING
Be aware that stored electrical energy remains in the electrical cabinet (capacitors)
until 30 minutes after the main switch is set to 'OFF'.

OXYFUEL CUTTING 12
 Safety

CAUTION
Welding on the machine is not permitted.

CAUTION
For stable and reliable operation it is necessary to comply with the maintenance and
lubrication instructions.

● Dispose used hydraulic oil and oil filter in compliance with local environmental
regulations.

● Visually inspect the pneumatic and hydraulic tubes during maintenance for wear and
damage.

● Do not change the settings of valves and pressure regulators.

● After maintenance, make sure all hydraulic and pneumatic connections are correctly
installed and tightened.

● After maintenance put back all safety devices (i.e. covers and fences).

3.6 Noise level

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The noise level is approximately 70 dB(A) during free running. During operation the
noise level can exceed 85 dB(A) for example caused by material transport and falling
parts.

Ear protection:

> 80 dB(A) recommended

> 85 dB(A) mandatory

3.7 CE-Certificate

If applicable, additional safety equipment (e.g. fences, light screens etc.) must be
placed to comply with the CE regulations. Type of safety equipment, installation
details and position etc. of the safety equipment depends on the machine type and the
local situation.

The supplier is responsible to ensure that the machine complies with the CE
regulations. If not included in the scope of supply, the customer has to guarantee that
all safety equipment is installed before commissioning of the machine.

OXYFUEL CUTTING 13
 Safety

The CE-Certificate is granted only, when all necessary safety equipment is installed
and only than the CE-marking plate is placed on the machine adjacent to the machine
type plate.
2015-04-08 EN [AI-002]

OXYFUEL CUTTING 14
 Safety

3.8 Safety labels

Not permitted for persons with pacemaker

Unauthorized access not permitted

No open fire

No smoking

Danger electrical voltage

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Danger potentially explosive atmospheres

Danger laser radiation

Danger optical radiation

Cutting danger fingers

Cutting danger

OXYFUEL CUTTING 15
 Safety

Jamming danger

Jamming danger hands

Danger or risk due to obstacles

Danger or risk due to obstacles (tape)

Slipping danger
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Danger rotating rollers

Danger rotating parts

Warning: Read the manual!

Wear eye and ear protection

Wear safety gloves

OXYFUEL CUTTING 16
 Safety

Wear safety shoes

Wear protective breathing equipment

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OXYFUEL CUTTING 17
 Safety
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OXYFUEL CUTTING 18
 Description

4 Description
4.1 Process
One of the oldest processes used for cutting steel is the oxyfuel process.

Oxyfuel cutting is a thermal cutting process that is done with a fuel gas/oxygen flame
and cutting oxygen. The material is heated locally to ignition temperature (preheat)
and burned at this point in the stream of cutting oxygen. The produced heat by heating
flame and burning the material permits a continuous process of burning in the stream
of cutting oxygen. The reaction is in the width and in movement direction (feed
direction). The cutting oxygen jet blows away the mixture of oxides and melted metal
(cutting slag). This makes the cutting kerf.
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Legend:

1 Oxygen

2 Oxyfuel

3 Heating flame

4 Slag jet

Flame cutting of only possible if the material it meets these requirements:

● The heated material at ignition temperature must burn in the oxygen stream to make
fluid oxides which can be ejected.

OXYFUEL CUTTING 19
 Description

● The ignition temperature of the steel must be lower than its melting point. If the
temperature is higher the steel melts and flows away before cutting can take place.

● The burn heat of the material must be as high as possible and its thermal conductivity
as low as possible.

Important elements of oxyfuel cutting

● Cutting tip

● Preheat flame

● Oxygen stream

● Cutting speed

● Tip clearance

4.2 Oxyfuel cutting quality

The result of a correct oxyfuel cutting process causes:

● Square top corner (with minimum radius).

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● Cut face flat top to bottom (no undercut).

● Cut face square related to top surface.

● Clean smooth surface with near vertical drag lines.

● Little or no slag on bottom edge (easily removed by scraping).

OXYFUEL CUTTING 20
 Description

4.3 Oxyfuel gas supply

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Legend:

OXYFUEL CUTTING 21
 Description

1. Cutting oxygen gas supply 10 bar

370 L/min
2. Preheat oxygen gas supply 5 bar
65 L/min
3. Fuel gas supply 0,6 bar
4. External gas supply connections For details see also CRD
5. Machine Gantry bridge
5.1 2/2 Shut-off valve cutting oxygen
5.2 2/2 Shut-off valve preheat oxygen
5.3 2/2 Shut-off valve oxyfuel gas
5.4 6-way gas distribution cutting gas
5.5 6-way gas distribution preheat oxygen
5.6 6-way gas distribution oxyfuel gas
6. Torches
6.1 Proportional valve cutting oxygen
6.2 Proportional valve preheat oxygen
6.3 2/2 Shut-off valve oxyfuel gas For cutting torch
6.4 2/2 Shut-off valve oxyfuel gas For ignition torch
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6.5 Manual reducing valve for oxyfuel gas For ignition torch
6.6 Ignition torch
6.7 Cutting torch
6.8 Manual reducing valve(s) For cutting torch

4.4 Automatic clearance control

This section only gives a summary of topics.

OXYFUEL CUTTING 22
 Description

For detailed information see also the Original Equipment Manufacturer (OEM)
documentation.
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1 Guide rail

2 Control unit

3 Linear drive body cap

4 Torch clamp

5 Heat shield

6 Sensor connector unit

7 Ring electrode

8 Coax cable

The M 4000 automatic clearance control system controls the clearance automatically
between an oxyfuel torch and the workpiece.

A ring electrode, installed on the torch is used as a touchless clearance control

sensor. The measuring system uses the principle of an electrical capacitance between
the ring electrode and the workpiece. The clearance control is only possible with a dry
workpiece without influence of water.

OXYFUEL CUTTING 23
 Description
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OXYFUEL CUTTING 24
 Operation

5 Operation
5.1 Fuel gas choice
For the preheat of the steel a flame with gas/oxygen mixture is used. A number of gas
types are available to make a selection as cutting gas or preheat gas.

● Acetylene

● Propane

● Fuel gas mixtures (Mapp gas etc.)

● Propylene

● Natural gas

The function of the gas flame is to bring the steel up to the ignition temperature. The
ignition temperature is just under the melting temperature of the steel. A strong
directed oxygen flow comes out of the central part of the cutting nozzle. This oxygen
flow burns the steel. Because the high speed of the flow, the melted steel and slag are
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blown out of the kerf.

The cutting speed is mainly determined by the oxygen flow. The properties of the
flame have a large effect on the cutting speed and preheat time.

This table gives an overview of the flame temperature of different gas types at a
specific oxygen/gas ratio. General rule: gas types with the highest flame temperature
and the lowest oxygen consumption result in higher cutting speed.

Fuel gas Maximum flame temperature °C Oxygen to fuel gas ratio

Acetylene 3160 1.2 : 1

Propane 2810 4.3 : 1
MAPP 2927 3.3 : 1
Propylene 2872 3.7 : 1
Natural gas 2770 1.8 : 1

5.1.1 Acetylene
Acetylene gives a strong directed flame with the highest flame temperature of all the
fuel gases. The hotter flame gives a faster piercing time of the steel. The pierce time
with acetylene is about one third of the pierce time with propane.

Acetylene is used when the preheat time has effect on the total cutting costs. I.e. short
cutting lengths and frequently piercing.

The high temperature and the strong directed flame makes acetylene to the ideal gas
for cutting thin plates with a minimum deformation.

OXYFUEL CUTTING 25
 Operation

Acetylene cutting is also very applicable to make bevel cuts.

5.1.2 Propane
Propane is relatively cheap. Propane gives a lower flame temperature than acetylene.
The piercing time is longer and cutting speed is lower than with acetylene.

The benefit of cutting with propane:

● Good cutting surface

● Less slag formation

● Lower hardness of the cutting surface because of lower flame temperature

Propane has a larger consumption of oxygen than acetylene. For the maximum flame
temperature, the ratio of the volume of oxygen to fuel gas are 1.2 to 1 for acetylene
and 4.3 to 1 for propane.

5.1.3 MAPP
MAPP gas is a mixture of various hydrocarbons. The name comes from the original
chemical composition: MethylAcetylene-Propadiene Propane. The flame temperature
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is lower than acetylene. The preheat time for piercing is longer. MAPP has a lower
oxygen consumption than propane.

Mapp gas is very suitable for underwater cutting.

5.1.4 Propylene
Propylene is a liquid petroleum gas (LPG) product and has almost the same flame
temperature to MAPP (2872 °C compared to 2927 °C for MAPP). Propylene is hotter
than propane. Acetylene is hotter than propylene. Propylene has just as propane a
high oxygen to fuel gas ratio.

5.1.5 Natural gas

Natural gas has the lowest flame temperature of all used fuel gases. Natural gas is the
slowest for piercing and cutting speed.

5.2 Nozzle choice

Selection criteria cutting tips:

● Fuel gas

● Material thickness

OXYFUEL CUTTING 26
 Operation

5.2.1 Add torch

1 Select 'Machine' > 'Tool list' (F11).

2 Select the 'Oxyfuel torches' tab.

3 Press this button to open the 'New torch' window.

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In the 'General' group box select:

The type of material to cut.

The brand of the cutting nozzle.

Type of cutting nozzle.
Torch number.

The 'Settings' table is a default table in VACAM that belongs to the selected tool. It is
possible to change the setting to improve the cutting process. A graphical view of the
process is shown to help making changes when necessary. It is possible to select
three graphs:

OXYFUEL CUTTING 27
 Operation

Pressure control Shows:

● Preheat pressure

● Cutting pressure

● The fuel gas pressure is not shown because it is pre-set

at the supply pressure reducer.
Height control Shows:

● Torch lifting time

Speed control Shows:

● Cutting speed

The changes are stored with the applicable tool.

If the tool is deleted from the list and a new tool is added, the default table is used
again.

5.3 Set the clearance control sensor system

How to set the clearance control sensor system:
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1 Set the ring electrode for all torches approx. 4 mm higher than the tip of the nozzle.

NOTE
Make sure that the ring electrode is set the same for all torches.

NOTE
Make sure that the ring electrode is in the middle of the torch.

2 Move the selected torches to the operating position above the plate.

3 In the 'Oxyfuel setting' window [F7], press the [Automatic] button to set the selected
torches in automatic mode.

4 The selected torches move to the down position.

OXYFUEL CUTTING 28
 Operation

5 In the 'Oxyfuel setting' window [F7], use the 'Height Control' arrow buttons to set the
parameter 'OH' to 50%.
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6 Set the height of torches with the 'Clearance adjust' potentiometer (1) on the control
unit of the automatic clearance control (see page 22). Set the potentiometer (1) on +/-
50.

NOTE
Make sure that the height of all torches is the same.

7 Check the speed of clearance control with the 'Dynamic' potentiometer (2). Set the
potentiometer (2) on +/- 1.

5.4 Set gas pressure

How to set the gas pressure (see page 21):

1 Fully open all manual reducing valves on the torch(es).

2 Set the initial gas pressures at the supply pressure reducer (see page 30).

3 The pressure setting of the proportional valves is set in the 'Settings' table (see
page 27).

4 During cutting the gas pressure does not change so it is not necessary to change the
gas pressure settings during production.

5 If necessary regulate the gas pressures at the manual screen (see page 32) of the
operator panel.

OXYFUEL CUTTING 29
 Operation

5.4.1 Set gas and oxygen supply

For the optimal function of the cutting systems, a constant pressure is necessary.

Legend:

1 Shut-off valve main supply

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2 Main supply

3 Pressure reducer gas/oxygen supply to machine

4 Shut-off valve gas/oxygen supply to machine

5 Pressure gauge gas/oxygen supply to machine

6 Pressure gauge gas/oxygen main supply

Set procedure:

1 Close shut-off valve. (4)

2 Open shut-off valve. (1)

3 Regulate the oxygen/gas pressure to the machine with the gas pressure reducer. (3)
(see page 21)

4 Check for constant oxygen/gas pressure to the machine on the gauge. (5)

5 Open shut-off valve. (4)

NOTE
Do not completely open the valve against the seat. This is to prevent that the valve
seat sticks.

WARNING
Before machine start, check constant oxygen/gas pressure.

OXYFUEL CUTTING 30
 Operation

5.5 Preheat flame

1 Pre-set (see page 29) the fuel gas and oxygen pressures.

2 Ignite the flame.

3 Slowly set the preheat oxygen at the operator panel. Flame is carburizing.

4 Continue to set the preheat oxygen pressure to get a neutral flame.

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5 Too much preheat oxygen produces a not correct oxidizing flame

5.6 Cutting flame

1 Pre-set (see page 29) the cutting oxygen pressure.

2 Switch the preheat flame to the cutting flame.

3 Set the cutting oxygen pressure on the operator panel to get a correct flame form
(refer to the next figure) in relation to the preheat flame.

5.7 Cutting steel

The oxyfuel cutting process is automatic on the Voortman Cutting Systems. The
cutting system uses the cutting table of the tip.

OXYFUEL CUTTING 31
 Operation

If the cutting process is active the operator can change these parameters:

● Height control (on the operator panel)

● Speed control (on the operator panel)

● Flame control (see page 29) (on the oxyfuel torch or in the 'Oxyfuel setting' [F7])

● Preheat control

Cutting process on the machine:

NOTE
Make sure the pressure at the gas and oxygen supply is stable.

1 The torch starts with preheating the steel. This can be done at the edge or on surface
of the plate.

2 If the heated spot is on ignition temperature (cherry red) the system switches to the
cutting flame. The switch time is pre-set in the cutting table.

NOTE
Adjust the switch time on the operator panel when the material in not cherry red or the
material is sputtering. See the switch time on the operator panel.
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3 After the cutting flame switched on the machine starts with the lead-in and cuts the
product(s).

NOTE
Make sure the flow of slag is clean and not blocked.

4 When cutting is finished, the torch moves to the home position and the flame is
switched off.

5.8 VCS: Cutting unit manager: Cutting unit

oxyfuel
Select the 'Cutting unit oxyfuel' to open the manual operation functions. Press the [F7]
function key on the operator panel to quickly open the screen.

Manual buttons Explanation

The selected module moves to the rest position.

Press the [Actual Tool info] button to open the 'Edit torch'
dialog window.

OXYFUEL CUTTING 32
 Operation

Press this button to open the 'Manual Cutting' dialog window.

[Enter cuttinglength] button

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Press this button to select a specified length that must be cut

in X- or Y-direction.

[Use panelbuttons] button

Press this button to select the start direction. Use the

Operating panel buttons for manual cutting:

● When the torch moves in Y-direction, press [Arrow up] or

[Arrow down] button to move the torch to the corresponding X-
direction.

● When the torch moves in X-direction, press [Arrow left] or

[Arrow right] button to move the torch to the corresponding Y-
direction.

● Press the [Stop] button to stop cutting.

[Cut with multiple torches] button

OXYFUEL CUTTING 33
 Operation

Press this button to open the 'Cut with multiple torches' dialog
window.

● In this dialog window, set the cutting parameters.

[Strip cutting] button

Press this button to open the 'Strip cutting' dialog window.

● In this dialog window, set the cutting parameters.

Press these buttons to select the necessary oxyfuel flame

mode of operation.

● [Off] - Set the oxyfuel flame in off mode.

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● [Preheat] - Ignite or set the preheat oxyfuel flame.

● [Cut] - Ignite or set the cut oxyfuel flame.

● Hold the [Clean pit] button to blow unwanted materials out of

the pit.

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 Operation

Use these buttons to select the necessary height control mode

of operation.

Functions [Disable] button:

● Disable button (White): The height control is in automatic

mode.

● Disable button (Red): The height control is disabled. Change

the torch height with the manual button on the operator panel.

Function [Arrow up] and [Arrow down] buttons:

● Use these buttons to set the oxyfuel torch height. See the
parameter 'OH M' on the operator panel for the oxyfuel torch
height setting.

Function [Goto cutting height] button:

● Use this button to move the selected torches to the operating

position above the plate. The unit operates with the 'OH M'
parameter.

Actual state:
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● The actual state of the height control is shown in this group

box.

When a tool is selected, the actual and the necessary (in brackets) Oxygen
pressures are shown (Preheat and Cutting pressure).

Press these buttons to select the necessary Oxyfuel unit.

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 Operation
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 Automatic oxyfuel cutting process

6 Automatic oxyfuel cutting process

NOTE
First the operator sets the preheat and cutting flame on the machine.

NOTE
A number of cutting parameters are variable and can be set in the VACAM cutting
table.

Variable cutting parameters

● Preheat pressure O2 low (Bar)

● Preheat pressure O2 high (Bar)

● Cutting pressure O2 low (Bar)

● Cutting pressure O2 high (Bar)

● Cutting O2 rising time (ms)

● Torch lifting time (ms)

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● Preheat time with hole (edge start) (s)

● Preheat time without hole (surface start) (s)

● Pierce time (s)

● Kerf width (mm)

● Cutting speed (mm/min)

Overview of differences between the edge start and surface start.

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 Automatic oxyfuel cutting process

● The nesting must be changed with an edge start.

● The preheat time and pierce time are shorter.

● The pierce timer is used to change the preheat flame to cutting flame.

6.1 Surface start (default)

1 The operator moves the torch to the start position.

2 Press the [Start] button to ignite the preheat flame.

- The torch moves to working height

- The preheat flame heats a spot on the surface of the plate.

- The preheat time and pressure O2 high are specified in the VACAM table.

3 The torch is lifted before piercing procedure starts (step 6 up to 11).

- The torch lifting time is in the VACAM table.

4 During the pierce time the preheat flame changes to cutting flame.

5 When piercing starts the preheat pressure O2 high is set to preheat pressure O2 low.
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6 When piercing starts the cutting pressure O2 low is set.

7 When the cutting pressure O2 low is set, the cutting pressure O2 high is builds up.

- The build up time is specified in the cutting O2 rising time.

8 When piercing starts the torch movement starts with the lead-in.

9 During the total pierce cycle the torch moves with a predetermined speed.

10 During the pierce cycle the torch moves down to cutting height.

11 After the pierce cycle the auto height control of the torch is set and the machine is
cutting.

12 When cutting changes from one product to the next product, the flame goes to
preheat.

6.2 Edge start

The default cutting start position is on the plate surface. Use the CAD editor to change
the start position to edge start.

How to set edge start:

1 Open the nesting in the CAD Editor.

2 Press this button to switch nesting mode off.

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 Automatic oxyfuel cutting process

3 Right click on the line of the product to open the context menu.

4 Select 'Cutting parameters' in the context menu to open the 'Cutting parameters'
dialog window.
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5 Select the 'Edge start' checkbox.

6 Press the [OK] button to save the parameter.

7 Press the [OK] button to close the CAD Editor and save the plate nesting.

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 Automatic oxyfuel cutting process

6.2.1 Set edge start

The default cutting start position is on the plate surface. Use the CAD editor to change
the start position to edge start.

How to set edge start:

1 Open the nesting in the CAD Editor.

2 Press this button to switch nesting mode off.

3 Right click on the line of the product to open the context menu.
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 Automatic oxyfuel cutting process

4 Select 'Cutting parameters' in the context menu to open the 'Cutting parameters'
dialog window.
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5 Select the 'Edge start' checkbox.

6 Press the [OK] button to save the parameter.

7 Press the [OK] button to close the CAD Editor and save the plate nesting.

OXYFUEL CUTTING 41
 Automatic oxyfuel cutting process

6.3 Panel buttons

● Press the [Torch up] button to set the torch height.

● Press the [Torch down] button to set the torch height.

● Press the [Pause] button during cutting; the machine goes

on hold. Height goes to 50% and the oxy-flame goes to
preheat. In case of plasma the process stops.
Use the X-left/right and Y-left/right buttons on the
operating panel to move the torch away from the contour.
The position on the contour is stored and resume cutting
from this position is possible.

● Press the [Pause] button during preheat holds the timer.

Press the [Pause] button again to continue preheating.
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● Press the [Start] button during preheat to start piercing

immediately.

● Press the [Start] button when the machine is in pause; the

preheat process starts in the edge start mode. Press the
[start] button again to start cutting.
● Press the [Retrace forward] button to retrace the torch
forward. This function is active when the machine is in
pause mode.

● Press the [Retrace rearward] button to retrace the torch

rearward. This function is active when the machine is in
pause mode.

● Use these buttons to change the preheat time during

preheating. This time is used for the remaining automatic
cycle. To use this time for the next cycles, make the
changes in the cutting table.

● Press the [Rest position] button to move the gantry to the

rest position.

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 Automatic oxyfuel cutting process

● Press the [Re-ignition] button to re-ignite the flame (all

oxyfuel torches).

● Press the [Re-ignition] button to purge the system with

100% cutting oxygen. This function is active when the
machine is in stop mode.
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 Automatic oxyfuel cutting process
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OXYFUEL CUTTING 44
 Maintenance

7 Maintenance
7.1 Clean oxyfuel cutting tips
Be careful when cleaning the cutting tips because of the precision design (bore
design). Use a special tip cleaning tool to prevent damage the precision design.

Example tip cleaning tool:

7.2 Clean ring electrode

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Clean the ring electrodes of the oxyfuel torches.

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 Maintenance
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 Troubleshooting

8 Troubleshooting
8.1 Correct cutting

8.2 Incorrect cutting

Cutting speed too low
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Cutting speed to high

Nozzle too far from surface

Nozzle too near surface

Too much cutting oxygen

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 Troubleshooting

Too much preheat flame

Dirty nozzle used

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OXYFUEL CUTTING
49