Piranha CNC Plasma Cutting Table Operating Manual
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Piranha CNC Plasma Cutting Table Operating Manual

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CNC Plasma Cutting System
Operating Manual
Revised September 14, 2018
www.piranhafab.com
800-338-5471

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Summary of Contents for Piranha CNC Plasma Cutting Table

  • Page 1 CNC Plasma Cutting System Operating Manual Revised September 14, 2018 www.piranhafab.com 800-338-5471...

  • Page 3: Table Of Contents

    TABLE OF CONTENTS TABLE OF CONTENTS SAFETY ............................5 SPECIFICATIONS ........................23 INSTALLATION .......................... 25 OPERATIONS ..........................47 PROGRAMMING ........................85 MAINTENANCE ........................89 PARTS MANUAL ........................105 PIPE CUTTING ATTACHMENT (OPTIONAL EQUIPMENT) ............115 WATER MIST CHILLER (OPTIONAL EQUIPMENT) ..............137 APPENDIX A –...
  • Page 4 TABLE OF CONTENTS Sept-2018...

  • Page 5: Safety

    Do not become complacent about safety or completely dependent on safety devices. SUPERVISORS It is very important that a safe and appropriate working environment is provided for this Piranha equipment and in compliance with applicable federal and local industry standards. It is imperative that programmers, machine operators and maintenance personnel be trained adequately in the use and care of the equipment.
  • Page 6 MAINTENANCE PERSONNEL Only qualified personnel should make repairs on this equipment. Use caution and follow Piranha procedures when working on the machine. Be sure to observe the following guidelines: 1. Before performing maintenance or repair, turn the power OFF and follow lock out/tag out (zero energy shutdown) procedures.
  • Page 7 Only qualified personnel should make repairs on the machine. 1. Be familiar with the machine. Read and review the Piranha and vendor component manuals carefully. 2. Be alert in regard to the significance of the various warning indicators and be conscious of the functions of pushbuttons and other controls.
  • Page 8 SAFETY RISK OF ELECTRIC SHOCK DANGER Always verify that ALL electrical supplies are isolated before undertaking any service or maintenance work. The machine may have more than one electrical supply. Plasma cutting equipment uses high open circuit voltages to initiate the plasma arc. Normal load voltages are higher than experienced with other types of welding equipment.
  • Page 9 SAFETY EYE PROTECTION WARNING The plasma arc cutting process produces rays that can burn eyes and skin. Always wear eye protection with appropriate lens shades. LENS SHADE Arc Current AWS (USA) ISO 4850 Up to 100A No. 8 No. 11 100 –...
  • Page 10 SAFETY GROUNDING Input Power 1. Connect the ground lead of the four-conductor / three phase input cable to the electrical system ground in the disconnect box and the ground stud provided in the plasma arc supply. 2. Be sure all ground lugs are of adequate size to carry the rated current load. 3.
  • Page 11 SAFETY TOXIC FUMES Proper precautions must be exercised to prevent the exposure of others in the vicinity to toxic fumes that may be generated while plasma cutting. Certain chlorinated solvents such a perchloroethylene and trichlorethylene will decompose under ultra violet radiation to form phosgene and other gasses. Care must be taken to avoid the use of these solvents on materials being cut with plasma arc cutting equipment.
  • Page 12 SAFETY Nitrogen Dioxide Nitrogen dioxide gas is produced when nitrogen and oxygen in the air pass through the electric arc. A hazard may exist if uncontrolled, excessive levels of nitrogen dioxide are formed. With proper venting to the outside, the machine's internal ventilation system is adequate to control nitrogen dioxide during torch cutting, if the system is functioning normally.
  • Page 13 SAFETY Metal Fumes Metal fumes are produced when the plasma arc vaporizes the metal. A hazard may exist when uncontrolled, excessive levels of metal fumes are produced some vaporized metals form toxic gases. These metals may be in their pure metallic state, in an alloy, or in a coating such as paint or plating.
  • Page 14 SAFETY COMPRESSED GAS EQUIPMENT Gas cylinders should be mounted securely to a wall or other stable supporting device. Cylinders Compressed gas cylinders must be handled and used in accordance with appropriate national safety standards. • Never use a cylinder that is physically damaged or leaks. •...
  • Page 15 SAFETY HOSES Gas hoses used for plasma arc cutting systems adhere to the following color coding: Red ..... Acetylene Orange ..LPG Blue ..... Oxygen Black ... Inert gases and air Replace any hose that is damaged by physical abuse or from sparks, heat or open flame.
  • Page 16 SAFETY HOT SURFACES WARNING Components may remain hot for a considerable period of time. Always wear gloves to remove components and scrap from the bed. WARNING During prolonged periods of cutting, parts of the machine bed may become hot to the touch. WARNING Moving machinery can be dangerous.
  • Page 17 Internal Ventilation System Due to the noxious and toxic nature of many torch cutting by-products, Piranha recommends venting the machine's internal ventilation system (referred to as the "dust collector") to the outside atmosphere. This recommendation is especially important when the shop has one of the following: 1.
  • Page 18 As with any equipment that can create such interference (e.g., microwave ovens and TIG welders), people who have implanted heart pacemakers must exercise caution when working near the equipment. Piranha recommends that a person with a pacemaker who works near where plasma arc cutting is being performed should wear a Holter monitor for one day of work to record the existence of electromagnetic fields.
  • Page 19 The noise levels generated during plasma arc cutting may be as high as 105 decibels. This depends on the distance from the machine, arc, plasma torch nozzle design, gas velocity, material type, and plate thickness. Piranha recommends that each user check the sound levels in his own shop under normal operating conditions.
  • Page 20 ADDITIONAL SAFETY INFORMATION The general safety information presented in this chapter does not constitute a complete list of safety instructions for any particular configuration of the Piranha Plasma Cutting Table. Warnings and other safety information related to operations described in this manual are presented in the chapters in which those operations are explained.
  • Page 21 SAFETY FINAL SAFETY RECOMMENDATION Piranha strongly urges that problems encountered in the operation and maintenance of the equipment be reported to our Field Service Department. The department is prepared to give additional information and to answer questions in regard to the equipment.
  • Page 22 SAFETY Sept-2018...

  • Page 23: Specifications

    INSTALLATION SPECIFICATIONS Machine C404 C408 C510 49.0” 49.0” 61.0” X-axis Travel 49.0” 97.0” 121.0” Y-axis Travel Approximate Dimensions (in) 82L x 92W x 60H 138L x 92W x 60H 158L x 102 x 60H Approximate Weight (lbs) 1,500 2,000 2,500 Maximum Rapid Speed 393 inches/min CNC Control...
  • Page 24 INSTALLATION Sept-2018...

  • Page 25: Installation

    INSTALLATION INSTALLATION 1. INTRODUCTION Thank you for purchasing a Piranha C-Series Plasma Cutting Table. The following information will guide you from unpacking to setting up your table for your first cut. If something needs better explanation, please contact us. 2. PRIOR TO RECEIVING 2.1.
  • Page 26 INSTALLATION The following drawing shows the required space for the C-Series Plasma Cutting Table with optional Pipe Cutter MACHINE PIPE CUTTER “A” “B” WEIGHT WEIGHT 4’X4’ 88” 116” 1,500 lbs 800 lbs 4’X8’ 144” 116” 2,000 lbs 800 lbs 5’X10’ 164”...
  • Page 27 INSTALLATION 2.2. Floor Condition Piranha requires a concrete floor, in good condition, level to within +/- 0.500” (12.7mm). 2.3. Electrical Services The electrical supply to the machine and the plasma arc cutting system must be stable, with no spikes or electrical noise (interference) from other machinery.
  • Page 28 Option A: Air Dryer Unit (Piranha Part Number 230579 or equivalent) Piranha recommends using a stand-alone air dryer unit that consists of a water-oil-separator and a post filter for the plasma system to protect your machine. Piranha offers a dryer / filter combination.
  • Page 29 INSTALLATION 2.5. Fumes/Smoke Extraction Plan The machine will come pre-installed with a 11,000 m /h (6,500 ft /min) exhaust fan. Customer is responsible for providing further duct-work and filtration to meet federal, state, and local codes. Proper ventilation is required for operator safety and health – refer to the SAFETY section of this manual.
  • Page 30 INSTALLATION 3. AFTER RECEIVING Upon the arrival of equipment: 1. Inspect it visually for shipping damage. If damage is found, notify both the trucker's insurance company and MegaFab. 2. Compare the actual shipment with the invoice to verify that everything ordered has been received.
  • Page 31 INSTALLATION 3.1.1. Lifting with Crane (Recommended) 1. Remove securing straps/chains attached to the truck bed. 2. Obtain two straps of 20 feet length that are rated for the weight of the load (dependent on the size of machine) NOTE: Longer lifting straps may be required if the crane does not have hoist chains attached.
  • Page 32 INSTALLATION Strap Cable carrier guideway 5. Take each end of the strap and put chain through them and attach the eye hook back to the hoist chains. 6. Before lifting, make sure straps are even on both sides of the machine and tight underneath the machine and up against the table leg.
  • Page 33 INSTALLATION 3.1.2. Lifting with Forklift CAUTION: A forklift of adequate fork length (8 ft. minimum) is required to lift the machine otherwise the frame will get damaged. 1. Remove securing straps/chains attached to the truck bed. 2. Drive the forklift to the side of the truck at the lifting points shown in the picture below.
  • Page 34 INSTALLATION 4. Ensure that forks extend all the way through the machine base to the opposite side. Forks Cable carrier guideway center leveling 5. Begin to lift the machine above the truck bed and confirm that load is not tipping in either direction. 6.
  • Page 35 INSTALLATION 9. Install the supplied leveling pads at each corner of the machine by threading them into the bottom of the machine supports. On C408 and C510 models, two additional leveling pads are located in the center of each side. 10.
  • Page 36 INSTALLATION Installing Covers (5’ X 10’ only) 3.3. To meet the transportation regulations of load size, the motor covers are not pre-installed to the machine for shipment. The following procedure can be followed to install motor covers: 1. Locate both motor covers, 1 for each side. The picture below shows the cover for the motors.
  • Page 37 INSTALLATION 3.4. Leveling Before starting to level the machine, place your machine firmly on the ground with leveling pads already installed to the designated area where it will be seated permanently for operation. Procedure: 1. Place level on the y-axis of the machine surface as shown in the picture below.
  • Page 38 INSTALLATION Y-axis surface New pad to be adjusted X-axis Previous pad adjusted 5. Adjust the pad by loosening the lock nut and rotating the threaded bolt with a wrench until the surface is fully balanced. Tighten lock nut in similar manner as before. 6.
  • Page 39 INSTALLATION 3.5. Pneumatic Connection 3.5.1. Air to Machine 1. Install 8mm tubing into the 90-degree fitting on the end of the regulator. If 8mm tubing is not available, remove the 90-degree fitting and replace it with the supplied adapter for 1/4” NPT. 2.
  • Page 40 INSTALLATION 3.6. Electrical Connection CAUTION: Do not turn on the main circuit breaker until all the wiring is complete and verified by a qualified electrician. 3.6.1. CNC control 1. Run 230V 10/3 conductor wire through the knockout of CNC control and into the enclosure.
  • Page 41 BEFORE PROCEEDING. USE A LICENSED ELECTRICIAN FOR MAKING THE FINAL POWER CONNECTION. For units with a Hypertherm Powermax plasma system furnished by Piranha: 1. Insert the torch lead (from the cable carrier) into the front of the Hypertherm Powermax power supply 2.
  • Page 42 Piranha recommends adding a clamp to keep the torch lead from retracting into the cable carrier at this point. Use one of the screws holding the ventilation cover to mount the clamp.
  • Page 43 INSTALLATION 4. Expose the top side of the cable carrier by removing the plastic covers. Use a screwdriver to unsnap the plastic covers by gently prying up in the slots provided. 5. After running the torch leads, snap the plastic covers back in place. Take care to make sure that each cover is fully snapped in place.
  • Page 44 INSTALLATION 6. Insert the opposite end of the torch lead (from the cable carrier) into the front of the Hypertherm Powermax power supply 7. Insert the plug end from the Hypertherm interface cable into the connection at the top right on the rear panel of the Powermax power supply.
  • Page 45 INSTALLATION 11. Connect the ground clamp to the front of the Powermax power supply. The other end (with the spring-loaded clamp) should be connected to one of the slats on the work table (some models may have a separate ground tang for this purpose) 12.
  • Page 46 INSTALLATION 3.8. Power On Once all the cables are plugged in, the machine can now be powered on. 1. Close the door on the CNC Control Cabinet 2. Power on the circuit breaker from the supply line. 3. Turn on the CNC control disconnect (NOTE: Door must be closed or interlock will not allow power to be turned on) 4.

  • Page 47: Operations

    OPERATIONS OPERATIONS Prior to plasma cutting, the operator must prepare the program and machine so that the correct part is cut, the part is cut in the correct location on the raw material, and the part is of good quality. In order to do this, the operator must go through the following checklist: ✓...
  • Page 48 OPERATIONS 1. OPERATOR’S PANEL The operator’s panel is separated into two segments – the keypad and the display. The keypad is there for operator input into the machine control, and the display shows data and information to the operator. Display Emergency Stop Button Keypad...
  • Page 49 C. Press the top end of the red rocker switch (below the Emergency Stop button) until it latches in place. Power is now on, and you should see the Piranha HOME Page. Sept-2018...
  • Page 50 OPERATIONS 3. CNC CONTROL NAVIGATION The CNC Control menu is located at the bottom of the screen. The blocks shown correspond to the related FUNCTION keys at the top of the Operator’s keypad. In order to select the corresponding block, press the FUNCTION key (example: [F1] for AUTO in the diagram below).
  • Page 51 OPERATIONS The display provides a great deal of information: Feed rates Kerf Offset Value Program Name Cut ID Number Active Functions Graphical Display or Input/Output Program Status File Machine Position Parameter Values Sept-2018...
  • Page 52 OPERATIONS 4. ACTIVE FUNCTIONS There are several active functions that can be used when the machine is in ANUAL mode: 1 – Pressing the ‘1’ key will initiate a torch pierce 4 – Pressing the ‘4’ key will toggle the arc on and off 5 –...
  • Page 53 OPERATIONS 5. OPERATING THE MACHINE IN MANUAL MODE Manual mode is used to jog the machine without running it from a program. This is commonly used to bring the machine to the operator so that consumables can be changed, or to move the machine out of the way while the operator unloads finished parts, and loads new material.
  • Page 54 OPERATIONS 6. ADJUSTING SPEEDS Types of speeds: • RAPID SPEED – this is the speed that the machine uses when traversing between cuts (going from the end of one cut to the beginning of the next) • CUTTING SPEED – this is the speed at which the machine moves when the plasma torch is cutting (refer to the plasma system manufacturer’s cut charts for cutting speed information) •...
  • Page 55 OPERATIONS 7. USING THE TORCH HEIGHT CONTROL The torch height control serves three functions: a. Jogs the torch up and down b. Locates the torch to the correct position prior to initiating the arc c. Maintains the proper standoff between the torch and the workpiece while cutting The Display of the torch height control (on the left-hand side of the panel) shows the status of the height control.
  • Page 56 OPERATIONS Prior to cutting, the operator must set the initial pierce height, pierce delay and the arc voltage which establishes the cutting height: Setting initial height control and pierce delay: a. Rotate the INTERFACE/PARAMETER SHIFT dial until the following screen shows. Continue to rotate it until the orange indicator is displayed above the POSITION location.
  • Page 57 OPERATIONS 8. SETTING PIERCE DELAY The Pierce Delay parameter is in the SETTINGS portion of the CNC Control. 1. Determine the correct value for Pierce Delay from the Plasma OPERATION MANUAL cut charts. ADD 1.2 seconds to the value in the chart. 2.
  • Page 58 OPERATIONS 9. PREPARING THE PLASMA TORCH FOR CUTTING Prior to making the first cut, be sure to read the OPERATION MANUAL from the supplier of the plasma cutting power source and torch. Be familiar with all safety aspects of plasma cutting including eye protection, electrical safety, heat, and respiratory protection.
  • Page 59 OPERATIONS 10. METHODS OF SELECTING PROGRAMS There are three methods of selecting programs: A. Selecting a pre-programmed part or nest from the USB drive B. Selecting a file from CNC Control memory that has already been saved in the control C.
  • Page 60 OPERATIONS A. SELECTING A PROGRAM FROM USB DRIVE Insert a USB Thumb Drive into the slot on the CNC Control IMPORTANT: The USB Thumb Drive must be formatted to FAT32 File System or the CNC Control will not read the thumb drive.
  • Page 61 OPERATIONS From the MAIN SCREEN, Select [F3] EDIT: From the EDIT SCREEN, Select [F6] USB: From the USB SCREEN, Select [F1] INPUT: From the INPUT SCREEN, use arrow up/down to highlight program to be loaded and select [F1] COPY. Press ENTER to view the Program CODE: Sept-2018...
  • Page 62 OPERATIONS B. LOADING A PROGRAM FROM CONTROL MEMORY From the EDIT SCREEN, Select [F2] LOAD: From the LOAD SCREEN, use arrow up/down to highlight program to be loaded and press ENTER: Sept-2018...
  • Page 63 OPERATIONS After pressing ENTER, the selected program will be loaded, and the Program Code will display: Pressing [F7] VIEW, will display a graphical representation of the program: Once done, press ESC twice to return to the AUTO SCREEN. Sept-2018...
  • Page 64 OPERATIONS From the AUTO SCREEN, pressing [F4] VIEW will display a graphical representation of the Loaded Program. The red dots with numbers show the pierce points and cut order. The red crosshairs show the program zero location (location the operator needs to set PROGRAM ZERO). Loaded Program Sept-2018...
  • Page 65 OPERATIONS C. LOADING A PROGRAM FROM THE PARAMETRIC SHAPE LIBRARY The CNC Control has several common shapes that are used in the Metal Fabrication industry. The size of the features within each shape can be adjusted easily in order to achieve customer requirements. 1.
  • Page 66 OPERATIONS Shapes in Library 2: 3. To select a shape, use the arrow keys to highlight the name of the shape, and press [ENTER] 4. This is the shape from HOLE2 located in Library 2. In this shape, the holes are centered on the rectangle.
  • Page 67 OPERATIONS 5. Select each parameter by using the up and down arrow keys. After each parameter is changed, press the [ENTER] key. Once the changes are made, press F7 [APPLY] and the geometry will update to the new values. 6. Once you are satisfied with the geometry, press F8 [OK] and you will be directed to the HOME screen.
  • Page 68 OPERATIONS 10. SAVING AND EDITING FILES Once a file has been loaded on the control, or created using the SHAPE LIBRARY, it is important to save the file on the control. That way, the program can be called up again in the future, and it will be still in the control in case the power is cycled off and on.
  • Page 69 OPERATIONS 5. The program can be saved by pressing the F3 [SAVE] button. When this happens, a text box appears and the operator can type in the desired file name and press [ENTER]. Note: Be sure that the program name is not already taken in the directory. If you type in an existing file name, the new program will overwrite the previous program.
  • Page 70 OPERATIONS SETTING PROGRAM ZERO Part programs have a zero-starting point for (X0, Y0). This is identified by a red cross-hair on the screen, so the operator can see where zero is located relative to the parts cut within the program. This zero location must set before starting the program.
  • Page 71 OPERATIONS 12. SETTING KERF OFFSET When plasma cutting, a kerf (or opening) is produced by the plasma arc. The cutting current and cutting speed, as well as the diameter of the orifice in the plasma torch nozzle determine the width of the kerf. Typically, the amount of offset will range from 0.040”...
  • Page 72 OPERATIONS 13. AUTOMATIC OPERATION Before starting the machine in automatic operation, the program zero must be set, the kerf offset must set, and the correct program must be selected. Please refer to SETTING PROGRAM ZERO, SETTING KERF OFFSET and SELECTING A PROGRAM sections in this manual for further information.
  • Page 73 OPERATIONS 14. STOPPING THE MACHINE During operation, the machine can be stopped by either pressing the red CYCLE STOP button on the operator panel or by pressing one of the three EMERGENCY STOPS. The EMERGENCY STOP button immediately turns off all power to the drives and plasma torch.
  • Page 74 OPERATIONS 15. BREAK POINT RESUME After the system is paused from a CYCLE STOP, EMERGENCY STOP, or POWER OFF, the system saves the current torch position as a breakpoint. The breakpoint will remain active even if the system is turned off. If the program selected after power off is different from the program prior to power off, then the breakpoint will be lost.
  • Page 75 OPERATIONS If the torch has been moved, the following dialog will display. Use the arrow key to select one of these options: 1. The first option is ORI PATH RET (original path return). With this selection, the system will return the torch to where it stopped cutting. 2.
  • Page 76 OPERATIONS 16. NESTING The CNC control has a nesting function where parts can be automatically placed on a sheet of material for cutting. This can be used with items within the Shape Library, or with items that are programmed using the FastCAM programming system. NOTE: It is important that all individual part programs used in the nesting system return to the program zero point at the end of the program.
  • Page 77 OPERATIONS 3. Select the part program you wish to nest. This can be from the Shape Library (F1), or from a File (F2). NOTE: Only files from Shape Library #1 can be entered using the F1 key. If shapes are required from Shape Library #2, you must create the shape inside Shape Library #2 and save it to a file first.
  • Page 78 OPERATIONS 5. You will be prompted to input the number of parts. Type in the number of parts you wish to cut and press [ENTER]. The screen will then populate the parts onto the raw material: 6. Individual parts can be modified by selecting the part with the up and down arrow keys to select the part (on the right-hand side of the screen) and edit as follows: a.
  • Page 79 OPERATIONS 17. TRIM CUTS Use the following procedure to manually trim areas of the raw material (for example, trimming the used skeleton in order to save a remnant): 1. Press F2 [MANUAL] 2. Move the torch to the area you wish to begin by using the arrow keys. If you want to start on the edge of the material, move the torch above the material near the location you wish to begin.
  • Page 80 OPERATIONS 5. If edge starting, move the torch to the edge of the material you wish to pierce by using the arrow keys. Do not move too far away from the location you zeroed the torch. 6. Set the cutting speed by using the F+ / F- buttons until the desired cutting speed is shown in the upper left hand corner of the screen.
  • Page 81 OPERATIONS 18. SAVING CUT PARAMETERS There is a Material Library located in the CNC Control. This material library allows the operator to save cut conditions (Cutting Speeds, Arc Voltage). The Cutting Speed can then be loaded for any program – the Arc Voltage is a quick reference to be used to set the Torch Height Control.
  • Page 82 OPERATIONS 4. Prior to starting the program in AUTO mode, Cutting Speed can be automatically set by using the [Y] key prior to hitting the green start button. When the [Y] key is pressed, the following screen appears: 5. Enter the desired chart in the THICK line, and the remainder of the columns will populate one at a time as you press [ENTER].
  • Page 83 OPERATIONS 19. TEST MODE (DRY RUN) The TEST Mode function allows the operator to run the program without starting the torch. In AUTO mode, press the [X] button and the TEST location on the Display becomes illuminated. The operator can now press the START button and the program will run without cutting.
  • Page 84 OPERATIONS 20. CONTOUR MODE In CONTOUR MODE, the control will test run a rectangle around the entire outside of the program. This will allow the operator to see if the part program or nest will fit on the sheet of material as it is located on the machine. To run CONTOUR from AUTO mode, press the F7 [CONTOUR] key.

  • Page 85: Programming

    “dongle” which plugs into the USB port of your computer. For an additional cost, an upgrade to FastCAM Professional is available through Piranha. Please see Appendix A for setting up FastCAM.
  • Page 86 PROGRAMMING PROGRAMMING CODES G Codes CODE FUNCTION Fast positioning point to point Linear cutting Circular cutting clockwise Circular cutting anti-software Dwell (stop-delay) Inch Metric Back to reference point axis X Back to reference point axis Y Back to reference point axis X and Y Cancel compensation Compensation left Compensation right...
  • Page 87 PROGRAMMING M Codes CODE FUNCTION Stop program M02/M30 Program ended M07/08 Plasma cutter ON/OFF Sept-2018...
  • Page 88 PROGRAMMING Sept-2018...

  • Page 89: Maintenance

    MAINTENANCE MAINTENANCE The following maintenance items should be done on a planned basis: MAINTENANCE ITEM FREQUENCY Empty Slag Pan(s) Daily Inspect Slats and Replace where necessary Weekly Wipe Linear Guides X and Y Axis Weekly • Dry Rag; Then Apply Light Oil Lubricate X-Axis (1) and Y-Axis (2) Racks Quarterly •...
  • Page 90 MAINTENANCE ERROR CODE LIST ERROR Description CODE Overflow/illegal character(s) in program Division Overflow Error Starting/ending point of arc Error radius of arc Error condition of arc Overflow program line. No torch movement of this line Illegal Operation Emergency stop pressed Limit X+ Limit X- Limit Y+...
  • Page 91 MAINTENANCE MACHINE SETUP PARAMETERS For Starfire software version: • 3.1-2.8.0 or later • 3.1-2.8.0-FAT or later The parameters in the SETUP section of the control should be set as follows: INITIAL SETUPS FROM MAIN PAGE---> SETUP--->SPEED (F1) STARTUP 00020 00.30 TIMING（S）...
  • Page 92 MAINTENANCE PIERCE TIME 1.100 *3 OFF DELAY 00.00 DIS. COR. OFF ARCS SPEED OFF AHCS (MM/MIM) 00000 ANTICIP OFF AHC ANTICIP OFF AUTO-SIG (MM) 00000 AHCS AUTO-SIG DELAY (S) 01.0 AHCS AUTO-SIG DIS (MM) 00.0 SPEED OFF AHCS (MM/MIM) 00100 ARC ON M ORDER ARC OFF M ORDER FROM MAIN PAGE--->...
  • Page 93 MAINTENANCE INITIAL SETTINGS – MICROSTEP TORCH HEIGHT CONTROL Page A: StartSpeed: 300 AutoSpeed: 1500 TopSpeed: 3000 AutoSpeed: 600 SpeedRate: 10 Language: 1 Page B: SpeedRange: 20 Position: EffecRange: 100 Equivalent: 0.0024 PierceDel: 0 Compensate: 10 Position (in mm) changes with material thickness. Sept-2018...
  • Page 94 MAINTENANCE INPUTS AND OUTPUTS From the main menu, press F5 [DIAGNOSE] to access the inputs and outputs The following screen will appear The following is the list of inputs and outputs that are used on the C Series Plasma Table: OUTPUTS: M12 –...
  • Page 95 MAINTENANCE PROCEDURE - SETTING MACHINE ZERO If the machine has lost its zero-home position, use the following procedure to re-set MACHINE ZERO. MACHINE ZERO is different than PROGRAM ZERO - this procedure should not be used to set PROGRAM ZERO. 10.
  • Page 96 MAINTENANCE 15. In the parameters, find [DIR-ORIGIN] – set X00 Y00 16. Press F8 [SAVE] 17. Press [ESC] until you get back to the Home Screen 18. Press F2 [MANUAL] 19. Press F8 [ASSIST] 20. Press F6 [ORIGIN] 21. Press [ESC] until you get back to the Home Screen Sept-2018...
  • Page 97 MAINTENANCE 22. Choose F4 [SETUP] from the Home Screen 23. Choose F2 (SYSTEM) 24. In the parameters, find [DIR-ORIGIN] – set X to -1 and Y to -1 25. Press F8 [SAVE] Sept-2018...
  • Page 98 MAINTENANCE PROCEDURE – UPDATING CONTROL SOFTWARE FROM USB DRIVE 1. Before putting in the USB drive, push the update ARROW and turn on the power button; UPDATE ARROW USB PORT POWER BUTTON 2. When the screen starts to change, release the button; 3.
  • Page 99 MAINTENANCE PROCEDURE – SQUARING THE MACHINE The machine may become out of square if the bridge is pushed while power is off. This can also occur during shipping and handling – while moving the machine to its final location. Since the bridge was squared at the factory, the bridge bolts should still be in their factory set location and should not be loosened.
  • Page 100 MAINTENANCE 3. Set the dial on the indicator to zero 4. Turn the power switch on the CNC control off 5. Turn power off to machine (Main disconnect) Sept-2018...
  • Page 101 MAINTENANCE 6. Unplug the motor cable from Y2 Drive (the drive on the right hand side inside the electrical enclosure). To unplug the cable, squeeze the two tabs on either side of the plug and remove it from the drive. 7.
  • Page 102 MAINTENANCE 9. Push the Y2 side of the gantry until the dial indicator reads the desired amount (from step 1) 10. Turn CNC control off 11. Turn power off to machine (Main disconnect) 12. Plug the Y2 motor lead back into the Y2 Drive 13.
  • Page 103 MAINTENANCE 14. Turn CNC control on (machine must not be in E-stop condition) 15. Run squareness test again (step 1) 16. Repeat the procedure as necessary until the desired squareness is achieved Sept-2018...
  • Page 104 MAINTENANCE TROUBLESHOOTING GUIDE • Arc Voltage always reads Verify interface cable is wired correctly. zero on Arc Voltage Control Refer to the INSTALLATION section of the manual for correct wiring information. • Verify all wires to the Voltage Divider Card are securely terminated.

  • Page 105: Parts Manual

    PARTS MANUAL - SPECIFY MODEL NUMBER AND SERIAL NUMBER WHEN ORDERING PARTS PARTS MANUAL AUTOMATIC HEIGHT CONTROL ASSEMBLY PIRANHA PART # DESCRIPTION 230554 AHC ASSEMBLY FRONT PLATE 230543 AHC LIMIT SWITCH 230555 STEPPER MOTOR AHC 230556 TOP PLATE 230557 GUIDE ROD...
  • Page 106 PARTS MANUAL - SPECIFY MODEL NUMBER AND SERIAL NUMBER WHEN ORDERING PARTS AUTOMATIC HEIGHT CONTROL ASSEMBLY NOTE: Specify model and serial number when ordering PIRANHA PART # DESCRIPTION 230566 ANTI-CRASH ASSEMBLY 230567 TORCH HOLDER 230555 STEPPER MOTOR AHC Sept-2018...
  • Page 107 PARTS MANUAL - SPECIFY MODEL NUMBER AND SERIAL NUMBER WHEN ORDERING PARTS Y-AXIS DRIVE ASSEMBLY NOTE: Specify model and serial number when ordering PIRANHA PART # DESCRIPTION 230528 PROXIMITY SWITCH 230568 MACHINE RACK 230546 LINEAR GUIDE 230544 BEARING BLOCK (NOT SHOWN)
  • Page 108 PARTS MANUAL - SPECIFY MODEL NUMBER AND SERIAL NUMBER WHEN ORDERING PARTS AIR AND WATER INLET NOTE: Specify model and serial number when ordering PIRANHA PART # DESCRIPTION 230569 AIR REGULATOR 230530 WATER CHILLER SOLENOID 6MM 90 DEG. TUBING CONNECTOR...
  • Page 109 PARTS MANUAL - SPECIFY MODEL NUMBER AND SERIAL NUMBER WHEN ORDERING PARTS X-AXIS DRIVE ASSEMBLY NOTE: Specify model and serial number when ordering PIRANHA PART # DESCRIPTION 230534 MATERIAL BALL ROLLER 230539 HARD LIMIT STOP 230536 CABLE TRACK (PER METER)
  • Page 110 PARTS MANUAL - SPECIFY MODEL NUMBER AND SERIAL NUMBER WHEN ORDERING PARTS ELECTRICAL CABINET NOTE: Specify model and serial number when ordering 230551 230571 230572 PIRANHA PART # DESCRIPTION 230551 MICROSTEP ARC HEIGHT CONTROL 230571 GREEN PUSHBUTTON, LIGHTED 230572 STARFIRE 10.4" CONTROL PANEL...
  • Page 111 PARTS MANUAL - SPECIFY MODEL NUMBER AND SERIAL NUMBER WHEN ORDERING PARTS ELECTRICAL CABINET NOTE: Specify model and serial number when ordering PIRANHA PART # DESCRIPTION 230527 AC220/DC48V 230573 24V DRIVE FAULT RELAY 230574 24V CONTROL RELAY 230575 MAIN CONTACTOR...
  • Page 112 PARTS MANUAL - SPECIFY MODEL NUMBER AND SERIAL NUMBER WHEN ORDERING PARTS MISCELLANEOUS PARTS NOTE: Specify model and serial number when ordering PIRANHA PART # DESCRIPTION 230602 LEVELING FOOT 230535 FAN GUARD 230604 SLAG DRAWER (C-404 & C-408) 230605 SLAG DRAWER (C-510)
  • Page 113 PARTS MANUAL - SPECIFY MODEL NUMBER AND SERIAL NUMBER WHEN ORDERING PARTS ELECTRICAL DIAGRAM (MACHINES WITHOUT PIPE CUTTER) Sept-2018...
  • Page 114 PARTS MANUAL - SPECIFY MODEL NUMBER AND SERIAL NUMBER WHEN ORDERING PARTS ELECTRICAL DIAGRAM (MACHINES WITH PIPE CUTTER) Sept-2018...

  • Page 115: Pipe Cutting Attachment (Optional Equipment)

    PIPE CUTTING ATTACHMENT PIPE CUTTING ATTACHMENT (OPTIONAL EQUIPMENT) The Pipe Cutting Attachment is an option on new machines. It must be ordered with the machine – it cannot be retrofit onto an existing product. The pipe cutting attachment can cut round pipe and tube from 2” through 11.5” diameter. The location of the pipe cutting attachment is shown below –...
  • Page 116 PIPE CUTTING ATTACHMENT Components: Pipe/Plate Selector Switch Headstock Headstock Wrench Sept-2018...
  • Page 117 PIPE CUTTING ATTACHMENT Pipe Supports Pipe Cutter Base Sept-2018...
  • Page 118 PIPE CUTTING ATTACHMENT 1. AFTER RECEIVING Upon the arrival of equipment: a. Inspect it visually for shipping damage. If damage is found, notify both the trucker's insurance company and MegaFab. b. Compare the actual shipment with the invoice to verify that everything ordered has been received.
  • Page 119 PIPE CUTTING ATTACHMENT Lifting with Crane (Recommended) a. Remove securing straps/chains attached to the truck bed. b. Obtain two straps of not less than 6 feet (1829mm) with the second being 6” (152mm) longer than the first. The below picture shows the strap layout.
  • Page 120 PIPE CUTTING ATTACHMENT c. The first strap should be located 31” (787mm) from the of the chuck end of the pipe cutter attachment. d. The second strap should be located 74” (1880mm) from the of the chuck end of the pipe cutter attachment. The second strap should be approximately 6”...
  • Page 121 PIPE CUTTING ATTACHMENT e. The end of the pipe cutter attachment is aligned to be 9.8” (250mm) from the end of the plasma table as shown. f. The pipe cutting attachment is set parallel to the plasma table at a spacing of 16”...
  • Page 122 PIPE CUTTING ATTACHMENT g. The pipe cutting attachment must be leveled (using the four leveling pads) so that the height of the center of the chuck is 1.00” below the slat height of the table. The pipe cutting attachment must be leveled with the four leveling pads.
  • Page 123 PIPE CUTTING ATTACHMENT i. Next connect the cables to the relays as shown, there are 8 connections. Important – Relay’s may be in reverse order so it is important to go by wire numbers on relay Wire C11 will connect to terminal without wire behind it Wire C12 will connect to terminal in front of wire X12 Wire C13 will connect to terminal in front of wire X13 Wire C14 will connect to terminal in front of wire X14...
  • Page 124 PIPE CUTTING ATTACHMENT Sept-2018...
  • Page 125 PIPE CUTTING ATTACHMENT SWITCHING FROM PLATE-CUTTING TO PIPE-CUTTING 1. Change the X-axis limit to allow the torch to move over the center of the pipe: a. From the HOME screen, push F4 [SETUP] b. Then press F2 [SYSTEM] to see the following screen Sept-2018...
  • Page 126 PIPE CUTTING ATTACHMENT c. Change the X-Axis SOFTLIMI+ value to 94.0 d. Then Press the F8 [SAVE] to store the change e. Press [ESC] next to go back to home screen Sept-2018...
  • Page 127 PIPE CUTTING ATTACHMENT f. Press F2 [MANUAL] to go to manual move screen g. Move the torch in the X-axis until the torch is directly above the center of the pipe. h. Press the [ESC] button to go to home screen i.
  • Page 128 PIPE CUTTING ATTACHMENT j. Then press F2 [SYSTEM] to see the following Sept-2018...
  • Page 129 PIPE CUTTING ATTACHMENT k. Now change NUMERATOR X:00416 using the following formula i. Pipe Diameter * 3.14 * 25.4 1. Example for 2-inch diameter pipe 2. 2 * 3.14 * 25.4 = 159.512 round up to 160 3. Enter for NUMERATOR X:00160 l.
  • Page 130 PIPE CUTTING ATTACHMENT n. Turn off the power to the CNC Control using the Red Power Button o. Move the Pipe/Plate Selector Switch to “PIPE” p. Turn on power to the CNC Control using the Red Power Button Sept-2018...
  • Page 131 PIPE CUTTING ATTACHMENT q. Connect the plasma cutter ground clamp to the end of the pipe r. The pipe cutter attachment is now ready to use PROGRAMMING THE PIPE CUTTER When programming the pipe cutter, the programs are generated as if the pipe is unfolded in the flat condition.
  • Page 132 PIPE CUTTING ATTACHMENT SWITCHING FROM PIPE-CUTTING TO PLATE-CUTTING 1. Change the X-axis limit to allow the torch to move over the center of the pipe: a. From the HOME screen, push F4 [SETUP] b. Then press F2 [SYSTEM] to see the following screen Sept-2018...
  • Page 133 PIPE CUTTING ATTACHMENT c. Change the following values i. NUMERATOR X:00416 ii. DENOMINA- X:00125 iii. SOFTLIMI+ X:00061.0 d. Then Press the F8 [SAVE] to store the change Sept-2018...
  • Page 134 PIPE CUTTING ATTACHMENT e. Turn off the power to the CNC Control using the Red Power Button f. Move the Pipe/Plate Selector Switch to “PLATE” g. Turn on power to the CNC Control using the Red Power Button Sept-2018...
  • Page 135 PIPE CUTTING ATTACHMENT h. Connect the plasma cutter ground clamp plasma table bed i. Move torch back over the cutting bed i. The X < + software overtravel alarm will be on the screen but X can move in the minus direction of the table. This alarm will clear once the torch position is less than the normal plate cutting width (61”...
  • Page 136 PIPE CUTTING ATTACHMENT Sept-2018...

  • Page 137: Water Mist Chiller (Optional Equipment)

    WATER MIST CHILLER WATER MIST CHILLER (OPTIONAL EQUIPMENT) The Water Mist Chiller provides additional cooling of the work piece that may, in some cases, reduce warpage - especially in thinner material. This option consists of a water chiller, solenoid valve, and spray tube. The chiller must be connected to a separate 120 volt single phase wall outlet.
  • Page 138 WATER MIST CHILLER CONNECTIONS: 1. The inlet and outlet of the chiller must be connected together using 12 mm tubing on both ends of the supplied tee fitting. Connect the outlet of the tee fitting to the water solenoid located next to the incoming air regulator on the machine using 8 mm tubing.
  • Page 139 WATER MIST CHILLER In order to use the chiller: 1. Turn the power switch on 2. Press the lighted WATER CHILLER pushbutton on the CNC control so that it lights up. The chiller will now spray as the plasma torch is cutting. To disengage the chiller feature, simply turn the power switch off and press the pushbutton so that it no longer lights up.
  • Page 140 WATER MIST CHILLER Sept-2018...

  • Page 141: Appendix A - Fastcam Setup

    APPENDIX A – FastCAM SETUP APPENDIX A – FastCAM SETUP The Piranha C-series Plasma Table comes standard with a seat of FastCAM software. This software comes in a plastic case and consists of: 1. A disk containing the FastCAM Software 2.
  • Page 142 APPENDIX A – FastCAM SETUP How to set up FastCAM： Run the CD, choose ENGLISH, then choose START, and follow the instruction to finish installation; When you finish Fastcam installation, you will see a file holder FastCAM on your desktop: A.
  • Page 143 APPENDIX A – FastCAM SETUP Also, if you are a new user of FastCAM software, you need to finish INITIAL FASTCAM SETUPS (attached with this file) before you start to nest/import a part drawing. C. How to edit a part drawing? 1.
  • Page 144 APPENDIX A – FastCAM SETUP 4. Choose the functions you need and Enter: Sept-2018...
  • Page 145 APPENDIX A – FastCAM SETUP 5. Find the part drawing under certain path in your computer; 6. Use the tool bar on top to erase or add lines/circles/rectangles. D. How to create a part? ( How to use FastCAM to draw a part) We will draw a 4”...
  • Page 146 APPENDIX A – FastCAM SETUP i. input the Radius of Circle and Enter; ii. Your mouse become a white cross, click the right button of mouse, iii. choose Absolute co-ords, input the absolute co-ordinates of circle center, then Enter; Sept-2018...
  • Page 147 APPENDIX A – FastCAM SETUP 5. When you click and close the sub-page (push ESC if necessary), you will see a 4” square with a 1” round hole right in the middle; 6. Push Files on the top left of the tool bar, choose Save to save the part in a *.CAM file; or DXF Save to save the part in a *.DXF file.
  • Page 148 APPENDIX A – FastCAM SETUP E. How to set up lead-in/out? Set the lead in and lead out (the lead-in and lead-out will change according to the thickness and density of the material , once you finish setting lead-in and lead-out, you will not need to change the settings unless the thickness or density of the material, or the torch you use changes ): 1.
  • Page 149 APPENDIX A – FastCAM SETUP 5. If you want to choose Extension in ''External Entry'' settings to achieve higher precision, make sure you choose Extension on both ''Entry'' and ''Exit''. Normally, the length of extension is same as the length of entry/exit, and the blank to the right of the length of extension is the angle of extension line to entry/exit line, our default number is 1.181, which means 30 degrees;...
  • Page 150 APPENDIX A – FastCAM SETUP 7. when you finish all the FastPath settings, click to save. F. How to select/move lead-in/out location? 1. Select general lead-in/out location: i. Open FastNEST, click on the right of the tool bar on top; ii.
  • Page 151 APPENDIX A – FastCAM SETUP ii. click once, click the middle spot of the lead-in/out, both lead-in and out change color, then click at the spot where you want to move existing lead-in/out to (if only lead-in or lead-out change color, then you need to click twice to move existing lead-in/out the new spot); iii.
  • Page 152 APPENDIX A – FastCAM SETUP iii. Then when you have finished add part drawings, click Output, then Generate Output, then there is a page asking Move entry position? click (Y). Then you can move the entries by following the steps of ii and iii of step 2 here above, when you click , you can rename your NC output you just generated.
  • Page 153 APPENDIX A – FastCAM SETUP 5. In the picture right under the topic “G. How to select sheet size?”, if you choose Remnant CAM instead of Rectangle , then click , you can choose from your computer the remnant sheet you saved from nesting before.
  • Page 154 APPENDIX A – FastCAM SETUP Sept-2018...
  • Page 155 APPENDIX A – FastCAM SETUP I. How to create part program(NC file/.TXT file)? *Please refer to the file “3-PLASMA -create a part program to cut” for the complete operation. 1. Double click FastCAM file holder, then double click FastNEST; 2. Finish all the initial setup by following the steps in the file 3-CREAT A NESTING PROGRAM attached together with this file;...
  • Page 156 APPENDIX A – FastCAM SETUP 4. A page of Nest Part Data comes up, you can input the Require quantity of this part, the Priority level of this part and Permitted Rotation: i. Require quantity means how many pieces you need; ii.
  • Page 157 APPENDIX A – FastCAM SETUP 8. You can nest the part manually, the yellow frame is your material sheet, after you import/add part, you will be able to see the part inside the yellow frame. For example: i. Click one the part you want to move with left button of mouse, keep holding left it and do not let it go until the part move the better new spot;...
  • Page 158 APPENDIX A – FastCAM SETUP iii. Click the arrows on the tool bar, the part inside broken yellow lines will move to left/down/right/up as much as the limit goes. ( the Part to Part and Part to Plate distances can be set in FastNEST Parameters , you can find the page by clicking on the tool bar.
  • Page 159 APPENDIX A – FastCAM SETUP Sept-2018...
  • Page 160 APPENDIX A – FastCAM SETUP 11. Then the software will ask you all the questions which you choose on the left right side of FastNEST Parameters page (you can find the page by clicking on the tool bar. ) 12. Then you will see a page comes up on which you can rename the nesting file(.TXT file), save and copy that .TXT file to your USB, bright your USB to your PARANA plasma machine, you are ready to start cutting.
  • Page 161 APPENDIX A – FastCAM SETUP 2. On the right, in Preselect answers, check Resequence, then every time when you generate output, you will be able to edit part cutting sequence; 3. you can choose certain sequence or indicate the sequence by clicking the parts in the sequence you prefer: Sept-2018...
  • Page 162 APPENDIX A – FastCAM SETUP K. How to use remnant material sheet? To make the best use of your material sheet especially larger size ones, it is very important to save the remnant material sheet for the future cutting. 1. After adding all the parts, click on the tool bar on top, a Plate cutoff page will come up;...
  • Page 163 APPENDIX A – FastCAM SETUP 5. Choose (Y), and input file path where you want to save all the Remnant CAM files, or simply click Enter; 6. To use the remnant sheet: i. click , then choose Remnant CAM; ii. click , go to the same file path to find the remnant CAM, click Select, then click Done;...
  • Page 164 APPENDIX A – FastCAM SETUP Sept-2018...

  • Page 165: Appendix B - Parametric Shape Libraries

    APPENDIX B – Parametric Shape Library APPENDIX B – PARAMETRIC SHAPE LIBRARIES The following table shows all of the available parametric shapes, with their customizable values labeled. See pg. (XX) for instruction on how to cut a single part, or create a nested program using the parametric library.
  • Page 166 APPENDIX B – Parametric Shape Library 7. Chamfer 8. Roof Rec (2) 9. Flange (Single-Hole) 10. Octagon 11. Protrud 12. Ingconca- Sept-2018...
  • Page 167 APPENDIX B – Parametric Shape Library 13. Sector Ri- 14. Circular 15. Quadrate 16. U-Shape Sept-2018...
  • Page 168 APPENDIX B – Parametric Shape Library 17. Define T 18. Curved T- 19. Flange Hole (4-Hole Flange) 20. 6-hole Flange 21. Impeller 22. 2-Hole Flange R=L-HOLE R= L-OUT R=R- OUTR2 R=OUT-HOLE PLACES) Sept-2018...
  • Page 169 APPENDIX B – Parametric Shape Library Library 2 1. Bridge1 2. Bridge2 Do not use Do not use 3. Bridge3 4. Bridge4 Do not use Do not use 5. Arch 6. Groove Do not use 7. Diam 8. Hole2 Sept-2018...
  • Page 170 APPENDIX B – Parametric Shape Library 9. Fla-X 10. Lad 11. Rec 12. Rec8 Sept-2018...
  • Page 171 APPENDIX B – Parametric Shape Library 13. Tria 14. Rec 15. Rec-c 16. Rec-H 17. Circle2 18. Circle3 Sept-2018...
  • Page 172 APPENDIX B – Parametric Shape Library 19. Rec 20. Rec-c 21. Circle4 22. Rec Sept-2018...
  • Page 173 APPENDIX B – Parametric Shape Library 23. Rec 24. Pol 25. Hole Circle 26. Pol Do not use Sept-2018...
  • Page 174 APPENDIX B – Parametric Shape Library Sept-2018...

  • Page 175: Appendix C - Revisions To The Manual

    APPENDIX C – Manual Revisions APPENDIX C - REVISIONS TO THE MANUAL 3/10/2017 (INSTALLATION) CHANGED HYPERTHERM INTERFACE CABLE PART NUMBER 3/10/2017 (INSTALLATION) ADDED NOTE ON SETTING MACHINE ZERO AFTER INSTALLATION 4/11/2017 ADDED INFORMATION ON FASTCAM LICENSE AND DONGLE 4/13/2017 Added information on COMPENSATE to the Operations and Troubleshooting section 4/13/2017 Removed Pierce Delay information from ARC VOLTAGE CONTROL and added it to SETTINGS...
  • Page 176 APPENDIX C – Manual Revisions Sept-2018...

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