Lockformer Vulcan 1000B Operation Manual
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Lockformer Vulcan 1000B Operation Manual

Plasma cutting system
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H. WEISS MACHINERY & SUPPLY
V V V V V u l c a n
u l c a n
u l c a n
u l c a n
u l c a n
CUTTING
CUTTING
CUTTING
CUTTING
CUTTING
OPERA
OPERA
OPERA TION
OPERA
OPERA
711 OGDEN AVE. LISLE IL. 60535-1399
PHONE: (718) 605-0395 - www.hweiss.com
SYSTEMS
SYSTEMS
SYSTEMS
SYSTEMS
SYSTEMS
TION
TION
TION
TION
MODEL
MODEL
MODEL
MODEL
MODEL
PHONE 630-964-8000 FAX 630-964-5685
MANU AL AL AL AL AL
MANU
MANU
MANU
MANU
1000
1000
1000
B
B
B
1000
1000
B
B
6/2004

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  • Page 1 H. WEISS MACHINERY & SUPPLY PHONE: (718) 605-0395 - www.hweiss.com V V V V V u l c a n u l c a n u l c a n u l c a n u l c a n CUTTING CUTTING CUTTING...
  • Page 2 THE PHOTOS BEFORE ATTEMPTING TO OPERATE YOUR VULCAN MACHINE. THESE BRACKETS WERE USED TO SECURE THE MACHINE DURING SHIPPING. REMOVE THESE BRACKETS DO NOT ANCHOR THE TABLE TO THE FLOOR. A Lockformer installation technician will level the equipment and secure it to the floor.

  • Page 3: Safety Information

    H. WEISS MACHINERY & SUPPLY PHONE: (718) 605-0395 - www.hweiss.com Safety... Page 1 SAFETY INFORMATION YOU ARE NOT READY TO OPERATE THIS EQUIPMENT UNTIL YOU HAVE READ AND UNDERSTOOD THE SAFETY INFORMATION IN THIS MANUAL. SAFETY FIRST! All Personnel working with or near the Vulcan must read this section! In addition to the following guidelines, refer to Sections 1, 2, and 3 of this manual for additional safety information.
  • Page 4 H. WEISS MACHINERY & SUPPLY PHONE: (718) 605-0395 - www.hweiss.com Safety... Page 2 BURN SAFETY - Intense ultraviolet light, sparks, and hot metal produced by plasma arc cutting will harm exposed skin and eyes. Operators and bystanders must wear protective clothing and equipment to avoid hazards.
  • Page 5 H. WEISS MACHINERY & SUPPLY PHONE: (718) 605-0395 - www.hweiss.com Safety... Page 3 Stock containing or coated with significant percentages of beryllium, cadmium, lead, mercury, or zinc can all give off poisonous fumes when burned by plasma arc cutting. Do not cut this stock unless the operator, or anyone else subjected to the fumes, wears appropriate respiratory equipment, an air supplied helmet, or that the table ventilation system is working efficiently.
  • Page 6 H. WEISS MACHINERY & SUPPLY PHONE: (718) 605-0395 - www.hweiss.com Safety... Page 4 Before changing the torch parts, disconnect the main power or unplug the power supply. After changing the torch parts and returning the retaining cap to its operating position, plug the power supply in again.
  • Page 7 H. WEISS MACHINERY & SUPPLY PHONE: (718) 605-0395 - www.hweiss.com Safety... Page 5 Use the shortest possible lengths of hose to avoid damage, reduce pressure drop, and prevent possible volume flow restriction. Let the hose lie as straight as possible to prevent kinks when interconnecting system components.
  • Page 8 H. WEISS MACHINERY & SUPPLY PHONE: (718) 605-0395 - www.hweiss.com Safety... Page 6 SAFETY DEVICES - The plasma unit used on the Vulcan have safety interlocks to prevent danger to personnel and damage to machine. Never attempt to short out or override these interlocks! Check the interlocks and all safety related parts of the plasma unit frequently and replace them IMMEDIATELY if they are not working! The interlocks disconnect the power supply when the retaining cap is loosened.
  • Page 9 H. WEISS MACHINERY & SUPPLY PHONE: (718) 605-0395 - www.hweiss.com Safety... Page 7 PUBLICATION INDEX The Publication Index contains a list of publications dealing with plasma arc cutting equipment safety practices. American National Standards Institute, 1430 Broadway, New York, NY 10018 (212) 354-3300.
  • Page 10 H. WEISS MACHINERY & SUPPLY PHONE: (718) 605-0395 - www.hweiss.com Safety... Page 8 THIS SAFETY ALERT SYMBOL INDICATED IMPORTANT SAFETY MESSAGES IN THIS MANUAL. WHEN YOU SEE THIS SYMBOL CAREFULLY READ THE MESSAGE THAT FOLLOWS AND BE ALERT TO THE POSSIBILITY OF PERSONAL INJURY OR DEATH. WARNING BEFORE ANY MACHINE IS USED BY AN EMPLOYEE OR IS LOANED OR RENTED, MAKE ABSOLUTELY CERTAIN THAT THE OPERATOR(S) PRIOR TO...
  • Page 11 H. WEISS MACHINERY & SUPPLY PHONE: (718) 605-0395 - www.hweiss.com Safety... Page 9 WARNING, DO NOT HANDLE MATERIAL (COIL, SHEET OR BLANK) WITHOUT WEARING PROTECTIVE GLOVES. WARNING, NARROW OR UNSTABLE COILS MUST NOT BE TRANSPORTED WITHOUT THE AID OF BLOCKING AND/OR SIDE SUPPORTS DANGER, COILS MUST NEVER BE CARRIED OVER THE HEADS OF...
  • Page 12 H. WEISS MACHINERY & SUPPLY PHONE: (718) 605-0395 - www.hweiss.com Safety... Page 10 WARNING, DO NOT OPERATE ANY EQUIPMENT WITHOUT GUARDS AND COVERS INSTALLED IN PLACE. WARNING, KEEP THE WORK AREA CLEAR OF OBSTRUCTIONS AND THE FLOOR CLEAN AND DRY. WARNING, NEVER USE STOOLS, BOXES, CRATES OR SIMILAR ITEMS AS SUBSTITUTES FOR WORK PLATFORMS, SCAFFOLDING...
  • Page 13 The Lockformer Company 711 Ogden Ave., Lisle, IL. 60532 (630) 964-8000 TABLE OF CONTENTS Reference Photos Section 1. Preliminary Machine Installation Section 2. Operation and Procedures Section 3. Maintenance Section 4. Lockformer Assembly Drawings And Parts Lists Section 5. Troubleshooting...
  • Page 14 H. WEISS MACHINERY & SUPPLY PHONE: (718) 605-0395 - www.hweiss.com Vulcan 1000B REFERENCE PHOTOS PLASMA FLOATING PNEUMATIC TORCH HEAD TORCH LIFTER X-AXIS HOME PLATE "X" BEAM EMERGENCY STOP TOUCH SCREEN MONITOR / P.C. Y-AXIS SUPPORT TUBE X-AXIS DRIVE HOME SWITCH SYSTEM "X"...
  • Page 15 H. WEISS MACHINERY & SUPPLY PHONE: (718) 605-0395 - www.hweiss.com SECTION 1 PRELIMINARY MACHINE INSTALLATION Safety Uncrating Location of Machine Incoming Power Supply for Plasma Unit Grounding Procedure / Power Supply Ventilation 200 Foot Cable Category 5E Cable Set Up Procedure 5.7 / 5.8 Touch Screen Networking Procedures (3) Pages Optional Control Positions Drawing Number AA55773...
  • Page 16 H. WEISS MACHINERY & SUPPLY PHONE: (718) 605-0395 - www.hweiss.com Preliminary Installation... Page 1 The following information outlines the factory procedures for preliminary installation of the Lockformer Vulcan Cutting Machine. Appropriate Lockformer reference and assembly drawings accompany this manual. See section 4.
  • Page 17 Refer to accompanying Lockformer assembly drawings to assist in the correct arrangement of electrical connections for grounding. Figure # 1, which appears at the end of this section, is a Star Ground assembly drawing, showing suggested positioning for grounding wires.
  • Page 18 H. WEISS MACHINERY & SUPPLY PHONE: (718) 605-0395 - www.hweiss.com Preliminary Installation... Page 3 CONTROLLER EMERGENCY STOP GROUND LOCATION OPTION 2 GROUND LOCATION OPTION 1 STAR GROUND EMERGENCY STOP PLASMA ARC POWER SUPPLY Figure 1...
  • Page 19 H. WEISS MACHINERY & SUPPLY PHONE: (718) 605-0395 - www.hweiss.com Preliminary Installation... Page 4 6. VENTILATION (see SAFETY, FIRST foreword for additional information!) To remove the toxic gases that are generated when metal is vaporized, a suction system with minimum. 3000-3500 cfm. exhaust draw must be installed on the cutting table through the opening provided at the bottom on the end of table.
  • Page 20 H. WEISS MACHINERY & SUPPLY PHONE: (718) 605-0395 - www.hweiss.com Preliminary Installation... Page 5 5.7/5.8 TOUCH SCREEN NETWORKING PROCEDURES Vulcan 5.7/5.8 TouchScreen Networking Procedures Note: These configurations assume that the Vulcan Shop Computer and the Vulcan TouchScreen Computer are not being networked to a company-wide network. The company’s networking personnel must configure any networking to a company-wide network.
  • Page 21 H. WEISS MACHINERY & SUPPLY PHONE: (718) 605-0395 - www.hweiss.com Preliminary Installation... Page 6 To Set IP Address and Subnet 1. Select Start and Control Panel from the pop-up menu. 2. Choose Network Connections. 3. Right click on Local Area Connection and choose properties.
  • Page 22 H. WEISS MACHINERY & SUPPLY PHONE: (718) 605-0395 - www.hweiss.com Preliminary Installation... Page 7 To Change Vulcan User Number and Data Drive Before proceeding, verify the Vulcan Software has been loaded onto the TouchScreen computer. 1. Double click on the Vulcan Icon. The VSII main program window appears. 2.
  • Page 23 H. WEISS MACHINERY & SUPPLY PHONE: (718) 605-0395 - www.hweiss.com Preliminary Installation... Page 8 9. OPTIONAL CONTROL POSITIONS Option furnished is as specified on the original purchase agreement.
  • Page 24 H. WEISS MACHINERY & SUPPLY PHONE: (718) 605-0395 - www.hweiss.com SECTION 2 OPERATION AND PROCEDURES Quick Start Operational Procedure Operation Details Initial Torch/Head Set-Up Procedure Emergency Stop Plasma Unit Set-Up Exhaust Activation Illustration 1 Top View How to Operate a Vulcan Without a Touch Screen...
  • Page 25 H. WEISS MACHINERY & SUPPLY PHONE: (718) 605-0395 - www.hweiss.com Operation / Procedures... Page 1 1. QUICK START OPERATIONAL PROCEDURE Start up the office computer. Turn the power switch located on the rear of the V1000B to the ON position. Start the exhaust system.
  • Page 26 H. WEISS MACHINERY & SUPPLY PHONE: (718) 605-0395 - www.hweiss.com Operation / Procedures... Page 2 2. OPERATING PROCEDURE Detailed screen by screen operating instructions are contained on the following pages: Auto Cut Tab Options available when the A , is selected. In this window: Auto Cut Buttons: Initialize Button Loads a file, which tells the program what type of cutting table is...
  • Page 27 H. WEISS MACHINERY & SUPPLY PHONE: (718) 605-0395 - www.hweiss.com Operation / Procedures... Page 3 Downloading A Liner Job How to enter and download a L INER Entering a Liner Job Number: 1. Press the Liner Button. This will display the L INER UMBER 2 .
  • Page 28 H. WEISS MACHINERY & SUPPLY PHONE: (718) 605-0395 - www.hweiss.com Operation / Procedures... Page 4 Downloading A Part How to enter and download a P Entering a Part Number: Touch the P This will display the P UTTON NPUT UMBER Enter the Part Number you wish to cut and press enter.
  • Page 29 H. WEISS MACHINERY & SUPPLY PHONE: (718) 605-0395 - www.hweiss.com Operation / Procedures... Page 5 Downloading A Blank How to enter and download a B LANK Entering a Blank Number: To download a B , A Job must first be downloaded. LANK Touch the B This will display the B...
  • Page 30 H. WEISS MACHINERY & SUPPLY PHONE: (718) 605-0395 - www.hweiss.com Operation / Procedures... Page 6 Downloading A Job How to enter and download a J Entering a Job Number: Press the Job Button. This will display the J UMBER Enter the Job Number you wish to cut and touch enter. Enter the sheet number that you want to start from and touch enter.
  • Page 31 H. WEISS MACHINERY & SUPPLY PHONE: (718) 605-0395 - www.hweiss.com Operation / Procedures... Page 7 After A Job Has Been Downloaded Available options after the J is downloaded. In this window: Auto Cut Buttons: E x i t E x i t E x i t E x i t E x i t...
  • Page 32 H. WEISS MACHINERY & SUPPLY PHONE: (718) 605-0395 - www.hweiss.com Operation / Procedures... Page 8 After Start Cut Has been Pressed Options available after downloading a J and touching the S button. TART In this window: Auto Cut Buttons: P a u s e P a u s e P a u s e P a u s e...
  • Page 33 H. WEISS MACHINERY & SUPPLY PHONE: (718) 605-0395 - www.hweiss.com Operation / Procedures... Page 9 Manual Tab Options available when the M , is selected. ANUAL In this window: Manual Cut Buttons: T o r c h T o r c h T o r c h T o r c h T o r c h...
  • Page 34 H. WEISS MACHINERY & SUPPLY PHONE: (718) 605-0395 - www.hweiss.com Operation / Procedures... Page 10 Display Tab Options available when the D , is selected. ISPLAY In this window: Display Buttons: S h e e t S h e e t S h e e t S h e e t S h e e t...
  • Page 35 H. WEISS MACHINERY & SUPPLY PHONE: (718) 605-0395 - www.hweiss.com Operation / Procedures... Page 11 Options Tab These features are not currently available. In this window: Options Buttons: E x i t E x i t E x i t E x i t E x i t Exit Button exits and discards the Job data that has been downloaded.
  • Page 36 H. WEISS MACHINERY & SUPPLY PHONE: (718) 605-0395 - www.hweiss.com Operation / Procedures... Page 12 Fittings Tab When pressed the controller program will minimize to the tool bar. This allows access to the desktop. From the desktop the Vulcan program can be accessed by clicking on the icon. At this point you may enter a fitting or make changes to a job or part.
  • Page 37 H. WEISS MACHINERY & SUPPLY PHONE: (718) 605-0395 - www.hweiss.com Operation / Procedures... Page 13 3. INITIAL TORCH/HEAD SETUP PROCEDURE The distance of the torch to the material is critical and must be checked prior to cutting the job and adjusted if necessary.
  • Page 38 The gas (air) supply should be clean, dry, and free of oil to ensure maximum consumable life. A three stage filter assembly is recommended to filter the gas (air). CONTACT LOCKFORMER SERVICE DEPARTMENT FOR DETAILS. Before applying power to the Plasma unit, verify that the input gas (air) pressure is set according to the figure as shown in the Hypertherm operations manual.
  • Page 39 H. WEISS MACHINERY & SUPPLY PHONE: (718) 605-0395 - www.hweiss.com Operation / Procedures... Page 15 0, 120 POINT WORKPIECE WORKPIECE APPROXIMATE STOPS TORCH SETUP POINT 0,0 POINT (Home Position) ILLUSTRATION 1...
  • Page 40 H. WEISS MACHINERY & SUPPLY PHONE: (718) 605-0395 - www.hweiss.com Operation / Procedures... Page 16 7. HOW TO OPERATE A VULCAN WITHOUT A TOUCH SCREEN 3 Items Needed Computer: The best computer to use is your office computer, but any computer will work as long as it has Windows XP and Vulcan and shop data loaded.
  • Page 41 H. WEISS MACHINERY & SUPPLY PHONE: (718) 605-0395 - www.hweiss.com Operation / Procedures... Page 17 7. HOW TO OPERATE A VULCAN WITHOUT A TOUCH SCREEN (CONT.) 8. Click on System from the VSControl. a. Change Job Data Path to c:\ENGVUL b.
  • Page 42 H. WEISS MACHINERY & SUPPLY PHONE: (718) 605-0395 - www.hweiss.com SECTION 3 MAINTENANCE Safety Inspection and Upkeep Lubrication Reinstallation and Assembly of the Vulcan Torch Head Torch Height Adjustment Torch Lifter Adjustment...
  • Page 43 H. WEISS MACHINERY & SUPPLY PHONE: (718) 605-0395 - www.hweiss.com Maintenance... Page 1 1. SAFETY - Shut Off main power disconnect to cut off power from Vulcan (including Plasma Unit) before attempting to work on electrical circuits or performing any cleaning of machine that involves reaching in between parts that can move! Do not touch electrically hot parts! Keep cables dry, free of oil and grease, and protected at all times from damage by hot metal and sparks.
  • Page 44 H. WEISS MACHINERY & SUPPLY PHONE: (718) 605-0395 - www.hweiss.com Maintenance... Page 2 4. REINSTALLATION AND ASSEMBLY OF THE VULCAN TORCH HEAD Regular maintenance of the torch head includes resetting the torch height for the stock being cut, and cleaning; as described at the end of this section. If a torch head is ever to be removed and a new one installed, or if a torch head has to be reset, use the following procedure: 1.
  • Page 45 H. WEISS MACHINERY & SUPPLY PHONE: (718) 605-0395 - www.hweiss.com Maintenance... Page 3 PHOTO 2 TORCH MOUNTING SCREWS (2) PHOTO 3 2. Loosen the floating head's fastening screws as shown in photo 2, then remove the lower assembly from the torch head as shown in Photo 3. 3.
  • Page 46 H. WEISS MACHINERY & SUPPLY PHONE: (718) 605-0395 - www.hweiss.com Maintenance... Page 4 THREADED COLLAR PHOTO 4 4. Remove the torch assembly from the holder casting. Now remove the torch body by loosening the threaded collar. Unscrew housing to expose wires. ( See photo 4) PHOTO 5 5.

  • Page 47: Torch Assembly

    H. WEISS MACHINERY & SUPPLY PHONE: (718) 605-0395 - www.hweiss.com Maintenance... Page 5 TORCH ASSEMBLY SEE HYPERTHERM MANUAL T60M Machine Torch Assembly Item Part No. Description 083176* T60M Machine Torch Assembly with 35 ft (10.7 m) Lead 083177* T60M Machine Torch Assembly with 50 ft (1 5.2 m) Lead 128640 T60M Torch Main Body Replacement Kit 027889...
  • Page 48 H. WEISS MACHINERY & SUPPLY PHONE: (718) 605-0395 - www.hweiss.com Maintenance... Page 6 Torch height setting of casters resting on sheet is only a starting setting; see Section 2 for more information on setting torch properly for different thicknesses of stock. Whenever drastically changing thickness of stock to be cut (by 1/8"...
  • Page 49 H. WEISS MACHINERY & SUPPLY PHONE: (718) 605-0395 - www.hweiss.com SECTION 4 ASSEMBLY DRAWINGS AND PARTS LISTS Assembly Drawings: Sub Assembly X Beam AA55143 General Assembly AA55144 Pneumatic Connections AA55169 Sub Assembly Y Axis AA55335 X and Y Prox. Cables AA80504 / AA80505 Power In Cable AA85482...
  • Page 50 H. WEISS MACHINERY & SUPPLY PHONE: (718) 605-0395 - www.hweiss.com...
  • Page 51 H. WEISS MACHINERY & SUPPLY PHONE: (718) 605-0395 - www.hweiss.com...
  • Page 52 H. WEISS MACHINERY & SUPPLY PHONE: (718) 605-0395 - www.hweiss.com...
  • Page 53 H. WEISS MACHINERY & SUPPLY PHONE: (718) 605-0395 - www.hweiss.com...
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  • Page 60 H. WEISS MACHINERY & SUPPLY PHONE: (718) 605-0395 - www.hweiss.com...
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  • Page 62 H. WEISS MACHINERY & SUPPLY PHONE: (718) 605-0395 - www.hweiss.com...
  • Page 63 H. WEISS MACHINERY & SUPPLY PHONE: (718) 605-0395 - www.hweiss.com CONTROL AND DRIVE SYSTEM ELECTRICALS...
  • Page 64 H. WEISS MACHINERY & SUPPLY PHONE: (718) 605-0395 - www.hweiss.com CONTROL AND DRIVE ELECTRICALS...
  • Page 65 H. WEISS MACHINERY & SUPPLY PHONE: (718) 605-0395 - www.hweiss.com CONTROL AND DRIVE ELECTRICALS...
  • Page 66 H. WEISS MACHINERY & SUPPLY PHONE: (718) 605-0395 - www.hweiss.com...
  • Page 67 H. WEISS MACHINERY & SUPPLY PHONE: (718) 605-0395 - www.hweiss.com...
  • Page 68 H. WEISS MACHINERY & SUPPLY PHONE: (718) 605-0395 - www.hweiss.com...
  • Page 69 H. WEISS MACHINERY & SUPPLY PHONE: (718) 605-0395 - www.hweiss.com...
  • Page 70 H. WEISS MACHINERY & SUPPLY PHONE: (718) 605-0395 - www.hweiss.com...
  • Page 71 H. WEISS MACHINERY & SUPPLY PHONE: (718) 605-0395 - www.hweiss.com SECTION 5 TROUBLESHOOTING X and Y Axis Movement TS-1 Cutting Errors TS-1 Torch Movement TS-2 Computer Block TS-2 Error Codes TS-3...
  • Page 72 This Section was prepared to make it easier for operating personnel to solve such problems quickly, so it is not necessary to consult Lockformer in many cases. Caution Shut Off All Incoming Power To Check Any Electrical Components Before Servicing! 1.
  • Page 73 H. WEISS MACHINERY & SUPPLY PHONE: (718) 605-0395 - www.hweiss.com TS... Page 2 3. Torch Movement Machine moves rapidly when Auto Zeroing X- Check encoder cable. axis, followed by screen message: Axes: X Following Error Exceeded Torch will not raise or lower 1.

  • Page 74: Error Codes

    H. WEISS MACHINERY & SUPPLY PHONE: (718) 605-0395 - www.hweiss.com TS... Page 3 5. Error Codes...

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