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THERMACUT EX-TRACK Operator's Manual

Portable cnc cutting system
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PORTABLE CNC CUTTING SYSTEM
Operator Manual
Revision Date: December 01, 2019
Revision Number: 01.3
Language: English
EX-0-902-001
N-22063

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  • Page 1 PORTABLE CNC CUTTING SYSTEM Operator Manual Revision Date: December 01, 2019 Revision Number: 01.3 Language: English EX-0-902-001 N-22063...

  • Page 2: Foreword

    It is the responsibility of the operator/user to ensure the safe use/handling of the system, refer to Thermacut’s terms and conditions of sale for specific responsibilities and limitations on liability. Information in this document is subject to change without notice. The manual is for the convenience...

  • Page 3: Table Of Contents

    EX-TRACK ® INDEX Foreword ........................2 Safety precautions ......................2 1. SAFETY INSTRUCTIONS ................9 1.1. General system safety precautions ..............12 1.1.1. System safety ....................12 1.1.2. Personal protective equipment ..............12 1.1.3. Safety precautions prior to handling and operation ........13 1.2.
  • Page 4 EX-TRACK ® 5.1.1. Input voltage settings ..................33 5.1.2. EX-TRACK placement ..................33 ® 5.1.3. Oxy fuel nozzle choice ..................33 5.1.4. Regulated gas supply ..................33 5.1.5. Oxy fuel cut charts .................... 33 5.1.6. Pre-ignition check ..................... 34 5.2. Ignition and flame adjustment - oxy propane cutting ........34 5.3.
  • Page 5 EX-TRACK ® 9.4.1.9. Dry run [X] ...................... 52 9.4.1.10. Speed [Y] ..................... 53 9.4.2. Auto processing menu [MAIN MENU → F1 (AUTO)] ........53 9.4.2.1. Pierce point [F1 (SECTION)] ................ 53 9.4.2.2. Manual mode [F2 (MANUAL)] ..............53 9.4.2.3. Break point [F3 (BRK)] ................... 53 9.4.2.4.
  • Page 6 EX-TRACK ® 9.7.1.5. Delete line [F5] ....................66 9.7.1.6. USB [F6] ......................66 9.7.1.7. View [F7] ......................66 9.8. Setup [F4 PARAMER] ..................66 9.8.1. Process definition - speed ................66 9.8.2. Speed parameters [F1] ..................67 9.8.3. System parameters ..................68 9.8.4.
  • Page 7 EX-TRACK ® 9.11.3. M07 – cutting sequence start ............... 80 9.11.4. M08 – cutting sequence stop ............... 81 9.11.5. Additional M-codes ..................81 10. FAQ’s Operating the system ..............82 10.1. FAQ’s Operating the system ................83 10.2. Basic trouble shooting ..................85 10.3.
  • Page 8 EX-TRACK ® Shape 23 ........................108 Shape 24 ........................108 Shape 25 ........................109 Shape 26 ........................109 Shape 27 ........................109 Shape 28 ........................110 Shape 29 ........................110 Shape 30 ........................110 Shape 31 ........................111 Shape 32 ........................111 Shape 33 ........................

  • Page 9: Safety Instructions

    EX-TRACK ® SECTION 1. SAFETY INSTRUCTIONS: 1.1. General system safety precautions ................12 1.1.1. System safety ......................... 12 1.1.2. Personal protective equipment ................... 12 1.1.3. Safety precautions prior to handling and operation ..........13 1.2. Plasma/oxy fuel gas cutting safety awareness .............. 14 1.2.1.
  • Page 10 EX-TRACK ® Safety Instructions Many accidents are caused by disregard for basic safety rules in the operation, inspection and maintenance of devices. So carefully read, fully understand, and comply with the safety measures and precautions described in this instruction manual and on the system before operating, inspecting, and maintaining the system.
  • Page 11 EX-TRACK ® Warning symbols Symbol Title Meaning General General caution, warning and danger. Be careful not to get your Possible injury to fingers if caught in the insertion fingers caught! part. Caution: Electric shock! Possible electric shock under special conditions.

  • Page 12: General System Safety Precautions

    ® 1.1. General system safety precautions 1.1.1. System safety The EX-TRACK CNC System is fitted with an Emergency Stop or E-Stop Button. This button is used ® to isolate the system from the input (120V/220V) power source. It is intended for use in the case of an accident or emergency.

  • Page 13: Safety Precautions Prior To Handling And Operation

    Failure to do so can result in injury. 9. To reduce the risk of an accident, prohibit the touching of moving parts while the system is running. 10. DO NOT use the EX-TRACK for welding purposes the circuit boards will suffer catastrophic ®...

  • Page 14: Plasma/Oxy Fuel Gas Cutting Safety Awareness

    EX-TRACK ® 1.2. Plasma/oxy fuel gas cutting safety awareness It is essential that ALL operators of the system are aware of the potential danger/risk associated with Plasma/Oxy fuel Gas cutting operations. Keep “SAFETY” in mind! 1.2.1. Prevention of fire and explosion 1.

  • Page 15: Risk Of Fire

    2. Never cut into sealed or open canisters/containers that have been used for gases or flammable products. 3. Do not keep lighters or matches on your person. 4. When operating the EX-TRACK system, maintain a safe distance from the torch. ®...

  • Page 16: Safety In The Workplace

    EX-TRACK ® 6. Oxy fuel cutting, ensure that the nozzle is correctly seated and tightened so as not to damage the seat/sealing area and prevent “Flashbacks” to the system. • When fixing a nozzle to the torch, use two wrenches to avoid damage to the torch. Over tightening the nozzle will result in the nozzle overheating during the cutting process, making the nozzle more difficult to remove.
  • Page 17 EX-TRACK ® ATTENTION: Prior to starting the cutting process, perform a system/equipment check to ensure there are no gas leaks or visible damage to component parts. If during the cutting process there is the odor from a gas leak, immediately press the E-Stop button to isolate the electrical power supply, turn off the gas supply at the torch and then at the point of supply - Cylinder/Manifold.

  • Page 18: Location Of Warning And Safety Labels

    EX-TRACK ® SECTION 2. LOCATION OF WARNING AND SAFETY LABELS: Warning and Safety labels have been affixed to the system for the purpose of hazard awareness and correct use of the system. Prior to operating the system carefully read the labels and follow the instructions.
  • Page 19 EX-TRACK ® SAFETY !Caution! Caution! Read operator’s manual The symbol shown in this section means: !Caution! !Beware! Follow the safety instructions to avoid danger. ¡There are possible hazards with this procedure! Only qualified persons should install, operate, maintain and When you find this symbol in the manual or on the system, repair the system.
  • Page 20 EX-TRACK ® CUTTING CAN CAUSE FIRE OR FLYING SPARKS (ARC SPRAY) EXPLOSION CAN CAUSE INJURY, FIRE OR EXPLOSION FIRE PREVENTION Flying sparks are created during the metal cutting/gouging processes; the area should be kept free from flammables. • Use face shield/safety glasses with side protection.
  • Page 21 EX-TRACK ® SMOKE AND GASES CAN BE HAZARDOUS Induction heating of certain materials, adhesives, and fluxes may cause fumes or smoke. Breathing the fumes and smoke can be hazardous to your health • Work in a confined space only if it is well ventilated, •...

  • Page 22: Specification

    EX-TRACK ® SECTION 3. SPECIFICATION: 3.1. System overview ....................... 23 3.1.1. Main features ......................... 23 3.1.2. Range of application ..................... 23 3.2. System parts description ....................23 3.3. Technical parameters ....................... 24 3.4. Torch height controller..................... 24 3.5. Gas supply ......................... 25...

  • Page 23: System Overview

    EX-TRACK ® 3.1. System overview The EX-TRACK CNC Cutting System is the latest generation of high precision, programmable and ® portable cutting system designed for use in the workshop or on site. 3.1.1. Main features The system has a similar functionality to the fixed table type equipment fitted with a large gantry.

  • Page 24: Technical Parameters

    OX - Oxygen FG - Fuel gas (Propane) Name plate fixed to the back of the main unit. WARNING: Do not use EX-TRACK® CNC unit with high frequency ignition plasma systems! HF ignition can damage the unit. 3.3. Technical parameters Cutting area (mm) 1500 ×...

  • Page 25: Gas Supply

    EX-TRACK ® Torch lifting mechanism: comprises of lifting motor, lifting screw, guide shaft and fittings. Torch mounting assembly: comprises of connector, clamp and manual lifting wheel. The torch height and vertical positioning can be adjusted manually, so as to ensure that cut is square. For edge beveling, rotate the torch along the longitudinal or transverse direction to perform an angled cut.

  • Page 26: Unpacking And Assembly

    EX-TRACK ® SECTION 4. UNPACKING AND ASSEMBLY: 4.1. Packing list ......................... 27 4.2. System assembly ......................28 4.2.1. Parts check ........................28 4.2.2. Fitting the main unit on to the longitudinal guide rail ..........28 4.2.3. Fitting the transverse guide rail ................... 29 4.2.4.

  • Page 27: Packing List

    EX-TRACK ® 4.1. Packing list Upon receipt of the system, check that all parts have been received and that they are undamaged. shortages or damage, contact your supplier. Number Name Quantity Note Assembled parts Main unit (CNC unit) Transverse rails...

  • Page 28: System Assembly

    EX-TRACK ® 4.2. System assembly 4.2.1. Parts check Check that the main parts listed below have been receipted. Change lifting device to: 4.2.2. Fitting the main unit on to the longitudinal guide rail Place the longitudinal guide rail on an even well supported surface, and then carefully feed the main unit on to the rail guide (it is recommended that this is done with two people).

  • Page 29: Fitting The Transverse Guide Rail

    EX-TRACK ® 4.2.3. Fitting the transverse guide rail Pass the torch height motor lead (complete with plug) through the main unit case, then place the transverse rail in the horizontal plane, as shown in Figure 3, gently feed the rail in through the main unit until the rack meshes with the drive gear in the main unit.

  • Page 30: Gas Supply Connection

    Use a suitable leak test product, ensure that there are no leaks prior to use. The Oxy fuel hoses fitted to this system are standard Ø8mm internal diameter hoses. Where possible use the minimum length of hose between the gas supply point and the EX-TRACK , this ®...
  • Page 31 EX-TRACK ® Plug the torch height motor control lead in to the corresponding input on the main unit side panel. Ensure that there is a functional ground terminal on the input power lead. If not grounded, the operator is at risk of an electrical shock.

  • Page 32: Cutting Process

    ® SECTION 5. CUTTING PROCESS: 5.1. Prior to operating the system ................. 33 5.1.1. Input voltage settings .................. 33 5.1.2. EX-TRACK placement ................. 33 ® 5.1.3. Oxy fuel nozzle choice ................. 33 5.1.4. Regulated gas supply .................. 33 5.1.5. Oxy fuel cut charts ..................33 5.1.6.

  • Page 33: Prior To Operating The System

    5.1.1. Input voltage settings The CNC unit is pre-adjusted from the production on 230VAC. If you need input voltage 110VAC, open the CNC unit and switch the switching power supply to your desire input voltage. 5.1.2. EX-TRACK placement ® The EX-TRACK is to be sited on a well-supported foundation, ensure it is leveled prior to use, do not ®...

  • Page 34: Pre-Ignition Check

    EX-TRACK ® Work-piece Pressure Consumption Cutting thickness speed Nozzle type (bar) (Nl/h) (mm) (mm/min) Oxygen Fuel gas Cutting O Preheat O Fuel gas 5 - 10 1200 1180 660 - 550 10 - 15 2100 1180 550 - 490 15 - 30 0.25...

  • Page 35: Cut Quality

    EX-TRACK ® 5.3. Cut quality Acceptable cut quality is dependent upon many factors, quality that is acceptable in some instances may not be for others. Make a test cut prior to a production run to ensure the required cut quality has been achieved.

  • Page 36: Flashback And Backfire Prevention

    The supplied flashback arrestor is built in on the fuel gas supply at the torch, it is intended for use with Propane gas only, do not use it for any other gases. The EX-TRACK CNC System is not set up for Acetylene gas use.
  • Page 37 EX-TRACK ® Turning the torch off: 1. Close the oxygen preheating valve. 2. Close the fuel gas valve. 3. Close the oxygen cutting valve. Operator Manual, Revision T-1...
  • Page 38 EX-TRACK ® SECTION 6. SYSTEM OPERATION: 6.1. Oxy fuel cutting (prior to operation) ..............39 6.2. Plasma arc cutting (prior to operation) ............. 40 Operator Manual, Revision T-1...
  • Page 39 8. The operator should be aware that after cutting a profile, the torch should be raised to prevent a collision when moving to the next start point. 9. When using an overhead crane or other lifting device to move the cut profiles or scrap material, ensure that the EX-TRACK will not be damaged. ®...
  • Page 40 Interface Cable, the cable plugs in to the EX-TRACK on the left side Power in/ ® Connection. 3. Fit the torch height controller lead from the transverse rail to the EX-TRACK on the left ® side Power in/Connection. 4. Feed the plasma torch lead set through the transverse rail (it may be necessary to remove the rail cover) and fit the torch in to the torch mounting.
  • Page 41 EX-TRACK ® SECTION 7. MAINTENANCE: 7.1. Cleaning the system .................... 42 7.2. System lubrication ....................42 7.3. Drive motor adjustment ..................42 7.4. Oxy fuel nozzle maintenance ................42 Operator Manual, Revision T-1...
  • Page 42 7.1. Cleaning the system It is a requirement that the EX-TRACK CNC Cutting System is checked for cleanliness prior to, ® during and after the cutting process. Prior to any cleaning, isolate the electrical power supply to the system.
  • Page 43 EX-TRACK ® SECTION 8. CIRCUIT DIAGRAM: 13 I12 24V GND 8 / 15 24V GND 8 / 15 Operator Manual, Revision T-1...
  • Page 44 EX-TRACK ® 8.1. Plasma interface SYSTEM CNC INTERFACE CONNECTION Each type of signal is available through the system CNC interface connector located on the left side of the main unit. Use the chart with details of each signal type below when connecting the system interface lead to the plasma arc power supply.
  • Page 45 EX-TRACK ® SECTION 9. OPERATION: 9.1. Control panel functions ..................48 9.2. CNC system functions ..................48 9.3. System main menu ....................49 9.3.1. Menu features ....................49 9.3.2. Main function F-key menu ................50 9.4. Automatic function ....................50 9.4.1.
  • Page 46 EX-TRACK ® 9. 6. Manual mode ...................... 62 9.6.1. Manually controlled functions ................ 62 9.6.1.1. [↑] [↓] [←] [→] [UP] [DOWN] [LEFT] [RIGHT] directional control keys [G] 63 9.6.1.2. Mode switching [F1] ..................63 9.6.1.3. Step [F2] ......................63 9.6.1.4. More [F3] ......................63 9.6.1.4.1.
  • Page 47 EX-TRACK ® 9.10.6. System axes ....................77 9.10.7. G-codes ......................78 9.10.8. G92 – program zero point ................78 9.10.9. G90 – absolute commands ................78 9.10.10. G91 – incremental commands ..............78 9.10.11. G20 – imperial mode .................. 78 9.10.12.

  • Page 48: Control Panel Functions

    EX-TRACK ® 9.1. Control panel functions 1. Display 2. Input keys 3. Menu / Function keys 4. Start button 5. Stop button 6. Software update button 7. USB / Dongle port Note: USB port has low power for file transfer only.

  • Page 49: System Main Menu

    EX-TRACK ® CNC System Technical Specification Processor ARM processing chip Display 7” Color LCD, 800 x 480 resolution Input/output 13 - 16 photoelectric isolation input, 8-way photoelectric isolation output, including four-way relay output CNC Controlled Axes X, Y and Z (Vertical) with Height Controller Top speed <...

  • Page 50: Main Function F-Key Menu

    EX-TRACK ® 9.3.2. Main function F-key menu [F1] AUTO: Automatic CNC process control. [F2] MANUAL: Manually position the cutting torch. [F3] EDITOR: Edit/modify/USB input/USB output processing program. [F4] PARAMER: System parameter settings. [F5] DIAGNOSE: Check machine input and output information.

  • Page 51: Interfaces And Inputs

    BRAKE. Operational information bar indicates: machine activity or stopped, various system limit alarms and dwell period. 9.4.1.4. Input and output signals The EX-TRACK CNC System utilizes 8 input and 8 output ports. The display shows visual signals ® indicating the status of each input and output. The Input/output port is used for system diagnostics.

  • Page 52: System Coordinates Display

    EX-TRACK ® 9.4.1.6. System coordinates display The coordinates displayed can be in Metric (mm) or Imperial (inches), to switch between settings: See, Parameters-Control. The CNC/Operator panel input keys are used to control the functions below. [IGNITION] - Ignition function see M code M20...

  • Page 53: Speed [Y]

    EX-TRACK ® 9.4.1.10. Speed [Y] The speed function indicates the actual speed in Metric/Inch. The Feed ratio can be manually adjusted using the [F↑] and [F↓] keys. The speed can be manually entered, press the [F] key in the screen, at the top of the screen there is an input option for a numerical value to be entered using the keypad.

  • Page 54: Graphics Display [F4]

    EX-TRACK ® 9.4.2.4. Graphics display [F4] The on-screen graphics use a cursor to show a profile part or nest of profile parts to be cut, the cutting path of the torch and the completed cut area. Press [1] key to magnify the profile part Image, press up to 3x for a maximum 8x magnification.

  • Page 55: F1 Outline] Perimeter Function

    EX-TRACK ® 9.4.2.6.1. [F1 OUTLINE] PERIMETER FUNCTION The PERIMETER function is used to confirm the fit of a programmed profile part or nest on to a plate. The system performs a rapid perimeter check in the form of a rectangle; the torch movement can be observed for its travel within the perimeter of the plate.

  • Page 56: Mirror [F4]

    EX-TRACK ® Returning to Auto Mode MORE [F6] menu, the re-orientation process can be stopped, press the [F3] key. The degree of re-orientation is logged in the system, the process can be repeated as required. 9.4.2.6.3. Mirror [F4] This function lets the operator invert a profile part, creating an exact opposite hand duplicate.

  • Page 57: Tabbing - Bridge Function [F7 Break]

    EX-TRACK ® 9.4.2.6.6. Tabbing - bridge function [F7 BREAK] Creating tabs or bridge cutting, is performed by pre-determined stops in the cutting process, the size of tabs/bridges is dependent upon the profile part size, thickness and purpose of the tab/ bridge.

  • Page 58: Cutting Speed

    EX-TRACK ® 9.5.1. Cutting speed Prior to running a program, refer to the cut chart data for the process used, Oxy fuel/Plasma, material type and thickness, set the appropriate speed, then initiate the Auto Mode. During the cutting process, the feed rate can be adjusted up/down by the [F↑] [F↓] keys, pressing the [F] key, a numerical value input can be made using the keypad.

  • Page 59: Active Key Functions In Pause Mode

    EX-TRACK ® [STOP] Preheat Timer Extend, pressing the preheat timer key during the preheat process, this increases the preheat process duration. The pierce process can be activated by pressing the [START] key, the timer will stop. [STOP] Program Pause, pressing the [STOP] key during the cutting process, causes the system to ramp down to a halt, in the case of oxy fuel, the oxygen cut flow gas is switched off, in the case of plasma arc cutting, the arc is switched off.
  • Page 60 EX-TRACK ® [S↑] [S↓] Torch Up/Down, the [S↑] [S↓] keys are used to raise and lower the torch. [CUTOXY] Re-Start, use this key to manually restart the cutting process. [PIERCE] Re-Start, use this key to start the pierce process, the process defaults to Auto Mode, the system starts moving at a pre-determined time.

  • Page 61: Select Program

    EX-TRACK ® the torch Backwards/Forwards through the cutting sequence at a pre-determined speed, press [STOP] when the torch is at the desired position or the on-screen ERROR CODE G00 is displayed. Pressing keys [F6] [F7} will override the error code.

  • Page 62: Manual Mode

    EX-TRACK ® consumable parts and the parent material. Use the Edge Start setting, input the value 1, initiate a cut sequence in Auto Mode, when the torch reaches the pierce point, an on-screen prompt requires a pierce number. Pressing the [START]/[ENTER] key gives Pierce options: PIERCE HERE the pre-programmed cutting sequence pierces at this point.

  • Page 63: [↓] [←] [→] [Up] [Down] [Left] [Right] Directional Control Keys [G]

    EX-TRACK ® 9.6.1.1. [↑] [↓] [←] [→] [UP] [DOWN] [LEFT] [RIGHT] directional control keys [G] The directional control keys are used to position the torch; the speed of travel is faster than the cut speed. Using the [G] key function allows the torch to move non-stop in the direction of the pressed arrow until the arrow is re-pressed to stop the travel, alternatively, pressing the [STOP] key ends the movement.

  • Page 64: P-Start [F3] A P-End [F4]

    EX-TRACK ® 9.6.1.4.1. P-START [F3] a P-END [F4] This feature lets the operator check the alignment trueness of the plate to the system. The torch is moved to two positions along the nearest edge of the plate, the system software compensates for the out of true orientation of the plate.

  • Page 65: Editing Function

    EX-TRACK ® 9.7. Editing function In the system main menu press [F3 EDITOR] to enter the Editing Menu. See the image below. 9.7.1 Edit function 9.7.1.1. New [F1] Use this feature to create a new file that can be edited, using the keypad, manually enter the program code.

  • Page 66: Save [F3]

    EX-TRACK ® 9.7.1.3. Save [F3] Edited programs can be saved in the memory, they can be renamed using the keypad, a maximum of 12 characters can be used to name a file. Press [ENTER] to save changes and [ESC] to leave without change.

  • Page 67: Speed Parameters [F1]

    EX-TRACK ® 9.8.2. Speed parameters [F1] The speed parameters are accessed in the SETUP menu by pressing the [F1] key. START-SPEED: start up speed of the “X”-”Y” drive motors prior to reaching full speed, a lower speed causes less backlash when starting and stopping. Speed values are shown in Metric-mm/min or Imperial- inches/min.

  • Page 68: System Parameters

    NUMERATOR: numerical analysis used for positioning accuracy. MA ORIGIN: start point for the System Coordinates. REFERENCE POINT: start point for the Program Coordinates. DRILL OFFSETS: Function not used with EX-TRACK CNC SYSTEM. ® BACKLASH: Function not used with EX-TRACK CNC SYSTEM.

  • Page 69: Oxy Parameters

    EX-TRACK ® SOFT LIMIT-: Software controlled limit in - direction. Maximal - lenght of the movement (cutting area limitation). For activation SOFT LIMIT fuction go to CONTROL menu and set: SOFTWARE LIMITS EF - „1“ 9.8.4. OXY parameters The flame parameters are accessed in the SETUP menu by pressing the [F3] key.

  • Page 70: Plasma Parameters

    LINE DELAY-TIME: Use this function for big thicknesess - set this delay time for cutting in the corners or when the torch change the direction SELECT HI HOTUP M24 (0/1): Function not used with EX-TRACK CNC SYSTEM. ®...

  • Page 71: Control Parameters

    Edge starting can be used to cut thick and thin material. *NO-GRAPHIC: in Auto Mode, stops on-screen display of the program parts, time is saved when cutting a large nest/program. *SYNCHRO XZ:0 / YZ:1: function not used with EX-TRACK CNC SYSTEM. ®...
  • Page 72 *G41 /G42 CHECK EFF (0/1): check for kerf faults. No/0 ; Yes/1. *INITIAL CLEAR DOOR: program coordinates are automatically reset to zero when a program starts. *SELECT CYLINDER UP/DOWN: function not used with EX-TRACK® CNC SYSTEM. *SELECT AUTO-REFERENCE: torch can be automatically repositioned to the program zero point when the program ends.

  • Page 73: Thc

    EX-TRACK ® *BRIDGE LENGTH: length of bridge/tab. *DISPLAY CO: do not change this parameter. *SHOW KERF: cutting in Auto Mode, display the kerf offset. YES-”0”. 9.9.2. THC The THC parameters are accessed in the SETUP menu by pressing the [F6] key.

  • Page 74: Save [F7]

    MANUAL SPEED: the torch up/down speed for manual lift (up down manual speed). AUTO SPEED: the torch up/down speed for automatic lift. POSITION SPEED: the torch up/down speed for the initial position. 9.9.3. Save [F7] This key save all adjusted parameters to the internal memory of EX-TRACK unit. ® 9.9.4. Gallery function The gallery function is accessed in the Main Menu by pressing [F6].

  • Page 75: Graphics Library (Shape Development)

    EX-TRACK ® 9.9.6. Graphics library (shape development) Pick a shape from the graphics library, input the required dimensions into the Shape Evaluation Screen, nesting data can be added if needed. Validate all data/dimensional inputs using the [F6} OK key. By pressing the [ESC] key to exit the Shape Evaluation Screen, the shape is provisionally stored in the memory.

  • Page 76: Graphics Library (Nest Function)

    EX-TRACK ® 9.9.8. Graphics library (nest function) Input the required values for the number of rows and columns, the system software automatically calculates the row height and column width relative to the part size, manual adjustment is permitted to improve the layout. The Row-Offset function may be used when a staggered fit gives better results.

  • Page 77: File Types

    EX-TRACK ® N - Numbering, can be used on all or just some lines, operator aid. G - Motion, rapid feed, circular feed or offset value. M - Machine Function, action code, auxiliary command. T - Tool Selection, used in this system for “Flame” value.

  • Page 78: G-Codes

    EX-TRACK ® 9.10.7. G-codes Motion codes are used to define the systems programed motions such as rapid feed, circular feed, offset value etc. The default of program input values is positive (+) therefore only a negative (-) value requires input when programming.

  • Page 79: G00 - Rapid Travel

    EX-TRACK ® The G21 code is associated with Metric (mm) dimensional program input to the controller. The G21 code must be used at the start of the program. 9.10.13. G00 – rapid travel The G00 code is used for rapid travel between parts or positions in the program, it is also used for torch/consumable change/inspection, this action is performed at maximum speed.

  • Page 80: G41 - Kerf Left

    EX-TRACK ® 9.10.18. G41 – kerf left This turns on the kerf compensation factor to the left of the cutting path. 9.10.19. G42 – kerf right This turns on the kerf compensation factor to the right of the cutting path.

  • Page 81: M08 - Cutting Sequence Stop

    EX-TRACK ® The M07 code is used to start an automatic cutting sequence, with the following functions for oxy fuel and plasma. The sequence for oxy fuel cutting is: pauses system travel, starts preheat timer, turns on the cutting oxygen and starts the pierce timer, then system starts to travel. The sequence for plasma cutting is: pause system travel, implements height sensing function, plasma arc ignition.
  • Page 82 EX-TRACK ® SECTION 10. FAQ’s Operating the system: 10.1. FAQ’s Operating the system ................83 10.2. Basic trouble shooting ..................85 10.3. Software service instructions - Boot menu ............. 92 10.4. Backup and restore parameters ..............93 10.5. Changing System name text ................95 10.6.

  • Page 83: Faq's Operating The System

    EX-TRACK ® 10.1. FAQ’s Operating the system Q: How do you continue operation after a cutting stoppage during automatic cutting? A: The following functions can be used after cutting is stopped in the automatic mode: [STOP] key: The system will stop. The program can be continued immediately by pressing [START] key.
  • Page 84 EX-TRACK ® Q: Why does the system lock-up when reading the USB stick? A: If the USB stick checks out OK, there may be two reasons: 1. There may be system or hidden files on the USB stick that the CNC is attempting to read. Some system files will cause the CNC to repeatedly attempt to read a file which cannot be understood by the CNC, so it appears to be locked up.

  • Page 85: Basic Trouble Shooting

    EX-TRACK ® 10.2. Basic trouble shooting WARNING! HIGH VOLTAGE is present inside this system, ONLY suitably qualified personnel should remove the cover for the purpose of Service or Repair. ELECTRIC SHOCK CAN KILL! Fault This may Cause Solution mean System won’t • Drive Power...
  • Page 86 EX-TRACK ® Fault This may Cause Solution mean Initial Height • Check the IHS • Plug may be loose • Tighten or repair plug. Sensing does cable plug on or damaged. not work. Connector Panel at side of Main Unit.
  • Page 87 THERMACUT for evaluation. normal cutting program? operations. • The CNC appears • Drive motor is • Make sure the System is...
  • Page 88 EX-TRACK ® Fault This may Cause Solution mean One of the • Check wiring • Loose connection. • Secure all wiring motors does from drive amp connections. not turn. to motor. • Check the drive • Check for any • Correct settings of drive amplifier.
  • Page 89 EX-TRACK ® Fault This may Cause Solution mean The system • Check settings • Incorrect parameter • Record the settings for is locked up of SYSTEM setting. Numerator and Denominator in Manual or parameters. in the SYSTEM Parameters. Automatic Then reset the factory mode.
  • Page 90 EX-TRACK ® Fault This may Cause Solution mean USB stick • Try a different • The USB stick may • Use only a compatible USB cannot be read brand of USB not be compatible stick. stick. with this CNC. • Check the file • The USB stick...
  • Page 91 EX-TRACK ® Fault This may Cause Solution mean The system • Select a different • If the other • Check the program. will only cut a program and test programs will run, straight line, it the system. there is a problem...

  • Page 92: Software Service Instructions - Boot Menu

    EX-TRACK ® 10.3. Software service instructions - Boot menu There are three options within the Boot Menu for servicing the system. The Boot Menu is activated from the Main Menu. Press the [ESC] key repeatedly if required, to return to the Home Screen. Press sequentially keys [G] [G] [3] the Boot Menu will be shown as below.

  • Page 93: Backup And Restore Parameters

    EX-TRACK ® 10.4. Backup and restore parameters All system parameters can be backed up to, or restored from, a USB stick. They can also be saved in to permanent memory as the factory settings, although that procedure is not recommended for use by end users.
  • Page 94 The system firmware of controller can be updated through a USB stick. In case a system software update is supplied by THERMACUT and needs to be installed, carefully follow this procedure: 1. Copy the update file titled STARTCNC.EXE to a USB stick.

  • Page 95: Changing System Name Text

    System name information displayed on the main menu can be changed if necessary. The standard text is “THERMACUT THE CUTTING COMPANY”, and “EX-TRACK® CNC”, as shown below: The desired text must be entered into a text file called “NAME.txt”, to be supplied by THERMACUT ®...
  • Page 96 EX-TRACK ® Number Description Power switch Main power fuse Power connector Operator Manual, Revision T-1...
  • Page 97 5. Damage is caused by acts of nature, or force majeure. 6. Damage caused by incorrect/unauthorized use. 7. Unauthorized repair/modifications to the EX-TRACK CNC Cutting System. ® 8. Damage/failure caused by use of non Thermacut parts/components Operator Manual, Revision T-1...
  • Page 98 EX-TRACK ® SECTION 12. Certification and compliance symbols: S Mark; mark indicates that the power supply and torch are suitable for use in environments with danger of electrocution. The hand torches must have shielded consumable parts fitted to maintain mark compliance.
  • Page 99 EX-TRACK ® Appendix: Graphics library Shape 1 ........................101 Shape 2 ........................101 Shape 3 ........................101 Shape 4 ........................102 Shape 5 ........................102 Shape 6 ........................102 Shape 7 ........................103 Shape 8 ........................103 Shape 9 ........................103 Shape 10 ........................
  • Page 100 EX-TRACK ® Shape 42 ........................114 Shape 43 ........................115 Shape 44 ........................115 Shape 45 ........................115 Shape 46 ........................116 Shape 47 ........................116 Shape 48 ........................116 Shape 49 ........................117 Shape 50 ........................117 Notes: ......................... 118 Revision history: ......................
  • Page 101 EX-TRACK ® Shape 1 Shape 2 Shape 3 Operator Manual, Revision T-1...
  • Page 102 EX-TRACK ® Shape 4 Shape 5 Shape 6 Operator Manual, Revision T-1...
  • Page 103 EX-TRACK ® Shape 7 Shape 8 Shape 9 Operator Manual, Revision T-1...
  • Page 104 EX-TRACK ® Shape 10 Shape 11 Shape 12 Operator Manual, Revision T-1...
  • Page 105 EX-TRACK ® Shape 13 Shape 14 Shape 15 Operator Manual, Revision T-1...
  • Page 106 EX-TRACK ® Shape 16 Shape 17 Shape 18 Operator Manual, Revision T-1...
  • Page 107 EX-TRACK ® Shape 19 Shape 20 Shape 21 Operator Manual, Revision T-1...
  • Page 108 EX-TRACK ® Shape 22 Shape 23 Shape 24 Operator Manual, Revision T-1...
  • Page 109 EX-TRACK ® Shape 25 Shape 26 Shape 27 Operator Manual, Revision T-1...
  • Page 110 EX-TRACK ® Shape 28 Shape 29 Shape 30 Operator Manual, Revision T-1...
  • Page 111 EX-TRACK ® Shape 31 Shape 32 Shape 33 Operator Manual, Revision T-1...
  • Page 112 EX-TRACK ® Shape 34 Shape 35 Shape 36 Operator Manual, Revision T-1...
  • Page 113 EX-TRACK ® Shape 37 Shape 38 Shape 39 Operator Manual, Revision T-1...
  • Page 114 EX-TRACK ® Shape 40 Shape 41 Shape 42 Operator Manual, Revision T-1...
  • Page 115 EX-TRACK ® Shape 43 Shape 44 Shape 45 Operator Manual, Revision T-1...
  • Page 116 EX-TRACK ® Shape 46 Shape 47 Shape 48 Operator Manual, Revision T-1...
  • Page 117 EX-TRACK ® Shape 49 Shape 50 Operator Manual, Revision T-1...
  • Page 118 EX-TRACK ® Notes: Operator Manual, Revision T-1...
  • Page 119 EX-TRACK ® Revision history: 1. Revision Nr: 01.1 - 06/2019 Official release 2. Revision Nr: 01.2 - 10/2019 Page 24 - changed texts in table: Supply voltage - from: AC220V - 50HZ to: AC110V/230V - 50HZ Cutting speed (mm/min) - from: 50–2000 to: 50–3000 3.
  • Page 120 742 42 Šenov u Nového Jičína Fax: +1 (800) 972-6255 / +1 (603) 542-2867 CZECH REPUBLIC www.thermacut.com Tel.: +420 556 423 418, 440 THERMACUT-POLAND SP. Z O.O. Fax: +420 556 423 443, 444 Aleja Jana Łyska 3 E-mail: sales@thermacut.cz 43-400 Cieszyn obchod@thermacut.cz...
  • Page 121 686 01, Uherské Hradiště Czech Republic www.thermacut.cz sales@thermacut.cz THERMACUT®, FHT-EX® and EX-TRAFIRE® are registered trademarks of THERMACUT, k.s. and may be registered in Czech Republic and/or other countries. All other trademarks are properties of their respective owners. Operator Manual, Revision T-1...

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