Page 1 B-Series & C-Series Plasma Cutting System Safety, Operation, and Maintenance Manual With Microstep Gen 2 Original Instruction: English Version 2.7.1...
Page 2 Copyright This manual, including addendums, supplements, and other additions, is protected by copyright. All rights reserved. No part of this publication can be reproduced, transmitted, translated, or transferred, without the written consent of Piranha, subsidiary of MegaFab. © MegaFab 2019...
Page 3: Table Of Contents
Table of Contents Table of Contents ........................3 Chapter 1: INTRODUCTION ...................... 7 1.1. About Piranha ........................7 1.2. Contact Information ......................7 Chapter 2: SAFETY ........................8 2.1. Introduction ........................8 2.2. Safety Symbols Used in the Manual ................8 2.3.
Page 4 4.10. Installing Covers (5’ X 10’ Only) ..................47 4.11. Leveling ........................48 4.12. Machine and CNC Connections ..................50 4.12.1. Air to Machine ......................50 4.12.2. Electrical Connection CNC Control .................50 4.13. Plasma Power Supply Connections ................53 4.13.1. For Hypertherm Powermax plasma system furnished by Piranha: ......53 Piranha Plasma Table...
Page 5 4.13.2. For Hypertherm Powermax power supply not purchased from Piranha ....55 4.14. First Time Power On .....................59 Chapter 5: OPERATIONS ......................60 5.1. Operator’s Panel ......................60 5.2. CNC Control Navigation ....................61 5.3. Using the Torch Height Control ..................63 5.4. Operating Start Guide .....................64 5.4.1.
Page 6 10.4. Operation and Programming ..................153 10.4.1. Switching from Plate-Cutting to Pipe-Cutting ............153 10.4.2. Programming the Pipe Cutter ................156 10.4.3. Switching from Pipe-Cutting to Plate-Cutting ............157 Chapter 11: APPENDIX A - REVISIONS TO THE MANUAL ........... 160 Piranha Plasma Table...
Page 7: Chapter 1: Introduction
Chapter 1: INTRODUCTION 1.1. About Piranha Piranha is a subsidiary of MegaFab, based in Rockford Illinois. MegaFab is a manufacturer of metal fabrication machinery, including laser cutting machines, plasma cutting machines, ironworkers, press brakes, bending rolls, combination punching and cutting machines, and structural steel punching equipment. Equipment is sold under the Piranha, Whitney, and Bertsch brands.
Page 8: Chapter 2: Safety
2.1. Introduction Read this chapter on safety and the sections of vendor components manuals on safety before beginning to operate the Piranha Plasma Cutting Table. Do not become complacent about safety or completely dependent on safety devices. 2.2. Safety Symbols Used in the Manual This document uses the following symbols to highlight areas of importance.
Page 9: All Users
2.3.1. 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 10: Maintenance Personnel
2.3.2. 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 11: Operator
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 to the significance of the various warning indicators and be conscious of the functions of pushbuttons and other controls.
Page 12: Personal Protection
It is recommended that the cutting area be prepared in such a way as to minimize the reflection and transmission of ultraviolet radiation. Walls and other surface areas should be painted in dark colors to reduce reflection. Protective screens or curtains may be installed to avoid unnecessary ultraviolet transmission. Piranha Plasma Table...
Page 13: Noise
Noise levels that can cause discomfort or damage to hearing will vary greatly from one individual to another. Piranha recommends that ear protection be furnished to any worker who requests it, regardless of applicable industrial standards or tested noise levels.
Page 14: Safety Devices
All exposed electrical connections must be covered with the proper insulation material. Safety devices must be regularly checked for proper operation and replaced immediately if found to be inoperative. Piranha Plasma Table...
Page 15: Risk Of Electric Shock
2.6. Risk of Electric Shock Always verify that ALL electrical supplies are isolated before undertaking any service or maintenance work. The machine may have more than one electrical supply. Danger 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 16: Grounding
3. Make all connections tight to avoid resistance heating. Output 1. Connect all positive output ground leads to the material grid of the worktable. 2. Connect the material grid of the worktable to a good earth ground. Piranha Plasma Table...
Page 17: Fumes And Air Contamination
2.7. Fumes and Air Contamination 2.7.1. 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 ultraviolet radiation to form phosgene and other gasses.
Page 18: Metal Fumes
2.7.4. Metal Dust Metal dust is formed as metal vaporizes during torch cutting. A hazard may exist when uncontrolled, excessive levels of metal dust are produced. If there is proper venting to the Piranha Plasma Table...
Page 19: Internal Ventilation System
See dust collector vendor installation and operation manual for additional precautions. 2.7.5. 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.
Page 20: Fire, Explosion, And Burn Prevention
Assure that the bed is free of obstructions and no person or articles of clothing are in the proximity of moving parts when the machine is in operation. This safety precaution also applies when the machine is manually moved and when the plasma system is off. Piranha Plasma Table...
Page 21: Heat
2.8.2. Heat Plasma arc cutting creates a Heat-Affected Zone (HAZ) around the cut edge of the workpiece. Until the hot edges cool, the HAZ will burn an unprotected hand severely. When removing produced parts or skeletons from the machine, operators should wear heat-resistant, gauntlet-type gloves.
Page 22: Burn Prevention
• Clean out fine aluminum particles from the water table after each use. • See the plasma power supply safety manual for additional information. Piranha Plasma Table...
Page 23: Light And Radiant Energy
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 24: Compressed Gas Equipment
▪ Never use a regulator for any other gas than that for which it is intended. ▪ Never use a regulator that leaks, excessively creeps, or is physically damaged in any way. ▪ Never attempt to lubricate a regulator with oil or grease. Piranha Plasma Table...
Page 25: Hoses
2.10.3. 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 26: Additional Safety Information
2.11. 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 27 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 28: Chapter 3: Specifications
85 amps Air Plasma with downdraft 125 amps with water table option Torch Control Arc Voltage with Initial Height Sensing Torch Protection Pneumatic Breakaway Design 6500 cfm @ 1.25” H Exhaust Fan Available Options Pipe Cutting Attachment Drop-in Water Table Piranha Plasma Table...
Page 29: Machine View
3.1. Machine View C-Series B-Series Plasma SPECIFICATIONS...
Page 30 CNC Controller Plasma Power Supply: Powermax 85 shown, other models available Torch Consumables: will vary; see plasma power supply manual Piranha Plasma Table...
Page 31: Chapter 4: Installation
Chapter 4: INSTALLATION 4.1. Introduction and Checklist Thank you for purchasing a Piranha B- Series or 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.
Page 32 Electrical to CNC control 13. Plasma Connection a. For units with a Hypertherm Powermax plasma system furnished by Piranha b. To install a Hypertherm Powermax power supply, not purchased with the machine: 14. Fill the table with water and additive if applicable 15.
Page 33: Prior To Receiving
4.2. Prior To Receiving 4.2.1. Floor Condition Piranha requires a concrete floor, in good condition, level to within +/- 0.500” (12.7mm). 4.2.2. Space/Location/Weights The following drawing shows the required space for the C-Series Plasma Cutting Table without optional Pipe Cutter.
Page 34 C408 and C510 Machines with pipe cutters require shipment as an oversize (over width) load. It is not possible to ship these machines as a standard load. Refer to the chapter on the PIPE CUTTER for installation Note: information specific to machines with PIPE CUTTER. Piranha Plasma Table...
Page 35: Electrical Services
4.3. 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. 4.3.1. CNC Control A dedicated 230V / 30A single phase service is required for the CNC control. See section 4.12.2 Electrical Connection CNC Control on page 50 for connection information.
Page 36: Compressed Air & Gas
(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. 4.4.4. Option B: Three-Stage Filter System (Piranha Part Number 230634 or equivalent) This option uses a series of three different filters to remove moisture, oil, and particulate.
Page 37: Fumes & Smoke Extraction Plan
For most efficient smoke removal, the work table should be covered 80% in order to concentrate smoke collection at the source of the plasma cut. Piranha offers a dust collector and filter as an option. Please contact Piranha if interested in this option.
Page 38: Prepare Tools And Equipment
Use an additive that works as both a rust inhibitor and biocide. Plasma Green 9010, Piranha part number 230812, comes in a 5-gal (19 L) container. Follow the manufacturer’s instructions on safety, dilution, storage, and disposal. Pour the additive in all parts of the table equally for good distribution.
Page 39: Required Equipment/Tools
4.6. Required Equipment/Tools The following tools will be required for the installation and handling of the plasma table: 1. Metric Allen wrenches set 2. Two adjustable crescent wrenches for adjusting the leveling pads 3. Minimum of 3 ft. bubble level for leveling the machine on the floor 4.
Page 40: After Receiving
Damage caused to the machine through incorrect or careless maneuvers is not covered under the machine warranty. Piranha is not responsible for personal injury to any person while this machine is transported, unloaded or installed. It is important that the machine is lifted only at the specified lifting points.
Page 41: Lifting With Crane (Recommended)
4.8.1. 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). Longer lifting straps may be required if the crane does not Note: have hoist chains attached.
Page 42 12. Lower the machine to floor level and place it firmly on the ground at the designated area of operation. Ensure machinery skates are placed in all four corners of Note: the machine base, if they are used. Piranha Plasma Table...
Page 43: Lifting With A Forklift
4.8.2. Lifting with a Forklift A forklift of adequate fork length (8 ft. minimum) is required to lift the machine otherwise the frame will get damaged. Caution 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 44 Caution 8. Travel with forks close to the ground so the machine is not suspended very high in the air. This will reduce damage to the machine if accidently dropped. Piranha Plasma Table...
Page 45 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. Lower the machine to floor level and place it firmly on the ground at the designated area of operation.
Page 46: Unpacking
The Plasma unit may be heavy. For example, some 85A units weigh about 50lbs, but other units go up to 100lbs. Please see Plasma Power Supply operator’s manual for exact specifications. Caution 4. Lift and move the CNC control to the desired floor area. Piranha Plasma Table...
Page 47: Installing Covers (5' X 10' Only)
4.10. Installing Covers (5’ X 10’ Only) 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 48: Leveling
Tighten the lock nut slightly. (Do not fully tighten the lock nut yet) Lock Nut Threaded Bolt Crescent Wrench Place level on the x-axis surface adjacent to the leveling pad that was just adjusted in the last step as shown in the picture. Piranha Plasma Table...
Page 49 Y-axis surface New pad to be adjusted X-axis Previous pad adjusted 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.
Page 50: Machine And Cnc Connections
When the air is connected to the machine, the break-away function is enabled. If the torch is not straight, air will escape. Straighten the torch as needed at this point. Figure 4-3: Side View Crooked Torch (left) and Straight Torch (right) Piranha Plasma Table...
Page 51: Electrical To Cnc Control
4.12.2. Electrical Connection CNC Control Do not turn on the main circuit breaker until all the wiring is complete and verified by a qualified electrician. Caution 1. Run 230V 10/3 conductor wire through the knockout of CNC control and into the enclosure.
Page 52 Insert the plastic backing connector. c. Tighten the outside nut. 5. Shut the control door and close the latch. Turn the disconnect on and the interlock will engage. Piranha Plasma Table...
Page 53: Plasma Power Supply Connections
Caution 4.13.1. For Hypertherm Powermax plasma system furnished by Piranha: Insert the torch lead (from the cable carrier) into the front of the Hypertherm Powermax power supply. Slightly pull on the plug to make sure the connection is good.
Page 54 Figure 4-5: Ground Lead Clamped to Table (left) and Ground Tang on C-Series (right) Piranha Plasma Table...
Page 55: For Hypertherm Powermax Power Supply Not Purchased From Piranha
A Hypertherm Powermax 105 or 125 may be used if the optional drop-in water table is purchased. ▪ Hypertherm Interface Cable – 25 ft long (Piranha Part Number 230521 / Hypertherm Part Number 228351) ▪ 5/8” Diameter Tube Clamp (Qty 1) ▪...
Page 56 Leave off the last plastic clip as the torch lead exits each cable carrier (this will give the torch lead a more generous radius as it exits the cable carrier. Piranha Plasma Table...
Page 57 Insert the opposite end of the torch lead (from the cable carrier) into the front of the Hypertherm Powermax power supply 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. With power to the machine OFF, remove one of the 7/8”...
Page 58 (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) Connect the plasma power supply to the appropriate power connection per the manufacturer’s instructions using a licensed electrician. Rear Front Piranha Plasma Table...
Page 59: First Time Power On
4.14. First Time 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. Ensure all E-stops are out. (Two on the side of the bridge and one on the CNC control) 4.
Page 60: Chapter 5: Operations
(motors and drives), and the plasma arc is turned off. There are two additional Emergency Stop buttons, one on either side of the gantry. They all perform the same function. Emergency Stop Button Piranha Plasma Table...
Page 61: Cnc Control Navigation
5.2. 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 62 The display provides the following information: Program Name Feed rates Kerf Offset Value Cut ID Number Active Functions Parameter Machine Values Position Input/Output Status Graphical Display or Program File Piranha Plasma Table...
Page 63: Using The Torch Height Control
5.3. Using the Torch Height Control The torch height control serves three functions: 1. Jogs the torch up and down 2. Locates the torch to the correct position prior to initiating the arc 3. Maintains the proper standoff between the torch and the workpiece while cutting Current Arc Voltage Arc Voltage test Location test...
Page 64: Operating Start Guide
Failure to set these correctly will result in poor quality parts, or the inability to cut a part at all. Refer to the Operations Manual of the plasma system for cut charts which supply the correct setting for these parameters. An Piranha Plasma Table...
Page 65 example of a cut chart is shown below. Make sure to refer to the cut chart for your plasma system – not the information below. OPERATIONS...
Page 66: Powering The Machine On And Sending To Machine Home
Press the top end of the red rocker switch (below the Emergency Stop button) until it latches in place. Power is now on, and the Piranha HOME screen should appear. This also displays the main menu on the bottom. Piranha Plasma Table...
Page 67 5.4.1.2. Home the Machine The machine should be sent home on start up. If not done, X+ and Y+ will not know their limits and may cause hard overtravels. Press F2 [MANUAL]. Press F8 [ASSIST]. Press F5 [MEASURE]. The machine will travel to machine home.* The machine coordinates on the right-hand bottom of the screen should read zero.
Page 68 To jog even quicker, select high-speed jog by pressing F3 [H-SPED]. If you move too far in one direction, simply move it back. Move the torch so that the material can be safety loaded. Load the material. Press [ESC] to return to the main menu. Piranha Plasma Table...
Page 69: Prepare The Plasma Power Supply And Torch
5.4.2. Prepare the Plasma Power Supply and Torch The Operator’s Manual for the Plasma Power Supply is needed for this section and contains more information. Materials can often be cut at more than one amperage setting. This is referred to as a process.
Page 70 1 pierce. Some consumables may be able to last even 1000 starts. Hypertherm has videos available online on when consumables should be changed out: https://www.youtube.com/playlist?list=PLQzzZWV3v0c6JRYoIXryVKvXAPcAeB3H- Or search Youtube for: When to change out your Powermax consumables Piranha Plasma Table...
Page 71: Setting The Torch Height Controller
5.4.3. Setting the Torch Height Controller Prior to cutting, the operator must make sure the torch height controller is set correctly. This includes making sure it is in auto mode, setting the initial pierce height, doing the zero test, and finally setting the arc voltage, which establishes the cutting height. Make sure the height controller is set to Auto.
Page 72 Note: SENSITIVITY should be set nominally to 10. Lower numbers mean that the torch will react less quickly. Higher numbers will make the torch height adjust more quickly (however this may cause vibration or oscillation in the drive). Piranha Plasma Table...
Page 73: Setting Pierce Delay Time
5.4.4. Setting Pierce Delay Time The pierce delay can be changed in the AUTO screen. 1. Determine the correct value for Pierce Delay from the plasma OPERATION MANUAL cut charts. 2. ADD 1.5 seconds to the value in the chart. a.
Page 74: Adjusting Speeds
From the main menu, select [F1] AUTO. Note: Cutting speed must be changed in the AUTO mode. Press the letter F on the keypad. The value at the very top of the screen can now be changed. Piranha Plasma Table...
Page 75 Type in the desired speed. Use a decimal. For example, if the desired speed is 100, type in 100.0. Press ENTER. The feedrate will be displayed at the top. However, the machine uses a percent of total speed. For example, if you type in a feed of 145, the machine will change it to 144.
Page 76: Methods Of Loading Programs
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 the up/down arrows to highlight program to be loaded. Select [F1] COPY. Piranha Plasma Table...
Page 77 Press ENTER to view the Program CODE: Press ESC to get back to the main menu. To edit the program, continue to the section 5.4.7 Editing and Saving Files. If more than one program was loaded from the USB thumb drive, you will have to select which to run.
Page 78 Select [F2] LOAD: From the LOAD SCREEN, use arrow up/down to highlight program to be loaded. Use PgUp (Page up) and PgDn (Page down) to move a page at a time. Once on the correct program, press ENTER: Piranha Plasma Table...
Page 79 After pressing ENTER, the selected program will be loaded, and the program code will display: Pressing [F7] VIEW will display a temporary graphical representation of the program. Once done, press ESC twice to return to the Main screen. OPERATIONS...
Page 80 Lead-in Distance (initially – try ¼” to start and adjust from there) Lead-out Distance (initially – try ¼” to start and adjust from there) Select each parameter by using the up and down arrow keys. Enter the values desired. Decimal points are optional. Piranha Plasma Table...
Page 81 Once you are satisfied with the geometry, press [F7] OK and the HOME screen will appear. At this point, the geometry of the part has NOT been saved. While it can be run on the machine, it cannot be nested, modified, or used later. Continue to the section 5.4.7 Editing and Saving Files to save the file or to...
Page 82: Editing And Saving Files
M codes and G codes used on this machine. • Entire lines can be deleted by pressing [F5] DELL, which means delete line. • The entire file can be deleted by pressing [F4] DELF, which means delete file. Piranha Plasma Table...
Page 83 The program can be saved by pressing the [F3] SAVE button. A text box appears, and the operator can type in the desired file name. 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 84: Verify Program With View
From the main menu, or from Manual mode, select [F1] AUTO. Verify the program at the top is the desired program. If not, reload the program using the steps in 5.4.6.2 Loading A Program from Control Memory, on page 78. [Continued next page] Piranha Plasma Table...
Page 85 Press [F4] VIEW. This will display a graphical representation of the loaded program. a. The red dots with numbers show the pierce points and cut order. b. The red crosshairs show the program zero location, the location the operator needs to set PROGRAM ZERO. This will be done in the next section.
Page 86: Set Program Zero
*Programs created in the shape library will set program zero wherever the head is positioned at start. These programs use a G92 X0 Y0 to set program zero. Piranha Plasma Table...
Page 87: Verify Program Size On Material With Outline
5.4.10. Verify Program Size on Material with Outline Depending on software version, this may be called either contour or outline. When outline is pressed, a red rectangle appears around the outside edge of loaded program in the graphics. The torch head will physically move above the sheet following this rectangle.
Page 88: Setting Kerf Offset (Optional)
Advanced tips: Due to the angle of plasma cutting, holes will often benefit from zero offset. If the internal features require a different offset than the external features, it is recommended to adjust the size at the programming level, for example by resizing the internal features accordingly. Piranha Plasma Table...
Page 89: Automatic Operation
5.4.12. Automatic Operation Before starting the machine in automatic operation, double-check all other necessary steps have been completed in the checklist on page 64. Before starting automatic operation, make sure the operator understands how to stop the machine in case it is necessary.
Page 90: Stopping The Machine
However, this function will not work during the pierce or torch off commands (M07/M08). Either press CYCLE STOP again just after the pierce or torch off command or use the EMERGENCY STOP button instead. See section 5.6 Restarting a Cut for restarting programs after stopping. Piranha Plasma Table...
Page 91: Active Functions
5.5. Active Functions There are several active functions that can be used when the machine is in MANUAL mode: 1 – Pressing the ‘1’ key will initiate a torch pierce, and when restarting a program, starts the cut 4 – Pressing the ‘4’ key will toggle the arc on and off 5 –...
Page 92: Restarting A Cut
Both pierce numbers and line numbers can be used to restart a program at a certain point. However, if neither is known when a program restart is needed, the pierce number is easier to figure out. Simply count how many pierces have already been done, or how many parts have been cut. Piranha Plasma Table...
Page 93: Cycle Stop
5.6.1.2. Zero Test +1 In most cases when restarting a program, the height sensor will need to be re-initialized. This is done simply by pressing by pressing Zero Test button on the height controller over material, preferably close to the restarting point. When executing most restart functions, use the number 1 to turn the arc back on and start the cutting.
Page 94: Using Section To Restart
The following pop-up will appear. If the program line number is known, that can be selected. Otherwise, arrow down SELE N-PIERCES to select the pierce number. Press ENTER. Type in the number of the pierce to start on. In this example, it is 5. Press ENTER. Piranha Plasma Table...
Page 95 Press Cycle Start. This pop-up will appear. Arrow down to FROM REFERENCE. Press ENTER. The torch will travel to the start of the pierce picked earlier and show on the graphics. If this is not the correct location, press ESC and start over. Press the ZERO TEST on the torch height control to re-establish cutting height.
Page 96: Break Point Resume
If the current program matches the last program to run and the torch has not been moved, then it will continue the program from the break point. a. Use Zero Test +1 to start cutting. If the torch has been moved, the following dialog will display. Piranha Plasma Table...
Page 97 Use the arrow key to select one of these options: a. The first option is ORI PATH RET (original path return). With this selection, the system will return the torch to where it stopped cutting. This is usually the selection needed. i.
Page 98: Trim Cuts
It is important that the torch is located above clean material. On the Torch Height Control, switch the AUTO/MANUAL switch to MANUAL. On the Torch Height Control, press the ZERO TEST button. The torch should contact the material and move to the initial pierce height. Piranha Plasma Table...
Page 99 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. Still in manual mode on the controller, set the cutting speed one of two ways: press F, and type in the value and press enter.
Page 100: Finding Correct Arc Voltage When Cutting Copper
Test to come up with a gap that is somewhat close to the required distance – typically a value of 1 or 2 will be sufficient. 3. Move the torch to the edge of the material so that the center of the nozzle is on the edge of the material. Piranha Plasma Table...
Page 101 4. Turn the switch on the Microstep torch height controller to MANUAL. 5. Go to MANUAL mode on the Starfire control. Make sure that HIGH SPEED is NOT selected. Adjust the jogging feed rate to equal the Cut Speed called out in the Hypertherm manual by pressing F, typing in the feed, and pressing enter.
Page 102: Test Mode (Dry Run)
In TEST mode, the program defaults to maximum feedrate, not at the programmed cutting speed. To quit the TEST mode, press the [X] key again, and the TEST location no longer will be illuminated. Piranha Plasma Table...
Page 103: Other Functions
5.10. Other Functions 5.10.1. Rotate Under the Assist submenu, this function rotates the program by the degree entered. For example, if 90.0 is entered, the program will rotate 90° around the reference point. Because the point of rotation is around the reference point, and not the center of the part, the reference point may need to be moved.
Page 104: Nesting
Failure to do this will result in unusable nests. Use the following sequence to create nests: 1. From the HOME page, select F7 [NEST] 2. The following screen will appear. Press the F5 [MATL] key to adjust the size of the plate. Piranha Plasma Table...
Page 105 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 106 [LOAD] key to add more parts. 8. Once you are satisfied with the nest, press F8 [OK]. You will be prompted for a file name to save the nest. 9. You can now run the nest in AUTO mode. Piranha Plasma Table...
Page 107: Database
5.12. Database There is a Material Library located in the CNC Control, accessed through the Database button from the Home screen. It is a future feature and in development. OPERATIONS...
Page 108: Chapter 6: Programming
USB port of your computer. For an additional cost, an upgrade to the full ProNest is available through Piranha. While Piranha technicians can answer some questions, full training and support are available thru the experts at Hypertherm ProNest.
Page 109 6.1. ProNest Tips 6.1.1. Output Axis Confirm the output axis setting are correct in ProNest LT to match the machine, otherwise the programs will be rotated on the machine. This is done thru the settings>Output Axis menu. ✓ 6.1.2. Remnant Nesting A less known function of ProNest LT is the ability to create odd-shaped remnant sheets when creating a new nest.
Page 110: Programming Codes
Back to reference point axis Y Back to reference point axis X and Y Cancel compensation Compensation left Compensation right Absolute distance mode Incremental distance mode X, Y Reference point set-up, must be first line in program Piranha Plasma Table...
Page 111: M Codes
6.2.2. M Codes CODE FUNCTION Pause program M02/M30 Program end and return to reference M07/08 Plasma cutter ON/OFF PROGRAMMING...
Page 112: Chapter 7: Maintenance
Annually such as Shell Alvania EP-1 or Mobil Mobilux EP-1, or equivalent In addition, the operator should take care to clean the machine and surrounding areas regularly, as needed, in order to maintain a safe work environment. Piranha Plasma Table...
Page 113 7.1. Torch Height Control Linear Guides & Ball Screw Maintenance Press Estop on the machine and turn off the plasma supply before doing any maintenance. Take off the four bolts, two on either side, that hold the cover on the torch. Slip the cover off by bringing it up and under the torch lead.
Page 114 Optional: Bring the CNC out of the Estop and lower the torch. Press Estop again before cleaning or inspecting the torch. With the torch lower, it is easier to see and clean the linear guides and ball screw. Carefully replace the cover and 4 bolts. Piranha Plasma Table...
Page 115: Error Code List
7.2. Error Code List Error Code Description 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 116: Machine Setup Parameters
REFERENCE X:0000.00 Y:0000.00 OFFSET X:0000.00 Y:0000.00 CLEARANCE X:0000.00 Y:0000.00 DIR-ORIGIN X:-1 Y:-1 Negative (4’ x 4’ MACHINE) SOFTLIMI+ X:000049 Y:00049 (4’ X 8’ MACHINE) SOFTLIMI+ X:000049 Y:00097 (5’ X 10’ MACHINE) SOFTLIMI+ X:000061 Y:00121 SOFTLIMI- X:0000.00 Y:0000.00 Piranha Plasma Table...
Page 117 FROM MAIN PAGE---> SETUP--->PLAS (F4) Note TORCH LOCATE TIME 000.50 TORCHUP TIME (M70) 00.80 TORCHDN TIME (M71) ARC-FEEDBACK (0/1) DETECT DELAY 00.00 LOCATE CHECK (0/1) LOCATE CHECK (0/1) PIERCE TIME Varies OFF DELAY 00.00 DIS. COR. OFF ARCS SPEED OFF AHCS (MM/MIM) 00000 ANTICIP OFF AHC ANTICIP OFF AUTO-SIG (MM)
Page 118: Initial Settings - Microstep Torch Height Control
2 inches along the Y- direction past the reference zero point *4. PIERCE TIME: Pierce delay time changes according to the material thickness and is set in the Auto screen. 7.4. Initial Settings – Microstep Torch Height Control Please contact Piranha for the latest settings. Piranha Plasma Table...
Page 119: Inputs And Outputs
7.5. 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 B & C Series Plasma Table: OUTPUTS: M12 –...
Page 120: Procedure - Setting Machine Zero
Press F5 [MEASURE]. NOTE: As an alternative to the first three steps, you can simply jog the machine to the location you wish to set machine zero. Choose F4 [SETUP] from the Home Screen. Choose F2 [SYSTEM]. Piranha Plasma Table...
Page 121 In the parameters, find [DIR-ORIGIN] Set X00 Y00 Press F8 [SAVE]. Press [ESC] until the screen returns to the main screen. Press F2 [MANUAL]. Press F8 [ASSIST]. Press F6 [ORIGIN]. Press [ESC] until the screen returns to the main screen. MAINTENANCE...
Page 122 Choose F4 [SETUP] from the Home Screen. Choose F2 (SYSTEM) In the parameters, find [DIR-ORIGIN] – set X to -1 and Y to -1. Press F8 [SAVE]. Piranha Plasma Table...
Page 123: Updating Control Software Procedure
7.7. Updating Control Software Procedure FROM USB DRIVE 1. Before putting in the USB drive, push the update ARROW and turn on the power button. 2. When the screen starts to change, release the button. 3. When the screen stops changing, locate and note the version of STARFIRE control software on the screen.
Page 124: Squaring The Machine Procedure
60” machine is 72”, then the gantry needs to move .010” x (80/24) = .033” 7.8.2. Adjust the Squareness Set a dial indicator up against the gantry cover on the Y2 side of the machine (side opposite the cable carrier side) Piranha Plasma Table...
Page 125 Set the dial on the indicator to zero Turn the power switch on the CNC control off. Turn power off to machine (Main disconnect) MAINTENANCE...
Page 126 To unplug the cable, squeeze the two tabs on either side of the plug and remove it from the drive. Turn power back on to machine Turn CNC control on (machine must not be in E-stop condition) Piranha Plasma Table...
Page 127 Push the Y2 side of the gantry until the dial indicator reads the desired amount (from step 1) Turn CNC control off Turn power off to machine (Main disconnect). Plug the Y2 motor lead back into the Y2 Drive MAINTENANCE...
Page 128 Turn power back on to machine Turn CNC control on (machine must not be in E-stop condition) Run squareness test again (step 1) Repeat the procedure as necessary until the desired squareness is achieved Piranha Plasma Table...
Page 129: Troubleshooting Guide
7.9. Troubleshooting Guide The most common issues for a new user are often caused by simply skipping a step. Another common issue is hitting one too many buttons and changing a value that wasn’t to be changed. Issue Possible Solutions Cutting speed too fast or two slow To change the cutting speed, the machine must be in Auto mode.
Page 130 Try manually lowering the torch over an area with no material to check the torch travel. No Arc Check for faults on the plasma supply unit. Piranha Plasma Table...
Page 131 Issue Possible Solutions Arc may be inconsistent in materials coated with non-metallics, for example paint. If the Arc had been on for a little while and then it dropped, the duty-cycle limit may have been reached. See Plasma Supply Operation manual for specifics on your unit and its limits.
Page 132: Chapter 8: Parts Manual
Chapter 8: PARTS MANUAL 8.1. 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 230558 BACK PLATE 230559 GUIDE BLOCK 230560 PROX. SWITCH...
Page 133 Automatic Height Control Assembly Continued Specify model and serial number when ordering PIRANHA PART # DESCRIPTION 230566 ANTI-CRASH ASSEMBLY 230567 TORCH HOLDER 230555 STEPPER MOTOR AHC 230529 ANTI-CRASH SOLENOID (not shown) PARTS MANUAL...
Page 134: Y-Axis Drive Assembly
8.2. Y-Axis Drive Assembly Specify model and serial number when ordering PIRANHA PART # DESCRIPTION 230528 PROXIMITY SWITCH 230568 MACHINE RACK 230546 LINEAR GUIDE 230544 BEARING BLOCK (NOT SHOWN) 230533 DRIVE BELT 230526 PANSONIC SERVO MOTOR 400W Piranha Plasma Table...
Page 135: Air And Water Inlet
8.3. Air and Water Inlet Specify model and serial number when ordering PIRANHA PART # DESCRIPTION 230569 AIR REGULATOR 230530 WATER CHILLER SOLENOID 6MM 90 DEG. TUBING CONNECTOR 230570 AIR VALVE AND SOLENOID COVER 6 MM TUBING PARTS MANUAL...
Page 136: X-Axis Drive Assembly
8.4. X-Axis Drive Assembly Specify model and serial number when ordering PIRANHA PART # DESCRIPTION 230534 MATERIAL BALL ROLLER 230539 HARD LIMIT STOP CABLE TRACK (PER METER) (COMPLETE CARRIER 3M REQ’D) 230536 230568 MACHINE RACK 230546 LINEAR GUIDE 230544 BEARING BLOCK (NOT SHOWN)
Page 137: Electrical Cabinet
8.5. Electrical Cabinet Specify model and serial number when ordering 230571 230572 Piranha Part # Description MICROSTEP Generation 2 (Please contact Piranha) 230571 GREEN PUSHBUTTON, LIGHTED 230572 STARFIRE 10.4" CONTROL PANEL PARTS MANUAL...
Page 138: Electrical Cabinet
8.6. Electrical Cabinet Specify model and serial number when ordering Please contact Piranha for updated part numbers for the electrical cabinet. Piranha Part # Description 230527 AC220/DC48V 230573 24V DRIVE FAULT RELAY 230574 24V CONTROL RELAY 230575 MAIN CONTACTOR 230576...
Page 139: Miscellaneous Parts
8.7. Miscellaneous Parts 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) 230606 SLAG DRAWER WHEEL PARTS MANUAL...
Page 140 8.8. Consumables PowerMax Air Plasma 45/65/85/105 A Shielded Shield Piranha# Retaining Cap Piranha# Nozzle Piranha# 105 220993 3857R618 220854 3857R464 220990 3857R619 85 220817 3857R538 220854 3857R464 220816 3857R466 65 220817 3857R538 220854 3857R464 220819 3857R444 45 220817 3857R538 220854 3857R464...
Page 141: Chapter 9: Electrical Diagram
Chapter 9: ELECTRICAL DIAGRAM 9.1. Machines without Pipe Cutter ELECTRICAL DIAGRAM...
Page 142: Machines With Pipe Cutter
9.2. Machines with Pipe Cutter Piranha Plasma Table...
Page 143: Chapter 10: Pipe Cutting Attachment (Optional)
Chapter 10: PIPE CUTTING ATTACHMENT (Optional) 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 144: Components
10.1. Components: Pipe/Plate Selector Switch Headstock Headstock Wrench Piranha Plasma Table...
Page 145 Pipe Supports Pipe Cutter Base PIPE CUTTING ATTACHMENT (Optional)
Page 146: After Receiving
Damage caused to the machine through incorrect or careless maneuvers is not covered under the machine warranty. Piranha is not responsible for personal injury to any person while this machine is transported, unloaded or installed. ▪ It is important that the pipe cutting attachment is lifted only at the specified lifting points.
Page 147: Lifting With Crane (Recommended)
10.3.1. Lifting with Crane (Recommended) Remove securing straps/chains attached to the truck bed. 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. The load lift is approximately 800 lbs.
Page 148 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” longer than the first strap to pick the pipe cutter attachment up level. Piranha Plasma Table...
Page 149 The end of the pipe cutter attachment is aligned to be 9.8” (250mm) from the end of the plasma table as shown. The pipe cutting attachment is set parallel to the plasma table at a spacing of 16” (406mm) from surface of the plasma table Y axis way to the inside edge of the pipe cutting attachment.
Page 150 1.00” below the slat height of the table. The pipe cutting attachment must be leveled with the four leveling pads. Next, fasten the metal conduit from the pipe cutting attachment to the electrical box. Piranha Plasma Table...
Page 151 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 152 Piranha Plasma Table...
Page 153: Operation And Programming
10.4. Operation and Programming 10.4.1. Switching from Plate-Cutting to Pipe-Cutting Change the X-axis limit to allow the torch to move over the center of the pipe: From the HOME screen, push F4 [SETUP] Then press F2 [SYSTEM]. Change the X-Axis SOFTLIMI+ value to 94.0 PIPE CUTTING ATTACHMENT (Optional)
Page 154 Move the torch in the X-axis until the torch is directly above the center of the pipe. Tip: Run the torch down the length of the tube to check that it is parallel to the table and torch. Press the [ESC] button to go to home screen. Piranha Plasma Table...
Page 155 Press F4 [SETUP] button from the home screen. Then press F2 [SYSTEM]. Now change NUMERATOR X:00416 using the following formula: Pipe Diameter * 3.14 * 25.4 Example for 2-inch diameter pipe 2 * 3.14 * 25.4 = 159.512 round up to 160 Enter for NUMERATOR X:00160 Now change the DENOMINA- X:00125 to X:00256.
Page 156: Programming The Pipe Cutter
For example, if the pipe is 4” outside diameter, then the overall  = 4 x 3.14 = 12.56 inches. When programming a 4” circumference of the pipe is 4 x O.D. pipe, the programmer should assume a flat sheet with a width of 12.56 inches. Piranha Plasma Table...
Page 157: Switching From Pipe-Cutting To Plate-Cutting
10.4.3. Switching from Pipe-Cutting to Plate-Cutting Change the X-axis limit to allow the torch to move over the center of the pipe: From the HOME screen, push F4 [SETUP] Then press F2 [SYSTEM]. Change the following values: NUMERATOR X:00416 DENOMINA- X:00125 SOFTLIMI+ X:00061.0 Then Press the F8 [SAVE] to store the change.
Page 158 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” for C510 machines; 49” for C404 and C408 machines) The plasma table is now ready to use. Piranha Plasma Table...
Page 159 PIPE CUTTING ATTACHMENT (Optional)
Page 160: Chapter 11: Appendix A - Revisions To The Manual
Fixed the order of symbols in safety. (2.2) Added ground lead pics. (4.13) Added consumables and power supply to components (3.0) 11/9/20 2.7.1 NB: Water table additive dilution raised to 5%. Fixed reference issue in 4.3 Electrical Services Piranha Plasma Table...
Page 161 APPENDIX A - REVISIONS TO THE MANUAL...

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C series C404 C408 C510

Piranha B Series Safety, Operation And Maintenance Manual

Table of Contents

Chapter 1: INTRODUCTION

Chapter 2: SAFETY

Chapter 3: SPECIFICATIONS

: Installation

Chapter 4: INSTALLATION

Chapter 5: OPERATIONS

Chapter 6: PROGRAMMING

Chapter 7: MAINTENANCE

Chapter 8: PARTS MANUAL

Chapter 9: ELECTRICAL DIAGRAM

Chapter 10: PIPE CUTTING ATTACHMENT (Optional)

Chapter 11: APPENDIX A - REVISIONS to the MANUAL

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