ESAB Silhouette 1000 Instruction Manual
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ESAB Silhouette 1000 Instruction Manual

Cantilever cutting machine
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Silhouette 1000
Form Number 0558006575
Date: 12-01-06
Cantilever Cutting Machine
O P T IO N A L T O R C H
S T A T IO N S
Safety
Installation
Operation
Maintenance
Replacement Parts

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Summary of Contents for ESAB Silhouette 1000

  • Page 1 Silhouette 1000 Cantilever Cutting Machine O P T IO N A L T O R C H S T A T IO N S Safety Installation Operation Maintenance Form Number 0558006575 Replacement Parts Date: 12-01-06...
  • Page 2 ESAB. See standard ESAB terms and conditions of sale for a specific statement of ESAB’s responsibilities and limitations on its liability.
  • Page 3 In addition, more capabilities and features may be added in the future, which are not covered in this manual. ESAB Cutting Systems reserves the right to change or add features and capabilities without notice. Before...

  • Page 5: Table Of Contents

    Table of Contents Silhouette 1000 Contents Safety Introduction ................................1 General Cutting Machine Safety ........................2 Electrical Grounding ............................. 4 Operating A Cutting Machine ........................... 5 Working with Plasma Cutting Equipment ..................... 8 Working with Oxy-Fuel Gas Cutting Equipment ..................14 Working with Gas Control and Supply Systems ..................
  • Page 6 Table of Contents Torch Squaring ................................ 60 Tracer Mount and Leveling ..........................61 Interconnection of components........................63 Water Spray Installation ............................65 Automatic Ignitor ..............................67 Introduction ............................... 67 Ignitor installation ............................67 Ignitor Wiring Schematic ..........................69 Ignitor Setup ..............................70 Setup Procedure...............................
  • Page 7 Motorized Lift Maintenance ..........................107 Parts Section Introduction General Information .............................. 109 Ordering Information ............................110 Silhouette 1000, Basic Machine, 4 and 6FT. 0560938838 Rev OR............................... 111 Main Beam 2235502 Rev1 ................................114 Rail System Assembly 0560938839 Rev 1 ..............................116 Rail System Master Rail 0560938843 Rev 1 ..............................
  • Page 8 Table of Contents Motorized Lift 2237347 Rev 3 ................................123 Manifold Support Assembly 40201829 Rev 1 ............................... 125 Torch Bar Assembly 40901329 Rev 1 ............................... 126 Drive Motor Assembly-Rail 41001289 Rev 1 ................................ 128 Manual Torch Station 41001689 Rev 1 ................................ 130 Torch Holder 52675 Rev 1 ................................

  • Page 9: Safety

    Introduction The process of cutting metals with oxy-fuel or plasma equipment provides industry with a valuable and versatile tool. ESAB cutting machines are designed to provide both operation safety and efficiency. However, as with any machine tool, sensible attention to operating procedures, precautions, and safe practices is necessary to achieve a full measure of usefulness.

  • Page 10: General Cutting Machine Safety

    SECTION 1 Safety General Cutting Machine Safety Machine Starts Automatically. WARNING This equipment moves in various directions and speeds. Moving machinery can crush. • Only qualified personnel should operate or service equipment. • Keep all personnel, materials, and equipment not involved in production process clear of entire system area.
  • Page 11 Safety SECTION 1 Read and Understand This WARNING Operator’s Manual Before using machine. Failure to follow operating instructions could result in death or serious injury. • Read entire procedure before operating or performing any system maintenance. • Special attention must be given to all hazard warnings that provide essential information regarding personnel safety and/or possible equipment...

  • Page 12: Electrical Grounding

    SECTION 1 Safety Electrical Grounding Electrical grounding is imperative for proper machine operation and SAFETY. Refer to this manual’s Installation section for detailed grounding instructions. Electric Shock Hazard. WARNING Improper grounding can cause severe injury or death. Machine must be properly grounded before put into service.

  • Page 13: Operating A Cutting Machine

    Safety SECTION 1 Operating A Cutting Machine Crush Hazard. WARNING Moving machine can crush. Machine moves automatically. • Stay clear of rails and cutting table during operation. • Follow lockout procedure before servicing. Flying Debris and Loud Noise WARNING Hazards. Hot spatter can burn and injure eyes.
  • Page 14 SECTION 1 Safety Crush Hazard. WARNING • Moving parts can cut and crush. • Keep hands clear of drive gears. • Do not operate with any protective covers removed. • Follow lockout procedure before servicing. Hazardous Voltages. WARNING Electric shock can kill. •...
  • Page 15 Safety SECTION 1 Pinch Hazard. WARNING • Moving vertical slides can crush or pinch. • Keep hands clear of torch and slide during operation. Pinch Hazard. WARNING • Moving carriages can crush or pinch. • Keep hands clear of carriages during operation.

  • Page 16: Working With Plasma Cutting Equipment

    SECTION 1 Safety Working with Plasma Cutting Equipment Hazardous Voltages. WARNING Electric Shock Can Kill. • Do NOT touch plasma torch, cutting table or cable connections during plasma cutting process. • Always turn power off to plasma power supplies before touching or servicing plasma torch.
  • Page 17 Safety SECTION 1 Toxic Fume Hazard. WARNING The cutting process can produce poisonous fumes and toxic gases. Certain chlorinated solvents decompose and form phosgene gas when exposed to ultraviolet radiation. Do not cut metal or painted metals containing zinc, lead, cadmium or beryllium unless fume removal equipment is installed and operating properly.
  • Page 18 SECTION 1 Safety Radiation Hazard. WARNING • Arc rays can injure eyes and burn skin. • Wear correct eye and body protection. • Wear dark safety glasses or goggles with side shields. Refer to following chart for recommended lens shades for plasma cutting: Arc Current Lens Shade...
  • Page 19 Safety SECTION 1 Fume Hazard. WARNING Fumes and gases generated by the plasma cutting process can be hazardous to your health. • Do NOT breathe fumes. • Do not operate plasma torch without fume removal system operating properly. • Use additional ventilation to remove fumes if necessary.
  • Page 20 SECTION 1 Safety Hydrogen Explosion Hazard. WARNING Hydrogen explosions can cause personal injury or death. Hydrogen can create explosive gas pockets in the water table. These pockets will explode when ignited by sparks or the plasma arc. • Before cutting, be aware of possible hydrogen sources in the water table –...
  • Page 21 Safety SECTION 1 Explosion Hazard. WARNING Certain molten aluminum-lithium (Al-Li) alloys can cause explosions when plasma cut with water. Do not plasma cut the following Al-Li alloys with water: Alithlite (Alcoa) X1 (Alcoa) Alithally (Alcoa) Navalite (US Navy) 00 Alloy (Alcoa) Lockalite (Lockhead) X00A (Alcoa) Kalite (Kaiser)

  • Page 22: Working With Oxy-Fuel Gas Cutting Equipment

    SECTION 1 Safety Working with Oxy-Fuel Gas Cutting Equipment Electric Shock Hazard. WARNING Automatic torch igniters can cause electrical shock. Never touch an oxy-fuel cutting torch during an automatic ignite sequence. Spark Hazard. WARNING Heat, spatter, and sparks cause fire and burns.
  • Page 23 Safety SECTION 1 Burn Hazard. WARNING Oxy-fuel torch flames can cause severe burns. • Keep hands clear of oxy-fuel torches during automatic ignite sequence. • Always confirm that no one is near oxy- fuel torches before starting an ignite sequence or starting a program that initiates an ignite sequence.

  • Page 24: Working With Gas Control And Supply Systems

    SECTION 1 Safety Working with Gas Control and Supply Systems Explosion and Fire Hazard. WARNING Ordinary materials can explode and burn in the presence of oxygen. • Keep all equipment clean and in good operating condition. • Keep entire work area free from oil, grease, and other combustibles.
  • Page 25 Safety SECTION 1 Explosion and Fire Hazard. WARNING Oxygen and fuel gas mixtures can explode and burn. • Keep all equipment clean and in good operating condition. • Do not purge lines close to an ignition source (i.e., flame or cigarette), towards a person, or near clothing.
  • Page 26 SECTION 1 Safety Explosion Hazard. WARNING Compressed gas can explode. • Before using machine, check for leaks at gas connections on all regulators, valves, and torches. • Open gas valves slowly, and shut off when machine is inactive for an extended time. Also, bleed line pressure when machine is inactive for an extended time.

  • Page 27: Service Precautions

    Safety SECTION 1 Service Precautions Establish and Adhere to Preventive CAUTION Maintenance. A composite program can be established from recommended schedules in the instruction literature. Avoid leaving test equipment or hand tools on machine. Severe electrical or mechanical damage could occur to equipment or machine.

  • Page 28: Welding On And Around Machine

    SECTION 1 Safety Welding On and Around Machine Special precautions must be observed if any arc welding is performed on this CAUTION machine. Failure to observe the following precautions can result in large induced currents causing severe damage to electronic components in machine control system.

  • Page 29: Introduction

    Safety SECTION 1 Safety References Introduction The following nationally recognized publications on safety in welding and cutting operations are recommended. These publications have been prepared to protect persons from injury or illness and to protect property from damage, which could result from unsafe practices.

  • Page 30: Domestic

    Cutting with Oxygen-Fuel Gas Equipment,” Form 2035. ESAB Cutting Systems. • “Precautions and Safe Practices for Electric Welding and Cutting,” Form 52-529. ESAB Cutting Systems. • “Safety in Welding and Cutting” - ANSI Z 49.1, American Welding Society, 2501 NW 7th Street, Miami, Florida, 33125.

  • Page 31: International

    Safety SECTION 1 International VBG- Unfallverhütungsvorshriften VBG 1 General Provisions Allgemeine Unfallverhütungsvorshriften VBG 4 Electrical Equipment and operating Equipment Elektrische Anlagen VBG 15 Welding, Cutting and related working methods Schweißen un Schneiden un verwandte Verfahren VBG 48 Shot Blasting Works Strahlarbeiten VBG 61 Gases...
  • Page 32 SECTION 1 Safety VDE Regulations VDE - Vorschriften VDE 0100 Erection of power installations with normal voltages up to 1000 volts Bestimmungen für das Errichten von Stakstromanlagen mit Nennspannungen bis 1000 Volt VDE0113 Electrical equipment of industrial machines Elektrishe Ausrüstung von Industriemaschinen VDE 0837 Radiation safety of laser products;...
  • Page 33 Safety SECTION 1 TRG Technical Rules for Pressure gases TRG – Technische Regein für Druckgase TRG 100 General regulations for pressure gases Allgemeine Bestimmungen für Druckgase TRG 101 Pressure gases Druckgase TRG 102 Technical gas mixtures Technishe Gasgemische TRG 104 Pressure gases;...
  • Page 34 SECTION 1 Safety DIN Standards DIN-Normen DIN 2310 Part 1 Thermal cutting; terminology and nomenclature Teil 1 Thermsiches Schneiden, Allgemeine Begriffe und Bennungen Part 2 Thermal cutting; determination of quality of cut faces Teil 2 Thermsiches Schneiden, Ermittein der Güte von Schnittflächen Part 4 Thermal cutting;...
  • Page 35 Safety SECTION 1 Gas welding equipment hose couplings Gasschweißgeräte, Kupplungen DIN EN 626-1 Safety of machines, reduction of risks to health Sichereit von Maschinen, Reduzierung des Gesundheitsrisikos DIN EN 848-1 Single spindle vertical milling machines Fräsmaschine für einseitige Bearbeitung mit drehendem Werkzeug DIN EN 1829 High pressure water jet machines Hochdruckwasserstrahlschneidmaschine...
  • Page 36 SECTION 1 Safety Arrangement of protection devices Anordnung von Schutzeinrichtungen VDI Guidelines VDI 2906 Quality of cut faces on metallic workpieces; abrasive water jet cutting and arc plasma cutting Schnittflächenqualität beim Schneiden von Werkstücken aus Metall, Abrasiv-Wasserstrahischneiden und Plasmastrahischneiden VDI 2084 Room air;...

  • Page 37: Specifications

    Description SECTION  Specifications Outline Dimensions " E " " A " "B " " F " " D " " C " CUTTING AREA TRACING AREA AISLE WIDTH TORCH/TOOL SPEED SILHOUETTE FLOOR AREA STATIONS (IPM) MODEL # WIDTH LENGTH WIDTH LENGTH WIDTH...

  • Page 38: Performance

    SECTION  Description 7 '-6 " O P T IO N A L T O R C H S T A T IO N P A C K A G E S 2 4 " 1 1 " Performance Feature Edge Trace Speed 2 - 120 50.8mm - 2032mm...

  • Page 39: Capacities

    Cutting Isle Width 11 inches Tracing Area Model 1000-4: 4 ft. W X 4 ft. L Model 1000-6: 6 ft. W X 4 ft L Note: Station capacity is 4 when the machine is equipped with an ESAB ALFE control.
  • Page 40 SECTION  Description Notes...

  • Page 41: Installation

    Installation SECTION  Installation General Information Your Silhouette 1000 Shape Cutter was completely assembled and tested prior to shipment. Proper installation is required for dependable performance. Modification of the machine or its parts without the express approval of ESAB Welding and Cutting will void the warranty.

  • Page 42: Receipt Of Components

    SECTION  Installation Receipt of Components Examine all components and assemblies as they are unpacked and report any damage of shortages to the carrier and to ESAB Welding and Cutting for immediate replacement. • Remove all supports and packing materials. •...

  • Page 43: Site Preparation

    Installation SECTION  Site Preparation The customer is responsible for: • preparation of the foundation • unpacking the shipment • installing the rails • mounting machine on rails • some machine assembly • connection of utilities...

  • Page 44: Location Of The Machine

    Exposure to high frequency interference form neighboring equipment (i.e. plasma cutting systems) requires electronics of the Silhouette be provided with a separate grounding. This is to assure sufficient electrical isolation for reliable operation of the machine. Refer to ESAB manual F14-074 “Grounding” for more information.

  • Page 45: Foundation

    Installation SECTION  Foundation The following information are guidelines only and are not intended to be used as foundation specifications. • The floor should be level within ±0.5 in. and made of reinforced concrete (not asphalt) no less than 4 inches thick. If the existing floor is not of sufficient thickness or is not level, a new floor should be poured.

  • Page 46: Utility Requirements

    SECTION  Installation Utility Requirements All utilities must be must be routed in a way that does not interfere with the free movement of the gantry assembly along the full length of the track rail system. Electric Power The machine power requirements are determined by its configuration.

  • Page 47: Gas Supplies

    Installation SECTION  Gas Supplies Adequate supply is absolutely necessary for maximum machine performance. All pipelines and hoses must be clean and free of oil, combustible particles or WARNING other foreign matter that might cause performance or combustion problems. Prior to connecting fuel gas and oxygen lines to the machine or if the lines have been disconnected for any reason, the lines must be purged.
  • Page 48 SECTION  Installation Fuel Gas (Natural Gas, Propane, MAPP Gas) Oxygen Fuel Gas Metal Kerf Width Thickness Tip Size Speed IPM Cutting Pre-Heat Cutting Pre-Heat (inches) PSIG (inches) PSIG PSIG SCFH PSIG 0.125 20-25 15-20 12-14 15-20 24-28 0.04 0.250 20-25 20-25 22-26...
  • Page 49 10 microns and having no more than 500 ppm of foreign matter. Cutting Tables Cutting tables can be purchase form ESAB Cutting Systems or constructed to meet your needs. Items to consider in the purchase or construction of a cutting table are: •...
  • Page 50 SECTION  Installation Oxy-fuel Torches Oxy-fuel cutting torches are not included with the machine unless specifically ordered. The following requirements are given to aid in torch selection: • torch barrel diameter must be 1³/₈ in. (1.375) • torch rack must be ³/₁₆ in. (0.187) inches square •...

  • Page 51: Installation Of Components

    Read all of this procedure before NOTICE beginning. A thorough understanding of the steps nec- essary will save time. Installation of pedestals and rails. A 15 ft.. rail system for the Silhouette 1000 components is: • 1 preassembled master rail • 1 preassembled floater rail •...
  • Page 52 Bolt cradles to master and floater rails with racing table support angles on the inside. Floater Rail Table Support Angle Table Support Angle Master Rail Set rail to rail distance as shown, according to the model purchased. Silhouette 1000-4 55 inches Silhouette 1000-6 79 inches...
  • Page 53 Installation SECTION  Center the leveling pads on the cradle pedestals and position the rail system in the desired location. If the rail system is to be mounted to the floor, indicate the location of the anchors and install them accordingly.
  • Page 54 SECTION  Installation It is recommended to use floor anchors to NOTICE maintain alignment when the rail system is longer than 15 ft.. Rail extensions are always mounted behind the existing rail system (as viewed with the master rail on the right.) Connect together with spacing plates. Span the joints with the extension floater bar and the extension rack mount on the master rail.

  • Page 55: Forklift Technique

    Installation SECTION  Forklift Technique ENGAGE DISENGAGE Remember to disengage the drive. Clamp the main beam tray to a forklift fork to prevent the main beam assembly from rolling when the machine is picked up. Forklift Forks C-Clamp...

  • Page 56: Mounting Main Beam On Rails

    SECTION  Installation Mounting Main Beam on Rails Damage may occur when setting drive on CAUTION rails. Disengage the longitudinal drive before setting drive on rails to avoid damaging the drive pinion or rack. ENGAGE DISENGAGE Falling Equipment May Cause Serious Injury .

  • Page 57: Strongback Technique

    Installation SECTION  Strongback Technique Serious injury may occur when lifting heavy objects. CAUTION Always use proper lifting techniques when lifting or bending over. Falling Equipment May Cause Serious Injury . WARNING Use Extreme Caution. Machine is FRONT HEAVY and will roll when not supported properly.
  • Page 58 SECTION  Installation Support the machine at the four points indicated. Be sure to prevent the machine from rolling when it is picked up at the ends. Use plenty of muscle, the machine may weigh as much as 150 pounds or more.
  • Page 59 Installation SECTION  Lower the beam and place the upper outboard bearing on the floater rail. The lower outboard bearing will make contact with the rail because of the machine weight distribution. Upper Outboard Bearing Floater Rail Lower Outboard Bearing...
  • Page 60 SECTION  Installation ENGAGE DISENGAGE Remember to disengage the drive. Set the master carriage on the round rail.
  • Page 61 Installation SECTION  Place the table on the table rails between the floater and master rails. Disengage the cross drive and move the torch bar to the extreme right travel. Measure the distance from the bottom of the tracer mount plate and the table surface. Write it down if necessary.
  • Page 62 SECTION  Installation Check cantilever level over the forward cradle position with a spirit level. Adjust the floater rail Spirit Level check over all cradle positions leveling pad as needed. Reposition the gantry over the next cradle. Recheck and adjust as required. Continue this procedure until the machine is level down the floater rail.
  • Page 63 Installation SECTION  Loosen the bearing block mount bolts and roll the Bearing Block Mount Bolts machine back and forth a few inches. This will allow the bearings to seat on the rail. Tighten the block mount bolts.
  • Page 64 SECTION  Installation Mount the manifold to the back of the cantilever beam assembly. Connect hoses from the gas panel to the manifold inlet. Oxygen Fuel Gas...
  • Page 65 Installation SECTION  Connect oxygen and fuel gas hoses. Hoses are labeled “Preheat”, “Cutting” and “Fuel”. Be certain to keep preheat to preheat and cutting to cutting when connecting to the manifold. Fuel Gas Supply Preheat Supply Cutting Supply Fuel gas to manifold Preheat Oxygen to Manifold Cutting Oxygen to Manifold Fuel Gas to Torch...
  • Page 66 SECTION  Installation View the station carriage bearings while rolling it back and forth Adjust the jack screws to cause the upper and lower carriage bearings to make contact with the torch bar...

  • Page 67: Torch Station Mounting

    Installation SECTION  Torch Station Mounting Remove the block mount bolt and station stop block Roll the station on the torch bar Re-mount the station stop block.

  • Page 68: Torch Squaring

    SECTION  Installation Torch Squaring Place torch in torch holder, turning the height adjustment knob to lower. Use a carpenters square to check the squareness to the cutting surface . Check both parallel to the cross and rail axes. Adjust by loosening bolt depending on required adjustment.

  • Page 69: Tracer Mount And Leveling

    Installation SECTION  Tracer Mount and Leveling Mount the tracer on the tracer mount plate using the 3 bolts as shown. Do not tighten until after leveling. Position the reference block under the tracing eye cover. Reference Block...
  • Page 70 SECTION  Installation The machine must be leveled before this operation is completed. To set the tracer height, slide the reference block between the tracing table and the tracer. See note below. Thread the jack bolts until they make contact with the tracer mount.

  • Page 71: Interconnection Of Components

    Installation SECTION  Interconnection of components. Attach the cut oxygen solenoid cable and both drive motor cables to the top of tracer control unit. Connections are labeled. Plug tracer control power cable into any standard 115VAC outlet with ground. See Grounding Instructions. Install the oxygen and fuel gas hoses to the inlet side of the machine gas flow valves using standard 0.375 inch supply hoses and fittings.
  • Page 72 SECTION  Installation Connect the supplied hoses from the outlet side of the manifold on the manifold support arm to the torches. Ensure the integrity of preheat to preheat, cut oxygen to cut oxygen and fuel gas to fuel gas connections. Hoses are labeled to help keep connections straight From Gas Panel Check Valve...

  • Page 73: Water Spray Installation

    Installation SECTION  Water Spray Installation Mount the control valve in the pre-designated mount hole on gas control panel. Align movement IGNITOR with on/off indicators and tighten nut to lock in FUEL place. WATER P.H. OXY IGNITOR DISENGAGE Water Spray Control Valve Install water manifold in front of gas manifold on mount arm.
  • Page 74 SECTION  Installation Clamp water spray heads to torches using bracket and position bottom of spray heads about 1 inch From WaterManifold above bottom of torch tip.

  • Page 75: Automatic Ignitor

    Installation SECTION  Automatic Ignitor Introduction The automatic oxy-fuel torch ignitor system provides hands free ignition for the multiple oxy-fuel torches. This system uses a high voltage spark between an electrode and the plate surface to ignite oxy-fuel preheat flames. When the system is energized, preheat fuel gas and oxygen flow from the torch nozzle.
  • Page 76 SECTION  Installation Slide the Ignitor Mount on to the torch over tip. Fasten the ignitor cable to the ignitor transformer and the electrode holder, running the cable along the gas hoses to the manifold and down. Secure with plastic cable wraps. High voltage cable Insulator Ignitor Transformer (inside the Ignitor Module)

  • Page 77: Ignitor Wiring Schematic

    Installation SECTION  Ignitor Wiring Schematic L I N E B L K G R N W H T B L K T O R C H C O N T R O L R E F . P / N 6 6 4 0 7 C O N N E C T O R W I R I N G P I N 1 B L A C K...

  • Page 78: Ignitor Setup

    SECTION  Installation Ignitor Setup Do this procedure before using ignitors the first time and check regularly. Burn hazard. WARNING Oxy-fuel torch flames can cause severe burns. Do not touch ignitors or torch during the five second ignite time the ignition spark is on.

  • Page 79: Setup Procedure

    Installation SECTION  Setup Procedure Adjust ignitor electrode on each torch so electrode end is just below the bottom and at least 1/2” (13mm) away from the torch nozzle. Electrode Ignition spark Plate Preheat gases...

  • Page 80: Preparation For Initial Power-Up

    SECTION  Installation Preparation for Initial Power-up Purging Lines Oil, dust and other foreign matter must be purged from all gas lines CAUTION before operation of this machine. Failure to purge the lines may result in a hazardous explosion or performance issues.

  • Page 81: Mechanical Check

    Installation SECTION  Mechanical Check Check the installation and assembly carefully. Check all mechanical assemblies and parts to be sure that they are correctly assembled and all hardware is tight.
  • Page 82 SECTION  Installation Notes...

  • Page 83: Introduction

    Introduction O P T IO N A L T O R C H S T A T IO N S The Silhouette 1000 is basic in its design and simple to operate. The drives can be easily disengaged for quick repositioning of the rail and transverse carriages.

  • Page 84: Tracer

    SECTION 4 Operation HL-0 Tracer For more complete instructions, consult your Linatrol HL-90 Manual. All tracing and auto functions are controlled with the tracer front panel. Basic function areas are identified at the left. On/Off Switch Speed Control Direction Control Movement Drive Low/High Speed Ranges Mode Switch: See details...
  • Page 85 Operation SECTION 4 Movement ON/OFF. 2 position switch. When in the Off position (illustrated) drive amplifiers are not allowed. Movement - High or Low Range. 2 position switch. High range is 0 to maximum. Low range is 0 to 24 IPM.

  • Page 86: Template Preparation

    SECTION 4 Operation Template Preparation Introduction The template pattern is simple but it is an important detail of the tracer machine control. A great amount of time, effort and material can be wasted by a poorly prepared template. Patterns can be black lines or silhouettes drawn on white paper, or a cutout of white paper or card laid on a black table top.

  • Page 87: Template Guidelines

    Operation SECTION 4 Template Guidelines Factors that are associated to the template preparation that influence the tracing operation include: • Contrast between line and background. • Cleanliness of the pattern. • Width of the line in line-draw patterns. • Type of material on which the patterns are drawn.

  • Page 88: Drawing Materials

    SECTION 4 Operation Drawing Materials Types of Material Remarks Commercial Pattern Paper Use black India ink or (H or HB) firmly drawn pencil. Ideal material for durability, dimensional stability and contrast. Bristol Board (Buff or White) Excellent contrast. Likely to absorb moisture. Art Board (Buff or White) Similar to Bristol Board.

  • Page 89: Machine Operation

    Operation SECTION 4 Machine Operation Introduction The tracer can work either in the tracer mode, using a pattern or in the cutting mode for manual cutting. Straight Line Cutting (without template) Turn on Tracer/Control Select the Mode Switch to Strip and select desired speed range Place the drive switch...

  • Page 90: Tracer Controlled Cutting (With Template)

    SECTION 4 Operation Tracer Controlled Cutting (with template) Place the Power, Drive and Cut Oxygen switches to OFF. Place the template on the tracing table. Turn power ON. Place the Mode switch in Strip and select the desired speed rate. Place the Drive switch in ON and using the Direction switch and speed control, pilot the machine to the initial desired position.

  • Page 91: Lost Cut Procedure

    Operation SECTION 4 Lost Cut Procedure If the tracer loses the pattern edge while cutting, it will be necessary to return the to the lost point and resume cutting. Losing the tracing is covered in the maintenance section with other troubleshooting subjects. Procedure: Retrace the pattern to the point of cut loss.

  • Page 92: Kerf Compensation

    SECTION 4 Operation Kerf Compensation Tracer controlled cutting of dimensional shapes requires compensation for the kerf by the cutting torch. Kerf compensation is accomplished by offsetting the tracer head and cutting torch with respect to the top template line edge. The necessary kerf during cutting is determined by: •...
  • Page 93 Operation SECTION 4 There are 4 examples of cut/trace scenarios. Example 1. The control is set for “zero” kerf offset. With zero offset, the kerf width centerline (tool) corresponds to template line edge. The resulting cut part will be Torch tip centerline smaller (or larger …...
  • Page 94 SECTION 4 Operation Example 2. Illustrates a “white to black inside trace-cut”. With tracer and torch travel directions as shown, the compensation is inside of the template line. Note direction of travel is counter-clockwise. Tracing eye representation Pattern line Pierce Part Tool Path Location...
  • Page 95 Operation SECTION 4 Example 3. Illustrates “white to black” outside trace-cut. With the torch and tracer travel direction as shown, the tracer is offset to the outside of the template. Establish the amount of kerf required based on measured kerf width. Tracing eye Note direction of travel is clockwise around the representation...
  • Page 96 SECTION 4 Operation Example 4. Illustrates a “black to white” trace-cut. With travel direction as shown, the tracer is offset to the outside of the pattern line. Establish the amount of offset required based on measured kerf width. Note direction of travel is counter-clockwise. Tracing eye representation Pattern line...

  • Page 97: Notes On Pattern And Kerf Requirements

    Operation SECTION 4 Notes on Pattern and Kerf Requirements. • Pattern lines should be drawn with uniform density and high contrast to the pattern background. Optimum tracing performance is achieved with patterns consisting of a dense black line on a white background. Corners should be smoothly drawn and the line should not have breaks.

  • Page 98: Torch Carriage Positioning

    SECTION 4 Operation Torch Carriage Positioning Torch carriages ride on rail bearings and must be locked when placed in their cutting position. 2 toggle clamps are mounted for this purpose. Rubber stops push on the cross axis slide locking the carriage in place.

  • Page 99: Silhouette 1000 Maintenance

    Maintenance SECTION  Silhouette 1000 Maintenance General Information The Silhouette 1000 Shape Cutter is designed to operate over a long period of time with a minimum of maintenance. However, continued satisfactory operation of the machine depends upon the careful performance of a few simple inspection and cleaning procedures.

  • Page 100: Daily Inspection And Maintenance

    SECTION  Maintenance Daily Inspection and Maintenance. Inspect the entire machine each day before operating. Check all parts and components visually and perform the following steps to check machine systems and operation. Refer to the troubleshooting subsection for identifying and faults or malfunctions. Inspect all operating parts of the machine for cleanliness.
  • Page 101 Maintenance SECTION  Check the machine drive operation by operating the machine in both axes with the direction knob. Drive speed may be varied with the Speed Knob to see that the drives are functioning properly. Check operation of the solenoid valve which controls gas flow to the torches.

  • Page 102: Periodic Inspection And Maintenance

    SECTION  Maintenance Periodic Inspection and Maintenance When daily inpsection checks have been regularly perfomed, these additional inspections are required less frequently, approximately every 60 to 80 hours of operation. • Check for loose wiring and tighten connections if required. •...

  • Page 103: Lubrication

    Maintenance SECTION  Lubrication This machine is designed to operate without lubrication of any kind. Bearings CAUTION are sealed and should never be lubricated or cleaned with solvent. Do not lubricate drive rack, drive pinons or other machine parts. CAUTION It is suffiecint to keep all such parts clean and free of foreign materials.

  • Page 104: Rail System

    SECTION  Maintenance Rail System Rails may be bumped, nearby machinery vibration or temperature variations are factors that may result in the rails becoming un-level. Rails should be level checked monthly (or more often if conditions warrant). Refer to Installation Section for rail leveling procedures.

  • Page 105: Tracing Table

    Maintenance SECTION  Tracing Table Keep the tracing table clean and clear of dirt and debris.
  • Page 106 SECTION  Maintenance Troubleshooting The troubleshooting subsection serves as an aid in diagnosing potential operational problems. This chart should be used in conjuction with the tracer manual. Problem Possible Cause Solution No machine movement (manual Power switch on control is in OFF Move switch to ON position or phototracer) position...
  • Page 107 Maintenance SECTION  Edge of parts not square with Torch not vertical Adjust torch surface Cutting table not level Level table Cut part short in dimension Pattern incorrect or does not allow Check pattern reset kerf for kerf Tracer head not vertical Realign head Drag on outboard bearing Rearrange hoses and cables so there...
  • Page 108 SECTION  Maintenance Tracer/Torch Bar and Torch Carriages The tracer/torch bar and torch carriages provide the transverse motion of these components in the cutting operation. The bar runs on the surface hardened round rail mounted on top of the cantilever beam and bearing bar mounted on the bottom of the cantilever beam.
  • Page 109 Maintenance SECTION  Cutting torches are mounted in the torch holder so that a pinion on the adjustment knob shaft meshes with the torch barrel rack. The torch holder may be turned in the torch holder clamp so that the torch may be rotated in a transverse plane (Y-Z).

  • Page 110: Gas Supply System

    SECTION  Maintenance Gas Supply System The gas supply system includes flow control valves, IGNITOR solenoid valves (fuel gas and oxygen), gas manifold FUEL blocks and interconnecting hose assemblies for WATER fuel, preheat oxygen and cutting oxygen. Supplies P.H. OXY to the machine must be externally regulated to IGNITOR DISENGAGE...
  • Page 111 Maintenance SECTION  A periodic cleaning of the solenoid valve is desirable. Time between cleanings will vary depending on the shop environmental conditions. In general if the voltage to the solenoid coil is correct, sluggish valve operation or excessive leakage will indicate cleaning is required.

  • Page 112: Solenoid Disassembly Procedure

    SECTION  Maintenance Solenoid Disassembly Procedure Remove nut from the top of the valve Slide the housing and coil form sleeve assembly. Valve Wrench Unscrew the sleeve from the body using the (Not to Scale) valve wrench If foreign matter is causing valve malfunction, it will be between the plunger and the seat body.

  • Page 113: Electrical System

    Maintenance SECTION  Electrical System See Tracer Manual...

  • Page 114: Motorized Lift

    SECTION  Maintenance Motorized Lift Description This electric lift has three main components. Motor, gear box and torch holder. The torch is held in the in line with 5 sealed ball bearings. One bearing is on an eccentric shaft for torch barrel (handle) tension adjustment.

  • Page 115: Motorized Lift Maintenance

    Maintenance SECTION  Motorized Lift Maintenance • Clean Rack on torch to prevent buildup on pinion • Adjust eccentric bearing just enough to prevent “rocking” of the torch. DO NOT Overtighten. • Clean torch handle to encourage smooth Motor not shown this view operation VIEW A-A...
  • Page 116 SECTION  Maintenance Notes...

  • Page 117: General Information

    Parts purchased from vendors by ESAB are listed by ESAB part numbers. Hardware is specified as items in the parts list but normally doesn’t have an ESAB part number. Do not use this number as a recommended quantity of spare parts.

  • Page 118: Ordering Information

    Also, give machine model number and serial number. Address all inquiries to your local ESAB Distributor or to ESAB Cutting Systems, P.O. Box 100545, Florence, South Carolina, 29501. This manual may contain part illustrations NOTICE not applicable to your specific machine.

  • Page 119: Silhouette 1000, Basic Machine, 4 And 6Ft

    Replacement Parts SECTION 6 Silhouette 1000, Basic Machine, 4 and 6FT. 060 Rev OR REF. REF. O P T IO N A L T O R C H S T A T IO N P A C K A G E S...
  • Page 120 TEST TEMPLET, SQUARE F14100 VIDEO, SILHOUETTE 1000 12510133 NAMEPLATE - ESAB 2234954 DECAL, ESAB/LTEC - YELLOW 2234957 DECAL, ESAB/LTEC - CLEAR 1 2236315 HL90 W/OUT DR. HS #332 2236502 DECAL, SILHOUETTE 10000 (CLEAR) 2238956 TAG, METAL AMT MEMBER 5014450 TEMPLET, MATERIAL SAMPLES...
  • Page 121 Replacement Parts SECTION 6 ITEM PART NUMBER DESCRIPTION 64407 1/2" BONDING STRAP LE 64914 AC OUTLET STRIP (CSA) 66321 EARTH GROUND TEST DEC 66423 CUT SOLENOID CABLE 66424 CXA DRIVE MOTOR CABLE 67121 2871, HEYCO BUSHING .31 ID. 67330 HEYCO 1217, SR-6N-4, .3 93000601 WIRE 600V 90C MTW 6AW 954698...

  • Page 122: Main Beam

    SECTION 6 Replacement Parts Main Beam 0 Rev1 15 14 13 10 17 9 8 7 D E T A I L D E T A I L 13 14 15 20 11 6 15 12 D E T A I L 12 14 15...
  • Page 123 Replacement Parts SECTION 6 Parts List ITEM PART NUMBER DESCRIPTION 41001149 MAIN BEAM WELD ASSY -SIL 1000-4 41011121 SHAFT - RAIL 4004111 RAIL SUPPORT 41011115 REAR BRACE - SIL 1000 4101115 GUIDE BAR 41013161 SPRING BLOCK -RAIL 41011117 BEARING AXLE 51216 BEARING SCREW...

  • Page 124: Rail System Assembly

    SECTION 6 Replacement Parts Rail System Assembly 060 Rev 1 4 6 5 View A-A Parts List ITEM PART NUMBER DESCRIPTION 0560938843 RAIL ASSY - MASTER SIL -1000 0560938840 FLOATER RAIL ASSY 4110199 CRADLE WELD ASSY 1000-6 41001929 CRADLE WELD ASSY 1000-4 24 3/8 -16 UNC x 1"...

  • Page 125: Rail System Master Rail

    Replacement Parts SECTION 6 Rail System Master Rail 0604 Rev 1 14 15 9 13 12 16 15 14 17 6...
  • Page 126 SECTION 6 Replacement Parts Parts List ITEM PART NUMBER DESCRIPTION 0560938844 RAIL, MASTER WELD ASSY 0560988227 RAIL, 1" RD HARDENED 180" LG. 0560938883 RACK MOUNT BAR 0560988226 EXTRUSION RACK MTG - SHADOW 2 - SIL 1000 0560938851 RACK MOUNT BAR 8" 56996507 STOP, MACHINE 0560938882...

  • Page 127: Rail System Floater Rail

    Replacement Parts SECTION 6 Rail System Floater Rail 06040 Rev 1 4 5 6 Parts List ITEM PART NUMBER DESCRIPTION 0560938845 RAIL, FLOATER WELD ASSY 4101915 FLOATER RAIL BAR 0560938884 FLOATER RAIL BAR 36" 1/4-20 UNC x 3/4 LG. SHCS 1/4 LOCK WASHER 1/4 FLAT WASHER...

  • Page 128: Master Carriage

    SECTION 6 Replacement Parts Master Carriage 060 Rev 1 5 6 4 Parts List ITEM PART NUMBER DESCRIPTION 4110129 MASTER CARRIAGE WELD ASSY 41012135 SPACER 41001239 BEARING BLOCK ASSY 1/4-20 UNC x 3/4 LG. HEX HD CAP SCREW 1/4 FLAT WASHER 1/4 LOCK WASHER...

  • Page 129: Bearing Block Assembly

    Replacement Parts SECTION 6 Bearing Block Assembly 116 Rev OR Parts List ITEM PART NUMBER DESCRIPTION 40030123 Bearing Block 61338087 1/4-20 X 1/2 Set Screw 70512143 Bearing Spacer 51216 Bearing 70212145 Bearing Stud...

  • Page 130: Station Control Assembly

    SECTION 6 Replacement Parts Station Control Assembly 0 Rev 1 P R I S E C D O W N D O W N D O W N D O W N D O W N Parts List ITEM PART NUMBER DESCRIPTION 66421 MOTORIZED TORCH CONTROL...

  • Page 131: Motorized Lift

    Replacement Parts SECTION 6 Motorized Lift 4 Rev  Motor not shown VIEW A-A Motor Boot not shown...
  • Page 132 SECTION 6 Replacement Parts...

  • Page 133: Manifold Support Assembly

    Replacement Parts SECTION 6 Manifold Support Assembly 7 11 4001 Rev 1 12 8 11 7 Parts List ITEM PART NUMBER DESCRIPTION 40201819 MANIFOLD SUPPORT WELD ASSY 2115696 NIPPLE, BLACK PIPE 1/4 NPT 60601075 1/4" NPT PIPE PLUG 68023 MANIFOLD BRASS 43150520 COUPLING 1/4 NPT F-F BLACK PIPE 0560995891...

  • Page 134: Torch Bar Assembly

    SECTION 6 Replacement Parts Torch Bar Assembly 4001 Rev 1 25 29 22 24 23 28 29 30 25 29 32 33 29 25 28 29 29 31...
  • Page 135 Replacement Parts SECTION 6 Parts List ITEM PART NUMBER DESCRIPTION 4091315 TORCH BAR GUIDE RAIL 4091311 TORCH BAR 41013115 Y -DRIVE RACK 50.12 LG. 41013123 STOP BLOCK 41014133 PLATE, MOUNT, TRACER EYE 51220 REF. BOTTOM BEARING BLOCK ASSY. 40030123 BEARING BLOCK 51217 SPACER 51216...

  • Page 136: Drive Motor Assembly-Rail

    SECTION 6 Replacement Parts Drive Motor Assembly-Rail 41001 Rev 1...
  • Page 137 Replacement Parts SECTION 6 Parts List ITEM PART NUMBER DESCRIPTION 51254 THRUST RACE 51255 THRUST BEARING, NEEDLE 41001369 BOTTOM PLATE WELD ASSY (B) 41001269 BOTTOM PLATE WELD ASSY (A) 41012171 DRIVE GEAR MODIFIED .375 ID 42010185 SPACER, THRUST BEARING 42010153 THRUST PLATE 61292631 BOLT, SHLDR.

  • Page 138: Manual Torch Station

    SECTION 6 Replacement Parts Manual Torch Station 410016 Rev 1 7 20 6 17 9 5 18 9 8 10 18 17 6 21 7 14 19 22...
  • Page 139 Replacement Parts SECTION 6 Parts List ITEM PART NUMBER DESCRIPTION 41016183 TORCH SLIDE FRAME 4101617 TORCH MOUNT BAR 2239842 TORCH CLAMP HOLDER 52675 TORCH HOLDER ASSY 56996481 CLAMP TOGGLE 4101613 BEARING BLOCK ( UPPER) 22802401 BEARING .312 ID x .86 OD x .312 WIDE 56996487 NEOPRENE CAP 1/4-20 UNC x .5 LG.

  • Page 140: Torch Holder

    SECTION 6 Replacement Parts Torch Holder 6 Rev 1 Parts List ITEM PART NUMBER DESCRIPTION 51338 TORCH HOLDER BODY ASSY MACHINED 1691111 MACHINED ALUMINUM HANDWHEEL 13012155 PINION 32 DP. 16T 14.5 PA 13012183 WASHER PINION 61300976 #10-24 x 7/8 FILLISTER HD SCREW 61307006 #10-32 x 1/2 FILLISTER HD SCREW 61330084...

  • Page 141: Tracing Table Assembly

    Replacement Parts SECTION 6 Tracing Table Assembly 411001 Rev 1 Parts List ITEM PART NUMBER DESCRIPTION 41101501 TABLE TOP 41101519 TABLE FRAME 61311305 #10 x 2 IN. ROUND HEAD WOOD SCREWS...

  • Page 142: Budget Ignitor Assembly

    SECTION 6 Replacement Parts Budget Ignitor Assembly 000 Rev A...

  • Page 143: Torch Ignitor Module

    Replacement Parts SECTION 6 Torch Ignitor Module 6 Rev OR Parts List ITEM PART NUMBER DESCRIPTION 57000323 ASSY, IGNITER BUDGET 51422 BUSHING 52709 IGNITOR CABLE ASSY 51432 IGNITOR 115V 199N06 LABEL 4 X 2 THERMAL 52705 WIRE HARNESS 70210155 POLYBAG 8 X 10.5 86601001 BUBBLE WRAP 956813...

  • Page 144: Torch Ignitor Control Module

    SECTION 6 Replacement Parts Torch Ignitor Control Module 6 Rev 1 Parts List ITEM PART NUMBER DESCRIPTION 66412 JUNCTION BOX ASSY 66407 IGNITION CONTROL BOX...

  • Page 145: Ignition Control Box

    Replacement Parts SECTION 6 Ignition Control Box 6640 Rev B 10 11 12 Parts List ITEM PART NUMBER DESCRIPTION 51249 Pwr Cable 50927 Fuse Holder 950553 Fuse 3A, SB 2236156 Control Box Cover 50928 Switch 52425 Strain Relief 51917 Strain Relief 66388 Ignition Control Box 50924...

  • Page 146: Ignitor J-Box And Wiring Diagram

    SECTION 6 Replacement Parts Ignitor J-Box and Wiring Diagram 6641 Rev OR L I N E B L K G R N W H T B L K T O R C H C O N T R O L R E F .
  • Page 147 Replacement Parts SECTION 6 Parts List ITEM PART NUMBER DESCRIPTION 2062026 REF CONNECTOR BODY 52145 REF CON CONCT 51101 REF CONTACT SEAL 41014121 REF IGNITOR MOUNT BRACKET 41014123 REF STATION JUNCTION BOX 563803 REF TERMINAL STRIP 994718 REF MARKER STRIP 52471 REF TERMINAL LUG 52472...

  • Page 148: Motorized Station Control Box

    SECTION 6 Replacement Parts Motorized Station Control Box 6641 Rev OR 25 23 24 21 1 21 6 21 2 21 18...
  • Page 149 Replacement Parts SECTION 6 Parts List ITEM PART NUMBER DESCRIPTION 66437 FUSE BLOCK, 3AG SGL POLE 52950 TRANSFORMER STANCOR P6376 2081951 SWITCH MOMENTARY 41014145 COVER MTZ TORCH CONTROL 41014137 SHELL-MTZ TORCH CONTROL 2235814 KULKA T-BLOCK #600-6 1002600 CHASSIS, MTR TRCH CONTROL 52425 STRAIN RELIEF 52547...

  • Page 150: Oxygen Pierce Rate Control Assembly

    SECTION 6 Replacement Parts Oxygen Pierce Rate Control Assembly 060141 Rev  3 / 8 " I D O X Y G E N H O S E 1 / 4 " B S I Z E F I T T I N G T O R C H 3 / 8 "...
  • Page 151 Replacement Parts SECTION 6 Parts List ITEM PART NUMBER DESCRIPTION 182W82 ELBOW STREET 90 1/4 NPTF x 1/4 NPTM 43150520 COUPLING 1/4 NPT F-F BLACK PIPE 2059553 VALVE, 3 WAY SOLENOID 2236750 TEE, STREET 1/4 NPTF x 1/4 NPTM 83389 ADAPTER 1/4 NPT - 'B' OXY 0560940441 OXY PIERCE CONTROL BOX ASSY...

  • Page 152: Oxygen Pierce Rate Control Box

    SECTION 6 Replacement Parts Oxygen Pierce Rate Control Box 06040441 Rev 1 Parts List DESCRIPTION ITEM PART NUMBER ANSI B18.6.3 - No. 6 - 32 - 3/8 00560940443 TIME RELAY SOCKET, 27E122 0560939153 RELAY, TIME DELAY #CB-1003B-70 0560986784 ENCL DRL J-BOX LANCER 1 2 0 V A C B L K - 1 8...
  • Page 154 Customer / Technical Support (843)-664-4405 (800) ESAB-123 (372-2123) ESAB Welding and Cutting Products PO Box 100545 Ebenezer Rd Florence, SC 29501-0545 http://www.esab.com http://www.esabcutting.com ESAB Cutting Systems - Canada 6010 Tomken Road Mississauga, Ontario Canada L5T 1X9 Phone: (905) 670-0220 Fax: (905) 670-4879...

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