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A6 Standard Lift Assembly m3 CAN Plasma System: Instruction Manual

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0% found this document useful (0 votes)
378 views79 pages

A6 Standard Lift Assembly m3 CAN Plasma System: Instruction Manual

Uploaded by

Julio De la Rosa
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd

®

A6 Standard Lift Assembly


m3 CAN Plasma System

Instruction Manual
24
24
23
23

Form Number 0560946014 REV 05


Date: 02/20/12
2
2
Be sure this information reaches the operator.
You can get extra copies through your supplier.

caution
These INSTRUCTIONS are for experienced operators; if you are not fully familiar with the
principles of operation and safe practices for arc welding and cutting equipment, we urge
you to read booklet “Precautions and Safe Practices for Arc Welding, Cutting, and
Gouging” (Form 52-529). Do NOT permit untrained persons to install, operate, or maintain
this equipment. Do NOT attempt to install or operate this equipment until you have read
and fully understand these instructions. If you do not fully understand these instructions,
contact your supplier for further information. Be sure to read Safety Precautions before
installing or operating this equipment.

USER RESPONSIBILITY
This equipment will perform in conformity with the description thereof contained in this manual and accompa-
nying labels and/or inserts when installed, operated, maintained and repaired in accordance with the instruc-
tions provided. This equipment must be checked periodically. Malfunctioning or poorly maintained equipment
should not be used. Parts that are broken, missing, worn, distorted or contaminated should be replaced imme-
diately. Should such repair or replacement become necessary, the manufacturer recommends that a telephone
or written request for service advice be made to the Authorized Distributor from whom it was purchased.

This equipment or any of its parts should not be altered without the prior written approval of the manufacturer.
The user of this equipment shall have the sole responsibility for any malfunction which results from improper
use, faulty maintenance, damage, improper repair or alteration by anyone other than the manufacturer or a ser-
vice facility designated by the manufacturer.

READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.

PROTECT YOURSELF AND OTHERS!


A6 Plasma Lift Assembly

Contents
Safety

Precautions������������������������������������������������������������������������������������������������������������������������������������������������������������������� 3

Enclosure Class������������������������������������������������������������������������������������������������������������������������������������������������������������� 4

General Safety Recommendations��������������������������������������������������������������������������������������������������������������������������� 5

Description

Introduction������������������������������������������������������������������������������������������������������������������������������������������������������������������ 7

Major Components������������������������������������������������������������������������������������������������������������������������������������������������������ 8

A6 Lift/Cable Block Diagram�������������������������������������������������������������������������������������������������������������������������������������� 9

Technical Specifications�������������������������������������������������������������������������������������������������������������������������������������������� 10

Installation

Mounting ���������������������������������������������������������������������������������������������������������������������������������������������������������������������11

Electrical Interfacing������������������������������������������������������������������������������������������������������������������������������������������������� 13

Station Grounding����������������������������������������������������������������������������������������������������������������������������������������������������� 16

Maintenance

Preventative Maintenance Schedule���������������������������������������������������������������������������������������������������������������������� 17

Daily������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������� 17
Weekly�������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������� 18
Monthly������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������ 18
Semi-Annually������������������������������������������������������������������������������������������������������������������������������������������������������������������������������ 18

1
A6 Plasma Lift Assembly

Maintenance Procedures

INA Slide Cleaning and Lubrication ����������������������������������������������������������������������������������������������������������������������� 20

Reassemble INA Slide���������������������������������������������������������������������������������������������������������������������������������������������������������������� 24

INA Slide Flange Bearing Replacement Procedure���������������������������������������������������������������������������������������������� 26

Omni Crash Protection ��������������������������������������������������������������������������������������������������������������������������������������������� 30

Description������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������30
Function Description����������������������������������������������������������������������������������������������������������������������������������������������������������������� 31
Replacing / Adjusting the Omni® Sensor���������������������������������������������������������������������������������������������������������������������������� 32
Omni® Sensor Installation�������������������������������������������������������������������������������������������������������������������������������������������������������� 33
Omni® Mechanical Alignment������������������������������������������������������������������������������������������������������������������������������������������������36
Disassembly���������������������������������������������������������������������������������������������������������������������������������������������������������������������������������� 37
Lubrication������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������38

Limit Switch Positioning and Adjustment ������������������������������������������������������������������������������������������������������������ 39

Technical Descriptions and Troubleshooting

Encoder Height Control�������������������������������������������������������������������������������������������������������������������������������������������� 40

Introduction����������������������������������������������������������������������������������������������������������������������������������������������������������������������������������40
Encoder Station Constant ([Link]) Reference Chart���������������������������������������������������������������������������������������������������� 41
Setting Station Constants using distance calculations ������������������������������������������������������������������������������������������������� 41

AVHC Introduction and Offset Adjustment���������������������������������������������������������������������������������������������������������� 42

Basic A6 Lift Assembly Troubleshooting��������������������������������������������������������������������������������������������������������������� 43

Yaskawa Junma Servopack™ Alarm Indicators����������������������������������������������������������������������������������������������������� 45

2
A6 Plasma Lift Assembly

Safety Precautions
Users of ESAB welding and plasma cutting
equipment have ultimate responsibility for ensuring
that anyone who works on or near the equipment
observes all relevant safety precautions. Safety
precautions must meet requirements that apply to
this type of welding or plasma cutting equipment.

All work must be carried out by trained personnel


well acquainted with operation of welding or
plasma cutting equipment. Incorrect operation of
equipment may lead to hazardous situations which
can result in injury to the operator and damage to
equipment. The following recommendations should
be observed in addition to standard regulations that
apply to the workplace.
1. Anyone who uses welding or plasma cutting
equipment must be familiar with:
……Proper operation.
……Location of emergency stops.
……Designed function.
……Relevant safety precautions.
……Welding and/or plasma cutting.
2. Operators must ensure that:
……No unauthorized person within the working
area of equipment when it is started up.
…… No one is unprotected when plasma arc is
struck.
3. The workplace must be:
……Suitable and
……Free from drafts.
4. Personal safety equipment:
…… Always wear recommended personal safety
equipment, such as safety glasses, flame proof
clothing, and safety gloves.
…… Do not wear loose fitting items, such as
scarves, bracelets, rings, etc., which could become
trapped or cause burns.

3
A6 Plasma Lift Assembly

5. General precautions:
……Make sure return cable is connected securely.
……Work performed on high voltage equipment
may only be carried out by a qualified
electrician.
…… Appropriate fire extinguishing equipment
must be clearly marked and close at hand.
……Lubrication and maintenance must not be
carried out on equipment during operation.

Enclosure Class
Maximum
The IP code indicates the enclosure class, i.e. the
Tilt Allowed
degree of protection against penetration by solid
objects or water. Protection is provided against
touch with a finger, penetration of solid objects
greater than 12mm and against spraying water up to
60 degrees from vertical. Equipment marked IP23S
15° may be stored, but is not intended to be used out-
side during precipitation unless sheltered.

If equipment is placed on a surface that slopes

CAUTION
more than 15°, toppling over may occur.
Personal injury and/or significant damage to
equipment is possible.

WELDING AND PLASMA CUTTING CAN

WARNING CAUSE INJURY TO YOURSELF AND


OTHERS. TAKE PRECAUTIONS WHEN
WELDING OR CUTTING. ASK FOR YOUR
EMPLOYER’S SAFETY PRACTICES WHICH
SHOULD BE BASED ON MANUFACTURERS’
HAZARD DATA.

4
A6 Plasma Lift Assembly

General Safety
Recommendations
ELECTRIC SHOCK - Can kill.
• Ground welding or plasma cutting units in
accordance with applicable standards.
• Do not touch live electrical parts or electrodes
with bare skin, wet gloves, or wet clothing.
• Insulate yourself from earth ground and the
workpiece.
• Ensure your working stance is safe.
FUMES AND GASES - Can be dangerous to health.
• Keep your head out of the fumes.
• Use ventilation, extraction at the arc, or both, to
take fumes and gases away from your breathing
zone and the general area.

ARC RAYS - Can injure eyes and burn skin.


• Protect your eyes and body, using correct
welding/plasma cutting screens and filter lens.
• Wear protective clothing.
• Protect bystanders with suitable screens or
curtains.

FIRE HAZARD - Sparks (spatter) can cause fire. Make


sure that there are no flammable materials nearby.
NOISE - Excessive noise can damage hearing.
• Protect your ears, using ear protection.
• Warn bystanders of the risk.
MALFUNCTION - Call for expert assistance in the
event of malfunction.

READ AND UNDERSTAND THE INSTRUCTION

CAUTION
MANUAL BEFORE INSTALLING OR OPERATING.

PROTECT YOURSELF AND OTHERS!

5
A6 Plasma Lift Assembly

To avoid personal injury and/or equipment dam-

CAUTION
age, lift using method and attachment points
shown below.

6
A6 Plasma Lift Assembly

Description Introduction
The A6 lift assembly provides vertical motion for the
PT-36 plasma torch, using a typical motor, screw, and
slide configuration. The motor turns an enclosed
spindle screw, which in turn raises/lowers the lifting
plate along linear rails. Directional commands given
from CNC determines direction of lift travel. Fixed
limit switches are included to prevent upper and
lower over travel.

The lift assembly also contains components


necessary to control height over work surfaces;
initial, piercing, and cornering heights are encoder-
controlled during the plasma cycle through use
of SDP files. During part production, standoff
is automatically controlled by taking voltage
measurements between torch nozzle and work
surface.

Finally, A6 lifts include Omni Soft Touch® assemblies


to protect the system during station crashes.
Proximity switches monitor torch position in
mounting. If the torch is jarred in any direction,
process movement will stop and an error report will
be sent to CNC. Illustrations on following pages will
detail major lift components and their location. For
illustrated part breakdown, see end section of this
manual.

7
A6 Plasma Lift Assembly

Major Components

1 Lift electrical enclosure and adaptor plate


2 Electrical soft touch box (option)
3 INA precision slide assembly
4 Lift motor
5 Limit switch assembies (upper/lower)
6 Torch bundle guide ring
7 OMNI mounting bracket
8 Plasma warning label
9 Electrical soft touch wire (option)
10 OMNI soft touch® assembly
11 Plasma splatter shield
12

8
A6 Plasma Lift Assembly

A6 Lift/Cable Block Diagram

1 Input Power
2 ACON (CAN)
3 Motor
4 Encoder
5 Switch Interface
6 Crash Protection
7 Soft Touch Interconnection
8 Electrical Soft Touch
9 Torch Touch Wire
10 VDR

NOTE - gray dashed line denotes optional electric soft


touch components.

9
A6 Plasma Lift Assembly

Technical Specifications
• Lift Speed: 450 IPM [11.43m per minute]
• Approximate Vertical Travel: 8.1” [205.5 mm]
• Approximate Weight of Lift Assembly: 36 lbs.
[16.3 kg]
• Torch Barrel Size: 85.7 mm
• Component Tolerances
……IHS Accuracy: ± 0.5 mm
……Encoder Accuracy: ± 0.25 mm
……Voltage Accuracy: ± 1 volt

10
A6 Plasma Lift Assembly

Installation Mounting
Both the A6 lift and electronics enclosure come
complete with adaptor plates that enable mounting
to almost any vertical surface. See illustrations
below for spacing requirements and hole pattern
dimensions.

NOTE - Lift adaptor


plate can be positioned
over entire length of
slide assembly.
[40.00 mm]
1.57

2.68
[68.00 mm]
[671.58 mm]
26.44

O 0.33
[8.38 mm]
x6 HOLES
[107.95 mm]
4.25
[107.95 mm]
[81.64 mm]

4.25
3.21

4.41
[112.01 mm]

9.98
8.10 [205.50 mm] [253.54 mm]
(VERTICAL TORCH TRAVEL)

A6 Lift Assembly dimensions

11
A6 Plasma Lift Assembly

Ensure lift assembly is mounted


NOTICE plumb; use a torpedo level and
adjust mounting bolts as needed.

Torpedo Level

A6 electrical enclosure w/
adaptor plate

NOTE - electrical enclosure can


be mounted in any manner;
just ensure cables are not under
any strain or twisted.

11.00
[279.4 mm]

0.34 THRU
x4 HOLES
4.87 5.87
[123.7 mm] [149.1 mm]

12.00
[304.8 mm]

12
A6 Plasma Lift Assembly

Electrical Interfacing
After lift assembly and electrical enclosure have
been mounted, make the following electrical
connections:
1. Lift Input Power (4 pin, male_female):
connection is from control interface box AHC
Power to lift electrical enclosure SB2.
2. ACON cable (M12, 8 pin, male_male):
connection is from control interface box CAN #
connector to lift electrical enclosure SB1.

m3 CAN OEM Interface Box

CAN # connection used will vary


NOTICE depending on your system configuration.
See System Interconnection manual (PN
0558008527) to determine your system
configuration.

3. Junma Motor cable: connection is from lift


motor to Yaskawa® amplifier connector CNB
(inside lift electrical enclosure).
4. Junma Encoder cable: connection is from
lift encoder to encoder splice cable open
connection (inside lift electrical enclosure).
5. Switch Interface cable (M12, 5 pin male_
female): connection is from lift electrical
enclosure SB4 to lift assembly limit switches.
6. Crash Protection cable (M12, 8 pin male_
female): connection is from lift electrical
enclosure SB3 to Omni® Soft Touch proximity
sensor.

13
A6 Plasma Lift Assembly

Lift Electrical Enclosure


connection guide

6 OR 7
2
1

4
A

3 5
1 SB2 - Input Power
2 SB1 - ACON
3 Motor Cable clamp
4 Encoder Cable clamp
5 SB4 - Switch Interface
6 SB3 - Crash Protection OR
7 SB3 - Soft Touch Interconnection
A SB5 - VDR cable from RAS box

14
A6 Plasma Lift Assembly

The following connections will need to be made if


your plasma station has electrical soft touch option
installed:
7. Soft Touch Interconnection cable (M12, 8 pin
female-female): connection is from lift electrical
enclosure SB3 to soft touch enclosure ST1.

The Soft Touch Proximity cable (#7) will


NOTICE replace the Crash Protection cable (#6) on
plasma stations utilizing electrical soft
touch option.

See block diagram on page 9 above for


details.

8. Soft Touch Proximity cable (M8 female socket_


free wire end): connection is from X3 (inside
soft touch electrical enclosure) to Omni® Soft
Touch proximity sensor.

Electrical Soft Touch Enclosure 9. Torch Touch wire (14-16AWG, in-line terminal_
Connection Guide torch clamp): connection is from soft touch
board X4 to torch clamping ring. Attach this
clamping ring to metal portion of PT-36 torch
body.

9 8

Soft touch enclosure lid was made transparent to show box detail.

15
A6 Plasma Lift Assembly

DO NOT cut under water if electrical

CAUTION soft touch option is installed on


your plasma station!

Station Grounding
Before placing the plasma station into operation,
ensure that the following grounding points are
established:
• Lift Electrical Enclosure
• Soft Touch Electrical Enclosure
Grounding points should be fastened to bare,
unpainted metal and should measure less than 2Ω
(ohms) on a digital multimeter.

Do not use star washers to establish

CAUTION grounding points!


Star washers do not cut painted surfaces
adequately enough to establish ground
potential; ground surfaces should be
against bare metal.

16
A6 Plasma Lift Assembly

Maintenance Preventative Maintenance


Schedule
Time periods suggested below are based on average
plasma station usage. If station is employed in
a heavy usage cycle, used outdoors, or used on
a multi-torch cutting machine, suggested time
intervals should be shortened. Regularly scheduled
maintenance will significantly increase the life and
performance of your equipment.

Read all instruction manual’s safety

CAUTION and maintenance procedures


before beginning any preventative
maintenance!

Daily
• Wipe dust and fume buildup from lift assembly
and components.
• Check for worn or damaged cables on all lift
subassemblies.
• Ensure all mechanical fasteners and electrical
connections are correct; no stripping of
hardware, connections are tight, exposed wires,
etc.
• Check that both upper and lower limit switches
are functioning correctly.
• Use your CNC’s station travel buttons to ensure
lift assembly has proper, smooth movement.
• Replace worn PT-36 torch consumables.
• Test Omni® crash protection function; ensure
that when plasma torch is jarred in any direction
that a crash signal appears at the CNC.

17
A6 Plasma Lift Assembly

Weekly
• Check alignment of lift assembly.
• Check Omni® proximity sensor position and
adjust, if required.
• Check encoder IHS height.
• Clean and lubricate INA slide assembly (see
procedure on page 14).

Monthly
• Check alignment, clean and lubricate Omni®
crash assembly (see procedure on page 19).

Semi-Annually
• Inspect guide strip cover on INA slide assembly;
if cracks are present or surface begins to curl,
replace it and both endplates.

This guide strip is an integral part for

CAUTION ensuring inside of the slide assembly


remains free of contaminants.

• Repeat all previous maintenance procedures.


• Consider calling your ESAB Service
Representative to schedule an semi-annual
station inspection.

Many replacement parts subject to wear


NOTICE or used in preventative maintenance
schedules are available directly through
ESAB Cutting Systems.

See “Consumables and Spare Parts”


section in Replacement Parts portion of
this manual before ordering.

18
A6 Plasma Lift Assembly

Maintenance Procedures The following section contains maintenance


procedures for the lift assembly and components.
This section will provide some basic troubleshooting
methods to return your station to correct operation.
Only qualified maintenance personnel should utilize
these procedures.

19
A6 Plasma Lift Assembly

INA Slide Cleaning and


3 Lubrication
1 In order for the INA slide assembly to perform at
optimum levels, it will need to be inspected, cleaned
and lubricated on a weekly basis. The following
procedure will detail steps necessary to correctly
disassemble, clean and lubricate your slide assembly:
1. Disconnect motor cable, crash proximity cable
and touch wire, if installed.

2. Remove (4) cap screws attaching height


control/crash assembly Support Bracket to INA
2 slide.
3. Wipe the outside surface of the slide strip seal
1 Torch support bracket with a clean dry cloth..
2 Slide strip seal (magnetic surfaces lie underneath)
3 Slide carriage

2
1 Wiper with teflon
3 2 End Plate
3 Cover Strip
4
4 End Plate Rollers
5 Magnetic Strip (Reference)
5

Do not attempt to disassemble slide in

CAUTION order to clean ball screw nut. This will not


be necessary for cleaning or lubrication.

20
A6 Plasma Lift Assembly

4. Dis-assemble end plate and wiper assembly,


both top and bottom (shown).

Step 4

Step 5

5. Remove the two screws holding the cover strip


mount bar, top and bottom.

6. Remove the strip seal from the mount bar on


top and bottom. Bottom mount bar is shown
at the left.

Remove the cover strip (both


screws) from the mount bar

21
A6 Plasma Lift Assembly

7. Remove end plate from the cover strip by


sliding it off the end of the cover strip, top and
bottom.
Pull seal strip from station
mount slide

8. Remove the strip seal by lifting the seal above


the station mount slide. The seal will pull out
of a slot in the station mount slide as shown.
Magnetic Strips
9. Wipe magnetic surfaces clean of debris,
carefully not allowing any dust or debris to
transfer to the ball screw or linear rails.

10. Move slide carriage to downward travel limit


and wipe ball screw with clean, dry cloth.
Repeat process with carriage in upward travel
limit.

11. Repeat process for linear rails, located under


the ball screw.
12. Apply lithium based NGLI 2 grease to entire ball
screw / linear rail surface.

22
A6 Plasma Lift Assembly

13. Inspect the end plate rollers for wear or


Linear rail surface damage. Replace if wear is detected.
(hidden in this view
14. Inspect the end plate wipers for wear or
damage. Damage may occur if lift limit
switches are not set properly.
Ball Screw

Linear Bearing
Linear Rail

Ball Screw Nut

Ball Screw

Front

A-6 Lift Top View

Slide cover wipers will likely be

CAUTION damaged if lift limit switches are not


set properly.
Dysfunctional cover wipers will shorten
component life and add service cost.
Damaged Wiper
Replace if damaged.

Follow the limit switch setting instructions


specified in this maintenance section.

23
A6 Plasma Lift Assembly

Reassemble INA Slide


1 1. Place the cover strip through the end plate as
shown in the path at the left.

2
5

3
4

1 Wiper with teflon


2 End Plate
3 Cover Strip
4 End Plate Rollers
5 Magnetic Strip (Reference)

2. Push the cover strip through the slot of the


slide plate.

Push cover strip through the


slot in the slide plate.

3. Reassemble wiper and end plate to the slide


plate with the 2 cap screws.
4. Repeat steps 1 and 3 for the other end plate.

24
A6 Plasma Lift Assembly

5. Re-assemble the cover strip mount bars to the


cover strip. DO NOT tighten these screws yet.
The cover strip will not be taut resulting in a
poor seal. This slack will be eliminated later.

6. Screw mount bars to the slide, top and bottom.


Tighten these screws.

Lower slide limit

7. Eliminate cover slack by first driving the slide


until the bottom limit switch is activated.
8. Tighten the cover mount screws on the bottom
mount.
9. Raise the lift slide to the upper limit.
10. Tighten the upper cover mount screws.
11. Reassemble torch mount and sensor
Slide Cover Mount Screws connections.

Upper slide limit

25
A6 Plasma Lift Assembly

INA Slide Flange Bearing


Replacement Procedure
Under normal operating conditions, replacement
of this bearing should not be necessary; this lift was
designed to provide many years of dependable
service with proper preventative maintenance
performed on a monthly basis. Symptoms of a
failing flange bearing include chatter and increased
vibration - should it be necessary to change the
flange bearing, a procedure is provided below:

Many replacement parts subject to wear


NOTICE or used in preventative maintenance
schedules are available directly through
ESAB Cutting Systems.

See “Consumables and Spare Parts”


section in Replacement Parts portion of
this manual before ordering.

1. Repeat steps #1-3 of cleaning/lubrication


1 procedure from previous page.

2. Remove cap screws attaching lift motor (1) to


motor adaptor plate (2).

2 3. Remove cap screws attaching motor adaptor


plate (2) to upper actuator mount (3).

3 4 4. Remove both cap screws from upper actuator


front cover (4).

1 Motor / Encoder
2 Motor adaptor plate
3 Upper actuator mount
4 Upper actuator front cover

26
A6 Plasma Lift Assembly

DO NOT loosen or remove (4) cap

CAUTION screws holding upper actuator


mount to slide assembly under any
circumstances!

Doing so will cause the slide


assembly to be misaligned and non-
repairable.

5. Remove motor coupling assembly (2) from ball


screw shaft.

2 1
3
4

6. Remove ball screw locknut by removing two


1 Motor adaptor plate inner setscrews.
2 Motor coupling
3 Ball screw locknut 7. Remove four cap screws holding flange
4 Flange bearing unit bearing unit (4) to upper actuator mount (7).
Pull bearing and ball screw away from actuator.
5 Strip seal cover
6 Magnetic seals
7 Upper actuator mount

27
A6 Plasma Lift Assembly

8. Use a gear puller or similar device to pull


bearing off end of ball screw.

Be careful not to "mushroom" end of ball

CAUTION screw when removing bearing.

9. Push replacement bearing onto ball screw


journal.
10. Apply Loctite® 242 (blue) to four flange bearing
cap screws and partially thread into place.

Ensure idler end of ball screw seats itself


NOTICE inside flange bearing unit.

11. Using flange bearing alignment fixture (ESAB


PN 0560947817), line up ball screw. Alignment
fixture will fit into grooves present in upper
actuator mount (7).
12. Finish tightening four flange bearing cap
screws:

Torque specification = 11 [Link] [1.24 N.m].

13. Apply Loctite® 242 to new locknut (3) and


Ball screw thread it onto ball screw. Tighten locknut
alignment fixture so bearing is pushed up against the collar
reference surface on ball screw:

Torque specification = 10-12 [Link] [1.13-1.36


N.m].

14. Reinstall two setscrews into locknut and


replace upper actuator front cover.
Ball screw locknut

28
A6 Plasma Lift Assembly

15. Reinstall four cap screws into motor adaptor


1 plate (2) and attach to upper actuator mount
(3).

Torque specification = 11 [Link] [1.24 N.m]


16. Reinstall motor/encoder (1) to adaptor plate (2)
2 using M4 cap screws.

Torque specification = 26 [Link] [2.93 N.m]


17. Replace strip seal cover.
3 4
18. Reinstall Omni® support bracket and station
cables.

1 Motor / Encoder
2 Motor adaptor plate
3 Upper actuator mount
4 Upper actuator front cover

Ensure strip seal cover is not gathering (or

CAUTION "puckering") at either end. Move carriage


assembly back and forth and alternate
adjusting the seal’s hardware.

29
A6 Plasma Lift Assembly

Omni Crash Protection

1
Description
The Soft Touch Omni® unit is a patented crash
protection and plate sensing device.

8
5

1 To electrical enclosure
2 Sensor Cable
3 Proximity Sensor Body
4 Torch Handle Clamp (2)
5 Sensitivity gap
6 Sensor Contact Stud
7 Lock Nut
8 Bellows

30
A6 Plasma Lift Assembly

Function Description
Horizontal movement occurs when the torch runs
into the side of the cutting table. The horizontal
movement is transferred vertically through a unique
patented design using precision bearings. During
this vertical movement, the gap (1) between sensor
(2) and contact stud (3) widens causing a voltage
drop. This 15v drop allows the CNC to recognize an
operation fault. If the torch experiences a vertical
force such as a part flipping or torch driving into
plate, this gap will again widen and voltage drop
will occur, stopping all movement.

31
A6 Plasma Lift Assembly

Replacing / Adjusting the Omni®


Sensor

Procedure:
1. Disconnect the cable from sensor by
unscrewing connector.

2. Loosen lock nut.

3. Unscrew sensor and remove.

32
A6 Plasma Lift Assembly

Omni® Sensor Installation

See your machine schematic set for cable


NOTICE wiring instructions for this equipment.

1. Thread provided jam nut on new sensor.


2. Thread sensor into brass insert hole until sensor
touches contact stud (1).

11

Sensor may bottom out on threads before


NOTICE sensor touches contact stud. Lift torch
assembly and try to turn the sensor down
more to confirm sensor is touching. Adjust
stud up if sensor threads are bottoming out
and repeat procedure.

3. Make a reference mark on brass threaded insert


in line with a mark on jam nut.
4. From the position of contact between stud and
sensor, rotate sensor barrel out one full turn.
One full turn results in a gap of 1mm.

33
A6 Plasma Lift Assembly

The sensitivity range of the


NOTICE proximity sensor is 1.5 mm.
By turning sensor back out one full turn
from maximum downward position, crash
sensitivity will be approximately 0.5 mm.
Crash sensitivity can be adjusted ± from
this point by a ¼ turn. A larger gap will
result in a more crash sensitive device.

GREATER
Sensitivity

lesser
Sensitivity

Incidental crash detection may

CAUTION result in having the gap between


proximity sensor and contact stud
too great.
No Protection -
If gap is larger than working range of
Possibility of equipment
damage when crashed

Gap greater than 1.5 mm

Least sensitive - no gap


sensor, protection will not be available.

Conversely, inadequate torch protection


may result if gap is set too small. Using
Most sensitive - a gap that is as large as operationally
1.5 mm gap
convenient is recommended (no incidental
crashes).
Possibility of production interuption
due to incidental crash detection

Effectiveness of OMNI
Proximity Gap Size

34
A6 Plasma Lift Assembly

Sensor cable damage may result

CAUTION from twisting.


Disconnect cable before rotating Omni®
proximity sensors.

5. Tighten jam nut.


6. Reattach cable to sensor.

35
A6 Plasma Lift Assembly

Omni® Mechanical Alignment


The Soft Touch Omni® Protection Device requires
precise mechanical alignment to function properly.
Poor mechanical alignment causes false crashes,
hard touches and torch/holder damage. Check
mechanical alignment monthly and lubricate at that
time.

To check for proper alignment:


1. Move plasma station to a serviceable location,
preferably not over cutting table.
2. Turn off all machine power and all plasma
auxiliary equipment power.

Electric Shock Kills!

DANGER Always turn power off on the plasma


console before doing maintenance on a
plasma torch!

3. Remove both torch clamps and lift torch from


holder.
4. Grasp torch body and twist from side to side.
If there is any visible twisting movement in the
torch, the Omni will need adjustment.
5. Hold torch body while trying to move torch
laterally in all directions. If there is any visible
lateral play in torch holder, it will require
adjustment.

The Omni device may also need realignment if a


crash signal cannot be cleared or the torch has
horizontal play in the torch holder.

36
A6 Plasma Lift Assembly

Disassembly
1. Remove (2) screws holding upper torch clamp
5
5 to torch and remove. Repeat for bottom clamp.
11 2. Remove front end of plasma torch
consumables; torch body/bundle can now be
pulled up through torch holder.
3. Remove (3) screws fastening Omni to support
22 bracket; these are on the underside of support
bracket.

33
11

44

1 Torch clamps
2 Bellows clamps
3 Bellows
4 Torch
5 Proximity Cable

4. Remove (3) screws holding the cover on Omni


device and lift cover off.
5. Loosen (2) clamps holding baffles and lift boot
out of way.

Omni Cover - Top

37
A6 Plasma Lift Assembly

Lubrication
While unit is disassembled, inspect and lubricate
roller bearings.
1. Remove one of three bearing retainer plates.
1 Do not lose any roller bearings – they can fall
out of raceway when retainer plate is removed.
2. Clean bearings (if necessary) and lubricate well
with silicone grease.
3. Reassemble bearing retainer plate and move to
next set of bearings.

1 Lubricate roller bearings


2 Bearing retainer plates

38
A6 Plasma Lift Assembly

Limit Switch Positioning and


Adjustment
It is critical that A6 lift assemblies have a minimum
1 of 7.87” [200mm] of vertical travel. In order for this
to be achieved, both upper and lower travel limit
switches should be positioned in the following
2 manner:
A. Upper Limit Switch: distance between upper
actuator mount (bottom surface) and upper
limit switch adaptor plate (top surface) needs
to be 2.75” [69.85mm].
B. Lower Limit Switch: distance between lower
3 actuator mount (top surface) and lower limit
switch adaptor plate (bottom surface) needs to
be 1.50” [38.1mm].

To adjust either limit switch positions, loosen both


M2 screws; adaptor will slide freely along lift slotted
surface.

1 Lift Upper Actuator mount


2 Upper Limit Switch Adaptor plate (top surface)
A
3 Lift Clamping slot
4 Lower Limit Switch Adaptor plate (shown w/ switch hidden)
5 Lift Lower Actuator mount (top surface)

39
A6 Plasma Lift Assembly

Encoder Height Control


Technical Descriptions and
Troubleshooting Introduction
This method for controlling initial height allows
faster cycle times when cutting multiple parts with
a single torch by eliminating unnecessary vertical
movement. Plate thickness is input (.SDP/.TDF file)
and is used to calculate precise slow down positions
from total available stroke (distance of torch tip in
upper travel position to table slat surface). These
constants define operation of lift for encoder height
control, software slow down functions and plate
thickness input.

Piercing
Height
Cutting
Height
Initial
Height HF Pierce Travel AHC
Delay Delay Delay Delay

Pilot Arc Travel Arc Voltage


Arc Starts Starts Height Control
Turns On

Encoder Height

40
A6 Plasma Lift Assembly

Encoder Station Constant ([Link])


Reference Chart

Constant Number Channel Number Description


43 * Encoder Pulses / meter (Low 16 Bit)
44 * Encoder Pulses / meter (High 16 Bit)
94 Distance: ULS <--> Table Slat (Low 16 Bit)
95 Distance: ULS <--> Table Slat (High 16 Bit)
98 * Distance: Ref Sensor #1 <--> #2 (Low 16 Bit)
99 * Distance: Ref Sensor #1 <--> #2 (High 16 Bit)
100 * Distance: Ref Sensor #1 <--> Nozzle (Low 16 Bit)
101 * Distance: Ref Sensor #1 <--> Nozzle (High 16 Bit)

*NOTE = these values will be set at factory.

Setting Station Constants using


distance calculations
Due to varying table heights, plate thickness, and
lift mounting, the end user will often times need
to reconfigure station constants. In cases where
measurements must be taken and affect constant
values, use the following method for computation.

Example: Distance between upper limit switch and


table slat ([Link] 94 & 95).

Measure distance from torch tip when plasma lift is


in upper most travel position to table slat surface.
Subtract 1 inch to allow for any possible table out of
Measured Distance from level condition. 9 inches will be used in an example
Torch Tip to Table Slat for this calculation.
1. 9” – 1” (safety clearance) = 8”
2. Convert inches to micrometers =
Table Slat 8” x 25.4 x 1000 = 203200
3. Convert value into hexadecimal = 319C0
4. Split into two 16 bit (or word) values =
0003 & 19C0
5. Convert these two values back into decimal
0003 = 3 19C0 = 6592
6. [Link] 95 = 3 & [Link] 94 = 6592

41
A6 Plasma Lift Assembly

AVHC Introduction and Offset


Adjustment
Higher Higher
=
Voltage Standoff The Arc Voltage Height Control system (AVHC)
maintains plasma torch height above work piece
Standoff during cutting.

Scrap Part The AVHC system maintains torch height (“standoff”)


Lower Lower
=
Voltage Standoff by measuring arc voltage, comparing this measured
voltage to the reference voltage in the selected
.SDP / .TDF file, then adjusting torch up or down to
maintain that voltage. A longer arc means higher arc
voltage; higher arc voltage results in higher standoff;
and vise versa.

This reference value is predetermined in the .SDP /


.TDF file, based on several other cutting parameters,
such as amperage, nozzle orifice size, and cutting
speed. Operators can also change desired arc
voltage in parameter window by adjusting Main Arc
Voltage parameter. However, it is good practice to
rename this modified .SDP / .TDF file - this way the
original file is still available for use.

Piercing
Height
Cutting
Height
Initial
Height HF Pierce Travel AHC
Delay Delay Delay Delay

Pilot Arc Travel Arc Voltage


Arc Starts Starts Height Control
Turns On

Encoder Height

The .SDP / .TDF plasma parameters Ignition


NOTICE Height, Pierce Height, and Cutting Height
are distances controlled by Encoder Height
Control. AVHC is not utilized until AFTER
cutting cycle begins.

42
A6 Plasma Lift Assembly

Basic A6 Lift Assembly


Troubleshooting
With proper preventative maintenance performed
on the A6 lift assembly, it will provide many years
of precision and reliable service. However, issues
may arise over time, even with most proactive PM
schedules. Information is provided below to correct
some common assembly failure modes that may
occur and return it to normal operation:

Plasma station attempts to fire in mid-air:

Remove shield cup from PT-36 torch and check for


debris adhering to inside surface; it is likely that torch
is receiving a false touch signal (shield cup to nozzle).
Vision 50P CNC will deliver an on-screen warning
message in this event.

If carriage position is past either


NOTICE slowdown soft limit, no on-screen warning
message will be displayed on Vision CNC.

Overload fault indicator on Yaskawa


servopack™ will not clear:

Seen after the station has been "slammed" into


either lower or upper hard limit; first attempt to
reset power to plasma station by disconnecting
input power cable and reconnect after 10 seconds.
If fault persists, physically remove motor from slide
assembly and shaft will release. Re-install motor to
slide assembly. After fault indicator has been reset,
check condition of carriage endplates and wipers;
replace if damage is present (see Replacement Parts
section, page 12 for part numbers, if required).

43
A6 Plasma Lift Assembly

Motor turning with brakes attempting to hold:

This failure is characterized by brakes producing


large, audible squeaking sound with plasma
station activated. Under normal conditions, when
lift is commanded to move, coil will energize and
brake will release with an audible click. Test the
components by:
1. Open lift electrical enclosure
2. Locate ACON Junma MCU unit.
3. Remove wires from MCU connector X157-5 and
6.
4. Turn station on and measure voltage across
these wires. If +24VDC is measured, MCU unit is
operating correctly.
5. To discern if brake has failed, turn station off
and measure resistance across brake leads (see
schematics in back of this manual). Replace
motor if you read a short (less than 2Ω).

This failure can also be indicated by a


NOTICE pre-lit Overload fault indicator (AL2) on
the Yaskawa Servopack™ unit; this entails
that brakes are preventing the motor from
moving.

No audible sound should be present.

44
A6 Plasma Lift Assembly

Yaskawa Junma Servopack™


Yaskawa JUNMA Servopack Alarm Indicators
The Yaskawa Junma Servopack unit is responsible
for motor speed, direction, and acceleration as
well as encoder count and pulse monitoring. It
also communicates directly with the Vision CNC,
1 forming a closed-loop monitoring system. Tables on
following pages will describe the servopack’s alarm
2 displays, their cause and meaning, and generalized
information for corrective action:

1 Alarm Indicator 1
2 Alarm Indicator 2
3 Alarm Indicator 3

45
A6 Plasma Lift Assembly

Table 1 - Speed Errors

Alarm Alarm Condition Corrective


Display Name Trigger Cause Action

Speed Error Power was turned ON. A servopack fault occurred. Replace the servopack.

AL1 = On Phases U, V, and W in


AL2 = Off servomotor are wired to
AL3 = Off Servo was turned ON. wrong terminals. Correct wiring.

Encoder wiring is incorrect.

Malfunction occurred due Take measures against noise for encoder


to noise in encoder wiring. wiring.

A servopack fault occurred. Replace the servopack.


Phases U, V, and W in
servomotor are wired to
wrong terminals. Correct wiring.
Servomotor operation
was started or was
switched to high speed
operation. Encoder wiring is incorrect.

Malfunction occurred due Take measures against noise for encoder


to noise in encoder wiring. wiring.

Position pulse reference


input has exceeded 10,000
pulses per revolution. Correct reference value input.

A servopack fault occurred. Replace the servopack.

46
A6 Plasma Lift Assembly

Table 2 - Overload Errors

Alarm Alarm Condition Corrective


Display Name Trigger Cause Action

AL1 = Off
AL2 = On
AL3 = Off Overload Power was turned on. A servopack fault occurred. Replace the servopack.

Servo was turned ON or


servomotor did not Servomotor main circuit
operate for a reference cable wiring is incorrect or
input from the controller. its contact wiring is faulty. Check and correct servomotor wiring.
Encoder cable wiring is
incorrect or its contact
wiring is faulty.

A servopack fault occurred. Replace the servopack.


Drop in power supply Ensure power supply voltage is within
Normal operation voltage. permissible range.
Servomotor coil burned Measure coil resistance. If open, replace
out. servomotor.
Servomotor was operated
with holding brake Measure voltage of brake terminals and
engaged. release brake.
Ambient temperature
around servomotor Take measures to ensure working area is
exceeded 131°F (55 °C ). less than 131°F (55 °C ).

A servopack fault occurred. Replace the servopack.

47
A6 Plasma Lift Assembly

Table 3 - Encoder Errors

Alarm Alarm Condition Corrective


Display Name Trigger Cause Action
AL1 = On Power was turned on or
AL2 = On Encoder during servomotor Encoder wiring and contact
AL3 = Off Error operation. wiring are incorrect. Correct wiring.

Noise intererence occurred


because encoder cable Ensure encoder is no more than 20
distance is too long meters.
Disconnected encoder Replace encoder cable through ESAB
cable. Customer Service.

A zero point error occurred. Replace the servopack.

An encoder fault occurred.

Table 4 - Voltage Errors

Alarm Alarm Condition Corrective


Display Name Trigger Cause Action

Main power was turned ON


AL1 = Off again before the power
AL2 = Off Voltage Power was turned on or supply to servopack was Wait until servopack's REF indicator is
AL3 = On Error normal operation. completely OFF. OFF, and turn on main power again.

AC power supply voltage


exceeded permissible Ensure AC power voltage is within
range. specified range.

A servopack fault occurred. Replace the servopack.

48
A6 Plasma Lift Assembly

Alarm Alarm Condition Corrective


Display Name Trigger Cause Action
AL1 = Off Built-in
AL2 = On Fan Power was turned on or
AL3 = On Stopped during motor operation. Fan motor stopped. Replace cooling fan in Servopack.

Air intake is blocked. Inspect and clear obstruction.


Alarm Alarm Condition Corrective
Display Name Trigger Cause Action

System Replace the servopack and contact ESAB


ALL On Error Power was turned on. A servopack fault occurred. customer support.
Alarm Alarm Condition Corrective
Display Name Trigger Cause Action

All flash
on to off Power was turned on or Turn on main power again (operation of
at regular Reference during servomotor the servomotorcan continue during
intervals changed operation. N/A display of this alarm).

49
A6 Plasma Lift Assembly

50
A6 Plasma Lift Assembly

REPLACEMENT
PARTS 51
Replacement Parts

Table of Contents
Introduction
General Information��������������������������������������������������������������������������������������������������������������������������������������������������������������������������� 3
Ordering Information������������������������������������������������������������������������������������������������������������������������������������������������������������������������ 4

A6 INA Lift Assembly, OEM Kit


0560947165 Rev 01����������������������������������������������������������������������������������������������������������������������������������������������������������������������������� 5

A6 Lift Assembly
0560946827 REV 06��������������������������������������������������������������������������������������������������������������������������������������������������������������������������� 9

INA Slide Assembly


0560943744 Rev 01��������������������������������������������������������������������������������������������������������������������������������������������������������������������������� 11

m3 INA Station Box Assembly


0560945596 REV 06������������������������������������������������������������������������������������������������������������������������������������������������������������������������� 13

Omni Soft Touch Assy


0560941537 Rev 00��������������������������������������������������������������������������������������������������������������������������������������������������������������������������� 17

Wire Kit, Soft Touch


0560947295 Rev 02��������������������������������������������������������������������������������������������������������������������������������������������������������������������������� 19

Consumable and Spare Part Reference List


Part Numbers Vary���������������������������������������������������������������������������������������������������������������������������������������������������������������������������� 21

Replacement Parts
Replacement Parts

Replacement Parts
Replacement Parts

Introduction General Information

This section provides replacement parts information


and will assist during station maintenance. It is
arranged by functional groups or assemblies for easy
identification of individual parts and replaceable
assemblies. The Replacement Parts List consists of
a parts list for the main assembly and one for each
major assembly and subassembly. Item numbers
that identify parts in the illustration are given in the
list where applicable, along with part numbers and
descriptive information.

Common hardware items or other parts readily


available from commercial sources are not included.
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.

The end of this manual section has spare parts and


consumable reference sheets. Please use these when
ordering wear items and consumables, based on
your needs.

Replacement Parts
Replacement Parts

Ordering Information
When ordering replacement parts, order by part
number and complete part description as given in
the description column. 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.

To avoid unnecessary delays, positively


NOTICE identify your correct assembly before
ordering replacement parts.

Replacement Parts
Replacement Parts

A6 INA Lift Assembly, OEM Kit


0560947165 Rev 01

8 10 11 14 15 3

16
19
20
5
17
7
6
18
9
12
4
13
1
2

NOTE:
1. 0560947295 IS SELECTED FOR ELECTRICAL SOFT
TOUCH OPTION (QTY 1) AND INCLUDES SOFT TOUCH
BOX / BRACKET AND TOUCH WIRE KIT.

2. ELECTRICAL SOFT TOUCH OPTION CANNOT BE


REPLACEMENT

USED WITH UNDERWATER CUTTING.


PARTS

3. THIS DRAWING HAS THE ELECTRICAL SOFT TOUCH


OPTION DISPLAYED.

5
Replacement Parts

A6 CABLE INTERCONNECTION
BLOCK DIAGRAM

RAS

10

OEM
INTERFACE

1 SOFT
A6 LIFT
CNC 7 TOUCH
ELEC ENCL
ENCL
2

BOX 3 4 5 8

A6 LIFT / SLIDE CRASH


ASSEMBLY SENSOR

PLASMA
1 INPUT POWER 9
TORCH
2 ACON
3 MOTOR
4 ENCODER
5 SWITCH INTERFACE
6 CRASH PROTECTION
7 SOFT TOUCH INTERCONNECTION
8 SOFT TOUCH
REPLACEMENT

9 TORCH TOUCH WIRE


PARTS

10 VDR

NOTE - GRAY DASHED LINE DENOTES ELECTRIC SOFT TOUCH


OPTION COMPONENTS.
6
Replacement Parts

TABLE 1 - INPUT POWER CABLE TABLE 6 - CRASH PROXIMITY CABLE


LENGTH PART NUMBER LENGTH PART NUMBER
4m (13') 0560947087 3m 0560947812
5m (16') 0560947088 5m 0560947813
6m (19') 0560947089 10m 0560947814
7m (23') 0560947090 15m 0560947815
8m (26') 0560947091 20m 0560947816
9m (30') 0560947092
10m (33') 0560947093
15m (49') 0560947094 TABLE 7 - SOFT TOUCH INTER CABLE
20m (66') 0560947095 LENGTH PART NUMBER
3m 0560944138
5m 0560944139
TABLE 2 - ACON CABLE 10m 0560944140
LENGTH PART NUMBER 15m 0560947907
4m (13') 0558008467 20m 0560944141
5m (16') 0558008468
6m (19') 0558008469
7m (23') 0558008470
TABLE 8 - SOFT TOUCH PROX CABLE
8m (26') 0558008471
LENGTH PART NUMBER
9m (30') 0558008472
3m 0560947867
10m (33') 0558008473
5m 0560947868
15m (49') 0558008478
20m (66') 0558008479 10m 0560947869
15m 0560947870
20m 0560947871
TABLE 3 - MOTOR CABLE
LENGTH PART NUMBER
TABLE 10 - VDR CABLE
3m 0560946843
LENGTH PART NUMBER
5m 0560946844
4m (13') 0560947068
10m 0560946845
5m (16') 0560947077
15m 0560946846
20m 0560946847 6m (19') 0560947069
7m (23') 0560947070
8m (26') 0560947071
9m (30') 0560947072
TABLE 4 - ENCODER CABLE
10m (33') 0560947078
LENGTH PART NUMBER
15m (49') 0560947073
3m 0560946848 20m (66') 0560947074
5m 0560946849
10m 0560946850
15m 0560946851
20m 0560946852

TABLE 5 - SWITCH INTERFACE CABLE


REPLACEMENT

LENGTH PART NUMBER


3m 0560947825
PARTS

5m 0560947826
10m 0560947827
15m 0560947828
20m 0560947829

7
Replacement Parts

PARTS LIST
ITEM QTY PN DESCRIPTION
1 1 0560945596 ELEC ENCLOSURE, INA LIFT
2 1 0560946827 LIFT ASSY, A6 SA
3 1 0560947283 ADPT PLATE, ELEC ENCL
4 1 0560947284 COVER PLATE, ELEC ENCL
5 REF 0560947295 ELECTRIC SOFT TOUCH OPTION KIT
6 1 2081816 PLASMA WARNING LABEL
7 1 2132645 BRKT, PLASMA DANGER
8 4 ANSI B [Link] M - M8 x 1.25 Hex Nut
9 4 ANSI B18.3.4M - M6 x 1 x 16 Button SHCS - Metric
10 4 ANSI B18.3.4M - M8 x 1.25 x 25 Button SHCS - Metric
11 10 DIN 125 - A 8.4 Flat Washer
12 4 DIN 126 - 6.6 Flat Washer
13 4 DIN 128 - A6 Spring Washer
14 4 DIN 128 - A8 Spring Washer
15 4 DIN 7991 - M5x12 Countersunk Screw - Metric
16 1 ISO 4014 - M8 x 40 Hex-Head Bolt
17 4 ISO 4032 - M3.5 Hex Nut
18 4 ISO 4032 - M6 Hex Nut
19 1 ISO 4032 - M8 Hex Nut
20 4 ISO 7045 - M3.5 x 6 - 4.8 - Z Pan Head Screw - Metric
21 PICK SEE TABLE 1 CABLE, INPUT POWER
22 PICK SEE TABLE 2 CABLE, ACON
23 PICK SEE TABLE 3 CABLE, MOTOR
REPLACEMENT

24 PICK SEE TABLE 4 CABLE, ENCODER


25 PICK SEE TABLE 5 CABLE, INA SWITCH INTERFACE
PARTS

26 PICK SEE TABLE 6 CABLE, CRASH PROTECTION


27 PICK SEE TABLE 7 CABLE, INTERCONNECT
28 PICK SEE TABLE 8 CABLE, SOFT TOUCH PROX, SHLD
29 PICK SEE TABLE 10 CABLE, VDR
8
REPLACEMENT PARTS

A6 Lift Assembly
0560946827 REV 06

22

15
17 11 4

8 25
16
19 1
22 1 10
14 9
5
7 21 20 6 13
14

18

14 7 21 20 6 13

26
REPLACEMENT
PARTS

12

A6 Lift Assembly 9
REPLACEMENT PARTS

PARTS LIST
ITEM QTY PART NUMBER DESCRIPTION
1 14 0006101002 HEXAGON SOCKET CAP SCREW M4X16
2 3 0006101008 [Link].-ISO4762-M4X10
3 4 0006101014 [Link].-ISO4762-M5X16-8.8
4 2 0006101023 [Link].-ISO4762-M6X10-
5 6 0006101112 [Link].-ISO4762-M8X30-
6 4 0006101120 [Link].-ISO4762-M3X16-8.8-
7 4 0006102002 [Link].-ISO1207-M2X6-
8 1 0006118113 HEX. S. BH SCR-ISO7380-M3X6-A2
9 6 0006130008 HEXAGON NUT GALVANIZED M 8
10 6 0006150006 WASHER GALVANIZED B8
11 2 0006157013 [Link]-DIN128-B6-
12 1 0558008301 PT-36 TORCH CAN VERSION (4.5’)
13 2 0560935261 MICRO SWITCH SR-3-E-SW
14 1 0560941537 ASSY OMNI SOFT TOUCH M3 PROX
15 1 0560943743 200W JUNMA MOTOR WITH BRAKE
16 1 0560943744 INA SLIDE, 217MM STROKE, 4MM LEAD
17 1 0560943754 HOSE SUPPORT - SMALL GANTRY
18 1 0560943761 SLIDE ADAPTER PLATE
19 1 0560943762 CAM LIMIT SWITCH
20 2 0560943763 SWITCH ADAPTER PLATE
21 2 0560943769 TEE NUT M2
22 1 BRKT SUPPORT OMNI CRASH JUNMA AHC-SA
23 1 0560946828 CONNECTOR M12 FEMALE 5 PIN
24 1 0560947830 OEM A6 LIFT ASSEMBLY SCHEMATIC
25 1 0560948448 NAMEPLATE A6 LIFT
26 1 0560949375 MAGNETIC SHIELD ASSY
27 620 0560950354 HEAT SHRINK 3/8” BLACK
28 220 0560950440 HEAT SHRINK 1/2” BLACK
REPLACEMENT

29 1 0560950514 LABEL WARNING PINCH HAZARD


PARTS

10 A6 Lift Assembly
Replacement Parts

INA Slide Assembly


NOTE 1
0560943744 Rev 01

NOTES:

1. DO NOT LOOSEN OR REMOVE THESE FOUR BOLTS


UNDER ANY CIRCUMSTANCES! THIS WILL CAUSE
BALLSCREW MISALIGNMENT.

(6.47 [164.30 mm])


(14.90 [378.40 mm])

REPLACEMENT
PARTS

11
Replacement Parts

1
1

5
5

6
6 3

2
2

NOTES:

SEE SECTION 5 OF THIS MANUAL FOR PROCEDURE


ON FLANGE (SUPPORT) BEARING REPLACEMENT.
THE BEARING SHOULD NOT BE CHANGED WITHOUT
ALIGNMENT FIXTURE.

REPLACEABLE PARTS LIST - INA LIFT


ITEM QTY PN DESCRIPTION
1 1 0560942894 ASSY, MOTOR COUPLING
2 1 0560942892 THRUST BEARING PLATE
3 1 0560947294 REPLACEMENT KIT, FLANGE BEARING, INA LIFT
4 1 0560942891 SHAFT ADAPTOR
5 1 0560942893 COVER, GUIDE STRIP
6 1 0560942895 ASSY, CARRIAGE ENDPLATE WIPER
7 1 0560942897 END PLATE ASSY W/ WIPER
REPLACEMENT
PARTS

12
REPLACEMENT PARTS

m3 INA Station Box Assembly


6 11
0560945596 REV 06
9 5
6 11
9 5

34 6 10

34 6 10

31
29
28
31
29
28

14 16
7
3
4 14
3416
15
7
3
4 34
15
36 6 10 33 REPLACEMENT
PARTS

2
2436 6 10 33
20

24 213
34
20
20 21 26
13
34
20 21 26

21 8 34
25
21 8 34 m3 INA Station Box Assembly 13
25
REPLACEMENT PARTS

12

35
32
REPLACEMENT
PARTS

14 m3 INA Station Box Assembly


REPLACEMENT PARTS

PARTS LIST
ITEM QTY GIN DESCRIPTION
1 1 0004654140 END PLATE
2 1 0006100008 HEX. SCREW-ISO4017-M4X12-
3 2 0006101008 [Link].-ISO4762-M4X10
4 6 0006101318 CHEESE HEAD SCREW ISO7045 M5 X 10
5 4 0006118111 ISO7380-M6X10-A2 HEXAGON SOCK. BUTTON HEAD SCREW
6 7 0006130035 [Link]-S1-ISO4032-M4-
7 2 0006150003 WASHER GALVANIZED A4
8 4 0006150004 WASHER GALVANIZED A5
9 4 0006150005 WASHER GALVANIZED B6
10 6 0006157017 [Link]-DIN128-B4
11 1 0006159018 TOOTH LOCKED WASHER DIN6797 V4,3
12 1 0558954035 LABEL CE LOGO
13 1 0560941432 BUS BAR, COPPER
14 1 0560943507 MCU JUNMA INTERFACE
15 1 0560944331 SERVOPACK
16 1 0560944343 DIN RAIL MOUNTING 35MM X 7.5MM
17 1 0560944430 A6 M3 PLASMA BOX SCHEMATIC
18 1 0560945363 JUNMA ENCODER SPLICE CABLE
19 1 0560945373 JUNMA I/O SIGNAL CABLE
20 1 0560945374 CNA CONNECTOR
21 1 0560945375 CNA CONNECTOR
22 1 0560945584 ASSY, STATION CONTROL BOX
23 1 0560945597 FACE PANEL ASSEMBLY, M3, INA
24 1 0560945881 TRANSFORMER, 12/24 VSEC 80 VA
25 8 0560946204 QUICK WIRE TERMINAL CONNECTOR 90°
26 1 0560947161 FILTER, EMI, 250VAC 5A
27 1 0560948185 PLUG SET MCU JUNMA W/O L.
28 1 0560948408 CONTACT INSERT 12 PIN
29 1 0560948410 PLASTIC SLEEVE HOUSING REPLACEMENT
30 1 0560948411 HALF SCREW CONNECTION (7-14MM)
PARTS

31 1 0560948412 HALF SCREW CONNECTION(4-6.5MM)


32 1 0560950378 NAMEPLATE 2.38 X 3.38
33 4 0560950488 GROUND CLIP
34 4 0560950489 RING TERMINAL LUG
35 1 0560950490 GROUND DECAL
36 9 0560950498 TERMINAL INLINE FEMALE 0.25” X 14-16AWG

m3 INA Station Box Assembly 15


REPLACEMENT PARTS

Spacer Page
REPLACEMENT
PARTS

16 m3 INA Station Box Assembly


Replacement Parts

Omni Soft Touch Assy 14 SECTION A A


2

0560941537 Rev 00 13
7
11

34 6

B 10 B
9
14
5
19 8
31 4
15 31
25 3
18 22
2
17 1

33

32

35 23 A
21 22

31
12
REPLACEMENT

26
PARTS

25
22
SECTION B B A
17
Replacement Parts

BILL OF MATERIALS
QUANTITIES ARE IN U/M ESTIMATED BY INVENTORY
ITEM PART NO. QTY. DESCRIPTION
NO.
1 2238468 1 SLEEVE, TORCH HOLDER
2 2233370 2 CLAMP, TORCH
3 2238469 1 RING, TORCH MOUNTING
4 0560936077 1 COVER OMNI SOFT TOUCH W/PROX
5 2157761 3 SLEEVE, SPRING
6 2238471 1 BEARING HOUSING
7 2238478 1 BRACKET, TOP CLAMP
8 2209090 3 SPRING, COMPRESSION DIE
9 2233364 3 STUD, (METRIC)
10 05N00080 3 NUT, HEX ~ M5-0.8
11 -- REF LOCK NUT M8-1.0
12 05S24010 4 SCREW, SET,CONE PT. HEX SOC. ~ M5-0.8 X 10 MM LG.
13 04S12012 3 SCREW, HEX SOC HD. CAP ~ M4-0.7 X 12 MM LG.
14 0560935243 1 PROX M8 4W PNP QD
15 2238484 1 BLOCK
16
17 57000462 12 PIN, DOWEL ~ .250 DIA X .50 LG
18 23211302 2 SCREW, HEX SOC HD. CAP ~ M3-0.5 X 16 MM LG.
19 -- 1 SCREW,HEX HD. CAP ~ M5-0.8 X 45 MM LG.
20
21 2238473 2 PLATE, BEARING ADJUSTMENT
22 03S12006 7 SCREW, HEX SOC HD. CAP ~ M3-0.5 X 6 MM LG
23 2238472 2 RETAINER, BEARING PLATE
24
25 2238485 1 RETAINER, NON-ADJUSTMENT
26 06S26020 4 SCREW, HEX SOC HD. CAP S.S. ~ M6-1.0 X 20 MM LG.
27
28 03S12012 2 SCREW, HEX SOC HD. CAP ~ M3-0.5 X 12 MM LG.
29
30
31 05N01080 8 NUT, HEX JAM ~ M5-0.8
32 2231375 2 CLAMP, WORM 5" DIA.
33 2238860 1 BOOT
34 77500101 A/R GREASE, SILICONE
35 03S12008 12 SCREW, HEX SOC HD. CAP ~ M3-0.5 X 8 MM LG
REPLACEMENT
PARTS

18
Replacement Parts

Wire Kit, Soft Touch


0560947295 Rev 02

4 5 6 7

PARTS LIST
ITEM QTY PN DESCRIPTION
1 1 0560946810 ASSY, SOFT TOUCH BOX
2 1 0560947291 SOFT TOUCH BRACKET
3 1 0560947293 WIRE KIT, SOFT TOUCH
4 8 DIN 125 - A 6.4 Flat Washer
5 4 M5x0.8 x 16 SHCS - Metric
6 4 DIN 127 - A 5 Spring Washer
7 4 M - M5 x 0.8 Hex Nut
REPLACEMENT
PARTS

19
Replacement Parts

Spacer Page
REPLACEMENT
PARTS

20
Replacement Parts

Consumable and Spare Part The following section was designed to assist
operators in identifying and ordering maintenance/
Reference List consumable parts. Items listed below are parts that
will need replacement at least on a yearly basis,
many with smaller maintenance intervals. Quantities
Part Numbers Vary suggested are estimated, based on normal machine
usage, product lead times and availability; end users
will need to best decide what quantities to purchase
based on their production schedule.

The parts represented here, at some point,


NOTICE will be necessary to maintain the process
tool. Please dial our toll free number for
pricing and availability or contact your
nearest distributor.
1-800-ESAB-123
BASIC SPARE PARTS, A6 INA LIFT
ESAB PN 0560947289

PARTS LIST
ITEM QTY PN DESCRIPTION
1 1 0560935261 MICROSWITCH SR-3-E-SW
2 1 0560942894 MOTOR COUPLING
3 1 0560942891 ADAPTOR
4 1 0560942893 COVER PLATE
5 1 0560942897 ENDPLATE (w/WIPERS)
6 1 0560947294 FLANGE BEARING REPLACEMENT KIT
7 1 0560935243 PROXIMITY SENSOR, M8 PNP

EXTENDED SPARE PARTS, A6 INA LIFT


ESAB PN 0560947290

PARTS LIST
ITEM QTY PN DESCRIPTION
1 1 0560935261 MICROSWITCH SR-3-E-SW
2 1 0560942894 MOTOR COUPLING
REPLACEMENT

3 1 0560942891 ADAPTOR
4 1 0560942893 COVER PLATE
PARTS

5 1 0560942897 ENDPLATE (w/WIPERS)


6 1 0560947294 FLANGE BEARING REPLACEMENT KIT
7 1 0560935243 PROXIMITY SENSOR, M8 PNP
8 1 0560943743 JUNMA MOTOR

21
Replacement Parts

Spacer Page
REPLACEMENT
PARTS

22
Revision History:’

• 04 - Updated vertical torch travel dimension on Page 11 and updated replacement parts.
• 05 - Updated schematic 0560947830_D03 per CN-124043.
Customer // Technical Support
(843) 664-4405
(800) ESAB-123 (372-2123)

ESAB Welding and Cutting Products


PO BOX 100545 Ebenezer Road
Florence, SC 29501-0545
[Link]

ESAB Cutting Systems – Canada


6010 Tomken Road
Mississauga, Ontario Canada L5T 1X9
Phone: (905) 670-0220
Fax: (905) 670-4879

ESAB Cutting Systems GMBH


Robert-Bosch-Strasse 20
Postfach 1128
D-61184 Karben 1
Phone 011-49-6039-400
Fax 011-49-6039-403-02
[Link]

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