Baileigh Industrial PT-105HD-W User manual

OPERATOR’S MANUAL
CONTROLLER OPERATION
MODEL: PT-105HD-W
REPRODUCTION OF THIS MANUAL IN ANY FORM WITHOUT WRITTEN APPROVAL OF BAILEIGH INDUSTRIAL IS
PROHIBITED. Baileigh Industrial does not assume and hereby disclaims any liability for any damage or loss caused
by an omission or error in this Operator’s Manual, resulting from accident, negligence, or other occurrence.
Edition 1 01/2022
Baileigh Industrial
1625 Dufek Drive
Manitowoc, WI 54220
Phone: [phone]
Fax: [phone]
[email protected]

Table of Contents
INTRODUCTION............................................................................................................. 1
GENERAL NOTES.......................................................................................................... 1
SAFETY INSTRUCTIONS ..............................................................................................2
SAFETY PRECAUTIONS ...............................................................................................5
Dear Valued Customer:................................................................................................... 5
TECHNICAL INFORMATION AND SUPPORT...............................................................7
Read This Manual .......................................................................................................7
Work Condition............................................................................................................7
Maintenance................................................................................................................7
High Voltages..............................................................................................................7
Technical Support Contact ..........................................................................................8
Cleaning ...................................................................................................................... 8
INTRODUCTION............................................................................................................. 9
System Characteristics................................................................................................9
Technical Standard.................................................................................................... 10
System Interface........................................................................................................ 10
SYSTEM BOARD AND MAIN INTERFACE.................................................................. 11
Operating Board Introduction..................................................................................... 11
Power On Process and Main Interface...................................................................... 12
Function index of main interface................................................................................14
CUTTING FUNCTION................................................................................................... 15
Speed Control and Adjustment.................................................................................. 16
Forward ..................................................................................................................... 17
Backward................................................................................................................... 17
Edge Cutting / Offset Cutting / Return....................................................................... 18
Back to Reference Function ...................................................................................... 18
Perforation Point Selection........................................................................................ 19
Dynamic Amplification ............................................................................................... 19
Cutting Exit................................................................................................................ 19
Frame Function ......................................................................................................... 20
PART OPTIONS ........................................................................................................... 21
[F1] Mirror.................................................................................................................. 21
Angle Adjustment ...................................................................................................... 22
Array.......................................................................................................................... 23
Zoom in/out................................................................................................................ 27
Select row/number..................................................................................................... 27
Operation after select row/number ............................................................................ 28
Restore...................................................................................................................... 28
MANUAL FUNCTION.................................................................................................... 29
Fixed Moving Function .............................................................................................. 29
Continuous Moving Function..................................................................................... 30
Fixed Length Moving................................................................................................. 30

Breakpoint Recovery................................................................................................. 30
FILE OPERATION ........................................................................................................ 31
Files in the Hard Disk ................................................................................................ 31
Files in the U Disk...................................................................................................... 31
Search File ................................................................................................................ 32
Edit Code................................................................................................................... 32
New Code.................................................................................................................. 32
Compile Code............................................................................................................ 32
PARAMETER SETTING............................................................................................... 33
Common Parameters ................................................................................................ 33
Flame Parameters..................................................................................................... 34
Plasma Parameters................................................................................................... 35
System Parameters................................................................................................... 37
Parameter Import....................................................................................................... 39
Parameter Export ...................................................................................................... 39
Save Parameters.......................................................................................................39
DIAGNOSIS FUNCTION............................................................................................... 40
Diagnosis Interface Index.......................................................................................... 41
Output Diagnosis....................................................................................................... 42
Key-Press Diagnosis................................................................................................. 43
System Self-Check.................................................................................................... 44
Date and Time...........................................................................................................45
SHAPES ....................................................................................................................... 46
Choose Graph........................................................................................................... 47
G, M Code Guide....................................................................................................... 48

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INTRODUCTION
The quality and reliability of the components assembled on a Baileigh Industrial machine
guarantee near perfect functioning, free from problems, even under the most demanding working
conditions. However, if a situation arises, refer to the manual first. If a solution cannot be found,
contact the distributor where you purchased our product. Make sure you have the serial number
and production year of the machine (stamped on the nameplate). For replacement parts refer to
the assembly numbers on the parts list drawings.
Our technical staff will do their best to help you get your machine back in working order.
In this manual you will find: (when applicable)
•Safety procedures
•Correct installation guidelines
•Description of the functional parts of the machine
•Capacity charts
•Set-up and start-up instructions
•Machine operation
•Scheduled maintenance
•Parts lists
GENERAL NOTES
After receiving your equipment remove the protective container. Do a complete visual inspection,
and if damage is noted, photograph it for insurance claims and contact your carrier at once,
requesting inspection. Also contact Baileigh Industrial and inform them of the unexpected
occurrence. Temporarily suspend installation.
Take necessary precautions while loading / unloading or moving the machine to avoid any injuries.
Your machine is designed and manufactured to work smoothly and efficiently. Following proper
maintenance instructions will help ensure this. Try and use original spare parts, whenever
possible, and most importantly; DO NOT overload the machine or make any modifications.
Note: This symbol refers to useful information throughout the manual.

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LEARN TO RECOGNIZE SAFETY INFORMATION
This is the safety alert symbol. When you see this symbol on
your machine or in this manual, BE ALERT TO THE
POTENTIAL FOR PERSONAL INJURY!
Follow recommended precautions and safe operating
practices.
UNDERSTAND SIGNAL WORDS
A signal word –DANGER, WARNING, or CAUTION is
used with the safety alert symbol. DANGER identifies
a hazard or unsafe practice that will result in severe
Injury or Death.
Safety signs with signal word DANGER or WARNING are
typically near specific hazards.
General precautions are listed on CAUTION safety signs.
CAUTION also calls attention to safety messages in this
manual.
IMPORTANT
PLEASE READ THIS OPERATORS MANUAL CAREFULLY
It contains important safety information, instructions, and necessary operating
procedures. The continual observance of these procedures will help increase your
production and extend the life of the equipment.
SAFETY INSTRUCTIONS

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SAVE THESE INSTRUCTIONS.
Refer to them often and use them to instruct others.
PROTECT EYES
Wear safety glasses or suitable eye protection
when working on or around machinery.
PROTECT SKIN
Keep hands and body protected from the plasma arc and hot sparks.
The heat from the plasma arc is very intense and can pierce the skin
resulting in serious burns. Always wear gloves and suitable clothing.
DO NOT touch hot piece part without gloves.
FUMES AND GASES
The plasma cutting process produces fumes and gases that can be
hazardous to your health. If the area is not properly ventilated to remove
them, use an air supplied respirator.
ELECTRICAL AND MAGNETIC FIELDS
Electric current and magnetic fields (EMF). These magnetic fields can
influence pacemakers, medical implant, sensitive electronic equipment,
and loose metallic objects. Persons with a pacemaker or medical implant
must stay back at least 12 inches (30cm). Prolonged exposure to EMF
may have other health effects which are not yet known.

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CUTTING SPARKS
A spark or piece of hot metal can fly out of the arc while cutting.
Remove all flammable materials from the plasma cutting area. Wear
approved eye protection, and proper hand and body protection.
Make sure the cutting tip is not grounded when sitting idle, which
could cause heat buildup, resulting in a possible fire.
BEWARE OF PINCH POINTS
Keep hands and fingers clear of all potential pinch points. These
include sprockets and chains along with belts and pulleys.
ELECTRICAL SHOCK CAN KILL
The plasma arc process uses and produces high voltages that can
severely injure or kill. Disconnect power source before performing
service or repairs. Insulate yourself from the piece part or other
components in the weld circuit.
HIGH VOLTAGE
USE CAUTION IN HIGH VOLTAGE AREAS. DO NOT assume the
power to be off. FOLLOW PROPER LOCKOUT PROCEDURES.
EMERGENCY STOP BUTTON
In the event of incorrect operation or dangerous conditions, the machine
can be stopped immediately by pressing the E-STOP button. Twist the
emergency stop button clockwise (CW) to reset. Note: Resetting the E-
Stop will not start the machine.

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SAFETY PRECAUTIONS
Metal working can be dangerous if safe and proper operating procedures are not followed. As
with all machinery, there are certain hazards involved with the operation of the product. Using the
machine with respect and caution will considerably lessen the possibility of personal injury.
However, if normal safety precautions are overlooked or ignored, personal injury to the operator
may result.
Safety equipment such as guards, hold-downs, safety glasses, dust masks and hearing protection
can reduce your potential for injury. But even the best guard won’t make up for poor judgment,
carelessness or inattention. Always use common sense and exercise caution in the workshop.
If a procedure feels dangerous, don’t try it.
REMEMBER: Your personal safety is your responsibility.
Dear Valued Customer:
•All Baileigh Industrial machines should be used only for their intended use.
•Baileigh Industrial does not recommend or endorse making any modifications or alterations to
a Baileigh Industrial machine. Modifications or alterations to a machine may pose a substantial
risk of injury to the operator or others and may do substantial damage to the machine.
•Any modifications or alterations to a Baileigh Industrial machine will invalidate the machine's
warranty.
PLEASE ENJOY YOUR BAILEIGH INDUSTRIAL MACHINE!....PLEASE ENJOY IT SAFELY!
1. FOR YOUR OWN SAFETY, READ INSTRUCTION MANUAL BEFORE OPERATING THE
MACHINE. Learn the machine’s application and limitations as well as the specific hazards.
2. Only trained and qualified personnel can operate this machine.
3. Make sure guards are in place and in proper working order before operating machinery.
4. Remove any adjusting tools. Before operating the machine, make sure any adjusting tools
have been removed.
5. Keep work area clean. Cluttered areas invite injuries.
6. Overloading machine. By overloading the machine, you may cause injury from flying parts.
DO NOT exceed the specified machine capacities.
7. Do not force tool. Your machine will do a better and safer job if used as intended. DO NOT
use inappropriate attachments in an attempt to exceed the machines rated capacity.
WARNING:FAILURE TO FOLLOW THESE RULES MAY RESULT IN
SERIOUS PERSONAL INJURY

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8. Use the right tool for the job. DO NOT attempt to force a small tool or attachment to do the
work of a large industrial tool. DO NOT use a tool for a purpose for which it was not intended.
9. Dressing material edges. Always chamfer and deburr all sharp edges.
10.Dress appropriate. DO NOT wear loose fitting clothing or jewelry as they can be caught in
moving machine parts. Protective clothing and steel toe shoes are recommended when using
machinery. Wear a restrictive hair covering to contain long hair.
11.Use eye and ear protection. Always wear ISO approved impact safety goggles. Wear a full-
face shield if you are producing metal filings.
12.Do not overreach. Maintain proper footing and balance at all times. DO NOT reach over or
across a running machine.
13.Stay alert. Watch what you are doing and use common sense. DO NOT operate any tool or
machine when you are tired.
14.Check for damaged parts. Before using any tool or machine, carefully check any part that
appears damaged. Check for alignment and binding of moving parts that may affect proper
machine operation.
15.Observe work area conditions. DO NOT use machines or power tools in damp or wet
locations. Do not expose to rain. Keep work area well lighted. DO NOT use electrically
powered tools in the presence of flammable gases or liquids.
16.Keep children away. Children must never be allowed in the work area. DO NOT let them
handle machines, tools, or extension cords.
17.Store idle equipment. When not in use, tools must be stored in a dry location to inhibit rust.
Always lock up tools and keep them out of reach of children.
18.DO NOT operate machine if under the influence of alcohol or drugs. Read warning labels
on prescriptions. If there is any doubt, DO NOT operate the machine.
19.Sparks and hot material from cutting can easily go through small cracks and openings into
adjacent areas.
20.Do not cut where the atmosphere might contain flammable dust, gas, or liquid vapors such as
from gasoline.
21.Wear oil-free protective garments such as leather gloves, heavy shirt, high shoes or boots,
cuffless trousers, and a cap.
22.Watch for fire and keep a fire extinguisher close by.
23.Turn off power before checking, cleaning, or replacing any parts.
24.Be sure all equipment is properly installed and grounded according to national, state,and local
codes.
25.Inspect power and control cables periodically. Replace if damaged or bare wires are exposed.
Bare wiring can kill! DO NOT touch live electrical components or parts.

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26.Keep all cords dry, free from grease and oil, and protected from sparks and hot metal.
27.DO NOT bypass or defeat any safety interlock systems.
28.Learn the function and controls of the controller, the automatic height control, the torch power
supply, and the provided software packages. Know the location of the ON - OFF switch and
the “E”- STOP button.
29.Keep visitors a safe distance from the work area.
TECHNICAL INFORMATION AND SUPPORT
Read This Manual
Read and understand this instructional manual, the cutting machine manuals, and your
employer’s safety practices.
Note: This product is not designed to be field serviceable.
Work Condition
•Working Temperature, -10℃-60℃. Relative Humidity, 0-85%.
•Operation Voltage, DC 24V.
•The controller should be installed in a cab which can provide protection from powder.
•The controller would be better used in the situation without high voltage radiation.
Maintenance
•KEEP HANDS CLEAR of dangerous moving machinery. All control action, including manual
action, can be executed using the front panel keys or remote interface.
•Loose fitting clothing or ties may become entangled in the machinery. These items should not
be worn while operating the machine.
•This controller should only be operated by trained person.
•Do not open the controller unless obtaining the authorization.
•Do not let any acid or alkalescent substance corrode the controller.
High Voltages
•Electric shock can kill. Be sure this equipment is safely installed in accordance with enclosed
procedures and specifications.
•Avoid contact with electrical wires and cabling while power is on.
•Only trained person can operate this controller.

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Technical Support Contact
Our technical support department can be reached at 920.684.4990 and asking for the support
desk for purchased machines. Tech Support handles questions on machine setup, schematics,
warranty issues, and individual parts needs: (other than die sets and blades).
For specific application needs or future machine purchases contact the Sales Department at:
[email protected], Phone: [phone], or Fax: [phone].
Note: The photos and illustrations used in this manual are representative only and
may not depict the actual color, labeling or accessories and maybe intended to illustrate technique
only.
Note: The specifications and dimensions presented here are subject to change
without prior notice due to improvements of our products.
Cleaning
The controller is exposed to a lot of dust and grit as with a plasma table, keep it covered when
not being used. Use light to moderate pressure compressed air to blow the dust off the controller.
To clean the controller screen without damaging it, use a clean, soft microfiber cloth and gently
wipe the screen. Most of the dirt will come off this way. If there are still a few stubborn spots,
dampen the cloth slightly with plain water or a very weak solution of distilled vinegar and water.
Wring the cloth tightly, and gently wipe the screen again. This should take care of any remaining
spots. Gently dry the screen with another microfiber cloth.
The molded plastic frame and touch pad buttons can be wiped gently using a slightly dampened
cloth of plain water or a very weak solution of distilled vinegar and water. Be careful not to get any
liquid into the USB port or onto the rocker switch.
Avoid touching the screen. Pressing on the LCD screen can damage the screen with scratches
and possibly breaking the screen. Also, do not stick things to the screen like sticky notes, etc.,
this will block the view of the screen for the operator to monitor the operation.
WARNING: DO NOT USE gasoline or other petroleum products to clean
the machine. They have low flash points and can explode or cause fire.

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INTRODUCTION
The F2500T digital controller can control the motion of
two axes, which is apt to the application of plasma
cutting. The controller provides menu / illustration for
each operation which provides convenient operation.
The controller uses high speed DSP and ARM as its core
to assure the cutting process to be stable. The motion
control algorithm is optimized so that the machine will be
more stable and reliable, which in turn will increase the
life of the motor and other mechanical parts.
System Characteristics
•15 inches LCD with industrial VGA interface.
•Chinese/English file system and menu, and the menu
can be switched by a single key.
•Support the EIA code (G code) and various FastCAM,
FreeNest, SmartNest, IBE software.
•Compact keyboard design and easy to input files.
•Graphics have some operations such as Proportion, Rotate, and Mirror.
•Graphics can be arrayed in matrix, interaction, and stacked modes.
•Steel plate can be adjusted according to any steel edge.
•Coordinate system can be customized to support the two-dimensional coordinates of all eight
kinds.
•Self-diagnostic function, to diagnose the key status and all the IO status, facilitate inspection
and debug.
•Provide a front USB interface for copying files.
•Import and export files by single or all files.
•Display time, week, and clock.
•Parameter’s backup.
•Support THC.
•Plasma arc feedback, positioning feedback, automatically shut down the arc at the corner.
•Support edge cutting. It can save the preheat time for the thick steel plate.
•Movement speed can be real-time acceleration, and deceleration.

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•According to plate thickness, the cutting speed is automatically restricted by a speed limit in
the corner, effectively preventing over burn.
•Select row and column manually.
•Dynamic/static illustration of the process, graphics zoom in / out, dynamically tracking cut-off
point under zooming state.
•Starting speed and acceleration can be set by your convenience.
•Automatically memorize the working situation and the last cutting point when powered off.
•"Cutting offset" function can avoid wasting the steel plate when the nesting of the plate is
calculated wrong.
Technical Standard
•Control Axis: 2
•Control accuracy: +/-0.001mm
•Coordinate range: +/- 99999.999mm
•Maximum pulses: 200kHz
•Maximum speed: 15000 mm/m
•Maximum lines of code: 150000 lines
•Maximum size of single code file: 4MByte
•Time resolution: 10ms
•Working Voltage: DC 24V in put
•Working Temperature: -10℃- 60℃.
•Relative Humidity: 0 - 95%.
System Interface
•15 pins interface of 2 axis of the motor drive.
•25 pins interface of 16 channels optical couple output ports, max back flow current 300mA.
•25 pins interface of 16 channels optical couple input ports, max output current 300mA.
•USB interface on the front panel.
•Extend IO input/output ports, PWM input ports, and analog input ports.

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SYSTEM BOARD AND MAIN INTERFACE
Operating Board Introduction
[F1] –[F10]: Function key in different interfaces.
[S↑/PgUP]: Page-up key of code interface or Torch up in other interfaces.
[S↓/PgDn]: Page-down key of code interface or Torch down in other interfaces.
[F+/HOME]: Accelerate or skip to the head of the code line.
[F-/END]: Decelerate or skip to the tail of the code line.
[1] –[9]: During the cutting process, change the cutting speed to the ratio of the speed limit you
have set, for example press [1], change the cutting speed to 10% of the speed limit you have set,
press [2], change the cutting speed to 20% of the speed limit you have set.

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Power On Process and Main Interface
When powered on, the system will go for the process of self-scan.
In the starting process, there are 3 seconds to countdown, before the countdown is over, if
pressing [F2], it will enter the bios starting interface (please take the reference of the appendix 2
to run bios). If pressing any other key, it will jump over the countdown and directly enter the
welcome interface.
If pressing no key, it will countdown to 0 and then enter the welcome interface.
F1 = (System software update)
F2 = (Welcome picture update)
F3 = (Motion update)
F4 = (System backup)
F5 = (System recovery)
F6 = (Start system)
In the welcome interface, press any key to enter the main interface automatically.

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In the main interface, press [F1] –[F8] for the following functions:
[F1]: ShapeLib: Pressing F1 to enter the Shape Library including 45 common shapes, and most
of them have plate size and hole size.
[F2]: Files: You can load local files, U disk files or edit, import, export and delete codes.
[F3]: PartOption: Accesses actions of mirroring, rotation, plate adjusting, plate arraying, selecting
row and hole or code edition etc.
[F4]: Setups: setting all parameters.
[F5]: Diagnose: including input ports diagnosis, output ports diagnosis, keyboard diagnosis,
system self-check, date setting, and system self-defines.
[F6]: ZoomIn: Zoom in the shape in full screen.
[F7]: ManualMove: Manually move the machine.
[F6]: Zero: Clear the coordinate of X and Y before starting cut or after cutting over.
[X]: CutSpeed: Setting the cutting speed.
[Y]: ManualSpeed: Setting the manual moving speed.
[Z]: Kerf: Setting the kerf’s compensate value.
[F]: Manual: Setting the mode of manual movement including keepMov (keep movement),
StepMov (step movement), ContiMov (continue movement). The selected mode is a black
background.
[G]: StepDis: Setting the distance of the fixed length.
[M]: Selecting the cutting mode including Flame Cu (flame cutting), Plasma C (plasma cutting),
and Demo run.

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Function index of main interface

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CUTTING FUNCTION
In the main interface, press the [SPACE] to enter the cutting interface, shown as follows:
Show the current workpiece’s cutting path, including the slotted value. Show the G-code being
processed, shows the current and next line.
Show the current cutting speed, during processing, you can press the keyboard's number keys
[1] –[9] to achieve quick speed regulation. For example, press the number [3], the speed is
automatically adjusted to 30%; press the number [8], the speed is automatically adjusted to 80%
of the preset speed.
X shows the absolute coordinate of the torch in X direction. Y shows the absolute coordinate of
the torch in Y direction. In the cutting interface:
•Press [X]: Modify the current maximum cutting speed.
•Press [Y]:Manually adjusts the current program speed up to the machine's maximum set value.
•Press [F]: Change the current manual move method.

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•Press [G]: Modify the current fixed-length fixed long-distance move.
•[START ([F9]): Start cutting.
•[STOP ([F10]): Parking, the system can suspend all on-going actions.
Cutting Operation Index
•[F1]: The torch moves back along the cutting path.
•[F2]: The torch moves forward along the cutting path.
•[F3]: Return to the starting point of cutting torch, i.e., the starting point
of the current workpiece.
•[F4]: Decrease the cutting speed, each press will decrease the speed
by 1%.
•[F5]: Increase the cutting speed, each press will increase the speed by
1%.
•[F6]: Reduce the preheat time, skip the remaining preheat time, and the
system automatically records preheat time.
•[F7]: Increase the preheat time once every 15 seconds.
•[F8]: When the system is suspended, for selecting perforation point;
when the system begins to move, for the dynamic amplification.
•Four direction keys (Up, down, left and right): Use to manually move the
torch.
Speed Control and Adjustment
Normal Speed Adjustment
In automatic operation, or when the system is suspended, in the cutting
interface the system can regulate speed.
On the operation screen, press and release the [F5] or [PRE], will increase
the speed at a rate of 1% per click. Press and hold the [F5] or [PRE], the
speed rate will continuously increase to 100%. The 100% speed rate will
be equal to the cutting speed set within the “Setup” parameter.
On the operation screen, press and release the [F4] or [NEXT], will
decrease the speed at a rate of 1% per click. Press and hold the [F4] or [NEXT], the speed rate
will continuously decrease to 1%.
Quick Speed Adjustment
In automatic operation, or when the system is suspended, in the cutting interface the system can
carry out quick speed regulation.

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In the cutting interface, on the operation panel, press the number keys [1] –[9], the speed will
quickly adjust to the corresponding percentage of the key pressed times 10. For example, press
[3], adjust to 30% of the speed limit you have set, press [8], adjust to 80% of the speed limit you
have set.
Forward
In the automatic function screen, press key [F2], the machine starts to move without real cutting.
The process does not include any ignition, perforation and any other I/O working. The machine
just moves the torch according to the graphic figure.
The function can be used to check the trail and code before you start the real cutting process.
Press the [F10] “STOP” key to stop the trial process if you want.
Backward
During the running process, if you want to go backward according to the origin trail to (maybe the
material was not cut through), you can follow the following direction:
•First, press [F10] “STOP” key to set the machine at pause status.
•In the automatic function screen, press [F3] key (Back) to make the machine go backward
along the original path.
•When the torch reaches the position you need, press [F10] “Stop” key to stop it. You may
press the [F2] key to go forward if the machine went backwards too much.
Note: The backward or forward function may be used repeatedly to make the
machine reach an ideal position.
•When the torch reaches the position you need, press [F9] “START” key again, if the current
cutting code is G01, G02 or G03, system will automatically perforate before performing these
procedures, and then continue the current program, if the current row is not G01, G02 or G03,
the system will directly continue the current line program.