ESAB Silhouette 1000 User manual

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

The equipment described in this manual is
potentially hazardous. Use caution when installing,
operating and maintaining this equipment.
The purchaser is solely responsible for the safe
operation and use of all products purchased,
including compliance with OSHA and other
government standards. ESAB Cutting Systems
has no liability for personal injury or other
damage arising out of the use of any product
manufactured or sold by ESAB. See standard
ESAB terms and conditions of sale for a specic
statement of ESAB’s responsibilities and
limitations on its liability.
ESAB Cutting Systems is not responsible for
any errors that may appear in this document.
Information in this document is subject to change
without notice.
This manual is ESAB Part No. 0558006575
This manual is for the convenience and use of the
cutting machine purchaser. It is not a contract
or other obligation on the part of ESAB Cutting
Systems.
* ESAB Cutting Systems, 2006
Printed In U.S.A.

Preface
This machine is a cantilevered gantry cutting
machine manufactured by ESAB Cutting Systems of
Florence, South Carolina. It may be equipped with
either oxy-fuel or plasma cutting equipment. It is
designed to provide years of dependable, accurate,
repeatable part cutting, with a high degree of
reliability, ease of service and operation.
There are optional features and congurations
available. However, not all options described in this
manual are present on all machines. In addition,
more capabilities and features may be added in the
future, which are not covered in this manual. ESAB
Cutting Systems reserves the right to change or add
features and capabilities without notice. Before
operating the machine, one should become familiar
with this manual in its entirety, with special attention
to the SAFETY section.
Revision History
12/01/06: Original: Replaces manual number 51227
with part revisions, additional information and new
illustrations.

Table of Contents TOC
Silhouette 1000 Contents
Safety
Introduction............................................................................................................................................................. 1
General Cutting Machine Safety....................................................................................................................... 2
Electrical Grounding ............................................................................................................................................. 4
Operating A Cutting Machine ........................................................................................................................... 5
Working with Plasma Cutting Equipment..................................................................................................... 8
Working with Oxy-Fuel Gas Cutting Equipment......................................................................................... 14
Working with Gas Control and Supply Systems.......................................................................................... 16
Service Precautions.............................................................................................................................................. 19
Welding On and Around Machine ................................................................................................................... 20
Introduction....................................................................................................................................................... 21
Safety References................................................................................................................................................... 21
Domestic............................................................................................................................................................. 22
International ...................................................................................................................................................... 23
Specications
Outline Dimensions............................................................................................................................................... 29
Performance ............................................................................................................................................................ 30
Requirements.......................................................................................................................................................... 30
Capacities.................................................................................................................................................................. 31
Installation
Receipt of Components....................................................................................................................................... 34
Site Preparation ...................................................................................................................................................... 35
Location of the Machine...................................................................................................................................... 36
Foundation............................................................................................................................................................... 37
Utility Requirements............................................................................................................................................. 38
Electric Power.................................................................................................................................................... 38
Grounding.......................................................................................................................................................... 38
Gas Supplies ...................................................................................................................................................... 39
Installation of Components................................................................................................................................ 43
Installation of pedestals and rails............................................................................................................... 43
Forklift Technique............................................................................................................................................ 47
Mounting Main Beam on Rails........................................................................................................................... 48
Strongback Technique................................................................................................................................... 49
Torch Station Mounting ...................................................................................................................................... 59
Table of Contents

TOC Table of Contents
Torch Squaring........................................................................................................................................................ 60
Tracer Mount and Leveling................................................................................................................................. 61
Interconnection of components....................................................................................................................... 63
Water Spray Installation....................................................................................................................................... 65
Automatic Ignitor .................................................................................................................................................. 67
Introduction....................................................................................................................................................... 67
Ignitor installation ........................................................................................................................................... 67
Ignitor Wiring Schematic .............................................................................................................................. 69
Ignitor Setup...................................................................................................................................................... 70
Setup Procedure............................................................................................................................................... 71
Preparation for Initial Power-up........................................................................................................................ 72
Purging Lines..................................................................................................................................................... 72
Mechanical Check............................................................................................................................................ 73
Operation
Introduction............................................................................................................................................................. 75
HL-90 Tracer ............................................................................................................................................................. 76
Template Preparation........................................................................................................................................... 78
Introduction....................................................................................................................................................... 78
Template Guidelines....................................................................................................................................... 79
Drawing Materials............................................................................................................................................ 80
Machine Operation................................................................................................................................................ 81
Introduction....................................................................................................................................................... 81
Straight Line Cutting (without template) ................................................................................................ 81
Tracer Controlled Cutting (with template).............................................................................................. 82
Lost Cut Procedure.......................................................................................................................................... 83
Kerf Compensation................................................................................................................................................ 84
Notes on Pattern and Kerf Requirements...................................................................................................... 89
Torch Carriage Positioning.................................................................................................................................. 90
Table of Contents

Table of Contents TOC
Silhouette 1000 Maintenance
General Information.............................................................................................................................................. 91
Daily Inspection and Maintenance. ................................................................................................................. 92
Periodic Inspection and Maintenance............................................................................................................ 94
Lubrication ............................................................................................................................................................... 95
Rail System................................................................................................................................................................ 96
Tracing Table............................................................................................................................................................ 97
Gas Supply System................................................................................................................................................. 102
Solenoid Disassembly Procedure............................................................................................................... 104
Electrical System..................................................................................................................................................... 105
Motorized Lift ......................................................................................................................................................... 106
Description......................................................................................................................................................... 106
Motorized Lift Maintenance............................................................................................................................... 107
Parts Section
Introduction
General Information.............................................................................................................................................. 109
Ordering Information ........................................................................................................................................... 110
Silhouette 1000, Basic Machine, 4 and 6FT.
0560938838 Rev OR............................................................................................................................................... 111
Main Beam
2235502 Rev1........................................................................................................................................................... 114
Rail System Assembly
0560938839 Rev 1.................................................................................................................................................. 116
Rail System Master Rail
0560938843 Rev 1.................................................................................................................................................. 117
Rail System Floater Rail
0560938840 Rev 1.................................................................................................................................................. 119
Master Carriage
0560938837 Rev 1.................................................................................................................................................. 120
Bearing Block Assembly
51216 Rev OR............................................................................................................................................................ 121
Station Control Assembly
2235503 Rev 1.......................................................................................................................................................... 122
Table of Contents

TOC Table of Contents
Motorized Lift
2237347 Rev 3.......................................................................................................................................................... 123
Manifold Support Assembly
40201829 Rev 1 ....................................................................................................................................................... 125
Torch Bar Assembly
40901329 Rev 1 ....................................................................................................................................................... 126
Drive Motor Assembly-Rail
41001289 Rev 1........................................................................................................................................................ 128
Manual Torch Station
41001689 Rev 1........................................................................................................................................................ 130
Torch Holder
52675 Rev 1............................................................................................................................................................... 132
Tracing Table Assembly
4113001 Rev 1 .......................................................................................................................................................... 133
Budget Ignitor Assembly
57000323 Rev A....................................................................................................................................................... 134
Torch Ignitor Module
69972 Rev OR........................................................................................................................................................... 135
Torch Ignitor Control Module
69973 Rev 1 .............................................................................................................................................................. 136
Ignition Control Box
66407 Rev B.............................................................................................................................................................. 137
Ignitor J-Box and Wiring Diagram
66412 Rev OR........................................................................................................................................................... 138
Motorized Station Control Box
66421 Rev OR........................................................................................................................................................... 140
Oxygen Pierce Rate Control Assembly
0560939141 Rev 2................................................................................................................................................... 6-142
Oxygen Pierce Rate Control Box
0560940441 Rev 1.................................................................................................................................................. 6-144
Table of Contents

Safety Section
SAFETY
DANGER
WARNING
CAUTION
CAUTION
NOTICE
Safety SECTION 1
1
The process of cutting metals with oxy-fuel or
plasma equipment provides industry with a
valuable and versatile tool. ESAB cutting machines
are designed to provide both operation safety
and eciency. However, as with any machine
tool, sensible attention to operating procedures,
precautions, and safe practices is necessary to
achieve a full measure of usefulness. Whether
an individual is involved with operation,
servicing, or as an observer, compliance with
established precautions and safe practices must
be accomplished. Failure to observe certain
precautions could result in serious personnel
injury or severe equipment damage. The following
precautions are general guidelines applicable when
working with cutting machines. More explicit
precautions pertaining to the basic machine and
accessories are found in the instruction literature.
For a wide scope of safety information on the eld of
cutting and welding apparatus, obtain and read the
publications listed in the Recommended References.
The following words and symbols are used
throughout this manual. They indicate dierent
levels of required safety involvement.
Used to call attention to immediate
hazards which if not avoided, will result in
serious personal injury or death.
Introduction
Used to call attention to potential hazards
that could result in personal injury or loss
of life.
Used to call attention to hazards that
could result in minor personal injury or
equipment damage.
Used to call attention to minor hazards to
equipment.
Used to call attention to important
installation, operation or maintenance
information not directly related to safety
hazards.
Safety

Safety Section
SAFETY
WARNING
SECTION 1 Safety
2
Machine Starts Automatically.
This equipment moves in various
directions and speeds. Moving machinery
can crush.
Only qualied personnel should
operate or service equipment.
Keep all personnel, materials, and
equipment not involved in production
process clear of entire system area.
Keep gear racks and rails clear of
debris or obstructions, such as tools or
clothing.
Fence o entire work cell to prevent
personnel from passing through area
or standing in the working envelope of
the equipment.
Post appropriate WARNING signs
at every work cell entrance. Follow
lockout procedure before servicing.
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General Cutting Machine Safety

Safety Section
SAFETY
Safety SECTION 1
3
WARNING
WARNING
Read and Understand This
Operator’s Manual Before using
machine.
Failure to follow operating instructions
could result in death or serious injury.
Read entire procedure before
operating or performing any system
maintenance.
Special attention must be given to all
hazard warnings that provide essential
information regarding personnel
safety and/or possible equipment
damage.
All safety precautions relevant to
electrical equipment and process
operations must be strictly observed
by all having system responsibility or
access.
Read all safety publications made
available by your company.
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Read and Understand All Safety
Warning Labels On Machine.
Failure to follow safety warning label
instructions could result in death or
serious injury.
Refer to operator’s manual for additional
safety information.

Safety Section
SAFETY
Electrical Grounding
CAUTION
SECTION 1 Safety
4
Electrical grounding is imperative for proper
machine operation and SAFETY. Refer to this
manual’s Installation section for detailed grounding
instructions.
Electric Shock Hazard.
Improper grounding can cause severe
injury or death.
Machine must be properly grounded
before put into service.
Improper Grounding Can Damage
Machine and Electrical Components.
Machine must be properly grounded
before put into service.
Cutting table must be properly grounded
to a good Earth ground rod.
WARNING

Safety Section
SAFETY
WARNING
WARNING
WARNING
Safety SECTION 1
5
Flying Debris and Loud Noise
Hazards.
Hot spatter can burn and injure eyes.
Loud noise can injure ears.
Wear goggles to protect eyes from
burns and ying debris generated
during operation.
Wear ear protection as required for
cutting various materials.
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Burn Hazard.
Hot metal can burn.
Do not touch metal plate or parts
immediately after cutting. Allow metal
time to cool, or douse with water.
Do not touch plasma torch
immediately after cutting. Allow torch
time to cool.
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Crush Hazard.
Moving machine can crush.
Machine moves automatically.
Stay clear of rails and cutting table
during operation.
Follow lockout procedure before
servicing.
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Operating A Cutting Machine

Safety Section
SAFETY
WARNING
WARNING
SECTION 1 Safety
6
Crush Hazard.
Moving parts can cut and crush.
Keep hands clear of drive gears.
Do not operate with any protective
covers removed.
Follow lockout procedure before
servicing.
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Hazardous Voltages.
Electric shock can kill.
Do not operate with any protective
covers removed or electrical
component boxes open.
Follow lockout procedures before
servicing.
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Safety Section
SAFETY
WARNING
WARNING
Safety SECTION 1
7
Pinch Hazard.
Moving vertical slides can crush or
pinch.
Keep hands clear of torch and slide
during operation.
Pinch Hazard.
Moving carriages can crush or pinch.
Keep hands clear of carriages during
operation.
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Safety Section
SAFETY
WARNING
SECTION 1 Safety
8
Hazardous Voltages.
Electric Shock Can Kill.
Do NOT touch plasma torch, cutting
table or cable connections during
plasma cutting process.
Always turn power o to plasma power
supplies before touching or servicing
plasma torch.
Always turn power o to plasma power
supplies before opening or servicing
plasma plumbing or ow control box.
Do not touch live electrical parts.
Keep all panels and covers in place
when machine is connected to power
source.
Insulate yourself from workpiece and
electrical ground: wear insulating
gloves, shoes and clothing.
Keep gloves, shoes, clothing, work
area, and equipment dry.
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Working with Plasma Cutting
Equipment

Safety Section
SAFETY
Safety SECTION 1
9
Toxic Fume Hazard.
The cutting process can produce
poisonous fumes and toxic gases.
Certain chlorinated solvents decompose
and form phosgene gas when exposed to
ultraviolet radiation.
Do not cut metal or painted metals
containing zinc, lead, cadmium or
beryllium unless fume removal equipment
is installed and operating properly.
Keep cutting area well ventilated.
Wear proper breathing mask when
cutting galvanized metal and use
proper ventilation and fume removal
methods.
Insure chlorinated solvents are not in
cutting area.
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WARNING

Safety Section
SAFETY
WARNING
SECTION 1 Safety
10
Radiation Hazard.
Arc rays can injure eyes and burn skin.
Wear correct eye and body protection.
Wear dark safety glasses or goggles
with side shields. Refer to following
chart for recommended lens shades
for plasma cutting:
Arc Current Lens Shade
Up to 100 Amps Shade No. 8
100-200 Amps Shade No. 10
200-400 Amps Shade No. 12
Over 400 Amps Shade No. 143.
Replace glasses/goggles when lenses
are pitted or broken.
Warn others in area not to look directly
at the arc unless wearing appropriate
safety glasses.
Prepare cutting area to reduce
reection and transmission of
ultraviolet light.
Paint walls and other surfaces with
dark colors to reduce reections.
Install protective screens or curtains to
reduce ultraviolet transmission.
Noise hazard.
Noise from plasma arc can damage
hearing.
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WARNING

Safety Section
SAFETY
WARNING
CAUTION
Safety SECTION 1
11
Fume Hazard.
Fumes and gases generated by the plasma
cutting process can be hazardous to your
health.
Do NOT breathe fumes.
Do not operate plasma torch without
fume removal system operating
properly.
Use additional ventilation to remove
fumes if necessary.
Use approved respirator if ventilation
is not adequate.
Spark Hazard.
Heat, spatter, and sparks cause re and
burns.
Do not cut near combustible material.
Do not cut containers that have held
combustibles.
Do not have on your person any
combustibles (e.g. butane lighter).
Pilot arc can cause burns. Keep torch
nozzle away from yourself and others
when activating plasma process.
Wear correct eye and body protection.
Wear gauntlet gloves, safety shoes and
hat.
Wear ame-retardant clothing that
covers all exposed areas.
Wear cuess trousers to prevent entry
of sparks and slag.
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Safety Section
SAFETY
SECTION 1 Safety
12
Hydrogen Explosion Hazard.
Hydrogen explosions can cause personal
injury or death.
Hydrogen can create explosive gas
pockets in the water table. These pockets
will explode when ignited by sparks or the
plasma arc.
Before cutting, be aware of possible
hydrogen sources in the water table
– molten metal reaction, slow chemical
reaction and some plasma gases.
Explosive gas pockets accumulate
underneath the cutting plate and
inside the water table.
Clean slag (especially ne particles)
from bottom of table frequently. Rell
table with clean water.
Do not leave plate on table overnight.
If water table has not been used for
several hours, vibrate or jolt it to break
up hydrogen pockets before laying
plate on the table.
If possible, change water level between
cuts to break up hydrogen pockets.
Maintain water pH level near 7
(neutral).
Programmed part spacing should be
a minimum of twice the kerf width to
ensure material is always under the
kerf.
If cutting underwater, aerate water
under plate with compressed air to
prevent hydrogen pockets.
If cutting above water, use fans to
circulate air between plate and water
surface.
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WARNING