Piranha B Series Guide

B-Series & C-Series Plasma Cutting System
Safety, Operation, and Maintenance Manual
With Microstep Gen 2
Original Instruction: English Version 2.7.1

Piranha Plasma Table 2
Revision and Validity
Revised 11/9/2020
Starfire Software version 3.1-2.8.4-FAT and newer
Valid for Machines with Microstep Generation 2 as seen below
Copyright
This manual, including addendums, supplements, and other additions, is protected by
copyright. All rights reserved. No part of this publication can be reproduced, transmitted,
translated, or transferred, without the written consent of Piranha, subsidiary of
MegaFab.
© MegaFab 2019

INTRODUCTION 3
Table of Contents
Table of Contents....................................................................................................................... 3
Chapter 1: INTRODUCTION...................................................................................................... 7
1.1. About Piranha.................................................................................................................. 7
1.2. Contact Information ......................................................................................................... 7
Chapter 2: SAFETY ................................................................................................................... 8
2.1. Introduction...................................................................................................................... 8
2.2. Safety Symbols Used in the Manual................................................................................ 8
2.3. All Users.......................................................................................................................... 9
2.3.1. Supervisors............................................................................................................... 9
2.3.2. Maintenance Personnel............................................................................................10
2.3.3. Operator...................................................................................................................11
2.4. Personal Protection........................................................................................................12
2.4.1. Eye Protection..........................................................................................................12
2.4.2. Noise........................................................................................................................13
2.5. Safety Devices................................................................................................................14
2.6. Risk of Electric Shock.....................................................................................................15
2.6.1. Input Connections....................................................................................................15
2.6.2. Grounding................................................................................................................16
2.7. Fumes and Air Contamination ........................................................................................17
2.7.1. Toxic Fumes ............................................................................................................17
2.7.2. Air Contamination.....................................................................................................17
2.7.3. Metal Fumes............................................................................................................18
2.7.4. Metal Dust................................................................................................................18
2.7.5. Internal Ventilation System.......................................................................................19
2.8. Fire, Explosion, and Burn Prevention..............................................................................20
2.8.1. Hot Surfaces............................................................................................................20
2.8.2. Heat.........................................................................................................................21
2.8.3. Sparks......................................................................................................................21
2.8.4. Burn Prevention .......................................................................................................22
2.8.5. Cutting Aluminum on a Water Table.........................................................................22
2.9. Light and Radiant Energy...............................................................................................23
2.10. Compressed Gas Equipment........................................................................................24
2.10.1. Cylinders................................................................................................................24

Piranha Plasma Table 4
2.10.2. Pressure Regulators...............................................................................................24
2.10.3. Hoses.....................................................................................................................25
2.11. Additional Safety Information........................................................................................26
Chapter 3: SPECIFICATIONS...................................................................................................28
3.1. Machine View.................................................................................................................29
Chapter 4: INSTALLATION.......................................................................................................31
4.1. Introduction and Checklist ..............................................................................................31
4.2. Prior To Receiving..........................................................................................................33
4.2.1. Floor Condition.........................................................................................................33
4.2.2. Space/Location/Weights...........................................................................................33
4.3. Electrical Services..........................................................................................................35
4.3.1. CNC Control.............................................................................................................35
4.3.2. Plasma System........................................................................................................35
4.3.3. Earth Ground ...........................................................................................................35
4.4. Compressed Air & Gas...................................................................................................36
4.4.1. Air Connection Requirements...................................................................................36
4.4.2. Gas Supply Requirements .......................................................................................36
4.4.3. Option A: Air Dryer Unit............................................................................................36
4.4.4. Option B: Three-Stage Filter System........................................................................36
4.5. Fumes & Smoke Extraction Plan....................................................................................37
4.5.1. Exhaust Fan.............................................................................................................37
4.5.2. Water Table .............................................................................................................37
4.6. Required Equipment/Tools .............................................................................................38
4.7. After Receiving...............................................................................................................40
4.8. Unloading.......................................................................................................................40
4.8.1. Lifting with Crane (Recommended)..........................................................................41
4.8.2. Lifting with a Forklift .................................................................................................43
4.9. Unpacking ......................................................................................................................46
4.10. Installing Covers (5’ X 10’ Only)....................................................................................47
4.11. Leveling........................................................................................................................48
4.12. Machine and CNC Connections....................................................................................50
4.12.1. Air to Machine........................................................................................................50
4.12.2. Electrical Connection CNC Control.........................................................................50
4.13. Plasma Power Supply Connections..............................................................................53
4.13.1. For Hypertherm Powermax plasma system furnished by Piranha:..........................53

INTRODUCTION 5
4.13.2. For Hypertherm Powermax power supply not purchased from Piranha..................55
4.14. First Time Power On.....................................................................................................59
Chapter 5: OPERATIONS.........................................................................................................60
5.1. Operator’s Panel.............................................................................................................60
5.2. CNC Control Navigation .................................................................................................61
5.3. Using the Torch Height Control.......................................................................................63
5.4. Operating Start Guide.....................................................................................................64
5.4.1. Powering the Machine On and Sending to Machine Home.......................................66
5.4.2. Prepare the Plasma Power Supply and Torch..........................................................69
5.4.3. Setting the Torch Height Controller ..........................................................................71
5.4.4. Setting Pierce Delay Time........................................................................................73
5.4.5. Adjusting Speeds.....................................................................................................74
5.4.6. Methods of Loading Programs .................................................................................76
5.4.7. Editing and Saving Files...........................................................................................82
5.4.8. Verify Program with View.........................................................................................84
5.4.9. Set Program Zero.....................................................................................................86
5.4.10. Verify Program Size on Material with Outline .........................................................87
5.4.11. Setting Kerf Offset (Optional) .................................................................................88
5.4.12. Automatic Operation...............................................................................................89
5.4.13. Stopping the Machine.............................................................................................90
5.5. Active Functions.............................................................................................................91
5.6. Restarting a Cut..............................................................................................................92
5.6.1. Background Information on Restarting.....................................................................92
5.6.2. Cycle Stop................................................................................................................93
5.6.3. Using Section to Restart...........................................................................................94
5.6.4. Break Point Resume ................................................................................................96
5.7. Trim Cuts........................................................................................................................98
5.8. Finding Correct Arc Voltage when Cutting Copper........................................................100
5.9. Test Mode (Dry Run)....................................................................................................102
5.10. Other Functions..........................................................................................................103
5.10.1. Rotate ..................................................................................................................103
5.11. Nesting.......................................................................................................................104
5.12. Database....................................................................................................................107
Chapter 6: PROGRAMMING...................................................................................................108
6.1. Programming Codes.....................................................................................................110

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6.1.1. G Codes.................................................................................................................110
6.1.2. M Codes ................................................................................................................111
Chapter 7: MAINTENANCE ....................................................................................................112
7.1. Error Code List .............................................................................................................113
7.2. Machine Setup Parameters ..........................................................................................116
7.3. Initial Settings –Microstep Torch Height Control ..........................................................118
7.4. Inputs and Outputs.......................................................................................................119
7.5. Procedure - Setting Machine Zero................................................................................120
7.6. Updating Control Software Procedure ..........................................................................123
7.7. Squaring the Machine Procedure..................................................................................124
7.7.1. Determine How Much Out of Square the Machine is:.............................................124
7.7.2. Adjust the Squareness...........................................................................................124
7.8. Troubleshooting Guide .................................................................................................129
Chapter 8: PARTS MANUAL...................................................................................................132
8.1. Automatic Height Control Assembly..............................................................................132
8.2. Y-Axis Drive Assembly .................................................................................................134
8.3. Air and Water Inlet........................................................................................................135
8.4. X-Axis Drive Assembly .................................................................................................136
8.5. Electrical Cabinet..........................................................................................................137
8.6. Electrical Cabinet..........................................................................................................138
8.7. Miscellaneous Parts .....................................................................................................139
Chapter 9: ELECTRICAL DIAGRAM.......................................................................................141
9.1. Machines without Pipe Cutter.......................................................................................141
9.2. Machines with Pipe Cutter............................................................................................142
Chapter 10: PIPE CUTTING ATTACHMENT (Optional)..........................................................143
10.1. Components:..............................................................................................................144
10.2. After Receiving...........................................................................................................146
10.3. Unloading...................................................................................................................146
10.3.1. Lifting with Crane (Recommended)......................................................................147
10.4. Operation and Programming.......................................................................................153
10.4.1. Switching from Plate-Cutting to Pipe-Cutting........................................................153
10.4.2. Programming the Pipe Cutter...............................................................................156
10.4.3. Switching from Pipe-Cutting to Plate-Cutting........................................................157
Chapter 11: APPENDIX A - REVISIONS TO THE MANUAL...................................................160

INTRODUCTION 7
Chapter 1: INTRODUCTION
1.1. About Piranha
Piranha is a subsidiary of MegaFab, based in Rockford Illinois. MegaFab is a
manufacturer of metal fabrication machinery, including laser cutting machines, plasma
cutting machines, ironworkers, press brakes, bending rolls, combination punching and
cutting machines, and structural steel punching equipment. Equipment is sold under the
Piranha, Whitney, and Bertsch brands.
1.2. Contact Information
Congratulations on the purchase of a genuine Piranha Plasma Machine. If there are
questions regarding the machine, or if you need help, please use the following:
For technical support:
Via Phone: [phone]
Via Email: [email protected]
For ordering parts and consumables:
Via Phone: [phone]
Via Email: [email protected]
Please have the serial number or model ready when calling.
Piranha
650 Race St. • P.O. Box 1206
Rockford IL 61105, USA
www.piranhafab.com

Piranha Plasma Table 8
Chapter 2: SAFETY
2.1. Introduction
Read this chapter on safety and the sections of vendor components manuals on safety
before beginning to operate the Piranha Plasma Cutting Table.
Do not become complacent about safety or completely dependent on safety devices.
2.2. Safety Symbols Used in the Manual
This document uses the following symbols to highlight areas of importance.
Note:
Indicates information easily overlooked, or of special
importance.
Caution
Indicates a hazardous situation with low risk that could
result in minor injury and/or damage to machine.
Danger
Indicates a hazardous situation with high risk that could
result in injury or death.
Please do not underestimate the importance of other text not designated by any symbols.
Warning
Indicates a hazardous situation with medium risk that
could result in moderate injury.

SAFETY 9
2.3. All Users
Read this manual thoroughly before operating the machine.
Read the Torch Height Control Manual before operating the machine.
Read the CNC Control Operator Manual before operating the machine.
2.3.1. Supervisors
It is very important that a safe and appropriate working environment is provided for this
Piranha equipment and in compliance with applicable federal and local industry
standards.
It is imperative that programmers, machine operators and maintenance personnel be
trained adequately in the use and care of the equipment. These employees should
receive the proper instruction in order to have a complete understanding of the operation
of this machine before beginning to program, operate or service it.
Careful programming and debugging of new programs is essential for successful
operation of this machine. Use program Stop Codes to stop machine motion for operator
removal of parts or scrap.
Never allow operators to place any part of their body into the machine while the machine
is active. Ensure that all personnel understand the function and use of EMERGENCY
STOP and CYCLE STOP button.

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2.3.2. Maintenance Personnel
Only qualified personnel should make repairs on this equipment. Use caution and follow
Piranha procedures when working on the machine. Be sure to observe the following
guidelines:
1. Before performing maintenance or repair, turn the power OFF and follow lock
out/tag out (zero energy shutdown) procedures. Also, follow any lock out/tag out
procedures applicable to your specific plant requirements.
2. Wear safety glasses and other personal protective equipment as required by
applicable federal, local industry, and plant safety program standards.
3. Wear proper clothing. Do not wear watches, rings, jewelry, or loose-fitting
clothes.
4. Read and review the manual carefully.
5. Be familiar with the operation of the machine.
6. Practice preventative maintenance. Inspect the equipment regularly and repair or
replace worn components and tooling. Read the vendor components manuals for
any additional preventative maintenance.
7. Always replace safety guards and other safety devices removed for service and
make sure that they are fully functional before operating the equipment.
8. Never remove, jumper out or bypass a safety device to permit machine
production.
9. Never place yourself in a hazardous situation to observe a problem and ask
someone else to operate the machine. This could be a very dangerous and life-
threatening situation.