Piranha CNC Plasma Cutting Table User manual

CNC Plasma Cutting System
Operating Manual
Revised September 14, 2018
www.piranhafab.com
800-338-5471

TABLE OF CONTENTS
Sept-2018
3
TABLE OF CONTENTS
SAFETY ....................................................................................................................................... 5
SPECIFICATIONS....................................................................................................................... 23
INSTALLATION.......................................................................................................................... 25
OPERATIONS ............................................................................................................................ 47
PROGRAMMING....................................................................................................................... 85
MAINTENANCE ........................................................................................................................ 89
PARTS MANUAL ..................................................................................................................... 105
PIPE CUTTING ATTACHMENT (OPTIONAL EQUIPMENT) ......................................................... 115
WATER MIST CHILLER (OPTIONAL EQUIPMENT) .................................................................... 137
APPENDIX A –FASTCAM SETUP ............................................................................................. 141
APPENDIX B –PARAMETRIC SHAPE LIBRARIES ....................................................................... 165
APPENDIX C - REVISIONS TO THE MANUAL ............................................................................ 175

TABLE OF CONTENTS
Sept-2018
4

SAFETY
Sept-2018
5
SAFETY
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.
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. Insure that all personnel understand the function and use of
EMERGENCY STOP and CYCLE STOP button.

SAFETY
Sept-2018
6
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.

SAFETY
Sept-2018
7
OPERATOR
This equipment has been designed with operator safety in mind (when used under
normal operating conditions). The user must always be alert to the possibility of
dangerous situations. Always exercise care and caution. Report any minor
problems immediately, so that they can be corrected before becoming major
difficulties. Only qualified personnel should make repairs on the machine.
1. Be familiar with the machine. Read and review the Piranha and vendor
component manuals carefully.
2. Be alert in regard to the significance of the various warning indicators and be
conscious of the functions of pushbuttons and other controls. Use the controls
properly. Review and understand the operation of the EMERGENCY STOP
function and the CYCLE STOP function.
3. Never operate the equipment unless it is in good working order.
4. Wear safety glasses and other personal protective equipment as required by
applicable federal, local industry and plant safety program standards.
5. Wear proper clothing. Do not wear watches, rings, jewelry or loose-fitting
clothes.
6. Avoid all moving parts of the machine or workpiece when setting up or operating
the equipment. Never reach into the machine while it is active. Use the
EMERGENCY STOP or CYCLE STOP function to stop machine motion. Never
use the machine DWELL time code for parts removal or other operator
intervention activities that puts the operator in a hazardous position.
7. Recognize and avoid unsafe operating conditions.
8. Maintain a clean work area. Avoid accidents by keeping work areas clean and
neat.
9. Never leave the machine in an unsafe condition.
10. Never leave a machine running unattended.
11. Never remove or bypass safety devices.
12. Report any unsafe conditions, personal injury or machine problems immediately
to your appropriate supervisor(s) and safety manager(s). In case of personal
injury notify Piranha Service Department giving a brief description and date
reported injury occurred.
13. Never operate the machine with someone within a hazardous area.

SAFETY
Sept-2018
8
RISK OF ELECTRIC SHOCK
Plasma cutting equipment uses high open circuit voltages to initiate the plasma arc.
Normal load voltages are higher than experienced with other types of welding
equipment. Extreme CAUTION must be exercised when operating or servicing this
equipment.
PERSONAL PROTECTION
•Keep the operator’s body and clothing dry.
•Do not stand, sit, or lie in/on any wet surfaces when using this equipment.
•Never work in a damp or wet area without proper insulation against electric
shock.
•Disconnect main power before servicing the torch, power supply or service
connections to the plasma arc system, or any part of the machine bed.
•Wear adequate personal equipment (overalls, gloves, safety boots etc.) when
operating the machine.
•Remove or secure articles of clothing, such as ties and loose sleeves, which may
catch or be drawn into moving machinery.
DANGER
Always verify that ALL electrical supplies are isolated before
undertaking any service or maintenance work. The machine may
have more than one electrical supply.
WARNING
Plasma arc can cause injury and burns.
Verify that no person is in the proximity of the plasma torch at any
time that the plasma system is switched on. Serious burn and
electrical shock hazards exist, even when the plasma cutting system
is not active.

SAFETY
Sept-2018
9
EYE PROTECTION
LENS SHADE
Arc Current
AWS (USA)
ISO 4850
Up to 100A
No. 8
No. 11
100 –200A
No. 10
No. 11 –12
200 –400A
No. 12
No. 13
Above 400A
No. 14
No. 14
Medical treatment facilities and a qualified first aid person should be available for
immediate treatment of flash burns to the eyes and skin.
It is recommended that the cutting area be prepared in such a way as to minimize
the reflection and transmission of ultra violet radiation. Walls and other surface
areas should be painted in dark colors to reduce reflection. Protective screens or
curtains may be installed to avoid unnecessary ultra violet transmission.
INPUT CONNECTIONS
1. A wall mounted line isolating switch, fused as required by local electrical codes,
must be fitted as close as possible to the plasma arc power supply.
2. Three-phase input conductors must be sized to carry the rated current of the
plasma arc power supply.
3. Primary power cable must be provided with a minimum 600v rating.
WARNING
The plasma arc cutting process produces rays that can burn eyes and
skin. Always wear eye protection with appropriate lens shades.
WARNING
Frequently inspect the cable for damage or cracking of the cover.
Bare wiring can kill. Replace damaged cable immediately.

SAFETY
Sept-2018
10
GROUNDING
Input Power
1. Connect the ground lead of the four-conductor / three phase input cable to the
electrical system ground in the disconnect box and the ground stud provided in
the plasma arc supply.
2. Be sure all ground lugs are of adequate size to carry the rated current load.
3. Make all connections tight to avoid resistance heating.
Output
1. Connect all positive output ground leads to the material grid of the work table.
2. Connect the material grid of the work table to a good earth ground.
BURN PREVENTION
High intensity ultraviolet and infrared radiation is produced by the plasma arc and is
of similar intensity to typical high current welding arcs. This radiation is damaging to
the eyes and skin. As the operator comes closer to the torch, the level of exposure
increases rapidly.
WARNING
The operator and any other persons working in the
vicinity of the arc must wear proper protective clothing
and equipment.

SAFETY
Sept-2018
11
TOXIC FUMES
Proper precautions must be exercised to prevent the exposure of others in the
vicinity to toxic fumes that may be generated while plasma cutting.
Certain chlorinated solvents such a perchloroethylene and trichlorethylene will
decompose under ultra violet radiation to form phosgene and other gasses. Care
must be taken to avoid the use of these solvents on materials being cut with plasma
arc cutting equipment. Containers of these solvents and other degreasing agents
should be removed from the immediate area around the plasma arc.
Metals coated with or containing significant amounts of lead, cadmium, zinc,
mercury or beryllium can produce harmful concentrations of toxic fumes when the
plasma arc cuts. Adequate local exhaust ventilation must be used or the operator
must be supplied with special equipment to guarantee a supply of fresh air such as a
respirator or air supplied helmet.
Metals coated with materials that emit toxic fumes must not be cut unless:
1. The coating is removed prior to cutting.
2. The area is adequately ventilated.
3. The operator is supplied with fresh air breathing equipment.
AIR CONTAMINATION
The plasma cutting process generates large quantities of hot metal dust and fumes
that would be hazardous if uncontrolled.
A blower pulls a vacuum through the fume extraction assembly in the bed of the
machine. The blower pulls the dust-laden air through a customer supplied filter
before exhausting the air to the environment.
The gases listed below either are produced normally during plasma arc cutting or
can form under certain conditions.
Ozone
Ozone is produced by the reaction of the plasma arc's ultraviolet radiation with oxy-
gen in the air. Uncontrolled, excessive levels of ozone can constitute a hazard.
When there is proper venting to the outside and the machine's internal ventilation
system is functioning properly, there is adequate control of ozone during torch
cutting.

SAFETY
Sept-2018
12
Nitrogen Dioxide
Nitrogen dioxide gas is produced when nitrogen and oxygen in the air pass through
the electric arc. A hazard may exist if uncontrolled, excessive levels of nitrogen
dioxide are formed. With proper venting to the outside, the machine's internal
ventilation system is adequate to control nitrogen dioxide during torch cutting, if the
system is functioning normally.
Acetyl Chloride
Acetyl chloride gases form in the air surrounding the plasma arc when the airborne
vapors of chlorinated solvents or degreasers decompose upon being exposed to the
ultraviolet radiation of the arc. A hazard may exist if uncontrolled, excessive levels
of acetyl chlorides are formed. A pungent "sweetish" aroma similar to chlorine
bleach is the first sign that these gases are being produced. Shut down the plasma
arc cutting system immediately if you detect the acetyl chloride odor. Do not resume
cutting until you locate and control the source of the vapors.
Various cleaning solvents and vapor degreasers contain chemicals that decompose
rapidly when exposed to ultraviolet radiation.
If the solvents, cleaning solutions, or vapor degreasers used in the shop contain any
of the following chemicals, do not use them near the plasma arc cutting system:
1. trichloroethylene
2. trichloroethane
3. perchloroethylene
4. perchloroethane
5. trifluoro-trichloroethane (fluorocarbon-113)
These chemicals also decompose into small amounts of the toxic gases phosgene
and chlorine. You will notice the acetyl chloride odor long before phosgene or
chlorine levels become harmful.
The vapors can decompose up to several feet away from the arc, do not rely on the
machine's internal ventilation system to control solvent vapors and their products.
Do not use or store chlorinated solvents, cleaning solutions, and vapor degreasers
close to the machine, where the vapors can enter the torch-cutting area.
NOTE: It may prove advisable to provide separate ventilation for the
solvent/degreaser storage area.

SAFETY
Sept-2018
13
Metal Fumes
Metal fumes are produced when the plasma arc vaporizes the metal. A hazard may
exist when uncontrolled, excessive levels of metal fumes are produced some
vaporized metals form toxic gases. These metals may be in their pure metallic state,
in an alloy, or in a coating such as paint or plating.
Metals that are known to produce toxic fumes include beryllium, cadmium, lead,
manganese, mercury, and zinc. Beryllium products require particular care, because
their fumes are highly toxic. If there is proper venting to the outside and the
machine's internal ventilation system is functioning normally, there should be
adequate control of metal fumes during torch cutting.
Metal Dust
Metal dust is formed as metal vaporizes during torch cutting. A hazard may exist
when uncontrolled, excessive levels of metal dust are produced. If there is proper
venting to the outside and the machine's internal ventilation system is functioning
normally, there should be adequate control of metal dust during torch cutting. For
proper ventilation, at least 90% of the worktable should be covered by the workpiece
(or other sheet metal covers).
See dust collector vendor installation and operation manual for additional
precautions.
FIRE PREVENTION
All combustible materials must be removed from the immediate cutting area to at
least 35 feet away. Appropriate fire extinguishing equipment must be available in
the immediate cutting area.
After cutting, be sure to allow the metal to cool sufficiently before handling or before
allowing contact with combustible materials.
Never plasma cut empty containers that have held toxic or potentially explosive
materials. Those containers must be thoroughly cleaned according to national
standards prior to cutting or welding.
Never plasma cut in an atmosphere that contains heavy concentrations of dust,
flammable gas, or combustible liquids (such as petrol).
WARNING
Since plasma arc cutting produces hot metal, sparks,
and slag, precautions must be taken to prevent fire or
explosions.

SAFETY
Sept-2018
14
COMPRESSED GAS EQUIPMENT
Gas cylinders should be mounted securely to a wall or other stable supporting
device.
Cylinders
Compressed gas cylinders must be handled and used in accordance with
appropriate national safety standards.
•Never use a cylinder that is physically damaged or leaks.
•Never move or transport a cylinder without the protective valve cover in place.
•Never use a gas cylinder or its contents for any other purpose than that for which
it is intended.
•Never lubricate cylinder valves with oil or grease.
•Never allow electrical contact such as welding arcs with cylinders.
•Never expose cylinders to excessive heat, sparks, slag, or open flames, which
may cause rupture.
•Never use hammers, wrenches or other tools to open stuck valves. Send these
cylinders back to the supplier.
Pressure Regulators
All regulators used to operate plasma equipment must be maintained in proper
working condition.
Faulty equipment can cause equipment damage or operator injury. Faulty
equipment must be serviced at the manufacturers designated facility by trained
repair technicians.
•Never use a regulator for any other gas than that for which it is intended.
•Never use a regulator that leaks, excessively creeps, or is physically damaged in
any way.
•Never attempt to lubricate a regulator with oil or grease.

SAFETY
Sept-2018
15
HOSES
Gas hoses used for plasma arc cutting systems adhere to the following color coding:
Red ............. Acetylene
Orange........ LPG
Blue............. Oxygen
Black ........... Inert gases and air
Replace any hose that is damaged by physical abuse or from sparks, heat or open
flame.
Lay hoses out straight to prevent kinks.
Coil excess hose and place out of the way to prevent loose connections, or other
damage.
Keep hose lengths to a minimum to prevent damage, reduce pressure drop and
prevent possible volume flow restriction.
Please refer to national standards for more information on hoses.
SAFETY DEVICES
Plasma arc units are provided with certain safety interlocks designed to prevent
equipment damage and/or personal injury.
Never short out or in any way attempt to defeat the safety interlock devices.
All exposed electrical connections must be covered with the proper insulation
material.
Safety devices must be regularly checked for proper operation and replaced
immediately if found to be inoperative.
WARNING
Never attempt to operate the plasma unit with any of the power supply
covers not in place. This is extremely hazardous to the operator and
any other person in the area. It also prevents the equipment from
properly cooling critical components and could result in equipment
damage.

SAFETY
Sept-2018
16
HOT SURFACES
Assure that the bed is free of obstructions and no person or articles of clothing are in
the proximity of moving parts when the machine is in operation. This safety
precaution also applies when the machine is manually moved and when the plasma
system is off.
IMPORTANT
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.
WARNING
Components may remain hot for a considerable period of time.
Always wear gloves to remove components and scrap from the bed.
WARNING
During prolonged periods of cutting, parts of the machine bed may
become hot to the touch.
WARNING
Moving machinery can be dangerous.

SAFETY
Sept-2018
17
Sparks
Sparks form as the plasma arc torch vaporizes metal. These sparks are tiny
droplets of extremely hot molten metal and are a possible fire hazard. The volume
of sparks formed and the area over which they are scattered depend on several
variables. These variables include the type and thickness of the material being cut,
the cutting current, and the feed rate. Where practical, keep all combustible material
at least 35 ft. (10.7 m) away from the plasma arc work area. Where this is not
practical, protect all combustible materials with close fitting, flame proof covers or
shields. Protect wooden or other combustible floors by covering them with sand or
installing fire-resistant shields. Shield any wall openings, floor openings, cracks,
ducts, or conveyors within 35 ft. (10.7 m) of the torch to prevent sparks from passing
into adjacent areas.
WARNING
Sparks from the cutting process may ignite flammable items in the
machine bed which may then be drawn into the extraction unit,
possibly causing a fire.
NOTE: Be sure to use an approved facemask and approved eye protection
when cleaning or servicing the dust collector.
NOTE: Plasma arc cutting systems can produce large volumes of fumes. If
you exhaust fumes to the outside atmosphere, additional air
pollution control devices may be in order to conform to local, state,
and federal government ordinances. Air pollution control devices
are the responsibility of each individual user.
Internal Ventilation System
Due to the noxious and toxic nature of many torch cutting by-products, Piranha
recommends venting the machine's internal ventilation system (referred to as the
"dust collector") to the outside atmosphere. This recommendation is especially
important when the shop has one of the following:
1. Low ceilings and/or confined area
2. Large amount of welding and/or torch cutting near the plasma system
3. Poor cross plant ventilation

SAFETY
Sept-2018
18
LIGHT AND RADIANT ENERGY
When it is necessary to look directly at the arc for diagnostic purposes, do so briefly.
Use shade #10 welding glass (for up to 200 amps) or shade #12 (for 200 amps).
During operation, use a shade not less than #8.
WARNING
Do not look directly at the arc without proper eye protection.
NOTE: During plasma arc cutting, clothing worn should conform to the
instructions presented in the General Safety Requirements section
of this manual.
Ultraviolet rays and other radiant energy reflected off the workpiece can produce
sunburn. Therefore, when plasma arc cutting is being performed, anyone working
within 25 feet (7.5M) of the arc should wear an approved, protective full-face mask, a
long-sleeved shirt, gloves, and long pants.
Operations, such as edge cutting, that can cause the arc to be exposed to view
should be avoided, because they can increase exposure to radiant energy.
Shield personnel at nearby workstations from accidental exposure to radiant energy
by the use of non-reflective, fireproof enclosures, open at the top and at floor level to
allow air to circulate freely.
The pilot arc in the plasma cutting systems is initiated and stabilized by a
high-voltage signal. This signal can create electromagnetic interference.
As with any equipment that can create such interference (e.g., microwave ovens and
TIG welders), people who have implanted heart pacemakers must exercise caution
when working near the equipment. Piranha recommends that a person with a
pacemaker who works near where plasma arc cutting is being performed should
wear a Holter monitor for one day of work to record the existence of electromagnetic
fields. A qualified doctor should review the recorded data with the pacemaker
manufacturer to determine whether the worker can safely continue working in the
area on which the study is based.
NOTE: There is no history of problems caused to pacemakers by the
plasma arc cutting equipment that have been reported to Piranha.

SAFETY
Sept-2018
19
HEAT
Plasma arc cutting creates a Heat-Affected Zone (HAZ) around the cut edge of the
workpiece. Until the hot edges cool, the HAZ will burn an unprotected hand
severely.
1. When removing produced parts or skeletons from the machine, operators should
wear heat-resistant, gauntlet-type gloves.
2. The torch, cutter bars, ducting, and dust collector become hot during torch
cutting. Avoid contact with these components unless you are wearing
heat-resistant gloves.
NOISE
The noise levels generated during plasma arc cutting may be as high as 105
decibels. This depends on the distance from the machine, arc, plasma torch nozzle
design, gas velocity, material type, and plate thickness. Piranha recommends that
each user check the sound levels in his own shop under normal operating
conditions.
Based on those findings, provide adequate ear protection to all personnel who must
work near the machine, in accordance with applicable local, state, and federal
industry standards.
NOTE: Noise levels that can cause discomfort or damage to hearing will
vary greatly from one individual to another. Piranha recommends
that ear protection be furnished to any worker who requests it,
regardless of applicable industrial standards or tested noise levels.
WARNING
Exposure to noise from the cutting process can damage hearing.
Wear appropriate ear protection when operating the machine or
when working in the proximity of the machine.

SAFETY
Sept-2018
20
ADDITIONAL SAFETY INFORMATION
The general safety information presented in this chapter does not constitute a
complete list of safety instructions for any particular configuration of the Piranha
Plasma Cutting Table. Warnings and other safety information related to operations
described in this manual are presented in the chapters in which those operations are
explained. Specific equipment being used by the customer and its particular
application in the customer's factory may require supplementary safety information.
NOTE: It is the responsibility of the customer’s company to make sure
safety information covering the equipment being used and its
particular application is available to personnel operating and
maintaining the equipment and is read by them.
SAFETY STANDARDS PUBLICATIONS
It is recommended that companies using the kind of equipment covered in this
manual consult the applicable Safety Standards publications available from the
agencies listed below:
OSHA
Superintendent of Documents
U. S. Government Printing Office
Washington, DC 20402-9371, USA
Tel: [phone]
ANSI
American National Standards Institute
11 West 42nd Street
13th Floor
New York, NY 10036-8002, USA
Tel: [phone]
Fax: [phone]
NFPA
National Fire Protection Association
P.O. Box 9101
1 Batterymarch Park
Quincy, MA 02269-9101, USA
Tel: [phone]
1-800-344-3555
Fax: [phone]