Toptech Rate-Tech DAGGER-II User manual

Portable CNC Cutting Machine
Operation Manual
Rate-Tech Co., Ltd.
建议所有建议所有与操作或保养管理有关的人员，在进行任何
操作前，必须仔细阅读本说明书，以便以最佳方式操作本装置。

INTRODUCTION
Thank you very much for purchasing this product. Please read this instruction
manual thoroughly to ensure correct, safe and effective use of the machine. Please
read the manual first to understand how to operate and maintain the machine. The
colleague’s coordination on work site is essential for safety and smooth operation.
Please make sure you read, understand and take all the necessary safety
precautions.
SAFETY PRECAUTIONS
This product is designed to be safe, but it can cause serious accidents if not
operated correctly. Those who operate and repair this machine must read this
manual thoroughly before operating, inspecting and maintaining the machine.
Keep the manual near the machine so that anyone who operates the machine
can refer to it if necessary.
Do not use the machine carelessly without following the instructions in the
manual.
Use the machine only after you completely understood the contents of the
manual.
If any explanation in the manual is difficult to understand, contact our
company or sales service office.
Keep the manual near by at all times and read it as many times as necessary
for a complete understanding.
If the manual becomes lost or damaged, place an order with our company or
sales service office for a new one.
When transferring the machine to a new owner, be sure to hand over this
instruction manual as well.

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QUALIFICATIONS FOR MACHINE OPERATOR
Operators and repair staff of this machine must completely understand the
contents of the instruction manual and they must have one of the following
certificates：
1. Gas welding foreman license
2. Gas welding training courses Certificate
3. Certificate recognized by the Ministry of Labor

Symbol Title Meaning
General
General caution, warning, and danger.
Be careful not to get
your fingers caught.
Possible injury to fingers if caught in the
insertion part.
Caution: Electric shock!
Possible electric shock under special
conditions.
Ground this equipment.
Operators must ground the equipment
using the safety grounding terminal.
Pull out the power
plug from the outlet.
Operators must unplug the power plug
from the outlet when a failure occurs or
when there is a danger of lightning.
Caution against bursting
Possible bursting under certain conditions.
General
General warning.
Caution: Hot!
Possible injury due to high temperature
under certain conditions.
Caution: Ignition!
Possible ignition under certain conditions.

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Contents
1. Safety Information……………………………………………… 4
1.1 General machine safety precautions………………………………………… 4
1.2 Cutting safety precautions …………………………………………………… 6
2. Brief Introduction to Cutting Machine………………………… 9
2.1 Main Features ……………………………………………………………… 9
2.2 Wide Usage ………………………………………………………………… 9
2.3Equipment Composition……………………………………………………… 9
3. Machine Installation…………………………………………… 10
3.1Overview……………………………………………………………………… 10
3.2Completion Machine Installation……………………………………………… 10
3.3 Addition of Plasma Cutting……………………………………………………14
3.4Gas Supply of Relevant Devices……………………………………………… 14
3.5Control Profile………………………………………………………………… 15
4. Brief Introduction to Mechanical Parts………………………… 15
4.1Mechanical Movement Structure …………………………………………… 15
4.2Cutting Torch Device………………………………………………………… 15
4.3Cutting Torch Lifting Device………………………………………………… 15
4.4Cutting Torch Holding Device……………………………………………… 15
4.5Fluid System ………………………………………………………………… 15
5. Machine Maintenance and Preservation……………………… 16
5.1Machine Cleaning…………………………………………………………… 16
5.2Machine Lubrication………………………………………………………… 16
5.3Machine Adjustment………………………………………………………… 16
5.4Cleaning of Torch Head………………………………………………………16
6. Cutting Torch …………………………………………………… 17
7. Shutdown of Cutting Torch……………………………………… 17
8. Operation Procedures of CNC Cutting Machine ……………… 17
9. Instructions to Warranty………………………………………… 19
10. Cutting Data …………………………………………………… 20
11. Circuit Diagram ……………………………………………… 22

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1. Safety Information
Disregard the basic safety rules can cause many accidents during operation,
inspection, and maintenance. Carefully read, understand, and master the safety
measures and precautions described in this instruction manual of the machine
before operating, inspecting, and maintaining the machine. The safety messages
are classified as indicated on the machine safety labels:
■ WARNING
This word is used in a warning message and a warning label is positioned at
places that could cause injury or serious accident.
■ DANGER
The danger symbol indicates that serious injuries and major damage will be
possible if not avoided. It is also used as a warning label.
■ CAUTION
This word is used in a caution message and a caution label is positioned at places
that could cause slight injury or machine damage. This is also used as a caution
for frequent dangerous actions.
■ NOTICE SIGNS
This is a sign to show machine operators and maintenance engineers items that relate
directly to damage of machines and surrounding facilities and equipment.
1.1 General machine safety precautions
Read and fully understand the following important safety information:
1.1.1 Machine safety
1. The machine casing is mainly made of aluminum alloy to reduce weight. For this
reason, be careful not to drop a heavy item on the machine, or not drop the
machine when carrying it, since the alloy is not designed to withstand such
impact.

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2. When mounting hoses to the torch and distributor, tighten the nut with the
attached wrench. After mounting, be sure to check there is no gas leak with a
detection liquid. If a gas leak is found, retighten the nut firmly.
3. When fixing a tip to the torch, tighten the nut with the two wrenches attached. In
addition, avoid damaging the taper part of the tip since this may cause backfire.
4. Never disassemble the machine other than during maintenance and inspection.
Otherwise, malfunction will result.
5. Never remodel the machine. Remodeling is very dangerous.
6. When changing the travel direction, make sure that the direction switch is in the
neutral (stop) position, and operate the direction switch after the machine has
stopped.
7. Always turn the power off when not used.
8. Never use the machine outdoors when the weather is wet. This will cause
failure of the machine and could cause a fatal accident by electric shock.
1.1.2 Safety clothing
1. Be sure to wear protector's gauntlets, goggles, helmet, and
safety shoes during operation.
2. Avoid operating the machine with wet clothes or hands in order
to prevent electric shock.
1.1.3 Operation and handling safety precautions
1. Read this instruction manual before operating the machine.
2. Mount and center the machine correctly and confirm correct motion before
operation.
3. Prior to connecting the power plug with the socket, make sure the power
switch in OFF position (turn the switch clockwise or counterclockwise to the
stop position).
4. Prior to operating the machine, check the safety of the surroundings to avoid
accidents.
5. Never move the machine while the preheat flame is on.
6. When an operation is carried out at a higher position, be careful that the
splashes and slugs may hurt others at lower position.
7. Be sure that the clutch is in state of meshing before operation, any
improper state may cause accidents.
8. Be careful that the hands may be caught in erecting guide rail.
9. When cutting along the guide rail, be sure to fix the small guide roller
properly.
10. Erect the preheat board properly to avoid affection to the guide rail.
11. To avoid that holder of torch from falling, use the bolt on the sliding
holder to fix it.
12. Be sure to hold tight of handles in moving the equipment.

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13. Prior to moving guide rail, be sure to move the equipment out of the guide
rail.
1.1.4 Electrical system precautions
1. Be sure to check the input power voltage of the machine before operation. The
input power voltage should be in the range of +10% of the rated voltage. The
machine should not be operated out of this range.
2. Be sure to keep the layout of power cable reasonable, so that the cables will not be
caught in the equipment operation.
3. Be sure to ground the power cable or use a socket with earth wire.
4. Stop operation and turn off the power in the following cases, and ask a
qualified electrician to repair the machine.
1) Broken or abraded cables
2) When the machine has been in contact with water, or in case of liquid
damage to the machine.
3) Abnormal machine operation despite operating the machine according to
the instruction manual
4) Machine breakdown
5) Poor machine performance that requires repair
5. Periodically inspect the electrical system.
1.1.5 Maintenance and inspection precautions
1. Ask a qualified electrician to perform repair and inspection service.
2. Disconnect the power plug before inspecting and repairing the machine.
3. Maintain the machine periodically.
1.2 Cutting safety precautions
Strictly observe the safety rules and precautions to ensure the safety of gas
cutting operations. Operators and supervisors MUST keep safety in mind.
1.2.1 Prevention of explosion
1. Never cut pressurized cylinders or hermetically sealed containers.
2. Ensure sufficient ventilation for gas cutting to prevent the air from becoming stale.

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1.2.2 Pressure regulator safety precautions
1. Before starting operation, check that all pressure regulators are operating correctly.
2. Ask a skilled repair engineer to perform maintenance and inspection service.
3. Do not use pressure regulators from which gas is leaking, nor malfunctioning
pressure regulators.
4. Do not use pressure regulators smeared with oil or grease.
1.2.3 High-pressure gas cylinder safety precautions
1. Never use broken cylinders or cylinders from which gas are
leaking.
2. Install cylinders upright and take measures to prevent them from falling.
3. Use only for specified purposes.
4. Do not use the cylinders which smeared with oil or grease.
5. Install cylinders in a place free from heat, sparks, slag, and open flame.
6. Contact the distributor if the container valves will not open.
7. Never use a hammer, wrench, or other tools to forcibly open container valves.
1.2.4 Safety precautions for hoses
1. Use the oxygen hose for transferring oxygen gas only.
2.Replace cracked hoses or other hoses damaged by sparks, heat, unshielded fire, etc.
3.Install hoses without twisting.
4.To prevent breakage of hoses, take great care during operation and transportation.
5.Do not hold the hoses when moving the machine.
6.Periodically check the hoses for damage, leakage, fatigue, loose joints, etc, to
ensure safety.
7. Cut hoses to the minimum possible length. Short hoses reduce hose damage and
pressure drop, as well as reduce the flow resistance
1.2.5 Safety precautions for fire
Take safety precautions to prevent fire prior to gas cutting. Ignoring hot metal,
sparks, and slag could cause a fire.
1. Keep a fire extinguisher, fire extinguish sand, bucket full of water, etc. ready on
the site where gas cutting is performed.
2. Keep flammables away from the cutting area to avoid exposure to sparks.
3. Always cool down steel plates that have become hot after cutting, as well as
hot cut parts or scrap, before bringing them close to flammables.
4. Never cut containers to which flammable materials are stuck.
1.2.6 Safety precautions for skin burns

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Observe the safety precautions to prevent skin burns. Ignoring heat, spatter, and
sparks during operation could cause a fire or burned skin.
1.Do not perform cutting near flammables. (Move flammables well away from the
sparks.)
2.Do not cut containers filled with flammables.
3.Do not keep lighters, matches, and other flammables nearby.
4.Flames from the torch will burn the skin. Keep your body away from the torch
and tip, and check the safety before operating the switches and valves.
5. Wear the correct protectors to protect your eyes and body.
6. Correctly tighten the tip to prevent backfire.
7. When fixing a tip to the torch, tighten the nut with the two wrenches attached.
8. If the tip is tightened excessively, it will be heated during cutting and tightened
still more, making it difficult to remove the tip.
9. Avoid damaging the taper of the tip since this may cause backfire.
10. Check with soapsuds for any leakage of gas from the connection part of the
distributor, hose and torch.
11. Be sure to check the following when igniting:
Install the torch on the torch holder before ignition.
Always wear the required protectors (gauntlets, helmet, goggles, etc.)
Check for any obstacles, dangerous materials and flammables near or in
the direction of cutting. Determine the gas pressure.
The gas pressure must be within the appropriate range. (For the gas
pressure, refer to the Cutting Data.)
12. The torch, tip and heat shield are heated to a very high temperature. Always
wear gauntlets when handling them. Also the surface after cutting is very hot
so do not touch it even while wearing gauntlets.
13. Do not move the machine when the preheat flame is on.
2. Brief Introduction to Cutting Machine:
This cutting machine is a modern cutting device controlled by digital program.

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Besides the automation of cutting operation, it also features high cutting
precision, high material utilization rate and high production efficiency. With the
advancing of machine electronic technologies and computer technologies, CNC
cutting machine is taken seriously by a growing number of enterprises and is
thus widely applied in the production due to its favorable man-machine
interaction operation interface, powerful auxiliary supporting functions, and
relatively low equipment investment.
2.1 Main Features
★The numerical control function of this machine is same as that of large
gantry-type CNC cutting machine. It is capable of cutting any complicated plane
figures. It applies to oxygen and gas flame cutting and plasma cutting. It is as
convenient and flexible as semi-automatic cutting trolley. This machine can be moved
at will without occupying any fixed yard.
★The programming jacking of this machine is simple. It cannot only conduct
manual programming of simple graphs but also implement the automatic
programming of random and complicated graphs through programming software
presented with the machine. Interactive conversational mode is adopted for this
software. The graphic data is automatically switched. Manual coding is not required.
After clearing of part drawings mapped by using AutoCAD, DXF files will be directly
accessed. Then, they will be discharged through programming software. G code files
required for cutting are directly generated after selection of proper programming
parameters.
★Convenient and flexible file transmission and storage: USB interface is
supported. The users may output the files required for cutting to U disk. Then, insert
the U disk to the USB interface of the mini-type cutting machine to implement file
transmission.
★Simple and convenient operation: during operation, this machine can be either
used as a semi-automatic trolley for manual cutting or used as a large CNC machine
for automatic cutting.

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2.2. Wide Usage
The machine can be widely used in industries like automobile, shipbuilding,
petrochemical engineering, boiler pressure vessel, engineering machinery and
light-industry machinery. It is applicable for the cutting and blanking of sheet metals
like carbon steel (flame cutting), stainless steel, aluminum and copper (plasma). This
product is especially suitable for single-piece and batch production of profiled
surfaces.
2.3. Equipment Composition
The main parts of this machine include main engine, vertical and horizontal driving
devices, guide rail, cutting torch component, gas supply system, electrical control
system, plasma cutting devices, etc.. The contour of the machine is shown as follows:
1.
Horizontal driving motor
2.
Vertical guide rail unit
3.
Gas supply interface
4.
Control system
5.
Main body unit
6.
Solenoid valve control unit
7.
Motor-driven ascend/descend device
8.
Vertical driving motor

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9.
Cross arm unit
10.
Flame unit
11.
AVC UNIT （built-in）
(1) Effective cutting scope of cross arm:
Effective cutting 1000L: full length of 1900mm
Effective cutting 1250L: full length of 2110mm
Effective cutting 1500L: full length of 2500mm
(2) Effective cutting scope of track foundation:
Effective cutting 1500L: full length of 2050mm
Effective cutting 2500L: full length of 3090mm
Effective cutting 3000L: full length of 3540mm
(3) Control of main body
3. Machine Installation
3.1. Overview
In order to make sure the machine can be smoothly moved and operated, the
machine must be placed on a steel plate with relatively small vibration or the machine
must be fixed. Meanwhile, it is required to avoid placing the machine in the open air
to assure its cutting quality and operating performance.
3.2. Completion Machine Installation
After receiving the mini-type CNC cutting machine, the user shall count the
article according to the packing list and place it in a reliable position (note: the U disk
software decryption dog of programming software optic disk shall be properly
collected. NESTING SOFT IS OPTION). The equipment shall be split and packed
separately. After the equipment arrives at the user’s site, the user is required to
assemble the equipment independently. The assembly process is shown as follows:
3.2.1. Count articles necessary to installation.
(1) List of Devices of Standard Machine:
Main body: 1 piece (including power line and 8P control line)
Vertical foundation track: 1 piece; cutting range optional (effective 1500L, 2500L

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and 3000L)
Cross arm: 1 piece; cutting range optional (effective 1000L, 1250L and 1500L)
Motor-driven ascend/descend device: 1 piece
Flame cutting unit: 1 set (including solenoid valve control unit)
Motor-driven ascend/descend and solenoid valve control line: 1
Fuse: 2
Cutting nozzle: 0#, 1# and 2# (RATE-TECH, 106 series optional)
1
Power line
2
Main engine
3
Fuse
4
Motor-driven ascend/descend
5
Solenoid valve distribution unit
6
Motor-driven ascend/descend and solenoid valve control line
7
Cross arm
8
Vertical foundation track
9
Cutting torch
10
Flame cutting torch unit

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(2) List of added plasma devices: (customer optional)
AVC control cabinet: (built-in)
Plasma initial positioning fixture unit: 1 set (RT89001296)
Arc voltage feedback control cable: 1 (RT95D01896)
Arc voltage control cable: 1 (RT95D01910)
3.2.2. Connection of Main Body Unit with Vertical Guide Rail
Firstly, pace the vertical guide rail on a flat ground. Next, match the guide rail
slider beneath the main engine with the straight-line guide rail and then gently
push it to the vertical guide rail (see Figure 1).
Proximity switch

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3.2.3. Installation of Cross Arm
Gently deliver the horizontal aluminum guide rail to the horizontal guide pulley
according to the direction shown in the diagram to assure smooth gearing of rack
and engine block. (See Figure 2)
3.2.4. Assembly of Motor-driven Ascend/Descend Device, Distributor and
Solenoid Valve Bank
Install the motor-driven ascend/descend device in the mounting plate and use M6
hexagon socket screw to install and fix it. Install the distributor and solenoid
valve bank at the outlet joint of cross arm. Use open-end wrench to lock the nut
tightly. Install the flame cutting torch rack on the motor-driven ascend/descend
cutting torch support. Use fastening bolt to fix it. Connect the rubber hose
connector to the outlet of regulating valve. Use open-end wrench to lock the nut
tightly. Install the protective cover finally. (See Figure 3)
Cross arm
Main body unit

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1
Outlet of regulating valve
2
Distributor and solenoid valve bank
3
Motor-driven ascend/descend device
4
Cutting torch support
5
Mounting plate
6
Outlet joint
7
Flame unit
8
Cross arm
9
Distributor and solenoid valve bank
10
Motor-driven ascend/descend device
11
Protective cover
3.2.5. Connect the joints of pre-oxygen leather hose, quick-oxygen leather hose
(fitted with solenoid valve) and gas leather hose on the cutting torch to the guide
equipment in order and tighten each joint screw.
Note: The gas joint screw is reversely toothed. Marks are left on the joint and nut.
During connection, anticlockwise screwing shall be carried out.
3.2.6. Connection to Gas Source
Use soap lye method to check the air tightness of the gas channel under the working
pressure. After it is confirmed that there is no leakage, the installation of the
equipment is completed. Then, the equipment can be put into use.
3.3. Addition of Plasma Cutting in Standard Machine (with arc
voltage regulated up)
The standard machine of this model is a flame cutting machine. If the customer

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selects plasma cutting, plasma devices shall be added. Addition method: disassemble
solenoid valve, distributor, rubber hose, flame cutting torch and flame support and add
plasma initial positioning fixture unit. Connect the proximity switch line to the initial
positioning wire 3P. Replace the original solenoid valve and motor-driven
ascend/descend control line with plasma motor-driven ascend/descend control line.
Remove the upper cover of the main control cabinet and add AVC control cabinet.
Connect the plug, and add arc voltage control wire, start arc signal wire and switch
the controller system into plasma cutting model. (See Figure 8)
Plasma initial positioning fixture(Proximity switch line)
Bolt-on
Arcing signal line
Bolt-on
Arc voltage control line
Bolt-on
AVC control cabinet
Bolt-on
Rubber hose
Disassembly
Cutting torch and cutting torch support
Disassembly
Upper cover of control cabinet
Disassembly
3.4. Addition of Plasma Cutting in Standard Machine (with arc
voltage regulated up)

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The standard machine of this model is a flame cutting machine. If the customer
selects plasma cutting, plasma devices shall be added. Addition method: disassemble
solenoid valve, distributor, rubber hose, flame cutting torch and flame support and add
plasma initial positioning fixture unit. Switch the master control system to plasma
cutting model. (Use plasma motor-driven ascend/descend control line to replace
solenoid valve control line and motor-driven ascend/descend control line.)
3.5. Addition of Flame Cutting Function in Plasma Devices
If the customer selects plasma cutting, flame devices shall be added. Addition method:
install solenoid valve, distributor, rubber hose, flame cutting torch and flame support
and remove plasma fixture unit. Switch the master control system to plasma cutting
model, and use the spanner to tighten the connecting lock nut. Carry out pressure test
through ventilation and use soap water to wipe the connection to check if it is gas
leaking. (Replace plasma motor-driven ascend/descend control line with solenoid
valve control line and motor-driven ascend/descend control line.)
3.6. Gas Supply of Relevant Devices
The device gas inlet interface is the Ф8mm gas-type fitting according to the national
standard. The user may decide the length of gas supply pipe according to the distance
between gas source and device and the cutting stroke. Please use the minimum
pipeline length, thus avoiding the reduction of gas flow. The user must add an about
200-mesh gas filter at the gas supply interface to assure clean gas source and prevent
the impurities in the pipeline from damaging the solenoid valve and blocking the
cutting pipeline.
3.7. Addition of Second Flame Gun (upon customer’s demand)
3.8. Addition of Cutting Platform (upon customer’s demand)
3.9. Control Profile