BAILEIGH PT-22 (01) PDF DOCUMENT

Metal working can be dangerous if safe and proper operating procedures are not followed. Using the BAILEIGH PT-22 with respect and caution will considerably lessen the possibility of personal injury. However, if normal safety precautions are overlooked or ignored, personal injury to the operator may result. Safety equipment such as guards, hold-downs, safety glasses, dust masks and hearing protection can reduce your potential for injury. But even the best guard won’t make up for poor judgment, carelessness or inattention. Always use common sense and exercise caution in the workshop. If a procedure feels dangerous, don’t try it. Your personal safety is your responsibility.

1. FOR YOUR OWN SAFETY, READ INSTRUCTION MANUAL BEFORE OPERATING THE MACHINE. Learn the machine’s application and limitations as well as the specific hazards.

2. Only trained and qualified personnel can operate this machine.

3. Make sure guards are in place and in proper working order before operating machinery.

4. Remove any adjusting tools. Before operating the machine, make sure any adjusting tools have been removed.

5. Keep work area clean. Cluttered areas invite injuries.

6. Overloading machine. By overloading the machine you may cause injury from flying parts. DO NOT exceed the specified machine capacities.

7. Dressing material edges. Always chamfer and deburr all sharp edges.

8. Do not force tool. Your machine will do a better and safer job if used as intended. DO NOT use inappropriate attachments in an attempt to exceed the machines rated capacity.

9. Use the right tool for the job. DO NOT attempt to force a small tool or attachment to do the work of a large industrial tool. DO NOT use a tool for a purpose for which it was not intended.

10. Dress appropriate. DO NOT wear loose fitting clothing or jewelry as they can be caught in moving machine parts. Protective clothing and steel toe shoes are recommended when using machinery. Wear a restrictive hair covering to contain long hair.

11. Use eye and ear protection. Always wear ISO approved impact safety goggles. Wear a full-face shield if you are producing metal filings.

12. Do not overreach. Maintain proper footing and balance at all times. DO NOT reach over or across a running machine.

13. Stay alert. Watch what you are doing and use common sense. DO NOT operate any tool or machine when you are tired.

14. Check for damaged parts. Before using any tool or machine, carefully check any part that appears damaged. Check for alignment and binding of moving parts that may affect proper machine operation.

15. Observe work area conditions. DO NOT use machines or power tools in damp or wet locations. Do not expose to rain. Keep work area well lighted. DO NOT use electrically powered tools in the presence of flammable gases or liquids.

16. Keep children away. Children must never be allowed in the work area. DO NOT let them handle machines, tools, or extension cords.

17. Store idle equipment. When not in use, tools must be stored in a dry location to inhibit rust. Always lock up tools and keep them out of reach of children.

18. DO NOT operate machine if under the influence of alcohol or drugs. Read warning labels on prescriptions. If there is any doubt, DO NOT operate the machine.

19. Sparks and hot material from cutting can easily go through small cracks and openings into adjacent areas.

20. Do not cut where the atmosphere might contain flammable dust, gas, or liquid vapors such as from gasoline.

21. Wear oil-free protective garments such as leather gloves, heavy shirt, high shoes or boots, cuffless trousers, and a cap.

22. Watch for fire and keep a fire extinguisher close by.

23. Turn off power before checking, cleaning, or replacing any parts.

24. Be sure all equipment is properly installed and grounded according to national, state, and local codes.

25. Keep all cords dry, free from grease and oil, and protected from sparks and hot metal.

26. Inspect power and control cables periodically. Replace if damaged or bare wires are exposed. Bare wiring can kill! DO NOT touch live electrical components or parts.

27. DO NOT bypass or defeat any safety interlock systems.

28. Learn the function and controls of the controller, the torch power supply, and the provided software packages. Know the location of the ON – OFF switch.

29. Keep visitors a safe distance from the work area.

PROTECT EYES: Wear safety glasses or suitable eye protection when working on or around machinery.

PROTECT AGAINST NOISE: Prolonged exposure to loud noise can cause impairment or loss of hearing. Wear suitable hearing protective devices such as ear muffs or earplugs to protect against objectionable or uncomfortable loud noises.

BEWARE OF PINCH POINTS: Keep hands and fingers away from the servo motors drive belt and pulleys when performing maintenance. Keep motor guards in place at all times while the machine is running.

FUMES AND GASES: The plasma cutting process produces fumes and gases that can be hazardous to your health. If the area is not properly ventilated to remove them, use an air supplied respirator.

ELECTRICAL SHOCK CAN KILL: The plasma arc process uses and produces high voltages that can severely injure or kill. Disconnect power source before performing service or repairs. Insulate yourself from the piece part or other components in the weld circuit.

PROTECT SKIN: Keep hands and body protected from the plasma arc and hot sparks. The heat from the plasma arc is very intense and can pierce the skin resulting in serious burns. Always wear gloves and suitable clothing. DO NOT touch hot piece part without gloves.

ELECTRICAL AND MAGNETIC FIELDS: Electric current used with plasma cutting creates electric and magnetic fields (EMF). These magnetic fields can have an effect on pacemakers and other sensitive electronic equipment. If you wear a pacemaker or similar device contact your doctor before operating this type of equipment. Prolonged exposure to EMF may have other health effects which are not yet known.

CUTTING SPARKS: A spark or piece of hot metal can fly out of the arc while cutting. Remove all flammable materials from the plasma cutting area. Wear approved eye protection, and proper hand and body protection. Make sure the cutting tip is not grounded when sitting idle, which could cause heat buildup, resulting in a possible fire.

HIGH VOLTAGE: USE CAUTION IN HIGH VOLTAGE AREAS. DO NOT assume the power to be off. FOLLOW PROPER LOCKOUT PROCEDURES.

Your BAILEIGH PT-22 machine is shipped complete. Separate all parts from the packing material and check each item carefully. Make certain all items are accounted for before discarding any packing material. Immediately discard any plastic bags and packing materials to eliminate choking and suffocation hazards to children and animals.

Cleaning:

WARNING: DO NOT USE gasoline or other petroleum products to clean the machine. They have low flash points and can explode or cause fire.

CAUTION: When using cleaning solvents work in a well-ventilated area. Many cleaning solvents are toxic if inhaled.

Your machine may be shipped with a rustproof waxy coating and/or grease on the exposed unpainted metal surfaces. Fully and completely remove this protective coating using a degreaser or solvent cleaner. Moving items will need to be moved along their travel path to allow for cleaning the entire surface. For a more thorough cleaning, some parts will occasionally have to be removed. DO NOT USE acetone or brake cleaner as they may damage painted surfaces. Follow manufacturer’s label instructions when using any type of cleaning product. After cleaning, wipe unpainted metal surfaces with a light coating of quality oil or grease for protection.

Important: This waxy coating is NOT a lubricant and will cause the machine to stick and lose performance as the coating continues to dry.

A – Welded and assembled plasma water table with stepper motor drive axis system.

B – Tool bracket plate

C – Hand torch holder plate

D – Bracket mounting hardware

E – Automation torch holder

F – Handheld controller

G – Adjustable slide for handheld torch

H – “X” axis cable carrier

I – Motor control electronics

Also Included:

(1) – Baileigh Industrial operator’s manual with wire interconnect diagram.

(1) – DSP hand held controller User’s Guide.

(1) – 110V power cable for control enclosure

(1) – Plasma start/stop signal cable

(1) – Handheld controller interconnect cable.

(1) – Flash Drive with preloaded .nc (G code) files.

IMPORTANT: Lifting and carrying operations should be carried out by skilled workers, such as a truck operator, crane operator, etc. If a crane is used to lift the machine, attach the lifting chain carefully, making sure the machine is well balanced.

Follow these guidelines when lifting with a truck or trolley:

• The lift truck must be able to lift at least 1.5 – 2 times the machine’s gross weight.

• Make sure the machine is balanced. While transporting, avoid rough or jerky motion, and maintain a safe clearance zone around the transport area.

• Use a fork lift with sufficient lifting capacity and forks that are long enough to reach the complete width of the machine.

• Remove the securing bolts that attach the machine to the pallet.

• Approaching the machine from the side, lift the machine on the frame taking care that there are no cables or pipes in the area of the forks.

• Move the machine to the required position and lower gently to the floor.

• Level the machine so that all the supporting feet are taking the weight of the machine and no rocking is taking place.

Consider the following when looking for a suitable location to place the machine:

• Overall weight of the machine.

• Weight of material being processed.

• Sizes of material to be processed through the machine.

• Space needed for auxiliary stands, work tables, or other machinery.

• Clearance from walls and other obstacles.

• Maintain an adequate working area around the machine for safety.

• Have the work area well illuminated with proper lighting.

• Keep the floor free of oil and make sure it is not slippery.

• Remove scrap and waste materials regularly, and make sure the work area is free from obstructing objects.

• If long lengths of material are to be fed into the machine, make sure that they will not extend into any aisles.

• LEVELING: The machine should be sited on a level, concrete floor. Provisions for securing it should be in position prior to placing the machine. The accuracy of any machine depends on the precise placement of it to the mounting surface.

• FLOOR: This tool distributes a large amount of weight over a small area. Make certain that the floor is capable of supporting the weight of the machine, work stock, and the operator. The floor should also be a level surface. If the unit wobbles or rocks once in place, be sure to eliminate by using shims.

• WORKING CLEARANCES: Take into consideration the size of the material to be processed. Make sure that you allow enough space for you to operate the machine freely.

• POWER SUPPLY PLACEMENT: The power supply should be located close enough to the machine so that the power cord is not in an area where it would cause a tripping hazard. Be sure to observe all electrical codes if installing new circuits and/or outlets.

1. Locate and unroll the cable track assembly.

2. Remove the two socket head capscrews from the torch trolley face plate.

3. Position the track bracket so that the cable track will lay flat in the track channel and install and tighten the two socket head capscrews.

4. Remove the four screws at the end of the track channel.

5. Position the cable track over the mounting holes and secure in place using the four screws.

Attaching an Automation Torch:

1. Loosen handle (A) by turning counter clockwise (ccw).

2. Slide the torch body (B) into the top of the torch holder (C) until it engages the threaded wheel.

3. Slowly turn knob (D) counter clockwise (ccw) to lower the torch.

4. When the desired height is reached, turn handle (A) clockwise (cw) to tighten the torch in the holder.

5. If the torch you will be using is of a different body style or diameter you will need to provide a holder that can be attached to the mounting plate.

Hand Torch Mounting:

1. Remove the automation torch mounting block and back plate.

2. Install the tool holder angle bracket onto the mounting back plate.

3. Install the lifter assembly onto the angle bracket.

4. Install the torch mounting plate onto the lifter so that the torch plate is pointing toward either the front or back of the table.

5. Place the hand torch tip into the one-piece collar.

6. Set the torch tip into the eye bolt and then level the torch holder so that the tip of the torch is parallel to the cut material.

7. Hold the torch in the level position and secure the torch handle to the holder slot(s) using a U-bolt which is large enough to fit around your torch handle. When the U-bolt is tightened it will pull the torch tip snug toward the inside of the eye bolt.

8. Tighten the nut on the back of the torch holder collar (eye bolt) to prevent it from rotating.

Note: The eye bolt will not clamp tight onto the torch. This prevents damage to the torch tip as well as allows easier changing of consumables.

1. Insert the end of a small flat bladed screwdriver into the opening of the cross member as shown by the arrow.

2. Apply downward force to pop off the cross member. Remove only those necessary to allow you to route the torch cable. Note: Using 2 flat blade screw drivers with even pressure will prevent breakage of the cross members. Additionally, extending the X axis to the full + direction will allow the track to lay flat in the tray. This will support the track evenly to further assist removal and installation of the cross members.

3. Allow for a loop from the torch to the entry point of the cable track. This will help to eliminate unnecessary stress on the cable.

4. When finished routing the cable, re-attach the cross members to the cable track. Use a firm pressure until you hear a snap, indicating they are locked back into place.

IMPORTANT: Be careful not to kink or flatten the torch cable during installation.

Add water to the table until the water level is between the top of the cross channels to about 1/2 way up the material supports.

Drain, clean and refill will be based upon usage. Heavy usage will fill the table with debris while light usage will allow bacteria to grow. Add a general anti-bacterial as needed.

If the table will be unused for 2 or more weeks at a time, it is recommended to drain the tank until the next usage.

CAUTION: HAVE ELECTRICAL UTILITIES CONNECTED TO MACHINE BY A CERTIFIED ELECTRICIAN! Check if the available power supply is the same as listed on the machine nameplate.

WARNING: Make sure the grounding wire (green) is properly connected to avoid electric shock. DO NOT switch the position of the green grounding wire if any electrical plug wires are switched during hookup.

Power Specifications:

Your BAILEIGH PT-22 is wired for 110 volts, 60Hz alternating current. Before connecting the tool to the power source, make sure the machine is cut off from the power source. Before switching on the power, you must check the voltage and frequency of the power to see if they meet with the requirement, the allowed range for the voltage is ±5%, and for the frequency is ±1%.

Considerations:

• Observe local electrical codes when connecting the machine.

• The circuit should be protected with a time delay fuse or circuit breaker with an amperage rating slightly higher than the full load current of the machine.

• A separate electrical circuit should be used for your tools. Before connecting the motor to the power line, make sure the switch is in the “OFF” position and be sure that the electric current is of the same characteristics as indicated on the tool.

• All line connections should make good contact. Running on low voltage will damage the motor.

• In the event of a malfunction or breakdown, grounding provides a path of least resistance for electric current to reduce the risk of electric shock. The plug must be plugged into a matching outlet that is properly installed and grounded in accordance with all local codes and ordinances.

Extension Cord Safety:

Extension cords should be in good condition and meet the minimum wire gauge requirements listed below. An undersized cord decreases line voltage, causing loss of power and overheating.

The only interface between the table control and the plasma cutter is a 2-wire connection for the Start/Stop signal. These connections will be made by the customer and must match exactly between the wires within the harness from the table to the plasma cutter.

The two wires (R-1 and R-3) are used for the plasma arc Start/Stop signal. This is a normally open circuit. When a relay within the console is energized and closes, the plasma cutter/torch will fire and continue until the relay is de-energized. These are NOT polarity sensitive.

1. Locate and unwrap the start stop cable on the left side of the table.

2. Route the cable to the plasma cutter. This is typically routed with or very near the torch cable. Ensure it will not become entangled or create a trip hazard.

3. Connect the start stop cable to the plasma cutter cable which comes with the plasma cutter.

4. Connect one of the brown wires (typically R-1) to one of the plasma start stop wires (typically #3).

5. Connect the other brown wire (typically R-3) to the other plasma start stop wires (typically #4).

IMPORTANT: IT IS THE RESPONSIBILITY OF THE CUSTOMER TO VERIFY THAT THESE CONNECTIONS ARE CORRECT FOR THE PLASMA CUTTER BEING USED! The following tables are for reference only. Contact the manufacturer of your plasma cutter for specific set up information.

Thermal Dynamics

HyperTherm

Miller

NOTE: Steps 1 thru 4 of this procedure should be followed each time the table is turned on. The plasma cutter will NOT be turned on during this procedure. This procedure is also a good way to test run a part without cutting to verify the process.

1. Do not power up the plasma cutter.

2. Turn the power switch on the control box to ON.

3. The screen on the handheld unit will show “All axis home”. Press the ORIGIN OK button. The torch head will move to the home position (corner). This position on the table is controlled by proximity sensors to stop the gantry travel.

4. Using the “X+, Y+” keys, move the torch toward the center of the table at least 1mm on each axis. This distance will vary based upon several variables of the part and the associated operating code.

5. After stopping, press the XY-0 key to establish the 0, 0 origin.

6. Insert the flash drive (U-Disk) into the USB port on the hand held controller.

7. Press the RUN/PAUSE key to display the option of selecting internal programs or programs from the USB flash drive.

8. With the U Disk file list highlighted, press ORIGIN OK.

9. Scroll through the files using the (#1) button to go up or the (#5) button to go down, and press ORIGIN OK when the desired .nc file is highlighted.

10. Parameters for that program will now be displayed. This is the speed that the torch will travel at during the cutting process. They may be edited at this point to adjust for specific materials. This will be explained in more detail later. Press ORIGIN OK. The controller should now run the program and return to the origin point when done.

11. You can dry run additional programs at this point if so desired by repeating steps 7 thru 10 above.

CAUTION: Always wear proper eye protection with side shields, safety footwear, and leather gloves to protect from burrs and sharp edges.

1. Check that the interconnect cables have been properly installed and that electrical service has been provided to the control box. (110V, 60hz.)

2. Place the material to be cut on the table, secure it, and attach the ground clamp that comes from the power unit directly to the material.

3. Make sure the consumables in the torch are correctly installed and properly sized for the intended application (consult the plasma cutter manual).

4. Make sure dry air is connected to the power unit and the correct pressure is set.

5. Power up the control box and the power unit.

6. With the “All axis home” highlighted, press the ORIGIN OK button. The torch head will move to the home position (corner). This position on the table is controlled by proximity sensors to stop the gantry travel.

7. Using the (“X+, Y+”) keys, move the torch toward the center of the table at least 1mm on each axis. (You may press both “X&Y” keys simultaneously for an angular motion.) This distance will vary based upon several variables of the part and the associated operating code.

8. After stopping, press the XY-0 key to establish the 0, 0 origin. The origin is now different from the Home position.

9. Consult the plasma cutter manual chart with the amperage you are running at, and the type of material you are cutting. Locate your material thickness and find the value in (mm) for the Torch Working Height. If you are using the automatic or machine torch, loosen the torch mounting bracket handle. Position the torch tip above the material at the working height value from the chart.

10. Convert the Pierce Delay value from the chart to milliseconds and enter that value into the handheld controller as Arc Delay. (Example: 0.40 seconds = 400ms.) This value is found in the controller by pressing MENU – AUTO PRO SETUP and scrolling down to Arc Delay. Enter the value and press OK.

11. When you change to a different thickness material, establish the new Initial Pierce Height between the shield cap and the material.

12. Insert the flash drive (U-Disk) into the USB port on the hand held controller.

13. Press the RUN/PAUSE key to display the option of selecting internal programs or programs from the USB flash drive.

14. With the U Disk file list highlighted, press ORIGIN OK.

15. Scroll through the files using the (#1) button to go up or the (#5) button to go down, and press ORIGIN OK when the desired .nc file is highlighted.

16. Parameters for that program will now be displayed. This is the speed that the torch will travel at during the cutting process. They may be edited at this point to adjust for specific materials. If no changes are required press the OK key. If changes are needed, use the (“X+, Y+”) keys to scroll to the line to be changed and then press the RUN/PAUSE key. Enter the new value and press OK. Repeat for any other line that needs to be changed.

17. Protect your eyes with a welding helmet or welding goggles.

18. Press ORIGIN OK. The controller should now run the program and return to the origin point when done.

19. The torch should proceed to the pierce location and start the cut.

20. When finished cutting, the torch will return to the last origin and stop.

Pierce and Cut Height is the distance between the material surface and the bottom (closest surface) of the torch. While it is necessary to have the proper height, first time cutters commonly err toward having too large a cut height. This will generally improve as the operator learns how the table and the material react during cutting.

• Cut Height too low: Can cause issues with the cut quality.

• Cut Height too high: Can cause issues with the cut quality.

• Correct Height: Provides the best possible cut.

Consult your plasma cutter manual for suggested cutting speeds and heights for the material and amperage you are cutting at. The tables included with the cutter manual provide good starting points for all the settings needed to cut a given material.

This is the procedure used to determine the setting for the best possible cut on the BAILEIGH PT-22.

1. Verify that the material is clean and free of oil, paint, and rust.

2. Verify that the ground clamp is clamped directly to the material to be cut.

3. Starting with the settings in the chart (from the plasma cutter) do a test cut at a fixed cut height.

4. Make sure your test piece is flat in the area you are cutting. A 3 inch square works for starters.

5. If it doesn’t pierce all the way through at the beginning – increase the pierce time.

6. If it pierces but then “rooster tails” during the cut – reduce the cut speed.

7. If the cut edges have dross on them that can be easily chipped off – increase the cut speed until it “rooster tails” then back off the speed until the rooster tail just goes away – you now have the best speed.

8. Now using those pierce time and cut speed adjust the cut height until the edge bevel is the best you can get.

9. If the edges are narrow at the top like a pyramid then the torch is too low so raise the cut height.

10. If the edge is narrow at the bottom lower the cut height.

11. Finally measure the width of the cut and that is your new kerf setting.

WARNING: Make sure the electrical disconnect is OFF before working on the machine. Maintenance should be performed on a regular basis by qualified personnel.

Daily Maintenance:

• Check daily for any unsafe conditions and fix immediately.

• Check that all nuts and bolts are properly tightened.

• On a weekly basis clean the machine and the area around it.

• Lubricate threaded components and sliding devices.

• Apply rust inhibitive lubricant to all non-painted surfaces.

• Do a general cleaning by removing dust, metal powder, and metal scrap from the table.

• Inspect the torch consumables for wear, and clean or replace as necessary.

Weekly Maintenance:

• Thoroughly clean the machine.

• Check any exposed electrical wiring for wear or damage.

• Inspect the power unit ground clamp for wear or damage.

Monthly Maintenance:

• Tighten any loose bolts, nuts, or screws on the machine.

• Keep roller bearings and sliding surfaces well lubricated.

• Wipe down lead screws.

Water Table Maintenance:

Using a table with just plain water will result in rusted slats and rust on the material being cut if left on the table for any length of time. It is therefore recommended to add a chemical such as Plasma Green® or an equivalent product, to the water. Chemicals such as this are designed to keep rust and odors in check and inhibit bacteria growth. Follow manufacturers recommendations as to how often to change the water.

The BAILEIGH PT-22 uses proximity switches on the X and Y axis to set the Home position (Machine Origin). Proximity switches activate using a mating surface as an activator. The air gap between the switch and mating surface should be 3/64” – 5/64” (1 – 2mm). If the gap is too small, they could contact and cause damage. If the gap is too large, the switch may not activate.

IMPORTANT: DO NOT squeeze or clamp on the proximity switch body too hard or overtighten the mounting nut. This will crush the internal circuitry of the proxy which will require a replacement switch.

Y-Axis Adjustment:

1. Move the Y axis in the negative direction until the sensor bracket is over top of the proxy.

2. Measure the air gap between the bracket and the proxy. The air gap should be between 3/64″ and 5/64″ (1-2mm).

3. Loosen and adjust the clamping nuts to allow the proxy to extend or retract as needed to create the correct air gap.

4. Hold the proxy in position and just to the point that the switch will not move.

5. Test the switch function by pressing the Home button and allowing the system to read the proximity switch.

X-Axis Adjustment:

6. For the X axis, remove the proxy mounting plate and using a straight edge across the opening, measure gap to the flat surface of the ball screw nut.

7. Now measure how far the proxy switch extends through the mounting plate. This measurement should be 3/64” to 5/64” less than the full gap measurement.

8. Loosen and adjust the clamping nuts to allow the proxy to extend or retract as needed to create the correct air gap.

9. Hold the proxy in position and just to the point that the switch will not move.

10. Test the X axis after installing the mounting plate and switch assembly.

WARNING: Make sure the electrical disconnect is OFF before working on the machine.

BobCAD-CAM is supported to run on Windows 7, Windows 8, and Windows 10. A 64 Bit System is needed.

Windows (Minimum)

• 64-bit Operating System

• 3GB RAM

• 256 MB Graphics Card* that supports OpenGL 1.1

• Intel® or AMD® Processors**

• 2GHz Processor

• Windows 10, Windows 8 or Windows 7

• Windows Indexing Service Must Be Enabled

• IE9 or above

Windows (Recommended)

• 6GB RAM or More on Windows 8 x64 Operating System

• 1GB Graphics Card*

• Intel® or AMD® Processors**

• 2GHz Processor (Multi-core) or higher

• Windows 10

Note:

*BobCAD-CAM’s stability is dependent on the graphics card ability to process information; integrated memory graphics cards may work but are not recommended. ATI® or NVIDIA® graphics cards with dedicated memory are recommended. The graphics card’s software driver must be updated to the current software drivers released by the graphics card manufacturer. 4K displays are not currently supported and may require reducing your screen resolution.

**BobCAD-CAM is not supported on Apple Macintosh®-based machines.