J a a a . KOIKE ARONSON, INC. PNC-12 EXTREME MANUAL 635 West Main Street » P.O, Box307 Arcade, New York 14008 Telephone 800-252-5282 Fax (585) 457-3517 Visit us on the web@www.koike.com 16¢5KOIKE PNC-12 EXTREME fear Peer Changing Language. Changing Unit of Measure.. Import files from USB. Changing Long Name Support Choosing Cut Files. Backing up Parameters....... Setting Array.. Restoring Parameters..... Setting Start Point...... Rotating Parts. Mirroring Parts. Oxy-Fuel Guide..... Oxy-Fuel Cutting Process. Torch Height Control (THC). Initial Height Sense (IHS) Setting Pierce Tim Torch Break Away. Hypertherm® Interface Guide. REFERENCES: Trouble Shooting Guide Koike Cutting Tip Chart Hypertherm® Bulletin 806200 (PM65) Hypertherm® Bulletin 807060 (PM65/85/105/125 Hypertherm® NestMasterTM PNC12 Extreme Parts Map PNC12 Extreme Initial Setup GuidePNC 12 EXTREME MANUAL - 16CS SAFETY » In This Section: 1.1 Introduction ceoeteorece 1.2 Notes, Cautions, and Warnings 1.3 Symbols and Warning Labels .. 1.4 General Safety... 1.4.1 Safe Workspace. 1.4.2 Electrical Hazards un 41.4.3 Fire and Explosion Prevention . 1.4.4 Compressed Gas Safety. 4.4.5 Personal Protective Equipment. 15 Safety, Plasma Cutting List of Illustrations Figure 1.1 Glossary of Symbols MwPNC 12 EXTREME MANUAL -16CS, 1.1 Introduction ‘The most important thing to know about this machine is how to operate it safely. It is the user's responsibility to read and understand this manual before attempting to install, operate, or service the equipment. Mechanical, electrical, and chemical dangers may be present on the machine. Follow all the safety precautions detailed below and throughout the manual for your safety and the safety of others. Failure to observe the safety precautions may cause serious injury or death. ‘The machine should be maintained and repaired by qualified technicians. Parts that are broken, worn, distorted, or contaminated should be replaced immediately. Koike recommends that a request for service be made either to your Koike authorized dealer or directly 10 the Koike service department. This is not a complete list of safety precautions. Local, state, and federal regulations should also be followed. In addition, read and follow manuals provided wits equipment integrated with the un 1.2 _ Notes, Cautions, and Warnings ‘This manual contains notes, cautions, and warnings that cal special attention to conditions that can lead to unsafe situations or that requir addtional information, The following formats ate used foreach: NOTE: A note offers additional information, such as an operating tip, that aids the user in operating the machine. A CAUTION: A caution describes a situation that may cause damage to machine and offers advice to avoid or rectify the situation. A WARNING! 4 warning describes a situation that presents a physical danger to the operator and offers advice to avoid or rectify the situation. Warnings display an applicable symbol for each type of danger (e.g., fire, explosion, electric shock)PNC 12 EXTREME MANUAL - 16CS. 1.3 Symbols and Warning Labels ‘Symbols and warning labels that may be used in this manual or on the unit identify specific dangers involved in the operation of this unit. Below is a glossary of symbols and their meanings. A» Zz PoisowToxic Gas Hazard Explosion Hazard Compressed Gas Hazard Do Not Touch—Hot Surace Insulated Gloves Required ) Proper Clothing Required Electrical Hazard Fre Hazard Eye Exposure Hazard Ground the Unit Cutting Tool Hazard }) NoOpen Flames. Do Not Remove Guards ‘Arc Flash Eye Protection Equipment Required Insulated Footwear Required ) Approved Respirator Required Figure 1.4 Glossary of symbols,PNC 12 EXTREME MANUAL 1.4 General Safety 1.4.1 Safe Workspace A Ensure a safe workspace surrounding the cutting machine: © Maintain a walkway surrounding the machine. * Consider surrounding the machine with a fence to limit access. © Do not climb on the table. * Change consumables while standing on the floor in front of the machine. ‘© Be aware of other workers in the area, * Operate the machine ina safe area and be aware of machine movements 1.4.2 Electrical Hazards A A Follow these safety rules to avoid electric shock: ‘© Only trained and authorized personnel may open this equipment. + Use lock out/tag out procedures to prevent t2e unintentional startup of equipment while someone is working on it * Connect and maintain electrical grounds to the equipment according to local costes and NEPA 70. Improper installation can lead to equipment malfunction and personal injury. * Verify that machine voltage and supply voltages are the same before turning on the power switch, Transformers are provided with taps to accommodate various supply voltages, Machine damage or erratic operation may result from improper supply voltage. Contact a certified electrician for proper installation. ‘© Never operate this machine unless all electrical enclosure covers are securely closed. Exposed electrical components present severe shock and fire hazards, ‘* Provide a wall-mounted disconnect switch with properly sized fuses or circuit breakers for both the cutting machine power and the plasma power supply. Mounting this switch in close proximity to the cutting machine allows the operator to turn off the power supply ‘quickly in an emergeney situation * Conform to all local codes and NFPA 70 for primary wiring sizes and types. ‘+ Inspect the primary power cord frequently for damage or cracking of the electrical insulation. Touching bare wiring can be fatal. Do not use the system with a damaged power cord. If a power cord is damaged, replace it immediately, ‘* Make sure that all electrical connections are tight to avoid excessive heating. ‘+ When plasma cutting, clamp the work cable to the workpiece (not the portion that will fall away) or to the work table, maintaining good metal-to-metal contact. ‘+ Keep the working area dry to avoid electric shock,PNC 12 EXTREME MANUAL. Optional Plasma Systems: For proper grounding, plasma systems require supplemental ground rods to be driven into the earth. See Section 3.3.1.2 Grounding Procedure for more information about supplemental grounding rods. 1.4.3 Fire and Explosion Prevention A Caution: Do not connect a welding ground to any part of the machine. Doing so will damage its electronic controls. Evidence of welding ground connection to the machine will void any warranty. A EXPLOSION HAZARD Do Not Cut Aluminum On The Water Table- Doing so Can Result in Serious Personal Injury or Death ‘© Plasma cutting aluminum on a water table causes the release of free hydrogen. ‘+ Aluminum partictes will chemically react with the water producing this free hydrogen gas. ‘+ Free hydrogen gas may collect under the work piece and/or inside the air bladder and ‘can detonate when plasma cutting or cutting scrap with a hand torch resulting in @ serious hydrogen explosion hazard.PNC 12 EXTREME MANUAL A A Prevent fire and explosion by complying with standards: ‘To prevent fire and explosion, the installation and use of the equipment must be in compliance with, the latest editions of the following standards: National Fire Protection Association (NFPA) Standard 51B: “Standard for Fire Prevention During Welding, Cutting, and Other Hot Werk” National Fire Protection Association (NFPA} Standard 51: “Standard for the Design and Installation of Oxygen-Fuel Gas Systems for Welding, Cutting, and Allied Process” ‘American Welding Society (AWS) Standard C4.2/C4.2M:2009: “Recommended Practices for Safe Oxyfuel Gas Cutting Torch Operation” ® Fire Prevention Tips: Remove combustible material from the immediate cutting area. Never use oxygen to ventilate the area or clean off clothing. Keep oil, grease, and combustible dust away from all oxygen equipment. Always purge oxygen and fuel lines separately. Never use the oxygen hose for any other gas than oxygen. ‘Make fire extinguishers available in the cutting area,PNC 12 EXTREME MANUAL 1.4.4 Compressed Gas Safety Gas cylinders can explode if damaged. Follow these rules to ensure safe handling of gas cylinder © Handle and use compressed gas cylirders in accordance with safety standards published by the Compressed Gas Association (CGA) and Canadian Standards Association (CSA), ‘+ Never use a eylinder that leaks or i physically damaged ‘Never use a cylinder that is not upright and secured in place. ‘Never move or transport a cylinder without the protective valve cover in place ‘© Never use a gas cylinder or its contents for any purpose other than that for which it is intended. + Never lubricate cylinder valves with oil or grease. * Never expose cylinders to excessive heat, sparks, slag, or open flame. + Never use hammers, wrenches, or other tools to open stuck cylinder valves. + Never cover the gas panel without venting the bottom of the cover (fuel gases are heavier than ai). + Use oily comect yas eylinders, egulaturs, uses, and filings designed for the specific application. ‘Label and color-code all gas hoses to identify the type of gas in each hose. ‘+ Regularly inspect check valves for proper function, Do not remove or bypass check valves. © Always open gas valves slowly. + Replace hoses that are damaged by physical abuse, sparks, heat, or open flame.PNC 12 EXTREME MANUAL 1.4.5 Personal Protective Equipment Limit Your Exposure To Hazards: Proper clothing and personal protective devices must be worn to prevent burns and exposure to ultraviolet light. { Cutting will produce sound pressure that causes hearing damage. Proper hearing { protection must be worn to avoid pernanent hearing loss. protect your eyes from physical damage from fying debris. Special eye Eye protection must be wor at all times while operating this equipment to \ protection is described below for cutting processes. protection while cutting. For plasma cutting, the plate must conform to the following: Atc Current up to 300 Amps: Shade No. 9 Are Current 300 to 400 Amps: Shade No. 12 ‘Are Current over 400 Amps: Shade No. 14 @ A helmet with the proper filter plate must be worn for eye and face 1.5 Safety, Plasma Cutting The plasma arc produces intense heat, visible, and invisible radiation. Follow the rules below to avoid injury: * Use eye and skin protection when working with plasma cutting equipment to prevent UV burns * When cutting, wear an approved respirator and provide proper ventilation. * Quench freshly cut metal or allow it to cool tefore handling it or bringing it in contact with combustible materials. * Leave the workpiece in place on the worktable until the cutting cyele is complete. * Before servicing the plasma torch or changing consumables, disconnect the plasma power supply. * Plasma cutting, especially of aluminum or magnesium, may cause an accumulation of explosive gas below the plate. Do not allow cluminum or magnesium dross to accumulate in the water table, * Read and follow the safety instructions provided with your plasma supply.PNC 12 EXTREME MANUAL - 16CS Welcome to the PNC 12 me! Press “Start” to continue | an, *PNC 12 EXTREME MANUAL - 16CS Below is the Main Screen that will show once your machine is turned onPNC 12 EXTREME MANUAL - 16CS COMMON FUNCTION KEYS + Fi-(Patterns) — © Will access the 48 pre-loaded shapes that you can edit from the controller and cut- out ©. These shapes can be edited (lead in/out, scaling, sizing, etc) from the PCN control > Note: #44 is a Rosetta and is a motion test shape that cannot be cut. It is to be used for troubleshooting only.PNC 12 EXTREME MANUAL - 16CS * F2-(Files) — ‘© This function allows access to memory files, both those saved to the PNC Hard Drive or USB © Notice that the menu option at the bottom of the screen will change * Fi (HDD File) to view files saved to the PNC Hard Drive + F2 (USB) to view files on a USB drive + F3 (Search) allows to search by Text © There are 10 folders listed and are available to save your Choose the desired folder by using the numeric key pad on the CNC to view your saved files * F3-(Parts) — © Notice that the menu option at the bottom of the screen will change srt shi oetellbeebtes ©. This is where you can change your start point, rotate the shape, create an array scale the size of the shape up or down, select pierce points, etc. © Additional instructions starting on page 17 Goi Gl Ge te es eS GS" oe eee ae ae aedPNC 12 EXTREME MANUAL - 16CS * F8(OK)- © Any changes will not take effect until you press F8 (OK) * Space button- ‘© Provides additional menu options * F2 (Dry Run) runs the current program without firing the torch * F3 (Border) is useful to see if a shape will fit on a plate quickly. It frames the shape into a square and traces the square * F4 (Speed-) Decreases speed during the “Dry run” + FS (Speed +) Increases seed during the “Dry Run” * ESC button- © Return the screen back to the previous menu “PNC 12 EXTREME MANUAL - 16CS IMPORTING FROM USB DRIVE 1. From the Maln Soren, press F2 (Files) 2. From the new menu, press F2 (USB File) 3, Choose the desired part using the arrow key pad on the CNC 4, Press F6 (Copy HDD) 5. Key in the name you want to call your part . Press F8 (OK) or Enter . Proceed to instructions for CHOOSING A FILE TO CUT (page 16) NoPNC 12 EXTREME MANUAL - 16CS IMPORTING TO A SPECIFIC FOLDER 1. From the Main Screen, press F2 (Files) 2. Choose from the available files by using the numeric key pad on the CNC, press Enter . From the new menu, press F2 (USB File) . Choose the desired part using the arrow key pad on the CNC . Press F6 (Copy HDD) . Key in the name you want to call your Press F8 (OK) or Enter }. Proceed to instructions for CHOOSING A FILE TO CUT (page 16) nNPNC 12 EXTREME MANUAL - 16CS CHOOSING A FILE TO CUT 1. 2 3. ou From the Main Screen, press F2 (Files) Press Fi (HDD File) Choose from the available files by using the numeric key pad on the CNC, press Enter NC ». Press F8 (OK) . The shape will load and you will return to the Main ScreenPNC 12 EXTREME MANUAL - 16CS HOW TO SET AN ARRAY * ARRAY: Cutting multiple copies of the same part at the same time This is an example of an ARRAY 1, After choosing the part you wish to cut, from the Main Screen, Press F3 (Parts) — notice that the menu option have changed at the bottom of the screenPNC 12 EXTREME MANUAL - 16CS 2. Press F3 (Array) - this will bring up another menu showing different types of arrays. ARRAY EXAMPLES Fi Matrix F3 E co ee cou faPNC 12 EXTREME MANUAL - 16CS 3. After selecting the type of array you want, screen below will come up 4, Select the amount of rows and columns. 5. The program requires at least 2 in either row or column and one in the alternate row/column to cut just two of the same shape. 6, Row Length and column length are shown in Millimeters and this is the minimum amount of material the CNC needs to cut the shape > NOTE: You may find that you need more space in between shapes so add to these numbers accordingly. Below is an example of one column and two row matrix array 20PNC 12 EXTREME MANUAL - 16CS 7. Confirm the programmed Cut mode, Cut Speed and Kerf are appropriate for your application > For Plasma systems ~ refer to your Plasma Power Supply Manual > For Oxy/Fuel systems — refer to the Koike Cutting Tip Chart under “References”, also available at www.koike.com ‘The red letters in the middle right hand box are short cut keys To access the short cut keys ~ press SHIFT and the # . to access Kerf — press SHIFT N You can change your [X] Cut Speed, [N] Kerf, and [M] Cut mode using the shortcut from the main screen aPNC 12 EXTREME MANUAL - 16CS HOW TO SET THE START POINT 1. Set the start point > Notice the black crosshair is still on the first original shape- this is where the machine will start the cut process. 2. Press Fi (Start Pnt) - it will bring up the menu shown below 3. Choose any one of these start points — the cross hair will move the point you have selected 4, Press F8 (OK) and it will turn blue - press F8 (OK) again to set the start point > NOTE: Itis recommended to start from the Lower Left corner of the plate and work to the right to avoid the cross bar from being in their way while the machine cutsPNC 12 EXTREME MANUAL - 16CS 5. Confirm the programmed Cut mode, Cut Speed and Kerf are appropriate for your application > For Plasma systems - refer to your Flasma Power Supply Manual > ~ refer to the Koike Cutting Tip Chart under “References”, For Oxv/Fuel systems also available at www.koike.com The red letters in the middle right hand box are short cut keys To access the short cut keys — press SHIFT and the # .2. to access Kerf ~ press SHIFT N You can change your [X] Cut Speed, [N] Kerf, and [M] Cut mode using the ‘shortcut from the main screenPNC 12 EXTREME MANUAL - 16CS HOW TO ROTATE A PART After you have selected the shape you wish to cut you may find that it will fit better on your plate by rotating the part. 1. After choosing the part you wish to cut, from the Main Screen, press F3 (Parts) — notice that the menu option at the bottom of the screen have changed N 2. Press F2 (Rotate) - this will bring up another menu showing rotation options 3. Press F2 (Angle Input) — another menu will show (continue to step 4) eoPNC 12 EXTREME MANUAL - 16CS 4, Input the degree you need the part to rotate Example: To rotate the part 90 degrees put 90.00 in for angle and press F8 (OK) to confirm the eg ces EE 5. The part has now rotated 90 degrees 6. Press F8 (OK) to confirm the changesPNC 12 EXTREME MANUAL - 16CS 7. Confirm the programmed Cut mode, Cut Speed and Kerf are appropriate for your application > For Plasma systems — refer to your Plasma Power Supply Manual > For Oxy/Fuel systems ~ refer to the Koike Cutting Tip Chart under “References also available at www.koike.com The red letters in the middle right hand box are short cut keys To access the short cut keys — press SHIFT and the # i.e, to access Kerf ~ press SHIFT N You can change your [X] Cut Speed, [N] Kerf, and [M] Cut mode using the shortcut from the main screen 2%PNC 12 EXTREME MANUAL - 16CS HOW TO SET MIRROR IMAGES * MIRROR CUTS: cutting identical shapes at the same time but with the structure reversed 1. After choosing the part you wish to cut, from he Main Screen, press F3 (Parts) — notice that the menu option at the bottom of the screen have changed 2. There will be two options on the right of the screen, a red [X] and [Y] * Press either the X or Y button on the key pad and the part will mirror image itself 3, Press F8 (OK) to confirm the changes SS i os cy moPNC 12 EXTREME MANUA| 16CS 4, Confirm the programmed Cut mode, Cut Speed and Kerf are appropriate for your application > For Plasma systems ~ refer to your Plasma Power Supply Manual > For Oxy/Fuel systems ~ refer to the Koike Cutting Tip Chart under “References”, also available at www.koike.com ‘The red letters in the middle right hend box are short cut keys To access the short cut keys — press SHIFT and the # i.e, to access Kerf — press SHIFT N You can change your [X] Cut Speed, [N] Kerf, and [M] Cut mode using the shortcut from the main screen 2PNC 12 EXTREME MANUAL - 16CS OXY-FUEL CUTTING GUIDE Oxy-Fuel cutting requires you to take in account variables that are constantly changing. Your pierce time on a plate of steel will change with temperature and the material condition. > Note: To cut with oxy-fuel the Height Control must be turned off. Nir e— 1. Install the solenoid pack and the Oxy-Fuel torch > See Installation Guide for details > Note: The three pin connector is not used for Oxy-Fuel cutting 2PNC 12 EXTREME MANUAL - 16CS 2. Set your parameters under the FLAME selection ‘These parameters are going to change depending on the fuel/gas that you are using and the material that you are using. > The tip size, speed, kerf, and regulator pressures can be found on our web site. This information i This information is critical to achieve a good cut!! > Refer to the Koike Cutting Tip Chart under “References”, also available at www. koike.com, Below is an example of starting parameters, this is an example only ~ each machine will need to be adjusted according to the variables that are constantly changing. This is an Example only 3. The most important parameters are: Low preheat Pierce 3 Blow time Pierce up time Pierce down time 4. Press F8 (Save) to save changesPNC 12 EXTREME MANUAL - 16CS 5. Confirm the programmed Cut mode, Cut Speed and Kerf are optimum > For Oxy/Fuel systems ~ refer to the Koike Cutting Tip Chart under “References”, also available at www.koike.com ‘The red letters in the middle right hend box are short cut keys To access the short cut keys ~ press SHIFT and the # i.e, to access Kerf ~ press SHIFT N ‘You cat chaniye your [X] Cut Speed, [N] Kerf, and [M] Cut mode using the shortcut from the main screen 6. You are now ready to cut atPNC 12 EXTREME MANUAL - 16CS OXY-FUEL CUT PROCESS + This screen show below will give you a live countdown of the machine cut process after you start a cut. + You can see the “Low Heat” Icon is green - this indicates the machine preheat time in seconds and will count down until the next step. * Increase or Decrease preheat time by pressing F6 or F7 - this adds and subtracts 10 seconds each time it is pressed 2PNC 12 EXTREME MANUAL - 16CS OXY-FUEL CUT PROCESS CON'T * After each step of the cut process is completed the green icon will go to the next step you have programed and start that process. * Observing this during a cut will help you fine tune the parameters to meet your cutting needs * Once you have verified that all of the parameters are set optimally you will need to light the torch. LIGHITNG THE OXY-FUEL TORCH 1. Move the machine torch to a place on the table that is not blocked by steel and you can light the torct 2. Press the Ignite button on the control panel * This will allow gas to reach the manually adjustable valves. * Slightly crack open the RED valve - this is your fuel/gas valve + Light the flame using a striker * Quickly introduce oxygen to the flame by slowly opening the GREEN valve. This should give you a blue controllable flame. * Continue to open your RED and GREEN valves until you achieve a good neutral flame + The BLACK valve is your cut oxygen and it should be opened all the way This is a good neutral flame This is a proper flame set at the cut height 2PNC 12 EXTREME MANUAL - 16CS 3. Raise the torch and move it to your pierce point 4, Lower the torch until you have a nice star pattern flame 5. Press the Start button on the controller, it will prompt you to pressing Enter, press Enter 6. The machine will start the Low preheat countdown, then it will raise the torch and start to pierce while lowering the torch back to the Cut height you set when you manually adjusted the flame to the plate. * If the cut speed is set properly you will hear a lapping sound and your cut will have smooth vertical lines and a sharp top and bottom edge ‘© Any slag or dross should easily chip right off aPNC 12 EXTREME MANUAL - 16CS (TREME OXY/FUEL CUTTING PARAMTERS PNC-1: ! Move to next piercing point ‘Stops atend point Move (auttingy LowProheattime Stays at Plereing point 8 2 i Torch downtime é a Fasidiee rs. SePNC 12 EXTREME MANUAL - 16CS fORCH HEIGHT CONTROL (THC) The PNC-12 Height Control is important to have set up properly. * The adjustments that need to be made for it to operate properly are specific to your plasma system. > The information that you need from your plasma manual: © Initial Pierce Height © Voltage © Pierce Delay Time * Continue to page 36 for instruction on Turning on the Torch Height Control This chart is an Example only English . Seti ction Seti moterar | T= Tints plevce | Pierce | Best Quality Settings [ Production Settings qflaterial | to-work | '™MelPieree | “Delay [cut Cut icknoss | Bictsnes ia Time | sooty | Votage | ct, | voltage in in [ 2% [seconds| ipm Volts ipm Volts 00 [250 122 | 336 | 121 02 | 185 128 290 | 123 0.15 | 260 180 128 i60_| 126 os 70 126 86 127 % 131 86 131 0.18 | 300 0.08 10 36 134 37 133 15 138 29 135 22 14 Edge Start 2 i 145 13 148 10 powerMmax6s/86 Operator Manual 3-29 6PNC 12 EXTREME MANUAL - 16CS 'URNING ON TORCH HEIGHT CONTROL (THC) 1. Press the blue AVC button on the top of the machine. It will ight up to indicate that the height control is on. > Note: To cut with oxy-fuel the Height Control must be turned off. 2. Press the hand button this turns on the autcmatic control of the height control system, The red “En Auto” LED will light up. ater Be fac”PNC 12 EXTREME MANUAL - 16CS Initial Heiaht s Hs + The Initial Height Sense (IHS) is where you set your pierce height. + This setting is dependent on the thickness of the material you are cutting. You want to use the recommended settings your plasma manual states for the material that you are going to pierce. * The machine will pierce and the torch will lower to the proper cut height automatically. ‘Property setting this will extend the life of your corsumables. Testing the (IHS) 1, Press the IHS TEST button and watch the torch lower to the piate 2. When the torch hits the plate it will automatically retract to the setting you have programmed. 3. To change the amount the torch retracts, tun the knob labeled SET IHS. Arc Voltage Control (AVC) * The Arc Voltage Control (AVC) is where you progra the PNC exactly as your plasma manual states, In the above example (page 36) the manual calls this setting "VOLTAGE” > Note: Finding the optimum setting for your cut will require fine tuning your own settings. Every machine has a its own variables including different resistance and slag buildup on the cutting slats. ARC VOLTAGE eee... wise Una de Pen dion dd combed de al bua.PNC 12 EXTREME MANUAL - 16CS Setting the pierce time ‘+ Below is a picture of the controls for setting the pierce. * The optimum setting is found in your plasma manual. (A) The pierce setting controls how long the plasma system fires before the PNC starts to move. ‘The optimum pierce time allows for full penetration of the material you are cutting before the machine starts to cut the shape. A Yvemp #6 hemesin oo Cc by Arc Test ARC Test (8) Pressing the ARC Test button will momentarily fre the plasma system to make sure everything is interfaced properly and that you achieve a full pierce. UP/DOWN (C) The UP/DOWN buttons will raise and lower the torchPNC 12 EXTREME MANUAL - 16CS ‘Torch Break Away + The torch break away is part of the height control system ‘+ There are two proximity switches built into the torch clamp and they have red LED's built into them. © When both proximity switches are satisfied the LED's will ight up * Both proximity switches must be satisfied ‘© When they are not adjusted properly one or both LED's will not light up and this will cause the torch to automatically rise up and remain in the raised state until they are satisfied again * It is important to keep the magnets clean in the breakaway. If metal dust builds up it can cause the system to operate improperly. Properly satisfied One Prox. Switch not satisfied Breakaway trippedPNC 12 EXTREME MANUAL - 16CS o_o BEFORE STARTING YOUR PLASMA CUT: Confirm the programmed Cut mode, Cut Speed and Kerf are appropriate for your application > For Plasma systems ~ refer to your Plasma Power Supply Manual = ‘The red letters in the middle right hand box are short cut keys To access the short cut keys — press SHIFT and the # i.e. to access Kerf — press SHIFT N You can change your [X] Cut Speed, [N] Kerf, and [M] Cut mode using the shortcut from the main screen > You are now ready to cut “PNC 12 EXTREME MANUAL - 16CS CHANGING LANGUAGE, UNITS, PARAMETER BACKUP/ RECOVERY Below is the main screen when the machine boots up. HOW TO CHANGE LANGUAGE 1. From the Main Screen, press F5 (Diagnose) —the menu below will show 2. Press F8 (SystemDef) — the menu below will showPNC 12 EXTREME MANUAL - 16CS 3. Press F6 (Language) and it will bring a dropdown menu - choose the appropriate language 4, Press Enter (DO NOT PRESS F8) 5. Turn off the main power switch and restart the PNC Machine 6, It the PNC does not show the new language, restart the machine a second timePNC 12 EXTREME MANUAL - 16CS HOW TO CHANGE UNITS 1. Press F5 (Diagnose) -the menu below will show 2.Press F8 (SystemDef) — the menu below will show 3. Press F3 (Define) and it will ask for a password. The password is 1396 4“PNC 12 EXTREME MANUAL - 16CS 4. After you have entered the password you will see this screen. It is very important that you do not change anything on this screen. Anythin ill not be able to be reset with a parameter restore and could ruin the_machine. a Z 5. Press F5 (Option) — the menu below will show } = SPNC 12 EXTREME MANUAL - 16CS 1, Go to the “Unit” using the arrow yad on the CNC, press Enter 7. It will bring a dropdown menu ~ choose the appropriate language, press F8(Save) or Enter 6. Using the drop down from “Unit” — choose the appropriate Units (Metric or Inches) 8. Turn off the main power switch and restart the PNC Machine 9. It the PNC does not show the new units, restart the machine a second timePNC 12 EXTREME MANUAL - 16CS HOW TO CHANGE THE “LONG NAME SUPPOR’ When naming a file, the PNC will default to abbreviating the file names Use the following instructions to turn on the “LONG NAME SUPPORT” so that the PNC will show the entire file name (no abbreviations) 1. Press F5 (Diagnose) —the menu below will show 2. Press F8 (SystemDef) — the menu below will show aPNC 12 EXTREME MANUAL - 16CS 4, After you have entered the password you will see this screen. It is very important that you do not change anything on this screen. Anything changed on this i Ke reset with a parameter restore and could ruin the machine. 5. Press FS (Option) — the menu below will showPNC 12 EXTREME MANUAL - 16CS 6. Goto the “Long Name Support” using the arrow key pad on the CNC, press Enter 7. It will bring a dropdown menu — choose the appropriate language, press F8(Save) or Enter 8. Using the drop down choose “Yes” 9. Turn off the main power switch and restart the PNC Machine 10. It the PNC does not show the new changes, restart the machine a second timePNC 12 EXTREME MANUAL - 16CS ——————— HOW TO BACKUP PARAMETER SETTINGS + Important: It is highly recommended that the parameters be set up and backed-up immediately! This will prevent an operator from accidentally changing a parameter that should not be changed. * Be sure to back up if you have changed parameters and you want them to be saved as the new baseline for your machine * By backing up your new parameters it will replace the factory parameters and when you do a parameter restore it will revert back to what you have saved instead of the factory parameters 1. Press F5 (Diagnose) —the menu below will show 2. Press F8 (SystemDef) — the menu below will showPNC 12 EXTREME MANUAL - 16CS 3. Choose F2 (PM Backup) and it will ask for a password. The password is 1396 4. The parameters are now backed up 2 ts Gs pw ‘ 2 oyPNC 12 EXTREME MANUAL - 16CS HOW TO RESTORE PARAMETER SETTINGS * Important: It is highly recommended that the parameters be set up and backed-up immediately!! This will prevent an operator from accidentally changing a parameter that should not be changed. > See page 49 for instructions on backing up original parameters The parameter restore is the first step to try if you are having problems with your machine. Restore the parameters if the machine isn’t running correctly or you changed something that you cannot remember how to change it back. 1. Press FS (Diagnose) —the menu below will show 2.Press F8 (SystemDef) = the menu below will showPNC 12 EXTREME MANUAL - 16CS 3. Press Fi (Recovery) and it will ask for a password. The password is 1396 4. The parameters have now been restoredPNC 12 EXTREME MANUAL - 16CS —————— Hypertherm® References > SAFTEY NOTE: Make sure all power is turned off and disconnected before any electrical work on the plasma system. > SAFTEY NOTE: There will be high voltage going between the lasma system an: height control on the = HYPERTHERM® INTERFACE GUIDE The following instructions apply to the Hypertherm® Powermax 45, 65, 85,105, 125 © Interfacing the PNC12 will REQUIRE: Koike part #0818312900- Hypertherm® Interface Cable This part # includes: 25' Interface Cable Strain Relief 1. Interface Cable * Remove the cable labeled CN2 from the packaging and remove the metal male ‘two prong connector. Solder the green and black wires trom the connector to the Hypertherm®@ interface cable. ‘* This is the plasma start signal, pins 3 and 4 on the Hypertherm® connector (Page 3- 21 in the Hypertherm® Powermax manual) Refer to the following table when connecting the Fowermas65 or Powermax@S to a torch height controller or CNC controler with a machine interface cable. Signal [Type connector [Cable wires kets | [Stat input Normally open, isa (Green, black ———} (start 18 VOC open circuit voltage at | plasma) [START terminals. Requires dry i jer contact closure to activalo. IfPNC 12 EXTREME MANUAL - 16CS 2. Take the CN1 and strip the outer layer of insulation and shielding back so the cable can flex around the tight bends required to reach the connection point inside the plasma system. > NOTE: CN1 cable on the PNC-12: © The PNC 12 BLACK CN1 wire is NEGATIVE © The PNC 12 WHITE CN1 wire is POSITIVE > NOTE: The COLORS of the wires WILL NOT MATCH ets This must be hooked up properly as shown above or it will to the PNC-12PNC 12 EXTREME MANUAL - 16CS 3. Install the Strain Relief = Remove the cover on the plasma system - there is an indexed “Access Point” on the lower right side on the rear of the plasma system * This “Access Point” that will need to be drilled out to 19/32” for the strain relief. Rear pane! 4. To complete the Hypertherm® interface process, read and understand the appropriate Hypertherm® service bulletin: * Field Service bulletin 806200 for Powermax 45 * Field service bulletin 807060 for Powermax 65/85 105/125 * They are also available at Hypertherm® web site www.hypertherm.comPNC 12 EXTREME MANUAL - 16CSKOIKE PNC-12 EXTREME TROUBLE SHOOTING GUIDE aiid Pee D pares Torch will not Lower... Pierce time is too long or shot Torch piercing on plate or too close to plate. Machine is firing plasma torch in the air. Torch diving into plate during cut. Main machine unit will not move......... Torch Breakaway does not reset proper! Machine runs but glitches during plasma cuttin: Machine jogs continuously or in short steps. Machine slows drastically in corners..... Aup_WWWHN oNPNC 12 EXTREME INSTALLATION GUIDE - 16CS 1. Torch will not lower © If cutting Oxy/Fuel: o Check height control — if must be OFF <_— « If cutting Plamsa: o Check the Proximity Switches - BOTH lights should be illuminated = If they are NOT illuminated — A. Check the alignment by placing two coins in between the magnets on each of the proximity switches * They are wired in series, so one will come on, then the other will come on. ¢ If they illuminate then they must be lowered so they always reset after the IHS test B. Check for damages and continuity on cable CN3 © Pin 1 to 1, Pin 2 to 2, Pin3 to3 ® These connectors are solder type and can be repaired 2PNC 12 EXTREME INSTALLATION GUIDE - 16CS 2. Pierce time is too long or short © Check that the “SET PIERCE” knob on the upper right hand of the height control is set appropriately. © If pierce time still will not adjust, check the plasma parameters, Parameters>Plasma>Pierce Time * Change this setting to 0.7 sec 3. Torch is piercing on plate or too close to plate © Check that the “SET IHS” knob on the upper left hand side of the height control is set appropriately. Most likely it will need to be increased. 4. Machine is firing plasma torch in air © Change parameters - go to: o Parameters>Plasma>INITIAL HEIGHT SENSING TIME > NOTE: Your machine may not show it as “Initial Height Sensing Time” — but it will always be the 4™ parameter from the top © Change this setting to 1.0 sec Check that the Torch Breakaway is resetting properly — both proximity switches should illuminate immediately after the torch touches the plate. If they do not illuminate and reset the torch will continue to rise,PNC 12 EXTREME INSTALLATION GUIDE - 16CS 5. Torch is diving into plate during cut ® Check the ARC VOLTAGE on your height control panel * Check the CUT SPEED - if the cut speed is too slow the height control will lower the torch during the cut > NOTE: These values work together — lower CUT SPEED will need to have an increased ARC VOLTAGEPNC 12 EXTREME INSTALLATION GUIDE - 16CS 6. The machine will not move A. Check to make sure the machine is online. The Yellow button to the left of the Power Switch should be illuminated. B. Check the Emergency Stop Button - if it has been engaged it will stay engaged until it is rotated and then it will pop back out. C. If the machine is very cold (Sub-zero temperatures) and makes a clicking sound, then the grease in the sealed bearings are too cold. The work environment will have to be increased to eliminate the problem.PNC 12 EXTREME INSTALLATION GUIDE - 16CS 7. The torch breakaway does not reset properly A. Clean the Torch Brake away magnets - dirt and dust can buildup on the magnets. Simply wipe them clean on a regular basis. B. Check the torch height o Raise the torch up all the way and press “IHS TEST”. If the torch breakaway resets then the torch is too low when starting the cut. o Raise the torch 2 inches off the material before beginning the cut C. Check the plasma leads for appropriate length o Remove the plasma torch leads from the break away and make sure there is no preload or twist on the cable. © If the torch leads are too short they will pull tight when the lifter lowers this causes preload — pull more cable through the cross bar to provide more length to lifter. o. If the torch leads are too long there will be too much weight from the extra lead and cause preload — pull cable back through the cross bar to minimize the preload at the torch breakaway 8. Machine will run but glitch ring plasm: in A. This is typically due to electrical noise interference associated with High frequency plasma units o Remove the torch leads from the cross bar and run it externally to the torch clamp. If this resclves the problem, contact the plasma manufacturer and request a shielding kit. B. Interference can also be caused by TIG welding. Check the area to make sure there is no TIG welding being performed near the PNC-12. o Standard MIG welding will not affect the PNC-12PNC 12 EXTREME INSTALLATION GUIDE - 16CS 9. Machine jogs continuous! in si * Check the JOG mode on the controller - above the X/Y coordinates, next to the red "F”, it will say JOG > MmtrMV/Step MV/or ContMV (mode will change each time you press “F”). o MMtrMV - this mode allows the machine to move while a direction key is continually pressed. When the direction key is released the machine stops. StepMV _ this mode allows the machine to move a defined distance in the direction of the key being pressed. The defined distance can be changed by pressing “G”. The value is displayed directly below JOG on the control screen. ContMV — this mode allows the machine to move when a direction key is pressed and the machine continues moving until the direction key is pressed a second time.PNC 12 EXTREME INSTALLATION GUIDE - 16CS 10. Machine slows drastically in corners * Check the parameters: Parameters>Plasma>"SMALL ARC LIMIT” OR “SMALL CICLE CLAMP SPEED” > NOTE: Your machine may not show it as “SMALL ARC LIMIT” — but it will always be the 6™ parameter from the top * Change the parameter to ZERO (0)High Quality Gas Cutting Tips = Design Each KOIKE utting tip is designed for proper gas clfciency and to provide the highest cutting ‘accuracy, * Safety All 100 series and Epoch series cutting tips are designed to help prevent damaging flashbacks and backfires into the torch. * Quality Every cutting tip is checked for fom, ft and function then fited and cjced to ensure thatthe preheat flame and jet oxygen are of KOIKE KOIKE enjoys a worldwide reputation as 2 leader in the feld of gas cutting machines. KOIKE's reputation is due in large part (o their finely crafted gas cutting tips. Since a poor tip can ruin the performance of an excellent cutting machine, KOKE has concentrated is efforts on research and development of 85 cutting tips. KOIKE's approach sets it apart from its competition by virtue of their commitment to continuously fund research and development of thelr cutting systems. KOIKES clients benefit from their long history of gas cutting manufacture, torch research and development, and experience cutting various materials such innovations as test machines co check tip efficiency. Superior customer support means superior cutting tip performance. If you want your cutting manufactured to rigorous standaids so that they cut accurately, safely and economically, then KCIKE is your choice. Against a sustained flashback when using a genuine Koike cutting tip (Camaged torch and genuine Koike cutting tip must be relumed) KOIKE ARONSON, INC. / RANSOME106D7 Divergent High Speed Tip High Quality Cuts To ensure tp quality, KOIKE checks the surface obtained by real cutting and uses the following criteria to achieve a quality cutting surface: * Even cutting surface (small kerf) = No top slag = Minimal upper edge melt = No bottom slag In additional co saisying the previously mentioned criteria, KOIKE demands that it’s tips also meet the following conditions: * Cutting operation with high speed * A steady and safe cutting operation * Cutting with efficient gas consumption To achieve the above criteria and conditions 2 KOIKE tip must maintain superior oxygen cutting flow and an efficient yet, uniform pre-heat flame. To do this KOIKE reserached: * Various tip shapes and sizes of the Inlet part of the cutting oxygen tip * Pre-heat oxygen and fuel gas mixtures in the pipes, the gas mixing chamber, and the election outlet As a result of this work KOIKE developed the divergent tip. The cutting outlet of this tip has a divergent shape to it This tip Is the result of extensive engineering design by the KOIKE engineeting department, KOIKE uses a unique patented stainless steel lining to ensure the divergent tips durability. The divergent tip technology was developed to process small holes of non- flight meral KOIKE’s commitment to research and design of gas cutting tips is demonstrated in the high quality of is finished productSince gas welding and cuting operations are particularly vulnerable to explosions and other unwanted accidents, any small flame and flash-up must be avoided, Consequently, KOIKE is committed to ensure safe cutting operations for i's customers. Inthe area relating t0 tip design, significant attention has been paid to the prevention of backfire. Backfire can be classified into three types: |. Backfire: Pre-heat oxygen flows back into the torch, 2. Flashbacks The flame flashes atthe tip edge 3. Sustained Flashback: Flows back to the gas mixing point cf the tip and melts it ‘The most dangerous of these are the flashback and sustained flashback. KOIKE has resolved these two conditions through Its rigorous research and design process. With regards to flashback, KOIKE has developed the venturi effect of the tip for fuel. Conventional middle-pressure tips may force the backflow of are-heat oxygen into the fuel gas which introduces mixing gas into the mixing tube. This is usually encountered with difficuk situations conceming the torch itself ot with the sheet being cut ‘The flashback occurs when the fuel is supplied. KOIKE's soluion to this is @ provide the venturi effect to the cutting tip. This Is done by means of the high-speed pre-heat oxygen, Fuel Gas is sucked into the tip in order to prevent the mixing gas in the ‘otch pipe, and thus flashback duting ignition is prevented ‘The sustained flashback might occur when the dp is clogged up with slag during the cutting operation. KOIKE has found that the ideal proportion of the diameter between pre-heat oxyger, fuel gas and gas mixing chamber will produce an extinguishing elect of the tlame when the tip is clogged up. Ihe sustained flashback as well as the backlire is thus prevented, Prevention of backfte is one of the examples of how KOIKE strives for better products, sparing nothing in its research, design and manufacturing. [IPG GAS KOIKE: Standard 106 Standard tp JO6HC Standard tip for hand cutting and portable cutting 106D7 Divergent high-speed ti 1O6M Heavy preheat oxygen tip 1O6M7 Heavy presheat oxygen tip (divergent high-speed ype) 406NT Standard Tip (K-82 only) EPOCH Out mixing type tip (only for EPOCH torch) IPG GAS Victor and Oxweld™ Type Z2VKF7_ Divergent high speed tp (only for Victor™ type torch) (OKP7 Divergent high speed tip (nly for Oxweld™ type torch) ACETYLENE = KOIKE’s Standard 102 Standard tip 1O2HC Standard tp for hand cuting and portable cutting 102D7 Divergent high-speed tip 402ST_ Standard Tip (K-82 only) (APP, HPG™ & CHEMTANE2™ - KOIKE Standard 103. Standard tp 103D7_ Divergent high-speed tip FOR NATURAL GAS - KOIKE’s Standard 107 Standard tip 1O7D7_ Divergent high-speed tpIne elrialeteele-leloe Brat nel uno BFE oWelelelael leet — Te Eee Laleleel-lolet pal eel wel-lelal fafa lela fel-lolotel al so") Sree Coan Whe ‘Gilg | tt fal Samet Sages Soe Sal aay Nate i ‘cscs eee Fab fl Cg pe Some Saye SabaS ok Se Sr ae cove Co Som Son Sa min rie A “GRE | catieTname |G wan, =r ‘oomnpioc ne Bee Ty pen el Seg bt fel dee 2 nae Sone Sa Set Som Se Seahsuse eB BFa SEEReSegrwe mee ot LE el ee Se es Perfect Manufacturing System To Product A Quality Tip KOIKE offers it’s clients precision tips that are safe while at the same time capable of reducing cost of the cutting operation. Each tip is produced according to KO KE's precise 4-step system: + A committed research department + Attalented design department + A Tully automated and state-of-the-art manufacturing facility + An inspection group that makes sure KOIKE’s finished product is within strict tolerances before it goes to the client AIL KOIKE tips are manufactured to the most rigorous standards, and tailored to meet any requirements it’s clients may have. I@koike Aronson inc. P.O. Box 307, Arcade, New York 14009 Phone (585) 482-2400 Fax (685) 457-3517 a ple www.koike.com CUTTING THs 01/16 KENG45° Raw Are Voltage Kit sion d’are brute Field Service Bulletin j Bulletin de service sur le terrain 806200 — Revision 4 — July 2014 Révision 4 — Juillet 2014 | Ef auze ner Be he om we YPC tici aaAypertheran tne. Etna Road, P.O. Box 5010 Hanover, NH 08766 USA 603-643-3441 Tel (Main Ottice) {603-643-5852 Fax (All Departments) info@hypertherm.com (Main Ottice Email) 900-648-9876 Tel (Technical Service) technical service@hypertherm.com (Technical Service Email) ‘900-737-2678 Tet (Customer Service) customer service@hypertherm.com (Customer Service Email) (866-649-7711 Tel [Return Materials Authorization) (977-971-2878 Fax (Return Materials Authorization) ‘eturn.matesils@hypertherm.com (RMA email) Aypertherm Plasmatectnik GmbH Technologiepark Hanau Rodenbacher Chaussee 6 0-68457 Hanau-Wollgang, Deutschland 49 6181 58 2100 Tel 49 6181 58.2134 Fox 449 6181 58 2123 (Technical Service) ‘Ayperthorm (5) Pte td. 82 Genting Lane Media Centre Annexe Block #401-01 Singapore 849567, Republic of Singapore 65 6847 2489 Tes 685 6847 2400 Far 86 84 2489 (Tochnteal Service) ‘Aypertorm (Shanghai) Trading Co.,Ltd. Unit 301, South Builaing 495 ShangZhong Rosd Shanghai, 200287 PRChina 86-21-60740008 Tel 86-21-60740893 Fax © Hypectherm ne. 2014. Alright esorad. Tous dts serves. ‘yportborm Europe B.W. Veartveld 9 4104 SE Roosendaal, Nederland 91 165 696907 Tel 81 165 596901 Fax 381 165 586908 Tel (Marketing) 431 165 596800 Tol (Technical Servics) 10 800 4973 7843 Tel (Technical Service) ‘Ayportnorm Japan tt. Level 9, Edoberi Center Building 2-1-1 Edobori, Nishi-ky (Osaka 680-0002 Japan 81 6 6226 1189 Tel 81 6.6225 1164 Fax ‘yportbarma Brasil Ltda. Rua Bras Cubes, 231 ~ Jardim Mala Guaruihos, SP - Brasil CEP 07115-030 55 11 2409 2636 Te! 85 11 2408 0462 Fay Nyportierm México, 8.4. do 0. ‘Avenida Toluca No, 444, Ansxo f, Colonia Olivar de los Padres Dalegacién Alvaro Obregén México, D.F C.P.01780 $2 86 5681 8108 Tel 52 56 5683 2127 Fax Ayportoorm Korva Branch #3004 Centum Leaders Mark B/D, 1514 Woo-dong, Haeundae-qu, Busan Korea, 612-889 82 51 747 0858 Tel 82 81 701 0858 Fax Powarmax and Hyperthern ae radars of Hyperther Ie nd maybe registered in tho Ustad States andor other counts. ll oar trademarke ae the propa of he raspoctve helo. PPowermax et Hypertherm sont des marques dHyperthrn In. qui peuvent ire diposées sux Elas-Unis evou dans utes pays. Totes fs autos ‘marques commerciales sont la propriété de leurs denture respects.Powermax45 Raw Arc Voltage Kit Introduction WARNING! ELECTRIC SHOCK CAN KILL Disconnect electrical power before performing any maintenance. Safety and Compliance Menual (80669C) for more safety precau Purpose This feld service bulletin explaine how to inetell a customer-eupplied machine Interface cable that does not use the internal 50:1 voltage divider on the Powermax4. Notice: Installation of the system at the installed site is subject to the epproval ofthe Local Inepaction Authorities (UA). Without approval ofthe LIA, modification ofthe factory installed wiring voids the safely test marks (or example, cOSAus, COG, CE, GOSTTR, UkrSEPRO, C-Tick, Kvaite, EAC) applied to the produet in the Hypertherm factory, and the Safely certificates provided by Hyperthonn become invalid after madiication Tools and materials needed Wire stripgaers Wire crimpers Assorted Philips® and TORX® sorewdrivers Eloctic dil with 2 15 mm or 19/32 inch dil bit 0.78 mm? or 18 AWG, 2 wire, non-shielded cable similar to OLFLEX® 190 (601802) 1M4 (#8) insulated ring terminals, MB (#10) insulated ring terminals 228352 Kit contents Part number Description ‘Quantity 008278 ‘Strain raliet 1 Powermax45 Field Service Bulletin 806200 3