Hypertherm Edge II Instruction Manual (IM)

Operator’s Manual I

TABLE OF CONTENTS

SECTION 1: SAFETY ............................................................................................................................1

Read This Manual...............................................................................................................................1

Dangerous Machinery.........................................................................................................................1

High Voltages......................................................................................................................................1

Product Listings...................................................................................................................................2

Type “M” and “P” Controls .................................................................................................................2

Type “E” and “V” Controls..................................................................................................................2

Type “B” Controls................................................................................................................................2

SECTION 2: OVERVIEW .......................................................................................................................3

Introduction .........................................................................................................................................3

ShapeWizard®.....................................................................................................................................3

Teach/Trace........................................................................................................................................3

Shape Libraries...................................................................................................................................4

Program Upload and Download..........................................................................................................4

SoftMotion...........................................................................................................................................4

Cutting Options ...................................................................................................................................4

Mirror function .................................................................................................................................4

Rotate function ................................................................................................................................4

Scale function..................................................................................................................................4

Repeat function ...............................................................................................................................4

Programming Features .......................................................................................................................5

Manual Data Input (MDI).................................................................................................................5

Communications Link......................................................................................................................5

Graphical program display ..............................................................................................................5

Built-in Parametric Shape Library....................................................................................................6

Teach/Trace ....................................................................................................................................6

Performance Features ........................................................................................................................6

Installation and Setup Features..........................................................................................................7

Hardware Specifications .....................................................................................................................7

Model Numbering System...................................................................................................................8

Model Numbers...............................................................................................................................8

Front Panel Layout..............................................................................................................................9

Screen Hierarchy...........................................................................................................................10

Key & Menu Functions......................................................................................................................11

Help Screen ......................................................................................................................................11

Show Contents..............................................................................................................................11

Find................................................................................................................................................11

Main Screen......................................................................................................................................12

Preview Window............................................................................................................................12

Watch Window ..............................................................................................................................12

Shape Manager.............................................................................................................................12

Files...............................................................................................................................................12

Part Options...................................................................................................................................12

Setups ...........................................................................................................................................13

View Part/View Sheet....................................................................................................................13

Change Cut Mode .........................................................................................................................14

Change Consumable.....................................................................................................................14

Zero Positions ...............................................................................................................................14

Shape Manager Screen....................................................................................................................15

Shape Library................................................................................................................................15

Text Editor.....................................................................................................................................15

Shape Wizard................................................................................................................................15

II Operator’s Manual

Teach Trace.................................................................................................................................. 15

Nester............................................................................................................................................ 15

Files.................................................................................................................................................. 16

Load from Disk.............................................................................................................................. 16

Save to Disk.................................................................................................................................. 16

Download from Host ..................................................................................................................... 16

Upload to Host .............................................................................................................................. 16

Resume Last Part ......................................................................................................................... 16

Show Certain Files........................................................................................................................ 17

Show All Files ............................................................................................................................... 17

Setups Screen.................................................................................................................................. 18

Cutting........................................................................................................................................... 18

Cut Types...................................................................................................................................... 18

Disable Control ............................................................................................................................. 18

Watch............................................................................................................................................ 18

Password ...................................................................................................................................... 18

Diagnostic ..................................................................................................................................... 18

Change to Metric Units/English Units........................................................................................... 18

Change Consumable........................................................................................................................ 19

New Torch Tip............................................................................................................................... 19

New Electrode............................................................................................................................... 19

Reset Database ............................................................................................................................ 19

Setups........................................................................................................................................... 19

Upload Database .......................................................................................................................... 19

Save Database ............................................................................................................................. 19

Key Functions................................................................................................................................... 20

SECTION 3: SETUPS.......................................................................................................................... 21

Cutting .............................................................................................................................................. 21

Plate Size...................................................................................................................................... 21

Cut Mode ...................................................................................................................................... 21

Trial/Cut Speed............................................................................................................................. 21

Marker 1 / Marker 2 Speed ........................................................................................................... 21

Kerf................................................................................................................................................ 22

Dwell Time .................................................................................................................................... 22

Arc Radial Error ............................................................................................................................ 22

Dwell Override .............................................................................................................................. 22

Optional Program Stop ................................................................................................................. 22

EIA I & J Codes.............................................................................................................................22

EIA F-Code Override .................................................................................................................... 22

Speed +/- Affects F-Codes........................................................................................................... 22

EIA Decimal Shift.......................................................................................................................... 22

Process Select Override ............................................................................................................... 22

Station Select Override................................................................................................................. 22

Auto Torch Spacing Override ....................................................................................................... 23

G97 Loop Count Prompt............................................................................................................... 23

Show Traverse Segments ............................................................................................................ 23

Retain Skew Adjustment............................................................................................................... 23

Kerf Variable / Kerf Offset............................................................................................................. 23

Marker Offsets 1 - 12 .................................................................................................................... 23

THC Voltage Offset....................................................................................................................... 23

Marker On Time (Type “B” Configuration Only)............................................................................ 23

Marker Off Time (Type “B” Configuration Only)............................................................................ 23

Cut Types ......................................................................................................................................... 24

Oxy Fuel ........................................................................................................................................... 25

I/O Configuration Type “M”, “P” and “V”........................................................................................ 25

Operator’s Manual III

I/O Configuration Type “M”, “P” and “V”........................................................................................25

I/O Configuration Type “B” ............................................................................................................26

I/O Configuration Type “B” (Timing Diagram) ...............................................................................26

Ignition Time..................................................................................................................................26

Low Preheat ..................................................................................................................................26

High Preheat..................................................................................................................................27

Pierce Time ...................................................................................................................................27

Moving Pierce Time.......................................................................................................................27

Creep Time....................................................................................................................................27

Primary Torch Up Time.................................................................................................................27

Primary Torch Down Time.............................................................................................................27

Pierce Torch Up Time ...................................................................................................................27

Pierce Torch Down Time...............................................................................................................27

Cut Off Time..................................................................................................................................27

Bleedoff Time................................................................................................................................27

Igniters...........................................................................................................................................27

Preheat During Cut........................................................................................................................27

Plasma ..............................................................................................................................................28

I/O Configuration Type “M”, “P” and “V”........................................................................................28

I/O Configuration Type “M”, “P” and “V” (Timing Diagram)...........................................................28

I/O Configuration Type “B” ............................................................................................................29

I/O Configuration Type “B” (Timing Diagram) ...............................................................................29

Start Time (Type “B” Configuration Only)......................................................................................29

Purge Time....................................................................................................................................29

Pierce Time ...................................................................................................................................29

Creep Time....................................................................................................................................30

Cut Off Time..................................................................................................................................30

Torch Down Time..........................................................................................................................30

Arc Off Time ..................................................................................................................................30

Stop Time......................................................................................................................................30

Set Arc Current..............................................................................................................................30

Corner Current Percent.................................................................................................................30

Retry Transfer Fail.........................................................................................................................30

Transfer Time................................................................................................................................31

Arc on Feedback ...........................................................................................................................31

Ignition...........................................................................................................................................31

Dual Grid/THC...............................................................................................................................31

Dual Grid/THC Start ......................................................................................................................31

Partial Raise..................................................................................................................................31

Torch Down During Cut.................................................................................................................31

Torch Down Between Cuts............................................................................................................31

Marker...............................................................................................................................................32

Marker Interface ............................................................................................................................32

I/O Configuration Type “M”, “P” and “V” (Timing Diagram)...........................................................33

Ignition Time..................................................................................................................................33

Marker On Time ............................................................................................................................33

Marker Off Time ............................................................................................................................33

Marker Up Time.............................................................................................................................33

Marker Partial Up Time .................................................................................................................33

Marker Down Time........................................................................................................................33

Set Arc Current..............................................................................................................................33

Corner Current Percent.................................................................................................................33

Ignition...........................................................................................................................................33

Cut Control Used for Marking........................................................................................................34

Marker Down/Up With Each Marker On/Off..................................................................................34

Arc On Feedback ..........................................................................................................................34

IV Operator’s Manual

Partial Raise.................................................................................................................................. 34

Down On During Mark .................................................................................................................. 34

Down On Between Marks............................................................................................................. 34

Laser................................................................................................................................................. 35

Laser Sequence 1......................................................................................................................... 35

Test Lifter...................................................................................................................................... 35

I/O Configuration Type “V” (Timing Diagram)............................................................................... 36

Laser Sequence 2......................................................................................................................... 36

Test Lifter...................................................................................................................................... 36

I/O Configuration Type “V” (Timing Diagram)............................................................................... 37

Purge Time ................................................................................................................................... 37

Shutter Time ................................................................................................................................. 37

Power Ramp Time........................................................................................................................ 37

Pierce Time................................................................................................................................... 37

Start Pierce Time.......................................................................................................................... 37

Pierce Complete Time .................................................................................................................. 37

After Pierce Time .......................................................................................................................... 37

Creep Time ................................................................................................................................... 37

Beam Off Time.............................................................................................................................. 37

IHS in Manual ............................................................................................................................... 38

Retract Full/Partial ........................................................................................................................ 38

Nozzle Contact IHS....................................................................................................................... 38

Laser Cut Logic............................................................................................................................. 38

Water Jet .......................................................................................................................................... 39

I/O Configuration Type “M”, “P” and “V” (Timing Diagram)........................................................... 39

Purge Time ................................................................................................................................... 39

Pierce Time................................................................................................................................... 39

Creep Time ................................................................................................................................... 40

Abrasive Off Time ......................................................................................................................... 40

Abrasive Charging ........................................................................................................................ 40

Watch................................................................................................................................................ 41

None.............................................................................................................................................. 41

Input/Output .................................................................................................................................. 42

Position ......................................................................................................................................... 42

Following Error.............................................................................................................................. 42

Temperature ................................................................................................................................. 42

Speedometer ................................................................................................................................ 42

Oxy Fuel Torch Tip ....................................................................................................................... 42

Plasma Torch Tip.......................................................................................................................... 42

Plasma Electrode.......................................................................................................................... 42

Process Data ................................................................................................................................ 42

SECTION 4: SHAPE MANAGER........................................................................................................45

Shape Library ................................................................................................................................... 45

Selecting a Simple Shape............................................................................................................. 45

Text Editor ........................................................................................................................................ 46

Show Original Text........................................................................................................................ 46

Delete Part.................................................................................................................................... 46

Shape Wizard................................................................................................................................... 47

Manual Line Edit ........................................................................................................................... 47

Replace Segment ......................................................................................................................... 48

Insert Before Segment.................................................................................................................. 48

Insert After Segment..................................................................................................................... 48

Remove Segment ......................................................................................................................... 48

Teach Trace ..................................................................................................................................... 50

Start Corner .................................................................................................................................. 50

Operator’s Manual V

Tracing Pitch..................................................................................................................................50

Arc Radial Error.............................................................................................................................51

Auto Closure Detect ......................................................................................................................51

Closure Over/Under Lap ...............................................................................................................51

Kerf Direction.................................................................................................................................51

Traverse/Pierce.............................................................................................................................51

Tracing a part ................................................................................................................................51

Plate Remnant Trace....................................................................................................................52

Nester™............................................................................................................................................54

Manual Nesting.................................................................................................................................54

Main Screen Layout ......................................................................................................................54

Add Part.........................................................................................................................................55

Remove Part..................................................................................................................................55

Cut Earlier......................................................................................................................................55

Cut Later........................................................................................................................................55

View Sheet / View Part..................................................................................................................55

Arrow Key ( Distance ) ..................................................................................................................55

Setup.............................................................................................................................................55

Done..............................................................................................................................................55

Setup.................................................................................................................................................56

Arrow Motion .................................................................................................................................56

Autoposition...................................................................................................................................56

Clear Nest......................................................................................................................................56

Done..............................................................................................................................................56

Using Nester™..................................................................................................................................57

Adding Parts..................................................................................................................................57

Saving a Nest................................................................................................................................58

HyperNest – CNC® Automatic Nesting Software..............................................................................59

Main Screen Layout ......................................................................................................................59

Setup.................................................................................................................................................60

Automatic Nesting .........................................................................................................................60

Part Spacing..................................................................................................................................60

Plate Edge Spacing.......................................................................................................................60

Program Origin..............................................................................................................................60

Cut Direction..................................................................................................................................60

Return to Nest Start.......................................................................................................................60

Using HyperNest – CNC®.................................................................................................................61

Adding Parts..................................................................................................................................61

Remove Part..................................................................................................................................63

Nest Summary...............................................................................................................................64

Main Screen View of Nest.............................................................................................................66

SECTION 5: FILES ..............................................................................................................................67

Load from Disk..................................................................................................................................67

Load from ......................................................................................................................................67

Files...............................................................................................................................................67

File name/Diskette file name.........................................................................................................68

Preview..........................................................................................................................................68

Load to...........................................................................................................................................68

Hard drive file name ......................................................................................................................68

Resume Last Part..........................................................................................................................68

Show Certain Files ........................................................................................................................68

Show All Files................................................................................................................................68

Resume Last Part Features..............................................................................................................69

Rush Job Interrupt.........................................................................................................................69

Automated Power Loss Recovery.................................................................................................69

VI Operator’s Manual

Save to Disk ..................................................................................................................................... 70

Save to.......................................................................................................................................... 70

File name/Diskette file name ........................................................................................................ 70

Save Original Text ........................................................................................................................ 70

Save from......................................................................................................................................70

Files............................................................................................................................................... 70

Hard drive file name...................................................................................................................... 71

Preview ......................................................................................................................................... 71

Save KeyLog to Disk.....................................................................................................................71

Download from Host......................................................................................................................... 72

Download from.............................................................................................................................. 72

Files............................................................................................................................................... 72

Remote file name.......................................................................................................................... 72

Preview ......................................................................................................................................... 73

Download to.................................................................................................................................. 73

Local file name.............................................................................................................................. 73

Upload to Host.................................................................................................................................. 74

Upload to.......................................................................................................................................74

Remote file name.......................................................................................................................... 74

Upload from .................................................................................................................................. 74

Files............................................................................................................................................... 74

Local file name.............................................................................................................................. 75

Preview ......................................................................................................................................... 75

Loading Of Invalid Files.................................................................................................................... 75

SECTION 6: LIBRARY SHAPES........................................................................................................ 77

Library Shape Setup......................................................................................................................... 77

Rectangle.......................................................................................................................................... 78

Circle................................................................................................................................................. 78

Triangle............................................................................................................................................. 79

Trapezoid.......................................................................................................................................... 80

Slant Rectangle ................................................................................................................................ 80

Gambrel Rectangle........................................................................................................................... 81

Roofed Rectangle............................................................................................................................. 81

Oval .................................................................................................................................................. 82

Circle w/ Flat Side............................................................................................................................. 82

Circle Slice........................................................................................................................................ 83

Straight Slots .................................................................................................................................... 83

Angled Slots ..................................................................................................................................... 84

Horizontal Rip................................................................................................................................... 84

Vertical Rip ....................................................................................................................................... 85

Flange............................................................................................................................................... 85

Gusset .............................................................................................................................................. 86

8 Sided.............................................................................................................................................. 86

Rectangle w/ Convex Corners.......................................................................................................... 87

Rectangle w/ Concave Corners........................................................................................................ 87

Flange Slice...................................................................................................................................... 88

Elbow................................................................................................................................................ 88

Flange Repair Ring........................................................................................................................... 89

Rectangle w/ Rectangular Hole........................................................................................................ 89

Rectangle w/ Circular Hole............................................................................................................... 90

Rectangle w/ Tab.............................................................................................................................. 90

Rectangle w/ Notch .......................................................................................................................... 91

Rectangle w/ Radius......................................................................................................................... 91

Convex Rectangle ............................................................................................................................ 92

Concave Rectangle .......................................................................................................................... 92

Operator’s Manual VII

Triangle w/ Concave Side.................................................................................................................93

Polygon w/ Concave Side.................................................................................................................93

Slant Rectangle with Radius.............................................................................................................94

Cross.................................................................................................................................................94

4 Sided Convex Rectangle ...............................................................................................................95

4 Sided Concave Rectangle.............................................................................................................95

Pipe Mount........................................................................................................................................96

Bolt Hole Circle .................................................................................................................................96

Bolt Hole Flange................................................................................................................................97

Bolt Hole Rectangle ..........................................................................................................................97

Bolt Hole Rectangle w/ Convex Corners ..........................................................................................98

Bolt Hole Rectangle w/ Center Hole.................................................................................................98

Bolt Hole Rectangle w/ Center Hole and Convex Corners...............................................................99

Rounded L-Bracket...........................................................................................................................99

Horseshoe.......................................................................................................................................100

Convex Roof Trapezoid w/ Hole.....................................................................................................100

Convex Roof Polygon w/ Hole........................................................................................................101

Pulley Cover....................................................................................................................................101

Paddle Blind....................................................................................................................................102

Water Pump Gasket........................................................................................................................102

Sprocket..........................................................................................................................................103

Text .................................................................................................................................................103

Test Pattern.....................................................................................................................................104

SECTION 7: PART OPTIONS ...........................................................................................................105

Scale Factor ................................................................................................................................105

Rotate Angle................................................................................................................................105

Mirror X/Mirror Y..........................................................................................................................105

Kerf..............................................................................................................................................106

Repeat.............................................................................................................................................107

Straight Repeat ...........................................................................................................................107

Repeat Type................................................................................................................................107

Start Corner.................................................................................................................................107

Number of Rows..........................................................................................................................107

Number of Columns ....................................................................................................................107

X Pattern Offset/Y Pattern Offset................................................................................................107

Scrap Clearance..........................................................................................................................108

X Nest Distance/Y Nest Distance................................................................................................108

Staggered Repeat .......................................................................................................................108

Nested Repeat ............................................................................................................................109

Pattern Offsets ............................................................................................................................109

Nest Distance..............................................................................................................................109

Instructions for use......................................................................................................................111

Corner to Align with.....................................................................................................................111

Scrap Clearance..........................................................................................................................112

Skew Adjustment.........................................................................................................................112

Skew Reference..........................................................................................................................112

Edit Parameters...........................................................................................................................112

At Corner.....................................................................................................................................112

At Skew Point..............................................................................................................................112

SECTION 8: CUTTING ......................................................................................................................113

I/O Configuration Type “M”, “P” and “V”..........................................................................................113

Speed Increase ...........................................................................................................................114

Speed Decrease..........................................................................................................................114

Repeats.......................................................................................................................................114

VIII Operator’s Manual

Cut Delay Timers ........................................................................................................................ 114

Extend......................................................................................................................................... 115

Set Now ...................................................................................................................................... 115

Release....................................................................................................................................... 115

I/O Configuration Type “B”.............................................................................................................. 116

Automatic.................................................................................................................................... 116

Manual ........................................................................................................................................ 116

Test Run ..................................................................................................................................... 116

SECTION 9: PAUSE.......................................................................................................................... 117

Return to Start............................................................................................................................. 117

Backup and Forward on Path..................................................................................................... 117

Move to Pierce............................................................................................................................ 118

Change Cut Mode....................................................................................................................... 118

Change Move Speed.................................................................................................................. 118

Change Consumable .................................................................................................................. 118

On-Path Restart.......................................................................................................................... 118

Return to Path............................................................................................................................. 119

Move Part.................................................................................................................................... 119

Off-Path Restart.......................................................................................................................... 119

Rush Job Interrupt ...................................................................................................................... 120

Change Consumable...................................................................................................................... 120

Overview..................................................................................................................................... 121

Minutes per Pierce...................................................................................................................... 121

Arc Errors.................................................................................................................................... 121

Volts per Minute.......................................................................................................................... 122

Last Torch Tip Installed............................................................................................................... 122

Last Electrode Installed............................................................................................................... 122

New Torch Tip............................................................................................................................. 122

New Electrode............................................................................................................................. 122

Setups......................................................................................................................................... 122

Reset Database .......................................................................................................................... 122

Upload Database ........................................................................................................................ 122

Save Database ........................................................................................................................... 122

SECTION 10: MANUAL .................................................................................................................... 123

Return to Start............................................................................................................................. 123

Move Distance ............................................................................................................................ 124

Cut Distance ............................................................................................................................... 124

Manual Options........................................................................................................................... 125

Home Axes ................................................................................................................................. 125

View Sheet/View Part ................................................................................................................. 125

Change Manual Mode................................................................................................................. 126

Change Move Speed.................................................................................................................. 126

Zero Positions............................................................................................................................. 127

Rip Cutting .................................................................................................................................. 127

Manual Options .............................................................................................................................. 127

Raise Torch................................................................................................................................. 127

Lower Torch................................................................................................................................ 127

Manual Offset..............................................................................................................................128

Adjust Dual Gantry Skew............................................................................................................ 128

Home Axes..................................................................................................................................... 129

Transverse.................................................................................................................................. 129

Rail.............................................................................................................................................. 129

CBH............................................................................................................................................. 130

THC.............................................................................................................................................130

Operator’s Manual IX

Tilt................................................................................................................................................130

Rotate..........................................................................................................................................130

All.................................................................................................................................................130

Go To Home Position..................................................................................................................130

APPENDIX A: VOYAGER II™ ...........................................................................................................131

Voyager II™ Overview....................................................................................................................131

Cutting.............................................................................................................................................132

Setups.............................................................................................................................................133

Cut Types........................................................................................................................................133

Use Plasma 1 Data .....................................................................................................................133

Use Marker 1 Data ......................................................................................................................133

HD3070® Auto Gas Interface..........................................................................................................134

Save Data....................................................................................................................................134

Load Data....................................................................................................................................134

Test Cutting Gases......................................................................................................................135

Test Preflow Gases.....................................................................................................................135

HD3070® Auto Gas I/O................................................................................................................136

Inputs...........................................................................................................................................136

Outputs........................................................................................................................................136

HD3070® Part Program Support .................................................................................................136

HD4070® Overview.........................................................................................................................137

Cut Chart.....................................................................................................................................138

Power Supply Type .....................................................................................................................138

Torch Type ..................................................................................................................................138

Material Type...............................................................................................................................138

Current Settings ..........................................................................................................................138

Plasma / Shield Gases ................................................................................................................138

Cutting Surface ............................................................................................................................138

Material Thickness......................................................................................................................138

Water Muffler...............................................................................................................................138

Cut Speed....................................................................................................................................139

Kerf..............................................................................................................................................139

Set Arc Voltage ...........................................................................................................................139

Preflow Setting ............................................................................................................................139

Cutflow Settings ..........................................................................................................................139

Preflow Time................................................................................................................................139

Purge Time..................................................................................................................................139

Pierce Time .................................................................................................................................139

Creep Time..................................................................................................................................139

Save Data....................................................................................................................................140

Process Defaults .........................................................................................................................140

Save Database............................................................................................................................140

Load Database............................................................................................................................140

Test Preflow.................................................................................................................................140

Test Cutflow.................................................................................................................................140

Additional Features.........................................................................................................................141

HD4070® Part Program Support .................................................................................................141

Change Consumable...................................................................................................................142

FineLine Overview ..........................................................................................................................143

Cut Chart.....................................................................................................................................145

Power Supply Type .....................................................................................................................145

Torch Type ..................................................................................................................................145

Material Type...............................................................................................................................145

Current Settings ..........................................................................................................................145

Plasma / Shield Gases ................................................................................................................145

X Operator’s Manual

Cutting Surface ........................................................................................................................... 145

Material Thickness...................................................................................................................... 145

Water Muffler .............................................................................................................................. 145

Cut Speed................................................................................................................................... 146

Kerf.............................................................................................................................................. 146

Preflow Time............................................................................................................................... 146

Purge Time ................................................................................................................................. 146

Pierce Time................................................................................................................................. 146

Creep Time ................................................................................................................................. 146

Database Features ..................................................................................................................... 147

Save Data ................................................................................................................................... 147

Process Defaults......................................................................................................................... 147

Save Database ........................................................................................................................... 147

Load Database............................................................................................................................ 147

Test Preflow................................................................................................................................ 147

Test Cutflow................................................................................................................................ 147

FineLine Part Program Support.................................................................................................. 148

Change Consumable .................................................................................................................. 149

APPENDIX B: SENSOR™ THC........................................................................................................ 151

Sensor™ Torch Height Control Overview...................................................................................... 151

Cut Setups...................................................................................................................................... 152

THC Voltage Offset..................................................................................................................... 152

Plasma Setups ............................................................................................................................... 153

I/O Configuration Type “P” and “V”............................................................................................. 153

Test Lifter.................................................................................................................................... 153

I/O Configuration Type “P” and “V” (Timing Diagram)................................................................ 154

Retract Delay .............................................................................................................................. 154

Auto Voltage Set......................................................................................................................... 154

Set Arc Voltage........................................................................................................................... 154

Voltage Control ........................................................................................................................... 154

Ignition Output.............................................................................................................................154

IHS in Manual ............................................................................................................................. 155

Retract Full/Partial ...................................................................................................................... 155

Skip IHS Within........................................................................................................................... 155

Preflow During IHS ..................................................................................................................... 155

Nozzle Contact IHS..................................................................................................................... 155

Offset IHS ................................................................................................................................... 155

Auto Kerf Voltage Change.......................................................................................................... 156

Kerf Detect Reacquire Time ....................................................................................................... 156

Marker Setups ................................................................................................................................ 156

I/O Configuration Type “P” and “V”............................................................................................. 156

Purge Time ................................................................................................................................. 157

Start Time ................................................................................................................................... 157

Sample Voltage........................................................................................................................... 157

Set Arc Voltage........................................................................................................................... 157

Voltage Control ........................................................................................................................... 157

IHS in Manual ............................................................................................................................. 157

Retract Full/Partial ...................................................................................................................... 157

Skip IHS Within........................................................................................................................... 158

Preflow During IHS ..................................................................................................................... 158

Nozzle Contact IHS..................................................................................................................... 158

Process Watch ............................................................................................................................... 159

Input/Output ................................................................................................................................ 159

Position ....................................................................................................................................... 159

Plasma Process.......................................................................................................................... 159

Operator’s Manual XI

Main Cut Screen .............................................................................................................................160

Automatic THC Mode..................................................................................................................160

APPENDIX C: COMMAND® THC......................................................................................................161

Clear Error...................................................................................................................................161

I/O Configuration Type “M”, “P” and “V” (Timing Diagram).........................................................162

Purge Time..................................................................................................................................162

Pierce Time .................................................................................................................................162

Creep Time..................................................................................................................................162

Arc Off Time ................................................................................................................................162

Stop Time....................................................................................................................................163

Accel Delay..................................................................................................................................163

Retract Delay Time......................................................................................................................163

Ignition.........................................................................................................................................163

Voltage Control............................................................................................................................163

Retract Full/Partial.......................................................................................................................163

Retry On Transfer Fail.................................................................................................................163

Transfer Time..............................................................................................................................163

Set Arc Current............................................................................................................................163

Corner Current Percent...............................................................................................................163

Set Arc Voltage ...........................................................................................................................163

Homing Speed.............................................................................................................................164

Nozzle Ohmic Contact.................................................................................................................164

Preflow During IHS......................................................................................................................164

Main Cut Screen .............................................................................................................................165

Automatic THC Mode..................................................................................................................165

Extend .........................................................................................................................................165

Set Now.......................................................................................................................................165

Release .......................................................................................................................................165

Manual THC Mode ......................................................................................................................166

Extend .........................................................................................................................................166

Set Now.......................................................................................................................................166

Release .......................................................................................................................................166

Diagnostics......................................................................................................................................166

APPENDIX D: OPTIONAL DXF TRANSLATOR...............................................................................167

DXF Translator Overview................................................................................................................167

DXF Support................................................................................................................................167

Text Commands..........................................................................................................................167

Directional Commands................................................................................................................167

XII Operator’s Manual

Section 1: Safety 1

Section 1: Safety

Read This Manual

Read and understand this instructional manual, the cutting machine manuals, and your employer’s
safety practices. Note: This product is not designed to be field serviceable. Please return to an
authorized repair center for any required service.

Dangerous Machinery

Operation and maintenance of automated equipment involves potential hazards. Personnel should
take precautions to avoid injury.

Injury and entanglement may occur if hands and limbs come in contact with moving machinery.
KEEP HANDS CLEAR of dangerous moving machinery. All control, including manual, can be effected

using the front panel keys or remote interface.
Loose fitting clothing or ties may become entangled in the machinery. These items should not be

worn while operating or servicing the machine.

High Voltages

Electric shock can kill. Be sure this equipment is safely installed in accordance with enclosed
procedures and specifications.

Avoid contact with electrical wires and cabling while power is on.
This equipment should only be opened by trained service personnel.

Please refer to the appropriate appendix in the Installation Guide provided with your control for details
on safety certification for that product.

2 Operator’s Manual

Product Listings

Type “M” and “P” Controls

Note: This product has been designed and manufactured in accordance with CE and UL Safety

Standards.
UL has successfully tested and listed the type “ M” and ”P” (with 10.4” display) control products in

accordance with the applicable U.S. and Canadian Safety Standards. File number E178333. Note:
Suitable for pollution degree 2 environment only.

This appliance has been successfully tested and listed by CE under the following standards; EN
500081-2 1994, EN 61000-6-2 1999 and EN 55011:1998. Certificate number: Retlif R-3909N

Type “E” and “V” Controls

Note: This product has been designed and manufactured in accordance with CE and UL Safety

Standards.
UL has successfully tested and listed the type “E” and “V” control products in accordance with the

applicable U.S. and Canadian Safety Standards. File number E178333.
This appliance has been successfully tested and listed by CE under the following standards; EN

500081-2 1994, EN 61000-6-2 1999 and EN 55011:1998. Certificate number: Retlif R-3738N1

Type “B” Controls

Note: This product has been designed and manufactured in accordance with CE Safety Standards.

This appliance has been successfully tested and listed by CE under the following standards; EN
500081-2 1994, EN 61000-6-2 1999 and EN 55011:1998. Certificate number: Retlif R-3909N

Note: This product has not been safety tested for outdoor use.

Section 2: Overview 3

Section 2: Overview

Introduction

This control is a multi-axis digital control system specifically designed for shape-cutting machines and
is our latest effort in a long history of developing leading edge technology for the metal fabricating
industry. At the forefront of our design efforts is a commitment to ease-of-use. Programmable soft­keys simplifies the front panel and put the most common functions at your fingertips. Developed
around Microsoft Visual C++
generation of man-machine-interfaces to the most critical element in the shape cutting process, you,
the user.

With the maturing of High Tolerance Plasma and the emergence of Laser into the area of shape
cutting, you need a control that can accurately position the cutting device. SoftMotion brings the
power and the accuracy of the Intel Pentium
digital position loop and velocity loop running, you get smooth motion through the entire velocity
range, and the comfort of knowing the cutting device is at the preprogrammed position. You can
even verify this with a dynamic zoom function during cutting.

The control can be used with almost any two-dimensional shape-cutting table. Built-in logic is present
for Plasma, Oxy-Fuel, Marking, Waterjet and Laser. Regardless of your application, we will make
your shape cutting process more productive.

You can graphically key in part programs directly using ShapeWizard
waiting for delivery, set-up, and alignment of templates. Or you can select any of 53 shapes from the
parametric shape library. Using a host computer or CAD/CAM system, you can also download
custom part programs easily. We even supply you at no-charge a communications package to tie the
control to the rest of your management information. Whatever method is used, the control, with its
advanced graphical user interface (GUI), shortens set-up time, speeds productivity and simplifies
scheduling.

Our product is designed and developed around Microsoft Visual C++
Classes

®

. The operating environment is completely compliant with the year 2000 dating.

®

and the Microsoft Foundation Classes®, this control brings a new

®

microprocessor to your positioning table. With both a

®

on the front panel, without

®

and the Microsoft Foundation

ShapeWizard®

Allows you to graphically create simple part programs and store them on the internal hard disk
present in the control.

Teach/Trace

If configured with a tracing head, you can use the control to digitize almost any pattern, store it on the
internal hard disk, and further customize the program with ShapeWizard. The control has both smart­arc and smart-line translators to provide you with optimum program resolution.

4 Operator’s Manual

Shape Libraries

Graphically select the desired shape from the parts library. Then you simply add the dimensions you
want, and the scaled part, with your entered dimensions, will be displayed. There is even a Help Icon
to step you through the data entry.

Program Upload and Download

Communication is an integral part of today’s fabricating shop. All part programs that have been
entered in the control can be uploaded to a remote computer or file server with an integrated RS­232C/ RS-422 communications link. CAD generated programs can be downloaded at baud rates of
up to 115K baud and visually previewed on the color LCD display. Visual representation of part
programs, along with full alpha-numeric file name support, gives you the flexibility to manage your
data as you see fit. Use of the optional Network Card allows us to bring the latest in communication
technology for increased speed and productivity to your shape cutting controller.

SoftMotion

SoftMotion, a proprietary data buffer and interrupt structure that allows the control to generate all of
its motion control algorithms from the main Pentium
to tightly couple the motion control and I/O logic to the operator interface.

®

Processor. This architecture allows SoftMotion

Cutting Options

Flexibility in your cutting operation is the key to success. The control comes standard with the
following cutting functions to help you optimize material and plate usage. These functions work on
any program. After selecting one of these functions, the new part will be graphically displayed.

Mirror function

The mirror function can be used to create a mirror image of the part along either the X or Y-axis.

Rotate function

The rotate function can be used to rotate the current part.

Scale function

The scale function can be used to increase or decrease the current part by a programmed ratio.

Repeat function

The repeat function duplicates the part shape in either a straight, staggered or nested grid patterns.

Section 2: Overview 5

Programming Features

English and Metric operation for worldwide use. Each axis can have its own encoder-to-unit edge
rate.

Dynamic Kerf compensation with programmable kerf value.
Automatic Corner and Plate Alignment with programmable scrap clearance.
Shape Repeat with three grid patterns (straight, stagger, and nested) allows fast cutting of multiple

pieces.
Part mirroring in both X and Y axes.
Part rotation.
Scaling allows quick part resizing to original size.
Virtually no limit to the number of program names or workfile folders that can be stored on the internal

hard disk drive.
Punch or powder marker control with twelve programmable offsets.
Choice of industry-standard EIA RS-274D or ISO 6582 ESSI Part Programming Languages.

Manual Data Input (MDI)

Full screen ASCII text editor.
Allows writing, editing, and graphical review of part programs at the machine.

Communications Link

Preview Mode allows machine operator to graphically review and select programs for download.
Download part programs from CAD system, remote host computer, or other storage device via built-in

RS-232C/ RS-422 port.
Can accept EIA RS-274D or ESSI part programs.
Baud Rates of up to 115K Baud. Communication baud rates of 230K are obtainable using the

communication link software provided with the control.
Optional Network Card for connecting directly to a PC Network for part file allocation.

Graphical program display

Visually displa y any part program.
Display of real-time position and I/O information.
Display of actual cut path while cutting.

6 Operator’s Manual

Built-in Parametric Shape Library

Contains 53 commonly used shapes.
Simple Graphical prompts for entering all part dimensions.

Teach/Trace

Smart-arc and Smart-Line algorithms for optimum program size and contouring smoothness.
Converts your existing optical tracer templates to EIA RS-274D programs, and stored on the internal

hard disk drive.
Automatic part closure detection.
Allows multiple pierce points, lead-ins, lead-outs, and rapid traverse segments.
Upload taught part programs to CAD system, remote host computer, or other storage device.
Requires a separate optical tracer control system.

Performance Features

Digital servo positioning control for any cutting machine.
Control dynamic accuracy of 0.002 inch (0.051 mm) with 1000 edge/inch encoders.
Programmable cut speeds up to 3000 IPM (76,200 mmpm).
Variable segment length look ahead for optimum contouring performance.
Automatic corner slowdown and torch height disable for clean, sharp corners.
Speed Increase/Decrease buttons for optimizing machine cut speed.
Automatic Plate and Corner Alignment corrects for skewed plates.
Complete cut-loss recovery with backup and forward along path, off-path re-pierce and return-to-path,

and move pattern functions.
Rip Mode for straight-line cutting.
Jog control cutting.
Punch, powder or Plasma marker capability.
Manual jog control with position read-out for positioning torches.
Manual Nester™ and optional Hyper Nes t

productivity and increased plate utilization.
Automated Torch Spacing feature to position torch station spacing automatically through the part

program for standard and mirrored multi-torch cutting.
Rush Job Interrupt and Automated Power Loss Recovery features.

®

– CNC Automatic Nesting features for increased

Section 2: Overview 7

Installation and Setup Features

Selectable axis orientation for compatibility with all cutting machines.
Built in oxy-fuel interface with programmable pre-heat time, ignition, and creep speed.
Built in plasma interface with programmable purge time, ignition time, arc-off delay time, and arc-

transferred feedback.
Built in Laser interface with programmable shutter time, power ramp time and pierce time.
Built in Waterjet interface with programmable abrasive output and pierce time.
Programmable servo gains, speeds, Watch Window, machine parameters, and communication

parameters for flexible application.
Interfaces easily to most optical tracing systems for integrated control.
Complete built-in diagnostics for checkout and test.

Hardware Specifications

10.4” (264 mm) VGA Color DSTN LCD Display or optional Active Matrix TFT display.

5.0 Gbyte (or higher) hard disk and 1.44Mbyte Floppy disk drive.
433 MHz (or higher) Celeron
64 Mbytes of RAM. Upgrades up to 768 Mbyte RAM available.
Up to 64 lines of interface signals for cutting and motion logic (gas control, tracing system, markers,

homing, etc.) depending on I/O configuration.
Industrial grade enclosure and keypad designed to minimize RFI/EMI interference.
Surface mount printed circuit board technology.
Two axes optically isolated ±10VDC drive outputs and incremental encoder inputs. Optional axes

available for dual gantry, contoured bevel head, tilt angle and Sensor™ THC applications which is
expandable to 6 axes of motion.

+5VDC or +12VDC, single ended or differential encoder inputs.
Optically isolated serial ports with programmable baud rates to 115 K baud. Communication baud

rates of 230K are obtainable using the communication link software provided with the control.
Optional Network Card for connecting directly to a PC Network.

Universal power input (100-240 VAC; 47-63Hz).
Operating environment: 0 to 50°C (32 to 122°F); 95% relative humidity (non-condensing).

®

Processor is available.

8 Operator’s Manual

Model Numbering System

The control is available with the following hardware and software configurations. Features and control
configuration options in sof t war e are based on the I/O c onf iguration of the control. Generally, the
information presented in this guide is based on the I/O configuration as outlined below. Please refer
to your control I/O configuration for available features and product information. The specific
configuration is determined by the Model Number, as shown below:

H

Axis Configuration

2 = 2 Servo Axes
3 = 3 Servo Axes
4 = 4 Servo Axes
5 = 5 Servo Axes
6 = 6 Servo Axes
7 = 7 Servo Axes
8 = 8 Servo Axes
9 = 9 Servo Axes
A = 10 Servo Axes
B = 11 Servo Axes
C = 12 Servo Axes

I / O Configuration

B = Burny 3 / 5
M = MicroPath
P = PicoPath
V = Voyager

Power Supplies

0 = Standard Logic Supply
2 = Standard Logic Supply &
Auxiliary Supply with
+5, +/-12 & +24 vdc

Pointing Device

0 = None
1 = Industrial Mouse

LCD Type

X = None
0 = 10.4" Dual Scan DSTN
1 = 10.4" Active Matrix TFT
2 = 15" Active Matrix TFT

-

Memory

0 = 16 MBytes
1 = 32 MBytes
2 = 64 MBytes
3 = 128 MBytes
4 = 256 MBytes

--

Model Numbers

You may wish to record your Model Number in the space provided below.

Model Number Information

Model Number:

Serial Number:

Operating System

0 = Windows 95 / 98
1 = Windows NT
2 = Windows XP

APC

0 = None
1 = 1 APC
2 = 2 APC's

THC

0 = None
1 = 1 THC
2 = 2 THC's

Speed Pots

0 = None
1 = 1 Speed Pot
2 = 2 Speed Pots

Joystick

0 = None
1 = Joystick

Backup Hard Drive

0 = None
1 = 2 GBytes

Processor

0 = 166 MHz Pentium
1 = 200 MHz Pentium
2 = 266 MHz Pentium II
3 = 433 MHz Celeron
4 = 566 MHz Celeron

Section 2: Overview 9

Front Panel Layout

The front panel keypad of the control is shown below. In the upper center is the Color LCD display.
The power switch is located in the upper left-hand corner of the front panel. It is illuminated with a
green lamp when in the on position.

Located in the upper half of the control is the View Screen. The View Screen offers a simple to follow
graphical interface for the operator to view all aspects of control operation such as machine setup,
part file management, part programming and cutting operations.

Below the View Screen, there are several groups of push buttons or keys on the front panel. The
eight keys located directly below the display and labeled with Soft-Keys act as programmable keys.
The functions of these keys are shown in the display. This allows many different functions to be in­cluded without an excessive number of separate keys. It also provides complete flexibility for future
software features and enhancements.

The yellow key labeled HELP is for on-line documentation and help. Simply press this key at any
time and this document will be displayed.

The keys to the lower right of the front panel comprise the alpha numeric keypad, which is used for
entering data. To the far left, under the label Machine/Screen Navigation, are keys which control
manual motion and cursor location during data input. These include the MANUAL key (for Manual
Mode jogs) and the eight arrow keys (for jog and cursor direction).

The two keys under the label CUT are for program start and stop.
Behind the small door labeled FLOPPY DRIVE is the internal 3.5” 1.44Mbyte floppy disk drive. In

addition, there is a small potentiometer behind this door to adjust the LCD brightness and contrast.
This potentiometer should only need to be set once, at the time of installation, unless the control is
being operated in an extreme temperature environment.

Front Panel

10 Operator’s Manual

Operation Summary

The programming and operation of the control is menu-driven. The following diagram shows the
Screen Hierarchy for the menu structure.

The menu that appears in the display when the unit is first turned on is referred to throughout this
manual as the Main Menu. All other menus and functions are accessed at some level under Main
Menu, or else appear as part of a special operational sequence, such as when the cutting process is
interrupted during the middle of a part.

The DONE and CANCEL keys have special functions in relation to the menu structure. The DONE
key returns to the menu from which the present selection was entered and retains any changes that
were made. The CANCEL key returns to the menu from which it was entered and deletes/discards
any changes that were made. There are, however, some operations during which CANCEL is not
active.

Screen Hierarchy

Main Screen

Part Options Files

Repeat
Align

Manual Options

Manual

Manual Options
Home Axes

Change Consumable

Manual Options

Cut

Pause

Change Consumable

Manual Options

Load from Disk
Save to Disk
Download from Host
Upload to Host

Setups

Cutting
Cut Types

Password 2

Shape Manager

Text Editor
Shape Wizard

Teach Trace

Plasma

Cut Chart

Marker

Cut Chart
Laser
Water Jet

System Tools

VirusScan Tools

NJWin Tools

Part Options

Repeat

Password 3

Station Configuration
WatchOxy Fuel
Diagnostics

Control Information

Keyboard

Serial Port

Drives and Motors

I / O

Inputs
Outputs
Analog Inputs

Shape Library

Simple Shape

View Text

Part Options

Repeat

Password 1

Machine
Speeds
Link
I/O
Axes

Transverse
Rail
Dual Gantry
CBH
Tilt
Rotate
THC

Nester

Section 2: Overview 11

Key & Menu Functions

The following is a short form description of all menu functions in the control. This is only a brief
description of each function. Please consult the subsequent manual sections for more complete
information on operatio na l us age of specif ic k e ys.

Help Screen

This controller is equipped with an easy to follow help screen function. To access the internal help
screens press the yellow softkey to the top left of the keypad. Help information for the screen
currently being accessed will be displayed. Pressing the DONE softkey will exit the help screens and
return you to the last control screen accessed.

Show Contents

While at the help screen, the table of contents may be turned on and off by pressing the Show
Contents softkey. Use the up/down arrow keys to select a subject and press enter to view.
Press the previous/next key to move from the table of contents and the information screen and back.
While at the information screen, the up/down arrow keys are used to scroll through the information on
the selected topic.

Find

The find feature will search for a requested topic within a selected information screen.

12 Operator’s Manual

Main Screen

This is the top most screen and the one that the control powers up in.

Preview Window

This window displays the current part in memory with the overall dimensions for that part.

Watch Window

This is the right part of the screen where such things as the speedometer, positions, cut mode and
time are displayed. This part of the screen is configurable through the setups.

Shape Manager

This softkey takes you to the Shape Manager screen where you can load a simple shape, edit a part
using the text editor or shape wizard or teach trace a part.

Files

This softkey takes you to the Files screen where you can load, save, download or upload part files.

Part Options

This softkey takes you to the Part Options screen where the current part can be scaled, rotated,
mirrored and/or repeated.

Section 2: Overview 13

Setups

This softkey takes you to the setup screens.

View Part/View Sheet

View Part allows the viewing of the entire current part in the Preview Window.
View Sheet allows the viewing of a part as it would appear on the plate. Af ter pres s ing the View Shee t

softkey, the display window zooms out to show the part in relationship to the entire plate.

After zooming out, the displa y can be zoom ed in again b y press ing the + key, which causes horizontal
and vertical scroll bars to be displayed. Pressing the - key will zoom back out.

14 Operator’s Manual

While the scroll bars are displayed and the control is not cutting, the view of the plate can be shifted
horizontally and vertically by holding down a shift key and pressing the arrow keys. While the control
is cutting, the view will automatically be shifted as the cut path reaches one of the edges of the view.
This mode is useful in normal cutting to closely follow the cut-path while in zoom.

View Sheet is more useful when proper Plate Size values have been entered in Cutting Setups.

Change Cut Mode

Allows selection of Trial, Oxy Fuel, or Plasma cutting modes, depending on the setup configuration.
This softkey offers the selections of Automatic, Manual or Test Run for I/O type “B” configured
controls.

Change Consumable

This softkey takes you to the Change Consumable screen.

Zero Positions

This softkey zeros the current positions on the Transverse and Rail axes as well as the Dual Gantry
axis if used.

Section 2: Overview 15

Shape Manager Screen

The Shape Manager screen is used to retrieve a part from the Shape Library and edit part files.

Shape Library

Brings up the built-in library of 53 simple shapes.

Text Editor

Enters the full screen ASCII text editor. The current part in memory is loaded, allowing direct editing
of the selected part program.

Shape Wizard

Enters into the ShapeWizard
selected part program using an easy to use graphical interface to view changes as they are made.

Teach Trace

Enters the trace-teach menu, where with an optional tracing system, you can digitize a template.

Nester

Nester™ is a proprietary part nesting program which allows the operator to manually group or nest
selected parts together as one part program to conserve raw materials and maximize machine
utilization.

An optional Automatic Nesting feature is available as an add-on item to Nester™. This true shape,
single station, automatic nesting package allows quick and simple nesting of profiles on to selected
material sizes. Please contact your control vendor for information on adding this feature.

®

a graphical editor window. ShapeWizard® allows direct editing of the

16 Operator’s Manual

Files

From the Files screen the user may load or save parts on the control or an external location.

Load from Disk

Allows programs to be loaded from the internal disk drives or external mapped drives (network option)
into working memory.

Save to Disk

Allows the current program in memory to be saved to the internal disk drives or external mapped
drives ( network option ). This also accesses the Save Key Logging File screen.

Download from Host

Allows programs to be downloaded from a host computer to the internal disk drives over the selected
RS-232C/ RS-422 serial port.

Upload to Host

Allows programs from the internal disk drives to be uploaded to a host computer via the selected RS­232C/RS-422 serial port.

Resume Last Part

The Resume Last Part softkey will be visible when the Rush Job Interrupt or Automated Power Loss
Recovery feature is in use. These features allow the user to pause the current part program and
retain the part and current position information. This then allows the user to load and execute
another part program and return to the original part using the Resume Last Part softkey.

Section 2: Overview 17

Show Certain Files

This softkey allows the operator to show only certain files from the selected directory. Both the
asterisk and question mark may be used in defining the files to show. The asterisk is generated by
holding down the left shift key and pressing the backspace key. The question mark is generated by
holding down the right shift key and pressing the backspace key.

Show All Files

This softkey allows the operator to undo the Show Certain Files from above.
Note: An optional Network Card for connecting directly to a PC Network for part file allocation is

available.

18 Operator’s Manual

Setups Screen

The Setups Screen is used to configure the control for use.

Cutting

Allows programming of the different cutting parameters EIA program types, dwell times, etc.

Cut Types

Enters the cut type menu, which allows editing of gas control sequencing variables for oxy-fuel and
plasma cutting.

Disable Control

Pressing the Disable Control softkey disables the motion command from the control to the drive
system. While disabled, I/O points and encoder feedback are still active.

Watch

Allows programming of the user definable Watch Window.

Password

Enter a password to get to the supervisor password protected setup menu.

Diagnostic

Enters the diagnostics menu.

Change to Metric Units/English Units

Changes all parameters over to metric units or English units.

Section 2: Overview 19

Change Consumable

The Change Consumable Screen is used to track and record consumable life in a database. If the
New Torch Tip or New Electrode softkey is pressed every time a torch tip or electrode is changed, the
last information for the corresponding consumable will be added to a database. This database will
show the date a consumable was changed and how long it lasted in minutes, pierces, inches /
millimeters of travel and Arc Errors. Torch Tip and Electrode data can be recorded for up to twelve
Oxy torches and up to eight plasma torches. A special feature allows the user to add an additional
wear factor ( in minutes ) to compensate the database for the additional wear during piercing.
Additionally, a Change Consumable Output will be activated when the specified limit has been
reached. This output may be tied to an indicator lamp or alarm to prompt the operator to change the
consumable.

New Torch Tip

This softkey records when a new Oxy Fuel or Plasma torch tip has been installed on the machine.

New Electrode

This softkey tells the control that a new electrode had been installed on the cutting machine.

Reset Database

This softkey is used to reset the database on the control to have no torch tip or electrode information.

Setups

Pressing the Setups softkey access the control setups for adjustment of the cut process.

Upload Database

This softkey is used to upload the current database to a host computer running our link.

Save Database

This softkey is used to save the current database to the diskette.

20 Operator’s Manual

g

Key Functions

The alpha–numeric keypad is used to enter numeric data or text.
To enter a number, simply press the key. To enter a word, press
and hold the matching colo red shift key (up arrow) while pressing
the desired letter key. The + (plus) and – (minus) keys are used to
add and delete features at selection and check boxes.

A purple or blue arrow at t he left or right edge of the s oftkeys
indicates that that m ore softkeys and features are a vailable by
pressing the corresponding shift key on the alpha-numeric
keypad.

Pressing the space key inserts a space into the current data entry field. The space key
is also used to toggle between fixed logic settings ( i.e. setups - preheat sense input
open/closed ). The space key may also be used to add and delete features at selection
and check boxes.

Deletes the current character in the data entry field and backs up one position in the
field. Located above the Ba ck Space key are the * and ? characters which are used as

These keys activate jogging using the arrow keys when in the
manual mode. Manual key functions (indicated in green) are
available at the M anual, Pau se an d A lign Scre ens. Thi s ke ypad is
also used for navigating through a multi-variable dialog box
(indicated in yellow).

The Prev/Next buttons are used to move through the field boxes,
Page Up/Down is used to scroll and the arrow keys are used to
select items in a dialo

box.

Can be pressed at any time (except during cut) to return to the previous menu
without saving any changes. Located above the Cancel key are the \ and :
characters which are used for mapping network drives.

Causes the last number entered/toggled to be accepted. Located above the enter
key are the < and > characters whic h are used for mapping network drives.

Section 3: Setups 21

Section 3: Setups

Cutting

When entering the Setup menu the operator will be prompted for the following run-time parameters
for Trial Mode (no cutting), Oxy-Fuel, and Plasma cutting.

Plate Size

Specifies the dimensions of the current plate being cut. This dimension is used when loading a part
to determine if it will fit on the plate. It is also used for viewing the part in Screen View.

Cut Mode

Specifies the current cut mode. Trial/Test mode allows the operator to dry-run the current part
program without cutting. Press the left or right arrow keys to select the desired cut mode.

Trial/Cut Speed

Specifies the speed for the current cut mode. These speeds are saved independently for trialing and
cutting. Both speeds will be limited to the maximum machine speed. Cut and Trial speeds may be
executed at the embedded F-code speed withi n a part progr am.

Marker 1 / Marker 2 Speed

Specifies the speed for the selected Marker. These speeds are saved independently for each Marker
and are executed through the marker tool selection within a part program. Marker 1 is activated by
EIA RS-274D M09 and M10, or an ESSI 9 and 10. Marker 2 is activated by EIA RS-274D M013 and
M14, or an ESSI 13 and 14.

22 Operator’s Manual

Kerf

Specifies the amount of kerf (cutter compensation) that will be applied to the current part program.
Care should be taken when selecting a kerf value as this parameter can cause invalid geometries to
be generated. For example, adding a kerf of 0.5” to an arc with a radius of 0.25”. After entering a
kerf value, the kerf compensated cut path can be viewed by pressing the Kerf softkey under the Part
Options menu.

Dwell Time

Specifies the amount of dwell (delay) to be inserted into the current part program when an
appropriate RS-274D program block is reached. This time can be overridden in the part program.
For example in EIA programming a G04 X3 will cause a three second dwell to be inserted at the
current program block. A G04 with no X-code will insert a dwell with the current Dwell Time
parameter.

Arc Radial Error

Specifies the arc error tolerance to be used when checking the current segment for dimensional
accuracy. All ESSI or EIA programs are comprised of lines, arcs, and circles. Arc Radial Error is
used to make sure that the starting and ending radial vectors are within tolerance to describe a valid
geometry.

Dwell Override

When this parameter is enabled, embedded dwell G04 Xvalue codes in an RS-274D program will
override the operator entered dwell time.

Optional Program Stop

Allows overriding of the optional program stop code M01 in the current part program. If enabled, an
M01 code operates identically to M00. If disabled, the M01 code is ignored.

EIA I & J Codes

Selects Absolute or Incremental RS-274D programming mode. In Incremental mode, all offsets for X,
Y, I and J relative to the current block. In absolute, mode all X, Y, I and J are relative to an absolute
reference point unless changed by using a G92 program code.

EIA F-Code Override

When this parameter is enabled, embedded F-codes in an RS-274D program will override any
operator entered Cut Speed.

Speed +/- Affects F-Codes

When this parameter is enabled, the control will apply the speed increase/decrease percentage to all
embedded F-codes encountered in the part program

EIA Decimal Shift

Some programming styles are structured so that the decimal point in the EIA positioning affecting part
sizing is assumed. The EIA decimal shift parameter allows the operator to select the location of the
decimal point when translating parts by selecting normal or single for correct translation. The
selection should be set to Normal unless your part programs have only a single digit to the right of the
decimal point.

Process Select Override

When enabled, this feature will allow the part program to override the process select input.

Station Select Override

When enabled, this feature will allow the part program to override the currently selected station select
input.

Section 3: Setups 23

Auto Torch Spacing Override

When enabled, this feature will allow the part program to override the manually selected Torch
Spacing inputs.

G97 Loop Count Prompt

When Enabled this feature will post a message on the screen to enter the number of loops or repeats
to be selected when an EIA G97 code without a “T” value is encountered in the part program.

Show Traverse Segments

Allows traverse segment lines (displayed in yellow) to be turned OFF or ON during all part preview
displays.

Retain Skew Adjustment

The Retain Skew Adjustment feature is used to retain the last calculated plate skew for all
subsequent parts that are loaded. If disabled any new part that is loaded will remove any previously
calculated plate skew.

Kerf Variable / Kerf Offset

The Kerf Variable / Kerf Offset parameter is used to create a Kerf Variable table which assigns a
reference number (variable) to a Kerf value. Up to 200 variables may be entered to create a
reference table.

This Kerf Variable can then be used within a part program to define the kerf value when cutting. The
advantage to this is that as torch parts wear, the kerf value changes. If the Kerf Variable value is
updated as the consumable wears and ch ang es , the ne w value wi ll be ca ll ed b y the Kerf Variabl e
command with all programs loaded that use the variable.

The EIA-274D part code for left kerf variable is the G43 code.
Example: G43

D1 X0.06

Kerf Variable Setting
Kerf Variable

A number from 1-200 may be used

Kerf Data

The selected kerf value

Marker Offsets 1 - 12

Enter in values for up to twelve programmable marker offsets. The machine is offset by this amount at
maximum speed when the appropriate marker code is detected.

THC Voltage Offset

The THC Voltage Offset parameter is used to offset the individual Sensor THC™ Arc Voltages from
the master set Arc Voltage. This allows the individual THCs to be adjusted to compensate for
consumable wear and obtain optimum cut quality.

Marker On Time (Type “B” Configuration Only)
This parameter allows the operator to insert a time delay, which allows the marker to prepare for
operation prior to the start of Marker motion.

Marker Off Time (Type “B” Configuration Only)
This parameter allows the operator to insert a time delay, which allows the marker to complete
operation at the end of Marker motion.

24 Operator’s Manual

Cut Types

Your shape cutting control comes standard with several styles of built-in cut process logic which
allows the cut process timing to be configured for optimum performance. Selection will vary due to
control configuration.

Example:

In the Plasma Cut Type example provided above, various process timing adjustments may be made
to tune the process to the Plasma System and material being cut for the desired performance.
Pressing the space key allows the user to view a graphical diagram of the process logic

Additionally, each cut type has the ability to save and load the process setups in a file on the hard
drive or to a floppy diskette. The Purple arrow at the left edge of the softkeys indicates additional
softkeys are available. Pressing the shift key allows the Save Data and Load Data functions to be
available.

Section 3: Setups 25

Oxy Fuel

The control comes with the following built-in control logic for Oxy Fuel cutting. When Oxy Fuel is
selected, the following parameters are available to customize the logic for the particular metal being
cut. As these parameters are changed, the timing diagram below will change to show the new timing
parameters. This screen is located under the Cut Types softkey in the Setups.

Note: Pressing the Start key twice will bypass all timers and begin the cut.

I/O Configuration Type “M”, “P” and “V”

I/O Configuration Type “M”, “P” and “V”

Press the Space Key to view the timing diagram from setups.

26 Operator’s Manual

I/O Configuration Type “B”

I/O Configuration Type “B” (Timing Diagram)

Press the Space Key to view the timing diagram from Setups.

Ignition Time

Specifies the length of time that the oxy fuel igniter is held on at each ignition of the flame.

Low Preheat

For those cutting systems that are equipped with a Low Preheat feature, this parameter allows the
operator to input a timing delay to activate the Low Preheat output prior to the High Preheat.

Section 3: Setups 27

High Preheat

Specifies the length of time to wait at each pierce position for preheating the piece prior to piercing.
During the run-time, the operator may use the SET, EXTEND, or RELEASE softkeys to customize the
preheat length for the particular metal being cut.

Pierce Time

Specifies the amount of delay after the cutting gas is turned on before lowering the torch to the cut
position.

Moving Pierce Time

The Moving Pierce Time parameter specifies the amount of time that the Pierce Output remains on
while piercing with motion.

Creep Time

Specifies the amount of time after piercing the part that the torch travels at Creep Speed. Creep
Speed is determined by a setup parameter at the Speeds setup screen and is a percentage of the
programmed cut speed. After the Creep Time is completed, the control accelerates to full cut speed.
This parameter is helpful in allowing the operator to bring the cutting surface up to temperature and
completely pierce the metal before cutting at full speed.

Primary Torch Up Time

Specifies the amount of time used for torch lift after completing each cut. This is normally used to
provide torch head clearance and return the torch to its predefined rest position.

Primary Torch Down Time

Specifies the amount of time used to lower the torch at the beginning of each new cut. This is usually
longer than the Pierce Torch Down Time as it involves lowering the torch from its predefined rest
position.

Pierce Torch Up Time

Specifies the amount of time used for torch lift during piercing. This parameter is used to provide
distance between the torch tip and metal surface for cutting.

Pierce Torch Down Time

Specifies the amount of time used for torch lowering during piercing.

Cut Off Time

The Cut Off delay parameter species the amount of time the cut on output will remain on at the end of
a cut.

Bleedoff Time

Specifies the amount of time that the cut torch will pause to purge the oxygen at the end of a cut
segment before traversing to the next cut segment.

Igniters

When “No” is selected, this feature will turn the Preheat on between cut segments. This is to keep
the torch light for those cutting systems that do not have automatic torch igniters. For those cutting
systems which have automatic torch igniters or that control the torch gases outside of the control, set
this parameter to “Yes”. This tells the control not to turn on the Preheat between cut segments.

Preheat During Cut

Specifies whether the Preheat will be left on while cutting.

28 Operator’s Manual

Plasma

The control comes with the following built in control logic for Plasma cutting. When Plasma is
selected, the following parameters are available to customize the logic for the particular metal being
cut. As these parameters are changed, the timing diagram below will change to show the new timing
parameters.

I/O Configuration Type “M”, “P” and “V”

I/O Configuration Type “M”, “P” and “V” (Timing Diagram)

Press the Space key to view the timing diagram from setups.

Section 3: Setups 29

I/O Configuration Type “B”

I/O Configuration Type “B” (Timing Diagram)

Press the Space key to view the timing diagram from Setups.

Start Time (Type “B” Configuration Only)

The Start Time parameter is used to delay motion along the cut path when a tool is started or a tool is
lowered.

Purge Time

Specifies the time delay from torch ignition until motion is enabled if Arc On Feedback is OFF. Purge
Time should be set to zero if Arc On Feedback is ON.

Pierce Time

Specifies the time delay from when the torch completes lowering until motion is initiated at Creep
Speed. Used to allow the plasma torch to completely pierce the material before moving.

30 Operator’s Manual

Creep Time

Specifies the amount of time after piercing the part that the torch travels at Creep Speed. Creep
Speed is determined by a setup parameter at the Speeds setup screen and is a percentage of the
programmed cut speed. After the Creep Time is completed, the control accelerates to full cut speed.

Cut Off Time

The Cut Off delay parameter species the amount of time the cut on output will remain on at the end of
a cut. A negative Cut Off time up to one second may be used to terminate the cut output prior to the
end of the cut segment. This is used to compensate for response delays of the cut gases that will
maintain the cut arc and widen the cut path at the end of the cut segment.

Full Torch Up Time
Specifies the length of time to raise the torch at the beginning and end of each cut to provide
clearance over the cut pieces. If you are using an automatic height control system, set Torch Up
Time to zero.

Partial Torch Up Time
Specifies the length of time for a partial raise of the torch at the beginning and end of each cut to
provide clearance over the cut pieces. If you are using an automatic height control system, set Torch
Up Time to zero. Note: The Partial Raise parameter must be enabled.

Torch Down Time

Specifies the length of time to lower the torch at the beginning of each cutting cycle. If you are using
an automatic height control system, set Torch Down Time to zero.

Arc Off Time

Specifies the amount of delay to allow prior to indicating a lost cut signal. This can be useful in
helping to minimize nuisance trips when traveling over previously cut paths in complex nested parts.

Stop Time

Specifies the amount of time that motion will pause at the end of a cut. This pause is advantageous
for allowing the torch to completely raise and clear any cut irregularities before continuing to the next
cut segment.

Set Arc Current

The Set Arc Current feature allows the user to set the arc current at the plasma supply. This feature
uses the “Set Current BCD” output from the control to activate the BCD inputs at the plasma supply.
The Set Arc Current parameter is also available for the HD4070

®

via the serial link. EIA RS-274D part

program code G59 Vvalue Fvalue for setting current is supported.

Corner Current Percent

The Corner Current Percent feature allows the operator to select a reduced current setting to be
executed when cutting corners to improve cut quality. This value is a percentage of the Set Current (
above ) and is active when the Torch Height Disable Output is on. The Corner Current parameter is
also avai lable for the HD4070

®

via the serial link.

Retry Transfer Fail

The Retry On Transfer Fail feature is used to specify the number of times the control will attempt to
fire the torch in the event that the torch fails to ignite.

Section 3: Setups 31

Transfer Time

The Transfer Time parameter specifies the amount of time used to attempt ignition of the torch. The
ignition is confirmed by the Arc Sense Input (Arc on Feedback) to the control.

Arc on Feedback

Specifies whether an arc-on (also called Plasma Go, Current Sense, Arc Transferred) signal from the
plasma system to the control is used. With Arc On Feedback ON, the control waits for Cut Sense
input to activate before initiating machine motion.

Ignition

Enables use of the Ignition output for use in igniting the plasma torch. If your plasma system requires
a separate ignition signal, toggle Ignition to ON. If not, leave Ignition OFF.

Dual Grid/THC

The Dual Grid parameter enables use of the Torch Height Disable output. This output is used to
disable an automatic torch height sensor or reduce the plasma current in a switchable current plasma
system when machine speed is less than Plasma Hi/Lo Speed.

Dual Grid/THC Start

If Dual Grid is ON, the start mode can be configured to start (HI) or (LOW) at ignition time. For
switchable plasma systems, this usually means that in low mode the plasma system will only deliver
50% of the maximum output power.

Partial Raise

Enabling the Partial Raise feature will execute a tool raise at the end of the cut segment within a nest
for the time specified in the Partial Up Time parameter. Full raise will be executed at the end of the
final cut segment.

Torch Down During Cut

Turning on the Torch Down During Cut feature forces the torch down output to remain on throughout
the cut process. This is advantageous for pneumatic style torch lifters that require a constant output.

Torch Down Between Cuts

Turning on the Torch Down Between Cuts feature forces the Torch Down Output to remain on while
traversing between cut segments.

32 Operator’s Manual

Marker

The control comes with the following built in marker control logic for marking. When marking is
selected, the following parameters are available to customize the logic for the particular metal being
marked. As these parameters are changed, the timing diagram below will change to show the new
timing parameters. This screen is located under the Cut Types softkey in Setups.

Note: This screen feature is not available with type “B” configured controls.

Marker Interface

The Marking feature from the control is operated through the use of existing I/O points for cutting
torches on the control I/O connector. These I/O points may be switched from the cutting torch to the
marking tool by use of an external relay(s) activated by the Marker Output or the Marker Output may
be used to activate the marking tool.

Please refer to the Machine Interface section of this guide for exact I/O pinout information.

Section 3: Setups 33

I/O Configuration Type “M”, “P” and “V” (Timing Diagram)
Press the Space key to view the timing diagram from Setups.

Ignition Time

(Ignition Output) Specifies the length of time that the ignition output is held on at each ignition point.

Marker On Time

(Time Delay) This parameter allows the operator to insert a time delay, which allows the marker to
prepare for operation prior to the start of Marker motion.

Marker Off Time

(Time Delay) This parameter allows the operator to insert a time delay, which allows the marker to
prepare for operation prior to the end of Marker motion.

Marker Up Time

(Torch Up Output) Specifies the length of time to raise the marker at the beginning and end of each
mark.

Marker Partial Up Time

(Torch Up Output) Specifies the length of time for partial raise of the marker at the beginning and end
of each mark. Note: The Partial Raise parameter must be enabled.

Marker Down Time

(Torch Down Output) Specifies the length of time to lower the marker at the beginning of each
marking cycle.

Set Arc Current

The Set Arc Current feature allows the user to set the arc current at the Plasma Marking supply. This
feature uses the “Set Current BCD” output from the control to activate the BCD inputs at the Plasma
Marking supply. EIA RS-274D part program code G59 Vvalue Fvalue for setting current is supported.

Corner Current Percent

The Corner Current Percent feature allows the operator to select a reduced current setting to be
executed when cutting corners to improve marking quality. This value is a percentage of the Set
Current (above) and is active when the Torch Height Disable Output is on.

Ignition

(Ignition Output Enable) The Ignition Off/On selection allows the operator to use the Ignition Output
when marking if set to On.

34 Operator’s Manual

Cut Control Used for Marking

This parameter is used to determine if the Cut Control output is to be used for activating the Marking
tool. If set to no, the Marking Output would be used.

Marker Down/Up With Each Marker On/Off

The Marker Down/Up With Each Marker On/Off will command the send the appropriate Up/Down
Output commands at each Mark On/ Off.

Arc On Feedback

Specifies whether an arc-on signal from a plasma marking system to the control is used. With Arc On
Feedback ON, the control waits for Cut/Mark Sense input to activate before initiating machine motion.

Partial Raise

Enabling the Partial Raise feature will execute a tool raise at the end of the Mark within a nest for the
time specified in the Partial Up Time parameter. Full raise will be executed at the end of the final
Mark segment.

Down On During Mark

Turning on the Down On During Mark feature forces the torch down output to remain on throughout
the Marking process. This is advantageous for pneumatic style torch lifters that require a constant
output.

Down On Between Marks

Turning on the Down On Between Marks feature forces the Torch Down Output to remain on while
traversing between marking segments.

Note: Please refer to the Program Codes section of this guide for information on the Marker Font
Generator feature.

Section 3: Setups 35

Laser

Laser Sequence 1

The Purple arrow at the left edge of the softkeys indicates additional softkeys are available. Pressing
the shift key allows the test lifter function to be available.

Test Lifter

Pressing the Test Lifter softkey will command the torch lifter to lower to the plate, sense the plate and
retract to the pierce height.

36 Operator’s Manual

I/O Configuration Type “V” (Timing Diagram)
Press the Space key to view the timing diagram from Setups.

Laser Sequence 2

The Purple arrow at the left edge of the softkeys indicates additional softkeys are available. Pressing
the shift key allows the test lifter function to be available.

Test Lifter

Pressing the Test Lifter softkey will command the torch lifter to lower to the plate, sense the plate and
retract to the pierce height.

Section 3: Setups 37

I/O Configuration Type “V” (Timing Diagram)
Press the Space key to view the timing diagram from Setups.

Purge Time

Specifies the time delay from the start of the Laser Tool until motion is enabled.

Shutter Time

The Shutter Time parameter is used to specify the amount of time to open the shutter prior to the
Laser pierce.

Power Ramp Time

The Power Ramp Time parameter is used to specify the amount of time to Ramp up the Laser power
prior to the Laser pierce.

Pierce Time

Specifies the time delay from when Laser Tool completes lowering until motion is initiated at Creep
Speed. Used to allow the Laser Tool to completely pierce the material before moving.

Start Pierce Time

Specifies the time that the Pierce Control and Pierce Enable Outputs are ON for piercing.

Pierce Complete Time

Specifies the time that the Pierce Enable Output remains ON after the Start Pierce Time (Pierce
Control output) is completed.

After Pierce Time

Specifies the time delay after Pierce Complete Time (Pierce Enable Output) is completed and before
the Digital Beam Output comes on. The Pierce complete Output is ON during this time.

Creep Time

Specifies the amount of time after piercing the part that the torch travels at Creep Speed. Creep
Speed is determined by a setup parameter at the Speeds setup screen and is a percentage of the
programmed cut speed. After the Creep Time is completed, the control accelerates to full cut speed.

Beam Off Time

The Beam Off Time parameter species the amount of time the cut on output will remain on at the end
of a cut.

38 Operator’s Manual

Cut Height

The Cut Height setup parameter is used to select the desired cut distance from the plate. This will set
the initial cut height before the Laser Tool is activated.

Pierce Height

The Pierce Height setup parameter is used to select the desired Pierce Height. This may be entered
as a multiplication factor that is calculated times the Cut Height or an actual Pierce Height distance.

IHS in Manual

The IHS in Manual setup parameter allows the operator to select whether or not to use the Initial
Height Sense feature when operating the Sensor THC in manual mode.

Retract Full/Partial

Selects the retract distance to be set at Full or Partial. In the Full retract mode, the torch will retract to
the Home position. In Partial retract mode, the torch will retract to the set retract distance.

Partial Retract Distance

This setup parameter is used to select the THC Retract Distance when configured for partial retract
mode.

Start IHS Distance

The Start IHS Distance specifies the distance of travel for the THC to move the torch at high speed
before switching to low speed and beginning Initial Height Sense. Caution should be taken when
selecting this distance so that the torch does not crash into the plate.

Nozzle Contact IHS

This parameter would be set to ON to select the THC to use Contact Sense to detect the plate during
the IHS cycle.

Laser Cut Logic

Allows the user to select Cut Sequence 1 or Cut Sequence 2, thus changing the Laser timing.

Section 3: Setups 39

Water Jet

I/O Configuration Type “M”, “P” and “V” (Timing Diagram)

Press the Space key to view the timing diagram from Setups.

Purge Time

Specifies the time delay from torch ignition until motion is enabled.

Pierce Time

Specifies the time delay from when cutting tool completes lowering until motion is initiated at Creep
Speed. Used to allow the cutting tool to completely pierce the material before moving.

40 Operator’s Manual

Creep Time

Specifies the amount of time after piercing the part that the torch travels at Creep Speed. Creep
Speed is determined by a setup parameter at the Speeds setup screen and is a percentage of the
programmed cut speed. After the Creep Time is completed, the control accelerates to full cut speed.

Abrasive Off Time

The Abrasive Off delay parameter species the amount of time the abrasive will remain on at the end
of a cut.

Abrasive Charging

When selected, the Abrasive Charging feature will charge or fill the abrasive into the cutting system
for use while cutting.

Section 3: Setups 41

Watch

The control comes with a unique function for watching critical process related parameters during
cutting. The Watch window allows the operator to customize a certain portion of the screen to display
functions that are critical for your particular cutting operation. Whether it is Current Speed, Position,
I/O status, or torch consumable life, you now have the flexibility to display the information that you
want to see.

As these parameters are turned ON or OFF, the Watch window will be updated with the new
graphical widget. Widget is a GUI programmer’s term for defining icons which graphically display
information.

Several options are available to personalize the Watch window and not all options can be viewed at
one time. The options are grouped into two sizes of widgets or icons. Large widgets may be placed
into the upper position at the top of the Watch window or in the middle of the Watch window. Small
widgets are positioned in the lower left corner of the Watch Window next to the cut information and
clock. The cut information and clock at the lower right may not be edited.

Selections in the Watch window will change slightly based on the control I/O configuration and
machine option selections that have been enabled.

The Watch positions will allow for the following selections.

None

Selecting None will leave the selected position blank.

42 Operator’s Manual

Input/Output

Allows current state of selected Input, Outputs or Status information to be displayed during cutting.
This can be especially useful in debugging gas control sequencing problems. To add or delete a
desired Input, Output or Status point to the Input/Output list box, highlight the desired item and +
(add) or – (delete) keys on the alpha-numeric keypad.

Position

Allows the position for the selected axis to be displayed. Only two axes may be displayed at the
Upper or Middle locations. The Lower location will allow up to four axes to be displayed.

Following Error

Allows the Following Error to be displayed. Following Error is the distance between the position the
control has calculated and the actual position of the torch. A large Following Error may indicate that
the cut speed selected may be beyond the capability of the cutting system. Only two axes may be
displayed at the Upper or Middle locations. The Lower location will allow up to four axes to be
displayed.

Temperature

Selecting to add the Temperature Widgit to the Watch window will display the current temperature
inside the control in Fahrenheit or Celsius (selected at the Special Setups screen). Note: Specific
control hardware require d.

Speedometer

Allows cut speed, maximum machine speed and current machine speed to be graphically displayed
while cutting.

Oxy Fuel Torch Tip

Allows the selected oxy fuel torch tip ( 1- 12 ) consumable life to be graphically displayed while
cutting. This is especially useful in helping to determine when the torch tip should be replaced and
keeping track of torch tip data for statistical process control (SPC).

Plasma Torch Tip

Allows the selected plasma torch tip ( 1- 8 ) consumable life to be graphically displayed while cutting.
This is especially useful in helping to determine when the torch tip should be replaced and keeping
track of torch tip data for statistical process control (SPC).

Plasma Electrode

Allows the selected plasma electrode ( 1- 8 ) consumable life to be graphically displayed while
cutting. This is especially useful in helping to determine when the electrode should be replaced and
keeping track of electrode data for statistical process control (SPC).

Process Data

The Process Data option allows the user to view up to four selected items for a selected cut or
marking process. Process timers and status items for Oxy Fuel, Plasma, Marker, Waterjet and Laser
may be selected.

Note: The process data will only be displayed during the current cut process. Example: Plasma 1
process parameters will only be displayed in the Watch window at the main cut screen while cutting in
Plasma 1 Mode.

Section 3: Setups 43

Multiple Watch Windows
Up to ten different Watch windows may be configured on the control for quick selection and viewing of

the Watch icons.
To configure different Watch windows for viewing, first access the Watch setup screen. Press and

hold the Shift key ( Purple or Blue shift key ) followed by a number ( 0 – 9 ). As you press the Shift
key the current Watch window number will be displayed in the lower right corner of the screen.
Configure the Watch Window as desired.

To select a different Watch window, press and hold the Shift key followed by a number ( 0 – 9 ).
Configure the next Watch window as desired. Continue this process until all desired Watch Windows
have been configured.

To view the various Watch windows during operation, simply press and hold the shift key and the
corresponding number and the desired Watch Window will then be displayed.

Example:

44 Operator’s Manual

Section 4: Shape Manager 45

Section 4: Shape Manager

Shape Library

The control contains a built-in Shape Library with more than 53 commonly used shapes. These
shapes are parametric. Parametric shapes are shapes that are not fixed in size or geometry.

The Shape Library consists of more than 53 shapes as shown below. The screen is defined in colors,
from the easiest (green) to the hardest (black). The color pattern used for these different shapes is
copied after the system used by skiers to rate the difficulty of ski trails.

Selecting a Simple Shape

After pressing Shape Library from the Main Menu, the control display shows the Shape Library as
shown above. At this time, simply use the arrow keys to navigate to the desired shape you wish to
cut and press ENTER. If the selection is incorrect, press CANCEL and re-select the shape.

At this point, the shape is displayed with the default parameters, or the parameters from the last edit
session of this shape. Detailed information on the available shapes can be found in the following
section.

46 Operator’s Manual

Text Editor

This screen is for manually inputting or editing of a part program in either ESSI or EIA format. The
current part that is in memory will be displayed upon entering this screen. Done will save any
changes to the current part in memory. If you want to save the changes to the hard drive, go to the
Save to Disk screen. If you do not want to save any changes that were made, press Cancel on the
keyboard.

Show Original Text

Pressing the Show Original Text button allows the user to view and edit the part program in the
original format in which it was written.

Delete Part

The Delete Part button will delete the current part from the Text Editor so that a new part can be
constructed.

Section 4: Shape Manager 47

Shape Wizard

ShapeWizard, a proprietary graphical part editor, provides a user-friendly, graphical method of

editing part programs.

ShapeWizard

any changes that are made, when they happen. EIA RS-274D codes can be inserted directly as
ASCII text into a part program or, alternatively, segments can be created by specifying phrases in the
user's native language as a step-by-step process. EIA RS-274D codes need not be known.

ShapeWizard



allows a user to graphically view not only the segment that is being edited, but also



is accessed from the Shape Library menu.

Manual Line Edit

Pressing Manual Line Edit allo ws editing the highlighted line in the Text Editor windo w. The ASCI I
text entered must be valid EIA RS-274D codes or an error message will result. Below is a Text Editor
line as it appears immediately after the Manual Line Edit is pressed:

48 Operator’s Manual

Simply typing right over the line can erase the highlighted text or the line can be edited using the left
and right arrow keys.

Replace Segment

Replaces the segment highlighted in gray in the Text Editor window with the segment selected from
the Segment Type window as pictured belo w:

Insert Before Segment

Pressing this softkey causes the segment selected from the Segment Type window to be inserted
before the segment highlighted in gray in the Text Editor window.

Insert After Segment

Pressing this softkey causes the segment selected from the Segment Type window to be inserted
after the segment highlighted in gray in the Text Editor window.

Remove Segment

The segment highlighted in gray or blue in the Text Editor window is removed from the part program
when the Remove Segment softke y is pressed.

After the Manual Line Edit softkey has been pressed, the left and right arrow keys on the front panel
can be used to move left and right within the line being edited in the Text Editor window. They also
are used when entering segment parameters for new Segment Types such as:

Section 4: Shape Manager 49

While a text line is highlighted in blue, the Up and Down arrow keys are used to scroll vertically
through the part program. With each press of one of these keys, a new segment is highlighted. In
addition, the graphic representation of the part program in the Preview window is updated so that the
corresponding segment is highlighted in red or blue, depending on whether it is a cut segment or a
traverse.

The Up and Down arrow keys are also used when the Segment Type pop-up window is highlighted to
scroll vertically through the list of segments. The Segment Type pop-up window is pictured below:

The PAGE UP and PAGE DOWN keys can also be used wherever the Up and Down arrow keys are
used. The only difference is that instead of moving up or down one line, PAGE UP and PAGE DOWN
moves 20 lines at a time.

Pressing PREV and NEXT moves the edit focus to the next window. For example, when a user enters
ShapeWizard, the first line in the Text Editor window is highlighted. If a new segment selection is
desired, the user must press either PREV or NEXT until a selection in the Segment Type window is
highlighted. Pressing NEXT again will cause the control to skip ahead and once again highlight a line
in the Text Editor window. As a rule, NEXT always moves the selection flow ahead and PREV moves
it backwards.

As soon as it becomes highlighted, the Segment Type window expands or pops-up. This allows the
user to view a larger selection of segment types. See the picture above.

After a selection is made in the Segment Type window, pressing ENTER will cause the control to
display up to three parameters associated with the segment selected. Not all segments have any
parameters associated with them. For example, End Program does not need any additional
parameters.

50 Operator’s Manual

Teach Trace

The Teach Trace function of the control allows parts to be taught rather than programmed. The
position information from the taught part will remain as a part program that can be saved to disk for
future use.

The Teach Trace algorithms present in the control can recognize both arcs and lines. This will
reduce the overall memory required to store these parts and will improve the smoothness of the cut.
The taught part in memory is in EIA format and can be cut, saved or manipulated using any of the
part options.

The Teach Trace function must be used in conjunction with an optional stand-alone optical tracing
system.

Start Corner

The Start Corner setup parameter allows the user to select where the taught part will begin for proper
viewing on the screen.

Tracing Pitch

This determines how precisely to learn a part. The Tracing Pitch can be adjusted to trade off
resolution versus size of the taught part. This value does not affect the actual position resolution of
the part.

A good starting point for most tracing systems is 0.01”.

Section 4: Shape Manager 51

Arc Radial Error

Specifies the arc error tolerance to be used when checking the current segment for dimensional
accuracy. All ESSI or EIA programs are comprised of lines, arcs and circles. Arc Radial Error is
used to ensure that the starting and ending radial vectors are within tolerance to describe a valid
geometry.

Auto Closure Detect

This parameter is used to allow the control to detect that it has returned to the starting point. With this
feature ON, the control stops the motion of the tracer when the part is complete allowing a lead-out to
be programmed.

Closure Over/Under Lap

By specifying a positive value for this parameter, the control does not stop the tracer until it has gone
past the start point by the amount of this parameter. By specifying a negative value, the tracer stops
as soon as the tracing head position is within this parameter’s distance of the starting point. This is
only available if the Auto Closure Detect is ON.

Kerf Direction

Selects the desired kerf for cut segments.

Traverse/Pierce

Switches between the traverse and cut segments of the part as it is taught.

Tracing a part

To trace a part while at the Teach Trace screen, select Auto mode, then select traverse or pierce.
You may switch between traverse and pierce during the tracing procedure. Position the optical
sensor near the part drawing and press Start. Use the sensor positioning controls to direct the sensor
towards the part. Once the sensor has located the part, the tracing system will follow the part outline
until completion. When completed, press Done. The part file can now be cut, saved or edited.

Please refer to the instructions provided with your Optical tracing system for further details.

52 Operator’s Manual

Plate Remnant Trace

The Teach /Trace feature also supports the ability to trace in the outline of a plate remnant for use by a part
programmer to create new nests of parts to be cut on the remnant.

The user manually moves the torch (or a pointer) around the plate to define the outline of the material which
remains. When the path is completed (it doesn’t have to be a closed path), the operator presses the Done key
and the recorded axis motions are written to a standard part program format with moves recorded as incremental
routing moves. The movements will also display on the control’s screen in the same manner as displayed
during manual motion commands.

Once recorded, the part program can be uploaded via the serial link, or written to the floppy disk, so that the
programming department can use it to update their database to reflect the remaining material.

When first opened the system defaults to the automatic Teach/Trace mode which is used in conjunction with an
optical hea d for program gene ration. In order to use the manual func tion, simply select the softkey to choose
manual mode.

This will place the control in the manual control mode and also enables the Change Move Speed button to alter
the manual move speed. Pressing the Change Move Speed button repeatedly will cycle through the
programmed manual jog rate settings.

Section 4: Shape Manager 53

This will place the control in the manual control mode and also enables the Change Move Speed button to alter
the manual move speed. Pressing the Change Move Speed button repeatedly will cycle through the
programmed manual jog rate settings.

The operator should position the pointer or torch to the plate location where recording of the path is to begin.
Once at the start point, press the “Start” button to begin recording positions. The manual motion buttons may
now be used to trace out an arbitrary contour which defines the remaining plate area. When finished, press the
Done key to record the motions to the “current” part program.

The program may now be saved to the disk, or uploaded in the normal manner.

54 Operator’s Manual

Nester™

Nester™ is a proprietary part nesting program, which allows the operator to manually group or nest
selected parts together as one part program to conserve raw materials and maximize machine
utilization. This nesting program is designed to maximize the control features of graphical user
interface, simplified keypad operation and advanced communications software to provide quick,
simple and logical programming.

Additionally, an optional Automatic Nesting feature may be enabled to perform true shape, single
station, automatic nesting. With its advanced Graphical User Interface, ease of use and advanced
profile positioning algorithms, this Automatic Nesting feature can greatly improve the output of your
shape cutting operation by reducing overall process time and increasing plate utilization. Please
contact your control vendor for details on enabling this Automatic Nesting feature.

Manual Nesting

Main Screen Layout

The main viewing area is the largest area of the screen and is located in the upper left corner. The
edge of the plate is displayed in dark green. The plate size displayed is based on plate information
that has been selected at the main setup screen.

The upper right corner of the main screen displays the part program list for the nest in order of cut
sequence. In the lower right, part position and orientation information for the selected part program is
displayed and can be manipulated for use as new parts are added.

Section 4: Shape Manager 55

Add Part

Pressing the Add Part softkey accesses the screen, which allows the user to select a part program
from a selected source.

Remove Part

This softkey is used to remove the selected part from the nest parts list.

Cut Earlier

Pressing the Cut Earlier softkey will move the selected part program to an earlier position in the part
cut list. The sequence in which the parts are cut are changed, but not the selected part location in the
nest.

Cut Later

Pressing the Cut Later softkey will move the selected part program to a later position in the part cut
list. The sequence in which the parts are cut are changed, but not the selected part location in the
nest.

View Sheet / View Part

View Sheet allows the viewing of a part as it would appear on the plate. Af ter pres s ing the View Shee t
softkey, the display window zooms out to show the part in relationship to the entire plate.

After zooming out, the displa y can be zoom ed in again b y press ing the + key, which causes horizontal
and vertical scroll bars to be displayed. Pressing the - key will zoom back out.

More information on use of this feature is provided in the Manual cutting section.

Arrow Key ( Distance )

The Arrow Key allows the user to select one of five different preset move distances when the arrow
keys are pressed to locate parts in the nest. These five distances are definable and are selected in
the Nester™ Setup screen.

Setup

Pressing the Setup softkey accesses the Nester™ Setup screen for configuring the variable
parameters when using Nester™.

Done

The Done softkey is used to end the Nesting program, return to the Main Cut Screen and temporarily
save the nested program as the current part. At this point, the part can be cut or saved to disk
through the Shape Manager. Pressing the cancel key will return the user to the Main Cut Screen
without saving the nested program.

56 Operator’s Manual

Setup

The following Setup parameters are used to configure the manual nesting process for use.

Arrow Motion

At this screen, the user can select different move increment dimensions. These dimensions are used
as move distance references when the control arrow keys are pressed to place parts in position on
the plate.

Autoposition

Autoposition is an automated feature of the Nester™ software to search for the next available location
to place a part that is being added to the nested part list. Autoposition compares the overall block
dimensions of the selected part and searches for the next available block on the plate that is large
enough to accommodate the part being loaded. Values can be input for the Search Increment and
Scrap Clearance parameters that are used when searching for the next available part location.

Autoposition will not allow parts to be placed on top of other parts or inside other parts. This feature
is enabled or disabled by using the space key at the enable box.

Clear Nest

Clear Nest will delete all the parts located in the nested parts list from temporary memory.

Done

The Done softkey is used to end the nesting setup and return to the Nester™ main screen.

Section 4: Shape Manager 57

Using Nester™

To begin, first select the plate size requirements for the nest at the Main Setup screen. This
information is used to display the plate size and plate orientation at the main view screen to place
parts on the plate. The plate information is retained with the nested part program when saved.

Press the Nester™ softkey from the Shape Manager screen then enter the Nester™ Setup Screen to
configure the nesting software for use. Press Done to return to the Nester™ Main Screen to begin
placing parts in the nest.

Adding Parts

At the Nester™ Main Screen, press the Add Part softkey to add a new part to the nesting part list.
The first screen viewed will allow the user to select a part from the Simple Shape Library, from a disk
or from the host computer via link communications.

Once a part has been selected from either location, the user will be prompted to select the number of
pieces desired.

58 Operator’s Manual

As new parts are added, they will be displayed on the selected plate in preparation for final
placement.

At this screen, the part can be oriented, scaled and moved to final position. This is done by moving to
the Nester™ Part List by using the Prev/Next keys and then using the Up/Down arrow keys to select.
When the desired part file is highlighted, use the Prev/Next keys to move to the desired field to
manually offset, rotate, mirror and scale the part.

To position the selected part, use the Prev/Next keys to highlight the view screen. The view screen
will be outlined by a bold blue border indicating that the arrow keys are active. Pressing the arrow
keys will allow movement of the part to the desired location on the plate. Each time the arrow keys
are pressed, the selected part will move in the direction of the arrow by the increment set by the
Arrow Key distance softkey. By use of the arrow distance key, arrow keys and zooming in the view
field, exact placement of the desired part may be obtained.

Additional parts may be added to the nest in the same fashion as described above. To customize
your nest, you may decide to delete parts or add parts to the list and change the order in which they
are cut by use of the softkeys displayed. When finished, press Done to return to the Main Cut screen
and begin cutting the nest. The part nest is currently saved as a temporary file until another part is
loaded.

Saving a Nest

From the Main Cut screen, press the Files softkey to Save to Disk. From here the part can be saved
to a hard disk folder on the control or a diskette. The nested parts file may be saved as a nest or a
part. Saving as a nest will create a larger file, which will allow future modification of the nest through
Nester™. Nested parts saved as a part file cannot be modified.

Section 4: Shape Manager 59

HyperNest – CNC® Automatic Nesting Software

Optional HyperNest® - CNC feature - This true shape, single station, automatic nesting package
allows quick and simple nesting of profiles on to selected material sizes. With its advanced Graphical
User Interface, ease of use and advanced profile positioning algorithms, HyperNest
greatly improve the output of your shape cutting operation by reducing overall process time and
increasing plate utilization.

Main Screen Layout

The main viewing area is the largest area of the screen and is located in the upper left corner and is
used to preview manual nests. During an automatic nest, this area will remain blank. The plate size
used during Automatic nesting is based on plate information that has been selected at the main setup
screen.

The upper right corner of the main screen displays the list part programs and quantities of parts to be
automatically nested. In the lower right, locations to save the nested part program to a folder location
and to assign a file name.

®

- CNC can

Note: This software feature is protected both by a software enable and a hardware key (dongle)
installed on the control.

60 Operator’s Manual

Setup

Pressing the Setup softkey accesses the following setup parameters and are used to configure the
automatic nesting process for use. Note: If this feature is not available (greyed out), the feature has
not been enabled on your controller. Please contact your control vendor for details on how to enable
the Automatic Nesting feature.

Automatic Nesting

Switching the Automatic Nesting Parameter to ON enables the feature for use.

Part Spacing

The Part Spacing feature sets the spacing between parts during the Automatic Nesting process.

Plate Edge Spacing

This parameter allows the user to set spacing around the edge of the plate to be used during the
Automatic Nesting process.

Program Origin

The Program Origin ( nest start location ) may be set to lower left, upper left, bottom left or bottom
right.

Cut Direction

Cut Direction allows to user to select the direction the parts will be placed in during the Automatic
Nesting process. Options are: Left or Right, Right to Left, Top to Bottom and Bottom to Top.

Return to Nest Start

When enabled, the Return to Nest Start feature will insert a traverse segment back to the start point
at the end of the nest.

Section 4: Shape Manager 61

Using HyperNest – CNC®

To begin, first select the plate size requirements for the nest at the Main Setup screen. Press the
Nester™ softkey from the Shape Manager Screen then enter the Setup Screen to enable the
Automatic Nesting software feature and configure the setup parameters for use. Press Done to
return to the Main Screen and begin placing parts in the nest.

Adding Parts

At the Main Screen, press the Add Part softkey to add a new part to the nesting part list. The Add
Part screen will allow the user to select a part from the Simple Shape Library, from a disk or from the
host computer via link communications.

Once a part has been selected from the desired location, the user will be prompted to select the
number of pieces desired.

62 Operator’s Manual

As new parts are added, the part file name and quantity will be displayed in the parts list window in
the upper right corner of the screen in preparation for final placement during the Automatic Nesting
process.

Select the desired file location and assign a file then press the Nest Parts softkey to begin the
automatic nesting process. A progress window will be displayed during the nesting process.

Section 4: Shape Manager 63

Note: The nest process progresses quickly and not all shapes may be visible on screen or other
drawing anomalies may be noted during the nesting process.
In the event that more parts are selected than can fit on one plate, multiple plates or sheets (nested
program) files will be generated and saved in the selected folder with the selected file name, but a
numeric suffix will be added. Example: saving the part file as Nest may generate multiple part files
named NEST1.txt, NEST2.txt, NEST3.txt, etc.

Remove Part

A part may be removed from the part files list by highlighting the selected part in the files list and
pressing the Remove Part softkey prior to executing the nesting.

Note: The software feature on the control is protected by a hardware key or dongle. If the
hardeware key has been removed from the control, the following message will appear when the Nest
Parts softkey has been pressed.

64 Operator’s Manual

Nest Summary

Upon completion of the nest, the software will provide a summary of the Automatic Nesting process.

Statistical analysis of the process is provided for a number of sheets, time to execute nest, total nest
utilization and total number of shapes nested.

Note: Sheets that are generated with the exact same part configuration will be listed as “Sheet No. #
(total #). For the example above, the sheet number 5 thru 8 sheets are all the same and are listed as
“Sheet No.5 (4)”

Pressing the down arrow key will allow you to vie w an anal ysis of the parts used.

Section 4: Shape Manager 65

Pressing the down arrow key again will allow you to view the individual sheets produced and a listing
of the net utilization for the specific sheet.

Press Enter to accept the nest and have the first sheet become the current part. Press the Cancel
key to reject the nest and return to the main nesting screen to add or remove parts from the nest.

66 Operator’s Manual

Main Screen View of Nest

Note: Parts with open loops or other invalid geometries may not be able to be automatically nested.

It may be possible to manually nest parts which have been rejected by the Automatic Nesting
function.

Section 5: Files 67

Section 5: Files

Load from Disk

The following screen is used to load a part from a diskette or the hard drive. Once all the parameters
below are set, press ENTER on the keyboard to load the part.

Load from

The Load from list selects whether you load from the diskette or from a directory on the hard disk. To
select a different directory, use the ↑↑↑↑ and ↓↓↓↓ keys on the keyboard. To add a new directory, use the +
key on the keyboard. To remove a directory, use the - key on the keyboard.

Files

The Files listbox is a list of all the files that are in the Load from directory that can be loaded from the
disk. To scroll through different files, use the ↑↑↑↑, ↓↓↓↓, PAGE UP and PAGE DOWN keys on the
keyboard. To remove a file, use the - key on the keyboard. To select multiple files to load, highlight
the first file selection, then use the ↑↑↑↑ and ↓↓↓↓ keys while pressing the shift key to highlight the remaining
files. Note: Multiple file selection is only available if loading from the diskette to the hard drive.

68 Operator’s Manual

File name/Diskette file name

The File name /Diskette file name is the name of the file to load from disk/diskette.

Preview

When checked, the Preview checkbox allows the file that is selected in the Files listbox to be
previewed. To check or uncheck the box, press the SPACE key on the keyboard when the Preview
box has the focus.

Load to

The Load to list selects whether you load to the current part or to a directory on the hard disk. To
select a different directory, use the ↑↑↑↑ and ↓↓↓↓ keys on the keyboard. To add a new directory, use the +
key on the keyboard. To remove a directory, use the - key on the keyboard. Note: This selection is
only available if loading from the diskette.

Hard drive file name

The Hard drive file name is the name that you are giving the file you are loading on the hard drive.

Note: This selection is only available if loading from the diskette. Resume Last Part

The Resume Last Part softkey will be visible when the Rush Job Interrupt or Automated Power Loss
Recovery feature is in use. These features allow the user to pause the current part program and
retain the part and current position information. This then allows the user to load and execute
another part program and return to the original part using the Resume Last Part softkey.

Show Certain Files

This softkey allows the operator to search the selected folder for specific part files by using wildcard
type search tools. Both the asterisk (*) and question mark (?) can be used. To input the asterisk,
press the left shift key (purple) and the backspace key. To input the question mark, press the right
shift key (blue) and the backspace key.

Show All Files

This will allow the operator to switch from the selected “certain files” to viewing all files with the
predetermined file extensions.

Section 5: Files 69

Resume Last Part Features

Rush Job Interrupt

Rush Job Interrupt allows the user to pause the current part program and retain the part and current
position information. When at the Pause screen, press the Cancel key. A prompt will appear on
screen to ask the user if they wish to save the part information for later use.

If the user selects YES, the Resume Last Part button will be viewable at the Files Screen. The user
can then load and execute another part program and then return to the original part using the
Resume Last Part softkey. The part program and position will be resumed.

Automated Power Loss Recovery

The Automated Power loss recovery uses the Resume Last Part feature similar to the Rush Job
Interrupt. However, the Machine must be “Homed” to ensure proper positioning prior to resuming the
part.

This feature may also be used in the event of an “Overtravel” or similar fault.

70 Operator’s Manual

Save to Disk

The following screen is used to save a part to a diskette or the hard drive. Once all the parameters
below are set, press ENTER on the keyboard to save the part.

Save to

The Save to list selects whether you save to the diskette or to a directory on the hard disk. To select
a different directory, use the ↑↑↑↑ and ↓↓↓↓ keys on the keyboard. To add a new directory, use the + key o n
the keyboard. To remove a directory, use the - key on the keyboard.

File name/Diskette file name

The File name is the name that you are giving the file you are loading on the disk.

Save Original Text

Selecting the Save Original Text option will save the part to disk in its original programming format.

Note: This selection is not available if saving to the diskette from the hard drive. Save from

The Save from list selects whether you save from the current part or from a directory on the hard disk.
To select a different directory, use the ↑↑↑↑ and ↓↓↓↓ keys on the keyboard. To add a new directory, use

the + key on the keyboard. To remove a directory, use the - key on the keyboard. Note: This
selection is only available if saving to the diskette from the hard drive.

Files

The Files list box is a list of all the files that are in the Load from directory that can be loaded from the
disk. To scroll through different files, use the ↑↑↑↑, ↓↓↓↓, PAGE UP and PAGE DOWN keys on the
keyboard. To remove a file, use the - key on the keyboard. To select multiple files to load, highlight
the first file selection, then use the ↑↑↑↑ and ↓↓↓↓ keys while pressing the shift key to highlight the remaining

Section 5: Files 71

files. Note: This selection and Multiple file selection are only available if saving to the diskette from
the hard drive.

Hard drive file name

The Hard drive file name is the name that you are giving to the file loading on the hard drive. Note:
This selection is only available if saving to the diskette from the hard drive.

Preview

When checked, the Preview checkbox allows the file that is selected in the Files listbox to be
previewed. To check or uncheck the box, press the SPACE key on the keyboard when the Preview
box has the focus. Note: This selection is only available if saving to the diskette from the hard drive.

Save KeyLog to Disk

This feature is enabled when the Key Logging feature has been selected in setups.
The Key Logging feature is used as a troubleshooting diagnostic tool to record key presses made at

the control during operation. When enabled, all key presses and application faults will be saved to a
daily log file that may be sent to the control manufacturer for evaluation.

72 Operator’s Manual

Download from Host

The following screen is used to download a part from a host computer. Once all the parameters
below are set, press ENTER on the keyboard to start the download.

Download from

The Download from list selects which directory on the host computer you want to download from. To
select a different directory, use the ↑↑↑↑ and ↓↓↓↓ keys on the keyboard. To add a new directory, use the +
key on the keyboard. To remove a directory, use the - key on the keyboard.

Files

The Files list box contains a list of all the files in the Download from directory that can be downloaded
from the host computer. To scroll through different files, use the ↑↑↑↑, ↓↓↓↓, PAGE UP and PAGE DOWN
keys on the keyboard. To remove a file, use the - key on the keyboard.

To select multiple files to download, highlight the first file selection, then use the ↑↑↑↑ and ↓↓↓↓ keys while
pressing the shift key to highlight the remaining files.

Remote file name

The Remote file name is the name of the remote file that will be downloaded from the host computer.

Section 5: Files 73

Preview

When checked, the Preview checkbox allows the file that is selected in the Files list box to be
previewed. To check or uncheck the box, press the SPACE key on the keyboard when the Preview
box has the focus.

Download to

The Download to list selects whether you download to the current part in memory or to a directory on
the local hard disk. If you select one of the local directories, the following field is available: Local file
name. To select a different directory, use the ↑↑↑↑ and ↓↓↓↓ keys on the keyboard. To add a new directory,
use the + key on the keyboard. To remove a directory, use the - key on the keyboard.

Local file name

The Local file name is the user defined file name assigned to the file that is being downloading to the
hard drive.

74 Operator’s Manual

Upload to Host

The following screen is used to upload a part to a host computer. Once all the parameters below are
set, press ENTER on the keyboard to start the upload.

Upload to

The Upload to list selects which directory on the host computer that you want to upload to. To select
a different directory, use the ↑↑↑↑ and ↓↓↓↓ keys on the keyboard. To add a new directory, use the + key o n
the keyboard. To remove a directory, use the - key on the keyboard.

Remote file name

The Remote file name is the name you want the file that you are uploading to have on the host
computer.

Upload from

The Upload from list selects whether you upload the current part in memory or from a directory on the
local hard disk. If you select one of the local directories, the following fields are available: Files, Local
file name and Preview. To select a different directory, use the ↑↑↑↑ and ↓↓↓↓ keys on the keyboard. To add
a new directory, use the + key on the keyboard. To remove a directory, use the - key on the
keyboard.

Files

The Files list box contains a list of all the files that are in the Upload from directory that can be
uploaded to the host computer. To scroll through different files, use the ↑↑↑↑, ↓↓↓↓, PAGE UP and PAGE
DOWN keys on the keyboard. To remove a file, use the - key on the keyboard.

Section 5: Files 75

To select multiple files to upload, highlight the first file selection, then use the ↑↑↑↑ and ↓↓↓↓ keys while
pressing the shift key to highlight the remaining files.

Local file name

The Local file name is the name of the local file that will be uploaded to the host computer.

Preview

When checked, the Preview checkbox allows the file that is selected in the Files list box to be
previewed. To check or uncheck the box, press the SPACE key on the keyboard when the Preview
box has the focus.

Loading Of Invalid Files

While loading the desired part file, the control will check the part for proper geometry and other similar
errors. If a part is loaded in which an error is detected, a message will be posted on screen to
indicate the error. If the part is attempted to be loaded, the control will display the invalid line of code
from the text editor.

Example: In the following example, the line of code “XXXXXXXX” is invalid and has been highlighted
for easy detection. The part file may be corrected using the text editor. After the invalid code has
been corrected, the control will attempt to translate the part file and will indicate any additional invalid
codes.

76 Operator’s Manual

Section 6: Library Shapes 77

Section 6: Library Shapes

Library Shape Setup

Enter in the desired dimensions to obtain the part you require. There will be a small Help icon
in the lower right hand corner of the display to indicate which parameter the control is looking
for. The current parameter being entered will be highlighted with a yellow arrow bar.

While you are entering in parameters, the control is performing some general checks for proper
geometries. Should the control encounter a set of parameters that do not make sense, a warning
message will be displayed and the parameters in conflict will be highlighted in red. Note: It is not
possible to check for all improper geometries and it may still be possible to enter in a part that does
not make geometric sense.

As you are entering dimensional parameters, the control is automatically drawing your new shape
with the entered values. This is extremely useful in providing a visual check of the shape that has
been entered.

Lead-In, Lead-Out

Enter the appropriate value to ensure proper piercing (Lead-in) and gas bleed-off (Lead-out) to obtain
optimum cut quality.

The location for the lead-in and lead-out is fixed, but can be changed by using the ShapeWizard and
then saving the new shape to disk. Note: the Rectangle simple shape has the ability to select the
location for the lead-in and lead-out by pressing the SPACE key. Pressing the SPACE key will move
the lead-in and lead-out to the next available location.

Overburn Length

Overburn is used for parts that contain a circular element. Overburn specifies arc length that the
torch will travel past the circle closure point. The dimension entered is the chord length of the
overburn-arc.

In some cases it is desirable to have an underburn length. For these conditions, simply enter a
negative number for the Overburn length.

Part Type

Selects whether you want to cut the part as a separate Piece or a Hole in a larger part. Chain cut
options are available for simple shapes that have external cut paths.

Lead Type

Depending on the shape selected, the style of the Lead in/ Lead out may be selected as Radius, Lock
or Straight line. The Lock style Lead-in creates greater stability for the part and is only available if the
Part Type is set to Piece. Lead-in selection is only available if the Part Type is set to Piece or Hole.

After the shape has been entered, press DONE to return to the Main Menu.

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Rectangle

Circle

Section 6: Library Shapes 79

Triangle

L-Bracket

80 Operator’s Manual

Trapezoid

Slant Rectangle

Section 6: Library Shapes 81

Gambrel Rectangle

Roofed Rectangle

82 Operator’s Manual

Oval

Circle w/ Flat Side

Section 6: Library Shapes 83

Circle Slice

Straight Slots

84 Operator’s Manual

Angled Slots

Horizontal Rip

Section 6: Library Shapes 85

Vertical Rip

Flange

86 Operator’s Manual

Gusset

8 Sided

Section 6: Library Shapes 87

Rectangle w/ Convex Corners

Rectangle w/ Concave Corners

88 Operator’s Manual

Flange Slice

Elbow