Installation & Setup Guide 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
Front Panel Layout.............................................................................................................................. 3
Model Numbering System................................................................................................................... 5
Operation Summary............................................................................................................................6
Screen Hierarchy............................................................................................................................. 6
SECTION 3: DIAGNOSTICS .................................................................................................................7
Control Information .............................................................................................................................7
Hardware.........................................................................................................................................7
Software Versions ........................................................................................................................... 7
Control Information..........................................................................................................................8
Software Modules............................................................................................................................ 8
Voltage ............................................................................................................................................8
Fans................................................................................................................................................. 8
Limited Version................................................................................................................................ 8
THC Revision .................................................................................................................................. 8
System Diagnostics ............................................................................................................................9
Touch Screen Calibration................................................................................................................ 9
I/O .....................................................................................................................................................10
Inputs............................................................................................................................................. 10
Outputs ..........................................................................................................................................11
Analog ...............................................................................................................................................12
Expaned I/O...................................................................................................................................13
Keyboard........................................................................................................................................... 14
Serial Port ......................................................................................................................................... 16
Port ................................................................................................................................................16
Test................................................................................................................................................ 16
Send .............................................................................................................................................. 16
Received........................................................................................................................................16
Test Port ........................................................................................................................................16
Drives and Motors.............................................................................................................................17
Pulse Type.....................................................................................................................................18
Pulse Direction ..............................................................................................................................18
Pulse Magnitude............................................................................................................................ 18
Pulse Duration...............................................................................................................................18
Test Transverse/Rail/Dual Gantry/CBH ........................................................................................18
Test All...........................................................................................................................................18
Speed ............................................................................................................................................ 18
SERCOS Drives & Motors ................................................................................................................19
Error Messages................................................................................................................................. 21
Unable to Find HASP ....................................................................................................................23
Norton Ghost™ Utility .......................................................................................................................24
Instructions for Diskette Recovery ................................................................................................24
II Installation & Setup Guide
SECTION 4: PASSWORD SETUPS ................................................................................................... 27
Machine ............................................................................................................................................ 27
X Axis Orientation ......................................................................................................................... 27
Up Direction .................................................................................................................................. 27
Right Direction .............................................................................................................................. 28
Dual Gantry Installed .................................................................................................................... 28
CBH Installed ................................................................................................................................ 28
X and Y Motor/Encoder................................................................................................................. 28
Key Logging .................................................................................................................................. 28
Table Size ..................................................................................................................................... 28
THCs Installed .............................................................................................................................. 28
THC Installed On Axis / Analog ................................................................................................... 28
THC On......................................................................................................................................... 28
Command THCs Installed............................................................................................................. 28
SERCOS Machine............................................................................................................................ 29
Drive Type..................................................................................................................................... 29
Update Rate.................................................................................................................................. 29
Baud Rate ..................................................................................................................................... 29
Light Level..................................................................................................................................... 29
Drive I/O........................................................................................................................................ 29
RECO I/O at Address 50............................................................................................................... 29
Speeds.............................................................................................................................................. 30
Speed 0 To ................................................................................................................................... 30
Acceleration Rate.......................................................................................................................... 30
Fast Stop Deceleration Rate......................................................................................................... 31
Maximum Machine Speed ............................................................................................................ 31
Limited Machine Speed ................................................................................................................ 31
High Jog Speed ............................................................................................................................ 31
Medium Jog Speed....................................................................................................................... 31
Low Jog Speed ............................................................................................................................. 31
Minimum Corner Speed................................................................................................................ 31
Fast Home Speed ......................................................................................................................... 31
Slow Home Speed ........................................................................................................................ 32
Creep Speed Percentage ............................................................................................................. 32
Plasma Hi/Lo Speed Percentage.................................................................................................. 32
Plasma Distance To Corner.......................................................................................................... 32
Plasma Distance From Corner .....................................................................................................32
CBH Speed Setups (Shown only when enabled)............................................................................. 32
CBH Acceleration Rate................................................................................................................. 32
Maximum CBH Speed .................................................................................................................. 32
CBH High Jog / Home Speed .......................................................................................................32
CBH Low Jog / Home Speed........................................................................................................32
THC Speed Setups (Shown only when enabled)............................................................................. 33
THC Acceleration Rate ................................................................................................................. 33
Maximum THC Speed................................................................................................................... 33
THC Jog Speed ............................................................................................................................ 33
THC Home/Fast IHS Speed .........................................................................................................33
THC Slow IHS Speed ................................................................................................................... 33
Torch Height Disable Feature .......................................................................................................... 33
Tangent Angle............................................................................................................................... 33
Plasma Hi/Lo Speed Percentage.................................................................................................. 33
Plasma Distance To Corner.......................................................................................................... 34
Plasma Distance From Corner .....................................................................................................34
Ports ................................................................................................................................................. 35
Port Designation ........................................................................................................................... 35
Installation & Setup Guide III
Baud Rate......................................................................................................................................36
Parity .............................................................................................................................................36
Data Bits ........................................................................................................................................36
Time Out Delay .............................................................................................................................36
Transmit Delay ..............................................................................................................................36
Rewind...........................................................................................................................................36
Dialog Start.................................................................................................................................... 36
Dialog Done................................................................................................................................... 36
Dialog Prompt................................................................................................................................ 36
Dialog Pause ................................................................................................................................. 36
Dialog Acknowledge......................................................................................................................36
End of Transmission...................................................................................................................... 37
Using Phoenix Link........................................................................................................................ 37
Show Host File Names..................................................................................................................37
File Dump Mode ............................................................................................................................ 37
Allow M65 Auto Reload .................................................................................................................37
Auto Home before Auto Reload ....................................................................................................37
ESSI Program Termination ...........................................................................................................37
Download Updates ........................................................................................................................37
Use Multi Drop............................................................................................................................... 37
Address .........................................................................................................................................37
Control Monitoring .........................................................................................................................38
Flow control ................................................................................................................................... 38
During Jog on Path........................................................................................................................ 38
Retry on Time Out ......................................................................................................................... 38
Time Out........................................................................................................................................ 38
I/O .....................................................................................................................................................39
I/O Configuration Type “M”, “P” and “V” ........................................................................................39
Input Logic.....................................................................................................................................39
Logic Selection Box....................................................................................................................... 39
Input Selection............................................................................................................................... 39
Expanded I/O .................................................................................................................................... 40
Input Definitions............................................................................................................................. 41
Output Logic .................................................................................................................................. 46
Logic Selection Box....................................................................................................................... 46
Output Selection............................................................................................................................46
Output Definitions..........................................................................................................................46
Drive Enables ................................................................................................................................ 50
Initial Feedback Delay ...................................................................................................................50
Joystick Installed ...........................................................................................................................50
Speed Pot Installed .......................................................................................................................50
Plasma Override % .......................................................................................................................50
Oxy Fuel Override % .....................................................................................................................50
Trial Override %.............................................................................................................................50
Speed Pot Installed On .................................................................................................................50
Analog Offset 1- 12 .......................................................................................................................50
Input Logic.....................................................................................................................................51
Logic Selection Box....................................................................................................................... 51
Input Selection............................................................................................................................... 51
Input Definitions............................................................................................................................. 52
Output Logic .................................................................................................................................. 53
Logic Selection Box....................................................................................................................... 53
Output Selection............................................................................................................................53
Output Definitions..........................................................................................................................53
Drive Enables ................................................................................................................................ 54
Initial Feedback Delay ...................................................................................................................54
IV Installation & Setup Guide
Joystick Installed........................................................................................................................... 54
Speed Pot Installed....................................................................................................................... 54
Plasma Override % ....................................................................................................................... 55
Oxy Fuel Override %..................................................................................................................... 55
Trial Override % ............................................................................................................................ 55
Speed Pot Installed On................................................................................................................. 55
Analog Offset 1- 12....................................................................................................................... 55
Axes.................................................................................................................................................. 57
Transverse/Rail ................................................................................................................................ 57
Speed 0 To ................................................................................................................................... 57
Proportional Gain .......................................................................................................................... 57
Integral Gain ................................................................................................................................. 58
Derivative Gain ............................................................................................................................. 58
Feedforward Gain ......................................................................................................................... 58
Velocity Gain................................................................................................................................. 58
Servo Error Tolerance................................................................................................................... 58
Encoder Counts per inch .............................................................................................................. 58
Fault Ramp Time .......................................................................................................................... 58
Drive Type..................................................................................................................................... 59
DAC Polarity ................................................................................................................................. 59
Encoder Polarity............................................................................................................................ 59
Encoder Decode Mode ................................................................................................................. 59
Use Hardware Overtravels............................................................................................................ 59
Backlash Compensation ............................................................................................................... 59
Home............................................................................................................................................. 59
Absolute Home Position................................................................................................................ 59
Home Offset Distance................................................................................................................... 59
Home Switch Normally.................................................................................................................. 59
Home Direction ............................................................................................................................. 59
Use Marker Pulse ......................................................................................................................... 60
Use Software Travel Limits........................................................................................................... 60
Maximum Travel Limit................................................................................................................... 60
Minimum Travel Limit.................................................................................................................... 60
SERCOS AXES ............................................................................................................................ 61
SERCOS Drive Address ............................................................................................................... 61
Emulated Encoder Counts/ motor rev........................................................................................... 61
Dual Gantry ...................................................................................................................................... 62
Speed 0 To ................................................................................................................................... 62
Proportional Gain .......................................................................................................................... 62
Integral Gain ................................................................................................................................. 63
Derivative Gain ............................................................................................................................. 63
Feedforward Gain ......................................................................................................................... 63
Velocity Gain................................................................................................................................. 63
Skew Error Tolerance ................................................................................................................... 63
Encoder Counts per inch .............................................................................................................. 63
Drive Type..................................................................................................................................... 64
DAC Polarity ................................................................................................................................. 64
Encoder Polarity............................................................................................................................ 64
Encoder Decode Mode ................................................................................................................. 64
Use Home Limit Switch................................................................................................................. 64
Switch Offset Distance.................................................................................................................. 64
Backlash Compensation ............................................................................................................... 64
CBH .................................................................................................................................................. 65
Proportional Gain .......................................................................................................................... 65
Integral Gain ................................................................................................................................. 65
Derivative Gain ............................................................................................................................. 66
Installation & Setup Guide V
Feedforward Gain.......................................................................................................................... 66
Velocity Gain .................................................................................................................................66
Servo Error Tolerance ...................................................................................................................66
Encoder Counts per rev ................................................................................................................66
Drive Type ..................................................................................................................................... 66
DAC Polarity..................................................................................................................................67
Encoder Polarity ............................................................................................................................ 67
Encoder Decode Mode..................................................................................................................67
Follower Initially.............................................................................................................................67
Auto Home At Power Up ............................................................................................................... 67
Absolute Home Angle.................................................................................................................... 67
Home Offset Angle ........................................................................................................................67
Use Home Limit Switch .................................................................................................................67
Home Direction.............................................................................................................................. 67
Use Marker Pulse..........................................................................................................................67
Station Configuration ........................................................................................................................68
Main Screen ..................................................................................................................................68
Stations 1-4 / 5-8 ........................................................................................................................... 68
Reset .............................................................................................................................................68
Part Program Support ...................................................................................................................69
Station Selects ..............................................................................................................................69
Process Selects............................................................................................................................. 69
Station Configuration Variables..................................................................................................... 69
Overview........................................................................................................................................70
Command® THC Support .............................................................................................................. 71
HD4070® Support..........................................................................................................................71
FineLine 100 / 200 Support...........................................................................................................72
Special ..............................................................................................................................................73
Date ...............................................................................................................................................73
Time...............................................................................................................................................73
Display Time.................................................................................................................................. 73
Mouse Pointer ............................................................................................................................... 73
Motion Cursor................................................................................................................................73
Tangent Angle ............................................................................................................................... 73
File Extensions .............................................................................................................................. 73
Adding Folders .............................................................................................................................. 74
Deleting Folders ............................................................................................................................74
Deleting Files................................................................................................................................. 74
Mapping Drives .............................................................................................................................74
Configuring Watch.........................................................................................................................74
Adding Processes .........................................................................................................................74
Removing Processes ....................................................................................................................74
Force Simulation ...........................................................................................................................74
Tools Installed ...............................................................................................................................74
Message Enables..........................................................................................................................74
Ready to Start Cutting Message ...................................................................................................74
Kerf Too Large Warning Message ................................................................................................74
Homing Must Be Performed Message ..........................................................................................74
Values Have been Changed Message.......................................................................................... 75
Home Torch Height Control Message...........................................................................................75
Ready to Final Align Message.......................................................................................................75
Part Larger than Plate Message....................................................................................................75
Cut Chart Data Has Changed Message........................................................................................ 75
Save Part for Rush Job .................................................................................................................75
Latched Manual Keys....................................................................................................................75
Auto Drop Down ............................................................................................................................ 75
VI Installation & Setup Guide
Zero Positions ............................................................................................................................... 75
Auto Size App. .............................................................................................................................. 76
Language ...................................................................................................................................... 76
Password ...................................................................................................................................... 76
Special Password ......................................................................................................................... 76
Station Configuration Password ................................................................................................... 76
Temperature ................................................................................................................................. 76
Auto Update Max Consumable Life.............................................................................................. 76
Machine Position Resets .............................................................................................................. 76
Auto Gas Control .......................................................................................................................... 76
Arc Speed Limit Check ................................................................................................................. 76
Save Setups.................................................................................................................................. 77
Load Setups.................................................................................................................................. 77
Update Software ........................................................................................................................... 77
Update Help .................................................................................................................................. 77
System Tools ................................................................................................................................ 77
Restore Last Version .................................................................................................................... 77
Make Link Disk.............................................................................................................................. 77
System Tools – Windows® XP.......................................................................................................... 78
System Tools ................................................................................................................................ 78
Automated Backup........................................................................................................................ 78
Backup Hard Drive........................................................................................................................ 79
Scan Hard Disk ............................................................................................................................. 79
Antivirus™...................................................................................................................................... 81
Defragment Hard Disk .................................................................................................................. 82
Format Floppy Disk....................................................................................................................... 83
Reset Setups ................................................................................................................................ 83
Network and Remote Tools ......................................................................................................... 84
Windows XP® Remote Assistant................................................................................................... 84
Network Connection...................................................................................................................... 86
Network System Requirements: ................................................................................................... 86
NJWin® Tools................................................................................................................................ 87
Install NJWin®............................................................................................................................... 88
Uninstall NJWin®........................................................................................................................... 88
SECTION 5: PHOENIX LINK .............................................................................................................. 89
Phoenix Link Overview..................................................................................................................... 89
Phoenix Link ................................................................................................................................. 89
Port................................................................................................................................................ 89
Baud.............................................................................................................................................. 89
Folder............................................................................................................................................ 89
Files............................................................................................................................................... 90
Settings ......................................................................................................................................... 90
Test ............................................................................................................................................... 90
Files .................................................................................................................................................. 90
Show All Files ............................................................................................................................... 91
Show Extension in Name.............................................................................................................. 91
Add to Files ................................................................................................................................... 91
Remove from Files........................................................................................................................ 91
Settings............................................................................................................................................. 92
Allow M65 Auto Reload................................................................................................................. 92
Use Multi Drop .............................................................................................................................. 92
Add Control ................................................................................................................................... 92
Remove Control ............................................................................................................................ 92
Control Monitoring......................................................................................................................... 92
Installation ........................................................................................................................................ 93
Installation & Setup Guide VII
Minimum System Requirements ...................................................................................................93
Software............................................................................................................................................93
Change Master Folder...................................................................................................................94
Operating Multiple Links................................................................................................................95
Hardware...........................................................................................................................................97
Operating Phoenix Link..................................................................................................................... 97
Common Errors................................................................................................................................. 98
Error Messages................................................................................................................................. 99
Unable to Open Port (control) .......................................................................................................99
Unable to Open Port (host) ...........................................................................................................99
Unable to Initialize Port .................................................................................................................99
Port Failed ..................................................................................................................................... 99
Host Not Responding .................................................................................................................... 99
Communication Failed................................................................................................................... 99
Communications Time Out..........................................................................................................100
Checksum Error ..........................................................................................................................100
Warning: The Master Folder Selected does Not Contain any Folders ......................................100
APPENDIX A: MOTION OVERVIEW.................................................................................................101
General Motion Theory - Servo Loop Control................................................................................. 101
SERCOS Interface™ Overview ...................................................................................................... 107
APPENDIX B: MARINER™ & VOYAGER II™.................................................................................. 109
Mariner™ Overview ........................................................................................................................109
Voyager II™ Overview ....................................................................................................................110
Diagnostics......................................................................................................................................111
Drives & Motors...........................................................................................................................111
Password Setups ............................................................................................................................112
Machine...........................................................................................................................................112
Tilt Rotator Installed ....................................................................................................................112
Auto Home at Power Up..............................................................................................................112
Follower Initially...........................................................................................................................112
Dual Tilting Rotator Mode............................................................................................................112
Key Logging.................................................................................................................................113
THCs Installed.............................................................................................................................113
THC Installed On Axis / Analog..................................................................................................113
Speeds ............................................................................................................................................113
Rotate Acceleration Rate ............................................................................................................114
Maximum Rotate Speed..............................................................................................................114
Rotate High Jog Speed ............................................................................................................... 114
Rotate Low Jog Speed ................................................................................................................114
Tilt Acceleration Rate ..................................................................................................................114
Maximum Tilt Speed.................................................................................................................... 114
Tilt High Jog Speed .....................................................................................................................114
Tilt Low Jog Speed......................................................................................................................114
Rotate 1 & 2 Axes ...........................................................................................................................115
Absolute Home Angle..................................................................................................................115
Home Offset Angle ......................................................................................................................115
Tilt 1 & 2 Axes.................................................................................................................................116
Absolute Home Angle..................................................................................................................116
Home Offset Angle ......................................................................................................................116
Transverse 2 Axis ........................................................................................................................... 117
Minimum Torch Spacing.............................................................................................................. 117
Mirrored Marker Offsets ..............................................................................................................117
Tilt Rotator Part Codes ...................................................................................................................117
Laser ............................................................................................................................................... 118
VIII Installation & Setup Guide
Cut Chart..................................................................................................................................... 118
HD3070® Auto Gas Interface.......................................................................................................... 119
Save Data ................................................................................................................................... 119
Load Data ................................................................................................................................... 119
Test Cutting Gases ..................................................................................................................... 120
Test Preflow Gases..................................................................................................................... 120
HD3070® Auto Gas I/O ............................................................................................................... 121
Inputs .......................................................................................................................................... 121
Outputs ....................................................................................................................................... 121
HD4070® and HPR130™ Interface ................................................................................................ 122
Cut Chart..................................................................................................................................... 122
I/O and Diagnostics..................................................................................................................... 123
Miscellaneous ............................................................................................................................. 123
Remote Tools.............................................................................................................................. 123
Test Preflow ................................................................................................................................ 123
Test Cutflow ................................................................................................................................ 124
Test Pump................................................................................................................................... 124
Update Software ......................................................................................................................... 124
Inputs .......................................................................................................................................... 124
Outputs ....................................................................................................................................... 126
Outputs ( cont. ) .......................................................................................................................... 127
Serial Communication Interface.................................................................................................. 127
Multiple Supplies......................................................................................................................... 128
Inputs and Outputs...................................................................................................................... 128
Raise 1-4 and Lower 1-4........................................................................................................... 128
Cut Sense 1-4 ............................................................................................................................. 128
Ready to Fire PS 1-4 .................................................................................................................. 128
Hold Ignition ................................................................................................................................ 128
Reduce Current........................................................................................................................... 128
FineLine® Overview ........................................................................................................................ 130
Automatic Torch Spacing ............................................................................................................... 132
Automatic Torch Spacing Program Codes ................................................................................. 134
Automatic Torch Spacing I/O...................................................................................................... 134
APPENDIX C: PROGRAM CODES .................................................................................................. 135
EIA RS-274D .................................................................................................................................. 135
Directly Supported EIA Codes .................................................................................................... 135
Mapped EIA Codes..................................................................................................................... 137
Unsupported EIA Codes ............................................................................................................. 139
Unsupported EIA Codes ( cont. )................................................................................................ 140
EIA Comments............................................................................................................................ 140
ESSI................................................................................................................................................ 141
Mapped ESSI Codes .................................................................................................................. 141
Unsupported ESSI Codes........................................................................................................... 143
ESSI Comments ......................................................................................................................... 144
Unique Feature Codes ................................................................................................................... 144
Tilt / Rotator Part Codes ............................................................................................................. 144
Automatic Torch Spacing Program Codes ................................................................................. 144
Station Selects ............................................................................................................................ 145
Process Selects .......................................................................................................................... 145
Station Configuration Variables .................................................................................................. 145
HD3070® Auto Gas Overview......................................................................................................... 146
HD3070® Part Program Support................................................................................................. 146
HD4070® Part Program Support..................................................................................................... 147
FineLine Part Program Support...................................................................................................... 149
Sensor™ THC Part Program Support............................................................................................ 151
Installation & Setup Guide IX
Sub Parts ........................................................................................................................................152
Marker Font Generator ...................................................................................................................154
Internal Fonts...............................................................................................................................155
External Fonts .............................................................................................................................155
Custom Fonts .............................................................................................................................. 156
Serial Messaging ............................................................................................................................157
Overview......................................................................................................................................157
Baud Rate....................................................................................................................................158
Parity ...........................................................................................................................................158
Data Bits ......................................................................................................................................158
Flow Control ................................................................................................................................158
During Jog on Path...................................................................................................................... 158
Retry on Time Out ....................................................................................................................... 158
Time Out...................................................................................................................................... 158
Programming Code .....................................................................................................................159
Message Information...................................................................................................................159
Message Command Type ........................................................................................................... 160
Optional Format Value ................................................................................................................160
Specialty Characters Supported .................................................................................................160
Optional Format Character Assignments .................................................................................... 161
Optional Delay Time/Time Out Value.......................................................................................... 161
Message Text Content ................................................................................................................ 161
Non – Printing Characters ...........................................................................................................162
Exceptions / Additions .................................................................................................................162
Non Printing Character Table......................................................................................................163
APPENDIX D: EDGE II™ MACHINE INTERFACE ...........................................................................165
Rear Panel Layout....................................................................................................................... 165
Single Ended or Double Ended I/O Configuration .......................................................................... 166
Machine Interface ...........................................................................................................................167
I/O Configuration Type “P” and “M”.................................................................................................167
I/O Connector .............................................................................................................................. 167
I/O Configuration Type “P” ( Single Ended I/O ) ............................................................................. 168
Single Ended I/O Pinout ..............................................................................................................169
Drive/Encoder Connector ............................................................................................................170
Axes Assignments.......................................................................................................................170
Drive/Encoder Pinout ..................................................................................................................171
Drive/Encoder Pinout (For 3 and 4 Axes units)...........................................................................171
I/O Configuration Type “M” ( Double Ended I/O ) ........................................................................... 172
Double Ended I/O Pinout.............................................................................................................172
Drive/Encoder Connector ............................................................................................................173
Axes Assignments.......................................................................................................................173
Drive/Encoder Pinout ..................................................................................................................174
I/O Configuration Type “B” ..............................................................................................................175
I/O Configuration Type “B” ..............................................................................................................176
Oxy Fuel and Plasma Connectors ..............................................................................................176
Oxy Fuel Pinout...........................................................................................................................177
Plasma Pinout .............................................................................................................................177
Drive Connector ..........................................................................................................................178
Axes Assignments.......................................................................................................................178
Drive Pinout.................................................................................................................................178
Encoder Connectors.................................................................................................................... 179
Encoder Pinout............................................................................................................................179
THC and Joystick Interface.............................................................................................................180
Series 1 PCI Analog Card ........................................................................................................... 180
THC 1 .......................................................................................................................................... 180
X Installation & Setup Guide
THC 2.......................................................................................................................................... 180
Joystick ....................................................................................................................................... 181
THC and Joystick Cable Grounding ........................................................................................... 181
APPENDIX E: VOYAGER II™ MACHINE INTERFACE................................................................... 183
I/O Configuration Type “V” ( Single Ended I/O )............................................................................. 184
Single Ended I/O Pinout.............................................................................................................. 185
I/O Connector J5......................................................................................................................... 185
Mating Connector........................................................................................................................ 185
I/O Connector J6......................................................................................................................... 186
Mating Connector........................................................................................................................ 186
AC Input Pinout........................................................................................................................... 187
AC Input Mating Connector ........................................................................................................ 187
Drive/ Encoder Pinout ( J5- J10 )................................................................................................ 188
Drive/ Encoder Input Mating Connector...................................................................................... 188
Optional Analog / PWM Interface ................................................................................................... 189
Analog Card Options ...................................................................................................................... 189
Series 1 ISA Analog Card........................................................................................................... 189
J1 - Power................................................................................................................................... 189
TB1 - I/O ..................................................................................................................................... 189
TB2 - I/O ..................................................................................................................................... 189
TB3 - I/O ..................................................................................................................................... 190
Series 2 Analog/ PWM Interface Card........................................................................................ 191
J5 - I/O ........................................................................................................................................ 191
J6 - APC 2 J7 - Plasma 2 ........................................................................................................ 191
J8 - APC 1 J9 - Plasma 1 ....................................................................................................... 192
Plasma Mating Connector ( J7 & J9 ) ......................................................................................... 192
APPENDIX F: MARINER™ MACHINE INTERFACE ....................................................................... 193
AC Input Pinout........................................................................................................................... 193
E-Stop ......................................................................................................................................... 193
SERCOS Motion and I/O ............................................................................................................ 194
APPENDIX F: SERIAL PORTS......................................................................................................... 195
Control RS-232C DB-9 Pinout .................................................................................................... 195
RS-232C Connections to Host PC with 9-pin D-type connector................................................. 195
RS-232C Connections to Host PC with 25-pin D-type connector............................................... 196
Control RS-422 DB-9 Pinout....................................................................................................... 196
RS-422C Connections to Host PC with 9-pin D-type connector................................................. 196
RS-422 Connections to Host PC with 25-pin D-type connector ................................................. 196
Serial Port Jumpers .................................................................................................................... 197
RS- 232 / 422 Configuration ....................................................................................................... 197
APPENDIX G: ASCII CODES ........................................................................................................... 199
Control Codes ............................................................................................................................. 199
All Codes..................................................................................................................................... 200
APPENDIX H: SENSOR™ THC........................................................................................................ 201
Diagnostics ..................................................................................................................................... 201
Analog Input Series 1.................................................................................................................. 201
Analog Input Series 2.................................................................................................................. 202
Inputs / Outputs........................................................................................................................... 202
Analog Inputs .............................................................................................................................. 202
Sensor™ THC Axis Setups ............................................................................................................ 203
Stall Force................................................................................................................................... 203
Slide Length ................................................................................................................................ 203
Installation & Setup Guide XI
Home ...........................................................................................................................................203
THC Acceleration Rate................................................................................................................205
Maximum THC Speed .................................................................................................................205
THC Jog Speed...........................................................................................................................205
THC Home/Fast IHS Speed ........................................................................................................205
THC Slow IHS Speed..................................................................................................................205
THC I/O ...........................................................................................................................................206
Analog Offset 1 - 12 ....................................................................................................................206
Sensor™ THC Part Program Support.........................................................................................207
Installation and THC Interface ........................................................................................................208
Sensor™ THC w/ Series 1 ISA Analog Card and Series 2 Voltage Divider Card ......................208
Voltage Divider Card Pinout ( Series 2 ) .....................................................................................208
Control & Cable Pinout for Sensor™ THC .................................................................................. 209
I/O Configuration Type “V” ..........................................................................................................209
Sensor™ THC w/ Series 1 ISA Analog Card and Series 3 Voltage Divider Card ......................210
Voltage Divider Card Pinout ( Series 3 ) .....................................................................................210
Control & Cable Pinout for Sensor™ THC .................................................................................. 211
I/O Configuration Type “V” ..........................................................................................................211
Sensor™ THC w/ Series 2 Analog Card and Series 2 Voltage Divider Card ............................. 212
Voltage Divider Card Pinout........................................................................................................212
Sensor™ THC w/ Series 2 Analog Card and Series 3 Voltage Divider Card ............................. 213
Voltage Divider Card Pinout ( Series 3 ) .....................................................................................213
I/O Configuration Type “V” ..........................................................................................................214
Sensor™ THC w/ Series 1 PCI Analog Card and Series 2 Voltage Divider Card ...................... 215
Voltage Divider Card Pinout ( Series 2 ) .....................................................................................215
Control & Cable Pinout for Sensor™ THC .................................................................................. 216
I/O Configuration Type “P” ..........................................................................................................216
Sensor™ THC w/ Series 1 Analog Card and Series 3 Voltage Divider Card ............................. 217
Voltage Divider Card Pinout ( Series 3 ) .....................................................................................217
Control & Cable Pinout for Sensor™ THC .................................................................................. 218
I/O Configuration Type “P” ..........................................................................................................218
Calibration.......................................................................................................................................219
Series 1 Analog Card ..................................................................................................................219
Series 2 Analog Card ..................................................................................................................220
Series 2 and 3 Voltage Divider Card...........................................................................................220
APPENDIX I: COMMAND® THC........................................................................................................ 221
Machine Interface ...........................................................................................................................221
Port Designation..........................................................................................................................221
RS-422 Connections to Command® THC with 25-pin D-type connector ................................... 221
APPENDIX J: SPEED POT AND JOYSTICK ...................................................................................223
Speed Pot and Joystick Overview ..................................................................................................223
Analog Card I/O .............................................................................................................................. 223
Joystick Installed .........................................................................................................................224
Speed Pot Installed .....................................................................................................................224
Plasma Override % .....................................................................................................................224
Oxy Fuel Override % ...................................................................................................................224
Speed Pot Installed On ...............................................................................................................224
Analog Offset 1- 12 .....................................................................................................................224
Analog Input Diagnostics ................................................................................................................ 225
Inputs........................................................................................................................................... 225
Analog Inputs...............................................................................................................................225
I/O Interface ....................................................................................................................................226
Series 1 ISA Analog Card ...........................................................................................................226
Series 1 PCI Analog Card ........................................................................................................... 226
XII Installation & Setup Guide
THC and Joystick Cable Grounding ........................................................................................... 226
Series 2 Analog Interface Card................................................................................................... 227
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.
2 Installation & Setup Guide
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
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. The power switch is
illuminated 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 as 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 gives us complete flexibility should we
need to add a new feature at a later date.
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” 1.44 Mbyte 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
4 Installation & Setup Guide
Optional PC Style Keyboard
Optional USB Front Panel
Section 2: Overview 5
Model Numbering System
The control is available with the following hardware and software configurations. Features and control
configuration options in software are based on the I/O configuration 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
S = Sercos
I / O Configuration
B = Burny 3 / 5
M = MicroPath
P = PicoPath
V = Voyager
S = Sercos
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
3 = 15" Touch Screen
-
Memory
0 = 16 MBytes
1 = 32 MBytes
2 = 64 MBytes
3 = 128 MBytes
4 = 256 MBytes
5 = 512 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 = Installed
Processor
0 = 166 MHz
1 = 200 MHz
2 = 266 MHz
3 = 433 MHz
4 = 566 MHz
5 = 1.2 GHz
6 = 2.4 GHz
6 Installation & Setup Guide
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 Download from Host
Manual Options
Load from Disk
Save to Disk
Upload to Host
Save Log to Disk
Setups
Cut Types
Oxy Fuel
Plasma Machine
Cut Chart
Marker
Cut Chart
Laser
Cut Chart
Process Monitoring
Water Jet
Password 2
System Tools
VirusScan Tools
NJWin Tools
Password 3
Station Configuration
Shape Manager
Text Editor
Shape Wizard
Part Options
Repeat
Teach Trace
Control Information
I / O
Inputs
Outputs
Analog Inputs
Keyboard
USB Front Panel
Serial Port
Drives and Motors
Plasma System
Inputs
Outputs
Supply Information
Shape Library
Simple Shape
View Text
Part Options
Repeat
CuttingWatch
Password 1Diagnostics
Speeds
Link
I/O
Axes
Transverse
Rail
Dual Gantry
CBH
Tilt
Rotate
THC
Lens
Nester
Section 3: Diagnostics 7
Section 3: Diagnostics
Control Information
Shows the current software versions and hardware configuration of the control. This information is
required when contacting the factory for support. Below is a typical control information screen.
Hardware
The Hardware section shows the current hardware configuration which includes the Processor Type,
Processor Speed, Memory Installed, Hard Drive Size, Hard Drive Free Space and Motion Control
Card revision.
Software Versions
The Software Versions section shows the current version of the Control’s Operating System,
Operator Interface (software version), Virtual Device Driver and the Motion Control Card software.
8 Installation & Setup Guide
Control Information
The control Information section displays the Hardware Key number, the control model number, serial
number, control I/O type, axes enabled and I/O enabled.
Software Modules
The Software Modules information will display the optional software features which have been loaded
or have been enabled for use (e.g. DXF Translator, McAfee VirusScan Software or NJWIN font
Viewer).
Voltage
System Voltages at the motherboard will be displayed for motherboards equipped with this monitoring
feature.
Temperature
Temperature at the motherboard will be displayed for motherboards equipped with this monitoring
feature.
Fans
Fans speed at the motherboard will be displayed for motherboards equipped with this monitoring
feature.
Limited Version
The Limited Version information will be displayed if the control is operating on a trial version of
software. The version of software is available for 90 days of use and may be enabled for permanent
use through use of a password available from the control vendor.
THC Revision
The current Command
®
THC Interface and Real Time Revision Levels will be displayed at the Control
Information screen when enabled.
Section 3: Diagnostics 9
System Diagnostics
Pressing the System Diagnostics Softkey allows the user to use the optional INTEL® Active Monitor.
Note: A Mouse is required for screen navigation.
The INTEL
Additionally, this allows active alerts to set and posted on screen during operation.
Touch Screen Calibration
If your CNC is equipped with a Touch Screen Display, you will also have the option to launch a Touch
Screen Calibration utility for tuning touch screen response.
®
Active Monitor allows the user to view Cooling, Power and System information.
10 Installation & Setup Guide
I/O
Inputs
This test continuously monitors and displays the current state of all of the optically-isolated discrete
inputs in the control. The current state of each input, On or Off, is displayed to the left of the input
name. Below is an input screen with all of the inputs off.
Inputs displayed with a white background allow for the input name to be changed by the user. To
change the input name, use the Previous/Next arrow key to highlight the desired input and type the
new text for the input name. The input can then be connected to the control and used as
commanded in the part program. Example: The EIA W7 S1 code will pause the program and wait for
input 7 to become active.
A password is required when entering this screen.
Note: The number and name of the Inputs will vary due to control software and hardware
configurations.
Section 3: Diagnostics 11
Outputs
This test allows the activation of all optically-isolated discrete outputs in the control. Each Output’s
state can be changed by selecting the desired output with the PREV and NEXT keys and then
pressing the SPACE key. The current state of each output, On or Off, is displayed to the left of the
output name. Below is an output screen all of the outputs Off.
Warning: When manually activating the control’s outputs, Machine, Torch and Marker motion may
occur and the cutting device may activate.
Outputs displayed with a white background allow for the Output name to be selected by the user. To
change the output name, use the Previous/Next arrow key to highlight the desired output and type the
new text for the output name. The output can then be connected to the control and used as
commanded in the part program. Example: The EIA M22 and M23 code will turn on and off output
12.
Note: The number and name of the Outputs will vary due to control software and hardware
configurations.
12 Installation & Setup Guide
Analog
The Analog I/O Diagnostic screen allows the user to view the input state and activate opticallyisolated discrete outputs for the Analog Input card. The Analog Input card is used as an interface
card to support option Sensor THC, APC™, Joystick and external Speed Pot options.
Note: The Analog Input screen will vary slightly depending on control hardware configuration.
Section 3: Diagnostics 13
Expaned I/O
For controls equpped with more than 64 I/O a series of selection softkeys are avialable to access the
required Inputs. Ouputs and Analog I/O.
Note: The optional USB Front Panel I/O are not accessible form the I/O Diagnostics screen.
Functionality for the USB Front Panel may be tested through the Keyboard Diagnostics.
14 Installation & Setup Guide
Keyboard
This diagnostic screen allows each key of the control keyboard to be tested. To start the keyboard
test, press the ENTER key from within the keyboard diagnostic screen. As each key is pressed on
the control keyboard, the corresponding key will activate on the display. If any of the keys do not
activate on the display during the keyboard test, then the control keyboard may be defective and the
factory should be consulted for further instructions. To exit the keyboard test, press and hold either
Shift key and then press the CANCEL key. Below is the Keyboard Test Screen.
Section 3: Diagnostics 15
Optional USB Front Panel
16 Installation & Setup Guide
Serial Port
This diagnostic screen allows the testing of the control serial ports. To perform the test, install the
appropriate jumper or jumpers. If the serial port being tested is configured for RS-232, jump pin 2 to
pin 3. If the serial port being tested is configured for RS-422, jump pin 2 to pin 3 and pin 4 to pin 7.
Select the appropriate serial port to test and press the Test Port softkey to initiate the test. If the
serial port is functioning properly, the exact text in the Send window will appear in the Received
window. If the serial port is not functioning properly, a Communications Time Out message will
appear below the Received window. If the serial port test fails, then the control may be defective and
the factory should be consulted for further instructions. Below is a serial port test screen with a
successful test.
Port
The Port parameter is used to select which port will be tested.
Test
The Test feature is used to select a single or continuous signal is to be sent for testing.
Send
This window contains the text that will be transmitted during the serial port test.
Received
This window will contain the text that is received during the serial port test. If the test is successful, it
should match the text contained in the Send window.
Test Port
Used to initiate the serial port test on the selected port.
Section 3: Diagnostics 17
Drives and Motors
The Drives and Motors diagnostic screen allows a technician to send a direct signal to the drive
amplifiers without enabling the servo loop for testing purposes.
Warning! When sending direct signals to the drive amplifiers, unexpected motion on the cutting table
may occur and extreme caution should be used.
When the Drives and Motors screen has been pressed, the following warning message will appear.
Select OK and then enter the machine password to view the Drives and Motors screen.
18 Installation & Setup Guide
Pulse Type
Selects whether the signal that will be sent to the drive amplifier will be a single pulse or a repeated
pulse. If the repeated pulse is selected, the signal will continue until the Test softkey for that axis is
pressed again.
Pulse Direction
Selects whether the signal that will be sent to the drive amplifier will be a positive, negative or
alternating pulse.
Pulse Magnitude
Sets the voltage of the signal to be sent to the drive amplifier.
Pulse Duration
Sets the amount of time for each segment of the signal to be sent to the drive amplifier.
Test Transverse/Rail/Dual Gantry/CBH
The Test buttons will send the selected output signal to the appropriate drive amplifier. If a repeating
signal has been selected, any combination of available test buttons may be used for the test. Each
drive amplifier will be sent the selected output signal until the selected output softkey has been
pressed a second time to end the test.
Test All
Pressing the Test All softkey will send the selected output signal to all drive amplifiers.
Speed
The Speed window displays the current speed for each axis.
Section 3: Diagnostics 19
SERCOS Drives & Motors
Use of the SERCOS Interface™ allows the user to easily expand the number of axes available for
use. The form of communication with the drives for Motion commands is over a serial link using
diagnostic software provided by the Drive vendor.
Warning! When sending direct signals to the drive amplifiers, unexpected motion on the cutting table
may occur and extreme caution should be used.
When the Drives and Motors screen has been pressed, the following warning message will appear.
When entering the Drive and Motors Diagnostics screen the specific drive communications software
will be launched for the drive being used. Please refer to information supplied by the Drive vendor on
how to use the drive setup software for the specific drive being used. The following are some
examples of drive setup and tuning software.
DriveTop from Indramat
20 Installation & Setup Guide
PacSci 800Tools from Pacific Scientific
Note: screen resolution may temporarily change during use of the above utilities.
Section 3: Diagnostics 21
Error Messages
The control contains a number of error messages that will be displayed when programming, machine,
or internal errors are detected. A list of the more common error messages are explained below.
SERCOS Errors
A number of different errors can be posted from the SERCOS Interface™ for both motor and I/O
performance. The error messages are specific to the drive and I/O modules being used. Please refer
to information supplied by the Drive and I/O hardware supplier for appropriate response.
SERCOS Ring Not Running
This error indicates that communication with the SERCOS ring has been lost. Generally this is due to
a fault condition on the ring. Check SERCOS hardware and cycle power.
No Part Loaded
This message is displayed whenever the control does not contain a valid part program in memory. To
clear this error message, load a valid part program from either the Shape Library, hard drive, diskette
or from a Host system.
Part Larger than Plate
This message will be displayed if the part program that has been loaded is larger than the plate size
information in Setups. The operator may choose to ignore and continue the cut or return to Setups to
correct the plate size.
Kerf too Large, Arc/Line has Disappeared. Abort Cut?
This message is displayed when the Kerf size selected is too large and will affect the shape of the
part. The operator can continue to cut the part, abort the cut to review the Kerf information selected
or abort the cut to review the part program for any errors. Electing to continue cutting of a part
program which prompts the display of this error, may lead to unexpected results.
Cut Sense Lost
This message is displayed if the Arc ON Feedback setup parameter is enabled and the Cut Sense
input is deactivated by the plasma unit while cutting. When this condition occurs, the control displays
the Pause screen, which allows use of the Cut Recovery features to finish cutting the piece.
Communications Time Out
This message is displayed whenever the Host system does not respond within the Link Time Out
setup parameter for either a Host Upload or Download. To correct this problem, increase the Link
Time Out setup parameter and check the communications setup parameters on the Host system and
the control.
Host Not Responding
This message is displayed whenever the communications is lost to the Host system after the initial
communication was established. To correct this problem, try exiting and re-entering the Upload or
Download to Host screens to re-establish communications and/ or check the communications setup
parameters on the Host system and the control.
Scale Factor must be between .001 and 1000
This message is displayed whenever a value less than .001 or greater than 1000 is entered for a
Scaling Factor. To correct this problem, enter a value between .001 and 1000 for the Scaling Factor.
22 Installation & Setup Guide
Radius at Arc Beginning and Radius at Arc End are not within the Arc Radial Error Tolerance
This message is displayed whenever the radius beginning-arc and the radius-ending arc of a part
program are not within the Arc Radial Error setup parameter in the Main Setup screen. To correct this
problem, either increase the Arc Radial Error Tolerance setup parameter or correct the part program
itself.
Transverse Position Error Exceeded
This message is displayed whenever the current Transverse position error exceeds the Servo Error
Tolerance Setup parameter in the machine setups screen. It also may appear if the position feedback
loops are not operating properly, or the machine is being commanded to move or accelerate faster
than it is capable. To correct this problem, either increase the Servo Error Tolerance Setup parameter
in the machine setups screen, re-tune the system, decrease the Maximum machine speed setup
parameter or the acceleration rate setup parameter. Generally, this error is displayed when the
setting for Incremental or Absolute EIA I and J codes is set to the wrong state for the active part
program.
Rail Position Error Exceeded
This message is displayed whenever the current Rail position error exceeds the Servo Error
Tolerance Setup parameter in the machine setups screen. It also may appear if the position feedback
loops are not operating properly or the machine is being commanded to move or accelerate faster
than it is capable. To correct this problem, either increase the Servo Error Tolerance Setup parameter
in the machine setups screen, re-tune the system, decrease the maximum machine speed setup
parameter, or the acceleration rate setup parameter. This error generally indicates a servo drive or
motor problem. First check for fault indications on the servo drives.
Dual Gantry Position Error Exceeded
This message is displayed whenever the current Dual Gantry position error exceeds the Servo Error
Tolerance Setup parameter in the machine setups screen. It also may appear if the position feedback
loops are not operating properly or the machine is being commanded to move or accelerate faster
than it is capable. To correct this problem, either increase the Servo Error Tolerance Setup parameter
in the machine setups screen, re-tune the system, decrease the Maximum machine speed setup
parameter, or the acceleration rate setup parameter. This error generally indicates a servo drive or
motor problem. First check for fault indications on the servo drives.
Transverse Positive Hardware Overtravel Reached
This message is displayed whenever the control detects a positive limit switch in the Transverse axis.
This can also occur if the limit switch input is set for the wrong polarity or the limit switch wiring is not
properly connected. If the Transverse axis did trip the positive limit switch, use Manual mode to jog
the Transverse axis away from the limit switch. This error generally indicates a servo drive or motor
problem. First check for fault indications on the servo drives.
Rail Positive Hardware Overtravel Reached
This message is displayed whenever the control detects a positive limit switch in the Rail axis. This
can also occur if the limit switch input is set for the wrong polarity or the limit switch wiring is not
properly connected. If the Rail axis did trip the positive limit switch, use Manual mode to jog the Rail
axis away from the limit switch.
Transverse Negative Hardware Overtravel Reached
This message is displayed whenever the control detects a negative limit switch in the Transverse
axis. This can also occur if the limit switch input is set for the wrong polarity or the limit switch wiring
is not properly connected. If the Transverse axis did trip the negative limit switch, use Manual mode
to jog the Transverse axis away from the limit switch.
Section 3: Diagnostics 23
Rail Negative Hardware Overtravel Reached
This message is displayed whenever the control detects a negative limit switch in the Rail axis. This
can also occur if the limit switch input is set for the wrong polarity or the limit switch wiring is not
properly connected. If the Rail axis did trip the negative limit switch, use Manual mode to jog the Rail
axis away from the limit switch.
Transverse Positive Software Overtravel Reached
This message is displayed whenever the Transverse axis position is greater than the Maximum
Travel Limit setup parameter for the Transverse axis. When this occurs, use Manual mode to jog the
Transverse axis to a position within the Travel Limit setup parameters.
Rail Positive Software Overtravel Reached
This message is displayed whenever the Rail axis position is greater than the Maximum Travel Limit
setup parameter for the Rail axis. When this occurs, use Manual mode to jog the Rail axis to a
position within the Travel Limit setup parameters.
Transverse Negative Software Overtravel Reached
This message is displayed whenever the Transverse axis position is less than the Minimum Travel
Limit setup parameter for the Transverse axis. When this occurs, use Manual mode to jog the
Transverse axis to a position within the Travel Limit setup parameters.
Rail Negative Software Overtravel Reached
This message is displayed whenever the Rail axis position is less than the Minimum Travel Limit
setup parameter for the Rail axis. When this occurs, use Manual mode to jog the Rail axis to a
position within the Travel Limit setup parameters.
Dual Gantry Skew Error Exceeded
This error message is displayed when the control has detected a position error fault between the two
drive axes on the dual gantry. It also may appear if the position feedback loops are not operating
properly, or the machine is being commanded to move or accelerate faster than it is capable. To
correct this problem, either increase the Skew Error Tolerance Setup parameter in the machine
setups screen, re-tune the system, decrease the maximum machine speed setup parameter or the
acceleration rate setup parameter.
Need Station Selection
The Need Station Selection error message is displayed if the input for a station or process has not
been activated. Example: When cutting in Plasma mode, a Plasma 1 or Plasma 2 input may be
required to execute the selected Plasma cut process.
Buffer Time Out
This may appear if there is an instance where the motion buffer is full and cannot record the data
being saved. This error allows the operator stop the motion back up on path to the last pierce and
start over without a position error. This error should be reported to the control vendor.
CNC Time Out
This is a general error that may appear if there is an instance when any buffer is full and cannot
record the data being saved. This error allows the operator stop the motion back up on path to the
last pierce and start over. This error should be reported to the control vendor.
Unable to Find HASP
The HASP is Hardware protection key ( dongle ) that enables the software and features for use. If
the HASP is not installed the control will not work. If this message appears and the hardware key is
in place, please contact your control vendor for assistance.
24 Installation & Setup Guide
Norton Ghost™ Utility
In the unlikely event that an extreme system error has occurred which prevents the control from
operating, the Norton Ghost™ Utility is available on specified controls to replace core system files
and re-enable operation of the control. Norton Ghost™ must be previously installed on the control
hard drive with an appropriate ghost image file.
The Norton Ghost Utility works by allowing the user to retrieve an image file from the D: partition of
the hard drive to replace all data on drive C: The Ghost Image may be a factory default or custom
user created image files. NOTE: All current information on Drive C: will be lost. It is recommended
that a unique user image be created after table configuration which will include all the important table
settings.
This feature may be executed from the System Tools screen or through use of a diskette shipped with
the control. It may also be obtained from the control supplier on diskette or transmitted via the
Internet.
Norton Ghost™ is a Trademark of Symantec™ Corporation.
Create Diskette from E-mail
To create a Norton Ghost tool disk from the compressed software sent via the Internet:
The file sent by the Internet will be an auto-executable file which will place the required files onto a
diskette to be used at the control. First place a blank diskette into your PC. Double click on the
recovery EXE file. A message box will be displayed. Click on the “Create Floppy” button to execute.
The EXE will copy the new files to the floppy disk to take to the control.
Instructions for Diskette Recovery
Creating a Custom Image File: Place the Norton Diskette into the control and turn the unit on.
Norton Ghost will progress as follows.
“Starting PC DOS.......”
Current Copyright information will be displayed
“Select 1 to make a New Backup Image or 2 to restore existing [1,2]”
Press 1 to create a new back up image. Up to three custom images may be created. They are
created as “newest” to “oldest” image and are automatically assigned. The “original” ghost image is
the factory default and may not be over written.
Back up will begin automatically.
Section 3: Diagnostics 25
“--------------------------------Backing Up Drive, Please Wait --------------------------------“
Norton Ghost will launch as above indicating back up progress. The following Message will appear
when complete.
“-------------------- Back Up Complete, Please Remove Disk and Reboot -----------------------“
Remove the diskette. Turn the control Off and then On. Table setups and software updates may
need to be reloaded if the image is not current.
26 Installation & Setup Guide
Retrieving an Image File
Place the Norton Diskette into the control and turn the unit on. Norton Ghost will progress as follows.
“Starting PC DOS.......”
Current Copyright information will be displayed
“Select 1 to make a New Backup Image or 2 to restore existing [1,2]”
Press 2 to retrieve the back up image. Up to three custom images may be created. They are created
as “newest” to “oldest” image. The “original” ghost image is the factory default. The next message
allows the user to select which version to use when restoring.
“1. Newest.gho”
“2. Older.gho”
“3. Oldest.gho”
“4. Original.gho”
“Select the Number of the Image to restore from the choices above [1,2,3.4 ]”
Press the number for the desired image.
“--------------------------------Restoring, Please Wait --------------------------------“
Norton Ghost will launch as above indicating restore progress. The following Message will appear
when complete.
“--------------------End Restoring, Please Remove Disk and Reboot -----------------------“
Remove the diskette. Turn the control Off and then On. Table setups and software updates may
need to be reloaded if the image is not current.
Section 4: Password Setups 27
Section 4: Password Setups
The following setup screens are only available with the supervisory passwords. This will help prevent
unauthorized personnel from entering these screens.
Warning! Extreme care should be taken when changing these parameters as they may cause
machine damage if incorrectly set. Only trained service personnel should have access to these
passwords.
The “2865” password is provided for viewing of the Machine, Speeds, Link and Axes setups without
allowing changes. This password is useful for verifying setups without the danger of accidentally
changing them or revealing the supervisory password to an unauthorized user.
Note: After installation of the control to the cutting table or if any setup parameters are changed, it is
important to save the current setup file to both the hard drive and floppy disk for future reference.
Machine
X Axis Orientation
The control allows specifying the X axis as being either the Transverse or Rail axis. The default
setting is Transverse. This parameter should be set before cutting the part.
Up Direction
28 Installation & Setup Guide
This parameter defines the machine motion that will occur when the ↑ arrow key is pressed during
manual mode.
Right Direction
This parameter defines the machine motion that will occur when the → arrow key is pressed during
manual mode.
Dual Gantry Installed
Selecting Yes will enable the Dual Gantry axis and allows configuring of that axis.
CBH Installed
Selecting Yes will enable the Contour Bevel Head axis and allows configuring of that axis.
X and Y Motor/Encoder
Selecting this feature as Swapped will internally swap the X and Y Axis encoder signals. This feature
simplifies the installation to systems with alternate wiring configurations.
Key Logging
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. The files may be retrieved
and stored to diskette through the Files screen at the control. Please refer to the Files Screen
information provided in the operator’s guide for additional information on this feature.
Table Size
Enter a value for the active cutting area for the X and Y axis. These values are used to limit the Plate
size parameter in the cutting setup screen to the maximum size of the table.
THCs Installed
The THC Installed parameter defines the total number of Sensor™ THC Axes assigned for operation
at the control.
THC Installed On Axis / Analog
This setup parameter is used to define the THC Axis for use. The user can select which axis the THC
is to be commanded on, the analog input to use ( arc voltage feedback ) and which plasma.
THC On
The THC On parameter is used to indicate which processes are using Sensor™ THCs on the
control. This does not assign a process to a specific THC but rather updates the selected process
screens to enable any specific Sensor™ THC features. Refer to the Sensor™ THC appendix of this
guide for additional information on the setup and use of the Sensor™ THC.
Command THCs Installed
The Command
information on this feature, please refer to the Command
®
THC selection is used to enable the Command THC serial Link. For more
®
THC section of this guide.
Section 4: Password Setups 29
SERCOS Machine
The SERCOS interface requires configuration to establish communications for motion and I/O.
Drive Type
The user may select to use Pac Sci (Pacific Scientific) or Indramat ( Bosch Rexroth ) style drives.
Update Rate
The update rate for the ring may be selected for motion and I/O. One millisecond is recommended
but it is dependent on the capabilities of the hardware being used.
Baud Rate
Communication rate for the ring may be selected. This is determined by the type of drive and I/O
being used.
Light Level
The user has the ability to adjust the intensity of the light pulses used on the fiber optic ring. This
feature is used to compensate for diminished signal due to issues such as ring distance.
Drive I/O
The user may select to use I/O options directly supported on the Drive Amplifier. Options are None,
Overtravel and Home Switches only or All I/O. Note: The Drive I/O will populate the general purpose
I/O (both analog and digital) in order from the lowest SERCOS drive axis to the highest SERCOS
drive axis.
RECO I/O at Address 50
This parameter is set to Yes if the Indramat RECO I/O module is being used to expand the total
number of I/O being used on the fiber optic ring. Note: The RECO I/O will populate the general
purpose I/O (both analog and digital) following all drive I/O.
30 Installation & Setup Guide
Speeds
The Speeds setup screen is used for setting the various machine speeds for different operating
modes.
Given that the drives, motors, gearboxes and mechanics are capable, the control is capable of
operating over a wide range of speeds.
Speed 0 To
This parameter allows the technician to input selected speed ranges to customize the acceleration
rates for the various speeds selected. When a speed range lower than the maximum speed is
entered, a new range at the maximum machine speed setting will be created, up to a maximum of
five. To reduce the number of Speed To ranges, input the maximum machine speed into the range
that is to be the highest speed selection and the additional range fields will be removed from the
screen.
Acceleration Rate
All mechanical systems have different acceleration and deceleration rates to move the cutting device
smoothly. The higher the acceleration rate, the quicker the machine will get up to speed. The lower
the acceleration rate the smoother the machine will position the cutting device. This setup parameter
is used to determine both the acceleration and deceleration rate for all motion.
Enter a value in milligees for the desired acceleration rate. A milligee (milliG) is 1/1000 of a G, which
is the acceleration due to gravity. One milligee is approximately 0.384 inches per second
starting point for most systems is 10 mgee’s.
2
. A good
Section 4: Password Setups 31
Fast Stop Deceleration Rate
Activated by the Fast Stop or Torch Collision Input, the Fast Stop Deceleration Rate Parameter
specifies in milligees how quickly the system will stop when the Fast Stop Input is active. Generally,
this value is much higher then the Acceleration rate.
A milligee (milliG) is 1/1000 of a G, which is the acceleration due to gravity. One milligee is
approximately 0.384 inches per second
2
.
Maximum Machine Speed
Enter the maximum value at which the system is capable of contouring. This parameter will be used
to range limit all subsequent speed entries. In addition, it is used to scale the speedometer widget in
the Watch window during runtime operation.
The maximum speed at which the control can contour can be calculated with the following equation.
Maximum Contouring Rate (IPM) =
60 seconds
4 1 Inch 4 100,000 edges
minute User edges second
For example: the control could command a cutting machine with 4000 edges per inch resolution at
1,500 IPM.
Limited Machine Speed
The Limited Speed feature allows for a user-defined maximum machine speed when the Limited
Speed Input is active. This is commonly used to set a reduced machine speed for the purpose of
increased safety when testing or maintenance of the machine is being performed.
High Jog Speed
Enter a value for the desired high manual motion speed.
Medium Jog Speed
Enter a value for the desired medium manual motion speed.
Low Jog Speed
Enter a value for the desired low manual motion speed.
Minimum Corner Speed
This is the minimum speed to use when negotiating corners. The control has sophisticated
centripetal velocity and acceleration contouring algorithms, which should provide optimal cut quality
for most cut operations. In some situations it may be desirable to enter a minimum corner speed to
prevent over-burning at corners. In normal operations, this parameter should be set to zero.
Fast Home Speed
Enter the machine speed the control will use during the first phase of the homing sequence. During
the first phase, the cutting device will move towards the home limit switches at the fast rate.
32 Installation & Setup Guide
Slow Home Speed
Enter the machine speed the control will use during the second phase of the homing sequence.
During the second phase, the cutting device will move off the home limit switch and proceed to the
marker pulse. Upon detection of the marker pulse, the control will decelerate to a stop and perform a
small move in the opposite direction to the marker pulse.
Creep Speed Percentage
The Creep Speed Percentage parameter allows the operator to select what percentage of the
machine cut speed will be used when creeping. Generally, this is 25% of the cut speed.
Plasma Hi/Lo Speed Percentage
The Hi/Lo Speed specifies the percentage of the entered Cut Speed below which the control will
activate the Torch Height Disable output. The plasma system may use this output to switch from low
to high current or to disable the height control. Note: The Dual Grid/THC feature must first be enabled
at the Plasma Setups Screen.
Plasma Distance To Corner
The Plasma Distance to Corner parameter specifies the distance to the corner at which the plasma
system should switch from High current to low current and disable the Automated Height Sensor.
Distance to Corner is active whenever the speed drops below the Plasma Hi/Lo Percentage, or
segments intersect at an angle greater than the tangent angle. Note: The Dual Grid/THC feature
must first be enabled at the Plasma Setups Screen.
Plasma Distance From Corner
The Plasma Distance from Corner parameter specifies the distance from the corner when exiting, at
which the plasma system should enable the Automated Height Sensor. Distance from Corner is
active whenever the speed drops below the Plasma Hi/Lo Percentage, or segments intersect at an
angle greater than the tangent angle. Note: The Dual Grid/THC feature must first be enabled at the
Plasma Setups Screen.
For additional details on how the Torch Height Disable feature of this control operates, please refer to
the Cutting Section of this guide.
CBH Speed Setups (Shown only when enabled)
CBH Acceleration Rate
This parameter allows the operator to set the acceleration rate for smooth and stable movement of
the contoured bevel head. The higher the acceleration rate the quicker the CBH will get up to speed.
The lower the acceleration rate the smoother the machine will position the cutting device. Values are
entered in Rev/ Sec^2.
Maximum CBH Speed
Enter the maximum speed for the CBH rotation in Rev/Min.
CBH High Jog / Home Speed
Enter a value for the desired manual CBH jog and fast Home speed.
CBH Low Jog / Home Speed
Enter a value for the desired CBH slow home speed.
Section 4: Password Setups 33
THC Speed Setups (Shown only when enabled)
THC Acceleration Rate
This parameter allows the operator to set the acceleration rate for smooth and stable movement of
the Sensor™ Torch Height Control. The higher the acceleration rate, the quicker the THC will get up
to speed. The lower the acceleration rate, the smoother the machine will position the cutting device.
Values are entered in milligees.
Maximum THC Speed
Enter the maximum speed for the Sensor™ THC movement in inches per minute.
THC Jog Speed
Enter a value for the desired THC jog speed.
THC Home/Fast IHS Speed
The THC Home/Fast IHS Speed entered here is used to home the torch at the top of the slide and to
move the torch from the selected IHS height towards the plate, looking for the surface of the plate.
THC Slow IHS Speed
The THC IHS Speed is used to retract the torch after the plate has been sensed. The torch will retract
at this speed until the contact sense is lost. This determines the exact distance to the plate
regardless of any flexing of the plate. A very small speed is recommended for optimal accuracy.
Torch Height Disable Feature
The Torch Height Disable Feature is used to activate the Torch Height Disable output and “freeze” or
disable the automatic adjustment of the Automated Torch Height Control system and prevent diving
or crashing of the torch in corners. Note: The Dual Grid/THC feature must first be enabled in the
Plasma Setups screen.
This output is activated by the control based on the values of Plasma Hi/Lo % of Cut Speed, Plasma
Distance to Corner and Plasma Distance from Corner setup parameters. When any one of these
conditions is met, the Torch Height Disable feature will be implemented. The definition of a corner is
based on the tangent angle in the Special Password screen and the value of the Plasma Hi/Lo speed.
Tangent Angle
This parameter is used to set degree of the tangent angle for control motion. Segments within a part
that intersect at angles greater than the selected tangent angle will decel to zero or minimum corner
speed. Segments within a part that intersect at angles less than or equal to the selected tangent
angle will not decel, unless the next segment is a speed limited arc.
Plasma Hi/Lo Speed Percentage
The Hi/Lo Speed specifies the percentage of the entered Cut Speed below which the control will
activate the Torch Height Disable output. The plasma system may use this output to switch from low
to high current or to disable the height control.
34 Installation & Setup Guide
Plasma Distance To Corner
The Plasma Distance to Corner parameter specifies the distance to the corner at which the plasma
system should switch from low current to high current or disable the Automated Height Sensor.
Distance to Corner is active whenever the speed drops below the Plasma Hi/Lo Percentage, or
segments intersect at an angle greater than the tangent angle.
Plasma Distance From Corner
The Plasma Distance from Corner parameter specifies the distance from the corner when exiting, at
which the plasma system should enable the Automated Height Sensor. Distance from Corner is
active whenever the speed drops below the Plasma Hi/Lo Percentage, or segments intersect at an
angle greater than the tangent angle.
Example:
For the example illustrated below, the Torch Height Disable output will be activated based on the
values of the setup parameters.
Plasma Hi/Lo Percentage Value 90%
Distance to Corner Value .5 inches
Distance from Corner Value .5 inches
Tangent Angle Value 20 Degrees
For the above listed values, the Torch Height Disable output is active .5 inches before and .5 inches
after each 90 degree corner. The THD output is also activated as the torch accelerates away from
the pierce and through the arc due to the speed being below the Plasma Hi/Lo value. Finally,
because the arc intersects at greater than the 20 degree tangent angle, the THD output is activated
for .5 inches before and after the beginning of the arc, and is activated for .5 inches before and after
the end of the arc.
Section 4: Password Setups 35
Ports
The control comes standard with two RS-232C serial ports, which may be converted to an RS-422
configuration. For more information on the how to change the serial ports to the RS-422
configuration, please refer to Serial Port Connections. This port has been specially design with optoisolation and filtering to minimize EMI/RFI noise problems common in many cutting operations.
Parameters are enabled and disabled depending on Port feature selections.
The control may be configured to use the communication link provided on the control or the user may
enter information to create a custom communication link at the Link Screen to communicate with a
host computer. Information on how to access the Phoenix Communication Link Software is provided
later in this section.
Up to eight ports may be configured for use in software. Hardware provided with your control may
support a smaller number of communication ports.
The following parameters are available to help configure the Serial Ports for your specific
communications package and selected communication features.
Port Designation
This parameter allows the user to select which serial port will be configured for link use with the
following remote communication settings. Select Link, Messaging, HD4070, FineLine or Command
THC (type”V” controls).
36 Installation & Setup Guide
Baud Rate
Allows selection of the desired baud rate for the remote Communications Link. The available Baud
rates are shown. The control also incorporates a unique compression utility that allows the effective
baud rate to be doubled. For example, for links configured to run at 9600 baud, the effective rate will
be 19.2K Baud.
Note: For Serial Messaging communication speeds from 1200 Baud to 115200 Baud are available.
See Serial Messaging in the Program Code section for more information.
Parity
Enter the desired parity for the remote Communications Link.
Data Bits
Enter the number of data bits the remote link is using. This value is 8 for the link software included
with the control.
Time Out Delay
Enter the amount of time the control will wait prior to display communications error should it not be
able to establish a link with a remote device.
Transmit Delay
Enter the amount of delay the control will insert between each character that is transmitted over the
serial port. Some communications links require a small delay to avoid missing characters that have
been sent to them. This parameter should normally be set to zero.
The following parameters allow the user to create a custom communication link on the control by
entering the ASCII code equivalent to the character or symbol used by the host computer for dialog
start.
For example: The ASCII Decimal Code 33 is equal to the ! symbol
Rewind
This setup parameter is only enabled when Link File Dump Mode has been enable. Enter the ASCII
code equivalent to the character or symbol used by the host computer for tape rewind at the host tape
drive system. Enter the number zero to eliminate the rewind command.
Dialog Start
Enter the ASCII code equivalent to the character or symbol used by the host computer for dialog
start.
Dialog Done
Enter the ASCII code equivalent to the character or symbol used by the host computer for dialog
done.
Dialog Prompt
Enter the ASCII code equivalent to the character or symbol used by the host computer for dialog
rompt.
Dialog Pause
Enter the ASCII code equivalent to the character or symbol used by the host computer for dialog
pause.
Dialog Acknowledge
Enter the ASCII code equivalent to the character or symbol used by the host computer for dialog
acknowledge.
Section 4: Password Setups 37
End of Transmission
Enter the ASCII code equivalent to the character or symbol used by the host computer for dialog
acknowledge.
Using Phoenix Link
If you are using the Phoenix Communication link program supplied on the control select Yes and the
control will automatically enter the appropriate ASCII codes in to the communication link dialog
parameters listed above.
Show Host File Names
The Show Host File Names feature allows the user to select whether or not File Names are shown at
the Download from Host screen. This is a time saving feature for operators who have very large part
folders at the host computer and know the exact file name of the part program to be loaded. The
Using Phoenix Link parameter must be set to ON to enable this feature.
File Dump Mode
Select On to configure the link communication protocol to communicate with link programs which
operate in File Dump Mode. This will allow the control to accept part programs as one long
uninterrupted stream of information as with a tape reader style link.
Allow M65 Auto Reload
Available when a generic link communication has been enabled, this parameter allows the user to
select whether the EIA M65 code will be used as an Auto-reload code or ignored.
Auto Home before Auto Reload
When enabled, this feature automatically “homes” the machine before the next Auto reload (EIA M65
code), either serial Link or from Diskette, is executed
ESSI Program Termination
This parameter allows the operator to tell the control which ESSI code ( 0,63, 64 99, / or = ) is to be
used as machine stop.
Download Updates
The Download Updates parameter allows the operator to download control software updates through
the link communications to the host PC. To use this feature, the “Using Phoenix Link” parameter
must be set to yes. The new update file would then be placed in the same folder location as the Link
software. When the Update Software softkey is pressed at the Special Password screen, the control
will search for the new software update via the link rather than the floppy drive.
Use Multi Drop
Selecting the Use Multi Drop feature will allow the control to be enabled to work with the Phoenix link
software Multi Drop feature. The Multi Drop feature allows the Phoenix Link software to communicate
with multiple controls to one communications port at the host PC. Up to eight controls may be
supported with the Multi Drop feature.
Please note: The “Using Phoenix Link” parameter must be set to YES to enable this feature and
specific hardware (serial communications board Rev C or higher) may be required to support this
feature. Please contact your control supplier for more details.
Address
The Address Parameter defines the control identification address when using the Multi Drop
communications feature. The Phoenix Link software uses this address at the Host PC to know which
control it is communicating with.
38 Installation & Setup Guide
Control Monitoring
When enabled, the Control Monitoring feature allows the user to view control status at the host PC.
Status for File Name, position, cut mode and cut information is displayed. This feature is only
available with the Phoenix Link communication software.
Please refer to the Phoenix Link information section of this guide for additional information on the
Phoenix link.
The following additional parameters are available when Serial Messaging has been enabled. See
Serial Messaging in the Program Code section of this guide for more information.
Flow control
Select to use None, Xon/Xoff or Hardware.
During Jog on Path
The user may select whether messages will be sent when jogging Forward or Backward on Path
while at the Pause screen. Note: All messaging will stop when the Stop Key has been pressed or
the Remote Pause input becomes active.
Note: The Message Type 21 will not be executed for “Backup on Path”.
Retry on Time Out
For the Message Type 22 (which requires an acknowledgement from the external device after the
message) an automatic retransmit of the message may be sent. The user may select the number of
retries allowed before faulting from a lack of response from the external device. The fault prompt
“Message Error” will be displayed when in a Time Out condition.
Time Out
The Time Out value may be used for the Message Type 22 (which requires an acknowledgement
from the external device after the message) if there is no Time Out value used in the command string
of the program code. Refer to the Delay Time / Time Out information for more information.
Section 4: Password Setups 39
I/O
Pressing the I/O softkey allows the operator to configure the inputs and outputs for the shape cutting
table.
I/O Configuration Type “M”, “P” and “V”
Input Logic
The control comes standard with up to 32 discrete inputs. The Input Logic parameter is used as a
mask to determine whether or not the input is to be treated as a normally open contact or normally
closed contact. Entering a numerical value here will set all the Inputs to a predefined set of logic
states for all of the inputs.
With Input Logic set to zero (0), an active input will be displayed as active or On (green lamp) in the
input diagnostic screen.
Logic Selection Box
The Logic Selection Box allows the user to select the Logic state for each input to be either normally
open or normally closed. The Logic state for the inputs may be switched by selecting the desired
input and pressing the space key.
Input Selection
The Input Selection box feature is used to define which inputs will be used by the control and their
physical location on the control interface. All controls are shipped with the default selection of Inputs
and interface locations for the selected control Interface (I/O) configuration.
40 Installation & Setup Guide
Expanded I/O
When more than 64 I/O have been selected a pull down box will be available to assign I/O in the
higher I/O ranges.
Note: When the optional USB Front Panel is used the top 128 I/O will be assigned to USB I/O to
support the front panel
Section 4: Password Setups 41
Input Definitions
Input Description
Spare Spare inputs are activated through the part program. If a Spare input is
located in the part program, the control will pause the process until the
input state is detected. The Spare inputs may be used by use of specific
EIA “O” and “M” codes indicating the input number and function. Refer to
Appendix A in the operator’s manual for a complete description of these
commands.
Torch Up Sense Confirmation signal indicating that the torch is in the full up position.
Torch Down Sense Confirmation signal indicating that the torch is in the full down position.
Preheat Sense Confirmation signal indicating that the Preheat Input from the torch is
active.
Cut Sense Activation of this input indicates that the plasma arc has transferred to
the work piece. If the “Arc On Feedback” setup parameter is ON, then
machine motion will begin at the activation of this input. Type “M” and
“P” controls.
Tracer on Path Tracer On Path is used with the Teach Trace feature and indicates that
the tracing system has detected the template line.
Drive Disabled If the Drive Disabled input is activated, the control will stop all motion and
generate a fault message. Position information will be lost.
Remote Pause A Remote Pause input, when activated, will stop all control motion and
display the Pause screen. No motion will be allowed until this input is
deactivated.
Remote Start When a Remote Start input is detected, it will begin the selected program
cycle as if the Start button on the control had been pressed.
Program Inhibit The Program Inhibit input will force the control to command the motion
output to a zero (0) speed. This is generally used as a dwell to pause
motion during a tool change or as a pause from a PLC interface.
Raise/ Lower Torch The type “V” control has the ability to operate multiple Sensor™ THCs
which are commanded by the control, as separate axes. The Sensor™
THC Torch Raise and Torch Lower commands may be made through the
software softkeys or through the use of these external inputs to the
control.
Station Select Input The type “V” control system has the ability to operate multiple Sensor™
THCs which are commanded by the control as separate axes. The
control requires an input to indicate which Sensor™ THCs are active. Is
Input is also used for tracking of consumable data for the specified
Plasma or Oxy Torch. Station 1-8 are designated for Plasma and
stations 9-20 are designated for Oxy Fuel.
42 Installation & Setup Guide
X Home Switch This input indicates that the machine has traveled to its X axis home
position. If the X axis “Use Home Limit Switch” parameter is set to YES
and a Homing function is performed, the X axis moves in the specified
home direction at the Fast Home Speed until the input is activated. The
X axis then decelerates to a stop and moves in the opposite direction at
the Slow Home Speed until the switch is deactivated. Once the switch is
deactivated, the X axis will either decel to a stop or continue on until the
encoder marker pulse is detected, if the “Use Marker Pulse” parameter is
set to YES.
Y Home Switch This input indicates that the machine has traveled to its Y axis home
position. If the Y axis “Use Home Limit Switch” parameter is set to YES
and a Homing function is performed, the Y axis moves in the specified
home direction at the Fast Home Speed until the input is activated. The
Y axis then decelerates to a stop and moves in the opposite direction at
the Slow Home Speed until the switch is deactivated. Once the switch is
deactivated, the Y axis will either decel to a stop or continue on until the
encoder marker pulse is detected, if the “Use Marker Pulse” parameter is
set to YES.
Z Home Switch Z Axis Home Limit Switch indicates that the machine has traveled to its Z
axis home position. If the Z axis “Use Home Limit Switch” parameter is
set to YES and a Homing function is performed, the Z axis moves in the
specified home direction at the Fast Home Speed until the input is
activated. The Z axis then decelerates to a stop and moves in the
opposite direction at the Slow Home Speed until the switch is
deactivated. Once the switch is deactivated, the Z axis will either decel to
a stop or continue on until the encoder marker pulse is detected, if the
“Use Marker Pulse” parameter is set to YES.
Y Overtravel Switch This input indicates that the machine has traveled into its full positive
travel of a Y axis. If the hardware overtravels are enabled and this input
is activated, the control will stop all motion and generate a fault
message. Motion will not be re-enabled until the switch is deactivated.
X Overtravel Switch This input indicates that the machine has traveled into its full positive
travel of a X axis. If the hardware overtravels are enabled and this input
is activated, the control will stop all motion and generate a fault
message. Motion will not be re-enabled until the switch is deactivated.
Limit Switch This input indicates that the machine has traveled into its full positive
travel of an axis. If the hardware overtravels are enabled and this input is
activated, the control will stop all motion and generate a fault message.
Motion will not be re-enabled until the switch is deactivated. (Type “M”
configuration only)
Ready to Fire PS 1-4 Exclusive to the HD4070
Ready to Fire Input is used to ensure that all HD4070
®
multiple power supply configuration, the
®
power supplies
have completed each individual Initial Height Sense and are ready for
use. The torch ignition is held off by the Hold Ignition Input to the power
supply from the control.
Raise /Lower 4070 1-2 Exclusive to the HD4070
/ Lower 4070 Torch Input is used as a manual raise/lower command to
the selected HD4070
®
multiple power supply configuration, the Raise
®
integrated THC through the control serial – power
supply communication link.
Section 4: Password Setups 43
X +Overtravel Switch This input indicates that the machine has traveled into its full positive
travel in the X axis. If the hardware overtravels are enabled and this input
is activated, the control will stop all motion, generate a fault message
and only allow manual motion in the X axis negative direction.
X -Overtravel Switch This input indicates that the machine has traveled into its full negative
travel in the X axis. If the hardware overtravels are enabled and this input
is activated, the control will stop all motion, generate a fault message
and only allow manual motion in the X axis positive direction.
Y +Overtravel Switch This input indicates that the machine has traveled into its full positive
travel in the Y axis. If the hardware overtravels are enabled and this input
is activated, the control will stop all motion, generate a fault message
and only allow manual motion in the Y axis negative direction.
Y -Overtravel Switch This input indicates that the machine has traveled into its full negative
travel in the Y axis. If the hardware overtravels are enabled and this input
is activated, the control will stop all motion, generate a fault message
and only allow manual motion in the Y axis positive direction.
Power Supply OK This is an input used for the optional Automated Process Controller
(APC). It is used to confirm a ready condition from the Plasma Power
Supply before beginning the cut process.
Fast Stop The Fast Stop input is used as an urgent stop input command to the
control. When the Fast Stop input becomes active, the control will
decelerate motion using a special Fast Stop Decel parameter, and forces
the operator to the Pause Screen. One second after the input becomes
active, the Drive Enable output from the control will turn off and disable
motion. Position information and I/O points will be maintained while the
input is active. This will allow the operator to recover the last position
after the input has been cleared. Note: The Fast Stop Decel parameter
is located on the password protected Speeds setup screen.
Torch Collision The Torch collision input is used on torch systems with “break away”
style mounts. In the event that a torch should make contact with the
plate or any obstacle which causes the break away mount to release, an
input for the mount would be tied back to the control indicating a torch
collision has occurred. The operator will then be forced to the Pause
screen. While the input is active, the Cut output will be turned off and
manual motion will be enabled, allowing the operator to raise, lower and
move the torch position to clear the fault. Note: Position information,
motion command and I/O points are maintained, allowing the operator to
return to the cut path and resume cutting. This feature uses the Fast
Stop Deceleration rate. Manual raise inputs may be used.
Joystick ( Direction) The Joystick directional inputs ( Up, Down, Left and Right) are used to
command manual motion when using and external joystick.
Fume Extraction Sense If selected, the Fume Extraction input is used to confirm that a external
Fume Extraction system on the cutting table is operational prior to
beginning the cut. An option to override is displayed if the input has not
been satisfied at the time of the cut.
44 Installation & Setup Guide
Cut/Mark Sense 1& 2 Cut/Mark Sense ( arc on feedback ) is used to verify that the plasma
torch or marker tool has established the Arc for the selected process.
This indicates to the control that motion can begin. (Type “V” controls).
THC Cut Sense THC Cut Sense ( arc on feedback ) is used to verify that the plasma
torch or marker tool has established the Arc for the selected Sensor™
THC . This indicates to the control that motion can begin. (Type “V”
controls).
Plasma Select 1 & 2 The Plasma Select 1 & 2 are used to select which Plasma process logic
will be used by the control. These inputs are generally run by external
switches. (Type “V” controls).
Marker Select 1 & 2 The Marker Select 1 & 2 are used to select which Marker process logic
will be used by the control. These inputs are generally run by external
switches. (Type “V” controls).
Sensor THC Enable The type “V” control system has the ability to operate multiple Sensor™
THCs which are commanded by the control, as separate axes. The
control requires an input to indicate which Sensor™ THCs are active.
This input is now supported by the Station Select input.
THC Homing to Limit The THC Enable Input is used during Sensor™ THC Homing as the
Current Limit input if the “Home to Hard Stop Current Limited” option is
selected.
Nozzle Contact Sense The Nozzle Contact Sense Input is used during Sensor™ THC Initial
Height Sense to detect the location of the cut surface. This input is tied
back to the control through the external Voltage Divider Card.
THC Homing to Switch The Nozzle Contact Sense Input is used during Sensor™ THC Homing
as the Home Switch input, if the “Home to Switch” option is selected.
THC Automatic This input is used as an external input to switch the Sensor™ THC
between Automatic and Manual operation.
Speed Limit Input The Speed Limit Input is used to limit the machine speed for saftety
during machine testing and maintenance. When active, motion will be
limited to the user defined Limited Machine Speed selected in the
password protected Speeds screen
Tilt +/– Overtravel Switch This input indicates that the machine has traveled into its full positive
travel in the Tilt axis. If the hardware overtravels are enabled and this
input is activated, the control will stop all motion, generate a fault
message and only allow manual motion in the Tilt axis opposite
direction. The Tilt Overtravel Input is also used for Homing of the Tilt
Axis.
Tilt +/– Tilt +/- inputs are used for manual jog commands for the Tilt Axis.
Tilt Home Feature This feature uses the Tilt Overtravel Switch input to indicate that the
machine has traveled to its Tilt axis home position. When a Homing
function is performed, the Tilt axis moves in the specified home
direction at the Fast Home Speed until the input is activated. The Tilt
axis then decelerates to a stop and moves in the opposite direction at
Section 4: Password Setups 45
the Slow Home Speed until the switch is deactivated. Also see Tilt
Overtravel Switch
Rotate +/– Rotate +/- inputs are used for manual jog commands for the Rotate
Axis.
Rotate Home Switch This input indicates that the machine has traveled to its Rotate axis
home position. When a Homing function is performed, the Rotate axis
moves in the specified home direction at the Fast Home Speed until the
input is activated. The Rotate axis then decelerates to a stop, moves in
the opposite direction at the Slow Home Speed until the switch is
deactivated.
Pierce Complete The Pierce Complete input is used for the Laser Cut Process and is
used to confirm that the pierce is complete.
Gas Control Read Comp. The Gas Control Read Complete input is used as part of the HD3070
®
Automatic Gas Console communications to confirm communications is
complete.
Gas Control Error The Gas Control Error input is used as part of the HD3070
®
Automatic
Gas Console communications to notify of an error from the Auto Gas
Console.
Enable Oxy Fuel 1-12 These inputs are used for tracking of consumable data for the specified
Oxy Torch. This input is now supported by the Station Select input.
Enable Plasma 1-8 These inputs are used for tracking of consumable data for the specified
Plasma Torch. This input is now supported by the Station Select input.
Arc Error Counter 1-8 Used as part of the tracking for consumable data, this input triggers a
counter on the Change Consumable Screen. A Plasma Enable Input
must be mapped to have this enable available for use.
Test Lifter This Input is used to perform a test IHS function with a Sensor™ THC.
46 Installation & Setup Guide
Output Logic
The control comes standard with up to 32 discrete outputs. The Output Logic parameter is used as a
mask to determine whether or not the output is to be treated as a normally open contact or normally
closed contact.
Logic Selection Box
The Logic Selection Box allows the user to select the Logic state for each input to be either normally
open or normally closed. The logic state for the inputs may be switched by selecting the desired
Output and pressing the space key.
Output Selection
The Output Selection box feature is used to define which inputs will be used by the control, and their
physical location on the control interface. All controls are shipped with the default selection of
Outputs and interface locations for the selected control Interface (I/O) configuration.
Output Definitions
Output Description
Spare Spare outputs are activated through the part program. If a Spare
output is located in the part, the control will turn on the output as
directed. The Spare outputs may be used by use of specific EIA “W”
and “M” codes indicating the output number and function. Refer to
Appendix A in the operator’s manual for a complete description of
these commands.
Torch Up This output is used to raise the cutting torch. It is activated for the
“Primary Torch Up Time” and the “Pierce Torch Up Time” in oxy fuel
mode. It is activated for the “Torch Up Time” in plasma mode.
Torch Down This output is used to lower the cutting torch. It is activated for the
“Primary Torch Down Time” and the “Pierce Torch Down Time” in
oxy fuel mode. It is activated for the “Torch Down Time” in plasma
mode.
Ignition Control This output is used to turn on the igniters in oxy fuel mode or ignite
the plasma system in plasma mode.
Torch Height Disable
/Dual Grid Control This output is used to disable the automatic torch height controller in
plasma mode. It is activated whenever the current axis position is
within the “Plasma Distance To Corner” or the “Plasma Distance
From Corner” parameters while cutting a part. It is also active
whenever the current cutting speed drops below the result of
(Programmed Cut Speed x (Plasma High/Lo Speed/100)).
This Output is also used to reduce the plasma current in a switchable
current plasma system when the machine speed is less than the
Plasma Hi/Lo speed percentage.
Reduce Current Used with the HD4070
®
, this output switches the plasma to low
current mode.
Section 4: Password Setups 47
CNC/Tracer This output is used to control a CNC relay. The CNC relay
determines whether the control, tracing system or joystick is
commanding the amplifiers. This output is deactivated whenever the
control is off, in Teach Trace mode or is disabled. Otherwise it is
always activated.
Marker / Marker Enable This output is used to activate an external marking device. It can only
be activated by the appropriate “M” code in the part program. Refer
to Appendix A in the operator’s manual for a complete description of
appropriate “M” code commands.
Cut Control This output is used to enable the cutting oxygen in oxy fuel mode or
start the plasma system in plasma mode. This output can also be
used to activate a marking device.
Low Preheat Control The Low Preheat Control output is used to enable the low preheat
gas when cutting in oxy fuel mode. It is activated for the “Low
Preheat Time” when initiating a cut.
Preheat Control This output is used to enable the high preheat gas when cutting in
oxy fuel mode. It is activated for the “High Preheat Time” when
initiating a cut.
Key Press Indicator The Key Press Indicator output is activated whenever a key is
pressed on the control.
Motion Indicator The Motion Indicator output is activated whenever the control is
commanding machine motion.
Plasma Select The Plasma Select output is activated whenever the control is in the
Plasma cutting mode.
Bleed Off Gas The Bleed Off Gas Output is used by the Oxy fuel cut logic to send
an output to the Oxy torch to purge gases at the end of a cut. This
Output is on for the duration of the Bleed Off Time selected in
setups.
Pierce Control The Pierce Control Output is used by the Plasma and Oxy fuel cut
logic to send an output to the torch during the pierce. This Output is
on for the duration of the Pierce Time selected in setups.
Turn ON / Off Supply The Turn ON OR Turn Off Supply Output is used by the Optional
APC (Automated Process Controller) to turn On or Off the plasma
supply through the control
N2 Select The Turn On Supply Output is used by the Optional APC (Automated
Process Controller) to enable the use of nitrogen while cutting.
Drive Enable The Drive Enable Output is used to enable the Drives during normal
functions and to disable the Drives during fault conditions.
Shutter Open The Shutter Open Output is used exclusively with the Laser
cut logic and is used to open the Laser Shutter for use.
Assist Gas The Assist Gas Output is used exclusively with the Laser cut logic
and is used to activate the Assist gas.
48 Installation & Setup Guide
Digital Beam The Digital Beam Output is used exclusively with the Laser cut logic
and is used to activate the Digital Beam.
Laser Start The Laser Start Output is used exclusively with the Laser cut logic
and is used to activate the Laser System.
Abrasive Control The Abrasive Control Output is used exclusively with Water Jet cut
logic and activates the abrasive control adding abrasive to the cut
stream while cutting or for charging the abrasive prior to cutting.
Plasma Enables These outputs are used for external logic. The appropriate Output(s)
is on during plasma cutting, based on the Plasma Select Inputs.
Marker Enables These outputs are used for external logic. The appropriate Output(s)
is on during marking, based on the Marker Select Inputs.
Nozzle Contact Enable The Nozzle Contact Enable Output is active during Sensor™ THC
Initial Height Sense. This input is tied back to the control through the
external Voltage Divider Card. This output may also be used to
switch an external drive system to low output mode (if equipped )
during IHS for stall force plate sensing.
Hold Ignition The Hold Ignition Output is part of the Sensor™ THC operation and
used to hold ignition of the external Plasma Supply. This output may
be tied back to the control through the external Voltage Divider Card
or direct to the Power Supply depending on configuration.
Gas Flow Set 1 – 100 The Gas flow Set Output is used as part of the HD3070
®
Automatic
Gas Console communications (BCD) to set Gas Flow rates.
Valve Select 1 – 8 The Valve Select Output is used as part of the HD3070
®
Automatic
Gas Console communications to select the appropriate valves for
operation.
Gas Control Write The Gas Control Write Output is used as part of the HD3070
®
Automatic Gas Console communications to configure the unit for
operation.
Remote Test Operate The Remote Test Operate Output is used as part of the HD3070
®
Automatic Gas Console communications to Initiate the Remote Test.
Remote Test Preflow The Remote Test Preflow Output is used as part of the HD3070
®
Automatic Gas Console communications to test operation of Preflow
gases.
Remote Air Plasma The Remote Air Plasma Output is used as part of the HD3070
®
Automatic Gas Console communications to signal the Air Plasma
Output.
Remote H35/ N2 Plasma The Remote H35/N2 Plasma Output is used as part of the HD3070
®
Automatic Gas Console communications to signal the H35/N2
Output.
Remote O2 Plasma The Remote O2 Plasma Output is used as part of the HD3070
®
Automatic Gas Console communications to signal the O2 Output.
Section 4: Password Setups 49
Change Consumable This output becomes active when a consumable data value at the
Change Consumable Screen has reached it’s preset maximum.
Generally, this output is tied to an external indicator light or audible
alarm to prompt the system operator to change the appropriate
consumable ( torch tip / electrode ). The affected consumable data
must be reset at the Change Consumable Screen to clear the output.
Current Set BCD The Current Set BCD outputs are used to set the current at the
plasma power supply or marker supply for use. These outputs are
tied to the BCD inputs. Combinations of the current values are used
to attain the desired current set point.
Marker Control The Marker Control Output is used to activate the Marker tool when
in the Marking Process. Traditionally, the Marker tool is activated
through the combination of Marker Enable and Cut Control Outputs.
All the noted options are available and may be configured at the
Marker Setup screen for the desired process timing and operational
results.
Program Running The Program Running Output is active any time the control is
operating within a part program.
Station Enable 1-20 Station Select outputs are used to activate any function specific to a
torch station and are controlled through M37T and M38T codes
within a part program. Typically these are used to enable a torch
station for use. Stations 1-8 are plasma and stations 9-20 are oxy
fuel / other.
Station Lock 1-19 The Station Lock Outputs are used as part of the Automated Torch
Spacing feature. The Station lock is used to Lock the unused torch
station to the gantry or beam when not in use.
Station Clamp 1-19 The Station Clamp Outputs are used as part of the Automated Torch
Spacing feature. The Station Clamp is used to Clamp the selected
torch station to the transverse axis for standard cutting.
Station Mirror 1-19 The Station Clamp Outputs are used as part of the Automated Torch
Spacing feature. The Station Clamp is used to Clamp the selected
torch station to the transverse axis for mirrored cutting.
50 Installation & Setup Guide
Drive Enables
This setup parameter allows the user to select how the control responds to drive faults. If the setting
is Series, then all axes must complete their individual fault ramp times before the drives are disabled.
If the setting is independent, each drive is disabled immediately as soon as its axis fault ramp time is
finished.
Initial Feedback Delay
This feature allows the initial feedback from the Drive System to be held off after initial power up.
This allows the Drive System to fully enable prior to enabling the position loop.
Joystick Installed
Select “Yes” to enable the optional external Joystick. Not available for all control types and optional
control hardware required.
Speed Pot Installed
Select “Yes” to enable the optional external Speed Potentiometer. Not available for all control types
and optional control hardware required.
Plasma Override %
The Plasma Override feature is used in conjunction with the Speed Pot feature to set the minimum
and maximum range of adjustment of the plasma Speed Pot based on a percentage of the set cut
speed. The Speed Pot feature must be enabled for use.
Oxy Fuel Override %
The Oxy Fuel Override feature is used in conjunction with the Speed Pot feature to set the minimum
and maximum range of adjustment of the oxy fuel Speed Pot based on a percentage of the set cut
speed. The Speed Pot feature must be enabled for use.
Trial Override %
The Trial Override feature is used in conjunction with the Speed Pot feature to set the minimum and
maximum range of adjustment of the Trial Speed Pot based on a percentage of the set Trial speed.
The Speed Pot feature must be enabled for use.
Speed Pot Installed On
The Speed Pot installed on Parameter is used to assign Speed Pot inputs to the desired Analog Input
if a dedicated Speed Pot input is not available on the Analog input card being used.
Analog Offset 1- 12
The Analog Offsets 1 through 12 are used to correct for any imbalance or “Zero” the incoming analog
voltage to the Analog Input Card.
Section 4: Password Setups 51
I/O Configuration Type “B”
Input Logic
The control comes standard with five discrete inputs. The Input Logic parameter is used as a mask to
determine whether or not the input is to be treated as a normally open contact or normally closed
contact. Entering a numerical value here will set all the Inputs to a predefined set of logic states for
all of the inputs.
With Input Logic set to zero (0), an active input will be displayed as active or On (green lamp) in the
input diagnostic screen.
Logic Selection Box
The Logic Selection box allows the user to select the Logic state for each input to be either normally
open or normally closed. The logic state for the inputs may be switched by selecting the desired input
and pressing the space key.
Input Selection
The Input Selection box feature is used to define which inputs will be used by the control and their
physical location on the control interface. All controls are shipped with the default selection of Inputs
and interface locations for the selected control Interface ( I/O ) configuration.
52 Installation & Setup Guide
Input Definitions
Input Description
Spare Spare inputs are activated through the part program. If a Spare input is
located in the part, the control will pause the process until the input state
is detected. The Spare inputs may be used by use of specific EIA “W”
and “M” codes indicating the input number and function. Refer to
Appendix A in the operator’s manual for a complete description of these
commands.
Oxygen Cut Sense Activation of this input confirms that Cut Oxygen is on and that motion
can begin after any selected preheat or pierce dwells are completed.
Note: The control requires a transition on this input before it will
command any motion along the cut path. If an Oxygen Cut Sense output
is not available on the machine, the control’s Oxygen Start output can be
wired back into the Oxygen Cut Sense input.
Program Inhibit The Program Inhibit input will force the control to command the motion
output to a zero (0) speed. This is generally used as a dwell to pause
motion during a tool change or as a pause from a PLC interface.
Plasma Select If the Plasma Select input is on, the control will apply Plasma cut logic
while cutting. If off, it will assume Oxy Fuel cutting is required and Oxy
Fuel cut logic is applied when cutting. This is generally activated by use
of an external switch to indicate Plasma mode.
Arc On Sense Activation of this input indicates that the plasma arc has transferred to
the work piece. If the “Arc On Feedback” setup parameter is On, then
machine motion will begin at the activation of this input.
Drive Disabled If the Drive Disabled input is activated, the control will stop all motion and
generate a fault message. Position information will be lost.
Remote Pause A Remote Pause input, when activated, will stop all control motion and
display the Pause screen. No motion will be allowed until this input is
deactivated.
Limit Switch This input indicates that the machine has traveled into its full positive
travel of an axis. If the hardware overtravels are enabled and this input is
activated, the control will stop all motion and generate a fault message.
Motion will not be re-enabled until the switch is deactivated. (Type “M”
configuration only)
Remote Start When a Remote Start input is detected, it will begin the selected program
cycle as if the Start button on the control had been pressed.
Fast Stop The Fast Stop input is used as an urgent stop input command to the
control. When the Fast Stop input becomes active the control will
decelerate motion, using a special Fast Stop Decel parameter, and
forces the operator to the Pause Screen. One second after the input
becomes active, the Drive Enable output from the control will turn off and
disable motion. Position information and I/O points will be maintained
while the input is active. This will allow the operator to recover the last
Section 4: Password Setups 53
position after the input has been cleared. Note: The Fast Stop Decel
parameter is located on the password protected Speeds setup screen.
Torch Collision The Torch collision input is used on torch systems with “break away”
style mounts. In the event that a torch should make contact with the
plate or any obstacle which causes the break away mount to release, an
input for the mount would be tied back to the control indicating a torch
collision has occurred. The operator will then be forced to the Pause
Screen. While the input is active, the Cut output will be turned off and
manual motion will be enabled allowing the operator to raise, lower and
move the torch position to clear the fault. Note: Position information,
motion command and I/O points are maintained allowing the operator to
return to the cut path and resume cutting.
Output Logic
The control comes standard with eight discrete outputs. The Output Logic parameter is used as a
mask to determine whether or not the output is to be treated as a normally open contact or normally
closed contact.
Logic Selection Box
The Logic Selection box allows the user to select the Logic state for each input to be either normally
open or normally closed. The logic state for the inputs may be switched by selecting the desired
Output and pressing the space key.
Output Selection
The Output Selection box feature is used to define which inputs will be used by the control and their
physical location on the control interface. All controls are shipped with the default selection of
Outputs and interface locations for the selected control Interface ( I/O ) configuration.
Output Definitions
Output Description
Spare Spare outputs are activated through the part program. If a Spare
output is located in the part, the control will turn on the out put as
directed. The Spare outputs may be used by use of specific EIA “O”
and “M” codes indicating the output number and function. Refer to
Appendix A in the operator’s manual for a complete description of
these commands.
Oxygen Enable The Oxygen Enable Output is used to enable the oxygen circuit prior
to the Oxygen Start Output to begin the cut.
Oxygen Start This output is used to enable the cutting oxygen in oxy fuel mode
This output can also be used to activate a marking device.
Preheat This output is used to enable the high preheat gas when cutting in
oxy fuel mode. It is activated for the “High Preheat Time” when
initiating a cut.
Plasma Enable The Plasma Enable Output is used to enable the oxygen circuit prior
to the Plasma Start Output to begin the cut.
54 Installation & Setup Guide
Plasma Start This output is used to start the plasma system in plasma mode.
Plasma Height Disable This output is used to disable the automatic torch height controller in
plasma mode. It is activated whenever the current axis position is
within the “Plasma Distance To Corner” or the “Plasma Distance
From Corner” parameters while cutting a part. It is also active
whenever the current cutting speed drops below the result of
(Programmed Cut Speed x (Plasma High/Lo Speed/100)).
Plate Marker No. 1 This output is used to activate a marking device. This output is
enabled by marking codes within the part program.
Plate Marker No. 2 This output is used to activate a marking device. This output is
enabled by marking codes within the part program.
CNC Tracer This output is used to control a CNC relay. The CNC relay
determines whether the control, tracing system or joystick is
commanding the amplifiers. This output is deactivated whenever the
control is off, in Teach Trace mode or is disabled. Otherwise it is
always activated.
Bleed Off Gas The Bleed Off Gas output is used by the Oxy fuel cut logic to send
an output to the Oxy torch to purge gases at the end of a cut.
This Output is on for the duration of the Bleed Off Time selected
in setups.
Aux Tool Select The Auxiliary Tool Select Output is used with the type “B” I/O
configuration to allow the control to activate multiple tools on the
cutting table. The output is activated through use of Marking
codes (EIA M10 / M11) within the part program.
Drive Enable The Drive Enable Output is used to enable the Drives during
normal functions and to disable the Drives during fault
conditions.
Drive Enables
This setup parameter allows the user to select how the control responds to drive faults. If the setting
is Series, then all axes must complete their individual fault ramp times before the drives are disabled.
If the setting is independent, each drive is disabled immediately as soon as its axis fault ramp time is
finished.
Initial Feedback Delay
This feature allows the initial feedback from the Drive System to be held off after initial power up.
This allows the Drive System to fully enable prior to enabling the position loop.
Joystick Installed
Select “Yes” to enable the optional external Joystick. Not available for all control types and optional
control hardware required.
Speed Pot Installed
Select “Yes” to enable the optional external Speed Potentiometer. Not available for all control types
and optional control hardware required.
Section 4: Password Setups 55
Plasma Override %
The Plasma Override feature is used in conjunction with the Speed Pot feature to set the minimum
and maximum range of adjustment of the plasma Speed Pot based on a percentage of the set cut
speed. The Speed Pot feature must be enabled for use.
Oxy Fuel Override %
The Oxy Fuel Override feature is used in conjunction with the Speed Pot feature to set the minimum
and maximum range of adjustment of the oxy fuel Speed Pot based on a percentage of the set cut
speed. The Speed Pot feature must be enabled for use.
Trial Override %
The Trial Override feature is used in conjunction with the Speed Pot feature to set the minimum and
maximum range of adjustment of the Trial Speed Pot based on a percentage of the set Trial speed.
The Speed Pot feature must be enabled for use.
Speed Pot Installed On
The Speed Pot installed on Parameter is used to assign Speed Pot inputs to a desired the Analog
Input if a dedicated Speed Pot input is not available on the Analog input card being used.
Analog Offset 1- 12
The Analog Offsets 1 through 12 are used to correct for any imbalance or “Zero” the incoming analog
voltage to the Analog Input Card.
To calibrate the Analog Inputs, jumper the two pins specific to the input together and view the
incoming voltage at the Diagnostics Analog I/O screen. The incoming voltage should be zero. If any
voltage is displayed at the diagnostic screen, an Offset Voltage equal to the incoming voltage being
read can be entered here to “Zero” the incoming voltage. Please refer to the installation instructions
later in this section for more details.
56 Installation & Setup Guide
Section 4: Password Setups 57
Axes
Transverse/Rail
The following screen is identical for both the traverse and rail setup screens.
The control comes with both an advanced position and velocity servo loop. The following parameters
are available to help configure the servo loops for your specific drive and mechanical system.
Speed 0 To
This parameter allows the technician to input selected speed ranges to customize the gains for the
various speeds selected. Note: These speed parameters are directly tied to the Speed To field for
the acceleration rates previously noted on the Speeds setup screen. Changing these speed
parameters will replace the Speed To values entered at the Speeds setup screen.
Proportional Gain
Proportional Gain correlates to Elastic Stiffness in the control loop. Increasing the proportional gain
increases the static stiffness, but decreases response of the servo loop.
Under proportional loop control, the drive system will apply a restoring torque to the motor in
proportion the position error of the axis.
With a Proportional Gain too high, the system will be unstable which will result in overshoots, and a
generally “nervous” and shaky axis. This is also referred to as a “hot” control loop.
With a proportional gain too low, the system will respond in a loose or sloppy manner. This can be
seen in the test pattern when the outside corners become rounded and the circle segments do not all
meet in the center.
58 Installation & Setup Guide
Integral Gain
Integral Gain improves the positioning accuracy of the control loop. Integral Gain can be used to
compensate for static friction or gravity. Excessive Integral Gain can result in system instability.
For most shape cutting machines, this parameter should be set to Zero (0).
Derivative Gain
Derivative Gain helps to dampen out sudden changes in velocity. The higher the derivative gain, the
slower the response time to the control loop. For most velocity loop drives, this parameter will be set
to Zero (0).
Feedforward Gain
Feedforward Gain can be used to drive the following error to zero during machine motion. In all
digital control loops there is a finite amount of error that is introduced by the velocity command.
Increasing Feedforward Gain can reduce this introduced error.
Velocity Gain
When using a current loop amplifier, the internal velocity loop in the control can be used to provide
dampening without an external tachometer.
Using the internal velocity loop with a current loop amplifier can result in higher static stiffness,
smoother machine motion, and less overshoot.
Servo Error Tolerance
Allows the user to program the amount of servo loop Following Error to be allowed prior to display an
error message. The parameter is limited to a maximum value of five inches.
Encoder Counts per inch
Enter a value that is the number of encoder edges per inch of machine travel. It is possible to enter
fractional encoder units and the control will keep track of these fractions automatically. Encoder
Counts per inch are equal to the resolution of the encoder, multiplied by the encoder revolutions per
inch or mm (based on the machine drive gearing).
For example: The resolution of a 4X - 1000 line encoder counts both edges ( lines ) of channel A and
channel B to equal 4 counts per line multiplied by the 1000 lines per revolution would equal 4000
counts per revolution. If the encoder revolutions per inch to travel are 1:1, we would have 4000
encoder counts per inch of travel.
Encoder Counts/ Inch = 4 Counts/ Line x 1000 Lines/ Rev x 1 Rev/ Inch = 4000
Fault Ramp Time
This parameter sets the motion deceleration time after a fault occurs. At the end of “Fault Ramp
Time, The drives will be disabled.
Section 4: Password Setups 59
Drive Type
This parameter is used to tell the control what type of control loop to run. If you are running an
external velocity loop drive (indicated by having an integrated tachometer in the motor), select
Velocity. If you are running in torque mode (no tachometer), select Current.
DAC Polarity
This parameter allows changing of the analog output polarity to establish proper control loop
feedback without any wiring changes.
Encoder Polarity
This parameter allows changing of the encoder input polarity to establish proper counting for positive
machine motion without any wiring changes.
Encoder Decode Mode
Currently, the control only supports 4X encoder decode mode. This has been done to increase
positional accuracy.
Use Hardware Overtravels
Select whether or not the cutting machine will be using Hardware Overtravels. If Hardware
Overtravels are used, the control will disable feedback and display an error message if the inputs
become active. It is recommended that Hardware Overtravels be installed.
Backlash Compensation
The Backlash Compensation parameter is used to offset or compensate for any backlash in the
mechanics of the drive system.
Home
The Home parameter is used to activate use of the Home feature. Depending on control I/O
configuration, the table may be Homed to either a designated Home Switch or an Overtravel Switch.
The Home feature is used to set a known absolute physical position location on the cutting table that
is used for referencing future manual “Go to Home” and other motion commands. This is generally
performed through activation of a home switch positioned on the appropriate axis giving it a known
physical location.
When the Homing command is entered at the control, the control will move the axis towards the
Home Switches at the Fast Home Speed until the switches have been activated. Once the switches
have been activated, motion stops and then the axis moves in the opposite direction off switch at the
Slow Home Speed. The moment that the switch is deactivated, the position is recorded at the
control, providing an absolute reference point for future motion commands.
Absolute Home Position
Defines the position of the axis when the Home Limit Switch or Marker Pulse is detected.
Home Offset Distance
Allows the user to set an offset distance from the Home Limit Switch.
Home Switch Normally
If a Home Limit Switch is used, the user is prompted for switch polarity.
Home Direction
Determines which direction the axes will travel during phase one of the homing sequence.
60 Installation & Setup Guide
Use Marker Pulse
When enabled, the absolute home position will be assigned at the instant the marker pulse is
detected. It is recommended that the Marker Pulse be used for optimal homing repeatability.
Use Software Travel Limits
The control is capable of running with software Overtravel limit switches. These switches act just like
the hardware switches, but require no additional hardware.
Software Overtravels are only practical in cutting machines when Absolute RS-274D programming is
used.
Maximum Travel Limit
If Software Overtravels are enabled, the user is prompted for the maximum travel of the cutting
machine.
Minimum Travel Limit
If Software Overtravels are enabled, the user is prompted for the minimum travel of the cutting
machine.
Section 4: Password Setups 61
SERCOS AXES
The SERCOS Interface™ controls the position loop from the amplifier. As a result, limited information
for motion is required in the control setups. Tuning is performed through serial port diagnostic
software available at the Drives & Motors Diagnostic screen.
The following is a listing of the unique SERCOS parameters. Note: parameters will apply to all
SERCOS axes.
SERCOS Drive Address
Each Drive Axes is automatically assigned a Drive Address at the CNC. The appropriate drive
amplifier will be coded with the matching Drive Address to provide control motion to the correct
amplifier / motor on the SERCOS ring. Note: The drives may be physically located in any order on
the ring.
Emulated Encoder Counts/ motor rev
This parameter allows the user to adjust the number of counts per motor rev that the drive generates
over the SERCOS ring, to adjust resolution. This parameter is available for Pac Sci drives only.
Other drive types allow the emulated Counts /motor rev parameter to be set up in the drive tuning
software.
62 Installation & Setup Guide
Dual Gantry
The following setup screen is available if the control is configured for a Dual Gantry Axis.
The Dual Gantry Axis is commanded as a separate axis on the control that mirrors the output of the
main Rail Axis. Additionally, performance of the Dual Gantry Axis is compared to the main Rail Axis
and additional output command is given to keep the axis in position.
The definitions for the setup parameters are the same as for the Transverse/Rail Axes. However, the
number of selections are reduced as features for overtravels and homing do not apply.
Speed 0 To
This parameter allows the technician to input selected speed ranges to customize the gains for the
various speeds selected. Note: These speed parameters are directly tied to the Speed To field for
the acceleration rates previously noted on the Speeds setup screen. Changing these speed
parameters will replace the Speed To values entered at the Speeds setup screen.
Proportional Gain
Proportional Gain correlates to Elastic Stiffness in the control loop. Increasing the proportional gain
increases the static stiffness, but decreases response of the servo loop.
Under proportional loop control the drive system will apply a restoring torque to the motor in
proportion the position error of the axis.
With a Proportional Gain too high, the system will be unstable which will result in overshoots, and a
generally “nervous” and shaky axis. This is also referred to as a “hot” control loop.
Section 4: Password Setups 63
With a proportional gain too low, the system will respond in a loose or sloppy manner. This can be
seen in the test pattern when the outside corners become rounded and the circle segments do not all
meet in the center.
Integral Gain
Integral Gain improves the positioning accuracy of the control loop. Integral gain can be used to
compensate for static friction or gravity. Excessive Integral Gain can result in system instability.
For most shape cutting machines this parameter should be set to zero (0).
Derivative Gain
Derivative Gain helps to dampen out sudden changes in velocity. The higher the derivative gain, the
slower the response time to the control loop.
For most velocity loop drives this parameter will be set to zero (0).
Feedforward Gain
Feedforward Gain can be used to drive the following error to zero during machine motion. In all
digital control loops there is a finite amount of error that is introduced by the velocity command.
Increasing Feedforward Gain can reduce this introduced error.
Velocity Gain
When using a current loop amplifier, the internal velocity loop in the control can be used to provide
dampening without an external tachometer.
Using the internal velocity loop with a current loop amplifier can result in higher static stiffness,
smoother machine motion, and less overshoot.
Skew Error Tolerance
If the Dual Gantry Axis is installed, the user will be prompted for Skew Error Tolerance. This is the
amount of position error allowed between the master and slave gantry drive axes prior to an error
message being displayed.
Encoder Counts per inch
Enter a value that is the number of encoder edges per inch of machine travel. It is possible to enter
fractional encoder units and the control will keep track of these fractions automatically. Encoder
Counts per inch are equal to the resolution of the encoder, multiplied by the encoder revolutions per
inch (based on the machine drive gearing).
For example: The Resolution of a 4X - 1000 line encoder counts both edges (lines) of channel A and
channel B to equal 4 counts per line multiplied by the 1000 lines per revolution would equal 4000
counts per revolution. If the encoder revolutions per inch to travel is 1:1, we would have 4000
encoder counts per inch of travel.
Encoder Counts/Inch = 4 Counts/Line x 1000 Lines/Rev x 1 Rev/Inch = 4000
64 Installation & Setup Guide
Drive Type
This parameter is used to tell the control what type of control loop to run. If you are running an
external velocity loop drive (indicated by having an integrated tachometer in the motor), select
Velocity. If you are running in torque mode (no tachometer), select Current.
DAC Polarity
This parameter allows changing of the analog output polarity to establish proper control loop
feedback without any wiring changes.
Encoder Polarity
This parameter allows changing of the encoder input polarity to establish proper counting for positive
machine motion without any wiring changes.
Encoder Decode Mode
Currently the control only supports 4X encoder decode mode. This has been done to increase
positional accuracy.
Use Home Limit Switch
Selecting “Yes” will enable the Home feature for the Dual Gantry Axis. Note: The Z Home Switch
must first be defined and mapped to an input location in the I/O screen to enable this feature.
Switch Offset Distance
The Switch Offset Distance is used to specify any physical position offset between the Dual Gantry
and Rail Home Switch positions. This allows the control to very accurately position the two axes for
operation and remove any skew of the gantry.
Backlash Compensation
The Backlash Compensation parameter is used to offset or compensate for any backlash in the
mechanics of the drive system.
Section 4: Password Setups 65
CBH
The following setup screen is available if the control is configured for a Contour Bevel Head.
The definitions for the setup parameters are the same as for the Transverse/Rail Axes, with the
exception of Absolute Home Angle and Home Offset Angle. These two setup parameters serve the
same basic function as previously described but are measured in degrees of rotation rather than
inches or millimeters. However, the number of selections are reduced as these parameters are not
used with a Contour Bevel Head.
Proportional Gain
Proportional Gain correlates to Elastic Stiffness in the control loop. Increasing the proportional gain
increases the static stiffness, but decreases response of the servo loop.
Under proportional loop control, the drive system will apply a restoring torque to the motor in
proportion the position error of the axis.
With a Proportional Gain too high, the system will be unstable which will result in overshoots and a
generally “nervous” and shaky axis. This is also referred to as a “hot” control loop.
With a proportional gain too low, the system will respond in a loose or sloppy manner. This can be
seen in the test pattern when the outside corners become rounded and the circle segments do not all
meet in the center.
Integral Gain
Integral Gain improves the positioning accuracy of the control loop. Integral Gain can be used to
compensate for static friction or gravity. Excessive Integral Gain can result in system instability.
66 Installation & Setup Guide
For most shape cutting machines, this parameter should be set to zero (0).
Derivative Gain
Derivative Gain helps to dampen out sudden changes in velocity. The higher the Derivative Gain, the
slower the response time to the control loop.
For most velocity loop drives, this parameter will be set to zero (0).
Feedforward Gain
Feedforward Gain can be used to drive the following error to zero during machine motion. In all
digital control loops there is a finite amount of error that is introduced by the velocity command.
Increasing Feedforward Gain can reduce this introduced error.
Velocity Gain
When using a current loop amplifier, the internal velocity loop in the control can be used to provide
dampening without an external tachometer.
Using the internal velocity loop with a current loop amplifier can result in higher static stiffness,
smoother machine motion, and less overshoot.
Servo Error Tolerance
Allows the user to program the amount of servo loop Following Error to be allowed prior to display an
error message. The parameter is limited to a maximum value of 90 degrees.
Encoder Counts per rev
Enter a value that is the number of encoder edges per revolution of the Contour Bevel Head axis. It
is possible to enter fractional encoder units and the control will keep track of these fractions
automatically. Encoder Counts per rev are equal to the resolution of the encoder multiplied by the
encoder revolutions per rev.
For example: The Resolution of a 4X - 1000 line encoder counts both edges (lines) of channel A and
channel B to equal 4 counts per line time multiplied by the 1000 lines per revolution would equal 4000
counts per revolution.
Encoder Counts/Rev = 4 Counts/Line x 1000 Lines/Rev = 4000
Drive Type
This parameter is used to tell the control what type of control loop to run. If you are running an
external velocity loop drive (indicated by having an integrated tachometer in the motor), select
Velocity. If you are running in torque mode (no tachometer), select Current.
Section 4: Password Setups 67
DAC Polarity
This parameter allows changing of the analog output polarity to establish proper control loop
feedback without any wiring changes.
Encoder Polarity
This parameter allows changing of the encoder input polarity to establish proper counting for positive
machine motion without any wiring changes.
Encoder Decode Mode
Currently the control only supports 4X encoder decode mode. This has been done to increase
positional accuracy.
Follower Initially
This parameter is used to determine if the CBH axis will be On when the control is first powered up.
Auto Home At Power Up
Determines if the Contour Bevel Head will automatically go into the homing routine upon powering up
the control.
Absolute Home Angle
Defines the position of the axis when the home limit switch or marker pulse is detected.
Home Offset Angle
Allows the user to set an offset angle from the home limit switch.
Use Home Limit Switch
Tells the control to look for a home limit switch during phase one of the homing sequence.
Home Direction
Determines which direction the axes will travel during phase one of the homing sequence.
Use Marker Pulse
When enabled, the absolute home position will be assigned at the instant the marker pulse is
detected. It is recommended that the marker pulse be used for optimal homing repeatability.
68 Installation & Setup Guide
Station Configuration
This password protected screen for the Voyager™ II and Mariner™ controls is used to configure a
Plasma, Marker or Laser torch station for use. This provides a single location to assign the Tool
Selection, Process Selection and Lifter selection for the station. Up to eight stations for the Plasma 1
& 2 and Marker 1 & 2 process selections may be configured.
The “4532” password is provided for viewing of the Station Configuration setup screen without
allowing changes. This password is useful for verify setups without the danger of accidentally
changing them or revealing the supervisory password to an unauthorized user.
This Station configuration screen is also used to enable the serial link for the Command
as serial communication for the HD4070
®
and HPR130™ Plasma Systems.
Main Screen
®
THC as well
These stations may be selected for use through codes within the part program. These codes enable
the desired Station ( THC ) and are used in conjunction with the Process Select codes to configure
the desired cut / mark process for use.
When a Station Select has been executed through the program codes the corresponding Station
Select Output will be active.
Stations 1-4 / 5-8
The Stations 1-4 / 5-8 Softkey is used to access the desired Station for configuration.
Reset
The Reset Softkey may be used to reset or clear all Station setup parameters setting the values to
“None”.
Section 4: Password Setups 69
Part Program Support
The following program codes are used to enable a station for use. Station Select and Process Select
codes should be placed prior to the cut / mark.
Station Selects
Stations ( Lifter / THCs) may be selected / de-selected using an EIA-274D program code with the
following format.
Code Description
M19 Tvalue Cancel All Station Selections
M37 Tvalue Select Station 1-20 ( Tvalue )
M38 Tvalue De-Select Station 1-20 ( Tvalue )
Additionally, these Station Select program codes may be overridden using the user selected THC
inputs to the control. The feature to override the part program must be enabled at the Cutting Setup
Screen.
Process Selects
Process Selections may be selected using an EIA-274D program code with the following format.
Example: M36
Tvalue
Misc. M Code
Valve Identity
T1 = Plasma Process 1
T2 = Plasma Process 2
T3 = Marker Process 1
T4 = Marker Process 2
T5 = Laser Process
Station Configuration Variables
The following options are available for the station configuration
Lifter
None
Sensor THC
Command THC ( w/ Serial Link)
HD4070 Integrated THC 1 or 2 ( used only with the HD4070
®
power supply )
Other ( any stand alone Lifter Station )
Power Supplies
None HD4070 Torch 1or 2 Powermax series
Max100/ 100D HT4001 FineLine 100
Max200 HT4100 FineLine 200
HT2000 HT4400 Other ( any other Plasma system )
HD3070 HPR130
Marker
None ArcWriter FineLine 100 & 200
HD4070 Torch 1or 2 HPR130 Other ( any stand alone Marker )
Laser
Rofin RF 40 & 50 Rofin DC 35 Rofin TR 60 Other
70 Installation & Setup Guide
Station Selects may be overridden by manual inputs by setting the Station Select Override feature in
Cutting Setups to disabled.
Process Selects may be overridden by manual inputs by setting the Process Select Override feature
in Cutting Setups to disabled.
Overview
First press the Stations 1-4 or Station 5-8 Softkey to access the desired station. Select the
appropriate Lifter selection for the desired station from the list of available Lifter types. Next select
the appropriate tool ( Plasma Power Supply / Marker Tool ) selection for that station from the list of
available tools in the Plasma and Marker Process fields. The tool selection should reflect the actual
tools in use for that individual Lifter. The Station may be configured so that all four Plasma and
Marker Processes operate on one Station or distributed throughout all 8 stations. If needed, the
Reset Softkey may be used to reset or clear all Station setup parameters setting the values to “None”.
Selections made for the four processes and THC designations may limit the overall configuration.
Additionally, selection of some of certain power supplies may also limit configuration.
Section 4: Password Setups 71
Example: If Station 1 has been defined as having a Sensor™ THC and a MAX200
®
for Plasma
Process 1, no other power supply type can be selected for Plasma Process 1. However, MAX200
for Plasma Process 1 may be select at other stations if a Sensor THC has been selected.
®
Command
Selecting a Command THC as the lifter for a process enables the serial Link to be assigned for a
single Command
This also configures the selected Plasma / Marker Cut Types screen to display the Command
features. If a Command
®
THC Support
®
THC. Note: The actual serial port must be assigned on the Ports setup screen.
®
THC has been selected for a station but does not use the serial
®
THC
communication feature to the control, then the Lifter type should be set to “Other”.
Please refer to the Command
of the Command
HD4070
®
Support
The HD4070
configures the selected Plasma / Marker Cut Types screen to display the HD4070
HD4070
®
must be assigned to Stations 1 & 2. A second multi-dropped HD4070 may be assigned on
®
THC
®
feature establishes the Serial Link HD4070® Power Supply communication link and
®
THC section of this manual for additional information on the operation
®
features. A single
stations 3 & 4.
Each HD4070
HD4070
®
®
has the ability to use two Integrated Command® THCs. These are controlled by the
and as such have designated Station locations.
72 Installation & Setup Guide
In the previous example, you can see that the Cutting and Marking with the HD4070
Torch 1 is limited to Plasma Process 1 / Maker Process 1 on Station 1. Additionally, the Cutting and
Marking with HD4070
®
Integrated Torch 2 is limited to Plasma Process 2 / Maker Process 2 on
®
Integrated
Station 2. These stations may be configured to Cut or Mark or both. A second multi-dropped
HD4070 may be also be assigned on stations 3 & 4.
FineLine 100 / 200 Support
Serial communications to INNERLOGIC’s FineLine 100 and FineLine 200 may be enabled and
configured for use with selected THCs.
Section 4: Password Setups 73
Special
Date
Allows the user to enter the current date.
Time
The value for the current time would be entered at this parameter and displayed at the main screen.
Display Time
The Display Time parameter allows the user to select the display time to be shown in either AM/PM
format or 24 hour clock format.
Mouse Pointer
If the control has been equipped with the optional industrial mouse, select On to enable this feature.
Motion Cursor
This parameter allows the user to select the style of Motion Cursor used.
Tangent Angle
This parameter is used to set the degree of the tangent angle for control motion. Segments within a
part that intersect at angles greater than the selected tangent angle will decel to zero or minimum
corner speed. Segments within a part that intersect at angles less than or equal to the selected
tangent angle, will not decel unless the next segment is a speed limited arc.
File Extensions
74 Installation & Setup Guide
The parameter allows the user to enter the file extensions of the part files that will accepted at the
control.
Adding Folders
This parameter determines whether the control operator has the ability to add Folders from the parts
directory on the control or the host computer.
Deleting Folders
This parameter determines whether the control operator has the ability to delete Folders from the
parts directory on the control or the host computer.
Deleting Files
This parameter determines whether the control operator has the ability to delete Folders from the
parts directory on the control or the host computer.
Mapping Drives
This parameter determines whether the control operator has the ability to map to external drives from
the control through the optional Network feature.
Configuring Watch
When enabled, this parameter will allow the control operator to change the selected items in the
Watch Window.
Adding Processes
This feature allows to user to add new processes to the Laser cut charts when enabled
Removing Processes
This feature allows to user to remove processes to the Laser cut charts when enabled
.
Force Simulation
When activated, this feature will force the control into a simulation mode that will allow the control to
operate with motioned disabled and I/O feedback enabled.
Tools Installed
This setup parameter is used to select or limit the cut modes available to the control operator.
Message Enables
The following pull down box is used to enable and disable system messages. To change the status
of a message, highlight the selected message and press the Space key.
Ready to Start Cutting Message
When enabled, the Ready Message feature will display a ready message when the Start button is
pressed.
Kerf Too Large Warning Message
The Kerf Too Large Warning setup parameter allows the user to disable the “ Kerf Too Large”
warning message. This message is used to notify the user that when a part has been loaded and
translated at the control, a conflict with the cut paths has been detected for the given Kerf value and
that some detail may be lost when cut. Disabling the “Kerf Too Large” message may lead to
unexpected results and allow cutting of invalid parts.
Homing Must Be Performed Message
This message is used to prompt the operator to home the selected axis before motion can begin.
The selected axis must have homing enabled on the axes setup screen.
Section 4: Password Setups 75
Example:
Values Have been Changed Message
This message is displayed as a confirmation when it has been detected that the values within the
current configuration screen have changed. This ensures that changes are not made in error when
exiting the screen.
Home Torch Height Control Message
This message is used to prompt the operator to home the Sensor™ THC axis at power up and before
motion can begin.
Ready to Final Align Message
This message appears as part of the skew alignment function and is displayed just prior to final
motion to position the tool is executed.
Part Larger than Plate Message
This message is displayed when the dimensions of the part that have been loaded exceed the
selected plate dimensions.
Cut Chart Data Has Changed Message
This message is displayed as a confirmation when it has been detected that the values within the
current Cut Chart screen have changed. This ensures that changes are not made in error when
exiting the screen.
Save Part for Rush Job
This feature will enable or disable the Resume Part prompt for Rush Job Interrupt.
Latched Manual Keys
This parameter will enable or disable the Latched Manual Key feature which allows the manual
motion keys to remain on with a single key press.
Auto Drop Down
When enabled, the Auto Drop Down feature will automatically show the entire list of options at a
selection box.
Example:
Zero Positions
This parameter determines whether the control operator has the ability to zero positions. When
disabled, the zero positions softkey will be grayed out and will be unavailable to the operator.
76 Installation & Setup Guide
Auto Size App.
When enabled, the Auto Size App. feature is used for the demo software to size the application
software to full screen display or the standard size of 640x480 (disabled).
Language
The language selection parameter allows the user to select the language displayed on the control
from the available languages stored on the control. Languages may be added to the control by
performing the standard software update with a language specific update file. Eastern languages
may also require the installation of a font viewer to properly display the required characters. To
change to a different language, select the desired language and press the DONE softkey. You will
then be prompted to cycle power on the control for the new language to be displayed.
Password
The password parameter allows the user to enter a new password for machine setups. Numbers or
letters may be used.
Special Password
The password parameter allows the user to enter a new password for special setups. Numbers or
letters may be used.
Station Configuration Password
The password parameter allows the user to enter a new password for Station Configuration setups.
Numbers or letters may be used.
Temperature
The Temperature parameter allows the user to select that the internal control temperature be
displayed in Fahrenheit or Celsius in the Watch Window.
Note: Not available for all control types and optional control hardware required.
Auto Update Max Consumable Life
When enabled, this feature will continue to track the consumable life values beyond the user defined
set point and assign that maximum values as the new set point. If disabled, the user defined set point
for maximum consumable life will not be updated.
Machine Position Resets
When enabled, the Machine Position Resets feature will reset the absolute machine position when
the Zero Positions softkey is pressed. When disabled, pressing the Zero Positions softkey will not
reset the absolute machine position. Position information based on homing will not be lost. Only the
current incremental motion ( part ) position will be reset to zero.
Auto Gas Control
When enabled, this feature allows the control to communicate with the Auto Gas Console for the
HD3070
®
and allows access to the related setup parameters.
Arc Speed Limit Check
This feature allows the user the ability to turn off the Speed Limit Check performed by Softmotion for
arcs larger than 10”. This may be used to compensate for abrupt motion commands caused by nontangent line arc segments, smoothing out motion.
Section 4: Password Setups 77
Save Setups
Pressing the Save Setups button will save the current control setting to the floppy disk or hard drive.
A window will be displayed to select the drive and enter a file name.
Note: After installation of the control on the cutting table or if any setup parameters are changed, it is
important to save the current setup file to both the hard drive and floppy disk for future reference.
Load Setups
Pressing the Load Setups will load the selected control setting from the floppy or hard drive on to the
control. A window will be displayed to select the drive and enter the file name.
Update Software
Pressing the Update Software button will update the control operating software from a floppy disk.
Update Help
Pressing the Update Help button will update the control help files from a floppy disk.
System Tools
Pressing the System Tools button will access core Windows
®
features for system performance.
Features include Update Registry, Scan Hard Disk, Defrag Hard Disk and Format Diskette.
System Tools also accesses features for virus scanning and adding special fonts for some
languages.
Restore Last Version
Restore Last Version will restore the control to the previous version of system software.
Make Link Disk
The control is shipped with a proprietary Communication Link software used to communicate with a
host computer. Pressing this softkey will transfer the Link software to a floppy disk so it may be
loaded on to a host computer for use. Included with the software is a text file to instruct the user on
setup and use of the link.
78 Installation & Setup Guide
System Tools – Windows® XP
The control Systems Tools involves operational knowledge of Windows
should only be performed by qualified personnel.
Note: A reminder will be posted on screen when entering the Systems Tools that a Mouse and
Keyboard will be required for proper operation. The Mouse and Keyboard should be connected to the
control before entering the System Tools.
System Tools
®
XP operating system and
Automated Backup
The Automated Backup feature allows the user to select the frequency of the automatic reminder for
the backup of main hard drive information. At the selected time, the user will be prompted to backup
the system at power up.
Section 4: Password Setups 79
Backup Hard Drive
Pressing the Backup Hard Drive softkey will manually save the contents of the main hard drive to a
specified location on the control hard drive or mapped location using the Norton Ghost™ Utility. The
information from the backup location may also be restored using a diskette provided with the control.
Example
Note: After using Norton Ghost™, all files on Drive C: will be replaced. Control setups will need to be
reloaded.
Scan Hard Disk
Pressing the Scan Hard Disk softkey allows the user to scan the Hard Drive for viruses or to Scan the
Hard Drive for disk errors.
Scan Hard Disk - Selecting NO
using the Windows
®
XP CHKDSK ( check disk ) utility. This task should be performed approximately
will allow the user to scan the Hard Drive for errors and correct them
every three months depending on the number of files loaded to and removed from the control.
The Check Disk ( CHKDSK ) function cannot operate while the control software is in operation. You
will be prompted to press “Y” for yes to perform the Check Disk at the next boot up of the control.
80 Installation & Setup Guide
Scan Hard Disk - Selecting YES
Anti-virus software.
will allow the user to scan the Hard Drive for viruses using Norton’s
Section 4: Password Setups 81
Antivirus
™
The AntiVirus™ feature allows the operator to search files being loaded on to the control for known
viruses. Norton AntiVirus™ is a trademark of Symantec™ Corporation. Please contact your control
vendor for information on how to obtain the AntiVirus™
software for use on your control.
82 Installation & Setup Guide
Defragment Hard Disk
The Defragment Hard Disk feature will scan the control hard disk for file locations and rearranges
them for optimum performance. This task should be performed approximately every three months.
Section 4: Password Setups 83
Format Floppy Disk
Pressing the Format Floppy Disk softkey will format a floppy disk placed into the floppy drive. This is
advantageous in the event that the control has difficulty reading a floppy disk formatted by a
computer. Note: Formatting the diskette will remove any files that are stored on the diskette.
Reset Setups
Reset Setups will delete the current setup file, forcing default values to be loaded. A new setup file
can then be loaded on the control through the Special Password screen.
If the control supplier has installed a customized setup file containing information specific to the
cutting table, the Reset Setups Softkey is renamed Restore Setups. This custom setup file then
becomes the new default setup file and pressing the Restore Setup Key will return the control to the
original factory settings, as configured by the control supplier.
84 Installation & Setup Guide
Network and Remote Tools
The Network and Remote Tools functions involves operational knowledge of Windows
system and should only be performed by qualified personnel.
Pressing the Network Tools softkey accesses the Windows
®
XP Network Connection Utility and
Remote Assistant Utility.
Windows XP
Remote Assistance is a feature within Windows XP
over a TCP/IP connection with a control running the Windows XP
®
Remote Assistant
®
and allows a Remote Helper to view and chat
®
Embedded operating system. The
Remote Helper can also request to share control of the keyboard and mouse.
®
XP operating
Section 4: Password Setups 85
Some applications for Remote Assistance are:
1. Remote demonstrations of CNC software.
2. Show an operator certain features he may not be familiar with.
3. Online chat feature allows direct communication
4. Send or retrieve Software Updates, Database Files or other files with a Remote User.
5. Debug certain customer issues using Log Files.
6. Allow an operator to demonstrate a problem remotely.
Basic Instructions for use of Remote Assistance:
1. Operator connects control to network/internet.
2. Operator launches Remote Assistance Wizard and creates a Remote Assistance Invitation File
with password and saves it to floppy disk.
3. Operator E-mails the Remote Assistance Invitation File and password to the Remote Helper.
4. Remote Helper connects to network/internet and launches Remote Assistance Invitation File.
5. Operator accepts Remote Assistance dialog.
6. Chat windows are available to both the operator and Remote Helper to allow them to discuss the
feature or issue that is being reviewed remotely.
Requirements for the use of Remote Assistance on the Control:
Windows XP Embedded and Phoenix version 4.5 or 5.0 or higher.
Keyboard, mouse and internet connection ( network, dial-up, DSL or other TCP/IP compatible
network) is required for Remote Assistance. High speed connections preferred.
Note: The Remote Helper is not allowed to perform motion unless the control is in forced simulation
mode or is a demo version of software running on a desktop. Audio feature is not used.
This feature would only be used with the assistance of and external technician. Please contact your
control vendor if you require additional details on the use of this feature.
86 Installation & Setup Guide
Network Connection
The optional Network feature allows the control to be incorporated directly into an office PC Network
for part allocation. This feature is available on controls Windows XP
®
operating systems and requires
a factory supplied Network card to be installed. Please see your control vendor for additional details
on adding this feature.
Network System Requirements:
The Optional Networking feature is approved to work with
Window NT
Window NT
Window 98
®
Servers
®
Workgroups
®
Workgroups
To Map the control for loading files
Enable the Mapped Network Drive feature at the Special Password Screen.
At the files Screen, press the + Key. Enter the desired mapped drive location.
The control will automatically log on to the system at boot up.
Section 4: Password Setups 87
NJWin
The NJWin
NJWIN
languages. To view eastern languages, NJWIN
eastern language selected at the NJWIN
®
Tools
®
softkey will access the NJWin® font viewer set up screen.
®
is a font viewing software program that is used to display the proper characters for eastern
®
®
must be loaded on the control and the required
screen. The translated update/operating software must be
loaded onto the control and the required language selected at the special password screen.
Please contact your control vendor for software and information on languages available. NJWIN
registered trademark of NJStar Software Corporation.
®
is a
88 Installation & Setup Guide
Install NJWin
®
Press the Install NJWIN® softkey to install the NJWIN® font viewer software onto the control.
Uninstall NJWin
®
Press the Uninstall NJWIN® softkey to remove the NJWIN® font viewer software from the control.
Example:
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