Hypertherm EdgeTi Instruction Manual

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Page 1

Hypertherm

Shape Cutting Control

Operator’s Manual

Software Version 7.00 for Touch Screen CNCs

Making people and machines more productive through process Automation

Page 2

ISCLAIMER The information in this document is subject to change without notice and should not

be construed as a commitment by Hypertherm Automation Automation

assumes no responsibility for any errors that may appear.

RADEMARKS Hypertherm Automation is a wholly owned subsidiary of Hypertherm

ShapeWizard Gemini™, Voyager™ and Mariner™ are trademarks of Hypertherm Automation. HyperNest

and EDGE® are reg. trademarks of Hypertherm Automation.

, HyperCAD® and HyperNet® are reg. trademarks of Hypertherm

. Hypertherm

, Inc.

Automation. Nester™, APC™ and Sensor™ THC are trademarks of Hypertherm Automation. Command HD3070 HyPerformance™ and HPR130™ are trademarks of Hypertherm Automation. Microsoft Pentium NJWIN Virus Scan Norton AntiVirus™ and Norton Ghost are Trademarks of Symantec™ Corp. HASP

THC and HT 4400® are registered trademarks of Hypertherm®, Inc.

and HD4070® HyDefinition® Plasma are reg. trademarks of Hypertherm®, Inc.

and Microsoft logo are registered trademarks of the Microsoft Corporation.

and Celeron® are registered trademarks of Intel Corporation.

is a registered trademark of NJStar Software Corporation.

is a registered trademark of McAfee Associates, Inc.

is a registered trademark of Aladdin Knowledge Systems Ltd. SERCOS Interface™ is a trademark of SERCOS North America. Indramat™ is a trademark of Bosch Rexroth. Pacific Scientific™ is a trademark of Danaher Motion.

ATENTS Hypertherm Automation CNC products may be covered by one or all of the following

US Patents - US 6772040, US 6622058 or US6359251.

Printed in USA

Page 3

Operator’s Manual I

TABLE OF CONTENTS

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

PC Keyboard Layout......................................................................................................................... 12

Screen Hierarchy........................................................................................................................... 14

Key & Menu Functions...................................................................................................................... 15

Numeric Keypad ...............................................................................................................................17

Help Screen ...................................................................................................................................... 18

Show Contents ..............................................................................................................................18

Find................................................................................................................................................ 18

Main Screen...................................................................................................................................... 19

Preview Window............................................................................................................................ 19

Watch Window...............................................................................................................................19

Shape Manager............................................................................................................................. 19

Files ...............................................................................................................................................19

Part Options...................................................................................................................................19

Setups ...........................................................................................................................................20

View Part/View Sheet....................................................................................................................20

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

Change Consumable..................................................................................................................... 21

Zero Positions................................................................................................................................21

Shape Manager Screen ....................................................................................................................22

Shape Library ................................................................................................................................22

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II Operator’s Manual

Text Editor..................................................................................................................................... 22

Shape Wizard ............................................................................................................................... 22

Teach Trace.................................................................................................................................. 22

Nester............................................................................................................................................ 22

HyperCAD..................................................................................................................................... 23

HyperNEST................................................................................................................................... 23

Evaluation Timer ........................................................................................................................... 23

Files .................................................................................................................................................. 24

Load from Disk.............................................................................................................................. 24

Save to Disk.................................................................................................................................. 24

Download from Host ..................................................................................................................... 24

Upload to Host .............................................................................................................................. 24

Resume Last Part ......................................................................................................................... 24

Show Certain Files........................................................................................................................ 25

Show All Files ............................................................................................................................... 25

Setups Screen .................................................................................................................................. 26

Cutting........................................................................................................................................... 26

Process ......................................................................................................................................... 26

Disable Control ............................................................................................................................. 26

Watch............................................................................................................................................ 26

Password ...................................................................................................................................... 26

Diagnostics ................................................................................................................................... 26

Change to Metric Units/English Units ........................................................................................... 26

Change Consumable........................................................................................................................ 27

New Torch Tip............................................................................................................................... 27

New Electrode............................................................................................................................... 27

Reset Database ............................................................................................................................ 27

Setups........................................................................................................................................... 27

Upload Database .......................................................................................................................... 27

Save Database ............................................................................................................................. 27

SECTION 3: SETUPS.......................................................................................................................... 29

Cutting .............................................................................................................................................. 29

Cut Mode ...................................................................................................................................... 29

Kerf................................................................................................................................................ 29

Kerf Variable / Kerf Value ............................................................................................................. 29

Trial/Cut Speed ............................................................................................................................. 30

Marker 1 / Marker 2 Speed ........................................................................................................... 30

Plate Size...................................................................................................................................... 30

Vent Controls 1 - 50 ..................................................................................................................... 30

Marker Offsets 1 - 12 .................................................................................................................... 30

Dwell Time .................................................................................................................................... 30

Arc Radial Error ............................................................................................................................ 30

Dwell Override .............................................................................................................................. 31

Optional Program Stop ................................................................................................................. 31

EIA I & J Codes............................................................................................................................. 31

EIA F-Code Override .................................................................................................................... 31

Speed +/- Affects F-Codes ........................................................................................................... 31

EIA Decimal Shift .......................................................................................................................... 31

Process Select Override ............................................................................................................... 31

Station Select Override................................................................................................................. 31

Auto Torch Spacing Override ....................................................................................................... 31

G97 Loop Count Prompt............................................................................................................... 31

ESAB Multi Torch Support............................................................................................................ 31

Force G40 Kerf Disable ................................................................................................................ 32

G40 Used in Simple Shapes......................................................................................................... 32

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Operator’s Manual III

Auto Start after APA ......................................................................................................................32

EIA Code 2 Decimal Shift..............................................................................................................32

M17, M18 Used as Cut Codes ......................................................................................................32

M76 Rotary Shortest Path .............................................................................................................32

Show Traverse Segments ............................................................................................................. 32

Retain Skew Adjustment ............................................................................................................... 32

THC Voltage Offset ....................................................................................................................... 32

Process ............................................................................................................................................. 33

Oxy Fuel............................................................................................................................................34

Ignition Time.................................................................................................................................. 35

Low Preheat .................................................................................................................................. 35

High Preheat..................................................................................................................................35

Pierce Time ................................................................................................................................... 35

Moving Pierce Time....................................................................................................................... 35

Creep Time.................................................................................................................................... 35

Primary Torch Up Time ................................................................................................................. 36

Primary Torch Down Time.............................................................................................................36

Pierce Torch Up Time ...................................................................................................................36

Pierce Torch Down Time...............................................................................................................36

Cut Off Time ..................................................................................................................................36

Bleedoff Time ................................................................................................................................ 36

Igniters...........................................................................................................................................36

Preheat During Cut........................................................................................................................ 36

Staged Pierce................................................................................................................................ 36

Plasma .............................................................................................................................................. 37

Purge Time.................................................................................................................................... 38

Pierce Time ................................................................................................................................... 38

Creep Time.................................................................................................................................... 38

Cut Off Time ..................................................................................................................................38

Torch Down Time ..........................................................................................................................39

Arc Off Time ..................................................................................................................................39

Stop Time ......................................................................................................................................39

Retract Delay................................................................................................................................. 39

Set Arc Current.............................................................................................................................. 39

Corner Current Percent .................................................................................................................39

Retry Transfer Fail......................................................................................................................... 39

Transfer Time ................................................................................................................................ 39

Arc on Feedback ........................................................................................................................... 39

Ignition ........................................................................................................................................... 39

Dual Grid/THC............................................................................................................................... 39

Dual Grid/THC Start ...................................................................................................................... 40

Partial Raise ..................................................................................................................................40

Torch Down During Cut................................................................................................................. 40

Torch Down Between Cuts............................................................................................................40

HD3070® Auto Gas Interface ............................................................................................................41

Save Data...................................................................................................................................... 41

Load Data...................................................................................................................................... 41

Test Cutting Gases........................................................................................................................ 42

Test Preflow Gases .......................................................................................................................42

HD3070® Auto Gas I/O.................................................................................................................. 43

Inputs.............................................................................................................................................43

Outputs .......................................................................................................................................... 43

HD4070® and HPR™ Overview........................................................................................................ 44

Cut Chart .......................................................................................................................................45

Material Type................................................................................................................................. 45

Current Settings ............................................................................................................................45

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IV Operator’s Manual

Plasma / Shield Gases.................................................................................................................. 45

Material Thickness ........................................................................................................................ 45

Cut Speed ..................................................................................................................................... 46

Kerf................................................................................................................................................ 46

Set Arc Voltage ............................................................................................................................. 46

Preflow Setting.............................................................................................................................. 46

Cutflow Settings ............................................................................................................................ 46

Preflow Time ................................................................................................................................. 46

Purge Time ................................................................................................................................... 46

Pierce Time................................................................................................................................... 46

Creep Time ................................................................................................................................... 46

Save Process................................................................................................................................ 47

Reset Process............................................................................................................................... 47

Save Cut Charts............................................................................................................................ 47

Load Cut Charts............................................................................................................................ 47

Test Preflow .................................................................................................................................. 47

Test Cutflow .................................................................................................................................. 47

FineLine Overview............................................................................................................................ 49

Cut Chart....................................................................................................................................... 50

Material Type ................................................................................................................................ 50

Current Settings ............................................................................................................................ 50

Plasma / Shield Gases.................................................................................................................. 50

Material Thickness ........................................................................................................................ 50

Cut Speed ..................................................................................................................................... 51

Kerf................................................................................................................................................ 51

Preflow Time ................................................................................................................................. 51

Purge Time ................................................................................................................................... 51

Pierce Time................................................................................................................................... 51

Creep Time ................................................................................................................................... 51

Database Features ....................................................................................................................... 52

Save Process................................................................................................................................ 52

Reset Process............................................................................................................................... 52

Save Cut Charts............................................................................................................................ 52

Load Cut Charts............................................................................................................................ 52

Test Preflow .................................................................................................................................. 52

Test Cutflow .................................................................................................................................. 52

Change Consumable .................................................................................................................... 53

Marker............................................................................................................................................... 54

Marker Interface............................................................................................................................ 54

Ignition Time ................................................................................................................................. 55

Marker On Time ............................................................................................................................ 55

Marker Off Time ............................................................................................................................ 55

Marker Up Time ............................................................................................................................ 55

Marker Partial Up Time ................................................................................................................. 55

Marker Down Time........................................................................................................................ 55

Set Arc Current ............................................................................................................................. 56

Corner Current Percent................................................................................................................. 56

Ignition........................................................................................................................................... 56

Cut Control Used for Marking ....................................................................................................... 56

Marker Down/Up With Each Marker On/Off.................................................................................. 56

Arc On Feedback .......................................................................................................................... 56

Partial Raise.................................................................................................................................. 56

Down On During Mark .................................................................................................................. 56

Down On Between Marks ............................................................................................................. 56

Laser Overview................................................................................................................................. 57

Laser Cut Types Screen ............................................................................................................... 58

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Operator’s Manual V

Test Lifter.......................................................................................................................................58

Purge Time.................................................................................................................................... 59

New Gas Purge Time ....................................................................................................................59

Shutter Time.................................................................................................................................. 59

Power Ramp Time......................................................................................................................... 59

Pierce Time ................................................................................................................................... 59

Pulse On Time............................................................................................................................... 59

Pulse Off Time............................................................................................................................... 60

Creep Time.................................................................................................................................... 60

Beam Off Time .............................................................................................................................. 60

Postflow Time................................................................................................................................ 60

Cut Height......................................................................................................................................60

Pierce Height................................................................................................................................. 60

Lens Cut Position .......................................................................................................................... 60

Lens Pierce Position...................................................................................................................... 60

Pulse Laser Time ..........................................................................................................................60

Pulse Laser Power ........................................................................................................................ 60

Height Control Manual/Automatic .................................................................................................60

IHS in Manual................................................................................................................................ 60

Retract Full/Partial......................................................................................................................... 60

Partial Retract Distance................................................................................................................. 60

Start IHS Distance......................................................................................................................... 61

Preflow During IHS........................................................................................................................ 61

Nozzle Contact IHS .......................................................................................................................61

Nozzle Contact During Cut............................................................................................................ 61

Pierce Control Manual/Automatic.................................................................................................. 61

Pierce Mode Pulse/Blast ............................................................................................................... 61

Pierce Complete............................................................................................................................ 61

Next Pulse .....................................................................................................................................61

Cut Chart .......................................................................................................................................61

Laser Cut Chart Screen .................................................................................................................... 62

Material Type................................................................................................................................. 62

Specific Material ............................................................................................................................62

Process Power .............................................................................................................................. 62

Assist Gas .....................................................................................................................................62

Material Thickness ........................................................................................................................62

Focal Length.................................................................................................................................. 62

Nozzle............................................................................................................................................ 62

Test Gas ........................................................................................................................................ 63

Set Power ...................................................................................................................................... 63

Cut Speed......................................................................................................................................63

Kerf ................................................................................................................................................63

Pierce Height................................................................................................................................. 63

Lens Cut Position .......................................................................................................................... 63

Lens Pierce Position...................................................................................................................... 63

Resonator On Time .......................................................................................................................63

Purge Time.................................................................................................................................... 63

Pierce Time ................................................................................................................................... 63

Pulse On Time............................................................................................................................... 63

Pulse Off Time............................................................................................................................... 64

Creep Time.................................................................................................................................... 64

Pierce Complete............................................................................................................................ 64

Next Pulse .....................................................................................................................................64

Start Corner Power........................................................................................................................ 64

Minimum Corner Power................................................................................................................. 64

Save Process ................................................................................................................................ 65

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VI Operator’s Manual

Rest Process................................................................................................................................. 65

Save Cut Charts............................................................................................................................ 65

Load Cut Charts............................................................................................................................ 65

Pulse Laser Time .......................................................................................................................... 65

Pulse Laser Power........................................................................................................................ 65

Height Control Manual/Automatic ................................................................................................. 65

IHS in Manual ............................................................................................................................... 65

Retract Full/Partial ........................................................................................................................ 65

Partial Retract Distance ................................................................................................................ 65

Start IHS Distance ........................................................................................................................ 65

Preflow During IHS ....................................................................................................................... 65

Nozzle Contact IHS....................................................................................................................... 65

Nozzle Contact During Cut ........................................................................................................... 65

Pierce Control Manual/Automatic ................................................................................................. 66

Pierce Mode Pulse/Blast............................................................................................................... 66

Pierce Complete ........................................................................................................................... 66

Next Pulse..................................................................................................................................... 66

Cut Chart....................................................................................................................................... 66

Water Jet .......................................................................................................................................... 67

Purge Time ................................................................................................................................... 68

Pierce Time................................................................................................................................... 68

Creep Time ................................................................................................................................... 68

Abrasive Off Time ......................................................................................................................... 68

Abrasive Charging ........................................................................................................................ 68

Watch................................................................................................................................................ 69

None.............................................................................................................................................. 69

Input/Output .................................................................................................................................. 70

Position ......................................................................................................................................... 70

Following Error.............................................................................................................................. 70

Command Voltage ........................................................................................................................ 70

Temperature ................................................................................................................................. 70

Speedometer ................................................................................................................................ 70

Oxy Fuel Torch Tip ....................................................................................................................... 70

Plasma Torch Tip.......................................................................................................................... 70

Plasma Electrode.......................................................................................................................... 70

Jog Keys ....................................................................................................................................... 70

Process Data ................................................................................................................................ 70

Laser Nozzle ................................................................................................................................. 71

HPR Power Supply ....................................................................................................................... 71

Multiple Watch Windows............................................................................................................... 71

SECTION 4: SHAPE MANAGER........................................................................................................ 73

Shape Library ................................................................................................................................... 73

Selecting a Simple Shape............................................................................................................. 73

Text Editor ........................................................................................................................................ 74

Show Original Text........................................................................................................................ 74

Delete Part .................................................................................................................................... 74

Shape Wizard ................................................................................................................................... 75

Manual Line Edit ........................................................................................................................... 75

Replace Segment ......................................................................................................................... 76

Insert Before Segment.................................................................................................................. 76

Insert After Segment ..................................................................................................................... 76

Remove Segment ......................................................................................................................... 76

Teach Trace ..................................................................................................................................... 77

Start Corner .................................................................................................................................. 77

Tracing Pitch ................................................................................................................................. 77

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Operator’s Manual VII

Arc Radial Error............................................................................................................................. 78

Auto Closure Detect ...................................................................................................................... 78

Closure Over/Under Lap ...............................................................................................................78

Kerf Direction................................................................................................................................. 78

Traverse/Pierce .............................................................................................................................78

Tracing a part ................................................................................................................................78

Plate Remnant Trace ....................................................................................................................79

Nester™ ............................................................................................................................................ 81

Manual Nesting .................................................................................................................................81

Main Screen Layout ......................................................................................................................81

Add Part.........................................................................................................................................82

Remove Part..................................................................................................................................82

Cut Earlier......................................................................................................................................82

Cut Later........................................................................................................................................ 82

View Sheet / View Part..................................................................................................................82

Arrow Key (Distance) ....................................................................................................................82

Clear Nest......................................................................................................................................82

Setup ............................................................................................................................................. 82

Nester™ Setup..................................................................................................................................83

Arrow Motion ................................................................................................................................. 83

Autoposition................................................................................................................................... 83

Using Nester™.................................................................................................................................. 84

Adding Parts.................................................................................................................................. 84

Saving a Nest ................................................................................................................................86

HyperNest – CNC® Automatic Nesting Software.............................................................................. 87

Main Screen Layout ......................................................................................................................87

Automatic Nesting Setup ..................................................................................................................88

Automatic Nesting ......................................................................................................................... 88

Part Spacing.................................................................................................................................. 88

Plate Edge Spacing....................................................................................................................... 88

Program Origin ..............................................................................................................................88

Cut Direction.................................................................................................................................. 88

Return to Nest Start....................................................................................................................... 88

Using HyperNest – CNC®.................................................................................................................89

Adding Parts.................................................................................................................................. 89

Remove Part..................................................................................................................................91

Nest Summary............................................................................................................................... 92

Main Screen View of Nest ............................................................................................................. 94

HyperCAD®.......................................................................................................................................95

HyperNEST®.....................................................................................................................................96

SECTION 5: FILES ..............................................................................................................................99

Load from Disk.................................................................................................................................. 99

Load from ......................................................................................................................................99

Files ...............................................................................................................................................99

File name/Diskette file name ....................................................................................................... 100

Preview........................................................................................................................................100

Load to.........................................................................................................................................100

Hard drive file name .................................................................................................................... 100

Resume Last Part........................................................................................................................ 100

Show Certain Files ...................................................................................................................... 100

Show All Files.............................................................................................................................. 100

Resume Last Part Features ............................................................................................................101

Rush Job Interrupt.......................................................................................................................101

Automated Power Loss Recovery............................................................................................... 101

Save to Disk .................................................................................................................................... 102

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VIII Operator’s Manual

Save to........................................................................................................................................ 102

File name/Diskette file name ...................................................................................................... 102

Save Original Text ...................................................................................................................... 102

Save from.................................................................................................................................... 102

Files............................................................................................................................................. 103

Hard drive file name.................................................................................................................... 103

Preview ....................................................................................................................................... 103

Save KeyLog to Disk................................................................................................................... 104

Download from Host ....................................................................................................................... 105

Download from............................................................................................................................ 105

Files............................................................................................................................................. 105

Remote file name........................................................................................................................ 105

Preview ....................................................................................................................................... 106

Download to ................................................................................................................................ 106

Local file name............................................................................................................................ 106

Upload to Host................................................................................................................................ 107

Upload to..................................................................................................................................... 107

Remote file name........................................................................................................................ 107

Upload from ................................................................................................................................ 107

Files............................................................................................................................................. 108

Local file name............................................................................................................................ 108

Preview ....................................................................................................................................... 108

Loading Of Invalid Files.................................................................................................................. 109

SECTION 6: LIBRARY SHAPES ...................................................................................................... 111

Rectangle ....................................................................................................................................... 113

Circle............................................................................................................................................... 113

Triangle........................................................................................................................................... 114

L-Bracket ........................................................................................................................................ 114

Trapezoid........................................................................................................................................ 115

Slant Rectangle .............................................................................................................................. 115

Gambrel Rectangle......................................................................................................................... 116

Roofed Rectangle........................................................................................................................... 116

4 Sided Polygon ............................................................................................................................. 117

5 Sided Polygon ............................................................................................................................. 117

Oval ................................................................................................................................................ 118

Circle w/ Flat Side........................................................................................................................... 118

Circle Slice...................................................................................................................................... 119

Straight Slots .................................................................................................................................. 119

Angled Slots ................................................................................................................................... 120

Horizontal Rip ................................................................................................................................. 120

Vertical Rip ..................................................................................................................................... 121

Flange............................................................................................................................................. 121

Circle w/ Rectangular Hole............................................................................................................. 122

Gusset ............................................................................................................................................ 122

8 Sided............................................................................................................................................ 123

Rectangle w/ Convex Corners........................................................................................................ 123

Rectangle w/ Concave Corners...................................................................................................... 124

L-Bracket w/ Elbow Radii................................................................................................................ 124

Slant L-Bracket w/ Elbow Radii ...................................................................................................... 125

Trapezoid w/ Convex Corners........................................................................................................ 125

Flange Slice.................................................................................................................................... 126

Elbow.............................................................................................................................................. 126

Flange Repair Ring......................................................................................................................... 127

Rectangle w/ Rectangular Hole...................................................................................................... 127

Rectangle w/ Circular Hole............................................................................................................. 128

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Operator’s Manual IX

Rectangle w/ Circular Hole and Convex Corners ........................................................................... 128

Rectangle w/ Tab ............................................................................................................................129

Rectangle w/ Convex Tab............................................................................................................... 129

Rectangle w/ Notch.........................................................................................................................130

Rectangle w/ Slant Notch................................................................................................................130

Rectangle w/ Radius Notch.............................................................................................................131

Convex Rectangle........................................................................................................................... 131

Concave Rectangle......................................................................................................................... 132

Triangle w/ Concave Side ............................................................................................................... 132

Polygon w/ Concave Side ............................................................................................................... 133

Slant Rectangle with Radius ........................................................................................................... 133

Slant Rectangle with Circular Hole .................................................................................................134

Slant Rectangle w/ Beveled Corners ..............................................................................................134

Cross...............................................................................................................................................135

Cross w/ Circular Hole and Concave Inside Corners .....................................................................135

4 Sided Convex Rectangle .............................................................................................................136

4 Sided Concave Rectangle ........................................................................................................... 136

Pipe Mount...................................................................................................................................... 137

Bolt Hole Circle ............................................................................................................................... 137

Bolt Hole Flange .............................................................................................................................138

Bolt Hole Rectangle ........................................................................................................................ 138

Bolt Hole Rectangle w/ Convex Corners ........................................................................................139

Bolt Hole Rectangle w/ Center Hole ............................................................................................... 139

Bolt Hole Rectangle w/ Center Hole and Convex Corners .............................................................140

Rounded L-Bracket .........................................................................................................................140

Horseshoe.......................................................................................................................................141

Convex Roof Trapezoid w/ Hole .....................................................................................................141

Convex Roof Polygon w/ Hole ........................................................................................................142

Convex Roof Polygon w/ Oval Hole and Concave Bottom............................................................. 142

Pulley Cover.................................................................................................................................... 143

Paddle Blind.................................................................................................................................... 143

Water Pump Gasket........................................................................................................................ 144

Frame..............................................................................................................................................144

Pulley ..............................................................................................................................................145

Sprocket .......................................................................................................................................... 145

Text ................................................................................................................................................. 146

Test Pattern.....................................................................................................................................146

SECTION 7: PART OPTIONS ...........................................................................................................147

Scale Factor ................................................................................................................................147

Rotate Angle................................................................................................................................ 147

Mirror X/Mirror Y.......................................................................................................................... 147

Kerf ..............................................................................................................................................148

Repeat.............................................................................................................................................149

Straight Repeat ...........................................................................................................................149

Repeat Type................................................................................................................................ 149

Start Corner................................................................................................................................. 149

Number of Rows.......................................................................................................................... 149

Number of Columns ....................................................................................................................149

X Pattern Offset/Y Pattern Offset ................................................................................................149

Scrap Clearance.......................................................................................................................... 150

X Nest Distance/Y Nest Distance................................................................................................150

Staggered Repeat ....................................................................................................................... 150

Nested Repeat ............................................................................................................................151

Pattern Offsets ............................................................................................................................151

Nest Distance ..............................................................................................................................151

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X Operator’s Manual

Instructions for use...................................................................................................................... 152

Corner to Align with..................................................................................................................... 153

Scrap Clearance ......................................................................................................................... 153

Skew Adjustment ........................................................................................................................ 153

Skew Reference.......................................................................................................................... 153

At Corner..................................................................................................................................... 153

At Skew Point.............................................................................................................................. 153

Automatic Plate Alignment (APA)................................................................................................... 154

Five Point Align ........................................................................................................................... 154

Three Point Align ........................................................................................................................ 156

Program Code............................................................................................................................. 156

SECTION 8: CUTTING ...................................................................................................................... 159

Speed Increase........................................................................................................................... 160

Speed Decrease ......................................................................................................................... 160

Repeats....................................................................................................................................... 160

Cut Delay Timers ........................................................................................................................ 160

Extend......................................................................................................................................... 161

Set Now ...................................................................................................................................... 161

Release....................................................................................................................................... 161

Multitasking ................................................................................................................................. 162

SECTION 9: PAUSE.......................................................................................................................... 163

Return to Start............................................................................................................................. 163

Backup and Forward on Path ..................................................................................................... 163

Move to Pierce ............................................................................................................................ 164

Change Cut Mode....................................................................................................................... 164

Change Move Speed .................................................................................................................. 164

Change Consumable .................................................................................................................. 164

On-Path Restart .......................................................................................................................... 164

Return to Path............................................................................................................................. 165

Move Part.................................................................................................................................... 165

Off-Path Restart .......................................................................................................................... 165

Rush Job Interrupt ...................................................................................................................... 166

Change Consumable...................................................................................................................... 166

Overview ..................................................................................................................................... 167

Minutes per Pierce ...................................................................................................................... 167

Arc Errors.................................................................................................................................... 167

Volts per Minute .......................................................................................................................... 168

Last Torch Tip Installed............................................................................................................... 168

Last Electrode Installed............................................................................................................... 168

New Torch Tip............................................................................................................................. 168

New Electrode............................................................................................................................. 168

Setups......................................................................................................................................... 168

Reset Database .......................................................................................................................... 168

Upload Database ........................................................................................................................ 168

Save Database ........................................................................................................................... 168

SECTION 10: MANUAL .................................................................................................................... 169

Return to Start............................................................................................................................. 170

Move Distance ............................................................................................................................ 170

Cut Distance ............................................................................................................................... 170

Manual Options........................................................................................................................... 171

Home Axes ................................................................................................................................. 171

View Sheet/View Part ................................................................................................................. 171

Change Manual Mode................................................................................................................. 172

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Operator’s Manual XI

Change Move Speed...................................................................................................................172

Zero Positions..............................................................................................................................173

Rip Cutting...................................................................................................................................173

Manual Options............................................................................................................................... 173

Raise Torch .................................................................................................................................173

Lower Torch.................................................................................................................................173

Manual Offset ..............................................................................................................................174

Adjust Dual Gantry Skew ............................................................................................................174

Home Axes......................................................................................................................................175

Transverse...................................................................................................................................175

Rail ..............................................................................................................................................175

CBH .............................................................................................................................................176

THC .............................................................................................................................................176

Tilt................................................................................................................................................176

Rotate .......................................................................................................................................... 176

All................................................................................................................................................. 176

Go To Home Position ..................................................................................................................176

APPENDIX A: SENSOR™ THC ........................................................................................................177

Sensor™ Torch Height Control Overview....................................................................................... 177

Cut Setups ...................................................................................................................................... 178

THC Voltage Offset ..................................................................................................................... 178

Plasma Setups................................................................................................................................ 179

Test Lifter.....................................................................................................................................179

Retract Delay............................................................................................................................... 180

Auto Voltage Set .........................................................................................................................180

Set Arc Voltage ...........................................................................................................................180

Voltage Control............................................................................................................................ 180

Ignition Output .............................................................................................................................181

IHS in Manual.............................................................................................................................. 181

Retract Full/Partial....................................................................................................................... 181

Skip IHS Within............................................................................................................................181

Preflow During IHS...................................................................................................................... 181

Early Preflow if Skip IHS .............................................................................................................181

Nozzle Contact IHS .....................................................................................................................181

Nozzle Contact During Cut..........................................................................................................181

Offset IHS .................................................................................................................................... 181

Auto Kerf Voltage Change...........................................................................................................182

Kerf Detect Reacquire Time ........................................................................................................182

Marker Setups................................................................................................................................. 183

Test Lifter.....................................................................................................................................183

Purge Time.................................................................................................................................. 183

Start Time .................................................................................................................................... 183

Sample Voltage ...........................................................................................................................183

Set Arc Voltage ...........................................................................................................................183

Voltage Control............................................................................................................................ 184

IHS in Manual.............................................................................................................................. 184

Retract Full/Partial....................................................................................................................... 184

Skip IHS Within............................................................................................................................184

Preflow During IHS...................................................................................................................... 184

Nozzle Contact IHS .....................................................................................................................184

Process Watch................................................................................................................................ 185

Input/Output................................................................................................................................. 185

Position........................................................................................................................................185

Plasma Process ..........................................................................................................................185

Main Cut Screen ............................................................................................................................. 186

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XII Operator’s Manual

Automatic THC Mode.................................................................................................................. 186

APPENDIX B: COMMAND® THC...................................................................................................... 187

Clear Error .................................................................................................................................. 187

Purge Time ................................................................................................................................. 188

Pierce Time................................................................................................................................. 188

Creep Time ................................................................................................................................. 188

Arc Off Time................................................................................................................................ 189

Stop Time.................................................................................................................................... 189

Accel Delay ................................................................................................................................. 189

Retract Delay Time ..................................................................................................................... 189

Ignition......................................................................................................................................... 189

Voltage Control ........................................................................................................................... 189

Retract Full/Partial ...................................................................................................................... 189

Retry On Transfer Fail ................................................................................................................ 189

Transfer Time.............................................................................................................................. 189

Set Arc Current ........................................................................................................................... 189

Corner Current Percent............................................................................................................... 189

Set Arc Voltage ........................................................................................................................... 189

Homing Speed ............................................................................................................................ 190

Nozzle Ohmic Contact ................................................................................................................ 190

Preflow During IHS ..................................................................................................................... 190

Main Cut Screen............................................................................................................................. 191

Automatic THC Mode.................................................................................................................. 191

Extend......................................................................................................................................... 191

Set Now ...................................................................................................................................... 191

Release....................................................................................................................................... 191

Manual THC Mode...................................................................................................................... 192

Extend......................................................................................................................................... 192

Set Now ...................................................................................................................................... 192

Release....................................................................................................................................... 192

Diagnostics ..................................................................................................................................... 192

APPENDIX C: AUTOMATIC DXF IMPORT ...................................................................................... 193

DXF Import Overview ..................................................................................................................... 193

Raw DXF Files................................................................................................................................ 194

Lead Type ................................................................................................................................... 194

Length / Radius........................................................................................................................... 194

Angle........................................................................................................................................... 194

Auto Position Lead In.................................................................................................................. 194

Auto Corner Align Lead In .......................................................................................................... 194

Inside Lead Out........................................................................................................................... 195

Overburn ..................................................................................................................................... 195

Prepared DXF Files ........................................................................................................................ 196

Drawing Format .......................................................................................................................... 196

Text Commands.......................................................................................................................... 196

Directional Commands................................................................................................................ 197

Page 15

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 touch screen, front panel keys or remote interface.

Loose fitting clothing or ties may become entangled in the machinery. These items should not be worn while operating or servicing the machine.

High Voltages

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

Avoid contact with electrical wires and cabling while power is on.

This equipment should only be opened by trained service personnel.

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

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2 Operator’s Manual

Product Listings

Type “M” and “P” Controls

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

Standards.

UL has successfully tested and listed the type “ M” and ”P” 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

Page 17

Section 2: Overview 3

Section 2: Overview

Introduction

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

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

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

You can graphically key in part programs directly using ShapeWizard waiting for delivery, set-up, and alignment of templates. Or you can select any of 68 shapes from the parametric shape library. Using a host computer or CAD/CAM system, you can also download custom part programs easily. We even supply you at no-charge a communications package to tie the control to the rest of your management information. Whatever method is used, the control, with its advanced graphical user interface (GUI), shortens set-up time, speeds productivity and simplifies scheduling.

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

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

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

microprocessor to your positioning table. With both a

on the front panel, without

and the Microsoft Foundation

ShapeWizard®

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

Teach/Trace

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

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4 Operator’s Manual

Shape Libraries

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

Program Upload and Download

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

SoftMotion

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

Processor. This architecture allows SoftMotion

Cutting Options

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

Mirror function

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

Rotate function

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

Scale function

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

Repeat function

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

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Section 2: Overview 5

Programming Features

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

Dynamic Kerf compensation with programmable kerf value.

Automatic Corner and Plate Alignment with programmable scrap clearance.

Shape Repeat with three grid patterns (straight, stagger, and nested) allows fast cutting of multiple pieces.

Part mirroring in both X and Y axes.

Part rotation.

Scaling allows quick part resizing to original size.

Virtually no limit to the number of program names or workfile folders that can be stored on the internal hard disk drive.

Punch or powder marker control with twelve programmable offsets.

Choice of industry-standard EIA RS-274D or ISO 6582 ESSI Part Programming Languages.

Manual Data Input (MDI)

Full screen ASCII text editor.

Allows writing, editing, and graphical review of part programs at the machine.

Communications Link

Preview Mode allows machine operator to graphically review and select programs for download.

Download part programs from CAD system, remote host computer, or other storage device via built-in RS-232C/ RS-422 port.

Can accept EIA RS-274D or ESSI part programs.

Baud Rates of up to 115K Baud. Communication baud rates of 230K are obtainable using the communication link software provided with the control.

Optional Network Card for connecting directly to a PC Network for part file allocation.

Graphical program display

Visually display any part program.

Display of real-time position and I/O information.

Display of actual cut path while cutting.

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6 Operator’s Manual

Built-in Parametric Shape Library

Contains 68 commonly used shapes.

Simple Graphical prompts for entering all part dimensions.

Teach/Trace

Smart-arc and Smart-Line algorithms for optimum program size and contouring smoothness.

Converts your existing optical tracer templates to EIA RS-274D programs, and stored on the internal hard disk drive.

Automatic part closure detection.

Allows multiple pierce points, lead-ins, lead-outs, and rapid traverse segments.

Upload taught part programs to CAD system, remote host computer, or other storage device.

Requires a separate optical tracer control system.

Performance Features

Digital servo positioning control for any cutting machine. An optional SERCOS Interface™ allows expansion of motion axes and distributed I/O.

Control dynamic accuracy of 0.002 inch (0.051 mm) with 1000 edge/inch encoders.

Programmable cut speeds up to 3000 IPM (76,200 mmpm).

Variable segment length look ahead for optimum contouring performance.

Automatic corner slowdown and torch height disable for clean, sharp corners.

Speed Increase/Decrease buttons for optimizing machine cut speed.

Automatic Plate and Corner Alignment corrects for skewed plates.

Complete cut-loss recovery with backup and forward along path, off-path re-pierce and return-to-path, and move pattern functions.

Rip Mode for straight-line cutting. Jog control cutting.

Punch, powder or Plasma marker capability.

Manual jog control with position read-out for positioning torches.

Manual Nester™ and optional HyperNest productivity and increased plate utilization.

Automated Torch Spacing feature to position torch station spacing automatically through the part program for standard and mirrored multi-torch cutting.

Rush Job Interrupt and Automated Power Loss Recovery features.

– CNC Automatic Nesting features for increased

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Section 2: Overview 7

Installation and Setup Features

Selectable axis orientation for compatibility with all cutting machines.

Built in oxy-fuel interface with programmable pre-heat time, ignition, and creep speed.

Built in plasma interface with programmable purge time, ignition time, arc-off delay time, and arctransferred feedback.

Built in Laser interface with programmable shutter time, power ramp time and pierce time.

Built in Waterjet interface with programmable abrasive output and pierce time.

Programmable servo gains, speeds, Watch Window, machine parameters, and communication parameters for flexible application.

Interfaces easily to most optical tracing systems for integrated control.

Complete built-in diagnostics for checkout and test.

Hardware Specifications

15” TFT Touch Screen with 1024 x 768 resolution.

≥60Gbyte hard disk

≥1.3 GHz Processor.

512 Mbytes of RAM.

Up to 96 lines of interface signals for cutting and motion logic (gas control, tracing system, markers, homing, etc.) depending on I/O configuration. An optional SERCOS Interface™ allows expansion of I/O configuration.

Industrial grade enclosure and keypad designed to minimize RFI/EMI interference.

Surface mount printed circuit board technology.

Two axes optically isolated ±10VDC drive outputs and incremental encoder inputs which are expandable to 6 axes of motion. Up to twelve axes of motion and 1024 I/O available with optional SERCOS Interface™. Optional axes available for dual gantry, dual transverse, contoured bevel head, two rotate, two tilt angle and eight Sensor™ THC applications.. +5VDC single ended or differential encoder inputs.

Optically isolated serial ports with programmable baud rates to 115 K baud. Communication baud rates of 230K are obtainable using the communication link software provided with the control. Optional Network Card for connecting directly to a PC Network.

Universal power input (100-240 VAC; 47-63Hz). Individual models may vary. Refer to machine interface information for details.

Operating environment: 0 to 50°C (32 to 122°F); 95% relative humidity (non-condensing).

An optional Chiller for Mariner style controls is available.

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8 Operator’s Manual

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:

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 D = Edge Ti - DC amps

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 4 = 12.1" Active Matrix TFT

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 = Laser 2 = Plasma

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 7 = 3.06 GHz 8 = 1.3 GHz M

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Section 2: Overview 9

Front Panel Layout

This software is designed specifically for 15” TFT Touch Screen operation with 1024 x 768 or higher resolution and is used on all CNC models. Individual man machine interface (MMI) and front panels may vary.

Power Switch

Hypertherm Automation controls are equipped with a momentary contact power switch. Press briefly and release for controlled power on and power off the control. Pressing the power switch for 10 seconds will force a hard system shutdown of Windows and the control. Generally, a hard shutdown is not recommended.

Touch Screen

The touch screen software interface allows direct key input on the screen through the use of check boxes, radial boxes, drop down selections and data input. Data input boxes will automatically display a numeric or alphanumeric keypad depending on data type.

Front Panel (selected models)

ICON Legend

Emergency Stop

Start

Stop

Forward and Backward on Path

Torch Up / Down

Manual

Speed Pot (Manual Feedrate)

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10 Operator’s Manual

Front Panel Keypad (selected models)

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.

Key Functions

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

n alternate (ALT) soft key indicates that more soft keys and features are available by pressing this soft key on screen.

When the alternate soft key is displayed, the purple shift can also be used to view additional soft keys.

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Section 2: Overview 11

These keys activate jogging using the arrow keys when in the manual mode. Manual key functions (indicated in green) are available at the Manual, Pause and Align Screens. This keypad is also used for navigating through a multi-variable dialog box (indicated in yellow).

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

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

Deletes the current character in the data entry field and backs up one position in the field. Located above the Back Space key are the * and ? characters which are used as wild cards to search for files.

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

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

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12 Operator’s Manual

PC Keyboard Layout

Available as standard on selected models but may be added to all controls.

Keyboard Functions Function Keys F1-F8 are equivalent to the soft keys on the display screen. Function Key F9 is equivalent to the START key. Function Key F10 and Pause Key are equivalent to the STOP key. Function Key F11 is equivalent to the MANUAL MODE key. Function Key F12 is equivalent to the HELP key. Arrow direction keys are used for manual motion. The HOME key is equivalent to the PREV field key. The END key is equivalent to the NEXT field key. The [ key is equivalent to the purple arrow shift key. The ] key is equivalent to the blue arrow shift key. The Esc key is equivalent to the CANCEL key. To exit the control software press Alt F4. Warning: This will terminate the current application. To switch between applications press Alt Tab. Warning: The selected application window to be on top of the desktop and may cover or hide the control software application window.

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Section 2: Overview 13

Optional USB Front Panel (selected models)

ICON Legend

Single station torch selection. Upper switch position is automatic operation. Center switch position is OFF. Lower switch position is manual operation.

Manual Raise and Lower of selected station.

Manual ignition of torch.

Manual High Preheat.

Manual Low Preheat

Manual Cut Oxygen

All stations UP.

Automatic plate sensing (IHS) for pre-selected stations

Speed Pot

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14 Operator’s Manual

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

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

The OK and CANCEL keys have special functions in relation to the menu structure. The OK soft 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

Cut

Pause

Change Consumable

Manual Options

Load from Disk

Save to Disk

Save Log to Disk

Download from Host

Upload to Host

Cut Chart

Change Consumable

Manual Options

Manual

Manual Options

Home Axes

Part OptionsFiles

Repeat

Align

Manual Options

Setups

Cut Types Password 1Diagnostics

Oxy Fuel

Timing Diagram

Water Jet

Timing Diagram

Plasma

Timing Diagram

Cut Chart

Marker

Timing Diagram

Cut Chart

Laser

Timing Diagram

Cut Chart

Process Monitoring

Shape Manager

Shape Library

Simple Shape

View Text

Part Options

Repeat

Align

Manual Options

Control Information

I / O

Inputs

Outputs

Analog Inputs

Keyboard

USB Front Panel

Serial Port

Drives and Motors

Plasma System

Inputs

Outputs

Supply Information

Nester

Nester Setups

Load from Disk

Download from Host

Shape Library

Simple Shape

Speeds

Link

I/O

Sercos

Axes

Transverse

Rail

Dual Gantry

CBH

Tilt

Rotate

THC

Lens

Shape Wizard

Part Options

Repeat

Align

Manual Options

Cutting

WatchMachine

Password 3

Station Configuration

Password 2

System Tools

Backup Hard Drive

Scan Hard Disk

Defrag Hard Disk

Format Floppy Disk

Network Tools

Remote Assistant

Text Editor

Teach Trace

HyperCAD

HyperNest

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Section 2: Overview 15

Key & Menu Functions

The following is a short form description of all menu functions in the control. This is only a brief description of each function. Please consult the subsequent manual sections for more complete information on operational usage of specific keys. Note: Screens and features will vary depending on interface selection of Beginner, Intermediate or Advanced.

Screen Navigation

The eight keys located directly at the bottom of the display act as programmable soft keys. Soft keys allow many different functions to be included without an excessive number of separate keys. It also provides complete flexibility for future software features and enhancements.

Soft keys to accept (OK) and reject (Cancel) changes.

An alternate (ALT) ICON at the left or right edge of the soft keys indicates that that more soft keys and features are available by pressing this softkey.

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16 Operator’s Manual

The touch screen software interface allows direct key input on the screen through the use of check boxes, radial boxes, drop down selections and data input.

Pull Down Box (note arrow at left)

Press the arrow box to pull down and view selections.

Radial Button

Press the round box to select.

Check Box

Press the square box to enable.

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Section 2: Overview 17

Data Input

Data input boxes will automatically display a numeric or alphanumeric keypad depending on data type. Double click on the field to enter data.

Alpha Numeric Keypad

Numeric Keypad

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18 Operator’s Manual

Help Screen

This controller is equipped with an easy to follow help screen function. To access the internal help screens press the Help soft key. Help information for the screen currently being accessed will be displayed. Pressing the OK soft key will exit the help screens and return you to the last control screen accessed.

Show Contents

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

Find

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

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Section 2: Overview 19

Main Screen

This is the top most screen and the first available screen at power up.

Preview Window

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

Watch Window

This is the right part of the screen where such things as the speedometer, positions, cut mode and time are displayed. This part of the screen is configurable through the setups. Up to 10 different Watch Windows are available for viewing during use.

Shape Manager

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

Files

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

Part Options

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

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20 Operator’s Manual

Setups

This soft key takes you to the setup screens.

View Part/View Sheet

View Part allows the viewing of the entire current part in the Preview Window.

View Sheet allows the viewing of a part as it would appear on the plate. After pressing the View Sheet soft key, the display window zooms out to show the part in relationship to the entire plate.

Zoom +/- soft keys are available to change zoom level.

After zooming out, the display can be zoomed in again by pressing the + key, which causes horizontal and vertical scroll bars to be displayed. Pressing the - key will zoom back out.

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Section 2: Overview 21

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

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

Change Cut Mode

Allows selection of Trial, Oxy Fuel, Plasma, Waterjet and Laser cutting modes, depending on the setup configuration.

Change Consumable

This soft key takes you to the Change Consumable screen.

Zero Positions

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

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22 Operator’s Manual

Shape Manager Screen

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

Shape Library

Brings up the built-in library of 68 simple shapes.

Text Editor

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

Shape Wizard

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

Teach Trace

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

Nester

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

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

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

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Section 2: Overview 23

HyperCAD

The optional HyperCAD

feature is an easy to use 2D drawing application specifically designed for shape cutting. The software’s powerful CAD utilities let users import DXF and CNC files or draw from scratch. Files can be converted to graphical parts for editing and saving or go directly to cutting.

HyperNEST

The optional HyperNEST allow quick and simple nesting of profiles onto standard material sizes. With its advanced Graphical User Interface, HyperNEST

feature is a full featured, automatic true shape application designed to

greatly improves the output of any shape cutting operation.

Evaluation Timer

Trail version software will prompt the user with a notification of the number of “uses” left at each launch. To enable unlimited use, a password would be provided by the control vendor.

To launch the trial software, select the Evaluation Version.

Example:

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24 Operator’s Manual

Files

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

Load from Disk

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

Save to Disk

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

Download from Host

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

Upload to Host

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

Resume Last Part

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

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Section 2: Overview 25

Show Certain Files

This soft key allows the operator to show only certain files from the selected directory. Both the asterisk and question mark may be used in defining the files to show.

Keypad operation: The asterisk is generated by holding down the left shift key and pressing the backspace key. The question mark is generated by holding down the right shift key and pressing the backspace key.

Show All Files

This soft key allows the operator to undo the Show Certain Files from above.

Note: An optional Network Card for connecting directly to a PC Network for part file allocation is available.

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26 Operator’s Manual

Setups Screen

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

Cutting

Allows programming of the different cutting parameters and dwell times.

Process

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

Disable Control

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

Watch

Allows programming of the user definable Watch Window.

Password

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

Diagnostics

Enters the diagnostics menu.

Change to Metric Units/English Units

Changes all parameters over to metric units or English units.

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Section 2: Overview 27

Change Consumable

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

New Torch Tip

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

New Electrode

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

Reset Database

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

Setups

Pressing the Setups soft key accesses the control setups for adjustment of the cut process.

Upload Database

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

Save Database

This soft key is used to save the current database to the Diskette or USB memory stick.

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Section 3: Setups 29

Section 3: Setups

Cutting

When entering the Setup menu the operator can adjust the following run-time parameters for Trial Mode (no cutting), Oxy-Fuel, Plasma, Waterjet and Laser cutting.

Cut Mode

Specifies the current cut mode. Trial mode allows the operator to dry-run the current part program without cutting.

Kerf

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

Kerf Variable / Kerf Value

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

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This Kerf Variable can then be used within a part program to define the kerf value when cutting. The advantage to this is that as torch parts wear, the kerf value changes. If the Kerf Variable value is updated as the consumable wears and changes, the new value will be called by the Kerf Variable command with all programs loaded that use the variable.

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

Example: G43

D1 X0.06

Kerf Variable Setting

Kerf Variable

A number from 1-200 may be used

Kerf Data

The selected kerf value

Trial/Cut Speed

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

Marker 1 / Marker 2 Speed

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

Plate Size

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

Vent Controls 1 - 50

Enter in values for up to fifty programmable zones for fume extraction damper control. Based on the machine position the vent control outputs to activate dampers at the selected zone for increased performance.

Marker Offsets 1 - 12

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

Dwell Time

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

Arc Radial Error

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

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Dwell Override

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

Optional Program Stop

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

EIA I & J Codes

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

EIA F-Code Override

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

Speed +/- Affects F-Codes

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

EIA Decimal Shift

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

Process Select Override

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

Station Select Override

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

Auto Torch Spacing Override

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

G97 Loop Count Prompt

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

ESAB Multi Torch Support

When enabled this feature allows ESAB style ESSI part programs to map codes to specific station selects.

Mapped ESSI CODE

EIA CODE Description 7 M37 T1 Select Station 1 8 M38 T1 Deselect Station 1 13 M37 T2 Select Station 2 14 M37 T2 Deselect Station 2 15 M37 T3 Select Station 3 16 M38 T3 Deselect Station 3

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Force G40 Kerf Disable

In a part program Kerf is enabled and disabled using EIA G41/ G42 and G40 codes. Standard operation is to disable Kerf at the cut off even if the G40 Kerf Disable is not in a program. With this parameter, you can select to turn off the “forced” G40 Kerf Disable if no G40 is used in the program by setting the parameter to a “Disable” state.

G40 Used in Simple Shapes

Used in conjunction with the Force Kerf Disable parameter this allows the G40 code normally inserted in to a Simple Shape from the control Shape library to be omitted by setting the parameter to a “Disable” state.

Auto Start after APA

Used with the Automatic Plate Alignment feature, this allows the user to select to automatically begin cutting after completion of the Automatic Plate Alignment.

EIA Code 2 Decimal Shift

Some programming styles are structured so that the decimal point in the EIA positioning affecting part sizing is assumed. The EIA Code 2 Decimal Shift parameter allows the operator to select the location of the decimal point when translating parts by selecting normal or single for correct translation. The selection should be set to Normal unless your part programs require two decimal shift to the right of the decimal point.

M17, M18 Used as Cut Codes

This allows the EIA-274D M17 and M18 codes to be used for cut on and off commands when enabled.

M76 Rotary Shortest Path

When enabled, this allows the EIA-274D M76 Rotate go to Home command to select shortest path. When disabled it allows motion by longest path when homing. This is advantageous for some bevel head designs.

Show Traverse Segments

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

Retain Skew Adjustment

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

THC Voltage Offset

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

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Section 3: Setups 33

Process

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

Example:

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

Additionally, each cut type has the ability to save and load the process setups in a file on the hard drive or to a floppy Diskette or USB memory stick. Pressing the ALT key allows the Save Data and Load Data functions to be available.

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Oxy Fuel

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

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

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Press the Timing Diagram soft key to view the timing diagram from setups.

Ignition Time

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

Low Preheat

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

High Preheat

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

Pierce Time

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

Moving Pierce Time

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

Creep Time

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

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Primary Torch Up Time

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

Primary Torch Down Time

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

Pierce Torch Up Time

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

Pierce Torch Down Time

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

Cut Off Time

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

Bleedoff Time

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

Igniters

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

Preheat During Cut

Specifies whether the Preheat will be left on while cutting.

Staged Pierce

This unique feature works with selected outputs to perform the pierce in a staged progression of gas pressures.

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Plasma

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

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Press the Timing Diagram soft key to view the timing diagram from setups.

Purge Time

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

Pierce Time

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

Creep Time

Cut Off Time

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

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

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

Torch Down Time

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

Arc Off Time

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

Stop Time

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

Retract Delay

Retract Delay specifies the amount of time X/Y and lifter motion will pause at the end of a cut. This allows the cut process to finish before lifting the torch and moving to the next pierce.

Set Arc Current

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

via the serial link. EIA RS-274D part

program code G59 Vvalue Fvalue for setting current is supported.

Corner Current Percent

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

via the serial link.

Retry Transfer Fail

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

Transfer Time

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

Arc on Feedback

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

Ignition

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

Dual Grid/THC

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

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Dual Grid/THC Start

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

Partial Raise

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

Torch Down During Cut

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

Torch Down Between Cuts

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

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HD3070® Auto Gas Interface

This section outlines information specific to Hypertherm’s HD3070® Auto Gas Interface. The Auto Gas screen is available from the Cut Types screen.

Note: The Auto Gas feature must first be enabled at the Special Password screen and is designed for use with the six valve autogas console only

The top of the Auto Gas screen lists the valve parameter settings for the HD3070 the 3070

Auto Gas console are documented in the HD3070® manual. When the values are set,

. Valve settings for

these become the current setting and the operator can choose to save the file to the diskette, USB memory stick or hard drive.

The settings at the supply are updated at control power up, whenever the settings are changed at this screen or through commands in a part program Supply settings are also updated if power is lost and re-enabled at the power supply. There may be a brief delay as these power supply settings are communicated from the control to the power supply.

Save Data

Pressing the Save Data soft key will allow the operator to save the current Auto Gas setting to diskette, USB memory stick or hard drive for future use.

Load Data

Pressing the Load Data soft key will allow the operator to Load stored Auto Gas settings from diskette, USB memory stick or hard drive for use.

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If you save the data, a file is created with G59 codes with the selected valve settings. Here is an example of the data file where all percentages are set to zero.

G59 V65 B0 G59 V66 B0 G59 V67 B0 G59 V68 B0 G59 V69 B0 G59 V70 B0 G59 V71 B0

Test Cutting Gases

Pressing the Test Cutting Gases soft key allows the operator to test the HD3070

Cut Gases.

Test Preflow Gases

Pressing the Test Preflow Gases soft key allows the operator to test the HD3070

Preflow Gases.

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HD3070

The Interface to the HD3070

Auto Gas I/O

Auto Gas console is made through of Single Ended and BCD (Binary Coded Decimal) inputs. The BCD style of interface allows for exact settings by use of multiple inputs being active at any time. The active BCD inputs values are summed together to obtain the exact set point.

These I/O points are wired in the same fashion as our other Single Ended I/O points. The following I/O points are supplied for use of the HD3070

Auto Gas Console

Inputs

Gas Control Read Complete Gas Control Error

Outputs

Gas Control Write Remote Test Operate Remote Test Preflow Remote Air Plasma Remote H35/ N2 Plasma Remote O2 Plasma Gas Flow Set 1-100 (BCD) Valve Select 1-8 (BCD)

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HD4070® and HPR™ Overview

The Mariner ™ and Voyager III™ controls offer the additional option of interfacing directly to Hypertherm’s HD4070

HyDefinition®, HPR130™ and HPR260™ Plasma Supplies for setup. This feature has the ability to improve power supply setup and operational accuracy while having the flexibility to fine tune the process specific to the operator’s needs.

When using this advanced feature, all necessary power supply settings are transmitted from the control directly to the Plasma Supply configuring it for use via serial communications. The Plasma Supply setup is performed through the use of a Cut Chart (cut process parameter database) which is based on eight process variables. The combination of these eight process variables are tied to the settings for the cut process parameters (e.g. arc voltage, pierce delay, etc.) that are transmitted to the supply. For additional convenience, consumable part numbers for the Plasma supply are displayed at the Change Consumable screen.

This database allows the user to select factory recommended settings or amend the database for personalized settings. The Cut Chart information may be saved or loaded via the hard drive or floppy drive. The Cut Chart files containing the factory recommended settings are available from Hypertherm

Access to the Cut Chart data is available from the Plasma Cut Types or Marker Cut Types screen using the shift key, as indicated below. The Plasma Supply parameters must first be enabled in the password protected Station Configuration setups to allow the Cut Chart Information for the Plasma Supply to be available for use.

Note: Screen information will vary depending on THC selection.

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Cut Chart

The Cut Chart Database (cut process parameters) transmitted to the power supply is based on the following eight process variables.

Material Type

The Material Type, such as Mild Steel, Stainless Steel or Aluminum, may be selected.

Current Settings

The appropriate current setting for the material thickness and material type may be selected.

Plasma / Shield Gases

The appropriate Plasma / Shield gases for the desired process may be selected.

Material Thickness

The desired material thickness may be selected.

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The following are the Cut Process parameters within the database which are used to configure the process. Appropriate parameter information is transmitted to the power supply.

Cut Speed

Specifies the speed for the selected process variables.

Kerf

Specifies the amount of kerf (cutter compensation) that will be applied to the current part program.

Set Arc Voltage

The operator may input the desired Arc Voltage for the material being cut.

Cut Height

The Cut Height setup parameter is used to select the desired cut distance from the plate.

Pierce Height

The Pierce Height setup parameter is used to select the desired Pierce Height. This may be entered as a multiplication factor that is calculated times the Cut Height or an actual Pierce Height distance.

Preflow Setting

The appropriate Plasma / Shield Preflow percentages for the desired process may be selected.

Cutflow Settings

The appropriate Plasma / Shield Cutflow percentages for the desired process may be selected.

Preflow Time

Specifies the amount of time the Preflow gases are on.

Purge Time

Specifies the time delay from torch ignition until motion is enabled.

Pierce Time

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

Creep Time

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Save Process

Pressing the Save Process soft key allows the user to save the current process settings to the Hard drive creating a custom user database based on the eight process variables selected.

Reset Process

Pressing the Reset Process soft key allows the user to reset the current settings to factory recommend factory defaults based on the eight process variables selected.

Save Cut Charts

Pressing the Save Cut Charts soft key allows the user to save the current User and Factory databases to Diskette or USB memory stick. User files are designated with a .usr file extension and the factory files are designated with a .fac file extension

Examples of user and factory file names.

Mild Steel-HT4400-HD4070.usr Mild Steel-HT4400-HD4070.fac

Load Cut Charts

Pressing the load Cut Charts soft key allows the user to load the factory default database files which are supplied by Hypertherm in a Text file (.txt), user files (.usr) or factory files (.fac) from Diskette or USB memory stick.

Factory text file names.

Mild Steel Cut Chart Data mschart.txt Aluminum Cut Chart Data alchart.txt Stainless Steel Cut Chart Data sschart.txt

It is recommended that the Database be updated through the control rather than the Power Supply if the serial communications link is enabled.

Test Preflow

Pressing the Test Preflow soft key performs the Test Preflow Gases feature at the Plasma supply.

Test Cutflow

Pressing the Test Cutflow soft key performs the Test Cutflow Gases feature at the Plasma supply.

Notes:

- Please refer to the power supply operators manual for complete information on the operation and setup of the Plasma supply.

- A serial communications port for the Plasma supply must first be selected at the Port configuration screen to be enable the feature for use.

- The Plasma supply parameters must first be enabled in the password protected Station Configuration screen to allow the Cut Chart Information for the Plasma supply to be available for use.

- Power Supplies equipped with the Integrated Command setups. The Command

THC must first be enabled for use in the password protected Station

THC may be used with the control

Configuration Screen.

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Change Consumable

When the power supply link feature has been enabled, consumable data information may be viewed at the Change Consumable screen.

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FineLine Overview

The “Type V” control offers the additional option of interfacing directly to InnerLogic’s FineLine Power Supply for setup via a user selected RS-422 serial port. This advanced feature transmits all necessary power supply settings from the control directly to the FineLine power supply configuring it for use.

The power supply setup is performed through the use of a Cut Chart (cut process parameter database) which is based on eight process variables. The combination of these eight process variables are tied to the settings for the cut process parameters (e.g. arc voltage, pierce delay, etc.) that are transmitted to the supply. For additional convenience, consumable part numbers for the FineLine are displayed at the Change Consumable screen.

This database allows the user to select factory recommended settings or amend the database for personalized settings. The Cut Chart information may be saved or loaded via the hard drive or floppy drive. Specialized Cut Chart files containing the factory recommended settings are available from the control vendor.

The Power Supply parameter must first be enabled in the password protected Station Configuration setups to allow the Cut Chart Information for the feature to be enabled for use. Once selected at the Station Configurations screen, the port must then be selected for communications on the Ports setup screen and the selected port must then be configured as RS-422. For more information on configuration of the port, refer to the Ports information section of this guide.

Station Configuration (example)

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Access to the FineLine Cut Chart data is available from the Plasma Cut Types or Marker Cut Types screen using the shift key, as indicated below.

Note: Screen information will vary depending on THC selection.

Cut Chart

The Cut Chart Database (cut process parameters) transmitted to the power supply is based on the following eight process variables.

Material Type

The Material Type, such as Mild Steel, Stainless Steel or Aluminum, may be selected.

Current Settings

The appropriate current setting for the material thickness and material type may be selected.

Plasma / Shield Gases

The appropriate Plasma / Shield gases for the desired process may be selected.

Material Thickness

The desired material thickness may be selected.

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The following are the Cut Process parameters within the database which are used to configure the power supply. Appropriate parameter information is transmitted to the power supply.

1) Material Type – Mild Steel, Stainless Steel, Aluminum, or Mild Steel (Cold Rolled).

2) Thickness

3) Set Current

4) Pierce Delay

5) Set Preflow Pressure

6) Set Plasma Gas type

7) Set Plasma Pressure

8) Set Shield Gas Type

9) Set Shield Pressure

10) Set Process (Cut/Mark)

The following items are stored in the Cut Chart Data file and will be automatically updated on the control.

Cut Speed

Specifies the speed for the selected process variables.

Kerf

Specifies the amount of kerf (cutter compensation) that will be applied to the current part program.

Preflow Time

Specifies the amount of time the Preflow gases are on.

Purge Time

Specifies the time delay from torch ignition until motion is enabled.

Pierce Time

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

Creep Time

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Database Features

Save Process

Pressing the Save Process soft key allows the user to save the current process settings to the Hard drive creating a custom user database based on the eight process variables selected.

Reset Process

Pressing the Reset Process soft key allows the user to reset the current settings to factory recommend factory defaults based on the eight process variables selected.

Save Cut Charts

Examples of user and factory file names.

Mild Steel-Fineline200-Fineline200.usr Mild Steel- Fineline200-Fineline200.fac

Load Cut Charts

Pressing the load Cut Charts soft key allows the user to the factory default database files which are supplied by Hypertherm as a user files (.usr) or factory files (.fac) from Diskette or USB memory stick.

It is recommended that the Database be updated through the control rather than the Power Supply if the serial communications link is enabled.

Test Preflow

Pressing the Test Preflow soft key performs the Test Preflow Gases feature at the HD4070

Power

supply.

Test Cutflow

Pressing the Test Cutflow soft key performs the Test Cutflow Gases feature at the HD4070

Power

supply.

Notes:

- Please refer to the power supply operators manual for complete information on the operation and setup of the FineLine Power Supply.

- The FineLine Power Supply parameters must first be enabled in the password protected Station Configuration Screen to allow the Cut Chart Information for the FineLine to be available for use.

- Serial communications for the FineLine Power supply are established on the user select communication port. The port must be configured for RS-422 operation.

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Change Consumable

When the FineLine feature has been enabled, consumable data information may be viewed at the Change Consumable screen.

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Marker

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

Marker Interface

The Marking feature from the control is operated through the use of existing I/O points for cutting torches on the control I/O connector. These I/O points may be switched from the cutting torch to the marking tool by use of an external relay(s) activated by the Marker Output or the Marker Output may be used to activate the marking tool.

Please refer to the Machine Interface section of this guide for exact I/O pinout information.

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Press the Timing Diagram soft key to view the timing diagram from setups.

Ignition Time

(Ignition Output) Specifies the length of time that the ignition output is held on at each ignition point.

Marker On Time

(Time Delay) This parameter allows the operator to insert a time delay, which allows the marker to prepare for operation prior to the start of Marker motion.

Marker Off Time

(Time Delay) This parameter allows the operator to insert a time delay, which allows the marker to prepare for operation prior to the end of Marker motion.

Marker Up Time

(Torch Up Output) Specifies the length of time to raise the marker at the beginning and end of each mark.

Marker Partial Up Time

(Torch Up Output) Specifies the length of time for partial raise of the marker at the beginning and end of each mark. Note: The Partial Raise parameter must be enabled.

Marker Down Time

(Torch Down Output) Specifies the length of time to lower the marker at the beginning of each marking cycle.

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Set Arc Current

The Set Arc Current feature allows the user to set the arc current at the Plasma Marking supply. This feature uses the “Set Current BCD” output from the control to activate the BCD inputs at the Plasma Marking supply. EIA RS-274D part program code G59 Vvalue Fvalue for setting current is supported.

Corner Current Percent

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

Ignition

(Ignition Output Enable) The Ignition Off/On selection allows the operator to use the Ignition Output when marking if set to On.

Cut Control Used for Marking

This parameter is used to determine if the Cut Control output is to be used for activating the Marking tool. If set to no, the Marking Output would be used.

Marker Down/Up With Each Marker On/Off

The Marker Down/Up With Each Marker On/Off will command the send the appropriate Up/Down Output commands at each Mark On/ Off.

Arc On Feedback

Specifies whether an arc-on signal from a plasma marking system to the control is used. With Arc On Feedback ON, the control waits for Cut/Mark Sense input to activate before initiating machine motion.

Partial Raise

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

Down On During Mark

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

Down On Between Marks

Turning on the Down On Between Marks feature forces the Torch Down Output to remain on while traversing between marking segments.

Note: Please refer to the Program Codes section of this guide for information on the Marker Font Generator feature.

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Laser Overview

The Mariner ™ Controls offers a unique Laser process screen directly integrates to Hypertherm’s FAST Laser™ head. This feature has the ability to improve Laser setup and operational accuracy while having the flexibility to fine tune the process specific to the operator’s needs.

FAST Laser™ (F create a dual flow zone allowing significantly higher oxygen assist gas pressures in the tightly defined cut zone established by the beam geometry, without the uncontrolled burning in the surrounding zone normally induced by increased assist gas pressures. This accelerated high-velocity oxygen flow along the beam path not only increases cut speed by fueling the exothermic reaction, but also reduces sensitivity to common plate fabricating conditions and variables, most notably plate chemistry and condition.

With this technology, Hypertherm has introduced a line of laser cutting heads that utilize the FAST Laser™ process to deliver up to a 20% increase in cut speed over standard CO steel while also significantly expanding the capacity and quality range of plate laser cutting systems. These combined benefits produce substantial gains in productivity and unattended operation potential for dedicated plate lasers (4 to 6 kW) – whether integrated or retrofitted – while also offering expanded capacity range and cost performance for shared-duty systems (2 to 3 kW). The Hypertherm LH2100 head offers two different focal lengths: 7.5 and 10.0 inches; the LH2125 adds a

12.5-inch focal length option for thicker plate. The Hypertherm LH2125/2100 series is used on laser systems with 1.5” or 2.0” optics. The Hypertherm LH1575 head offers two different focal lengths: 5.0 and 7.5 inches for 1.5 inch optics.

Integrated with Hypertherm Automation’s Mariner™ CNC controller, on-board FAST Laser™ process intelligence coupled to process monitoring optics standard on LH-series cutting heads, achieves improved overall control of the cutting process with fewer system faults and reduced operator involvement. Dynamic Pierce Control senses and initiates each cut once the pierce is complete. These combined capabilities maximize uptime while minimizing total cycle time.

Note: Refer to Laser Information provided with the FAST Laser™ head for proper operation.

low Accelerated Screen Technology), utilizes an innovative patent-pending design to

laser heads on plate

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LASER

Laser Cut Types Screen

The Alt soft key at the left edge of the soft keys indicates additional soft keys are available. This allows for test lifter function to be available.

Test Lifter

Pressing the Test Lifter soft key will command the laser head THC1 lifter to lower to the plate, sense the plate and retract to the pierce height.

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Press the Timing Diagram soft key to view the timing diagram from setups.

Purge Time

Specifies the time delay for cutting gas purge before start of the laser cut motion is enabled.

New Gas Purge Time

Specifies the Gas Purge Time for switching from one cutting gas to another cutting gas.

Shutter Time

The Shutter Time parameter is used to specify the amount of time to open the shutter prior to the laser beam on.

Power Ramp Time

The Power Ramp Time parameter is used to specify the amount of time to ramp up the laser power prior to the laser pierce.

Pierce Time

Specifies the time delay from when laser head completes lowering until motion is initiated at creep speed for cutting. When Manual Pierce Control is selected, this is the total pierce time allowed. With Automatic Pierce Control is selected, this time is an additional delay after pierce is complete.

Pulse On Time

When Automatic Pulse Mode is selected for pierce control the user can select Pulse On and Off Time to adjust duty cycle response of the sensor pulses from the laser cutting head.

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Pulse Off Time

When Automatic Pulse Mode is selected for pierce control the user can select Pulse On and Off Time to adjust duty cycle response of the sensor pulses from the laser cutting head.

Creep Time

Specifies the amount of time after piercing the material that the laser head travels at Creep Speed for cutting. Creep Speed is determined by a setup parameter in the Speed Setup Screen and is a percentage of the programmed cut speed. After the Creep Time is completed, the control accelerates to full cut speed.

Beam Off Time

The Beam Off Time parameter specifies the amount of time the beam output will be turned off prior to he stop of motion. This feature can be used to tab parts for attachment to the skeleton.

Postflow Time

Specifies the amount of time that the cutting gas remains on after the cut is complete.

Cut Height

The Cut Height setup parameter is used to select the desired cut distance above the plate. This will set the initial cut height before the laser cut motion is activated. Cut Height is derived from the CHS signal and the calibration curve and represents cut distance from nozzle tip to the plate.

Pierce Height

The Pierce Height setup parameter is used to select the desired Pierce Height above the plate. This can be entered as a multiplication factor that is calculated times the Cut Height or an actual Pierce Height distance.

Lens Cut Position

Sets the focal lens position in the laser head for cutting.

Lens Pierce Position

Sets the focal lens pierce position in the laser head for cutting.

Pulse Laser Time

Sets the Laser Pulse Time duration for a one shot beam alignment.

Pulse Laser Power

Sets the Laser Pulse Power for a one shot beam alignment.

Height Control Manual/Automatic

Allows the user to either select a Manual or Automatic Height control for the laser head.

IHS in Manual

The IHS in Manual setup parameter allows the operator to select whether or not to use the Initial Height Sense feature when operating the Z axis lifter (THC1) in manual mode.

Retract Full/Partial

Selects the retract distance to be set at Full or Partial. In the Full retract mode, the laser head will retract to the Z-Axis Home position. In Partial retract mode, the laser head will retract to the set retract distance.

Partial Retract Distance

This setup parameter is used to select the THC 1 Retract Distance when configured for partial retract mode.

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Start IHS Distance

The Start IHS Distance specifies the distance of travel for the THC 1 to move the laser head at high speed before switching to low speed and beginning Initial Height Sense. Caution should be taken when selecting this distance so that the laser head does not crash into the plate.

Preflow During IHS

Selecting ON will activate Preflow gases during the IHS cycle.

Nozzle Contact IHS

This parameter would be set to ON to select the THC 1 to use Contact Sense to detect the plate during the IHS cycle.

Nozzle Contact During Cut

Nozzle Contact During Cut allows the CNC to detect contact with the plate and generates a fault if this condition occurs.

Pierce Control Manual/Automatic

Allows the user to select Manual or Automatic Pierce control. Automatic control uses sensors in the Laser head to detect when the pierce is complete. Manual mode uses a preset pierce time and preset laser program. Automatic mode dynamically controls laser duty cycle.

Pierce Mode Pulse/Blast

When Automatic Pierce is selected the user can select to use a definable pulse output or a single Blast.

Pierce Complete

The Automatic Pierce monitors the voltage of sensors in the laser head and compares them to the value set by this parameter to detect the completion of the pierce.

Next Pulse

Based on sensors in the laser head, the system can determine when the next Laser Pulse is delivered during Automatic Pierce control. The voltage is derived from the feedback of the sensors in the laser cutting head.

Cut Chart

A cut chart database allows the user to select factory recommended settings or amend the database for personalized settings. The Cut Chart information can be saved or loaded via the hard drive, floppy drive or USB memory stick. The Cut Chart files contain the factory recommended settings that are available from Hypertherm

Notes:

- Please refer to the FAST Laser™ operators manual for complete information on the operation

and setup of the FAST Laser™ head.

- The FAST Laser™ Laser parameters must first be enabled in the password protected Station

Configuration screen to allow use of the Cut Chart Information

- Specific Material, Process Power, Assist Gases, Material Thickness, Focal Length and Nozzle

data fields allow new values to be added. Double click on the field to enter an new value or press the Plus key “+” to add or “-“ to delete on the keypad.

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Laser Cut Chart Screen

The Cut Chart Database (cut process parameters) transmitted to configure the laser head are based on the following process variables. All values are user definable.

Material Type

The Material Type, such as Mild Steel, Stainless Steel or Aluminum, may be selected.

Specific Material

This is a user defined value to allow the user to create a custom database based on unique characteristics of the material type. Double click on the field or press the Plus key “+” to enter an new material name or “-“ to delete on the keypad.

Process Power

The appropriate process power (Wattage) for the material thickness and material type for the desired process.

Assist Gas

The appropriate Assist Gas for the desired process.

Material Thickness

The material thickness for the selected material type.

Focal Length

Specific Focal Length lens that needs to be installed in the laser head for the desired process.

Nozzle

Diameter and type of nozzle that needs to be installed for the desired process.

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Test Gas

Pressing the Test Gas soft key performs the Test Gas feature of the cutting assist gas delivery system.

The following are the Cut Process parameters within the database, which are then available to configure the specific process.

Set Power

The Set Power parameter allows the user set the power (watts) to be used during the cut process. This value can be less than the process power.

Cut Speed

Specifies the Cut Speed for the selected material process.

Kerf

Specifies the amount of kerf (cutter compensation) that will be applied to the current part program.

Cut Height

The Cut Height setup parameter is used to select the desired cut distance from the nozzle tip to the plate. Cut Height is derived from the CHS signal and the calibration curve.

Pierce Height

The Pierce Height setup parameter is used to select the desired Pierce Height. This may be entered as a multiple factor that is calculated value of the Cut Height or an actual Pierce Height distance.

Lens Cut Position

Sets the focal lens position in the laser head for cutting.

Lens Pierce Position

Sets the focal lens pierce position in the laser head for cutting.

Resonator On Time

During automated power up this allows a specific time for the resonator to power up.

Purge Time

Specifies the time delay from switching from one cutting gas type to another cutting gas type.

Pierce Time

Pulse On Time

When Automatic Pulse Mode is selected for pierce control the user can select Pulse on time to adjust the pulse.

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Pulse Off Time

When Automatic Pulse Mode is selected for pierce control the user can select Pulse on and off time to adjust the pulse. The Off Time starts when the sensor signal falls below the next pulse threshold.

Creep Time

Specifies the period after pierce complete that the laser head travels at Creep Speed. Creep Speed is determined by a setup parameter in the Speeds setup screen and is a percentage of the programmed cut speed. After Creep Time is complete, the control accelerates to full cut speed.

Pierce Complete

The Automatic Pierce monitors voltage of sensors in the laser head to detect completion of the pierce. This is used in conjunction with Pulse On Time, Pulse Off Time and next pulse.

Next Pulse

Based on sensors in the laser head, the system can determine when the next pulse occurs. The Next Pulse will be delivered when the voltage drops below the Next Pulse setting.

Start Corner Power

The Start Corner Power allows the user to define a speed where the corner power analog signal will be used to start to decrease laser power. This is defined as a percentage of cut speed. See Corner Power graph, where the example shows this set to 80%.

Minimum Corner Power

This parameter defines the minimum laser resonator power to switch when the cut speed reduces to zero in a corner. This is defined as a percentage of selected power (watts). See Corner Power graph, where the example shows 30%.

EXAMPLE of Corner Power Graph

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Save Process

Pressing the Save Process soft key allows the user to save the current process settings to the Hard drive creating a custom user database based on the eight process variables selected.

Rest Process

Pressing the Reset Process soft key allows the user to reset the current settings to factory recommend factory defaults based on the eight process variables selected.

Save Cut Charts

Load Cut Charts

Pressing the load Cut Charts soft key allows the user to the factory default database files which are supplied by Hypertherm in a Text file (.txt), user files (.usr) or factory files (.fac) from Diskette or USB memory stick.

Pulse Laser Time

Sets the Laser Pulse Time duration for a one shot beam alignment.

Pulse Laser Power

Sets the Laser Pulse Power for a one shot beam alignment.

Height Control Manual/Automatic

Allows the user to either select a Manual or Automatic Height control for the laser head.

IHS in Manual

The IHS in Manual setup parameter allows the operator to select whether or not to use the Initial Height Sense feature when operating the Z axis lifter (THC1) in manual mode.

Retract Full/Partial

Partial Retract Distance

This setup parameter is used to select the THC Retract Distance when configured for partial retract mode.

Start IHS Distance

The Start IHS Distance specifies the distance of travel for the THC to move the laser head at high speed before switching to low speed and beginning Initial Height Sense. Caution should be taken when selecting this distance so that the laser head does not crash into the plate.

Preflow During IHS

Selecting ON will activate Preflow gas during the IHS cycle.

Nozzle Contact IHS

This parameter would be set to ON to select the THC to use Contact Sense to detect the plate during the IHS cycle.

Nozzle Contact During Cut

Nozzle Contact During Cut allows the CNC to detect contact with the plate and fault.

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Pierce Control Manual/Automatic

Allows the user to select Manual or Automatic Pierce control. Automatic control uses sensors in the Laser head to detect when the pierce is complete

Pierce Mode Pulse/Blast

When Automatic Pierce is selected the user can select to use a definable pulse output or a single Blast.

Pierce Complete

The Automatic Pierce monitors voltage of sensors in the laser head to detect completion of the pierce.

Next Pulse

Based on sensors in the laser head, the system can determine when the next Pulse Pierce occurs during Automatic Pierce control. The voltage is derived from the feedback of the sensors.

Cut Chart

Notes:

- Please refer to the FAST Laser™ operators manual for complete information on the operation and setup of the FAST Laser™ head.

- The FAST Laser™ Laser parameters must first be enabled in the password protected Station Configuration screen to allow use of the Cut Chart Information

- Specific Material, Process Power, Assist Gases, Material Thickness, Focal Length and Nozzle data fields allow new values to be added. Double click on the field to enter an new value or press the Plus key “+” to add or “-“ to delete on the keypad.

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Water Jet

Press the Timing Diagram soft key to view the timing diagram from setups.

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Purge Time

Specifies the time delay from torch ignition until motion is enabled.

Pierce Time

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

Creep Time

Abrasive Off Time

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

Abrasive Charging

When selected, the Abrasive Charging feature will charge or fill the abrasive into the cutting system for use while cutting.

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Watch

The control comes with a unique function for watching critical process related parameters during cutting. The Watch window allows the operator to customize a certain portion of the screen to display functions that are critical for your particular cutting operation. Whether it is Current Speed, Position, I/O status, or torch consumable life, you now have the flexibility to display the information that you want to see.

As these parameters are turned ON or OFF, the Watch window will be updated with the new graphical widget. Widget is a GUI programmer’s term for defining icons which graphically display information.

Several options are available to personalize the Watch window and not all options can be viewed at one time. The options are grouped into two sizes of widgets or icons. Large widgets may be placed into the upper position at the top of the Watch window or in the middle of the Watch window. Small widgets are positioned in the lower left corner of the Watch Window next to the cut information and clock. The cut information and clock at the lower right may not be edited.

Selections in the Watch window will change slightly based on the control I/O configuration and machine option selections that have been enabled.

The Watch positions will allow for the following selections.

None

Selecting None will leave the selected position blank.

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Input/Output

Allows current state of selected Input, Outputs or Status information to be displayed during cutting. This can be especially useful in debugging gas control sequencing problems. To add or delete a desired Input, Output or Status point to the Input/Output list box, Double click the disired item or highlight the desired item and + (add) or – (delete) keys on the alpha-numeric keypad.

Position

Allows the position for the selected axis to be displayed. Only two axes may be displayed at the Upper or Middle locations. The Lower location will allow up to four axes to be displayed.

Following Error

Allows the Following Error to be displayed. Following Error is the distance between the position the control has calculated and the actual position of the torch. A large Following Error may indicate that the cut speed selected may be beyond the capability of the cutting system. Only two axes may be displayed at the Upper or Middle locations. The Lower location will allow up to four axes to be displayed.

Command Voltage

Allows the user to view directional motion command voltage being sent to the amplifier for velocity type drives. This displayed voltage also equates to current being commanded for motion in current type drives. Peak voltage can be displayed for a specified amount of time.

Temperature

Selecting to add the Temperature information to the Watch window will display the current temperature inside the control in Fahrenheit or Celsius (selected at the Special Setups screen).

Note: Specific control hardware required.

Speedometer

Allows cut speed, maximum machine speed and current machine speed to be graphically displayed while cutting.

Oxy Fuel Torch Tip

Allows the selected oxy fuel torch tip (1- 12) consumable life to be graphically displayed while cutting. This is especially useful in helping to determine when the torch tip should be replaced and keeping track of torch tip data for statistical process control (SPC).

Plasma Torch Tip

Allows the selected plasma torch tip (1- 8) consumable life to be graphically displayed while cutting. This is especially useful in helping to determine when the torch tip should be replaced and keeping track of torch tip data for statistical process control (SPC).

Plasma Electrode

Allows the selected plasma electrode (1- 8) consumable life to be graphically displayed while cutting. This is especially useful in helping to determine when the electrode should be replaced and keeping track of electrode data for statistical process control (SPC).

Jog Keys

Selecting the jog keys option allows a directional keypad to be added to the watch window for manual motion directly from the touch screen. The operator can press the hand ICON in the middle of the navigation pad to enable manual mode. Select the desired move speed and press the corresponding arrow for manual motion in the desired direction.

Process Data

The Process Data option allows the user to view up to four selected items for a selected cut or marking process. Process timers and status items for Oxy Fuel, Plasma, Marker, Waterjet and Laser

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may be selected. Note: The process data will only be displayed during the current cut process. Example: Plasma 1 process parameters will only be displayed in the Watch window at the main cut screen while cutting in Plasma 1 Mode.

Laser Nozzle

Laser Nozzle consumable life to be graphically displayed while cutting. This is especially useful in helping to determine when the nozzle should be replaced and keeping track of nozzle data for statistical process control (SPC).

HPR Power Supply

Allows the user to view status for inputs, outputs and gas pressures for the HPR autogas console. Up to four power supplies may be monitored. This is generally used for service diagnostics only.

Multiple Watch Windows

Up to ten different Watch windows may be configured on the control for quick selection and viewing of the Watch icons.

To configure different Watch windows for viewing, first access the Watch setup screen. Press the number ICON to enter a number or the Left/Right arrows to move up and down through the selections. The different Watch windows can be selected and viewed during operation using the same selection process.

Example:

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Section 4: Shape Manager

Shape Library

The control contains a built-in Shape Library with more than 68 commonly used shapes. These shapes are parametric. Parametric shapes are shapes that are not fixed in size or geometry.

The Shape Library consists of more than 68 shapes as shown below. The screen is defined in colors, from the easiest (green) to the hardest (black).

Selecting a Simple Shape

After pressing Shape Library from the Main Menu, the control display shows the Shape Library as shown above. Double click the desired shape you wish to cut and press OK. If the selection is incorrect, press CANCEL and re-select the shape.

Keypad operation: Use the arrow keys to navigate to the desired shape you wish to cut and press ENTER.

At this point, the shape is displayed with the default parameters, or the parameters from the last edit session of this shape. Detailed information on the available shapes can be found in the following section.

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Text Editor

This screen is for manually inputting or editing of a part program in either ESSI or EIA format. The current part that is in memory will be displayed upon entering this screen. The OK soft key will save any changes to the current part in memory. If you want to save the changes to the hard drive, go to the Files Save to Disk screen. If you do not want to save any changes that were made, press Cancel on the keyboard.

Changes can be made by pressing on the desired line of code. An alphanumeric keypad will be displayed to initiate changes.

Show Original Text

Pressing the Show Original Text button allows the user to view and edit the part program in the original format in which it was written.

Delete Part

The Delete Part button will delete the current part from the Text Editor so that a new part can be constructed.

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Shape Wizard

ShapeWizard®, a proprietary graphical part editor, provides a user-friendly, graphical method of

editing part programs.

ShapeWizard

any changes that are made, when they happen. EIA RS-274D codes can be inserted directly as ASCII text into a part program or, alternatively, segments can be created by specifying phrases in the user's native language as a step-by-step process. EIA RS-274D codes need not be known.

ShapeWizard

allows a user to graphically view not only the segment that is being edited, but also

is accessed from the Shape Library menu.

Manual Line Edit

Pressing Manual Line Edit allows editing the highlighted line in the Text Editor window. The ASCII text entered must be valid EIA RS-274D codes or an error message will result. The alphanumeric keypad will be displayed for line edits. Below is a Text Editor line as it appears immediately after the Manual Line Edit is pressed:

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Simply typing right over the line can erase the highlighted text.

While a text line is highlighted in blue, a new segment type can be selected and inserted into the program using soft keys. Additionally, a graphic representation of the part program in the Preview window is updated so that the corresponding segment is highlighted in red or blue, depending on whether it is a cut segment or a traverse.

The Segment Type pop-up window is pictured below:

Parameters associated with the segment type will also be displayed and can be edited.

Replace Segment

Replaces the segment highlighted in gray in the Text Editor window with the segment selected from the Segment Type window as pictured below:

Insert Before Segment

Pressing this soft key causes the segment selected from the Segment Type window to be inserted before the segment highlighted in gray in the Text Editor window.

Insert After Segment

Pressing this soft key causes the segment selected from the Segment Type window to be inserted after the segment highlighted in gray in the Text Editor window.

Remove Segment

The segment highlighted in gray or blue in the Text Editor window is removed from the part program when the Remove Segment soft key is pressed.

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Teach Trace

The Teach Trace function of the control allows parts to be taught rather than programmed. The position information from the taught part will remain as a part program that can be saved to disk for future use.

The Teach Trace algorithms present in the control can recognize both arcs and lines. This will reduce the overall memory required to store these parts and will improve the smoothness of the cut. The taught part in memory is in EIA format and can be cut, saved or manipulated using any of the part options.

The Teach Trace function must be used in conjunction with an optional stand-alone optical tracing system.

Start Corner

The Start Corner setup parameter allows the user to select where the taught part will begin for proper viewing on the screen.

Tracing Pitch

This determines how precisely to learn a part. The Tracing Pitch can be adjusted to trade off resolution versus size of the taught part. This value does not affect the actual position resolution of the part.

A good starting point for most tracing systems is 0.01”.

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Arc Radial Error

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

Auto Closure Detect

This parameter is used to allow the control to detect that it has returned to the starting point. With this feature ON, the control stops the motion of the tracer when the part is complete allowing a lead-out to be programmed.

Closure Over/Under Lap

By specifying a positive value for this parameter, the control does not stop the tracer until it has gone past the start point by the amount of this parameter. By specifying a negative value, the tracer stops as soon as the tracing head position is within this parameter’s distance of the starting point. This is only available if the Auto Closure Detect is ON.

Kerf Direction

Selects the desired kerf for cut segments.

Traverse/Pierce

Switches between the traverse and cut segments of the part as it is taught.

Tracing a part

To trace a part while at the Teach Trace screen, select Auto mode, then select traverse or pierce. You may switch between traverse and pierce during the tracing procedure. Position the optical sensor near the part drawing and press Start. Use the sensor positioning controls to direct the sensor towards the part. Once the sensor has located the part, the tracing system will follow the part outline until completion. When completed, press OK. The part file can now be cut, saved or edited.

Please refer to the instructions provided with your Optical tracing system for further details.

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Plate Remnant Trace

The Teach /Trace feature also supports the ability to trace in the outline of a plate remnant for use by a part programmer to create new nests of parts to be cut on the remnant.

The user manually moves the torch (or a pointer) around the plate to define the outline of the material which remains. When the path is completed (it doesn’t have to be a closed path), the operator presses the OK key and the recorded axis motions are written to a standard part program format with moves recorded as incremental routing moves. The movements will also display on the control’s screen in the same manner as displayed during manual motion commands.

Once recorded, the part program can be uploaded via the serial link, or written to the floppy disk or USB memory, so that the programming department can use it to update their database to reflect the remaining material.

When first opened the system defaults to the automatic Teach/Trace mode which is used in conjunction with an optical head for program generation. In order to use the manual function, simply select the soft key to choose manual mode.

This will place the control in the manual control mode and also enables the Change Move Speed button to alter the manual move speed. Pressing the Change Move Speed button repeatedly will cycle through the programmed manual jog rate settings.

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The operator should position the pointer or torch to the plate location where recording of the path is to begin. Once at the start point, press the “Start” button to begin recording positions. The manual motion buttons may now be used to trace out an arbitrary contour which defines the remaining plate area. When finished, press the OK soft key to record the motions to the “current” part program.

The program may now be saved to the disk, or uploaded in the normal manner.

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Nester™

Nester™ is a proprietary part nesting program, which allows the operator to manually group or nest selected parts together as one part program to conserve raw materials and maximize machine utilization. This nesting program is designed to maximize the control features of graphical user interface, simplified keypad operation and advanced communications software to provide quick, simple and logical programming.

Additionally, an optional Automatic Nesting feature may be enabled to perform true shape, single station, automatic nesting. With its advanced Graphical User Interface, ease of use and advanced profile positioning algorithms, this Automatic Nesting feature can greatly improve the output of your shape cutting operation by reducing overall process time and increasing plate utilization. Please contact your control vendor for details on enabling this Automatic Nesting feature.

Manual Nesting

Main Screen Layout

The main viewing area is the largest area of the screen and is located in the upper left corner. The edge of the plate is displayed in dark green. The plate size displayed is based on plate information that has been selected at the main setup screen.

The upper right corner of the main screen displays the part program list for the nest in order of cut sequence. In the lower right, part position and orientation information for the selected part program is displayed and can be manipulated for use as new parts are added.

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Add Part

Pressing the Add Part soft key accesses the screen, which allows the user to select a part program from a selected source.

Remove Part

This soft key is used to remove the selected part from the nest parts list.

Cut Earlier

Pressing the Cut Earlier soft key will move the selected part program to an earlier position in the part cut list. The sequence in which the parts are cut are changed, but not the selected part location in the nest.

Cut Later

Pressing the Cut Later soft key will move the selected part program to a later position in the part cut list. The sequence in which the parts are cut are changed, but not the selected part location in the nest.

View Sheet / View Part

View Sheet allows the viewing of a part as it would appear on the plate. After pressing the View Sheet soft key, the display window zooms out to show the part in relationship to the entire plate.

After zooming out, the display can be zoomed in again by pressing the + key, which causes horizontal and vertical scroll bars to be displayed. Pressing the - key will zoom back out.

More information on use of this feature is provided in the Manual cutting section.

Arrow Key (Distance)

The Arrow Key allows the user to select one of five different preset move distances when the arrow keys are pressed to locate parts in the nest. These five distances are definable and are selected in the Nester™ Setup screen.

Clear Nest

Clear Nest will delete all the parts located in the nested parts list from temporary memory.

Setup

Pressing the Setup soft key accesses the Nester™ Setup screen for configuring the variable parameters when using Nester™.

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Nester™ Setup

The following Setup parameters are used to configure the manual nesting process for use.

Arrow Motion

At this screen, the user can select different move increment dimensions. These dimensions are used as move distance references when the control arrow keys are pressed to place parts in position on the plate.

Autoposition

Autoposition is an automated feature of the Nester™ software to search for the next available location to place a part that is being added to the nested part list. Autoposition compares the overall block dimensions of the selected part and searches for the next available block on the plate that is large enough to accommodate the part being loaded. Values can be input for the Search Increment and Scrap Clearance parameters that are used when searching for the next available part location.

Autoposition will not allow parts to be placed on top of other parts or inside other parts. This feature is enabled or disabled by using the space key at the enable box.

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Using Nester™

To begin, first select the plate size requirements for the nest at the Main Setup screen. This information is used to display the plate size and plate orientation at the main view screen to place parts on the plate. The plate information is retained with the nested part program when saved.

Press the Nester™ soft key from the Shape Manager screen then enter the Nester™ Setup Screen to configure the nesting software for use. Press OK to return to the Nester™ Main Screen to begin placing parts in the nest.

Adding Parts

At the Nester™ Main Screen, press the Add Part soft key to add a new part to the nesting part list. The first screen viewed will allow the user to select a part from the Simple Shape Library, from a disk or from the host computer via link communications.

Once a part has been selected from either location, the user will be prompted to select the number of pieces desired.

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As new parts are added, they will be displayed on the selected plate in preparation for final placement.

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At this screen, the part can be oriented, scaled and moved to final position. This is done by moving to the Nester™ Part List and highlighting the file name. Then select the desired field to manually offset, rotate, mirror and scale the part.

To position the selected part, use the manual direction keys. The view screen will be outlined by a bold blue border indicating that the arrow keys are active. Pressing the arrow keys will allow movement of the part to the desired location on the plate. Each time the arrow keys are pressed, the selected part will move in the direction of the arrow by the increment set by the Arrow Key distance soft key. By use of the arrow distance key, arrow keys and zooming in the view field, exact placement of the desired part may be obtained.

Additional parts may be added to the nest in the same fashion as described above. To customize your nest, you may decide to delete parts or add parts to the list and change the order in which they are cut by use of the soft keys displayed. When finished, press OK to return to the Main Cut screen and begin cutting the nest. The part nest is currently saved as a temporary file until another part is loaded.

Saving a Nest

From the Main Cut screen, press the Files soft key to Save to Disk. From here the part can be saved to a hard disk folder on the control, Diskette or USB memory stick. The nested parts file may be saved as a nest or a part. Saving as a nest using the save as Nester File feature, will create a larger file which will allow future modification of the nest through Nester™. Nested parts saved as a part file cannot be modified.