Hypertherm HTA User Manual

Operator’s Manual I

TABLE OF CONTENTS

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Screen Hierarchy........................................................................................................................... 11

Key & Menu Functions......................................................................................................................12

Help Screen ...................................................................................................................................... 12

Show Contents .............................................................................................................................. 12

Find................................................................................................................................................ 12

Main Screen......................................................................................................................................13

Preview Window............................................................................................................................13

Watch Window...............................................................................................................................13

Shape Manager.............................................................................................................................13

Files ...............................................................................................................................................13

Part Options...................................................................................................................................13

Setups ...........................................................................................................................................14

View Part/View Sheet....................................................................................................................14

Change Cut Mode .........................................................................................................................15

Change Consumable..................................................................................................................... 15

Zero Positions................................................................................................................................15

Shape Manager Screen .................................................................................................................... 16

Shape Library ................................................................................................................................ 16

Text Editor ..................................................................................................................................... 16

Shape Wizard................................................................................................................................16

II Operator’s Manual

Teach Trace.................................................................................................................................. 16

Nester............................................................................................................................................ 16

HyperCAD..................................................................................................................................... 17

HyperNEST................................................................................................................................... 17

Evaluation Timer ........................................................................................................................... 17

Files .................................................................................................................................................. 18

Load from Disk.............................................................................................................................. 18

Save to Disk.................................................................................................................................. 18

Download from Host ..................................................................................................................... 18

Upload to Host .............................................................................................................................. 18

Resume Last Part ......................................................................................................................... 18

Show Certain Files........................................................................................................................ 19

Show All Files ............................................................................................................................... 19

Setups Screen .................................................................................................................................. 20

Cutting........................................................................................................................................... 20

Cut Types...................................................................................................................................... 20

Disable Control ............................................................................................................................. 20

Watch............................................................................................................................................ 20

Password ...................................................................................................................................... 20

Diagnostic ..................................................................................................................................... 20

Change to Metric Units/English Units ........................................................................................... 20

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

New Torch Tip............................................................................................................................... 21

New Electrode............................................................................................................................... 21

Reset Database ............................................................................................................................ 21

Setups........................................................................................................................................... 21

Upload Database .......................................................................................................................... 21

Save Database ............................................................................................................................. 21

Key Functions................................................................................................................................... 22

Optional PC Keyboard Layout.......................................................................................................... 23

Optional USB Front Panel ................................................................................................................ 24

ICON Legend ................................................................................................................................ 24

SECTION 3: SETUPS.......................................................................................................................... 25

Cutting .............................................................................................................................................. 25

Plate Size...................................................................................................................................... 25

Cut Mode ...................................................................................................................................... 25

Trial/Cut Speed ............................................................................................................................. 25

Marker 1 / Marker 2 Speed ........................................................................................................... 25

Kerf................................................................................................................................................ 26

Dwell Time .................................................................................................................................... 26

Arc Radial Error ............................................................................................................................ 26

Dwell Override .............................................................................................................................. 26

Optional Program Stop ................................................................................................................. 26

EIA I & J Codes............................................................................................................................. 26

EIA F-Code Override .................................................................................................................... 26

Speed +/- Affects F-Codes ........................................................................................................... 26

EIA Decimal Shift .......................................................................................................................... 26

Process Select Override ............................................................................................................... 26

Station Select Override................................................................................................................. 26

Auto Torch Spacing Override ....................................................................................................... 27

G97 Loop Count Prompt............................................................................................................... 27

ESAB Multi Torch Support............................................................................................................ 27

Force G40 Kerf Disable ................................................................................................................ 27

G40 Used in Simple Shapes......................................................................................................... 27

Auto Start after APA...................................................................................................................... 27

Operator’s Manual III

EIA Code 2 Decimal Shift.............................................................................................................. 27

Show Traverse Segments .............................................................................................................27

Retain Skew Adjustment ............................................................................................................... 27

Kerf Variable / Kerf Offset .............................................................................................................27

Marker Offsets 1 - 12..................................................................................................................... 28

THC Voltage Offset .......................................................................................................................28

Marker On Time (Type “B” Configuration Only) ............................................................................ 28

Marker Off Time (Type “B” Configuration Only) ............................................................................ 28

Cut Types.......................................................................................................................................... 29

Oxy Fuel............................................................................................................................................ 30

I/O Configuration Type “M”, “P” and “V” ........................................................................................30

I/O Configuration Type “M”, “P” and “V” ........................................................................................30

I/O Configuration Type “B” ............................................................................................................31

I/O Configuration Type “B” (Timing Diagram) ...............................................................................31

Ignition Time..................................................................................................................................31

Low Preheat .................................................................................................................................. 31

High Preheat..................................................................................................................................32

Pierce Time ................................................................................................................................... 32

Moving Pierce Time....................................................................................................................... 32

Creep Time.................................................................................................................................... 32

Primary Torch Up Time ................................................................................................................. 32

Primary Torch Down Time.............................................................................................................32

Pierce Torch Up Time ...................................................................................................................32

Pierce Torch Down Time............................................................................................................... 32

Cut Off Time .................................................................................................................................. 32

Bleedoff Time ................................................................................................................................ 32

Igniters........................................................................................................................................... 32

Preheat During Cut........................................................................................................................ 32

Plasma .............................................................................................................................................. 33

I/O Configuration Type “M”, “P” and “V” ........................................................................................33

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

I/O Configuration Type “B” ............................................................................................................34

I/O Configuration Type “B” (Timing Diagram) ...............................................................................34

Start Time (Type “B” Configuration Only)...................................................................................... 34

Purge Time....................................................................................................................................34

Pierce Time ................................................................................................................................... 34

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

Cut Off Time .................................................................................................................................. 35

Torch Down Time .......................................................................................................................... 35

Arc Off Time ..................................................................................................................................35

Stop Time ...................................................................................................................................... 35

Retract Delay................................................................................................................................. 35

Set Arc Current.............................................................................................................................. 35

Corner Current Percent ................................................................................................................. 35

Retry Transfer Fail......................................................................................................................... 35

Transfer Time ................................................................................................................................ 36

Arc on Feedback ...........................................................................................................................36

Ignition ...........................................................................................................................................36

Dual Grid/THC...............................................................................................................................36

Dual Grid/THC Start ......................................................................................................................36

Partial Raise .................................................................................................................................. 36

Torch Down During Cut.................................................................................................................36

Torch Down Between Cuts............................................................................................................36

Marker ...............................................................................................................................................37

Marker Interface ............................................................................................................................ 37

I/O Configuration Type “M”, “P” and “V” (Timing Diagram) ........................................................... 38

IV Operator’s Manual

Ignition Time ................................................................................................................................. 38

Marker On Time ............................................................................................................................ 38

Marker Off Time ............................................................................................................................ 38

Marker Up Time ............................................................................................................................ 38

Marker Partial Up Time ................................................................................................................. 38

Marker Down Time........................................................................................................................ 38

Set Arc Current ............................................................................................................................. 38

Corner Current Percent................................................................................................................. 38

Ignition........................................................................................................................................... 38

Cut Control Used for Marking ....................................................................................................... 39

Marker Down/Up With Each Marker On/Off.................................................................................. 39

Arc On Feedback .......................................................................................................................... 39

Partial Raise.................................................................................................................................. 39

Down On During Mark .................................................................................................................. 39

Down On Between Marks ............................................................................................................. 39

Laser................................................................................................................................................. 40

Water Jet .......................................................................................................................................... 41

I/O Configuration Type “M”, “P” and “V” (Timing Diagram)........................................................... 41

Purge Time ................................................................................................................................... 41

Pierce Time................................................................................................................................... 41

Creep Time ................................................................................................................................... 42

Abrasive Off Time ......................................................................................................................... 42

Abrasive Charging ........................................................................................................................ 42

Watch................................................................................................................................................ 43

None.............................................................................................................................................. 43

Input/Output .................................................................................................................................. 44

Position ......................................................................................................................................... 44

Following Error.............................................................................................................................. 44

Temperature ................................................................................................................................. 44

Speedometer ................................................................................................................................ 44

Oxy Fuel Torch Tip ....................................................................................................................... 44

Plasma Torch Tip.......................................................................................................................... 44

Plasma Electrode.......................................................................................................................... 44

Process Data ................................................................................................................................ 44

Laser Nozzle ................................................................................................................................. 44

HPR Power Supply ....................................................................................................................... 44

Multiple Watch Windows............................................................................................................... 45

SECTION 4: SHAPE MANAGER........................................................................................................47

Shape Library ................................................................................................................................... 47

Selecting a Simple Shape............................................................................................................. 47

Text Editor ........................................................................................................................................ 48

Show Original Text........................................................................................................................ 48

Delete Part .................................................................................................................................... 48

Shape Wizard ................................................................................................................................... 49

Manual Line Edit ........................................................................................................................... 49

Replace Segment ......................................................................................................................... 50

Insert Before Segment.................................................................................................................. 50

Insert After Segment ..................................................................................................................... 50

Remove Segment ......................................................................................................................... 50

Teach Trace ..................................................................................................................................... 52

Start Corner .................................................................................................................................. 52

Tracing Pitch ................................................................................................................................. 52

Arc Radial Error ............................................................................................................................ 53

Auto Closure Detect...................................................................................................................... 53

Closure Over/Under Lap............................................................................................................... 53

Operator’s Manual V

Kerf Direction................................................................................................................................. 53

Traverse/Pierce ............................................................................................................................. 53

Tracing a part ................................................................................................................................53

Plate Remnant Trace ....................................................................................................................54

Nester™ ............................................................................................................................................56

Manual Nesting ................................................................................................................................. 56

Main Screen Layout ......................................................................................................................56

Add Part.........................................................................................................................................57

Remove Part..................................................................................................................................57

Cut Earlier......................................................................................................................................57

Cut Later........................................................................................................................................ 57

View Sheet / View Part..................................................................................................................57

Arrow Key ( Distance ) ..................................................................................................................57

Setup ............................................................................................................................................. 57

Done ..............................................................................................................................................57

Nester™ Setup..................................................................................................................................58

Arrow Motion ................................................................................................................................. 58

Autoposition................................................................................................................................... 58

Clear Nest......................................................................................................................................58

Done ..............................................................................................................................................58

Using Nester™.................................................................................................................................. 59

Adding Parts..................................................................................................................................59

Saving a Nest ................................................................................................................................ 60

HyperNest – CNC® Automatic Nesting Software..............................................................................61

Main Screen Layout ......................................................................................................................61

Automatic Nesting Setup ..................................................................................................................62

Automatic Nesting ......................................................................................................................... 62

Part Spacing..................................................................................................................................62

Plate Edge Spacing.......................................................................................................................62

Program Origin .............................................................................................................................. 62

Cut Direction.................................................................................................................................. 62

Return to Nest Start....................................................................................................................... 62

Using HyperNest – CNC®................................................................................................................. 63

Adding Parts..................................................................................................................................63

Remove Part..................................................................................................................................65

Nest Summary............................................................................................................................... 66

Main Screen View of Nest .............................................................................................................68

HyperCAD®.......................................................................................................................................69

HyperNEST®.....................................................................................................................................70

SECTION 5: FILES ..............................................................................................................................73

Load from Disk..................................................................................................................................73

Load from ......................................................................................................................................73

Files ...............................................................................................................................................73

File name/Diskette file name .........................................................................................................74

Preview.......................................................................................................................................... 74

Load to...........................................................................................................................................74

Hard drive file name ......................................................................................................................74

Resume Last Part.......................................................................................................................... 74

Show Certain Files ........................................................................................................................74

Show All Files................................................................................................................................74

Resume Last Part Features .............................................................................................................. 75

Rush Job Interrupt.........................................................................................................................75

Automated Power Loss Recovery.................................................................................................75

Save to Disk ......................................................................................................................................76

Save to ..........................................................................................................................................76

VI Operator’s Manual

File name/Diskette file name ........................................................................................................ 76

Save Original Text ........................................................................................................................ 76

Save from...................................................................................................................................... 76

Files............................................................................................................................................... 76

Hard drive file name...................................................................................................................... 77

Preview ......................................................................................................................................... 77

Save KeyLog to Disk..................................................................................................................... 77

Download from Host ......................................................................................................................... 78

Download from.............................................................................................................................. 78

Files............................................................................................................................................... 78

Remote file name.......................................................................................................................... 78

Preview ......................................................................................................................................... 79

Download to .................................................................................................................................. 79

Local file name.............................................................................................................................. 79

Upload to Host.................................................................................................................................. 80

Upload to....................................................................................................................................... 80

Remote file name.......................................................................................................................... 80

Upload from .................................................................................................................................. 80

Files............................................................................................................................................... 80

Local file name.............................................................................................................................. 81

Preview ......................................................................................................................................... 81

Loading Of Invalid Files.................................................................................................................... 81

SECTION 6: LIBRARY SHAPES ........................................................................................................ 83

Library Shape Setup......................................................................................................................... 83

Rectangle ......................................................................................................................................... 84

Circle................................................................................................................................................. 84

Triangle............................................................................................................................................. 85

L-Bracket .......................................................................................................................................... 85

Trapezoid.......................................................................................................................................... 86

Slant Rectangle ................................................................................................................................ 86

Gambrel Rectangle........................................................................................................................... 87

Roofed Rectangle............................................................................................................................. 87

4 Sided Polygon ............................................................................................................................... 88

5 Sided Polygon ............................................................................................................................... 88

Oval .................................................................................................................................................. 89

Circle w/ Flat Side............................................................................................................................. 89

Circle Slice........................................................................................................................................ 90

Straight Slots .................................................................................................................................... 90

Angled Slots ..................................................................................................................................... 91

Horizontal Rip ................................................................................................................................... 91

Vertical Rip ....................................................................................................................................... 92

Flange............................................................................................................................................... 92

Circle w/ Rectangular Hole............................................................................................................... 93

Gusset .............................................................................................................................................. 93

8 Sided.............................................................................................................................................. 94

Rectangle w/ Convex Corners.......................................................................................................... 94

Rectangle w/ Concave Corners........................................................................................................ 95

L-Bracket w/ Elbow Radii.................................................................................................................. 95

Slant L-Bracket w/ Elbow Radii ........................................................................................................ 96

Trapezoid w/ Convex Corners.......................................................................................................... 96

Flange Slice...................................................................................................................................... 97

Elbow................................................................................................................................................ 97

Flange Repair Ring........................................................................................................................... 98

Rectangle w/ Rectangular Hole........................................................................................................ 98

Rectangle w/ Circular Hole............................................................................................................... 99

Operator’s Manual VII

Rectangle w/ Circular Hole and Convex Corners ............................................................................. 99

Rectangle w/ Tab ............................................................................................................................100

Rectangle w/ Convex Tab............................................................................................................... 100

Rectangle w/ Notch.........................................................................................................................101

Rectangle w/ Slant Notch................................................................................................................101

Rectangle w/ Radius .......................................................................................................................102

Convex Rectangle........................................................................................................................... 102

Concave Rectangle......................................................................................................................... 103

Triangle w/ Concave Side ...............................................................................................................103

Polygon w/ Concave Side ...............................................................................................................104

Slant Rectangle with Radius ...........................................................................................................104

Slant Rectangle with Circular Hole .................................................................................................105

Cross...............................................................................................................................................105

Cross w/ circular Hole .....................................................................................................................106

4 Sided Convex Rectangle .............................................................................................................106

4 Sided Concave Rectangle ........................................................................................................... 107

Pipe Mount......................................................................................................................................107

Bolt Hole Circle ............................................................................................................................... 108

Bolt Hole Flange .............................................................................................................................108

Bolt Hole Rectangle ........................................................................................................................109

Bolt Hole Rectangle w/ Convex Corners ........................................................................................109

Bolt Hole Rectangle w/ Center Hole ...............................................................................................110

Bolt Hole Rectangle w/ Center Hole and Convex Corners ............................................................. 110

Rounded L-Bracket ......................................................................................................................... 111

Horseshoe.......................................................................................................................................111

Convex Roof Trapezoid w/ Hole ..................................................................................................... 112

Convex Roof Polygon w/ Hole ........................................................................................................ 112

Convex Roof Polygon w/ Oval Hole and Concave Bottom.............................................................113

Pulley Cover.................................................................................................................................... 113

Paddle Blind....................................................................................................................................114

Water Pump Gasket........................................................................................................................ 114

Pulley ..............................................................................................................................................115

Sprocket ..........................................................................................................................................115

Text .................................................................................................................................................116

Test Pattern.....................................................................................................................................116

SECTION 7: PART OPTIONS ...........................................................................................................117

Scale Factor ................................................................................................................................117

Rotate Angle................................................................................................................................ 117

Mirror X/Mirror Y..........................................................................................................................117

Kerf ..............................................................................................................................................118

Repeat.............................................................................................................................................119

Straight Repeat ...........................................................................................................................119

Repeat Type................................................................................................................................119

Start Corner.................................................................................................................................119

Number of Rows.......................................................................................................................... 119

Number of Columns ....................................................................................................................119

X Pattern Offset/Y Pattern Offset ................................................................................................ 119

Scrap Clearance.......................................................................................................................... 120

X Nest Distance/Y Nest Distance................................................................................................120

Staggered Repeat .......................................................................................................................120

Nested Repeat ............................................................................................................................121

Pattern Offsets ............................................................................................................................121

Nest Distance .............................................................................................................................. 121

Instructions for use ...................................................................................................................... 122

Corner to Align with .....................................................................................................................123

VIII Operator’s Manual

Scrap Clearance ......................................................................................................................... 123

Skew Adjustment ........................................................................................................................ 123

Skew Reference.......................................................................................................................... 123

Edit Parameters .......................................................................................................................... 123

At Corner..................................................................................................................................... 123

At Skew Point.............................................................................................................................. 123

Automatic Plate Alignment (APA)................................................................................................... 124

SECTION 8: CUTTING ...................................................................................................................... 127

I/O Configuration Type “M”, “P” and “V” ......................................................................................... 127

Speed Increase........................................................................................................................... 128

Speed Decrease ......................................................................................................................... 128

Repeats....................................................................................................................................... 128

Cut Delay Timers ........................................................................................................................ 128

Extend......................................................................................................................................... 129

Set Now ...................................................................................................................................... 129

Release....................................................................................................................................... 129

I/O Configuration Type “B”.............................................................................................................. 130

Automatic .................................................................................................................................... 130

Manual ........................................................................................................................................ 130

Test Run ..................................................................................................................................... 130

SECTION 9: PAUSE.......................................................................................................................... 131

Return to Start............................................................................................................................. 131

Backup and Forward on Path ..................................................................................................... 131

Move to Pierce ............................................................................................................................ 132

Change Cut Mode....................................................................................................................... 132

Change Move Speed .................................................................................................................. 132

Change Consumable .................................................................................................................. 132

On-Path Restart .......................................................................................................................... 132

Return to Path............................................................................................................................. 133

Move Part.................................................................................................................................... 133

Off-Path Restart .......................................................................................................................... 133

Rush Job Interrupt ...................................................................................................................... 134

Change Consumable...................................................................................................................... 134

Overview ..................................................................................................................................... 135

Minutes per Pierce ...................................................................................................................... 135

Arc Errors.................................................................................................................................... 135

Volts per Minute .......................................................................................................................... 136

Last Torch Tip Installed............................................................................................................... 136

Last Electrode Installed............................................................................................................... 136

New Torch Tip............................................................................................................................. 136

New Electrode............................................................................................................................. 136

Setups......................................................................................................................................... 136

Reset Database .......................................................................................................................... 136

Upload Database ........................................................................................................................ 136

Save Database ........................................................................................................................... 136

SECTION 10: MANUAL .................................................................................................................... 137

Return to Start............................................................................................................................. 137

Move Distance ............................................................................................................................ 138

Cut Distance ............................................................................................................................... 138

Manual Options........................................................................................................................... 139

Home Axes ................................................................................................................................. 139

View Sheet/View Part ................................................................................................................. 139

Change Manual Mode................................................................................................................. 140

Operator’s Manual IX

Change Move Speed...................................................................................................................140

Zero Positions..............................................................................................................................141

Rip Cutting...................................................................................................................................141

Manual Options...............................................................................................................................141

Raise Torch ................................................................................................................................. 141

Lower Torch.................................................................................................................................141

Manual Offset .............................................................................................................................. 142

Adjust Dual Gantry Skew ............................................................................................................142

Home Axes......................................................................................................................................143

Transverse...................................................................................................................................143

Rail ..............................................................................................................................................143

CBH .............................................................................................................................................144

THC ............................................................................................................................................. 144

Tilt................................................................................................................................................144

Rotate ..........................................................................................................................................144

All................................................................................................................................................. 144

Go To Home Position .................................................................................................................. 144

APPENDIX A: MARINER™ & VOYAGER II™.................................................................................. 145

Mariner™ Overview ........................................................................................................................145

Voyager II™ Overview ....................................................................................................................146

Cutting............................................................................................................................................. 147

Setups .............................................................................................................................................148

Cut Types........................................................................................................................................ 148

Use Plasma 1 Data .....................................................................................................................148

Use Marker 1 Data ...................................................................................................................... 148

Laser Overview ............................................................................................................................... 149

Laser Cut Types Screen.............................................................................................................. 150

Test Lifter.....................................................................................................................................150

Purge Time..................................................................................................................................151

New Gas Purge Time ..................................................................................................................151

Shutter Time................................................................................................................................151

Power Ramp Time....................................................................................................................... 151

Pierce Time ................................................................................................................................. 151

Pulse On Time............................................................................................................................. 151

Pulse Off Time............................................................................................................................. 151

Creep Time.................................................................................................................................. 151

Beam Off Time ............................................................................................................................ 151

Postflow Time..............................................................................................................................151

Cut Height....................................................................................................................................152

Pierce Height...............................................................................................................................152

Lens Cut Position ........................................................................................................................152

Lens Pierce Position.................................................................................................................... 152

Pulse Laser Time ........................................................................................................................152

Pulse Laser Power ...................................................................................................................... 152

Height Control Manual/Automatic ...............................................................................................152

IHS in Manual..............................................................................................................................152

Retract Full/Partial.......................................................................................................................152

Partial Retract Distance............................................................................................................... 152

Start IHS Distance.......................................................................................................................152

Preflow During IHS......................................................................................................................152

Nozzle Contact IHS ..................................................................................................................... 152

Nozzle Contact During Cut..........................................................................................................152

Pierce Control Manual/Automatic................................................................................................ 153

Pierce Mode Pulse/Blast ............................................................................................................. 153

Pierce Complete..........................................................................................................................153

X Operator’s Manual

Next Pulse................................................................................................................................... 153

Cut Chart..................................................................................................................................... 153

Laser Cut Chart Screen.................................................................................................................. 154

Material Type .............................................................................................................................. 154

Specific Material.......................................................................................................................... 154

Process Power............................................................................................................................ 154

Assist Gases ............................................................................................................................... 154

Material Thickness ...................................................................................................................... 154

Focal Length ............................................................................................................................... 154

Nozzle ......................................................................................................................................... 155

Test Gas ..................................................................................................................................... 155

Set Power ................................................................................................................................... 155

Cut Speed ................................................................................................................................... 155

Kerf.............................................................................................................................................. 155

Pierce Height .............................................................................................................................. 155

Lens Cut Position........................................................................................................................ 155

Lens Pierce Position ................................................................................................................... 155

Sets the focal lens pierce position in the laser head for cutting. ................................................ 155

Resonator On Time..................................................................................................................... 155

Purge Time ................................................................................................................................. 155

Pierce Time................................................................................................................................. 155

Pulse On Time ............................................................................................................................ 155

Pulse Off Time ............................................................................................................................ 156

Creep Time ................................................................................................................................. 156

Pierce Complete ......................................................................................................................... 156

Next Pulse................................................................................................................................... 156

Start Corner Power ..................................................................................................................... 156

Minimum Corner Power .............................................................................................................. 156

Laser Process Monitoring ........................................................................................................... 157

Maximum Ratio ........................................................................................................................... 157

Minimum Ratio ............................................................................................................................ 157

Auto Adjust Speed ...................................................................................................................... 157

Adjustment Delay........................................................................................................................ 157

Over Combustion ........................................................................................................................ 157

Loss of Cut.................................................................................................................................. 157

Save Data ................................................................................................................................... 158

Process Defaults......................................................................................................................... 158

Save Database ........................................................................................................................... 158

Load Database............................................................................................................................ 158

Pulse Laser Time ........................................................................................................................ 158

Pulse Laser Power...................................................................................................................... 158

Height Control Manual/Automatic ............................................................................................... 158

IHS in Manual ............................................................................................................................. 158

Retract Full/Partial ...................................................................................................................... 158

Partial Retract Distance .............................................................................................................. 158

Start IHS Distance ...................................................................................................................... 158

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

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

Nozzle Contact During Cut ......................................................................................................... 158

Pierce Control Manual/Automatic ............................................................................................... 159

Pierce Mode Pulse/Blast............................................................................................................. 159

Pierce Complete ......................................................................................................................... 159

Next Pulse................................................................................................................................... 159

Cut Chart..................................................................................................................................... 159

Cut Chart..................................................................................................................................... 160

Material Type .............................................................................................................................. 160

Operator’s Manual XI

Specific Material .......................................................................................................................... 160

Process Power ............................................................................................................................ 160

Assist Gases................................................................................................................................160

Material Thickness ......................................................................................................................161

Focal Length................................................................................................................................ 161

Nozzle.......................................................................................................................................... 161

Set Power ....................................................................................................................................161

Cut Speed....................................................................................................................................161

Kerf ..............................................................................................................................................161

Cut Height....................................................................................................................................161

Pierce Height...............................................................................................................................161

Lens Cut Position ........................................................................................................................161

Lens Pierce Position.................................................................................................................... 161

Resonator On Time .....................................................................................................................161

Purge Time..................................................................................................................................161

Pierce Time ................................................................................................................................. 161

Pulse On Time............................................................................................................................. 161

Pulse Off Time............................................................................................................................. 161

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

Pierce Complete..........................................................................................................................162

Next Pulse ................................................................................................................................... 162

Start Corner Power...................................................................................................................... 162

Minimum Corner Power............................................................................................................... 162

Laser Process Monitoring............................................................................................................ 162

Maximum Ratio ...........................................................................................................................163

Minimum Ratio ............................................................................................................................163

Auto Adjust Speed....................................................................................................................... 163

Adjustment Delay ........................................................................................................................ 163

Over Combustion ........................................................................................................................163

Loss of Cut ..................................................................................................................................163

Save Data.................................................................................................................................... 163

Process Defaults ......................................................................................................................... 163

Save Database............................................................................................................................163

Load Database ............................................................................................................................ 163

Test Gas ......................................................................................................................................163

HD3070® Auto Gas Interface .......................................................................................................... 164

Save Data.................................................................................................................................... 164

Load Data....................................................................................................................................164

Test Cutting Gases...................................................................................................................... 165

Test Preflow Gases ..................................................................................................................... 165

HD3070® Auto Gas I/O................................................................................................................ 166

Inputs........................................................................................................................................... 166

Outputs ........................................................................................................................................166

HD4070® and HPR130™ Overview................................................................................................167

Cut Chart ..................................................................................................................................... 168

Material Type............................................................................................................................... 168

Current Settings ..........................................................................................................................168

Plasma / Shield Gases ................................................................................................................ 168

Material Thickness ......................................................................................................................168

Cut Speed....................................................................................................................................169

Kerf ..............................................................................................................................................169

Set Arc Voltage ...........................................................................................................................169

Preflow Setting ............................................................................................................................169

Cutflow Settings ..........................................................................................................................169

Preflow Time................................................................................................................................169

Purge Time..................................................................................................................................169

XII Operator’s Manual

Pierce Time................................................................................................................................. 169

Creep Time ................................................................................................................................. 169

Save Data ................................................................................................................................... 170

Process Defaults......................................................................................................................... 170

Save Database ........................................................................................................................... 170

Load Database............................................................................................................................ 170

Test Preflow ................................................................................................................................ 170

Test Cutflow ................................................................................................................................ 170

FineLine Overview.......................................................................................................................... 172

Cut Chart..................................................................................................................................... 174

Material Type .............................................................................................................................. 174

Current Settings .......................................................................................................................... 174

Plasma / Shield Gases................................................................................................................ 174

Material Thickness ...................................................................................................................... 174

Cut Speed ................................................................................................................................... 175

Kerf.............................................................................................................................................. 175

Preflow Time ............................................................................................................................... 175

Purge Time ................................................................................................................................. 175

Pierce Time................................................................................................................................. 175

Creep Time ................................................................................................................................. 175

Database Features ..................................................................................................................... 176

Save Data ................................................................................................................................... 176

Process Defaults......................................................................................................................... 176

Save Database ........................................................................................................................... 176

Load Database............................................................................................................................ 176

Test Preflow ................................................................................................................................ 176

Test Cutflow ................................................................................................................................ 176

Change Consumable .................................................................................................................. 177

APPENDIX B: SENSOR™ THC........................................................................................................ 179

Sensor™ Torch Height Control Overview ...................................................................................... 179

Cut Setups...................................................................................................................................... 180

THC Voltage Offset..................................................................................................................... 180

Plasma Setups ............................................................................................................................... 181

I/O Configuration Type “P” and “V” ............................................................................................. 181

Test Lifter .................................................................................................................................... 181

I/O Configuration Type “P” and “V” (Timing Diagram) ................................................................ 182

Retract Delay .............................................................................................................................. 182

Auto Voltage Set ......................................................................................................................... 182

Set Arc Voltage ........................................................................................................................... 182

Voltage Control ........................................................................................................................... 182

Ignition Output............................................................................................................................. 182

IHS in Manual ............................................................................................................................. 183

Retract Full/Partial ...................................................................................................................... 183

Skip IHS Within ........................................................................................................................... 183

Preflow During IHS ..................................................................................................................... 183

Early Preflow if Skip IHS ............................................................................................................. 183

Nozzle Contact IHS..................................................................................................................... 183

Nozzle Contact During Cut ......................................................................................................... 183

Offset IHS ................................................................................................................................... 183

Auto Kerf Voltage Change .......................................................................................................... 184

Kerf Detect Reacquire Time ....................................................................................................... 184

Marker Setups ................................................................................................................................ 184

I/O Configuration Type “P” and “V” ............................................................................................. 184

Purge Time ................................................................................................................................. 185

Start Time ................................................................................................................................... 185

Operator’s Manual XIII

Sample Voltage ........................................................................................................................... 185

Set Arc Voltage ...........................................................................................................................185

Voltage Control............................................................................................................................ 185

IHS in Manual..............................................................................................................................185

Retract Full/Partial.......................................................................................................................185

Skip IHS Within............................................................................................................................186

Preflow During IHS......................................................................................................................186

Nozzle Contact IHS ..................................................................................................................... 186

Process Watch................................................................................................................................187

Input/Output................................................................................................................................. 187

Position........................................................................................................................................ 187

Plasma Process ..........................................................................................................................187

Main Cut Screen .............................................................................................................................188

Automatic THC Mode ..................................................................................................................188

APPENDIX C: COMMAND® THC ...................................................................................................... 189

Clear Error ...................................................................................................................................189

I/O Configuration Type “M”, “P” and “V” (Timing Diagram) .........................................................190

Purge Time..................................................................................................................................190

Pierce Time ................................................................................................................................. 190

Creep Time.................................................................................................................................. 190

Arc Off Time ................................................................................................................................190

Stop Time .................................................................................................................................... 191

Accel Delay..................................................................................................................................191

Retract Delay Time...................................................................................................................... 191

Ignition .........................................................................................................................................191

Voltage Control............................................................................................................................ 191

Retract Full/Partial.......................................................................................................................191

Retry On Transfer Fail.................................................................................................................191

Transfer Time .............................................................................................................................. 191

Set Arc Current............................................................................................................................ 191

Corner Current Percent ............................................................................................................... 191

Set Arc Voltage ...........................................................................................................................191

Homing Speed............................................................................................................................. 192

Nozzle Ohmic Contact................................................................................................................. 192

Preflow During IHS......................................................................................................................192

Main Cut Screen .............................................................................................................................193

Automatic THC Mode ..................................................................................................................193

Extend .........................................................................................................................................193

Set Now .......................................................................................................................................193

Release .......................................................................................................................................193

Manual THC Mode ......................................................................................................................194

Extend .........................................................................................................................................194

Set Now .......................................................................................................................................194

Release .......................................................................................................................................194

Diagnostics......................................................................................................................................194

APPENDIX D: OPTIONAL DXF TRANSLATOR............................................................................... 195

DXF Translator Overview................................................................................................................ 195

DXF Support................................................................................................................................ 195

Text Commands .......................................................................................................................... 195

Directional Commands ................................................................................................................195

XIV Operator’s Manual

Section 1: Safety 1

Section 1: Safety

Read This Manual

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

Dangerous Machinery

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

Injury and entanglement may occur if hands and limbs come in contact with moving machinery.

KEEP HANDS CLEAR of dangerous moving machinery. All control, including manual, can be effected
using the front panel keys or remote interface.

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

High Voltages

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

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

This equipment should only be opened by trained service personnel.

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

2 Operator’s Manual

Product Listings

Type “M” and “P” Controls

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

Standards.

UL has successfully tested and listed the type “ M” and ”P” (with 10.4” display) control products in
accordance with the applicable U.S. and Canadian Safety Standards. File number E178333. Note:
Suitable for pollution degree 2 environment only.

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

Type “E” and “V” Controls

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

Standards.

UL has successfully tested and listed the type “E” and “V” control products in accordance with the
applicable U.S. and Canadian Safety Standards. File number E178333.

This appliance has been successfully tested and listed by CE under the following standards; EN
500081-2 1994, EN 61000-6-2 1999 and EN 55011:1998. Certificate number: Retlif R-3738N1

Type “B” Controls

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

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

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

Section 2: Overview 3

Section 2: Overview

Introduction

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

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

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

You can graphically key in part programs directly using ShapeWizard
waiting for delivery, set-up, and alignment of templates. Or you can select any of 66 shapes from the
parametric shape library. Using a host computer or CAD/CAM system, you can also download
custom part programs easily. We even supply you at no-charge a communications package to tie the
control to the rest of your management information. Whatever method is used, the control, with its
advanced graphical user interface (GUI), shortens set-up time, speeds productivity and simplifies
scheduling.

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

®

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

®

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

®

microprocessor to your positioning table. With both a

®

on the front panel, without

®

and the Microsoft Foundation

ShapeWizard®

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

Teach/Trace

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

4 Operator’s Manual

Shape Libraries

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

Program Upload and Download

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

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.

6 Operator’s Manual

Built-in Parametric Shape Library

Contains 66 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

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

10.4” (264 mm) VGA Color DSTN LCD Display or optional Active Matrix TFT display. 15” TFT Touch
Screen on some models.

40Gbyte (or higher) hard disk and 1.44Mbyte Floppy disk drive.

2.4 GHZ (or higher) Celeron

512 Mbytes of RAM.

Up to 64 lines of interface signals for cutting and motion logic (gas control, tracing system, markers,
homing, etc.) depending on I/O configuration.

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

Surface mount printed circuit board technology.

Two axes optically isolated ±10VDC drive outputs and incremental encoder inputs 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).

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

An optional Chiller for Mariner style controls is available.

®

Processor is available.

8 Operator’s Manual

Model Numbering System

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

H

Axis Configuration

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

I / O Configuration

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

Power Supplies

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

Pointing Device

0 = None
1 = Industrial Mouse

LCD Type

X = None
0 = 10.4" Dual Scan DSTN
1 = 10.4" Active Matrix TFT
2 = 15" Active Matrix TFT
3 = 15" Touch Screen

-

Memory

0 = 16 MBytes
1 = 32 MBytes
2 = 64 MBytes
3 = 128 MBytes
4 = 256 MBytes
5 = 512 MBytes

--

Model Numbers

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

Model Number Information

Model Number:

Serial Number:

Operating System

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

APC

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

THC

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

Speed Pots

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

Joystick

0 = None
1 = Joystick

Backup Hard Drive

0 = None
1 = Installed

Processor

0 = 166 MHz
1 = 200 MHz
2 = 266 MHz
3 = 433 MHz
4 = 566 MHz
5 = 1.2 GHz
6 = 2.4 GHz

Section 2: Overview 9

Front Panel Layout

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

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

Below the View Screen, there are several groups of push buttons or keys on the front panel. The
eight keys located directly below the display and labeled with Soft-Keys act as programmable keys.
The functions of these keys are shown in the display. This is supported directly on screen for units
with touch screen displays. Softkeys 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.

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

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

The two keys under the label CUT are for program start and stop.

Behind the small door labeled FLOPPY DRIVE is the internal 3.5” 1.44Mbyte floppy disk drive. In
addition, there is a small potentiometer behind this door to adjust the LCD brightness and contrast for
dual scan displays. This potentiometer should only need to be set once, at the time of installation,
unless the control is being operated in an extreme temperature environment.

Front Panel

10 Operator’s Manual

Optional PC Style Keyboard

Optional USB Front Panel

Section 2: Overview 11

Operation Summary

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

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

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

Screen Hierarchy

Main Screen

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

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

NJWin Tools

Text Editor

Teach Trace

HyperCAD

HyperNest

12 Operator’s Manual

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.

Help Screen

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

Show Contents

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

Find

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

Section 2: Overview 13

Main Screen

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

Preview Window

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

Watch Window

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

Shape Manager

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

Files

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

Part Options

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

14 Operator’s Manual

Setups

This softkey takes you to the setup screens.

View Part/View Sheet

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

View Sheet allows the viewing of a part as it would appear on the plate. After pressing the View Sheet
softkey, 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.

Section 2: Overview 15

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

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

Change Cut Mode

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

Change Consumable

This softkey takes you to the Change Consumable screen.

Zero Positions

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

16 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 53 simple shapes.

Text Editor

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

Shape Wizard

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

Teach Trace

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

Nester

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

An optional Automatic Nesting feature is available as an add-on item to Nester™. This true shape,
single station, automatic nesting package allows quick and simple nesting of profiles on to selected
material sizes. 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

Section 2: Overview 17

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:

18 Operator’s Manual

Files

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

Load from Disk

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

Save to Disk

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

Download from Host

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

Upload to Host

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

Resume Last Part

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

Section 2: Overview 19

Show Certain Files

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

Show All Files

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

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

20 Operator’s Manual

Setups Screen

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

Cutting

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

Cut Types

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

Disable Control

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

Watch

Allows programming of the user definable Watch Window.

Password

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

Diagnostic

Enters the diagnostics menu.

Change to Metric Units/English Units

Changes all parameters over to metric units or English units.

Section 2: Overview 21

Change Consumable

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

New Torch Tip

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

New Electrode

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

Reset Database

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

Setups

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

Upload Database

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

Save Database

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

22 Operator’s Manual

g

A

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.

purple or blue arrow at the left or right edge of the softkeys
indicates that that more softkeys and features are available by
pressing the corresponding shift key on the alpha-numeric
keypad.

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

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

These keys activate jogging using the arrow keys when in the
manual mode. Manual key functions (indicated in green) are
available at the 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 dialo

box.

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

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

Section 2: Overview 23

Optional PC Keyboard Layout

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.

24 Operator’s Manual

Optional USB Front Panel

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

Section 3: Setups 25

Section 3: Setups

Cutting

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

Plate Size

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

Cut Mode

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

Trial/Cut Speed

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

26 Operator’s Manual

Kerf

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

Dwell Time

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

Arc Radial Error

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

Dwell Override

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

Optional Program Stop

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

EIA I & J Codes

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

EIA F-Code Override

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

Speed +/- Affects F-Codes

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

EIA Decimal Shift

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

Process Select Override

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

Station Select Override

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

Section 3: Setups 27

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

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 to 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.

Show Traverse Segments

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

Retain Skew Adjustment

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

Kerf Variable / Kerf Offset

28 Operator’s Manual

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

This Kerf Variable can then be used within a part program to define the kerf value when cutting. The
advantage to this is that as torch parts wear, the kerf value changes. If the Kerf Variable value is
updated as the consumable wears and 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

Marker Offsets 1 - 12

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

THC Voltage Offset

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

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

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

Section 3: Setups 29

Cut Types

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

Example:

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

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

30 Operator’s Manual

Oxy Fuel

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

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

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

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

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

Section 3: Setups 31

I/O Configuration Type “B”

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

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

Ignition Time

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

Low Preheat

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

32 Operator’s Manual

High Preheat

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

Pierce Time

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

Moving Pierce Time

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

Creep Time

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

Primary Torch Up Time

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

Primary Torch Down Time

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

Pierce Torch Up Time

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

Pierce Torch Down Time

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

Cut Off Time

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

Bleedoff Time

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

Igniters

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

Preheat During Cut

Specifies whether the Preheat will be left on while cutting.

Section 3: Setups 33

Plasma

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

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

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

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

34 Operator’s Manual

I/O Configuration Type “B”

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

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

Start Time (Type “B” Configuration Only)

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

Purge Time

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

Pierce Time

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

Section 3: Setups 35

Creep Time

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

Cut Off Time

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

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

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

Torch Down Time

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

Arc Off Time

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

Stop Time

Specifies the amount of time that 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.

36 Operator’s Manual

Transfer Time

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

Arc on Feedback

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

Ignition

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

Dual Grid/THC

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

Dual Grid/THC Start

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

Partial Raise

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

Torch Down During Cut

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

Torch Down Between Cuts

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

Section 3: Setups 37

Marker

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

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

Marker Interface

The Marking feature from the control is operated through the use of existing I/O points for cutting
torches on the control I/O connector. These I/O points may be switched from the cutting torch to the
marking tool by use of an external relay(s) activated by the Marker Output or the Marker Output may
be used to activate the marking tool.

Please refer to the Machine Interface section of this guide for exact I/O pinout information.

38 Operator’s Manual

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

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

Ignition Time

(Ignition Output) Specifies the length of time that the ignition output is held on at each ignition point.

Marker On Time

(Time Delay) This parameter allows the operator to insert a time delay, which allows the marker to
prepare for operation prior to the start of Marker motion.

Marker Off Time

(Time Delay) This parameter allows the operator to insert a time delay, which allows the marker to
prepare for operation prior to the end of Marker motion.

Marker Up Time

(Torch Up Output) Specifies the length of time to raise the marker at the beginning and end of each
mark.

Marker Partial Up Time

(Torch Up Output) Specifies the length of time for partial raise of the marker at the beginning and end
of each mark. Note: The Partial Raise parameter must be enabled.

Marker Down Time

(Torch Down Output) Specifies the length of time to lower the marker at the beginning of each
marking cycle.

Set Arc Current

The Set Arc Current feature allows the user to set the arc current at the Plasma Marking supply. This
feature uses the “Set Current BCD” output from the control to activate the BCD inputs at the Plasma
Marking supply. EIA RS-274D part program code G59 Vvalue Fvalue for setting current is supported.

Corner Current Percent

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

Ignition

(Ignition Output Enable) The Ignition Off/On selection allows the operator to use the Ignition Output
when marking if set to On.

Section 3: Setups 39

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.

40 Operator’s Manual

Laser

I/O Configuration Type “V” only

Refer to Appendix A: Mariner™ & Voyager II information.

Section 3: Setups 41

Water Jet

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

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

Purge Time

Specifies the time delay from torch ignition until motion is enabled.

Pierce Time

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

42 Operator’s Manual

Creep Time

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

Abrasive Off Time

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

Abrasive Charging

When selected, the Abrasive Charging feature will charge or fill the abrasive into the cutting system
for use while cutting.

Section 3: Setups 43

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.

44 Operator’s Manual

Input/Output

Allows current state of selected Input, Outputs or Status information to be displayed during cutting.
This can be especially useful in debugging gas control sequencing problems. To add or delete a
desired Input, Output or Status point to the Input/Output list box, highlight the desired item and +
(add) or – (delete) keys on the alpha-numeric keypad.

Position

Allows the position for the selected axis to be displayed. Only two axes may be displayed at the
Upper or Middle locations. The Lower location will allow up to four axes to be displayed.

Following Error

Allows the Following Error to be displayed. Following Error is the distance between the position the
control has calculated and the actual position of the torch. A large Following Error may indicate that
the cut speed selected may be beyond the capability of the cutting system. Only two axes may be
displayed at the Upper or Middle locations. The Lower location will allow up to four axes to be
displayed.

Temperature

Selecting to add the Temperature Widgit to the Watch window will display the current temperature
inside the control in Fahrenheit or Celsius (selected at the Special Setups screen). Note: Specific
control hardware 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).

Process Data

The Process Data option allows the user to view up to four selected items for a selected cut or
marking process. Process timers and status items for Oxy Fuel, Plasma, Marker, Waterjet and Laser
may be selected. Note: The process data will only be displayed during the current cut process.
Example: Plasma 1 process parameters will only be displayed in the Watch window at the main cut
screen while cutting in Plasma 1 Mode.

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 HPR130™ autogas
console. Up to four power supplies may be monitored. This is generally used for diagnostics only.

Section 3: Setups 45

Multiple Watch Windows

Up to ten different Watch windows may be configured on the control for quick selection and viewing of
the Watch icons.

To configure different Watch windows for viewing, first access the Watch setup screen. Press and
hold the Shift key ( Purple or Blue shift key ) followed by a number ( 0 – 9 ). As you press the Shift
key the current Watch window number will be displayed in the lower right corner of the screen.
Configure the Watch Window as desired.

To select a different Watch window, press and hold the Shift key followed by a number ( 0 – 9 ).
Configure the next Watch window as desired. Continue this process until all desired Watch Windows
have been configured.

To view the various Watch windows during operation, simply press and hold the shift key and the
corresponding number and the desired Watch Window will then be displayed.

Example:

46 Operator’s Manual

Section 4: Shape Manager 47

Section 4: Shape Manager

Shape Library

The control contains a built-in Shape Library with more than 53 commonly used shapes. These
shapes are parametric. Parametric shapes are shapes that are not fixed in size or geometry.

The Shape Library consists of more than 53 shapes as shown below. The screen is defined in colors,
from the easiest (green) to the hardest (black).

Selecting a Simple Shape

After pressing Shape Library from the Main Menu, the control display shows the Shape Library as
shown above. At this time, simply use the arrow keys to navigate to the desired shape you wish to
cut and press ENTER. If the selection is incorrect, press CANCEL and re-select the shape.

At this point, the shape is displayed with the default parameters, or the parameters from the last edit
session of this shape. Detailed information on the available shapes can be found in the following
section.

48 Operator’s Manual

Text Editor

This screen is for manually inputting or editing of a part program in either ESSI or EIA format. The
current part that is in memory will be displayed upon entering this screen. Done will save any
changes to the current part in memory. If you want to save the changes to the hard drive, go to the
Save to Disk screen. If you do not want to save any changes that were made, press Cancel on the
keyboard.

Show Original Text

Pressing the Show Original Text button allows the user to view and edit the part program in the
original format in which it was written.

Delete Part

The Delete Part button will delete the current part from the Text Editor so that a new part can be
constructed.

Section 4: Shape Manager 49

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. Below is a Text Editor
line as it appears immediately after the Manual Line Edit is pressed:

50 Operator’s Manual

Simply typing right over the line can erase the highlighted text or the line can be edited using the left
and right arrow keys.

Replace Segment

Replaces the segment highlighted in gray in the Text Editor window with the segment selected from
the Segment Type window as pictured below:

Insert Before Segment

Pressing this softkey causes the segment selected from the Segment Type window to be inserted
before the segment highlighted in gray in the Text Editor window.

Insert After Segment

Pressing this softkey causes the segment selected from the Segment Type window to be inserted
after the segment highlighted in gray in the Text Editor window.

Remove Segment

The segment highlighted in gray or blue in the Text Editor window is removed from the part program
when the Remove Segment softkey is pressed.

After the Manual Line Edit softkey has been pressed, the left and right arrow keys on the front panel
can be used to move left and right within the line being edited in the Text Editor window. They also
are used when entering segment parameters for new Segment Types such as:

Section 4: Shape Manager 51

While a text line is highlighted in blue, the Up and Down arrow keys are used to scroll vertically
through the part program. With each press of one of these keys, a new segment is highlighted. In
addition, the graphic representation of the part program in the Preview window is updated so that the
corresponding segment is highlighted in red or blue, depending on whether it is a cut segment or a
traverse.

The Up and Down arrow keys are also used when the Segment Type pop-up window is highlighted to
scroll vertically through the list of segments. The Segment Type pop-up window is pictured below:

The PAGE UP and PAGE DOWN keys can also be used wherever the Up and Down arrow keys are
used. The only difference is that instead of moving up or down one line, PAGE UP and PAGE DOWN
moves 20 lines at a time.

Pressing PREV and NEXT moves the edit focus to the next window. For example, when a user enters
ShapeWizard, the first line in the Text Editor window is highlighted. If a new segment selection is
desired, the user must press either PREV or NEXT until a selection in the Segment Type window is
highlighted. Pressing NEXT again will cause the control to skip ahead and once again highlight a line
in the Text Editor window. As a rule, NEXT always moves the selection flow ahead and PREV moves
it backwards.

As soon as it becomes highlighted, the Segment Type window expands or pops-up. This allows the
user to view a larger selection of segment types. See the picture above.

After a selection is made in the Segment Type window, pressing ENTER will cause the control to
display up to three parameters associated with the segment selected. Not all segments have any
parameters associated with them. For example, End Program does not need any additional
parameters.

52 Operator’s Manual

Teach Trace

The Teach Trace function of the control allows parts to be taught rather than programmed. The
position information from the taught part will remain as a part program that can be saved to disk for
future use.

The Teach Trace algorithms present in the control can recognize both arcs and lines. This will
reduce the overall memory required to store these parts and will improve the smoothness of the cut.
The taught part in memory is in EIA format and can be cut, saved or manipulated using any of the
part options.

The Teach Trace function must be used in conjunction with an optional stand-alone optical tracing
system.

Start Corner

The Start Corner setup parameter allows the user to select where the taught part will begin for proper
viewing on the screen.

Tracing Pitch

This determines how precisely to learn a part. The Tracing Pitch can be adjusted to trade off
resolution versus size of the taught part. This value does not affect the actual position resolution of
the part.

A good starting point for most tracing systems is 0.01”.

Section 4: Shape Manager 53

Arc Radial Error

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

Auto Closure Detect

This parameter is used to allow the control to detect that it has returned to the starting point. With this
feature ON, the control stops the motion of the tracer when the part is complete allowing a lead-out to
be programmed.

Closure Over/Under Lap

By specifying a positive value for this parameter, the control does not stop the tracer until it has gone
past the start point by the amount of this parameter. By specifying a negative value, the tracer stops
as soon as the tracing head position is within this parameter’s distance of the starting point. This is
only available if the Auto Closure Detect is ON.

Kerf Direction

Selects the desired kerf for cut segments.

Traverse/Pierce

Switches between the traverse and cut segments of the part as it is taught.

Tracing a part

To trace a part while at the Teach Trace screen, select Auto mode, then select traverse or pierce.
You may switch between traverse and pierce during the tracing procedure. Position the optical
sensor near the part drawing and press Start. Use the sensor positioning controls to direct the sensor
towards the part. Once the sensor has located the part, the tracing system will follow the part outline
until completion. When completed, press Done. The part file can now be cut, saved or edited.

Please refer to the instructions provided with your Optical tracing system for further details.

54 Operator’s Manual

Plate Remnant Trace

The Teach /Trace feature also supports the ability to trace in the outline of a plate remnant for use by
a part programmer to create new nests of parts to be cut on the remnant.

The user manually moves the torch (or a pointer) around the plate to define the outline of the
material which remains. When the path is completed (it doesn’t have to be a closed path), the
operator presses the Done key and the recorded axis motions are written to a standard part program
format with moves recorded as incremental routing moves. The movements will also display on the
control’s screen in the same manner as displayed during manual motion commands.

Once recorded, the part program can be uploaded via the serial link, or written to the floppy disk, so
that the programming department can use it to update their database to reflect the remaining
material.

When first opened the system defaults to the automatic Teach/Trace mode which is used in
conjunction with an optical head for program generation. In order to use the manual function, simply
select the softkey to choose manual mode.

This will place the control in the manual control mode and also enables the Change Move Speed
button to alter the manual move speed. Pressing the Change Move Speed button repeatedly will
cycle through the programmed manual jog rate settings.

Section 4: Shape Manager 55

This will place the control in the manual control mode and also enables the Change Move Speed
button to alter the manual move speed. Pressing the Change Move Speed button repeatedly will
cycle through the programmed manual jog rate settings.

The operator should position the pointer or torch to the plate location where recording of the path is to
begin. Once at the start point, press the “Start” button to begin recording positions. The manual
motion buttons may now be used to trace out an arbitrary contour which defines the remaining plate
area. When finished, press the Done key to record the motions to the “current” part program.

The program may now be saved to the disk, or uploaded in the normal manner.

56 Operator’s Manual

Nester™

Nester™ is a proprietary part nesting program, which allows the operator to manually group or nest
selected parts together as one part program to conserve raw materials and maximize machine
utilization. This nesting program is designed to maximize the control features of graphical user
interface, simplified keypad operation and advanced communications software to provide quick,
simple and logical programming.

Additionally, an optional Automatic Nesting feature may be enabled to perform true shape, single
station, automatic nesting. With its advanced Graphical User Interface, ease of use and advanced
profile positioning algorithms, this Automatic Nesting feature can greatly improve the output of your
shape cutting operation by reducing overall process time and increasing plate utilization. Please
contact your control vendor for details on enabling this Automatic Nesting feature.

Manual Nesting

Main Screen Layout

The main viewing area is the largest area of the screen and is located in the upper left corner. The
edge of the plate is displayed in dark green. The plate size displayed is based on plate information
that has been selected at the main setup screen.

The upper right corner of the main screen displays the part program list for the nest in order of cut
sequence. In the lower right, part position and orientation information for the selected part program is
displayed and can be manipulated for use as new parts are added.

Section 4: Shape Manager 57

Add Part

Pressing the Add Part softkey accesses the screen, which allows the user to select a part program
from a selected source.

Remove Part

This softkey is used to remove the selected part from the nest parts list.

Cut Earlier

Pressing the Cut Earlier softkey will move the selected part program to an earlier position in the part
cut list. The sequence in which the parts are cut are changed, but not the selected part location in the
nest.

Cut Later

Pressing the Cut Later softkey will move the selected part program to a later position in the part cut
list. The sequence in which the parts are cut are changed, but not the selected part location in the
nest.

View Sheet / View Part

View Sheet allows the viewing of a part as it would appear on the plate. After pressing the View Sheet
softkey, 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.

Setup

Pressing the Setup softkey accesses the Nester™ Setup screen for configuring the variable
parameters when using Nester™.

Done

The Done softkey is used to end the Nesting program, return to the Main Cut Screen and temporarily
save the nested program as the current part. At this point, the part can be cut or saved to disk
through the Shape Manager. Pressing the cancel key will return the user to the Main Cut Screen
without saving the nested program.

58 Operator’s Manual

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.

Clear Nest

Clear Nest will delete all the parts located in the nested parts list from temporary memory.

Done

The Done softkey is used to end the nesting setup and return to the Nester™ main screen.

Section 4: Shape Manager 59

Using Nester™

To begin, first select the plate size requirements for the nest at the Main Setup screen. This
information is used to display the plate size and plate orientation at the main view screen to place
parts on the plate. The plate information is retained with the nested part program when saved.

Press the Nester™ softkey from the Shape Manager screen then enter the Nester™ Setup Screen to
configure the nesting software for use. Press Done to return to the Nester™ Main Screen to begin
placing parts in the nest.

Adding Parts

At the Nester™ Main Screen, press the Add Part softkey to add a new part to the nesting part list.
The first screen viewed will allow the user to select a part from the Simple Shape Library, from a disk
or from the host computer via link communications.

Once a part has been selected from either location, the user will be prompted to select the number of
pieces desired.

60 Operator’s Manual

As new parts are added, they will be displayed on the selected plate in preparation for final
placement.

At this screen, the part can be oriented, scaled and moved to final position. This is done by moving to
the Nester™ Part List by using the Prev/Next keys and then using the Up/Down arrow keys to select.
When the desired part file is highlighted, use the Prev/Next keys to move to the desired field to
manually offset, rotate, mirror and scale the part.

To position the selected part, use the Prev/Next keys to highlight the view screen. The view screen
will be outlined by a bold blue border indicating that the arrow keys are active. Pressing the arrow
keys will allow movement of the part to the desired location on the plate. Each time the arrow keys
are pressed, the selected part will move in the direction of the arrow by the increment set by the
Arrow Key distance softkey. By use of the arrow distance key, arrow keys and zooming in the view
field, exact placement of the desired part may be obtained.

Additional parts may be added to the nest in the same fashion as described above. To customize
your nest, you may decide to delete parts or add parts to the list and change the order in which they
are cut by use of the softkeys displayed. When finished, press Done to return to the Main Cut screen
and begin cutting the nest. The part nest is currently saved as a temporary file until another part is
loaded.

Saving a Nest

From the Main Cut screen, press the Files softkey to Save to Disk. From here the part can be saved
to a hard disk folder on the control or a diskette. The nested parts file may be saved as a nest or a
part. Saving as a nest will create a larger file, which will allow future modification of the nest through
Nester™. Nested parts saved as a part file cannot be modified.

Section 4: Shape Manager 61

HyperNest – CNC® Automatic Nesting Software

Optional HyperNest® - CNC feature - This true shape, single station, automatic nesting package
allows quick and simple nesting of profiles on to selected material sizes. With its advanced Graphical
User Interface, ease of use and advanced profile positioning algorithms, HyperNest
greatly improve the output of your shape cutting operation by reducing overall process time and
increasing plate utilization.

Main Screen Layout

The main viewing area is the largest area of the screen and is located in the upper left corner and is
used to preview manual nests. During an automatic nest, this area will remain blank. The plate size
used during Automatic nesting is based on plate information that has been selected at the main setup
screen.

The upper right corner of the main screen displays the list part programs and quantities of parts to be
automatically nested. In the lower right, locations to save the nested part program to a folder location
and to assign a file name.

®

- CNC can

Note: This software feature is protected both by a software enable and a hardware key (dongle)
installed on the control.

62 Operator’s Manual

Automatic Nesting Setup

Pressing the Setup softkey accesses the following setup parameters and are used to configure the
automatic nesting process for use. Note: If this feature is not available (greyed out), the feature has
not been enabled on your controller. Please contact your control vendor for details on how to enable
the Automatic Nesting feature.

Automatic Nesting

Switching the Automatic Nesting Parameter to ON enables the feature for use.

Part Spacing

The Part Spacing feature sets the spacing between parts during the Automatic Nesting process.

Plate Edge Spacing

This parameter allows the user to set spacing around the edge of the plate to be used during the
Automatic Nesting process.

Program Origin

The Program Origin ( nest start location ) may be set to lower left, upper left, bottom left or bottom
right.

Cut Direction

Cut Direction allows to user to select the direction the parts will be placed in during the Automatic
Nesting process. Options are: Left or Right, Right to Left, Top to Bottom and Bottom to Top.

Return to Nest Start

When enabled, the Return to Nest Start feature will insert a traverse segment back to the start point
at the end of the nest.

Section 4: Shape Manager 63

Using HyperNest – CNC®

To begin, first select the plate size requirements for the nest at the Main Setup screen. Press the
Nester™ softkey from the Shape Manager Screen then enter the Setup Screen to enable the
Automatic Nesting software feature and configure the setup parameters for use. Press Done to
return to the Main Screen and begin placing parts in the nest.

Adding Parts

At the Main Screen, press the Add Part softkey to add a new part to the nesting part list. The Add
Part screen will allow the user to select a part from the Simple Shape Library, from a disk or from the
host computer via link communications.

Once a part has been selected from the desired location, the user will be prompted to select the
number of pieces desired.

64 Operator’s Manual

As new parts are added, the part file name and quantity will be displayed in the parts list window in
the upper right corner of the screen in preparation for final placement during the Automatic Nesting
process.

Select the desired file location and assign a file then press the Nest Parts softkey to begin the
automatic nesting process. A progress window will be displayed during the nesting process.

Section 4: Shape Manager 65

Note: The nest process progresses quickly and not all shapes may be visible on screen or other
drawing anomalies may be noted during the nesting process.
In the event that more parts are selected than can fit on one plate, multiple plates or sheets (nested
program) files will be generated and saved in the selected folder with the selected file name, but a
numeric suffix will be added. Example: saving the part file as Nest may generate multiple part files
named NEST1.txt, NEST2.txt, NEST3.txt, etc.

Remove Part

A part may be removed from the part files list by highlighting the selected part in the files list and
pressing the Remove Part softkey prior to executing the nesting.

Note: The software feature on the control is protected by a hardware key or dongle. If the
hardeware key has been removed from the control, the following message will appear when the Nest
Parts softkey has been pressed.

66 Operator’s Manual

Nest Summary

Upon completion of the nest, the software will provide a summary of the Automatic Nesting process.

Statistical analysis of the process is provided for a number of sheets, time to execute nest, total nest
utilization and total number of shapes nested.

Note: Sheets that are generated with the exact same part configuration will be listed as “Sheet No. #
(total #). For the example above, the sheet number 5 thru 8 sheets are all the same and are listed as
“Sheet No.5 (4)”

Pressing the down arrow key will allow you to view an analysis of the parts used.

Section 4: Shape Manager 67

Pressing the down arrow key again will allow you to view the individual sheets produced and a listing
of the net utilization for the specific sheet.

Press Enter to accept the nest and have the first sheet become the current part. Press the Cancel
key to reject the nest and return to the main nesting screen to add or remove parts from the nest.

68 Operator’s Manual

Main Screen View of Nest

Note: Parts with open loops or other invalid geometries may not be able to be automatically nested.

It may be possible to manually nest parts which have been rejected by the Automatic Nesting
function.

Section 4: Shape Manager 69

HyperCAD®

HyperCAD® 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.

This simple CAD/CAM application lets you move easily from drawing to cutting.

HyperCAD

- English or Metric Units

- Part / Sheet viewing capabilities

- Scaling, mirroring or rotating of parts

- Repeating and copying of shapes

- Moving / modifying of lead-ins and lead-outs

- Add-on of chamfers, fillets and notches

- On-screen, full-part cutting simulation

- Built in Help functions

®

Features

This feature is offered as a limited use trial version. Please contact your control vendor for
information on enabling unlimited use of this feature. This package may be used on the CNC
equipped with mouse and PC keyboard or offline on a PC.

70 Operator’s Manual

HyperNEST®

HyperNEST® is a full featured, automatic true shape application designed to allow quick and simple
nesting of profiles onto standard material sizes. With its advanced Graphical User Interface,
HyperNEST

HyperNEST

HyperNEST

- Multi-torch nesting with a variable number of torches

- Bridging and chain cutting for common line cutting

- Extending consumable life

- “Move, drag and drop” manual interactive nesting

- Viewing and modifying of multiple sheets at the same time

- Multiple nesting scenarios for optimizing plate use and process cutting time

- Use of Wild Card parts to optimize plate utilization

- Automatic off-cut generation

- Built in Help functions

®

greatly improves the output of any shape cutting operation.

®

Features

®

also lets mechanized end users achieve

This feature is offered as a limited use trial version. Please contact your control vendor for
information on enabling unlimited use of this feature. This package may be used on the CNC
equipped with mouse and PC keyboard or offline on a PC.

Section 4: Shape Manager 71

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:

72 Operator’s Manual

Section 5: Files 73

Section 5: Files

Load from Disk

The following screen is used to load a part from a diskette or the hard drive. Once all the parameters
below are set, press ENTER on the keyboard to load the part.

Load from

The Load from list selects whether you load from the diskette or from a directory on the hard disk. To
select a different directory, use the ↑ and ↓ keys on the keyboard. To add a new directory, use the +
key on the keyboard. To remove a directory, use the - key on the keyboard.

Files

The Files listbox is a list of all the files that are in the Load from directory that can be loaded from the
disk. To scroll through different files, use the ↑, ↓, PAGE UP and PAGE DOWN keys on the
keyboard. To remove a file, use the - key on the keyboard. To select multiple files to load, highlight
the first file selection, then use the ↑ and ↓ keys while pressing the shift key to highlight the remaining
files. Note: Multiple file selection is only available if loading from the diskette to the hard drive.

74 Operator’s Manual

File name/Diskette file name

The File name /Diskette file name is the name of the file to load from disk/diskette.

Preview

When checked, the Preview checkbox allows the file that is selected in the Files listbox to be
previewed. To check or uncheck the box, press the SPACE key on the keyboard when the Preview
box has the focus.

Load to

The Load to list selects whether you load to the current part or to a directory on the hard disk. To
select a different directory, use the ↑ and ↓ keys on the keyboard. To add a new directory, use the +
key on the keyboard. To remove a directory, use the - key on the keyboard. Note: This selection is
only available if loading from the diskette.

Hard drive file name

The Hard drive file name is the name that you are giving the file you are loading on the hard drive.

Note: This selection is only available if loading from the diskette.

Resume Last Part

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

Show Certain Files

This softkey allows the operator to search the selected folder for specific part files by using wildcard
type search tools. Both the asterisk (*) and question mark (?) can be used. To input the asterisk,
press the left shift key (purple) and the backspace key. To input the question mark, press the right
shift key (blue) and the backspace key.

Show All Files

This will allow the operator to switch from the selected “certain files” to viewing all files with the
predetermined file extensions.

Section 5: Files 75

Resume Last Part Features

Rush Job Interrupt

Rush Job Interrupt allows the user to pause the current part program and retain the part and current
position information. When at the Pause screen, press the Cancel key. A prompt will appear on
screen to ask the user if they wish to save the part information for later use.

If the user selects YES, the Resume Last Part button will be viewable at the Files Screen. The user
can then load and execute another part program and then return to the original part using the
Resume Last Part softkey. The part program and position will be resumed.

Automated Power Loss Recovery

The Automated Power loss recovery uses the Resume Last Part feature similar to the Rush Job
Interrupt. However, the Machine must be “Homed” to ensure proper positioning prior to resuming the
part.

This feature may also be used in the event of an “Overtravel” or similar fault.

76 Operator’s Manual

Save to Disk

The following screen is used to save a part to a diskette or the hard drive. Once all the parameters
below are set, press ENTER on the keyboard to save the part.

Save to

The Save to list selects whether you save to the diskette or to a directory on the hard disk. To select
a different directory, use the ↑ and ↓ keys on the keyboard. To add a new directory, use the + key on
the keyboard. To remove a directory, use the - key on the keyboard.

File name/Diskette file name

The File name is the name that you are giving the file you are loading on the disk.

Save Original Text

Selecting the Save Original Text option will save the part to disk in its original programming format.

Note: This selection is not available if saving to the diskette from the hard drive.

Save from

The Save from list selects whether you save from the current part or from a directory on the hard disk.
To select a different directory, use the ↑ and ↓ keys on the keyboard. To add a new directory, use
the + key on the keyboard. To remove a directory, use the - key on the keyboard. Note: This
selection is only available if saving to the diskette from the hard drive.

Files

The Files list box is a list of all the files that are in the Load from directory that can be loaded from the
disk. To scroll through different files, use the ↑, ↓, PAGE UP and PAGE DOWN keys on the
keyboard. To remove a file, use the - key on the keyboard. To select multiple files to load, highlight
the first file selection, then use the ↑ and ↓ keys while pressing the shift key to highlight the remaining

Section 5: Files 77

files. Note: This selection and Multiple file selection are only available if saving to the diskette from
the hard drive.

Hard drive file name

The Hard drive file name is the name that you are giving to the file loading on the hard drive. Note:
This selection is only available if saving to the diskette from the hard drive.

Preview

When checked, the Preview checkbox allows the file that is selected in the Files listbox to be
previewed. To check or uncheck the box, press the SPACE key on the keyboard when the Preview
box has the focus. Note: This selection is only available if saving to the diskette from the hard drive.

Save KeyLog to Disk

This feature is enabled when the Key Logging feature has been selected in setups.

The Key Logging feature is used as a troubleshooting diagnostic tool to record key presses made at
the control during operation. When enabled, all key presses and application faults will be saved to a
daily log file that may be sent to the control manufacturer for evaluation.

78 Operator’s Manual

Download from Host

The following screen is used to download a part from a host computer. Once all the parameters
below are set, press ENTER on the keyboard to start the download.

Download from

The Download from list selects which directory on the host computer you want to download from. To
select a different directory, use the ↑ and ↓ keys on the keyboard. To add a new directory, use the +
key on the keyboard. To remove a directory, use the - key on the keyboard.

Files

The Files list box contains a list of all the files in the Download from directory that can be downloaded
from the host computer. To scroll through different files, use the ↑, ↓, PAGE UP and PAGE DOWN
keys on the keyboard. To remove a file, use the - key on the keyboard.

To select multiple files to download, highlight the first file selection, then use the ↑ and ↓ keys while
pressing the shift key to highlight the remaining files.

Remote file name

The Remote file name is the name of the remote file that will be downloaded from the host computer.

Section 5: Files 79

Preview

When checked, the Preview checkbox allows the file that is selected in the Files list box to be
previewed. To check or uncheck the box, press the SPACE key on the keyboard when the Preview
box has the focus.

Download to

The Download to list selects whether you download to the current part in memory or to a directory on
the local hard disk. If you select one of the local directories, the following field is available: Local file
name. To select a different directory, use the ↑ and ↓ keys on the keyboard. To add a new directory,
use the + key on the keyboard. To remove a directory, use the - key on the keyboard.

Local file name

The Local file name is the user defined file name assigned to the file that is being downloading to the
hard drive.

80 Operator’s Manual

Upload to Host

The following screen is used to upload a part to a host computer. Once all the parameters below are
set, press ENTER on the keyboard to start the upload.

Upload to

The Upload to list selects which directory on the host computer that you want to upload to. To select
a different directory, use the ↑ and ↓ keys on the keyboard. To add a new directory, use the + key on
the keyboard. To remove a directory, use the - key on the keyboard.

Remote file name

The Remote file name is the name you want the file that you are uploading to have on the host
computer.

Upload from

The Upload from list selects whether you upload the current part in memory or from a directory on the
local hard disk. If you select one of the local directories, the following fields are available: Files, Local
file name and Preview. To select a different directory, use the ↑ and ↓ keys on the keyboard. To add
a new directory, use the + key on the keyboard. To remove a directory, use the - key on the
keyboard.

Files

The Files list box contains a list of all the files that are in the Upload from directory that can be
uploaded to the host computer. To scroll through different files, use the ↑, ↓, PAGE UP and PAGE
DOWN keys on the keyboard. To remove a file, use the - key on the keyboard.

Section 5: Files 81

To select multiple files to upload, highlight the first file selection, then use the ↑ and ↓ keys while
pressing the shift key to highlight the remaining files.

Local file name

The Local file name is the name of the local file that will be uploaded to the host computer.

Preview

When checked, the Preview checkbox allows the file that is selected in the Files list box to be
previewed. To check or uncheck the box, press the SPACE key on the keyboard when the Preview
box has the focus.

Loading Of Invalid Files

While loading the desired part file, the control will check the part for proper geometry and other similar
errors. If a part is loaded in which an error is detected, a message will be posted on screen to
indicate the error. If the part is attempted to be loaded, the control will display the invalid line of code
from the text editor.

Example: In the following example, the line of code “XXXXXXXX” is invalid and has been highlighted
for easy detection. The part file may be corrected using the text editor. After the invalid code has
been corrected, the control will attempt to translate the part file and will indicate any additional invalid
codes.

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Section 6: Library Shapes 83

Section 6: Library Shapes

Library Shape Setup

Enter in the desired dimensions to obtain the part you require. There will be a small Help icon
in the lower right hand corner of the display to indicate which parameter the control is looking
for. The current parameter being entered will be highlighted with a yellow arrow bar.

While you are entering in parameters, the control is performing some general checks for proper
geometries. Should the control encounter a set of parameters that do not make sense, a warning
message will be displayed and the parameters in conflict will be highlighted in red. Note: It is not
possible to check for all improper geometries and it may still be possible to enter in a part that does
not make geometric sense.

As you are entering dimensional parameters, the control is automatically drawing your new shape
with the entered values. This is extremely useful in providing a visual check of the shape that has
been entered.

Lead-In, Lead-Out

Enter the appropriate value to ensure proper piercing (Lead-in) and gas bleed-off (Lead-out) to obtain
optimum cut quality.

The location for the lead-in and lead-out is fixed, but can be changed by using the ShapeWizard and
then saving the new shape to disk. Note: the Rectangle simple shape has the ability to select the
location for the lead-in and lead-out by pressing the SPACE key. Pressing the SPACE key will move
the lead-in and lead-out to the next available location.

Overburn Length

Overburn is used for parts that contain a circular element. Overburn specifies arc length that the
torch will travel past the circle closure point. The dimension entered is the chord length of the
overburn-arc.

In some cases it is desirable to have an underburn length. For these conditions, simply enter a
negative number for the Overburn length.

Part Type

Selects whether you want to cut the part as a separate Piece or a Hole in a larger part. Chain cut
options are available for simple shapes that have external cut paths.

Lead Type

Depending on the shape selected, the style of the Lead in/ Lead out may be selected as Radius, Lock
or Straight line. The Lock style Lead-in creates greater stability for the part and is only available if the
Part Type is set to Piece. Lead-in selection is only available if the Part Type is set to Piece or Hole.

After the shape has been entered, press DONE to return to the Main Menu.

84 Operator’s Manual

Rectangle

Circle

Section 6: Library Shapes 85

Triangle

L-Bracket

86 Operator’s Manual

Trapezoid

Slant Rectangle